Patent Description:
Conventional wooden roller coaster track is typically formed by layering dimensional lumber and bending the layers in the"weak" direction (e.g., a direction substantially perpendicular to the depth of each layer of dimensional lumber to match the overall profile of the underlying structure. The layers are then manually cut in the"strong" direction (e.g., along the width of the dimensional lumber) to create a curved path for the ride vehicle. Bending and cutting the track in this manner can require repeated adjustment which be costly and time consuming and can still leave slight imperfections in the track that adversely affect a passenger's enjoyment and comfort. In addition, this type of track assembly can require highly skilled labor which can be scarce and expensive. <CIT> discloses a wooden rail for a ride comprising a number of layers bonded with each other and milled to a precise rail form.

The present invention provides a method of manufacturing a roller coaster track as defined by Claim <NUM>. Further, preferable, features are presented in the dependent claims.

Various embodiments will become better understood with regard to the following description, appended claims and accompanying drawings wherein:.

Embodiments are hereinafter described in detail in connection with the views and examples of <FIG>, wherein like numbers indicate the same or corresponding elements throughout the views. A horizontal track portion <NUM> of a roller coaster track that defines a horizontal curve (e.g., a left/right turn) is generally depicted in <FIG>. The horizontal track portion <NUM> can include a right rail <NUM> and a left rail <NUM> that cooperate together to provide underlying support for a train car <NUM> (e.g., a ride vehicle) (see <FIG>). The right rail <NUM> and the left rail <NUM> can be spaced from each other to define a track width WO. The right rail <NUM> can include plurality of base layers <NUM>, a lower track layer <NUM>, and an upper track layer <NUM>. Each of the base layers <NUM>, the lower track layer <NUM>, and the upper track layer <NUM> can be arranged horizontally and stacked together such that the base layers <NUM> underlie the lower and upper track layers <NUM>, <NUM>, and the lower track layer <NUM> is sandwiched between the base layers <NUM> and the upper track layer <NUM>.

The layers <NUM>, <NUM>, <NUM> can be formed of wood such that the roller coaster is considered to be a wooden roller coaster. In one embodiment, the layers <NUM>, <NUM>, <NUM> can be formed of weather-resistant wood (e.g., pressure treated wood) such as pine, for example. Each of the base layers <NUM>, the lower track layer <NUM>, and the upper track layer <NUM> can be secured to each other with fasteners, glue, and/or dowels, or with any of a variety of suitable alternative attachment methods.

The base layers <NUM> can cooperate together to provide an underlying support structure for the lower and upper track layers <NUM>, <NUM>. The lower and upper track layers <NUM>, <NUM> can have respective interior portions <NUM>, <NUM> that extend beyond the base layers <NUM> (e.g., in a cantilevered arrangement) for accommodating wheels <NUM> of the train car <NUM> (see <FIG>). The lower and upper track layers <NUM>, <NUM> can define a travel path for the train car <NUM>. Running plates (not shown) can be provided on the top, sides, and bottom of the interior portions <NUM>, <NUM> to provide a running surface (e.g., a contact surface) for the wheels <NUM> of the train car <NUM>. In one embodiment, the running plates can be formed of plate steel.

Each layer <NUM>, <NUM>, <NUM> of the horizontal track portion <NUM> can be constructed of a plurality of discrete layer segments that are each laid end-to-end and in a contacting relationship with longitudinally adjacent layer segment (e.g., parallel to a travel path of the train car <NUM>). Referring now to <FIG>, each of the base layers <NUM> are shown to include a plurality of base layer segments <NUM> that each have a first end <NUM> and a second end <NUM>. The first end <NUM> of each base layer segment <NUM> can be in contact with the second end <NUM> of an adjacent base layer segment <NUM> at an interface location <NUM>. The lower track layer <NUM> is shown to include a plurality of lower track layer segments <NUM> that each have a first end <NUM> and a second end <NUM>. The first end <NUM> of each lower track layer segment <NUM> can be in contact with the second end <NUM> of an adjacent lower track layer segment <NUM> at an interface location <NUM>. The upper track layer <NUM> is shown to include a plurality of upper track layer segments <NUM> that each have a first end <NUM> and a second end <NUM>. The first end <NUM> of each upper track layer segment <NUM> can be in contact with the second end <NUM> of an adjacent upper track layer segment <NUM> at an interface location <NUM>.

Referring now to <FIG>, three of the base layer segments <NUM> are illustrated and will now be described. The first ends <NUM> of each base layer segment <NUM> can include a tab <NUM> and the second ends <NUM> of each base layer segment <NUM> can define a notch <NUM>. When the base layer segments <NUM> are laid end-to-end (e.g., longitudinally adjacent) and in a contacting relationship with each other (as illustrated in <FIG>), each tab <NUM> can extend into one of the notches <NUM> thus defining the interface location <NUM>. The interaction between the notches <NUM> and the tabs <NUM> can resist relative horizontal movement between the base layer segments <NUM> as well as provide visual indicators that facilitate validation of the relative physical orientation of between the base layer segments <NUM>. It is to be appreciated that the base layer segments <NUM> can have any of a variety of suitable alternative interlocking feature(s) disposed at the first end <NUM> and/or the second end <NUM> that facilitate lateral coupling between the base layer segments <NUM>.

Each base layer segment <NUM> can have a thickness T1 and a width W1 that is greater than the thickness T1. Each of the base layer segments <NUM> can include an upper surface <NUM> that extends along the width W1. The first and second ends <NUM>, <NUM> can be provided with indicia <NUM> (e.g., lettering and numbering engraved into, or otherwise applied to, the upper surface <NUM>) that identifies which ends of the base layer segments <NUM> are to be matched together during assembly, as well as which side of the track the base layer segments <NUM> are meant for. The indicia <NUM> also can include an arrow indicating the direction of the travel path of the roller coaster to identify the longitudinal orientation of each base layer segment <NUM>. It is to be appreciated that any of a variety of suitable alternative visual indicators (e.g., markings or engravings) can be used to validate the relative orientation of base layer segments <NUM> with respect to each other. Each of the base layer segments <NUM> can define a plurality of first vertical holes <NUM> and a plurality of second vertical holes <NUM>. Dowels (not shown) or other fasteners can be provided through the first vertical holes <NUM> and into corresponding holes in the immediately adjacent base layer <NUM> to couple the base layers <NUM> together.

