Patent Description:
Roller vehicle tracks, often referred to as roller coasters, have often been made from wood, especially older track. Wood track, even if constructed with laminations, has a lower strength compared to metal, and may be unable to withstand higher stress elements and tighter radiuses that are increasingly in demand by roller vehicle enthusiasts. Moreover, for metal tracks, rust may be a concern, even for painted or galvanized metal track, as a result of welding the track pieces together, which removes the painted or galvanized protective layer adjacent the welded areas, unless special measures are taken. Furthermore, welding may generate fumes that may be hazardous to the welders. Welding, heating and forming processes also may contribute to residual stresses or reductions in allowable design stress that can require the use of more and heavier materials in order to satisfy design requirements and be prone to fatigue cracking necessitating expensive inspection and maintenance procedures while in service.

What is needed is a roller vehicle track and method of manufacturing a roller vehicle track that does not suffer from these infirmities.

<CIT> discloses a method of fabricating an amusement park ride track utilizing stock, planar materials, namely comprising of creating elongated, curved structures from planar materials. A roller coaster track capable of being fabricated from multiple planar pieces without heating or bending.

<CIT> shows a strong, lightweight monorail guideway assembly for carrying a monorail train vehicle in transport having selectively joined load-bearing rails which are structurally reinforceable on site in relation to support columns holding the track in suspension. Variations in stresses placed on the track are accommodated by the track structure while minimizing overall weight and material consumption.

In one embodiment, a rolling vehicle track including a first wall and a second wall each positioned between and connected to a third wall and a fourth wall. The rolling vehicle track further includes a bracket having a first bracket portion, a second bracket portion, a third bracket portion, and a fourth bracket portion, the first bracket portion connected to the third wall, and the fourth bracket portion connected to the first wall. The rolling vehicle track further includes the first wall, the second wall, the third wall, and the fourth wall defining a first quadrilateral chamber. The rolling vehicle track further includes the first bracket portion, the second bracket portion, the third bracket portion, and the first wall defining a second quadrilateral chamber, the first wall, the second wall, the third wall, the fourth wall, and the bracket are interconnected without welding.

In one embodiment of the foregoing embodiments, the rolling vehicle track further includes a first strip connected to the third wall.

In one embodiment of the foregoing embodiments, the rolling vehicle track further includes a second strip connected to the second bracket portion.

In one embodiment of the foregoing embodiments, the rolling vehicle track further includes a third strip connected to the third bracket portion.

In one embodiment of the foregoing embodiments, the rolling vehicle track further includes the first wall and the second wall of the first quadrilateral chamber are nonparallel.

In one embodiment of the foregoing embodiments, the rolling vehicle track further includes the first wall and the second bracket portion of the second quadrilateral chamber are nonparallel.

In one embodiment of the foregoing embodiments, the rolling vehicle track further includes a distance between an end of the first wall and an end of the second wall in close proximity to the third wall is greater than a distance between an end of the first wall and an end of the second wall in close proximity to the fourth wall.

In one embodiment of the foregoing embodiments, the rolling vehicle track further includes a distance between an end of the first wall and an end of the second wall in close proximity of the third wall is less than a distance between an end of the first wall and an end of the second wall in close proximity to the fourth wall.

In one embodiment of the foregoing embodiments, the rolling vehicle track further includes the first wall, the second wall, the third wall, the fourth wall, and the bracket are interconnected with mechanical fasteners.

In one embodiment of the foregoing embodiments, the rolling vehicle track further includes a fourth strip positioned between a second strip and the second bracket portion.

In one embodiment of the foregoing embodiments, the rolling vehicle track further includes a fifth strip positioned between a third strip and the third bracket portion.

In one embodiment of the foregoing embodiments, the rolling vehicle track further includes the first quadrilateral defines a rectangle.

In one embodiment of the foregoing embodiments, the rolling vehicle track further includes the second quadrilateral defines a rectangle.

