Truss Plate Side Sheet Assembly

Abstract

A railcar frame includes a first side sheet assembly. The first side sheet assembly includes a first side sheet, a first top chord, and a first side sill. The first side sheet includes one or more truss structures formed within the first side sheet by removing a plurality of portions of the first side sheet according to a pattern. The first side sheet has a length along a first axis and a width along a second axis perpendicular to the first axis. The first top chord is welded to a top portion of the first side sheet along the first axis. The first side sill is welded to a bottom portion of the first side sheet along the first axis opposite the first top chord.

What is claimed is: 
     
         1 . A railcar frame, comprising a first side sheet assembly, wherein the first side sheet assembly comprises:
 a first side sheet, wherein the first side sheet comprises one or more truss structures formed within the first side sheet by removing a plurality of portions of the first side sheet according to a pattern, wherein the first side sheet has a length along a first axis and a width along a second axis perpendicular to the first axis;   a first top chord welded to a top portion of the first side sheet along the first axis; and   a first side sill welded to a bottom portion of the first side sheet along the first axis opposite the first top chord.   
     
     
         2 . The railcar frame of  claim 1 , further comprising a second side sheet assembly, wherein the second side sheet assembly comprises:
 a second side sheet, wherein the second side sheet comprises one or more truss structures formed within the second side sheet by removing a plurality of portions of the second side sheet according to the pattern, wherein the second side sheet has a length along the first axis and a width along the second axis perpendicular to the first axis;   a second top chord welded to a top portion of the first side sheet along the first axis; and   a second side sill welded to a bottom portion of the first side sheet along the first axis opposite the second top chord;   wherein the first side sheet assembly and the second side sheet assembly are coupled together.   
     
     
         3 . The railcar frame of  claim 2 , further comprising two bulkhead end assemblies at opposite ends of the lengths of each of first side sheet assembly and second side sheet assembly, wherein the bulkhead end assemblies are each are welded to each of the first side sheet assembly and the second side sheet assembly. 
     
     
         4 . The railcar frame of  claim 1 , wherein:
 the pattern comprises one or more series of alternating triangular removal portions; and   removing the plurality of portions of the first side sheet according to the pattern forms one or more truss structures with alternating orientations, wherein the alternating orientations are reflections about the second axis of the first side sheet.   
     
     
         5 . The railcar frame of  claim 1 , wherein the pattern is symmetric across the second axis along a midpoint of the first side sheet. 
     
     
         6 . The railcar frame of  claim 1 , wherein the density of removed portions of the first side sheet is not uniform across the first side sheet and the density is based on an anticipated load distribution on the first side sheet assembly. 
     
     
         7 . The railcar frame of  claim 1 , wherein thicknesses of truss structures in the plane of the first and second axes within the first side sheet near one or more anticipated load points are greater than thicknesses of truss structures further away from the one or more anticipated load points, wherein the anticipated load points comprise one or more ends of the first side sheet assembly and a midpoint of the first side sheet assembly. 
     
     
         8 . The railcar frame of  claim 1 , further comprising one or more support structures welded to a portion of the first side sheet assembly, wherein the one or more support structures increases the load capacity of the railcar frame proximate the one or more support structures. 
     
     
         9 . A method, comprising:
 providing a first side sheet having a length along a first axis and a width along a second axis perpendicular to the first axis;   forming one or more truss structures within the first side sheet by removing a plurality of portions of the first side sheet according to a pattern; and   welding the first side sheet to a top chord and a side sill to form a first side sheet assembly of a frame for a railcar.   
     
     
         10 . The method of  claim 9 , further comprising:
 providing a second side sheet having a length along a first axis and a width along a second axis perpendicular to the first axis;   forming one or more truss structures within the second side sheet by removing a plurality of portions of a sheet of metal according to the pattern; and   welding the second side sheet to a second top chord and a second side sill to form a second side sheet assembly of the frame of the railcar;   coupling the first side sheet assembly and the second side sheet assembly together.   
     
     
         11 . The method of  claim 10 , further comprising:
 welding two bulkhead end assemblies at opposite ends of the lengths of each of first side sheet assembly and second side sheet assembly, wherein the bulkhead end assemblies are each are welded to each of the first side sheet assembly and the second side sheet assembly.   
     
     
         12 . The method of  claim 9 , wherein:
 the pattern comprises one or more series of alternating triangular removal portions; and   removing the plurality of portions of the first side sheet according to the pattern forms one or more truss structures with alternating orientations, wherein the alternating orientations are reflections about the second axis of the first side sheet.   
     
     
         13 . The method of  claim 9 , wherein the pattern is symmetric across the second axis along a midpoint of the side sheet. 
     
     
         14 . The method of  claim 9 , wherein the density of removed portions of the first side sheet is not uniform across the first side sheet and the density is based on an anticipated load distribution on the first side sheet assembly. 
     
     
         15 . The method of  claim 9 , wherein thicknesses of truss structures in the plane of the first and second axes within the first side sheet near one or more anticipated load points of the frame is greater than thicknesses of truss structures further away from the one or more anticipated load points, wherein the anticipated load points comprise one or more ends of the first side sheet assembly and a midpoint of the first side sheet assembly. 
     
     
         16 . The method of  claim 9 , further comprising welding one or more support structures to the first side sheet assembly, wherein the one or more support structures increase the load capacity of the first side of the frame proximate the one or more support structures.