Referring now to <FIG>, three of the lower track layer segments <NUM> are illustrated and are similar to, or the same in many respects as, the base layer segments <NUM> illustrated in <FIG>. For example, each of the lower track layer segments <NUM> can comprise a first end <NUM> and a second end <NUM>. The first ends <NUM> can each include a tab <NUM> and the second ends <NUM> can each define a notch <NUM>. The first and second ends <NUM>, <NUM> can be provided with indicia <NUM>. Each of the lower track layer segments <NUM> can define a plurality of second vertical holes <NUM>. The lower track layer segments <NUM> can each have a thickness T2 and a width W2 that is greater than the thickness T2. Each of the lower track layer segments <NUM> can include an upper surface <NUM> that extends along the width W2 and an interior surface <NUM> that extends along the thickness T2. The width W2 of the lower track layer segment <NUM> can be wider than the width W1 of the base layer segments <NUM> such that the interior portion <NUM> (<FIG>) of the lower track layer <NUM> overhangs the base layers <NUM>.

Referring now to <FIG>, three of the upper track layer segments <NUM> are illustrated and are similar to, or the same in many respects as, the base layer segments <NUM> illustrated in <FIG>. For example, each of the upper track layer segments <NUM> can comprise a first end <NUM> and a second end <NUM>. Each of the first ends <NUM> of can include a tab <NUM> and each of the second ends <NUM> define a notch <NUM>. The first and second ends <NUM>, <NUM> can be provided with indicia <NUM>. Each of the upper track layer segments <NUM> can define a plurality of first vertical holes <NUM>. Dowels (not shown) or other fasteners can be provided through the first vertical holes <NUM> and into corresponding holes in the immediately adjacent lower track layer <NUM> to couple the upper track layer <NUM> and the lower track layer <NUM> together. The upper track layer segments <NUM> can each have a thickness T3 and a width W3 that is greater than the thickness T3. Each of the upper track layer segments <NUM> can include an upper surface <NUM> that extends along the width W3 and an interior surface <NUM> (<FIG>) that extends along the thickness T3. The width W3 of the upper track layer segment <NUM> can be wider than the width W1 of the base layer segments <NUM> such that the interior portion <NUM> (<FIG>) of the upper track layer <NUM> overhangs the base layers <NUM>.

Referring again to <FIG>, the base layers <NUM>, the lower track layer <NUM>, and the upper track layer <NUM> can be arranged horizontally and stacked together such that each of the layers <NUM>, <NUM>, <NUM> are laterally (e.g., vertically) adjacent to one another (e.g., in a direction that is perpendicular to the direction of travel of the train car <NUM>). The interior surfaces <NUM>, <NUM> (<FIG>) can define the overall contour of the right rail <NUM> (e.g., a gradual turn) for the roller coaster. Interior surfaces (e.g., <NUM>) of the base layer segments <NUM> can be contoured to substantially follow the interior surfaces <NUM>, <NUM> of the lower and upper track layers <NUM>, <NUM> such that the base layers <NUM>, the lower track layer <NUM>, and the upper track layer <NUM> are similarly contoured along the length of the right rail <NUM>. It is to be appreciated that the interior surfaces (e.g., <NUM>) of the base layer segments <NUM> are horizontally spaced from the interior surfaces <NUM>, <NUM> of the lower and upper track layers <NUM>, <NUM> enough to prevent contact with the wheel assemblies of the train.

The base layers <NUM> and the lower track layer <NUM> can be arranged to align the first vertical holes <NUM> with the first vertical holes <NUM> and the second vertical holes <NUM> with the second vertical holes <NUM>. Dowels (not shown) can be provided through the first vertical holes <NUM>, <NUM> to couple the base layers <NUM> and the lower track layer <NUM> together. Bolts <NUM> (one shown in dashed lines) can be provided through the second vertical holes <NUM>, <NUM> to facilitate securement of the base layers <NUM> and the lower track layer <NUM> together to an underlying structural member, such as a cross tie (not shown), for example. As illustrated in <FIG>, the second vertical holes <NUM> of the lower track layer <NUM> can be counter bored or otherwise recessed to allow the bolts <NUM> to be nested within the second vertical holes <NUM> such that the bolts <NUM> do not obstruct attachment of the upper track layer <NUM> to the lower track layer <NUM>.

Each layer <NUM>, <NUM>, <NUM> can be arranged such that the interface locations (e.g., <NUM>, <NUM>, <NUM>) between each pair of layer segments for a given layer is longitudinally offset (e.g., along the travel path of the train car <NUM>) from the interface locations of the laterally adjacent (e.g., overlying and/or underlying) layers. Each layer is accordingly positioned relative to the other laterally adjacent layers such that each layer segment overlaps (e.g., extends beyond) the laterally adjacent layer segment (e.g., disposed vertically above or beneath) to create a plurality of interface locations that are longitudinally offset from one another along the travel path of the train car. For example, as illustrated in <FIG>, the interface locations <NUM> of the lower track layer <NUM> can be longitudinally offset from the interface locations <NUM> of the base layer <NUM> (e.g., the underlying layer) and from the interface locations <NUM> of the upper track layer <NUM> (e.g., the overlying layer). Offsetting the interface locations in this manner can distribute the weight of the train car <NUM> more evenly than conventional prefabricated arrangements that have discrete rail sections that are laid end-to-end and connected together (e.g., via bolts, welding, or adhesive) at a butt joint (e.g., where the interface locations are vertically aligned), a splice, or a similar single-point rail joint that requires shear braces or other shear reinforcement to connect the rail sections together. In one embodiment, each layer segment of the layers <NUM>, <NUM>, <NUM> can be arranged to overlap an underlying interface location by about one-third of the overall length of the layer segment. For example, for layer segments that are about six feet long, the layer segments can be arranged to overlap an underlying interface location by about two feet.

