Composite rail tie apparatus and method

An apparatus capable of operating as a rail tie supporting track of a railroad, the apparatus comprising:

• a shell surface defining a shell and outer envelope thereof and capable of providing protection resisting damage to an interior of the apparatus by weather, including at least one of water and sun;
• a first fill within the envelope, the first fill being selected from an elastomer, another polymer, glass, and wood, remaining a solid at all stages of formation of the apparatus, and capable of resisting structural bending of the apparatus in response to loading by the track;
• a second fill, distinct from the first fill, located within the envelope, configured to occupy space between solid materials in the apparatus, and constituted in a liquid phase introduced to the solid and converted to a solid phase thereafter;
• and
• the materials forming the first and second fills being configured to receive and directly secure therewithin a fastener extending from the track thereinto.

A method of supporting a rail as a track in a railroad, the method comprising:

• providing an apparatus capable of operating as a rail tie, comprising a shell surface defining a shell and outer envelope thereof resisting damage by weather, including at least one of water and sun, a first fill, selected from an elastomer, another polymer, glass, and wood, located within the envelope, capable of resisting structural bending thereof in response to loading by the track, and a second fill, distinct from the first fill, located within the envelope, constituted in a liquid phase introduced to the solid and converted to a solid phase thereafter, and configured to occupy space between solid materials in the apparatus;
• positioning the apparatus on a ballast;
• positioning a rail on the apparatus;
• securing the apparatus to the rail by penetrating the apparatus onsite with fasteners urging the rail toward the apparatus.

An apparatus capable of operating as a rail tie supporting track of a railroad, the apparatus comprising:

• a shell surface defining a shell and outer envelope thereof and capable of providing protection resisting damage to an interior of the apparatus by weather, including at least one of water and sun;
• a first fill within the envelope, the first fill being selected from an elastomer, another polymer, glass, and wood, remaining a solid at all stages of formation of the apparatus, and capable of resisting structural bending of the apparatus in response to loading by the track;
• a second fill, distinct from the first fill, located within the envelope, configured to occupy space between solid materials in the apparatus, and constituted in a liquid phase introduced to the solid and converted to a solid phase thereafter;
• the materials forming the first and second fills being configured to receive and directly secure therewithin a fastener extending from the track thereinto
• the second fill securing to the first fill by at least one of a mechanical interference, an undercut, a chemical bond, and a mechanical texture bond;
• the first fill having a density less than that of the second fill;
• and
• the apparatus comprises a third fill distributed within the second fill and constituted by hollow bubbles formed of a solid wall enclosing a gas.