Composite Fittings Plate

This application claims priority to U.S. Provisional Application Ser. No. 63/635,731, entitled “COMPOSITE FITTINGS PLATE,” filed Apr. 18, 2024.

This disclosure generally relates to a composite fittings plate, and more particularly to a composite fittings plate for a railcar, such as a tank car.

Tank cars transport a wide variety of commodities including liquids, gases and other fluids. Tank cars may be equipped with various fittings for loading, unloading, monitoring, pressure relief, etc. Conventional top fittings include: fill holes; eduction pipes; safety vents; valves, such as pressure release valves; gauges; and the like. Bottom fittings may include a bottom outlet valve, as one example. A fittings plate joins the service equipment (i.e., fittings) to the tank car. The fittings plate is typically a circular shaped plate bolted to the tank to which the fittings are mounted. The fittings plate may be in contact with the lading.

The embodiments described herein include a composite fittings plate for a railcar, such as a tank car. Particular embodiments include non-metallic, fiber reinforced polymer (FRP) composite fittings plate for rail tank cars. Some embodiments use 100 percent FRP composite material, and FRP composite composition may be altered based on design intent and service application. The FRP composite fittings plate replaces existing rubber-lined metallic fittings plate or any other fittings plate in a retrofit program and/or new car production.

According to some embodiments, a fittings plate for attaching railcar fittings to a railcar comprises: a plate consisting of a non-metallic, FRP composite material. The plate comprises: a first set of one or more openings for attaching railcar fittings to the plate and a second set of one or more openings for attaching the plate to a railcar.

In particular embodiments, an opening of the first set of one or more openings comprises an integral spool and flange. The integral spool may be bonded to the plate. The integral spool may comprise one or more keyways.

In particular embodiments, the plate, spool and flange are integrally fused as a single piece. In particular embodiments, the integral spool is coupled to the fittings plate via a secondary overlay. In particular embodiments, the integral spool is coupled to the fittings plate via a grout ring.

In particular embodiments, the composition of the FRP material is based on a use of the railcar. In particular embodiments, the composition of the FRP material is based on a corrosiveness associated with an intended lading of the railcar. In particular embodiments, the FRP material is resistant to ultraviolet (UV) rays.

According to some embodiments, railway tank car comprises a tank for transporting a commodity, a nozzle coupled to the tank and providing access to the tank, and a fittings plate coupled to the nozzle for attaching railcar fittings to the railcar. The fittings plate comprises a plate consisting of a non-metallic, FRP composite material. The plate comprises a first set of one or more openings for attaching railcar fittings to the plate and a second set of one or more openings for attaching the plate to the nozzle.

Particular embodiments include one or more of the following advantages. In particular embodiments, the FRP composite fittings plate may last longer than current designs, such as traditional rubber lined metallic fittings plates that last about five years. This amounts to a significant cost reduction throughout the life of the railcar. An additional benefit is an improved customer experience and improved operations due to less down time because of the extended life span.

Another advantage is reduced manufacturing time compared to a traditional rubber coated fittings plate because applying the rubber coating is time and labor intensive.

Particular embodiments may reduce static electricity conductivity due to use of non-conductive material. Some embodiments may include improved heat transfer properties and provide a thermal break.

Some embodiments include improved ergonomics and ease of use during shop or maintenance operations because, for example, an FRP composite fittings plate may be approximately ⅓ the weight of a metallic design.

In some embodiments, exterior or interior coating or painting is not required because of the corrosion and ultra-violet resistance properties of the composite material.

Tank railcars transport a wide variety of commodities. To accommodate this, different types of fittings and number of fittings are used on the railcar, depending on the commodity and customer preferences, to load, unload, and check on the commodity. A fittings plate joins the fittings to the tank car. The fittings plate is typically a circular shaped plate bolted to the tank to which the fittings are mounted.

is a schematic drawing illustrating a side view of a railway tank car having a fittings plate. A customary railway tank carincludes a tank. Tankincludes a generally elongated hollow cylinderenclosed at a first endand a second end.

