Injection Molded Parts：Insulators, Plastic Dowels, Rail Pads
Injection molded parts in railway fasteners include insulators, plastic dowels, rail pads, which are made from durable plastics like PA66 or HDPE to provide electrical insulation, secure the rail, and protect concrete sleepers from vibration.
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Common injection molded parts
Insulators: These are used to electrically insulate the fasteners from the rail and sleeper, preventing stray currents and galvanic corrosion.
| Product | Rail Insulators for Railway Fastening System) |
| Raw Material | PA66, PA66+GF30%, HDPE, PA6 (Reinforced Nylon) |
| Standards | UIC, AREMA, BS, RDSO, DIN, JIS, ISCR, GB, VALEC, GOSTR- EASC, GB/T or other upon requirements |
| Weight | Depend on different models |
| Dimension | Depend on different models |
| Package | Moven bag, Box or other upon requirements |
| Delivery | Depends on order |
Plastic dowels/sleeves: Also called concrete inserts, these are pre-embedded in the concrete sleeper to secure the rail with a screw spike and prevent the screw threads from damaging the sleeper.
| Name | Rail plastic dowel | |
| Type | For different sizes of screw spikes or anchor bolts | |
| Material | Reinforced Nylon 66 (PA66: Nylon 66.69%, glass fiber 30%, other 1%) | HDPE |
| Technical specifications | Density:1.3-1.45g/cm3 | Density: 0.95-0.98g/cm3 Tensile strength: ≥19Mpa Elongation: >80% Melting point: 170-190°C Insulation resistance: ≥1×1010Ω Hardness:≥98A |
| Tensile strength: ≥170Mpa | ||
| Elongation: ≤4.4% | ||
| Bending Strength: ≥250Mpa | ||
| Impact Strength(No gap): ≥80KJ/m2 | ||
| Melting point:250-270°C | ||
| Insulation resistance:≥1×108Ω | ||
| Glass fiber content:30-35% | ||
| Hardness:≥110HRR | ||
| Color | Yellow, black, white, blue, green, just to name a few. | |
Rail pads: Placed between the rail and sleeper, these pads are made from injection molded plastic to absorb shock, reduce vibration, and minimize wear on the concrete.
Rubber rail pads for concrete sleepers
| Material: | rubber |
| Standard: | TB/T2626-95 |
| Application: | 43kg/m ,50kg/m, 60kg/m, 75kg/m rail |
| Models: | 43-7-7, 43-10-7, 50-7-9, 50-10-9, 60-10-17, 60-12-17 |
| Operation temperature: | -50~70 degrees |
| Certificate: | ISO9001:2008 |
| Notes: | Should be stored in clean, ventilated place. Don't put under direct sunlight, and keep away from heat sources and chemical reagents. Don't touch oil, organic solvent and other chemicals. |
Wedges and other components: Various other parts, such as wedges, sidepost insulators, and toe insulators, are also injection molded to provide specific functions within the fastening system.
Benefits of injection molding for railway fasteners
- Precision and consistency: Injection molding allows for the creation of highly precise and identical parts, which is critical for the performance and reliability of rail fastening systems.
- Durability: Many components are made from engineered plastics like PA66 or POM, which offer high strength, wear resistance, and long-term tensile strength.
- Cost-effectiveness: For high-volume production, injection molding is an economical manufacturing method.
- Design flexibility: It allows for the integration of features like electrical insulation and vibration damping into a single component, simplifying the overall assembly of the rail fastening system.
Application of Injection Molded Parts in Railway Fastener Systems
- Rail pads: Injection-molded pads are placed between the rail and the sleeper to absorb vibrations from passing trains, reducing stress and wear on the concrete sleeper. They are made from materials like EPDM, nitrile, or HDPE.
| Item | Components | Quantity/Set | Material |
|---|---|---|---|
| 1 | SKL Clip | 4 | 60Si2CrA |
| 2 | Screw Spike | 4 | Q235&35k&45# |
| 3 | Angle Plate | 4 | PA66+30%GF |
| 4 | Dowel | 4 | HDPE & PS66 |
| 5 | Rail Pad | 2 | Rubber & EVA & HAPE |
- Insulators: These are crucial for electrically isolating the rails, which is essential for traffic control signals. Injection molding allows for the creation of these components with high strength and dimensional accuracy.
E Type Rail Elastic Clip Fasteners System
| Item | Components | Quantity/Set | Material |
|---|---|---|---|
| 1 | Rail Clip | 4 | 60Si2MnA |
| 2 | Insert Shoulder | 4 | QT450-10 |
| 3 | Rail Insulator | 4 | PA66+30%GF |
| 4 | Rail Pad | 2 | Rubber & EVA & HAPE |
- Composite sleepers: Injection molding is used to create composite sleepers from recycled plastics, reinforced with materials like glass fiber. These are a durable, long-lasting alternative to traditional wooden or concrete sleepers, especially in areas where wood is restricted.
rail fastening Packaging & Delivery
Prior to shipment packaging of railway fasteners, classified organization must first be completed after product quality inspection. For fasteners with potential thread damage risks (such as high-strength bolts), spiral plastic protectors are sleeved over the threaded section, with the protector length covering the entire threaded area. For fasteners with holes (such as connecting plates), use custom-sized foam plugs to block the holes, preventing foreign matter ingress during transportation. Products of the same category are divided into several small batches according to order quantity. Each batch is bundled with abrasion-resistant paper tape, and corrugated cardboard separates the bundles. They are then entirely placed into corrugated boxes lined with EPE foam. Right-angle foam protectors are placed at all four corners inside the boxes to enhance impact resistance.
GNEE RAIL is a leading railway fastener manufacturer in China, holding production licenses issued by the Ministry of Railways. Leveraging advanced production technology and stringent quality inspection standards, we enhance product connection reliability. Our railway fastener products feature robust structural integrity, meeting track fixation requirements for heavy-haul railways and freight dedicated lines. Custom manufacturing is available based on customer drawings or samples. Our technical team responds promptly and optimizes production details, consistently adhering to the commitment of "supplying optimal products at optimal prices," serving global rail transit construction and maintenance enterprises.
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