Direct Fixation Block Assembly

Abstract

The disclosed solution relates to a block assembly that is configured for direct fixation of railway track elements. The block assembly is configured to be operatively connected to a rail fastener via a plurality of cast-in threaded insert fasteners. The block assembly may be placed on a concrete slab. Further, the block assembly may be partially buried in poured concrete. The block assembly comprises a plurality of indentations that interface with the poured concrete in order to maintain the position of the block assembly. The block assembly comprises a rebar assembly that is contained within the block assembly such that the integrity of the block assembly is increased without introducing problems typically associated with rebar extensions. Further, rebar assembly is configured with an optimized number of bends and welding points in order to increase integrity and reduce manufacturing costs.

1 . A block assembly ( 301 ), comprising:
 a plurality of indentations ( 308 Z) comprising a plurality of edges ( 309 Z), the plurality of indentations ( 308 Z) comprising an indentation ( 308 B), the indentation ( 308 B) comprising a first edge ( 309 BA) and a second edge ( 309 BB), the first edge ( 309 BA) and the second edge ( 309 BB) belonging to the plurality of edges ( 309 Z);   a plurality of cast-in threaded insert fasteners ( 315 Z), the plurality of cast-in threaded fasteners ( 315 Z) being disposed partially within the block assembly ( 301 ); and   a rebar assembly ( 401 ), the rebar assembly ( 401 ) being disposed entirely within the block assembly ( 301 ).   
     
     
         2 . The block assembly ( 301 ) of  claim 1 , the block assembly ( 301 ) further comprising:
 a first dorsal surface ( 329 ) comprising a second dorsal surface ( 331 ) and a plurality of dorsal surfaces ( 330 Z), the second dorsal surface ( 331 ) being straight at a first perimeter ( 341 A) of the block assembly ( 301 ), the plurality of dorsal surfaces ( 330 Z) being curved at the first perimeter ( 341 A) of the block assembly ( 301 ).   
     
     
         3 . The block assembly ( 301 ) of  claim 2 , the block assembly ( 301 ) further comprising:
 a first ventral surface ( 333 ) comprising a second ventral surface ( 335 ) and a plurality of ventral surfaces ( 334 Z), the second ventral surface ( 335 ) intersecting the plurality of indentations ( 308 Z) at a second perimeter ( 341 B) of the block assembly ( 301 ), the plurality of ventral surfaces ( 334 Z) being curved at the second perimeter ( 341 B) of the block assembly ( 301 ).   
     
     
         4 . The block assembly ( 301 ) of  claim 3 , wherein the first dorsal surface ( 329 ) is smaller than the first ventral surface ( 333 ). 
     
     
         5 . The block assembly ( 301 ) of  claim 3 , wherein the first perimeter ( 341 A) is shorter than the second perimeter ( 341 B). 
     
     
         6 . The block assembly ( 301 ) of  claim 3 , wherein the indentation ( 308 B) intersects at the center of a straight segment of the second perimeter ( 341 B). 
     
     
         7 . The block assembly ( 301 ) of  claim 1 , wherein the indentation ( 308 B) is defined by a first distance ( 310 B), a first plurality of distances ( 312 Z), a second distance ( 324 B), a third distance ( 311 B), a first plurality of angles ( 313 Z), and a second plurality of angles ( 314 Z). 
     
     
         8 . The block assembly ( 301 ) of  claim 1 , wherein a cast-in threaded insert fastener ( 315 BA) selected from the plurality of cast-in threaded insert fasteners ( 315 Z) comprises a raised cylindrical portion ( 318 BA), a plurality of holes ( 317 Z), a recessed portion ( 321 BA), a shaft ( 319 BA), and a plurality of bell portions ( 320 Z). 
     
     
         9 . The block assembly ( 301 ) of  claim 8 , wherein the shaft ( 319 BA) is partially disposed within the rebar assembly ( 401 ). 
     
     
         10 . The block assembly ( 301 ) of  claim 8 , wherein the raised cylindrical portion ( 318 BA) is configured to fit inside a hole ( 209 BA) of a fastener base ( 205 ). 
     
     
         11 . The block assembly ( 301 ) of  claim 1 , wherein the rebar assembly ( 401 ) comprises:
 a first rebar segment ( 405 );   a first plurality of rebar segments ( 406 Z);   a second plurality of rebar segments ( 407 Z);   a third plurality of rebar segments ( 409 Z);   a fourth plurality of rebar segments ( 410 Z); and   a fifth plurality of rebar segments ( 411 Z).   
     
