Door Assembly for Railcars

Abstract

A door assembly for a railcar includes a sliding system and a latching system. The sliding system is operable to slide the door to a side of the entrance of the railcar to provide an opening path to an entrance of the railcar. The sliding system comprises one or more rollers used for sliding the door. The latching system is operable to plug the door to the railcar such that the door moves inward toward the railcar, and unplug the door from the railcar such that the door moves outward from the railcar. The latching system comprises a lever operably coupled with two or more gears. The lever turns a particular number of rotations in a first direction to plug the door to the railcar. The lever turns the particular number of rotations in a second direction to unplug the door from the railcar.

1 . A door assembly for a railcar, comprising:
 a sliding system operable to slide a door to at least one side of the railcar to provide an opening path to an entrance of the railcar when the door is opened, wherein the sliding system comprises one or more rollers used for sliding the door; and   a latching system operable to:
 plug the door to the railcar such that the door moves inward toward the railcar when closing the door; and 
 unplug the door from the railcar such that the door moves outward from the railcar when opening the door, wherein the latching system comprises:
 a first gear with a first radius; 
 a second gear operably coupled with the first gear, having a second radius; 
 a lever operably coupled with the first gear and the second gear, wherein:
 the lever is operable to turn a particular number of rotations in a first direction to plug the door to the railcar; 
 the lever is operable to turn the particular number of rotations in a second direction to unplug the door from the railcar; and 
 a ratio of the first radius over the second radius is determined such that the lever is operable to turn when a force within a target force range is applied to turn the lever the particular number of rotations. 
 
 
   
     
     
         2 . The door assembly of  claim 1 , further comprising a locking system operable to lock the door, wherein the locking system comprises:
 a latch bar plate with a first length mounted on the door at one end, wherein the latch bar plate comprises a first space positioned within the latch bar plate; and   a latch hinge mounted on the door with the first length apart from the latch bar plate, wherein:
 the latch hinge comprises a loop-shaped component that fits into the first space; and 
 when the loop-shaped component is positioned in the first space, the door will be locked. 
   
     
     
         3 . The door assembly of  claim 1 , further comprising a sealing system operable to seal the door to the railcar when the door is closed, wherein the sealing system comprises:
 a plurality of sealing components attached to the interior surface of the door, comprising:
 a top portion sealing component attached to a top interior surface of the door; 
 a side portion sealing component attached to a side interior surface of the door; and 
 a bottom portion sealing component attached to a bottom interior surface of the door. 
   
     
     
         4 . The door assembly of  claim 3 , wherein:
 each of the plurality of sealing components comprises a sealing gasket that is in form of a ring; and   the sealing gasket is configured to fill the space between the door and the railcar when the door is in a plugged configuration.   
     
     
         5 . The door assembly of  claim 1 , further comprising a side sill operably coupled to a sealing system of the door, comprising a bracket plate that is configured to create a sealed region when the bracket plate makes contact with a sealing plate of the door. 
     
     
         6 . The door assembly of  claim 1 , further comprising a push pocket operable to interface with a device to open or close the door, wherein the push pocket comprises a pocket that is shaped to accept a piece of the device such that when the piece of the device is positioned inside the pocket, the device can push the door to open or close. 
     
     
         7 . The door assembly of  claim 6 , wherein:
 the device comprises a forklift; and   the piece of the device comprises a blade of the forklift.   
     
     
         8 . The door assembly of  claim 1 , wherein the door assembly is configured to be installed on a modular railcar such that a top portion of the modular railcar can be removed from a bottom portion of the modular railcar. 
     
     
         9 . The door assembly of  claim 8 , wherein:
 the top portion of the modular railcar comprises a roof, the door, and walls of the modular railcar; and   the bottom portion of the modular railcar comprises a floor of the modular railcar.   
     
     
         10 . The door assembly of  claim 1 , wherein a sealing height at a bottom of the door between the door and a floor of the railcar is adjustable based at least on one or more of a weight of a cargo carried by the railcar, a size of the door, a type of the railcar, and a size of the railcar. 
     
     
         11 . A railcar, comprising:
 a door; and   a door assembly operably coupled with the door, comprising:
 a sliding system operable to slide the door to at least one side of the railcar to provide an opening path to an entrance of the railcar when the door is opened, wherein the sliding system comprises one or more rollers used for sliding the door; and 
 a latching system operable to:
 plug the door to the railcar such that the door moves inward toward the railcar when closing the door; and 
 unplug the door from the railcar such that the door moves outward from the railcar when opening the door, wherein the latching system comprises:
 a first gear with a first radius; 
 a second gear operably coupled with the first gear, having a second radius; 
 a lever operably coupled with the first gear and the second gear, wherein: 
  the lever is operable to turn a particular number of rotations in a first direction to plug the door to the railcar; 
  the lever is operable to turn the particular number of rotations in a second direction to unplug the door from the railcar; and 
  a ratio of the first radius over the second radius is determined such that the lever is operable to turn when a force within a target force range is applied to turn the lever the particular number of rotations. 
 
 
   
     
     
         12 . The railcar of  claim 11 , wherein the door assembly further comprises a locking system operable to lock the door, wherein the locking system comprises:
 a latch bar plate with a first length mounted on the door at one end, wherein the latch bar plate comprises a first space positioned within the latch bar plate; and   a latch hinge mounted on the door with the first length apart from the latch bar plate, wherein:
 the latch hinge comprises a loop-shaped component that fits into the first space; and 
 when the loop-shaped component is positioned in the first space, the door will be locked. 
   
     
     
         13 . The railcar of  claim 11 , wherein the door assembly further comprises a sealing system operable to seal the door to the railcar when the door is closed, wherein the sealing system comprises:
 a plurality of sealing components attached to the interior surface of the door, comprising:
 a top portion sealing component attached to a top interior surface of the door; 
 a side portion sealing component attached to a side interior surface of the door; and 
 a bottom portion sealing component attached to a bottom interior surface of the door. 
   
     
     
         14 . The railcar of  claim 13 , wherein:
 each of the plurality of sealing components comprises a sealing gasket that is in form of a ring; and   the sealing gasket is configured to fill the space between the door and the railcar when the door is in a plugged configuration.   
     
     
         15 . The railcar of  claim 11 , wherein the door assembly further comprises a side sill operably coupled to a sealing system of the door, comprising a bracket plate that is configured to create a sealed region when the bracket plate makes contact with a sealing plate of the door. 
     
     
         16 . The railcar of  claim 11 , wherein the door assembly further comprises a push pocket operable to interface with a device to open or close the door, wherein the push pocket comprises a pocket that is shaped to accept a piece of the device such that when the piece of the device is positioned inside the pocket, the device can push the door to open or close. 
     
     
         17 . The railcar of  claim 16 , wherein:
 the device comprises a forklift; and   the piece of the device comprises a blade of the forklift.   
     
     
         18 . The railcar of  claim 11 , wherein the door assembly is configured to be installed on a modular railcar such that a top portion of the modular railcar can be removed from a bottom portion of the modular railcar. 
     
     
         19 . The railcar of  claim 18 , wherein:
 the top portion of the modular railcar comprises a roof, the door, and walls of the modular railcar; and   the bottom portion of the modular railcar comprises a floor of the modular railcar.   
     
     
         20 . The railcar of  claim 11 , wherein a sealing height at a bottom of the door between the door and a floor of the railcar is adjustable based at least on one or more of a weight of a cargo carried by the railcar, a size of the door, a type of the railcar, and a size of the railcar.