The base layers <NUM>, the lower track layer <NUM>, and the upper track layer <NUM> are shown to be arranged horizontally to form a horizontal curve (e.g., a left/right turn) of the horizontal track portion <NUM>. It is to be appreciated that a layer that is described as being arranged horizontally can be understood to mean that the width (e.g., W1, W2, W3) of the layer can extend substantially parallel to the running surface of the roller coaster defined by the lower and upper track layers <NUM>, <NUM>.

It is to be appreciated that although the right rail <NUM> is shown to have six base layers, any quantity of base layers can be used (e.g., one, two, three, four, five or more than six base layers). It is also to be appreciated that although the right rail <NUM> is shown to have two track layers, any quantity of track layers can be used (e.g., one or more than two track layers).

The left rail <NUM> illustrated in <FIG> can be understood to be similar to the right rail <NUM> described above, but instead configured for a left side of the horizontal track portion <NUM>. For example, as illustrated in <FIG>, the left rail <NUM> can include a plurality of base layers <NUM>, a lower track layer <NUM>, and an upper track layer <NUM>. Each of the layers <NUM>, <NUM>, <NUM> can be formed by respective pluralities of layer segments. Each of the layer segments can include an interior surface that is configured to follow the contour of the horizontal track portion <NUM> defined by the right rail <NUM>. Alternately, the track could be defined by a single rail, with track layers that extend beyond the base layers on both sides in order to accommodate a ride vehicle.

Each layer segment of the layers <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> can be fabricated from an individual piece of dimensional finished lumber (e.g., common pre-milled wood stock provided from a mill in standard lengths, widths, and thicknesses) in a factory or other controlled environment prior to delivery and assembly of the track at a destination site (e.g., an amusement park). Each layer segment can be fabricated by cutting a precise shape out of the dimensional finished lumber that can include at least some of the features described above (e.g., an interior surface, holes, and/or interface features). The shape of the layer segment can form a predefined two-dimensional curve of the track. The layer segments can be cut from the dimensional finished lumber using a CNC machine or other automated precision cutting device, such as a laser cutter, a plasma cutter, or a water jet cutter.

Before each layer segment is prefabricated, a computer model of the horizontal track portion <NUM> can first be generated. The computer model can facilitate mapping of the shape and position of each layer segment that is to be used to construct the horizontal track portion <NUM>. Each layer segment can then be cut using the parameters defined by the computer generated model. The horizontal track portion <NUM> can then be assembled from the precut layer segments. Since the shape and position of each layer segment is predefined by the computer model, the assembly of the horizontal track portion <NUM> can be more predictable than conventional construction methods. As a result, the construction of the horizontal track portion <NUM> can require less on-site manipulation than conventional arrangements which can reduce cost and inefficiencies and improve the overall quality of the horizontal track portion <NUM> as compared to these conventional construction methods.

For example, conventionally, wood roller coaster track is made by layering uncut structural lumber, bending that lumber in the weak direction, and then cutting a curved vehicle running surface in the strong direction by hand with power tools. Typically, it is necessary to stack multiple layers together before cutting the vehicle running surface in order to form the correct curve in the bent direction, as well as to match the path of the cut precisely between layers after that bending has occurred. This typically requires a highly skilled workforce (which can be scarce and expensive) and time-consuming repeated iterations to cut the board ends to ensure that each board is installed at the appropriate angle to maximize material usage while avoiding discontinuity or gaps between the boards. In addition, once the track has been initially constructed, the path and curve profile still needs to be fine-tuned by repeatedly detaching, repositioning, and reattaching the track to an underlying substructure until the path and curve profile is within an acceptable tolerance of the original engineering plans for the track.

By prefabricating the layer segments from a computer generated model and with an automated precision cutting device prior to assembly, the horizontal track portion <NUM> can be assembled at a destination site by simply assembling the layer segments in the order defined by the computer model. In some instances, the holes in each of the layer segments can be predrilled to ensure proper alignment among adjacent layer segments. As a result, the horizontal track portion can be more easily and more cost effectively assembled than conventional tracks and can provide a sturdier and more durable track without the need for a highly skilled labor force. In addition, since the proper curve shape of each layer segment is translated directly from the computer model to the other automated precision cutting device that is cutting the layer segments, the overall accuracy of the curve between adjacent layer segments can be maintained due to the consistent and repeatable cuts that are achievable with the automated precision cutting device.

It is to be appreciated that the layer segments can be modeled and prefabricated in such a way to allow for the interface locations of laterally (e.g., vertically) adjacent layers to be offset such that each layer segment overlaps the laterally adjacent layer segments (e.g., the layer segments that are disposed above and/or beneath a given layer segment). As such, the horizontal track portion <NUM> can be constructed without the use of a single-plane vertical joint that extends entirely across the track rail (e.g., a butt joint) as is oftentimes provided on conventional prefabricated track arrangements. It is also to be appreciated that the layer segments can be modeled and prefabricated to facilitate alignment of the interior surfaces (e.g., <NUM>, <NUM>) such that they create a smoother, more accurate curve than conventional wood track which has interior surfaces that are manually cut on site.

As described above, each prefabricated layer segment can be assigned a particular location on the horizontal track portion <NUM> based on the computer model of the horizontal track portion <NUM>. Each of the layer segments can be indexed and marked with indicia (e.g., <NUM>, <NUM>, <NUM>) that indicate the location of each track piece relative to the other track pieces. During installation, the installer can install the layer segments in a prescribed order provided by the manufacturer (e.g., based upon the computer model). As such, the installation can be more organized, efficient, cost effective and environmentally friendly than conventional arrangements that requires each board to be fabricated on site by hand with repeated cuts and/or manual adjustments.

