Door edge protector

Abstract

A door edge protection assembly for installation on a railcar. The railcar has a side wall, a roof rail running substantially horizontally along the top of the side wall, a roof extending upwardly and inwardly from the roof rail, and a plurality of decks for supporting vehicles thereon. The door edge protection assembly includes a door edge protection member for cushioning impacts between a vehicle door edge and at least one of the side wall, the roof rail, and the roof. In the preferred embodiment, the door edge protection assembly also includes a clip for supporting the deformable door edge protection member in the interior of the railcar. The clip lockingly engages the roof to provide positional stability of the deformable door edge protection member relative to the roof rail and roof.

Description

BACKGROUND OF THE INVENTION

[0001] This invention relates to bumper-type protective devices, and, more particularly, to door edge protectors placed inside railcars to protect against direct impact between door edges of vehicles within the railcar and the sides of the railcar when the vehicle doors are swung open.

[0002] Railcars are widely used in the United States and other countries to transport motor vehicles such as automobiles, vans, trucks and the like from manufacturing plants to distribution centers. One type of railcar that is often used for this purpose is referred to in the trade as an autorack. An example of a prior art autorack railcar is described in U.S. Pat. No. 3,426,704, entitled “Deck Section Lock Structure”.

[0003] Autorack railcars typically include a pair of side walls having a number of rectangular, perforated side panels between a series of vertical posts. A roof rail typically runs along the top of each side wall, and a roof extends upwardly and inwardly from the roof rail to substantially cover the interior of the railcar. Often, the roof is made of corrugated sheet metal. Autorack railcars usually have two or three interior decks for supporting vehicles.

[0004] One problem with the use of autorack railcars has been that workers sometimes caused damage to the vehicles by opening the vehicle doors far enough that the edges of the vehicle doors would strike the metallic side walls of the autorack railcar. Due to regulations regarding the cross-sectional size and shape of railcars, the railcars cannot be widened so that the vehicle doors cannot reach the side walls. The permitted profile, which limits height as well as width of the railcar, is particularly constraining with respect to the tri-level railcar because the roof may impinge on the lateral space needed to swing vehicle doors fully open on the top deck.

[0005] In the past, various kinds of door edge protection systems have been attached to auto rack sidewalls to protect vehicle door edges. One of the problems with some prior art systems has been that they may be pulled off of the vehicle interior due to their being used by workers as handholds. This has led to a requirement that certain door edge protection components be capable of withstanding a 150 lb. pull test.

[0006] Another problem with certain door edge protection systems has been that they do not provide sufficient protection for door edges because they are susceptible to breakage. Also, some door edge protection systems, while relatively soft as compared with the steel sidewalls of the railcar, may nevertheless damage the paint on vehicle door edges when a door is forcefully opened, due to the fact that the paint on new vehicles is often not fully cured during rail transport.

[0007] There remains a need for an improved door edge protector for use in commercial rail transport of automotive vehicles.

SUMMARY OF THE INVENTION

[0008] The invention permits reliable, economical and effective protection against metal-to-metal door edge impacts in auto rack railcars used in commercial shipment of automotive vehicles.

[0009] The invention preferably includes a plurality of deformable door edge protectors of a first configuration mounted directly on the side walls of the railcar, and clips for supporting deformable door edge protectors of a second configuration along the roof rail. The deformable door edge protectors cushion impacts between vehicle door edges and the side wall, the roof rail, and the roof.

[0010] Each of the deformable door edge protectors is preferably extruded from a compressible foam material such as an elastomeric foam. Each of the door edge protectors preferably comprises a base comprising a single flange and single bumper disposed beneath the flange. Openings are preferably provided in the flange to accommodate fasteners. In some embodiments, the bumper is of solid cross-section, except for interstices inherent in the foam material. In other embodiments, the bumper comprises a curved wall of generally U-shaped configuration joined to the base at vertically spaced locations.

[0011] Each clip engages the roof rail, the roof, or both, and preferably fits into a corrugation of the roof between the roof and the roof rail. In the preferred embodiment, a first portion of the clip lockingly engages at least one of the roof rail and the roof to provide the clip with general positional stability relative to the roof rail and roof, and a second portion of the clip provides a means to attach the deformable door edge protector to the clip. More specifically, the clip preferably has a hook at its lower end that extends around the bottom edge of the roof.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] FIG. 1 is a partial schematic elevational view of the interior of a tri-level autorack railcar showing the location and orientation of door edge protectors along a side wall and roof rail thereof in accordance with a first embodiment of the invention.

