End Post Gap Fill Assembly

Abstract

An end post gap fill assembly for an insulated rail joint includes a gap fill member including a head section at a first end of the gap fill member and a stem section extending from the head section to a second end of the gap fill member. The head section is configured to be positioned between respective head portions of first and second rails and the stem section is configured to be positioned between respective web portions and base portions of the first and second rails. A thickness of the gap fill member is consistent from the first end of the gap fill member to the second end of the gap fill member. A sealant is configured to fill a circumferential gap between an outer surface of the gap fill member and outer surfaces of the first and second rails.

The invention claimed is: 
     
         1 . An end post gap fill assembly for an insulated rail joint, the insulated rail joint comprising a first rail, a second rail aligned with the first rail and defining an end post gap between ends of the first rail and the second rail, a first rail joint bar, and a second rail joint bar, the first rail and the second rail each comprising a head portion, a web portion extending from the head portion, and a base portion extending from the web portion, the end post gap fill assembly comprising:
 a gap fill member having a first end, a second end positioned opposite the first end, a first face configured to abut the end of the first rail, and a second face configured to abut the end of the second rail, the gap fill member comprising a head section at the first end of the gap fill member and a stem section extending from the head section to the second end of the gap fill member, the head section configured to be positioned between the respective head portions of the first and second rails and the stem section configured to be positioned between the respective web portions and base portions of the first and second rails, the gap fill member having a length extending along a longitudinal axis of the gap fill member, a width extending perpendicularly to the longitudinal axis of the gap fill member, and a thickness extending from the first face to the second face, the thickness of the gap fill member is consistent from the first end of the gap fill member to the second end of the gap fill member; and   a sealant configured to fill a circumferential gap between an outer surface of the gap fill member and outer surfaces of the first and second rails.   
     
     
         2 . The end post gap fill assembly of  claim 1 , wherein the gap fill member comprises a high pressure fiberglass laminate, and wherein the gap fill member and the sealant are electrically insulating. 
     
     
         3 . The end post gap fill assembly of  claim 1 , wherein the width of the gap fill member at the head section is smaller than a width of the first and second rails at the head portions of the first and second rails. 
     
     
         4 . The end post gap fill assembly of  claim 3 , wherein the width of the gap fill member at the stem section is smaller than a width of the first and second rails at the web portions of the first and second rails. 
     
     
         5 . The end post gap fill assembly of  claim 4 , wherein the length of the gap fill member is smaller than a height of the first and second rails extending from a top surface of the head portions of the first and second rails to a bottom surface of the base portions of the first and second rails. 
     
     
         6 . The end post gap fill assembly of  claim 5 , wherein the first and second rails comprise a 115 RE railroad rail. 
     
     
         7 . The end post gap fill assembly of  claim 5 , wherein the first and second rails comprise a 136 RE railroad rail. 
     
     
         8 . The end post gap fill assembly of  claim 1 , further comprising tape configured to be applied to the head portions of the first and second rails to contain the sealant to the circumferential gap. 
     
     
         9 . A method of filling an end post gap for an insulated rail joint, the insulated rail joint comprising a first rail, a second rail aligned with the first rail and defining an end post gap between ends of the first rail and the second rail, a first rail joint bar, and a second rail joint bar, the first rail and the second rail each comprising a head portion, a web portion extending from the head portion, and a base portion extending from the web portion, the method comprising:
 inserting a gap fill member into the end post gap, the gap fill member having a first end, a second end positioned opposite the first end, a first face abutting the end of the first rail, and a second face abutting the end of the second rail, the gap fill member comprising a head section at the first end of the gap fill member and a stem section extending from the head section to the second end of the gap fill member, the head section positioned between the respective head portions of the first and second rails and the stem section positioned between the respective web portions and base portions of the first and second rails, the gap fill member having a length extending along a longitudinal axis of the gap fill member, a width extending perpendicularly to the longitudinal axis of the gap fill member, and a thickness extending from the first face to the second face, the thickness of the gap fill member is consistent from the first end of the gap fill member to the second end of the gap fill member, the gap fill member defining a circumferential gap between an outer surface of the gap fill member and outer surfaces of the first and second rails; and   filling the circumferential gap with a sealant, wherein the sealant is electrically insulating.   
     
     
         10 . The method of  claim 9 , further comprising:
 applying tape to at least a portion of the first and second rails prior to filling the circumferential gap with sealant, the tape configured to contain the sealant to the circumferential gap.   
     
     
         11 . The method of  claim 9 , further comprising:
 trimming the gap fill member to size prior to inserting the gap fill member into the end post gap.   
     
     
         12 . The method of  claim 11 , wherein the stem section at the second end of the gap fill member is trimmed to reduce the length of the gap fill member.