Molded Railroad Composite Cross Tie Unit

Abstract

A molded composite cross tie and two molded, non-metallic composite tie plates are molded into a single molded railroad composite cross tie unit. The molded railroad composite cross tie unit is fully assembled and ready for laying a ballast and accepting railroad track. The molded, non-metallic composite tie plates are molded with a cant onto which railroad track may be laid. The railroad track is secured by either traditional spikes or screws. When secured by screws, holes are molded with thread that is compatible with the screws used to hold the railroad track in place. One molded, non-metallic composite tie plate is molded into each end of the molded composite cross tie. The separation between the two molded, non-metallic composite tie plates is determined by the gauge of the railroad track.

1 . A molded railroad composite cross tie unit comprising a molded composite cross tie and two molded, non-metallic composite tie plates,
 a. wherein the molded composite cross tie and the molded, non-metallic composite tie plates are constructed of a polymer or composite with high tensile strength, high compressive strength, high shear strength, and high resistance to wear and friction;   b. wherein the molded composite cross tie is non-wooden;   c. wherein the molded railroad composite cross tie unit supports rails for a railroad, with the rails comprising an upper surface on which train wheels ride, and a rail base;   d. wherein the molded, non-metallic composite tie plates comprise an outer shoulder, an inner shoulder, and a center section, where the outer shoulder and the inner shoulder are separated by a distance approximately equal to the width of the rail base;   e. wherein the center section of the molded, non-metallic composite tie plate is tapered so that the higher side is nearer the outer side of the molded, non-metallic composite tie plate;   f. wherein the gauge for the molded railroad composite cross tie unit is that required by the railroad company;   g. wherein the molded composite cross tie has two ends;   h. wherein one molded, non-metallic composite tie plate is integrated into each end of the molded composite cross tie;   i. wherein the molded, non-metallic composite tie plates are positioned between about 0.3 and 1.0 inch above the surface of the molded composite cross ties;   j. wherein the molded, non-metallic composite tie plates have an outer end and an inner end, where the inner end is located toward the center of the molded railroad composite cross tie unit and the outer end is located away from the center of the molded railroad composite cross tie unit;   k. wherein for each molded, non-metallic composite tie plate an outer shoulder and an inner shoulder are formed with a separation approximately equal to the width of the rail base; and   l. wherein a plurality of holes is molded into the molded, non-metallic composite tie plates.   
     
     
         2 . The molded railroad composite cross tie unit as in  claim 1  where the molded composite cross ties are between 8-10 feet in length, 8-10 inches in width and about 3 to 10 inches in thickness. 
     
     
         3 . The molded railroad composite cross tie unit as in  claim 1  where the plurality of holes is threaded with diameters and thread designed to accept screws with matching thread configuration. 
     
     
         4 . The molded railroad composite cross tie unit as in  claim 1  where the plurality of holes is not threaded. 
     
     
         5 . The molded railroad composite cross tie unit as in  claim 1  where the composite is a hard, non-metallic material with a tensile strength of a minimum of 100,000 psi. 
     
     
         6 . The molded railroad composite cross tie unit as in  claim 1  where the composite is selected from the group consisting of linen phenolic, nylon, acrylic polymer, polyimide, glass epoxy, polystyrene, and polybenzimidazole.