[0013] FIG. 2 is a partial schematic elevational view of the interior of a bi-level autorack railcar showing the location and orientation of door edge protectors along a side wall thereof in accordance with a second embodiment of the invention.

[0014] FIG. 3 is a partial elevational cross-sectional view of a tri-level autorack railcar showing the location and orientation of door edge protectors in accordance with the first embodiment of the invention relative to the top deck of the tri-level autorack railcar.

[0015] FIG. 4 is a perspective view of a retainer button for securing a door edge protector to a side wall or clip.

[0016] FIG. 5 is an enlarged elevational cross-sectional view of a door edge protector and associated clip on a roof rail of a tri-level autorack railcar in accordance with the first embodiment of the invention.

[0017] FIG. 6 is a front view of the clip shown in FIG. 5.

[0018] FIG. 7 is a side view of the clip shown in FIG. 5.

[0019] FIG. 8 is a partial elevational cross-sectional view of a tri-level autorack railcar side wall showing the location and orientation of door edge protectors in accordance with the first embodiment of the invention relative to the middle deck of the tri-level autorack railcar.

[0020] FIG. 9 is an enlarged elevational cross-sectional view of one of the door edge protectors of FIG. 8.

[0021] FIG. 10 is a view of the door edge protection member of FIG. 5 taken substantially at line 10-10 and looking in the direction of the arrows, with the roof, roof rail and button fasteners not being shown.

[0022] FIG. 11 is a view of the door edge protection member of FIG. 10 taken substantially along line 11-11 in FIG. 10.

[0023] FIG. 12 is a cross-sectional view taken across line 12-12 in FIG. 11.

[0024] FIG. 13 is a cross-sectional view taken across line 13-13 in FIG. 11.

[0025] FIG. 14 is a cross-sectional view like that of FIG. 5, but showing a door edge protection member in accordance with a third embodiment of the invention.

[0026] FIG. 15 is a front view of a blank for forming a clip in accordance with a fourth embodiment of the invention.

[0027] FIG. 16 is a front view of a clip made from the blank of FIG. 15.

[0028] FIG. 17 is a side view of the clip of FIG. 16.

[0029] FIG. 18 is an enlarged cross-sectional view of a door edge protector in accordance with a further embodiment of the invention.

[0030] FIG. 19 is an enlarged cross-sectional view of a door edge protector in accordance with a further embodiment of the invention.

[0031] FIG. 20 is a front view of a blank for forming a clip in accordance with a fifth embodiment of the invention.

[0032] FIG. 21 is a front view of a clip made from the blank of FIG. 20.

[0033] FIG. 22 is a side view of the clip of FIG. 21.

[0034] FIG. 23 is a cross-sectional view taken along line 23-23 of the clip of FIG. 21.

[0035] FIG. 24 is a front elevational view of a door edge protection member in accordance with an embodiment of the invention.

[0036] FIG. 25 is an end view thereof.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0037] The invention is preferably embodied in a door edge protection assembly and a method of installation.

[0038] The described embodiments of the invention are preferably for use on a tri-level or bi-level autorack railcar, examples of which are schematically depicted in FIGS. 1 and 2, respectively. Generally, either the tri-level railcar 10 or the bi-level railcar 30 comprises a flatcar having a rack built thereon to support automobiles. The rack includes a support structure including a pair of vertical side walls (12 and 32, respectively) extending upward from side sills 14 (shown in FIG. 1). The railcar typically includes a corrugated roof 16 supported by a pair of roof rails extending along the tops of the side walls (12 and 32, respectively). The side walls may include a series of spaced vertical posts (20 and 40, respectively) extending from the side sills (14 in FIG. 1) up to the roof rails (18 and 38), with one or more side panels (22 and 42, respectively) supported and vertically aligned between adjacent posts (20 and 40). The posts may be supported adjacent the side sills by lower gussets (24 and 44, respectively) and adjacent the roof rails by upper gussets (shown in FIG. 1 at 26).

[0039] The side panels (22 and 42) preferably have apertures (not shown) therein for light and ventilation. Portions of the panels may be corrugated for increased rigidity.

[0040] Geometric profile constraints require that the top of the railcar be somewhat tapered (shown in FIG. 3). Thus, the transuerse dimension of the railcar is decreased above the roof rails.