In one embodiment of the foregoing embodiments, the rolling vehicle track further includes a boot for connecting a wood portion of the rolling vehicle track to a non-wood portion of the rolling vehicle track.

In a further embodiment, the rolling vehicle track includes a first wall and a second wall each positioned between and connected to a third wall and a fourth wall. The rolling vehicle track further includes a bracket having a first bracket portion, a second bracket portion, a third bracket portion, and a fourth bracket portion, the first bracket portion connected to the third wall, and the fourth bracket portion connected to the first wall. The rolling vehicle track further includes the first wall, the second wall, the third wall, and the fourth wall defining a first quadrilateral chamber. The rolling vehicle track further includes the first bracket portion, the second bracket portion, the third bracket portion, and the first wall defining a second quadrilateral chamber. The rolling vehicle track further includes a first strip connected to the third wall, a second strip connected to the second bracket portion, and a third strip connected to the third bracket portion. The rolling vehicle track further includes the first wall, the second wall, the third wall, the fourth wall, the bracket, the first strip, the second strip, and the third strip are interconnected without welding.

In a further embodiment of the foregoing embodiments, the rolling vehicle track further includes the first wall and the second wall of the first quadrilateral chamber are nonparallel.

In a further embodiment of the foregoing embodiments, the rolling vehicle track further includes the first wall and the second bracket portion of the second quadrilateral chamber are nonparallel.

In a further embodiment of the foregoing embodiments, the rolling vehicle track further includes a distance between an end of the first wall and an end of the second wall in close proximity to the third wall is greater than a distance between an end of the first wall and an end of the second wall in close proximity to the fourth wall.

In a further embodiment of the foregoing embodiments, the rolling vehicle track further includes a distance between an end of the first wall and an end of the second wall in close proximity of the third wall is less than a distance between an end of the first wall and an end of the second wall in close proximity to the fourth wall.

In a further embodiment of the foregoing embodiments, the rolling vehicle track further includes the first quadrilateral defines a rectangle.

In a further embodiment of the foregoing embodiments, the rolling vehicle track further includes the second quadrilateral defines a rectangle.

In a further embodiment of the foregoing embodiments, the rolling vehicle track further includes a boot for connecting a wood portion of the rolling vehicle track to a non-wood portion of the rolling vehicle track.

This invention allows for several innovations over other roller vehicle tracks made from steel or other suitable metal or material. This invention is planned to be substituted for wooden track on a roller vehicle track for partial or complete layouts, but may also be substituted for metal track or other suitable material for partial or complete layouts. This roller vehicle track construction will allow higher stress elements and tighter radiuses that are either difficult or impossible to fabricate with a conventional wood laminate track. This construction does not require welding, and does not utilize welding to permanently secure track members together (i.e., walls, brackets, cross members, strips as will be further discussed in more detail below) instead utilizing other manufacturing techniques and materials not requiring elevated temperatures such as mechanical fasteners, adhesives or other suitable techniques, allowing fabrication without complicated tools or equipment that is required for welded track and increasing the fatigue life of the track. The assembly process allows for all sides of the vehicle track components to be coated with rust prevention paint or galvanizing prior to assembly, without concerns over inadvertent removal of such protective layers during assembly, which would otherwise occur with welding. The open design also permits a greater number of locations to perform internal inspections to confirm vehicle track integrity.

Relative terms such as "lower," "upper," "horizontal," "vertical," "above," "below," "up," "down," "top" and "bottom" as well as derivative thereof (e.g., "horizontally," "downwardly," "upwardly," etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. Moreover, the features and benefits of the invention are illustrated by reference to the preferred embodiments. Accordingly, the scope of the invention being defined by the claims appended hereto.