Tank carmay be used to transport a variety of hazardous and non-hazardous liquid commodities. Fluid commodities may be loaded into tankthrough a variety of tank fittings attached to fittings plate(typical within a protective housing).

A headis coupled to cylinderat first end. Similarly, a headis coupled to cylinderat second end. Cylinderand headsandat least partially define tank.

Fittings plate(located inside protective housing) joins the fittings to tankvia nozzle. Fittings plateis typically a circular shaped plate bolted to tankvia nozzle. Fittings platemay be in contact with the lading.

is a schematic top view of a fittings arrangement, that includes a fittings plate. The illustrated fittings plate is an example of fittings plate, illustrated in.

Fittings plateis illustrated with a particular bolt pattern for attachment to a railcar, such as tank carillustrated in.also illustrates various fittingsjoined to fittings plate. Fittingsmay include fill holes; eduction pipes; safety vents; valves, such as pressure release valves; gauges; and the like.

Fittings platemay be coupled to tankvia nozzlevia a plurality of bolts.

is a schematic cross-section view of a fittings plate. This illustrated example is a cross section of fittings plateillustrated in. Fittings plateincludes one or more openings, which provide a means of commodity transfer and may also facilitate attachment of fittings.

A traditional fittings plate comprises a metallic (e.g., steel) plate. A fittings plate for tank car with corrosive lading may have a rubber lining or other linings applied on the surface of the metallic material. Rubber or other lining is used with reactive or corrosive commodities including, but not limited to, hydrochloric acid and bleach (sodium hypochlorite), so that the lading does not degrade the fittings plate nor does the metallic plate contaminate the lading. The aggressive commodities require the rubber lining application to typically be replaced every five years, which is expensive throughout the life of the railcar. When the rubber lining application is replaced, the fittings plate may also be replaced.

Particular embodiments replace, for example, the rubber-lined fittings plate described above with non-metallic, fiber reinforced polymer (FRP) composite fittings plate for tank cars. Particular embodiments may fit up to the same existing metallic tank nozzle and protective housing. Some embodiments use 100 percent FRP composite material, and FRP composite composition may be altered based on design intent and service application.

Particular embodiments and their advantages are best understood by reference to, wherein like reference numbers indicate like features. Particular embodiments include an FRP composite fittings plate with integral spools and flanges.

illustrate a composite fittings plate where the integral fitting spool and flange are bonded to the composite fittings plate.

is a schematic top view of a composite fittings plate with integral fitting spool and flange, according to particular embodiments. Fittings platecomprises a non-metallic FRP composite material.

Fittings platemay also include a set of one or more openings (not illustrated) for receiving fasteners (e.g., bolts, illustrated in) to attach fittings plateto railcar. In other embodiments, fittings platemay be coupled to railcarvia any other suitable fastener.

is a schematic isometric view of a composite fittings plate with integral fitting spool and flange, according to particular embodiments. The composite fitting plate comprises one or more integral spoolswith flanges. Spooland flangemay be used to join the various fittings (e.g., valves) to fittings plate. Spooland flangemay comprise a non-metallic FRP composite material. Spoolsmay be inserted into fittings plateas part of a composite layering process.

In some embodiments, the spool and flange may comprise the same non-metallic FRP composite material as fittings plate. In other embodiments, the spool and flange may comprise a different non-metallic composite material than fittings plate. For example, fittings platemay comprise a fiber-reinforced composite material and the spool and flange composite may not contain fiber reinforcement.

Although a single spool and flange is illustrated, this is for example purposes, and particular embodiments may include any suitable number and arrangement based on the requirements for a particular tank car type, service type, lading type, and/or customer specific requirements.

In particular embodiments the non-metallic FRP composite material may vary based on requirements for a particular tank car type, service type, lading type, and/or customer specific requirements.

is a schematic cross-section view of a bonded joint between a composite fittings plate and integral fitting spool and flange, according to particular embodiments. As illustrated, fittings platemay comprise a recessed portion into which spoolmay be inserted.

is a schematic cross-section detail view of the bonded joint in. As illustrated, the surfaces between spooland the recessed portion of fittings platemay be bonded via adhesive.