[0041] FIG. 3 shows the location and orientation of door edge protectors relative to the top deck 50 of the tri-level autorack railcar 10. The vehicles rest on the deck 50, and both are supported partially by deck braces 52. Bumper panels 58 may be used at the vertical posts 20 which project inwardly somewhat from the panels 22 of the side walls 32.

[0042] At the top of the side wall 32, the roof rail 18 supports the corrugated roof 16. The corrugated roof 16 has peaks 84 and valleys 86, with the roof rail 18 having a top face 90 for supporting the roof 16 along the coplanar valleys 86 near the bottom outside edge 82 of the roof 16.

[0043] Referring to FIG. 5, the deformable door edge protector 60 and its clips 100 are mounted along the roof rail 18. Each clip 100 has a lower portion 102 extending down to the bottom edge of the roof, and an upper portion 104 to which the deformable door edge protector is fastened. In some embodiments, e.g., the embodiment of FIGS. 3 and 5-7, portions 102 and 104 are substantially parallel and noncoplanar, and are connected integrally by step portion 114. Each clip 100 further includes a hooked tab 106 at it lower end for engaging the outside edge 82 of the corrugated roof 16 at one of its peaks 84. Each clip 100 also has a bent upper tab portion 116 at its opposite end that fits into the corrugation of the roof 16 to help laterally stabilize the clip 100 relative thereto, and to maintain spacing between the mounting surface of the clip and the roof so that a button fastener may be inserted through the opening 112 after installation of the clip on the railcar. The lateral edges 110 of the planar portion 108 of the lower portion 102 and of the bent tab portion 116 of the clip 100 may also provide lateral stabilization by contacting the corrugations. The step portion 114 of the clip also helps to maintain spacing between the mounting surface of the clip and the roof. Each of the clips 100 is preferably made from a one-piece, unitary metal blank punched to include the aperture 112 and bent to take the shape indicated in FIGS. 6 and 7.

[0044] The deformable door edge protection member 60 is preferably an elongated, extruded foam member, and includes a base 66 and a bumper 62 protruding slightly into the interior of the railcar to contact vehicle doors. The base 66 includes a flange having a series of spaced apertures 68 to enable the door edge protection member 60 to be affixed to clips 100 along the length thereof by the use of fasteners such as retainer buttons 72.

[0045] The door edge protection member 60 also includes a series of spaced fingers 64 frictionally interposed between the outer surface of the top face 90 of the roof rail 18 and the planar lower portion 108 of the clip 100. Grooves 70 between the fingers and the bumper 62 of the deformable door edge protection member 60 straddle the top of the roof rail 18. The fingers 64 in conjunction with the fastener through the flange 66, maintain the door edge protection member 60 in proper position along the interior of the railcar. The fingers keep the clip pressed against the roof to make it more difficult for it to work loose as a result of vibration. The engagement of the groove with the roof rail prevents the clip and the door edge protector from slipping downward. The groove 70 may have a width substantially greater than the thickness of the portion of the roof rail disposed therein so as to function as a deflection gap to provide space for the bumper 62 to deflect, upon contact, so that some of the energy of a door edge impact may be absorbed by the deformable material in a manner other than direct compression thereof.

[0046] The retainer button 72 is shown in FIG. 4. When the deformable door edge protection member 60 is being mounted to the clips 100, the apertures 68 of the flange of the protection member and the apertures 112 of the respective clips 100 may be aligned and juxtaposed, and the retainer button 72 may then be driven through the apertures to retain them in the alignment and juxtaposition. In particular, the circumferentially grooved shaft 80 of the button 72 penetrates the apertures and the circumferential grooves of the shaft provide resistance to separation. The button 72 is preferably driven until the inner surface 78 of the button head 74 meets the flange 66 of the protection member 60, thereby holding it tightly to the railcar. The button may be driven through the apertures by applying a force to the flat upper surface 76 of the button head 74.

[0047] In the preferred method of installation of the protection member 60 along the interior of the railcar 10 (best seen in FIGS. 5 and 10-13) one may start at one end thereof and sequentially insert the fingers 64 between the outer surface of the top face 90 of the roof rail 18 and the inner surface of the corrugated roof 16 in the corrugations. Each finger 64 is inserted between the roof rail 18 and the planar portion 108 of the clip 100 until the roof rail 18 reaches the top of the groove 70.

