Special track assembly and methods of making same

A method of making a special track assembly for supporting a train, the special track assembly being at least partially supportable by supporting material, the method comprising:

• (a) providing a special track segment comprising:
• at least one rail portion comprising a head for engaging wheels of the train comprising a plurality of top surfaces thereof, a foot securable to the supporting material, and a web connecting the head and the foot;
• a body portion connected to said at least one rail portion, the body portion comprising at least one pocket therein,
• the special track segment being at least partially defined by a plurality of exterior side surfaces and the top surfaces thereof;
• (b) inserting a lightweight filler material having a density substantially less than that of the special track segment in said at least one pocket, to substantially fill said at least one pocket and least partially define an exterior bottom surface of the special track segment;
• (c) cleaning the exterior side and bottom surfaces such that a primer is adherable thereto;
• (d) applying said primer to the exterior side and bottom surfaces to provide primed exterior surfaces thereon;
• (e) applying a layer of adhesive material to the primed exterior surfaces, to provide adhesive-covered exterior surfaces thereon;
• (f) applying a plurality of ribs comprising a resilient material to the adhesive-covered exterior surfaces, adjacent ones of the ribs being spaced apart from each other by predetermined distances to define gaps therebetween respectively;
• (g) attaching at least one wall portion of the resilient material to the ribs for bridging gaps to at least partially define a plurality of cavities between said adjacent ribs respectively, said at least one wall portion being deflectable for dissipating energy transmitted by movement of the special track segment relative to the supporting material;
• and
• (h) curing the ribs and said at least one wall portion, to form the ribs and said at least one wall portion into a unitary covering adhering to the exterior side and bottom surfaces for engagement with the supporting material.

A method of forming a resilient jacket for a special track segment for supporting a train, the special track segment comprising at least one rail portion comprising a head for engaging wheels of the train comprising a plurality of top surfaces thereof, a foot securable to supporting material, and a web connecting the head and the foot, and a body portion connected to said at least one rail portion, the special track segment being at least partially defined by a plurality of exterior surfaces and the top surfaces thereof, the special track being at least partially supportable by supporting material, the method comprising:

• (a) cleaning the exterior surfaces such that a primer is adherable thereto;
• (b) applying said primer to the exterior surfaces to provide primed exterior surfaces thereon;
• (c) applying a layer of adhesive material to the primed exterior surfaces, to provide adhesive-covered exterior surfaces thereon;
• (d) applying a layer of resilient material to the adhesive-covered exterior surfaces, the layer of resilient material comprising a plurality of cavities therein, each said cavity being at least partially defined by at least one wall portion deflectable for dissipating energy transmitted by movement of the special track segment relative to the supporting material;
• and
• (e) curing the layer of resilient material, to form the layer into a unitary covering adhering to the exterior surfaces for engagement with the supporting material.

A method of making a special track assembly for supporting a train, the special track assembly being at least partially supportable by supporting material, the method comprising:

• (a) providing a special track segment comprising:
• at least one rail portion comprising a head for engaging wheels of the train comprising a plurality of top surfaces thereof, a foot securable to the supporting material, and a web connecting the head and the foot;
• a body portion connected to said at least one rail portion,
• the special track segment being at least partially defined by a plurality of exterior surfaces and the top surfaces thereof;
• (b) providing at least one mold comprising at least one chamber for receiving a pourable material therein curable to form a first resilient material;
• (c) forming a plurality of outer pockets comprising a second resilient material located in predetermined positions respectively relative to the exterior surfaces, the outer pockets being located at least partially within said at least one chamber;
• (d) positioning said at least one mold adjacent to the exterior surfaces;
• (e) placing the pourable material in said at least one chamber to form at least one wall portion comprising the first resilient material at least partially enveloping the outer pockets;
• (f) curing the pourable material to form the first resilient material therefrom adhering to the exterior surfaces, said at least one wall portion and the outer pockets comprising a unitary covering which is deflectable for dissipating energy transmitted by movement of the special track segment relative to the supporting material;
• and
• (g) removing said at least one mold.