Adhesivemay comprise any suitable adhesive for bonding the two composite materials.

illustrate a composite fittings plate where the integral fitting spool and flange are coupled to the composite fittings plate via a grout ring and overmolding.

is a schematic top view of another composite fittings plate with integral fitting spool and flange, according to particular embodiments.is a schematic isometric view of another composite fittings plate with integral fitting spool and flange, according to particular embodiments.

is a schematic cross-section view of a grout ring between a composite fittings plate and integral fitting spool and flange, according to particular embodiments. The illustrated example includes a composite grout ring integrally attached to the wall of spoolto aid in structural support both in a horizontal and/or vertical loading scenario. The grout ring may be overmolded when infusing the cover plate to create an integral part. The grout ring is used as a composite embedment ring.

is a schematic cross-section detail view of the grout ring in. The detail view illustrates grout ringand gusset plate. In some embodiments, gusset plateprovides structural support for the spool neck.

illustrate a composite fittings plate where the integral fitting spool and flange include a keyway for additional bonding strength.

is a schematic top view of another composite fittings plate with integral fitting spool and flange, according to particular embodiments.is a schematic isometric view of another composite fittings plate with integral fitting spool and flange, according to particular embodiments.is a schematic cross-section view of a keyway lock between a composite fittings plate and integral fitting spool and flange, according to particular embodiments. As illustrated, spoolcomprises a plurality of keywaysaround its circumference. The keyways provide more area for adhesive between spooland fittings plate, facilitating a stronger bond. Some embodiments also include one or more grooves.

is a schematic cross-section detail view of the keyway lock in.is a schematic isometric view of a fitting spool and flange with keyway lock, according to particular embodiments.

illustrate a composite fittings plate where the integral fitting spool and flange are integrally infused with the composite fittings plate as one piece.

is a schematic top view of another composite fittings plate with integral fitting spool and flange, according to particular embodiments.is a schematic isometric view of another composite fittings plate with integral fitting spool and flange, according to particular embodiments.is a schematic section view of an integral composite fittings plate, fitting spool and flange, according to particular embodiments.is a schematic cross-section detail view of the joint in. As illustrated, fittings plate, spooland flangeare all formed as part of the same process and created as a single unit. A particular advantage is improved manufacturing efficiency because of fewer manufacturing steps.

illustrate a composite fittings plate where the integral fitting spool and flange are coupled with the composite fittings plate via a secondary overlay.is a schematic top view of another composite fittings plate with integral fitting spool and flange, according to particular embodiments.is a schematic isometric view of another composite fittings plate with integral fitting spool and flange, according to particular embodiments.is a schematic cross-section view of a secondary overlay joint between a composite fittings plate and integral fitting spool and flange, according to particular embodiments.is a schematic cross-section detail view of the secondary overlay joint in. In the illustrated example, the secondary overlay includes exterior nozzle attachment overlaycoupling the exterior of spoolto the top of fittings plate, interior nozzle tie incoupling the interior of spoolto the underside of fittings plate, and exterior nozzle repadcoupling exterior nozzle attachment overlayto fittings plate.

The FRP composite fittings plate is designed to last longer than current designs in the same service, facilitating a significant reduction in the total cost of ownership per railcar. The FRP composite fittings plate does not require an exterior or interior coating or rubber lining and thus reduces time spent in a maintenance shop throughout the life of the railcar. Reduced time in the maintenance shop also benefits the end customers because their railcar assets are not taken out of service as often, reducing down time. Additional benefits include light weight design as well as strong corrosion resistance.

Particular embodiments may target cars used in hydrochloric acid and bleach (sodium hypochlorite) service, but the embodiments described herein apply to other commodities and provide similar benefits such as reducing the total cost of ownership of the car and extend the useful life of the fittings plate.

The FRP composite fittings plate replaces existing rubber-lined metallic fittings plate or any other fittings plate in a retrofit program and/or new car production.

Modifications, additions, or omissions may be made to the systems and apparatuses disclosed herein without departing from the scope of the invention. The components of the systems and apparatuses may be integrated or separated. Moreover, the operations of the systems and apparatuses may be performed by more, fewer, or other components.