[0048] In the preferred method, the clips are inserted before or simultaneously with the fingers. If the clips are inserted before the fingers, they are manually held in place while the fingers are inserted. If they are to be inserted simultaneously with the fingers, the fingers are preferably sufficiently elastically compressible to compress enough to permit the hook to slide to the bottom of the corrugation, then expand to fill the space between the clip and the roof rail. If the clips are to be inserted simultaneously with the fingers, the clips may be attached to the flange 66 prior to installation of the door edge protection member on the car.

[0049] The ends of the door edge protection member 60 may be at the vertical posts 20 or the ends of the railcar 10, or at other desired locations.

[0050] Clips may be provided for all or some of the fingers 64. Where clips are to be provided for only some of the fingers, those fingers are aligned with apertures 68 in the flange 66 of the protection member 60.

[0051] When the hooked tab is about the roof edge and the roof rail is fully penetrated into the groove, the apertures 68 and 112 of the protective member and clip, respectively, should be aligned. With the flange 66 of the protective member held against the flange 104 of the clip and the apertures aligned, the button 72 is driven through the apertures simultaneously until the inner surface 78 of the button head 74 exerts a desired amount of pressure against the flange 66 of the protection member 60.

[0052] The protection member 60 is designed for use at the level of the roof rail 18 and thus is appropriate for absorbing impacts above the top deck 50 of tri-level autorack railcars.

[0053] FIGS. 8 and 9 illustrate the middle deck 54 of a tri-level autorack railcar 10, and door edge protectors suitable for this deck and other decks where the inwardly sloping roof is not of concern. Bumper panels 58 may be used to protect the vertical posts 20 which project inwardly somewhat from the panels 22 of the side walls 32. Between the vertical posts, an L-shaped deformable door edge protection member 120 is affixed to the side wall 32.

[0054] The L-shaped protection member 120, like protection member 60, is preferably is preferably a long, integral, deformable member, and has a bumper 122 for protruding into the interior of the railcar and for being disposed to contact vehicle doors when the doors are swung open.

[0055] The door edge protection member 120 also includes a flange 124 having a series of spaced apertures 126 for permitting the protection member 120 to be affixed to the side panels 22 of the side walls 32 along the length thereof by the use of fasteners, such as the retainer button 72 described above. The side panels 22 preferably have apertures (not shown) therein with which the apertures 126 of the flange 124 are aligned before driving the buttons 72 through the apertures.

[0056] As seen in FIG. 9, the bumper 122 and the flange 124 are generally perpendicular, thereby providing the general “L” shape, so that the bumper 122 protrudes into the interior of the railcar and is disposed to contact vehicle doors when the doors are swung open. The door edge protection members 60 may absorb contact energy partially or entirely through compression of the foam material.

[0057] The deformable door edge protection members 60 and 120 may be made of any of various deformable, resilient materials such as closed cell foam elastomers, open cell foam elastomers, and the like. The material may be a polyethylene foam having a density of between 1.5 and 2.5 lbs./cu. ft., e.g., 2.1 lbs./cu.ft., and preferably includes components to enhance weather resistance and UV resistance. The material also is preferably flame retardant. Specifically, the door edge protectors may extruded from UV-stabilized, flame retardant energy absorbing foam. After extrusion, apertures and/or horizontally elongated slots are punched, cut, or otherwise formed in the door edge protector to facilitate attachment to the side wall of the railcar, after which the door edge protector is preferably heat treated to provide a tough skin over its entire exterior, as well as the interiors of the apertures, as further described below. Potential providers of manufacturing services in connection with production of the door edge protectors include Nomaco Inc. of Zebulon, N.C. and Merryweather Foam Inc. of Sylacauga, Ala.

[0058] To provide the members 60 and 120 with sufficient durability and toughness to withstand repeated impacts, abrasion, and other potentially damaging events over periods of several years, they may be provided with a post-curing heat treatment to provide a tough outer skin. In this process, the extruded material is slowly cooled during or immediately after extrusion, and after this initial cooling the outer surface is heated to a temperature of 140° F. to 160° F.

[0059] The size of the deformable door edge protection members may vary, depending on the particular application. Preferably, however, each of the door edge protection members 60 and 120 has a horizontal dimension of at least three inches. The width of the groove 70 in the roof-mounted door edge protection member is approximately one half inch, and its depth is about two inches. The shapes of the bumpers 62 and 122 are such that their sloped surfaces deviate from the normal to the side walls 32 by less than 30 degrees. This helps them to resist bending.