One example of a method of designing, fabricating, and installing the horizontal track portion <NUM> will now be discussed. First, the overall layout of the horizontal track portion <NUM> is selected and designed using computer generated modeling. As part of the design process, the shape and features for each layer segment of the horizontal track portion <NUM> can be mapped out. Each of the layer segments can then be cut from dimensional finished lumber in a factory or other controlled environment using the mapping generated during the design process. Each layer segment can also be provided with indicia or other markings that indicate how the layer segment is to be installed relative to the other layer segments and/or ledgers (e.g., <NUM>) of the horizontal track portion <NUM>. Once the layer segments are fabricated, they can be delivered to the destination site for assembly. The horizontal track portion <NUM> can then be assembled by first constructing the bottommost base layer (e.g., <NUM>), then constructing the remaining base layers sequentially on top of the bottom most base layer, and then constructing the lower and upper track layers sequentially on top of the base layers. The layers can therefore be stacked along an assembly axis A1 (<FIG>) into an arrangement of layers that are oriented horizontally and are laterally adjacent to each other. The assembly axis A1 can be substantially perpendicular to the travel path of the train car <NUM> (e.g., in the x-direction shown in <FIG>) and to the widths (W1, W2, W3) of the layers and substantially parallel to the thicknesses (T1, T2, T3) of those layers. The interior surfaces (e.g., <NUM>, <NUM>, <NUM>) of each layer segment of the base layers <NUM> can define the overall path of the train car <NUM>. The running plates (not shown) can be assembled onto the top, sides, and bottom of the interior portions <NUM>, <NUM> of the lower and upper track layers <NUM>, <NUM>.

Although the fabrication and construction of the horizontal track portion <NUM> of track is described, it is to be appreciated that a vertical track portion (e.g., <NUM>) or some combination of vertical and horizontal track portions of track (e.g., a three-dimensional curve), as described in further detail below, can be constructed according to the principles and methods described above. It is also to be appreciated that although dimensional lumber is described above, the layer segments can be fabricated from any of a variety of suitable alternative substrates that can be cut with an automated precision cutting device, such as, for example, composite lumber or other wood stock (in dimensional shapes or sheet), thermoplastics or metals (e.g., steel).

Referring now to <FIG> and <FIG>, a vertical track portion <NUM> of a roller coaster track that defines a vertical curve (e.g., a hill) is generally depicted. Certain features of the vertical track portion <NUM> can be similar to, or the same in many respects as, the horizontal track portion <NUM> of the roller coaster track illustrated in <FIG>. For example, the vertical track portion <NUM> can include a right rail <NUM> that includes a plurality of base layers <NUM> (<FIG>), a lower track layer <NUM> (<FIG>), and an upper track layer <NUM> (<FIG>). The lower track layer <NUM> and the upper track layer <NUM> can be positioned over the base layers <NUM> and arranged horizontally. The lower track layer <NUM> and the upper track layer <NUM> can be formed of discrete layers (not shown). The lower track layer <NUM> and the upper track layer <NUM> can each include respective interior portions (not shown) that overhang the base layers <NUM>. Running plates (not shown) can be provided on the top, sides, and bottom of the interior portions to provide a running surface (e.g., a contact surface) for the wheels of the train cars. A plurality of ledgers <NUM> and cross ties <NUM> can underlie the base layers <NUM> to provide underlying support to the vertical track portion <NUM>.

The base layers <NUM> of the vertical track portion <NUM>, however, can be arranged vertically (instead of horizontally) in order to withstand the increased vertical forces (e.g., in the z-direction) associated with the train car traversing this section of track (e.g., a hill or valley), as will be described in further detail below. With the exception of being arranged vertically, the base layers <NUM> can be similar to, or the same as in many respects as, the base layers <NUM> illustrated in <FIG>. For example, as illustrated in <FIG>, each of the base layers <NUM> can include a plurality of base layer segments 128a that each have a first end 130a and a second end 132a and a plurality of base layer segments 128b that each have a first end 130b and a second end 132b. The base layer segments 128a, 128b can be laid end-to-end in an alternating fashion and in a contacting relationship with each other such that the first end 130a of each base layer segment 128a is in contact with the second end 132b of an adjacent base layer segment 128b at an interface location 134a, and the second end 132a of each base layer segment 128a is in contact with the first end 130b of an adjacent base layer segment 128b at an interface location 134b. In one embodiment, as illustrated in <FIG>, the first ends 130a, 130b and the second ends 132a, 132b can be notched such that when the base layer segments 128a, 128b are laid end-to-end in an alternating fashion and in a contacting relationship with each other, the first end 130a and the second end 132b interlock and the second end 132a and the first end 130b interlock to resist relative (e.g., vertical) movement between the base layer segments 128a, 128b. It is to be appreciated that the base layer segments 128a, 128b can have any of a variety of suitable alternative interlocking features that facilitate lateral coupling and/or visual indication of the relative physical positioning between the base layer segments 128a, 128b.

Each base layer <NUM> can be arranged such that the interface locations (e.g., 134a, 134b) between each pair of layer segments are longitudinally offset (e.g., along the travel path of the train car) from the interface locations of laterally (e.g., horizontally) adjacent layers (e.g., in a direction perpendicular to the travel path of the train car). Each layer segment can accordingly overlap (e.g., extend beyond) the interface locations of the adjacent layers to distribute the weight of the train cars more evenly than would be provided with a conventional butt joint (e.g., where the interface locations of laterally adjacent layers are aligned in a plane that is perpendicular to the travel path of the train car).

Referring again to <FIG> and <FIG>, each base layer segment 128a, 128b can have a thickness T11 (<FIG>) and a width W11 (<FIG>) that is greater than the thickness T11. Each of the base layer segments 128a, 128b can cooperate to define an upper surface <NUM> (<FIG>) that extends along the thicknesses T11 of base layers <NUM>. The lower track layer <NUM> and the upper track layer <NUM> can be routed along and secured to the base layers <NUM> such that the lower track layer <NUM> rests on the upper surface <NUM>. It is to be appreciated that a base layer (e.g., <NUM>) of the vertical track portion <NUM> that is described as being arranged vertically can be understood to mean that the thickness (e.g., T11) of the base layer <NUM> can extend substantially parallel to the running surface of the roller coaster defined by the lower and upper track layers <NUM>, <NUM>.

Referring again to <FIG>, each of the base layer segments 128a, 128b can define a plurality of first vertical holes <NUM>. Dowels (not shown) or other fasteners can be provided through the first vertical holes <NUM> and into corresponding holes in the immediately adjacent base layer <NUM> to couple the base layers <NUM> together. Each of the base layer segments 128a can have a length L1 and each of the base layer segments 128b can have a length L2 that is shorter than the length L1 of the base layer segments 128a. In one embodiment, the length L1 of the base layer segments 128a can be selected to be long enough to span at least two of the ledgers <NUM> such that the weight of the train cars is distributed among the cross ties <NUM>.

