Composite rail joint end post

An end post (30) for a rail joint assembly comprising:

• a top portion (12) having a profile substantially identical to cross-sectional shapes of rail head sections of first and second rails of the rail joint assembly;
• wherein the top portion (12) comprises a top portion inner area (15) distinct from and at least partially surrounded by a top portion outer area (13) disposed along a perimeter of the top portion;
• a base (16) having a profile substantially identical to cross-sectional shapes of rail base sections of first and second rails of the rail joint assembly;
• wherein the base (16) comprises a base inner area (19) distinct from and at least partially surrounded by a base outer area (17) disposed along a perimeter of the base;
• a stem (14) disposed between the top portion (12) and the base (16);
• wherein the top portion outer area (13) and the base outer area (17) consist essentially of a first electrically insulating material comprising a fiber reinforced polymer material;
• wherein the top portion inner area (15), stem (14) and base inner area (19) consist essentially of a second electrically insulating material comprising a polymer material;
• a plurality of first pieces (18A, 18B) of a third electrically insulating material comprising a ceramic material spaced apart and attached to, by adhesive or other means, an inner side of the top portion outer area (13) and to an inner side of the base outer area (17), wherein each of the plurality of first pieces (18A, 18B) is also disposed, in-part, within the second electrically insulating material in either the top portion inner area (15) or the base inner area (19);
• and
• a plurality of second pieces (18B) of the third electrically insulating material, wherein each of the plurality of second pieces (18B) is disposed, in-whole or in-part, within the second electrically insulating material in either the top portion inner area (15) or the base inner area (19).

A method for making an end post (30) for a rail joint assembly wherein the end post (30) comprises a top portion (12) and having a profile substantially identical to cross-sectional shapes of rail head sections of first and second rails of the rail joint assembly;

• wherein the top portion (12) comprises a top portion inner area (15) consisting essentially of a second electrically insulating material comprising a polymer material distinct from and at least partially surrounded by a top portion outer area (13) consisting essentially of a first electrically insulating material comprising a fiber reinforced polymer material disposed along a perimeter of the top portion (12);
• a base (16) having a profile substantially identical to cross-sectional shapes of rail base sections of first and second rails of the rail joint assembly;
• wherein the base (16) comprises a base inner area (19) consisting essentially of the second electrically insulating material distinct from and at least partially surrounded by a base outer area (17) consisting essentially of the first electrically insulating material disposed along a perimeter of the base (16);
• and a stem (14) consisting essentially of the second electrically insulating material disposed between the top portion (12) and the base (16), comprising:
• attaching, by adhesive or other means, a plurality of first pieces (18A, 18B) of a third electrically insulating material comprising a ceramic material spaced apart along an inner side of the top portion outer area (13) and spaced apart along an inner side of the base outer area (17),
• placing the top portion outer area (13) with attached first pieces (18A) and the base outer area (17) with attached first pieces (18A) spaced apart in a mold, wherein the mold defines one or more cavities for forming the top portion inner area (15), stem (14) and base inner area (19);
• placing a plurality of second pieces (18B) of the third electrically insulating material in the mold, wherein each of the plurality of second pieces (18B) is disposed, in-whole or in-part, within a mold cavity for forming either the top portion inner area (15) or the base inner area (19);
• and
• casting the second electrically insulating material comprising a polymer material within the one or more mold cavities to form the top portion inner area (15), stem (14) and base inner area (19) of the end post (30).