[0060] FIGS. 14-19 illustrate additional embodiments of the invention. FIG. 14 shows a deformable door edge protection member 200 and clip 202 similar to those discussed above, except as pointed out below. The shape of the door edge protection member 200 is somewhat different, in that the ratio of the horizontal dimension to the vertical dimension of its bumper 204 is somewhat greater, and in that the upper and lower surfaces of the bumper are substantially flat and parallel. Also, rather than relying on fingers to secure the door edge protection member and clip against downward displacement, an interference fit between the clip and the rail car structure is employed for this purpose.

[0061] The clip 202 of FIG. 14 has a first portion 206 that includes a hook 208 at the bottom for engaging the bottom of a roof sheet 210, and a portion 212 for mounting the foam member. A step 214 is provided near the hook such that the step interferes with the roof rail 216 when the clip is installed. FIG. 14 shows the clip in undeformed configuration, with upper portions 218 of the roof rail that interfere with the clip when installed shown in phantom. Thus, when installed, the step 214 will be deflected slightly toward the roof sheet, i.e., outward, by the contact with the roof rail. The clip is preferably made of a flexible, resilient spring steel so that the interference fit will result in stable engagement of the clip with the roof and roof rail. The roof rail also engages the bottom of the deformable foam member 200 to provided additional resistance to downward displacement of the assembly. The upper portions of the roof rail may be interposed between the foam member and the clip during and after installation.

[0062] A clip 220 in accordance with another embodiment is illustrated in FIGS. 16 and 17. The clip 220 of FIGS. 16 and 17 is substantially same as the clip 202 of FIG. 14, except as noted herein. The clip 220 includes an upper portion 236 comprising a front wall 222 having an aperture 224 to receive a button fastener, a side wall 226 extending along one side of the front wall, and top and bottom walls 228 and 230. As shown in FIG. 17, the lower portion 232 of the clip is angled so that it will be biased against the roof when the clip is installed, with the step 234 being biased inward against the roof rail.

[0063] The bottom wall 230 of the upper portion 236 is sloped at an acute angle to the front wall 222 to facilitate stable engagement between the underside of the bottom wall and the top of the roof rail. Preferably, the bottom surface of the bottom wall abuts the top edge of the roof rail so that the door edge protection member and clip will not slip downwardly during use. The biasing of the lower portion of the clip tends to maintain proper engagement between the bottom wall 230 and the roof rail.

[0064] The clip may be manufactured from the blank illustrated in FIG. 15 simply by bending the blank into the configuration shown in FIGS. 16 and 17, and welding the side wall 226 to the top and bottom walls 228 and 230 to provide additional strength and rigidity.

[0065] A clip 260 in accordance with another embodiment of the invention is illustrated in FIGS. 21-23. The clip 260 is formed of the stamping shown in FIG. 20. The clip 260 of FIGS. 21-23 is substantially the same as the clip 202 of FIG. 14, except as noted herein. The clip 260 includes an upper portion 276 comprising a front wall 262 having an aperture 264 to receive a button fastener, side walls 266 extending along both sides of the front wall 262, top and bottom walls 268 and 270, and a lower portion 272 extending from the bottom wall 270. As shown in FIGS. 22-23, the lower portion 272 of the clip 260 is angled so that it will be biased against the roof when the clip 260 is installed, with the a step 274 of the bottom wall 270 being biased inward against the roof rail. Extended portions 267 of the side walls 266 extend downward past the intersection of the front wall 262 and the lower portion 272. The extended portions 267 of the side walls 266 are insertable between the roof and the roof rail. The extended portions 267 of the side walls 266 provide additional support for the clip 260 when the clip 260 is installed.

[0066] The door edge protection system employing the clip 260 is preferably capable of withstanding a three phase 150 lb. pull test. Prior to the pull test, the clips are inserted into the roof corrugation recesses at about 2 to 2½ foot intervals, then the foam door edge protection members are attached with plastic fasteners. The first phase of the pull test comprises applying to the foam member a 150 lb. force directed toward the center of the car, very close to one clip. This applies about 150 lbs. of force to one clip. In the second phase, a 150 lb. force directed toward the center of the car is applied to the foam member midway between two clips to divide the force between the two clips. The third phase comprises pulling on the clip itself, attempting to pull it out of the roof corrugation. In the third phase, the force is directed upward parallel to the roof sheet. In all three phases, the force may be applied by wrapping a strap around the back of the door edge protection member and applying tension to the strap.