<FIG> shows a section of a full roller coaster track <NUM> used to rollably or rotatably carry a roller coaster car <NUM> as is well known. The full roller coaster track <NUM> uses support members <NUM> to interconnect roller coaster tracks <NUM>, <NUM>' or roller coaster track portions which are mirror images of one another relative to a plane <NUM> coincident with a center line <NUM>. As a result of roller coaster tracks <NUM>, <NUM>' being mirror images of one another, for brevity, only roller coaster track <NUM> will be further discussed in <FIG>, corresponding <FIG>, and <FIG>.

<FIG> and associated <FIG> show sequential steps for assembling an exemplary rolling vehicle track, often referred to as a roller coaster track <NUM> (<FIG>). <FIG> is an end view of roller coaster track <NUM>, with <FIG> being alternate embodiments thereof. The components of the track are secured together by mechanical fasteners such as rivets, nuts and bolts or other suitable components. Spatial or relative positioning terminology used for assembling roller coaster track <NUM> is based from the orientation of an end view of an end <NUM> (<FIG>) looking toward roller coaster track <NUM> as shown in <FIG>. As will be described in further detail below, the track components are cut from sheet stock using a surface method based on the geometry of the roller coaster track centerline <NUM> (<FIG>), which is the path the ride follows. The track, including curved portions such as those that turn, twist or otherwise curve in three-dimensions, may be designed on a computer using any appropriate computer-aided-design program which can also calculate how components which exist in three-dimensional space can be translated to <NUM>-D components for cutting from sheet stock, which may, for example, have a nominal thickness ranging from <NUM>,<NUM> (<NUM> inches) up to <NUM>,<NUM> (<NUM> inches).

As shown in <FIG>, a wall <NUM>, sometimes referred to as a flange or a bottom flange is placed or positioned on a fixture <NUM>. In one embodiment, fixture <NUM> may include features or components (not shown) utilized for temporarily positioning or for securing wall <NUM> in three-dimensional space, acting as both a jig and a structural support base for the track. Along with temporary fixtures (not shown) the developable surface of the walls of the track components, once assembled, will create the three-dimensional roller coaster track. Mechanical fasteners (not shown) secure fixture <NUM> to wall <NUM> (and other track components, as applicable or required). Optionally, fixture <NUM> may be secured to wall <NUM> or other track components by temporary welding, adhesive, or other assembly technique, if desired.

Once wall <NUM> has been positioned or placed on fixture <NUM>, as shown in <FIG> and <FIG>, a wall <NUM> having a plurality of opposed tabs <NUM>, <NUM> is installed or secured to wall <NUM>. More specifically, as shown in <FIG>, tabs <NUM>, which extend from wall <NUM>, are secured to wall <NUM> such as by mechanical fasteners <NUM>. Once tabs <NUM> are secured to wall <NUM>, as shown in <FIG> and <FIG>, a plurality of cross braces <NUM> each having opposed flanges <NUM>, <NUM> are installed or secured to wall <NUM> as needed. More specifically, flanges <NUM>, which extend from cross braces <NUM>, are secured to wall <NUM> such as by mechanical fasteners <NUM>. Once flanges <NUM> are installed or secured to wall <NUM>, as shown in <FIG> and <FIG>, a wall <NUM> having a plurality of opposed tabs <NUM>, <NUM> is installed or secured to wall <NUM> and cross braces <NUM>. More specifically, as shown in <FIG> and <FIG>, tabs <NUM>, which extend from wall <NUM>, are secured to wall <NUM> such as by mechanical fasteners <NUM>, and flanges <NUM> (<FIG>) opposite flanges <NUM> (<FIG>) of cross braces <NUM> (<FIG>) are secured to wall <NUM> such as by mechanical fasteners <NUM>.