Each of the base layers <NUM> can include shoulder features <NUM> that extend along the width of the right rail <NUM> and are configured to rest upon each of the ledgers <NUM>. Each of the shoulder features <NUM> can be shaped to have a lower surface that corresponds with the shape of an upper surface of the ledgers <NUM> to distribute the weight of the right rail <NUM> and/or the train cars more evenly upon the ledgers <NUM>. The shoulder features <NUM> can also serve as alignment points for the base layers <NUM> relative to the ledgers <NUM> during assembly of the right rail <NUM>.

Still referring to <FIG>, each of the base layers <NUM> can comprise distal base layer segments 128c that each define a stair stepped profile that allows for the right rail <NUM> to be easily integrated into a horizontal track arrangement when retrofitting the right rail <NUM> into an existing horizontal track portion of a track <NUM>. It is to be appreciated that for new construction, the distal base layer segments 128c might not be included as part of the overall track design.

One example method of designing, fabricating, and installing the vertical track portion <NUM> will now be described. First, the overall layout of the vertical track portion <NUM> is selected and designed using computer generated modeling. As part of the design process, the shape and features for each layer segment (e.g., 128a, 128b, 128c) of the vertical track portion <NUM> can be mapped out to define a vertical shape for the vertical track portion <NUM> that contributes to the vertical component of the travel path for the train car. Each of the layer segments can then be prefabricated (as described above) and delivered to the destination site for assembly. The vertical track portion <NUM> can then be assembled by first assembling each of the base layers (e.g., <NUM>) from the layer segments. Each of the base layers can be oriented vertically such that the thickness (e.g., T11) each base layer <NUM> extends along the width of the lower and upper track layers <NUM>, <NUM>. Each of the base layers can be stacked together along an assembly axis (e.g., A2 in <FIG>) that is substantially perpendicular to the travel path of the train car <NUM> and the width W11 of the base layers <NUM>. Once the base layers <NUM> are assembled, the interior surfaces of each layer segment of the base layers <NUM> can define the vertical component of the travel path of the train car.

Each base layer <NUM> can be arranged such that an interface location (e.g., 134a, 134b) between each pair of layer segments (e.g., 128a, 128b, 128c) for a given base layer is longitudinally offset (e.g., along the travel path of the train car) from the interface locations of the laterally (e.g., horizontally) adjacent layers (e.g., in a direction that is perpendicular to the travel path of the train car). Each base layer is accordingly positioned relative to the other laterally adjacent layers such that each layer segment overlaps (e.g., extends beyond) the layer segments of the laterally adjacent layers to create a plurality of layer segment interfaces that are longitudinally offset from one another (e.g., along the travel path of the train car <NUM>).

It is to be appreciated that each of the layer segments can be assembled on site to form the vertical track portion <NUM> in a layer-by-layer arrangement having the overlapping features described above which can distribute the weight of the train cars more evenly than conventional prefabricated track arrangements. For example, conventional prefabricated arrangements are typically formed of discrete rail sections (e.g., formed of wood or steel) and are prefabricated with planar ends (e.g., each rail section having a singular end surface that is disposed in a plane) and are laid end-to-end in an abutting relationship (e.g., at a butt joint, a splice, or a similar single-point rail joint. Each rail section is connected to an adjacent rail section with shear braces that connect the rail sections together and which can be susceptible to significant flexing, deformation, and even failure (e.g., in the z-direction shown in <FIG>) when a train car traverses the rail sections. By overlapping the interface locations of the layer segments, the base layers can be attached together (e.g., with bolts, adhesives, and/or dowels) without use of shear braces or other shear attachment arrangements that are otherwise used in conventional prefabricated arrangements.

It is to be appreciated that a left rail <NUM> of the vertical track portion <NUM> can be formed similarly as the right rail <NUM> described above, but configured to be provided on the left side of the vertical track portion <NUM>. It is also to be appreciated that the layer segments (e.g., 128a, 128b, 128c) of the right and left rails of the vertical track portion <NUM> can be fabricated in a similar manner as described above with respect to the horizontal track portion <NUM> in <FIG>. Alternately, the track could be defined by a single rail (e.g., a monorail), with track layers that extend beyond the base layers on both sides in order to accommodate a ride vehicle.

It is to be appreciated that by orienting the base layers (e.g., <NUM>) of the vertical track portion <NUM> vertically and in an offset arrangement as described above, the weight of the train cars of the roller coaster can be borne by the width of the base layers <NUM> and thus the base layers <NUM> can be less susceptible to vertical flexing and deformation when traversed by a train car than base layers that are horizontally oriented (e.g., layers <NUM>, <NUM>, <NUM> described above). As such, vertically oriented base layers (e.g., <NUM>) can be particularly suited for portions of the track that experience increased vertical forces (e.g., in the z-direction shown in <FIG>), such as hills and valleys, for example.

Referring now to <FIG>, one example of a method for manufacturing and installing the vertical track portion <NUM> is illustrated and will now be discussed. First, the overall layout of the right and left rails <NUM>, <NUM> of the vertical track portion <NUM> is selected and designed using computer generated modeling. As part of the design process, the shape and features for each layer segment (e.g., 128a, 128b, 128c) of the right and left rails <NUM>, <NUM> can be mapped out to define a vertical shape for the vertical track portion <NUM> of the track and prefabricated (as described above). As illustrated in <FIG>, the right rail <NUM> can then be assembled into discrete first and second rail sections 112a, 112b that are separate from each other and the left rail <NUM> can be assembled into discrete first and second rail sections 114a, 114b that are separate from each other.

Each of the discrete first and second rail sections 112a, 112b can comprise a plurality of base layer segments 128a, 128b, 128c that overlap each other to form a plurality of base layers <NUM> in a similar manner as described above with respect to <FIG> and <FIG>. Each of the base layer segments 128a, 128b, 128c can be secured together with fasteners (e.g., nuts and bolts) that extend substantially horizontally through the base layer segments 128a, 128b, 128c (e.g., though horizontal holes that are aligned through the base layer segments 128a, 128b, 128c). It is to be appreciated that the discrete first and second rail sections 114a, 114b of the left rail <NUM> can be assembled in a similar manner. A plurality of vertical holes <NUM> that are substantially perpendicular to the horizontal holes can then be drilled through the discrete first and second rail sections 112a, 112b, 114a, 114b.