[0067] In other embodiments, downward displacement might be prevented by engagement between the roof rail and the deformable foam member only, as by providing a groove, channel or the like in the bottom of the deformable member to receive the upper portion of the roof rail.

[0068] Deformable foam door edge protection members 240 and 242 in accordance with further embodiments of the invention are shown in FIGS. 18 and 19. FIG. 18 shows a foam door edge protection member for use on the side wall of a railcar. FIG. 19 shows a door edge protection member 242 intended for mounting along the roof rail of the same railcar. Each of the members comprises a base 244 having a single flange 246 with a series of openings 248 therein for receiving button fasteners. The single flange supports the member from above.

[0069] Each of the door edge protection members 240 and 242 further comprises a bumper 250 that includes a wall 252 extending from the bottom of the base toward the interior of the rail car, then back to join the base at a location spaced above its bottom. This configuration defines a hollow interior, which enables the middle section 254 to be pushed inward upon impact as a result of flexure of the wall 252. The exterior of the bumper is convexly curved, except that the top surface may be concave. Like the foam deformable members described above, the members of FIGS. 18 and 19 are preferably extruded and comprise elongated members which have sufficient horizontal dimensions to prevent contact between vehicle door edges and interior metal surfaces of the rail car. The flanges of the side panels intrude slightly over 1 in. into the railcar, and the vertical posts about 3 in. It is desirable that the door edge protectors have a horizontal dimension sufficient to avoid door edge contact with these surfaces during normal usage of the railcars. The door edge protectors preferably have a horizontal dimension of 3 in. or more, although a smaller horizontal dimension of, e.g., 2 in., may suffice, particularly if additional protection is provided adjacent the posts.

[0070] The member 240 of FIG. 18 preferably has a horizontal dimension of at least 2½ inches. To avoid unduly limiting the interior space available for opening the doors, and to avoid undue expense, the horizontal dimension preferably does not exceed 5 inches, and in the preferred embodiment is 3 inches. The thickness of the bumper wall 252 is preferably between ½ in. and ¾ in., and may be, e.g., ⅝ in.

[0071] In the embodiment of FIG. 19, which is intended for mounting on the roof rail, the horizontal dimension is preferably between 4 inches and 5 inches, and the wall thickness is preferably between ½ in. and 1 in., e.g., ¾ in.

[0072] In the embodiments of both FIG. 18 and FIG. 19, reinforcements may be provided around the apertures or slots to enable the door edge protectors to withstand the 50 lb. pull test described above. The reinforcements preferably are made of a tough, flexible sheet material such as a polymeric or plastic material. In one particular embodiment, the reinforcements are made of a polycarbonate material having a thickness of about 10 to 20 mils, and are of generally rectangular configuration. The reinforcements may be attached to either side of the bumper, and are preferably secured in place by adhesive. Each reinforcement that is attached to the back of a bumper preferably has a vertical dimension about the same as that of the back surface of its associated bumper, and a horizontal dimension of 3 to 5 in. Reinforcements attached to the front surface preferably have horizontal dimensions of 3 to 5 in., and vertical dimensions about the same as that of the flange of the associated door edge protection member. The reinforcements are shown at 256 and 258 respectively in FIGS. 18 and 19.

[0073] FIGS. 24 and 25 illustrate a one-piece, unitary extruded foam door edge protection member 280 in accordance with an additional embodiment of the invention, comprising a hollow bumper 282, and a flange 284 extending upward therefrom. A plurality of rectangular reinforcements 286 similar to those described above are secured by adhesive to the back surface of the member 280. Horizontally elongated slots are formed through the flange and reinforcements to facilitate attachment to the side wall of the railcar using button fasteners as described above.

[0074] All of the door edge protection members described herein are preferably capable of withstanding a 150 lb. pull test similar to that described above.

[0075] The embodiments described above represent only a few of many possible embodiments of the invention, and a significant range of alternative embodiments is contemplated to be within the scope of the invention. The invention is further described in the following claims.