Once wall <NUM> has been installed or secured to fixture <NUM> and cross braces <NUM>, as shown in <FIG> and <FIG>, a wall <NUM>, sometimes referred to as a top flange or flange, is installed or secured to walls <NUM>, <NUM>. More specifically, wall <NUM> is secured to tabs <NUM> of wall <NUM> and tabs <NUM> of wall <NUM> such as by mechanical fasteners <NUM>. As a result, as shown in <FIG>, walls <NUM>, <NUM>, walls <NUM>, <NUM>, and the outside bend radii transitioning between walls <NUM>, <NUM> and their respective tabs <NUM>, <NUM> and <NUM>, <NUM> define a chamber or a closed geometry <NUM> such as a quadrilateral. As further shown in <FIG>, for closed geometry <NUM>, walls <NUM>, <NUM> are parallel to one another, and walls <NUM>, <NUM> are parallel to one another, with walls <NUM>, <NUM> and walls <NUM>, <NUM> being perpendicular to one another, defining a rectangle. However, walls <NUM>, <NUM> may not be perpendicular to walls <NUM>, <NUM>, or stated another way, walls <NUM>, <NUM> may be nonparallel to one another, in order to allow optimal distribution of loads. For example, in one embodiment, as shown in <FIG>, for a chamber or closed quadrilateral geometry <NUM>, the ends of walls <NUM>, <NUM> in close proximity to wall <NUM> are separated by a distance <NUM> which is greater than a distance <NUM> separating the ends of walls <NUM>, <NUM> in close proximity to wall <NUM>, resulting in closed geometry <NUM> defining a trapezoid. That is, walls <NUM>, <NUM> are nonparallel, with the angle subtended between wall <NUM> and flange <NUM> forming part of closed quadrilateral geometry <NUM> being less than <NUM> degrees. In one embodiment, as shown in <FIG>, for a chamber or a closed quadrilateral geometry <NUM>, the ends of walls <NUM>, <NUM> in close proximity to wall <NUM> are separated by a distance <NUM> which is less than a distance <NUM> separating the ends of walls <NUM>, <NUM> in close proximity to wall <NUM>, resulting in a chamber or closed quadrilateral geometry <NUM> defining a trapezoid that is inverted compared to the trapezoid of <FIG>. That is, in <FIG>, walls <NUM>, <NUM> are nonparallel, with the angle subtended between wall <NUM> and flange <NUM> forming part of closed quadrilateral geometry <NUM> being greater than <NUM> degrees.

Once wall <NUM> is installed or secured to walls <NUM>, <NUM>, as shown in <FIG> and <FIG>, a plurality of brackets <NUM> is attached or secured to wall <NUM> and wall <NUM>. More specifically, each bracket <NUM> includes multiple bracket portions <NUM>, <NUM>, <NUM>, <NUM> between which corresponding bends <NUM>, <NUM>, <NUM> are formed. As shown, each bracket portion <NUM> is secured to wall <NUM> and each bracket portion <NUM> is secured to wall <NUM>, such as by mechanical fasteners <NUM>, with bracket portions <NUM>, <NUM>, <NUM>, and wall <NUM> (including flange <NUM> of wall <NUM>) defining closed geometry <NUM> or chamber such as a quadrilateral. As further shown in <FIG>, bends <NUM>, <NUM>, <NUM> are <NUM> degrees, as the surfaces of bracket portions <NUM>, <NUM> are perpendicular to one another, the surfaces of bracket portions <NUM>, <NUM> are perpendicular to one another, and the surfaces of bracket portions <NUM>, <NUM> are parallel to one another, and the surfaces of wall <NUM> and flange <NUM> are perpendicular to one another. As a result, the chamber or closed geometry <NUM> defines a rectangle. However, as an extension of previously discussed <FIG> and <FIG>, as is appreciated by one having ordinary skill in the art, the magnitude of bend <NUM> (<FIG>) is greater than <NUM> degrees, and the magnitude of bend <NUM> (<FIG>) is less than <NUM> degrees. As shown, the surfaces defining closed quadrilateral geometry <NUM> (<FIG>), <NUM> (<FIG>), <NUM> (<FIG>) and <NUM> (<FIG>) include corresponding surfaces of bracket portions <NUM>, <NUM> being parallel to one another, and surface of bracket portion <NUM> being perpendicular to each of surfaces of bracket portions <NUM>, <NUM>. However, in each of <FIG>, surface of wall <NUM> is not perpendicular to either of corresponding surfaces of bracket portions <NUM>, <NUM> defining closed quadrilateral geometries <NUM> (<FIG>) and <NUM> (<FIG>), and surface of wall <NUM> is similarly nonparallel to the surface of bracket portion <NUM> defining corresponding closed quadrilateral geometries <NUM> (<FIG>) and <NUM> (<FIG>).