As illustrated in <FIG> and <FIG>, a plurality of cross ties 153a can be installed beneath the discrete first rail sections 112a, 114a and can extend laterally between the discrete first rail sections 112a, 114a. Each of the cross ties 153a can be aligned with respective pairs of the vertical holes <NUM> in the discrete first rail sections 112a, 114a, as illustrated in <FIG>. As illustrated in <FIG>, each of the cross ties 153a can be attached to the discrete first rail sections 112a, 114a with bolts <NUM> that are provided through the vertical holes <NUM> of the discrete first rail sections 112a, 114a and through the cross tie 153a. It is to be appreciated that a plurality of cross ties 153b can be installed beneath the discrete second rail sections 112b, 114b in a similar manner.

Referring now to <FIG>, a pair of walk boards 162a can be attached to the cross ties 153a on opposite sides of the discrete first rail sections 112a, 114a. A pair of center boards 163a can be attached to the cross ties 153a between the discrete first rail sections 112a, 114a. The center boards 163a can be spaced from each other by a distance (e.g., by about <NUM> inches or less) that can prevent an installer from falling between the discrete first rail sections 112a, 114a. It is to be appreciated that a pair of walk boards 162b and center boards 163b can be installed among the discrete second rail sections 112b, 114b in a similar manner.

The discrete first rail sections 112a, 114a, the plurality of cross ties 153a, the pair of walk boards 162a, and the pair of center boards 163a (collectively the first vertical rail section 110a) and the discrete second rail sections 112b, 114b, the plurality of cross ties 153b, the pair of walk boards 162b, and the pair of center boards 163b (collectively the second vertical rail section 110b) can be prefabricated in a controlled environment at a manufacturing facility that is remote from the amusement park. Assembling the first and second vertical rail sections 110a, 110b first in a manufacturing facility can allow the first and second vertical rail sections 110a, 110b to be manufactured more precisely and with tighter tolerances than is currently possible with conventional stick building methods that occur at the amusement park site.

Referring now to <FIG>, once the first vertical rail section 110a has been assembled at the manufacturing facility, it can be loaded onto a tractor-trailer <NUM> via a crane <NUM> and delivered to the amusement park site with the tractor-trailer <NUM>. The first vertical rail section 110a can then be unloaded from the tractor-trailer <NUM> via a crane <NUM> at the amusement park. The crane <NUM> can lift the first vertical rail section 110a into place onto a substructure <NUM> that has already been constructed at the amusement park. The second vertical rail section 110a can be delivered to the amusement park site in a similar manner such that the first and second vertical rail sections 110a, 110b can be assembled similar to the manner in which conventional steel roller coasters are assembled. To this end, each of the first and second vertical rail sections 110a, 110b can be designed and engineered to be installed at a specific location along the track which can alleviate the need to repeatedly survey and adjust the track to achieve a desired curve profile as is common with conventional stick building methods that occur at the amusement park site.

Referring now to <FIG>, the first and second vertical rail sections 110a, 110b are shown to be placed onto the substructure <NUM> (e.g., by the crane <NUM> of <FIG>). The substructure <NUM> can include a plurality of ledgers <NUM> that extend laterally (relative to the travel path) and are configured to support the first and second vertical rail sections 110a, 110b. The ledgers <NUM> can be initially be positioned along the substructure <NUM> (e.g., during assembly of the substructure <NUM> and prior to placement of the first and second vertical rail sections 110a, 110b) to roughly match the overall curve profile defined by the first and second vertical rail sections 110a, 110b. When the first and second vertical rail sections 110a, 110b are placed on the substructure <NUM>, any of the ledgers <NUM> that do not provide adequate underlying support to the first and second vertical rail sections 110a, 110b can be repositioned and/or shimmed until each of the ledgers <NUM> adequately support the first and second vertical rail sections 110a, 110b. Since the first and second vertical rail sections 110a, 110b are prefabricated prior to delivery to the amusement park, the curve profile of the track is effectively set by the first and second vertical rail sections 110a, 110b and the substructure <NUM> is adjusted to conform to the first and second vertical rail sections 110a, 110b which can alleviate the need to adjust the track and the substructure simultaneously, as is common in conventional arrangements, which can be time consuming, expensive and imprecise. It is to be appreciated that the first and second vertical rail sections 110a, 110b can be prefabricated with any of a variety of design features that can aid in aligning and supporting the first and second vertical rail sections 110a, 110b on the substructure <NUM> (e.g., shoulder features <NUM> illustrated in <FIG>).

Referring now to <FIG>, the completion of the assembly of the right rail <NUM> will now be discussed. A first rail splice <NUM> and a second rail splice <NUM> can be provided. Each of the first and second rail splices <NUM>, <NUM> can be formed of base layer segments 128a, 128b in a similar manner as described above with respect to the discrete first and second right rail sections 112a, 112b. The first and second rail splices <NUM>, <NUM> can be prefabricated at the manufacturing facility and delivered to the amusement park site together with the first and second vertical rail sections 110a, 110b. The first and second rail splices <NUM>, <NUM> can be sandwiched against and can mate with proximal ends 113a, 113b of the discrete first and second rail sections 112a, 112b. The first and second rail splices <NUM>, <NUM> can be attached to the proximal ends 113a, 113b of the discrete right rail sections 112a, 112b with bolts (not shown) such that the discrete first and second rail sections 112a, 112b, and the first and second rail splices <NUM>, <NUM> complete the right rail <NUM> when installed. It is to be appreciated that the left rail <NUM> can be assembled in a similar manner.