     
         12 . The block assembly ( 301 ) of  claim 1 , wherein the block assembly ( 301 ) is configured to being operatively connected to a fastener assembly ( 201 ), the fastener assembly ( 201 ) being configured to operatively connect to a rail ( 102 ). 
     
     
         13 . The block assembly ( 301 ) of  claim 12 , wherein the fastener assembly ( 201 ) comprises a fastener base ( 205 ), the block assembly ( 301 ) comprising a first dorsal surface ( 329 ) configured to support an entire ventral surface the fastener base ( 205 ). 
     
     
         14 . A kit for deployment of a rail, the kit comprising:
 a block assembly ( 301 ), comprising:
 a plurality of indentations ( 308 Z) comprising a plurality of edges ( 309 Z), the plurality of indentations ( 308 Z) comprising an indentation ( 308 B), the indentation ( 308 B) comprising a first edge ( 309 BA) and a second edge ( 309 BB), the first edge ( 309 BA) and the second edge ( 309 BB) belonging to the plurality of edges ( 309 Z); 
 a plurality of cast-in threaded insert fasteners ( 315 Z), the plurality of cast-in threaded fasteners ( 315 Z) being disposed partially within the block assembly ( 301 ); and 
 a rebar assembly ( 401 ), the rebar assembly ( 401 ) being disposed entirely within the block assembly ( 301 ); and 
   a fastener assembly ( 201 ), the fastener assembly ( 201 ) being configured to operatively connect the rail ( 102 ).   
     
     
         15 . The kit of  claim 14 , wherein the indentation ( 308 B) is defined by a first distance ( 310 B), a first plurality of distances ( 312 Z), a second distance ( 324 B), a third distance ( 311 B), a first plurality of angles ( 313 Z), and a second plurality of angles ( 314 Z). 
     
     
         16 . The kit of  claim 14 , wherein a cast-in threaded insert fastener ( 315 BA) selected from the plurality of cast-in threaded insert fasteners ( 315 Z) comprises a raised cylindrical portion ( 318 BA), a plurality of holes ( 317 Z), a recessed portion ( 321 BA), a shaft ( 319 BA), and a plurality of bell portions ( 320 Z). 
     
     
         17 . The kit of  claim 14 , wherein the block assembly ( 301 ) further comprises:
 a first dorsal surface ( 329 ) comprising a second dorsal surface ( 331 ) and a plurality of dorsal surfaces ( 330 Z), the second dorsal surface ( 331 ) being straight at a first perimeter ( 341 A) of the block assembly ( 301 ), the plurality of dorsal surfaces ( 330 Z) being curved at the first perimeter ( 341 A) of the block assembly ( 301 ).   a first ventral surface ( 333 ) comprising a second ventral surface ( 335 ) and a plurality of ventral surfaces ( 334 Z), the second ventral surface ( 335 ) intersecting the plurality of indentations ( 308 Z) at a second perimeter ( 341 B) of the block assembly ( 301 ), the plurality of ventral surfaces ( 334 Z) being curved at the second perimeter ( 341 B) of the block assembly ( 301 ).   
     
     
         18 . The kit of  claim 17 , wherein the fastener assembly ( 201 ) further comprises:
 a fastener base ( 205 ) configured to being disposed on the first dorsal surface ( 329 ), wherein a ventral surface of the fastener base ( 205 ) is entirely in contact with the first dorsal surface ( 329 ).   
     
     
         19 . The kit of  claim 17 , wherein the first dorsal surface ( 329 ) is smaller than the first ventral surface ( 333 ) and the first perimeter ( 341 A) is shorter than the second perimeter ( 341 B). 
     
     
         20 . A method for installing a block assembly ( 301 ) at a concrete slab, the method comprising:
 placing the block assembly ( 301 ) on a surface of the concrete slab, the block assembly ( 301 ) comprising:
 a plurality of indentations ( 308 Z) comprising a plurality of edges ( 309 Z), the plurality of indentations ( 308 Z) comprising an indentation ( 308 B), the indentation ( 308 B) comprising a first edge ( 309 BA) and a second edge ( 309 BB), the first edge ( 309 BA) and the second edge ( 309 BB) belonging to the plurality of edges ( 309 Z); 
 a plurality of cast-in threaded insert fasteners ( 315 Z), the plurality of cast-in threaded fasteners ( 315 Z) being disposed partially within the block assembly ( 301 ); and 
 a rebar assembly ( 401 ), the rebar assembly ( 401 ) being disposed entirely within the block assembly ( 301 ); and 
   pouring, around the block assembly ( 301 ), a layer of concrete, the layer of concrete being in contact with the plurality of indentations ( 308 Z), the plurality of cast-in threaded insert fasteners ( 315 Z) being accessible above the poured layer of concrete.