Once bracket <NUM> is attached or secured to wall <NUM> and wall <NUM>, as collectively shown in <FIG>, <FIG>, a strip <NUM>, typically referred to as an upstop or upstop steel, and a strip <NUM>, typically referred to as a guide or guide steel, is attached or secured to bracket <NUM> to provide a surface to be directly engaged by upstop and guide wheels, respectively, of roller coaster car <NUM> (<FIG>). More specifically, as shown in <FIG>, strip <NUM> is secured to bracket portion <NUM> such as by mechanical fasteners <NUM>, and strip <NUM> is secured to bracket portion <NUM> by mechanical fasteners <NUM>. As shown in <FIG>, bracket portion <NUM> is disposed between strip <NUM> and wall <NUM>. Optionally, as shown in <FIG>, a strip <NUM> is disposed or positioned between bracket portion <NUM> and strip <NUM>, and a strip <NUM> is disposed or positioned between bracket portion <NUM> and strip <NUM>. In other embodiments, additional strips may be disposed or positioned between the corresponding bracket portions and their corresponding strips <NUM>, <NUM>. In one embodiment, the thickness of the strips may be the same. In one embodiment, the thicknesses of at least one of the strips may be different than the other strips. In one embodiment, the number of strips between bracket portion <NUM> and strip <NUM> may be the same as the number of strips between bracket portion <NUM> and strip <NUM>. In one embodiment, the number of strips between bracket portion <NUM> and strip <NUM> may be different from the number of strips between bracket portion <NUM> and strip <NUM>. Considerations regarding the number and thickness of the strips include, but are not limited to geometry, such as size of the radii of the bracket portion bends, as the bend radii of thicker material may otherwise result in excessive elastic strain values, resulting in undesirable plastic deformation during fabrication.

Once strips <NUM>, <NUM> are secured to respective bracket portions <NUM>, <NUM>, as collectively shown in <FIG>, <FIG>, a strip <NUM>, typically referred to as a road or road steel, is installed or secured to wall <NUM> and provides a surface to be engaged by running wheels of a roller coaster car.

Once strips <NUM>, <NUM> are secured to respective bracket portions <NUM>, <NUM>, <NUM>, a closed geometry <NUM> is defined by bracket portions <NUM>, <NUM>, <NUM>, wall <NUM>, tabs <NUM>, wall <NUM>, and strips <NUM>, <NUM> and corresponding bend radii transitioning between the bracket portions, as well as the bend radii transitioning between wall <NUM> and tabs <NUM>. As further shown in <FIG>, for closed geometry <NUM>, wall <NUM> and bracket portions <NUM> are parallel to one another. However, the wall <NUM> and bracket portions <NUM> may not be parallel to one another in order to allow optimal distribution of loads. That is, as a result of closed geometries <NUM>, <NUM> as previously discussed for <FIG> and <FIG> sharing a common wall <NUM> and defining quadrilaterals, respective closed geometries <NUM>, <NUM> of <FIG> and <FIG> each also define quadrilaterals.

In one embodiment, instead of opposed walls <NUM>, <NUM>, as shown in <FIG>, the walls, such as for a straight section of track may be consolidated into a single wall, such as shown in <FIG> with a web <NUM> of an I-beam <NUM>, which lacks a closed geometry <NUM> of <FIG>, but includes a closed geometry <NUM> similar to closed geometry <NUM> as shown in <FIG>.