Referring now to <FIG>, each of the right and left rails <NUM>, <NUM> can be attached to the ledgers <NUM> with a bracket <NUM>. In one embodiment, the bracket <NUM> can comprise a hurricane tie. Referring now to <FIG>, the lower and upper track layers <NUM>, <NUM> can be installed over the right rail <NUM>. In one embodiment, the center boards 163a, 163b can be used as a jig for the lower and upper track layers <NUM>, <NUM> during installation to create a proper curve for the lower and upper track layers <NUM>, <NUM>. As illustrated in <FIG>, a top running plate <NUM> can be installed over the upper track layer <NUM> and coupled thereto by a bolt (not shown). A bottom running plate <NUM> can be installed under the lower track layer <NUM> and coupled thereto by a bolt (not shown). A side running plate <NUM> can be installed on the lower track layer <NUM> and the upper track layer <NUM> adjacent to the top and bottom running plates <NUM>, <NUM> and coupled thereto by a bolt (not shown). Lower and upper track layers <NUM>, <NUM> and top, bottom, and side running plates <NUM>, <NUM>, <NUM> can be installed over the left rail <NUM> in a similar manner.

By manufacturing the first and second vertical rail sections 110a, 110b first in a manufacturing facility and then delivering the first and second vertical rail sections 110a, 110b to the amusement park site, the vertical track portion <NUM> can be installed more easily and efficiently and without the skilled labor often required for conventional wooden roller coaster tracks that are stick-built on-site (e.g., built entirely at the amusement park). As such, the vertical track portion <NUM> of the roller coaster can be manufactured and installed more efficiently and cost effectively than conventional roller coaster tracks. It is to be appreciated that the method for manufacturing and installing the vertical track portion <NUM> illustrated in <FIG> can also be used to manufacture and install the horizontal track portion <NUM> illustrated in <FIG>.

One example of a method for prefabricating a rail section having a complex, three-dimensional curve (e.g., a rail section with a curve in both the horizontal and vertical directions) will now be discussed. First, a computer model of the three-dimensional curve of the rail section is generated (e.g., using computer-aided design software). The computer model can identify the three-dimensional shapes of the various layer segments (e.g., <NUM>, <NUM>, <NUM>) that are necessary to form the base layer(s) (e.g., <NUM>) and the lower and upper track layers (e.g., <NUM>, <NUM>) for the three-dimensional curve. A planar shape for each of the layer segments can then be extrapolated/rendered from the three-dimensional shaped segments. Planar layer segments can then be cut from dimensional lumber (e.g., via a CNC machine in a factory or other controlled environment) based on the planar shapes extrapolated from the computer model to essentially form a temporary two-dimensional curve. The planar layer segments can then be stacked together on the track without attaching the planar layer segments to the track. The planar layer segments can then be bent into the three-dimensional curve shape (along the weak axis) and then permanently attached to the track (e.g., with bolts).

It is to be appreciated that the bending of the planar layer segments can be achieved through engineered stressing and without requiring the applied stresses that are often associated with conventional methods for forming three-dimensional curves (e.g., the pretensions between the track and underlying structure that cause additional stresses in the track that differ from and at times exceed the design stress). For example, in certain conventional arrangements, the boards that form each layer can be bent using a profiling process in which the boards are manually bent in a vertical direction (sometimes beyond the design curvature) in order to create a continuous curve between ledgers (e.g., <NUM>). In such an example, the boards can be bent by first attaching equipment to the substructure that selectively forces the boards into a desired direction by loading and stressing the boards and/or the structure differently than the loads and stresses that are typically imparted to the layer segments during normal operation of the roller coaster (e.g., during passage of the train car <NUM>). Once the boards are bent into a desired position, they can be secured to the substructure (e.g., with nails) which can introduce an undesirable prestress in the boards, the substructure, and/or the connections therebetween. In other conventional arrangements, the boards might be forcibly attached to a misplaced or imprecise ledger. If the underlying structure is not within tolerance, the track layers can be stressed differently than intended in the design. It is to be appreciated that by modeling the three-dimensional curve first and then cutting planar boards that are performed to create the three-dimensional curve when bent into position, much of these undesired prestresses on roller coaster track and substructure can be avoided which can prolong the useful life of the track.

Referring now to <FIG>, three base layer segments 228a, 228b, 228c are illustrated that cooperate to form part of a three-dimensional curve. As illustrated in <FIG>, each of the base layer segments 228a, 228b, 228c are substantially planar pieces (e.g., two-dimensional) that have been cut from dimensional lumber based upon a three-dimensional computer generated model as described above. When the base layer segments 228a, 228b, 228c are laid flat (e.g., in two-dimensions) and stacked together, as illustrated in <FIG>, the base layer segments 228a, 228b, 228c are not aligned. However, when the base layer segments 228a, 228b, 228c are collectively bent into the proper three-dimensional curve for the rail section, as illustrated in <FIG>, the base layer segments 228a, 228b, 228c can be substantially aligned to and can be attached to the track to form a continuous rail section. In one embodiment, each of the base layer segments 228a, 228b, 228c can comprise a longitudinal line 229a, 229b, 229c disposed thereon that indicates to a user when the base layer segments 228a, 228b, 228c have been bent into the proper shape. For example, when the base layer segments 228a, 228b, 228c are laid flat, as illustrated in <FIG>, the longitudinal line 229c on the base layer segment 228c can be askew to the longitudinal lines 229a, 229b of the base layer segments 228a, 228b. When the base layer segments 228a, 228b, 228c are collectively bent into the proper three-dimensional curve, the longitudinal line 229a, 229b, 229c of the base layer segments 228a, 228b, 228c can align, to indicate to a user that the base layer segments 228a, 228b, 228c are properly aligned and can be attached to the track. It is to be appreciated that the contour of the rail section illustrated in <FIG> has been exaggerated for purposes of illustration. It is also to be appreciated that although longitudinal lines 229a, 229b, 229c are described, any of a variety of alignment features are contemplated that provide a visual indication when the base layer segments 228a, 228b, 228c are aligned properly into a three-dimensional curve, such as, for example, holes, tabs, notches, fasteners or other indicia. It is further to be appreciated that any of a variety of suitable alternative layer segments, such as track layer segments, jig boards, and center boards, can be prefabricated with a complex, three-dimensional curve in a similar manner as described above with respect to the base layer segments 228a, 228b, 228c.