Claims

1. In an autorack railway car comprising a side wall, a roof rail running substantially horizontally along the top of said side wall, a corrugated roof extending upwardly and inwardly from said roof rail, and a plurality of substantially parallel decks capable of supporting vehicles thereon in commercial rail service, a door edge protection system comprising a deformable door edge protector and a plurality of clips, each said clip comprising a first portion extending into a corrugation of the roof between the roof and the roof rail, and a second portion attached to said deformable door edge protector, said first portion of each clip having a hook extending around the bottom edge of the roof to constrain the clip against upward displacement.

2. A door edge protection system in accordance with claim 1 wherein at least one of said deformable door edge protector and said clip engages the roof rail so that said roof rail constrains said deformable door edge protector and clip against downward displacement.

3. A door edge protection system in accordance with claim 1 wherein said clip is made of spring steel.

4. A door edge protection system in accordance with claim 1 wherein said clip is capable of insertion into said corrugation and into engagement with the bottom edge of the roof after attachment of the clip to the resilient door edge protector.

5. A door edge protection system in accordance with claim 1 wherein said second portion of said clip includes a front wall, a pair of side walls extending along edges thereof, a top wall, and a bottom wall, said side walls having portions extending downward past said bottom wall, said first portion of said clip with said hook extending from said bottom wall, said front wall including an aperture therein for receiving a fastener that attaches said deformable door edge protector to said clip.

6. A door edge protection system in accordance with claim 5 wherein said clip is stabilized by an interference fit with said roof and roof rail.

7. A door edge protection system in accordance with claim 6 wherein said portions of said side walls extend between said roof rail and said roof for providing stability.

8. A door edge protection system in accordance with claim 1 wherein said deformable door edge protector includes a series of fingers interposable between said roof and said roof rail.

9. A door edge protection system in accordance with claim 1 further including a flange on said deformable door edge protector for affixation to said clip.

10. A door edge protection system in accordance with claim 1 wherein said flange includes an aperture for receiving therein a fastener for attaching said clip to said deformable door edge protection member.

11. A door edge protection system in accordance with claim 1 wherein said deformable door edge protection member is made of a foam material having a tough outer skin.

12. A door edge protection assembly for installation on a railcar having a side wall, a roof rail running substantially horizontally along the top of said side wall, a roof extending upwardly and inwardly from said roof rail, and a plurality of substantially parallel decks for supporting vehicles thereon, said door edge protection assembly comprising:

a door edge protection member for cushioning impacts between a vehicle door edge and at least one of said side wall, said roof rail, and said roof; and

a clip for supporting said deformable door edge protection member in the interior of said railcar and lockingly engaging at least one of said roof rail and said roof to provide positional stability of said deformable door edge protection member relative to said roof rail and roof.

13. A deformable door edge protection member for installation into the interior of a railcar having a side wall and a plurality of substantially parallel decks for supporting vehicles thereon, said door edge protection member comprising:

a bumper having a sufficient horizontal dimension to prevent contact between a vehicle door edge and side panel flanges; and

a flange attachable directly to a railcar side wall panel for retaining said deformable door edge protection member on said side wall;

wherein said bumper and said flange form a one-piece, unitary, integral, compressible foam member having a generally L-shaped or P-shaped cross section.

14. A deformable door edge protection member in accordance with claim 13 wherein said bumper has a tough outer skin, and wherein said door edge protection member further comprises a reinforcement adhesively secured thereto.

15. In a railcar capable of transporting vehicles in commercial rail service, a deformable foam door edge protection member comprising a base having an upper mounting flange and a bumper comprising a flexible wall extending from the bottom of the base toward the interior of the railcar and back to rejoin the base at an intermediate region, thereby defining a hollow interior.

16. A deformable door edge protection member in accordance with claim 15 wherein said deformable door edge protection member is supported on a side wall of said railcar by said upper flange, and wherein said bumper has a curved, outwardly convex bottom surface, and a curved, outwardly concave top surface.

17. A deformable door edge protection member in accordance with claim 15 wherein said wall is curved.

18. A method of attaching door edge protection to a railcar interior comprising:

providing an elongated extruded foam protector;

attaching a series of clips to said protector; and

attaching said clips to the railcar interior.

19. A method of attaching door edge protection to a railcar interior in accordance with claim 18, wherein said step of attaching said clips to the railcar interior further comprises the step of inserting a portion of said clip between a roof rail and a roof of said railcar.

20. A method of attaching door edge protection to a railcar interior in accordance with claim 18, wherein said step of attaching said clips to the railcar interior further comprises the step of securing said clip in said interior with a hook portion of said clip extending around a bottom edge of a roof of said railcar.