It is to be understood that the sequence of steps may be different than proceeding sequentially in order from <FIG>.

As shown in <FIG>, and more specifically in <FIG>, an exemplary boot <NUM> may be used to connect a wood portion <NUM> of a roller coaster track to a corresponding non-wood portion, such as roller coaster track <NUM> as previously discussed. As shown in <FIG>, wood portion <NUM> includes laminate portions 90A, 90B, 90C, 90D that engage a step plate <NUM> having corresponding risers 94A, 94B, 94C separated by corresponding treads 96A, 96B, 96C. More specifically, the end of laminate portion 90D abuts riser 94A, the end of laminate portion 90C abuts riser 94B, and the end of laminate portion 90B abuts riser 94C. Further, a base <NUM> of boot <NUM> supports and is connected to laminate portion 90D proximate its end by mechanical fasteners <NUM>, tread 96A supports and is connected to laminate portion 90C proximate its end by mechanical fasteners <NUM>, tread 96B supports and is connected to laminate portion 90B proximate its end by mechanical fasteners <NUM>, and tread 96C supports and is connected to laminate portion 90A proximate its end by mechanical fasteners <NUM>. Step plate <NUM> permits operating loads at the spliced end of the wood portion to be distributed over a larger area.

It is to be understood that in other embodiments, the step plate may be adapted to accommodate a different number of laminate portions than four, and that the laminate portions may have different thicknesses.

As shown in <FIG>, and more specifically, <FIG>, boot <NUM> includes an opposed pair of side plates <NUM> secured to step plate <NUM>. As shown, each side plate <NUM> includes an opening <NUM>, permitting inspection of mechanical fasteners and surfaces of step plate <NUM> and base <NUM> subsequent to assembly and for maintenance. Boot <NUM> further includes plates <NUM>, <NUM> secured to a base <NUM> of step plate <NUM> opposite riser 92A that extends in a direction opposite plates <NUM>. As shown in <FIG>, which is a cross section taken along line <NUM>-<NUM> of <FIG>, plate <NUM> is connected to wall <NUM> of roller coaster track <NUM> and plate <NUM> is connected to wall <NUM> of roller coaster track <NUM>.

In the present disclosure, other than where otherwise indicated, all numbers expressing quantities or characteristics are to be understood as being prefaced and modified in all instances by the term "about.

Also, any numerical range recited herein is intended to include all sub-ranges subsumed therein. Any maximum numerical limitation recited herein is intended to include all lower numerical limitations subsumed therein and any minimum numerical limitation recited herein is intended to include all higher numerical limitations subsumed therein.

Claim 1:
A rolling vehicle track comprising:
a first wall (<NUM>) and a second wall (<NUM>) opposite to each other, each of the first wall (<NUM>) and the second wall (<NUM>) positioned between and connected to a third wall (<NUM>) and a fourth wall (<NUM>) that are opposite and parallel to each other;
a bracket (<NUM>) having a first bracket portion (<NUM>), a second bracket portion (<NUM>), a third bracket portion (<NUM>), and a fourth bracket portion (<NUM>), the first bracket portion (<NUM>) connected to the third wall (<NUM>) and parallel to each other, and the fourth bracket portion (<NUM>) connected to the first wall (<NUM>) and parallel to each other;
the first wall (<NUM>), the second wall (<NUM>), the third wall (<NUM>), and the fourth wall (<NUM>) defining a first quadrilateral chamber; and
the first bracket portion (<NUM>), the second bracket portion (<NUM>), the third bracket portion (<NUM>), and the first wall (<NUM>) defining a second quadrilateral chamber;
wherein the first wall (<NUM>), the second wall (<NUM>), the third wall (<NUM>), the fourth wall (<NUM>), and the bracket (<NUM>, <NUM>, <NUM>, <NUM>) are interconnected without welding.