<FIG> illustrates an alternative embodiment of a horizontal track portion <NUM> of a roller coaster track that is similar to, or the same in many respects as the horizontal track portion <NUM> illustrated in <FIG>. For example, the horizontal track portion <NUM> can include a right rail <NUM> and a left rail <NUM>. The right rail <NUM> and the left rail <NUM> can each include a plurality of base layers <NUM>, a lower track layer <NUM>, and an upper track layer <NUM> that are arranged horizontally. However, a pair of vertical guide boards <NUM> can be laterally adjacent to the base layers <NUM>. The vertical guide boards <NUM> can be provided along the outside of the right rail <NUM> and the left rail <NUM> such that the right rail <NUM> and the left rail <NUM> are disposed between the vertical guide boards <NUM>.

The vertical guide boards <NUM> can be configured (e.g., cut) to define a vertical component of the curve of the roller coaster track (e.g., similar to the way the vertical boards <NUM> described above define a vertical curve) for the base layers <NUM>. During assembly of the track, the vertical guide boards <NUM> can be attached first to ledgers (e.g., <NUM> (not shown)) to serve as a jig for attaching the base layers <NUM> thereto. For each of the right and left rails <NUM>, <NUM>, a bottommost layer of the base layers <NUM> (e.g., the base layer <NUM> most proximate to the ledgers) can then be butted against the vertical guide board <NUM> and attached at one end to the ledgers. The bottommost base layer <NUM> can then be bent in the weak direction (e.g., in the up/down direction) against the vertical guide boards <NUM> and attached to the ledgers to impart a vertical component into the curve. The bottommost base layer <NUM> and the vertical guide boards <NUM> associated therewith can cooperate to define a cross-sectional L-shape. The rest of the base layers <NUM>, and the lower and upper track layers <NUM>, <NUM> can then be attached over the bottommost base layer <NUM> in a similar manner. Once the construction of the right and left rails <NUM>, <NUM> is complete, the vertical guide boards <NUM> can be removed. It is to be appreciated that the vertical guide boards can be prefabricated in a similar manner as the base layers <NUM> of the vertical track portion <NUM> described above. It is also to be appreciated that vertical guide boards <NUM> can additionally or alternatively be provided on the inside of the right and left rails <NUM>, <NUM>.

<FIG> illustrates an alternative embodiment of a vertical track portion <NUM> of a roller coaster track that is similar to, or the same in many respects as the vertical track portion <NUM> illustrated in <FIG> and <FIG>. For example, the vertical track portion <NUM> can include a right rail <NUM> and a left rail <NUM>. The right rail <NUM> and the left rail <NUM> can each include a plurality of base layers <NUM>, a lower track layer <NUM>, and an upper track layer <NUM>. The base layers <NUM> can be arranged vertically and the lower and upper tracks <NUM>, <NUM> can overlie the base layers <NUM> and can be arranged horizontally. However, a pair of horizontal guide boards <NUM> can be laterally adjacent to the base layers <NUM>. The horizontal guide boards <NUM> can be provided along the inside outside of the right rail <NUM> and the left rail <NUM> such that horizontal guide boards <NUM> are disposed between the right rail <NUM> and the left rail <NUM>.

The horizontal guide boards <NUM> can be configured (e.g., cut) to define a horizontal component of the curve of the roller coaster track (e.g., similar to the way the horizontal boards <NUM> described above define a horizontal curve) for the base layers <NUM>. During assembly of the track, the horizontal guide boards <NUM> can be attached first to ledgers (e.g., <NUM> (not shown)) to serve as a jig for attaching the base layers <NUM> thereto. For each of the right and left rails <NUM>, <NUM>, an innermost base layer <NUM> (e.g., the base layer <NUM> most proximate to the opposite rail) can then be butted against the horizontal guide boards <NUM> and attached at one end to the ledgers. The innermost base layer <NUM> can then be bent in the weak direction (e.g., in the left/right direction) against the horizontal guide board <NUM> and attached to the ledgers to impart a horizontal component into the curve. The innermost base layer <NUM> and the horizontal guide boards <NUM> associated therewith can cooperate to define a cross-sectional L-shape. The rest of the base layers <NUM> can then be attached to the innermost base layer <NUM> in a similar manner and the lower and upper track layers <NUM>, <NUM> can be attached over the base layers <NUM> after that. In one embodiment, the horizontal guide boards <NUM> can be removed once the construction of the right and left rails <NUM>, <NUM> is complete. In another embodiment, the horizontal guide boards <NUM> can be left in place and a center board <NUM> (shown in dashed lines) can be installed between the horizontal guide boards <NUM> and can cooperate with the horizontal guide boards <NUM> to prevent an installer from falling between the right and left rails <NUM>, <NUM>. It is to be appreciated that the horizontal guide boards <NUM> can be prefabricated in a similar manner as the base layers <NUM> of the horizontal track portion <NUM> described above. It is also to be appreciated that horizontal guide boards <NUM> can additionally or alternatively be provided on the outside of the right and left rails <NUM>, <NUM>.

Referring now to <FIG>, various alternative track arrangements are illustrated that can be constructed using the principles and method described herein. It is to be appreciated that any variety of suitable alternative layers of a roller coaster track, such as jig boards and center boards, for example, can be prefabricated, constructed/manufactured and assembled according to the principles and methods described herein.

Claim 1:
A method for manufacturing a roller coaster track, the method comprising:
prefabricating a plurality of first layer segments (<NUM>) for the roller coaster track with an automated precision cutting device, wherein each first layer segment of the plurality of first layer segments comprises indicia (<NUM>) configured to identify an assembled position of the first layer segment within the roller coaster track;
prefabricating a plurality of second layer segments for the roller coaster track with the automated precision cutting device;
constructing, based on the indicia, a first layer (<NUM>, <NUM>, <NUM>) of the roller coaster track with the plurality of first layer segments such that each first layer segment of the plurality of first layer segments is in contacting relationship with a longitudinally adjacent first layer segment of the plurality of first layer segments at a first interface location; and
constructing a second layer (<NUM>, <NUM>, <NUM>) of the roller coaster track laterally adjacent to the first layer with the plurality of second layer segments (<NUM>) such that each second layer segment of the plurality of second layer segments is in contacting relationship with a longitudinally adjacent second layer segment of the plurality of second layer segments at a second interface location, wherein each of the first interface locations are longitudinally offset from the second interface locations.