A special track assembly for supporting a train, the special track assembly being at least partially supportable by a supporting material and adapted for connection with at least one straight track portion comprising a straight rail segment and a boot comprising electrically insulating material and partially covering the straight rail segment to define at least one exposed surface thereof, the special track assembly comprising:

• a special track segment comprising:
• at least one rail portion comprising a head for engagement with wheels of the train comprising a plurality of top surfaces thereof, a foot securable to the supporting material, and a web connecting the head and the foot;
• a body portion connected to said at least one rail portion;
• the special track segment being at least partially defined by a plurality of exterior surfaces and the top surfaces thereof;
• said at least one rail portion being substantially alignable with said at least one straight track portion upon respective ends of said at least one rail portion and said at least one straight track portion being positioned to abut each other;
• a layer of an electrically insulating material attached to the exterior surfaces for substantially electrically isolating the special track segment relative to the supporting material, the layer having been cured to form a unitary covering adhering to the exterior surfaces;
• a connecting element for electrically connecting the special track segment and the straight rail segment;
• and
• a connecting portion comprising the electrically insulating material for substantially electrically isolating at least the connecting element and said at least one exposed surface relative to the supporting material.

A method of forming a special track assembly for supporting a train, the special track assembly being at least partially supportable by a supporting material and including at least one straight track portion comprising a straight rail segment, the method comprising:

• (a) providing a special track segment comprising:
• at least one rail portion comprising a head for engagement with wheels of the train comprising a plurality of top surfaces thereof, a foot securable to the supporting material, and a web connecting the head and the foot;
• a body portion connected to said at least one rail portion,
• the special track segment being at least partially defined by a plurality of exterior surfaces and the top surfaces thereof;
• (b) electrically connecting the straight rail segment with the special track segment such that said at least one rail portion is substantially aligned with said at least one straight track portion, said at least one straight track portion being at least partially defined by a plurality of top surfaces thereof and a plurality of exterior surfaces thereof;
• (c) encapsulating the respective exterior surfaces of the special track segment and said at least one straight track portion with an electrically insulating material, for substantially electrically isolating the special track segment and the straight rail segment relative to the supporting material;
• and
• (d) curing the electrically insulating material to form the electrically insulating material into a unitary covering adhering to the exterior surfaces for engagement with the supporting material.

A method of forming a special track assembly for supporting a train, the special track assembly being at least partially supportable by a supporting material and including at least one straight track portion comprising a straight rail segment, the method comprising:

• (a) providing a special track segment comprising:
• at least one rail portion comprising a head for engagement with wheels of the train comprising a plurality of top surfaces thereof, a foot securable to the supporting material, and a web connecting the head and the foot;
• a body portion connected to said at least one rail portion,
• the special track segment being at least partially defined by a plurality of exterior surfaces and the top surfaces thereof;
• (b) electrically connecting the straight rail segment with the special track segment such that said at least one rail portion is substantially aligned with said at least one straight track portion, the straight rail segment being at least partially defined by a plurality of top surfaces thereof and a plurality of exterior surfaces thereof;
• (c) providing at least one mold comprising at least one chamber for receiving a pourable material curable to form an electrically insulating material, said at least one chamber being configured to form at least one wall portion substantially electrically isolating the special track segment and the straight rail segment relative to the supporting material;
• (d) positioning said at least one mold adjacent to the exterior surfaces;
• (e) placing the pourable material in said at least one chamber;
• (f) curing the pourable material to form the electrically insulating material therefrom into a unitary covering adhering to the exterior surfaces for engagement with the supporting material;
• and
• (g) removing said at least one mold.

A special track assembly for supporting a train, the special track assembly being at least partially supportable by a supporting material, the special track assembly comprising:

• a special track segment comprising:
• at least one rail portion comprising a head for engagement with wheels of the train comprising a plurality of top surfaces thereof, a foot securable to the supporting material, and a web connecting the head and the foot;
• a body portion connected to said at least one rail portion;
• the special track segment being at least partially defined by a plurality of exterior surfaces and the top surfaces thereof;
• a unitary covering comprising a layer of a first resilient material cured to adhere to the exterior surfaces;
• and
• the covering additionally comprising a plurality of outer pockets in which a second resilient material is positioned, the outer pockets being configured such that the covering is deflectable for dissipating energy transmitted by movement of the special track segment relative to the supporting material.