Rail Insulators For Rail Fastening System

Rail insulator, or Angle Plate is installed between Rail clip and steel rail, it's used to adjust rail gauge and insulate the rail from the clips. It is most widely used in the SKL Fastening System, the E Clip Fastening System and the Nabla Fastening System.

Rail insulators perform a fastening function by using the elastic properties of their material to securely hold the rail while absorbing and dissipating the forces from train movements and temperature changes. They provide a physically and electrically insulated connection between the rail and the baseplate or sleeper, preventing the mechanical fasteners from coming into direct contact and reducing wear, corrosion, and electrical current leakage.

Mechanical fastening

• Secure hold: The elastic material grips the rail firmly, securing it within the rail channel or against the baseplate.

• Load absorption: Insulators are designed to elastically absorb forces in both vertical and horizontal directions, dissipating the energy from train movements.

• Vibration and noise reduction: Their elastic properties dampen vibrations, which protects the track components from overstressing and reduces noise pollution.

• Wear and corrosion prevention: By creating a buffer between the metal rail and the fastening components, insulators protect the rail from wear and prevent corrosion caused by direct contact.

Electrical insulation

• Preventing short circuits: In electrified railways, insulators are made of high-dielectric material to prevent electrical currents from passing through the fasteners into the ground.

• Protecting signalling systems: They are essential for maintaining the integrity of track circuits used for signalling and safety systems.

• Concentrating current: By preventing current leakage, they ensure that the electrical current is used more effectively.

Nylon rail insulators are manufactured using injection molding, a process where molten nylon resin, often mixed with a glass fiber filler for strength, is forced into a mold to create the desired shape. The specific type of nylon, such as Nylon-6 or Nylon-66, and the amount of glass filler can vary based on the required performance specifications. After molding, the finished product is cooled, and its edges are cleaned of any excess material.

Manufacturing process

• Material preparation: Raw nylon (like Nylon-6 or Nylon-66) is mixed with glass fibers, a coloring agent (if needed), and other additives like UV stabilizers. The glass fiber content typically ranges from 20% to 35%.

• Injection molding: The mixture is heated to a molten state and injected under high pressure into a pre-made mold of the insulator's shape.

• Cooling: The molten plastic is allowed to cool and solidify inside the mold, taking on the mold's form.

• Demolding and finishing: The finished insulator is removed from the mold. The surface is inspected for defects like bubbles or warping, and any flash (excess material) is removed from the edges.

• Conditioning: The finished part is sometimes conditioned to absorb moisture to ensure dimensional stability.

The packaging of railway fasteners requires reinforced sealing and moisture-proof synergistic protection. For fasteners susceptible to humidity, first apply a thin, uniform layer of anti-rust wax on the surface. After the wax layer dries, wrap them in waterproof non-woven fabric, then place them into aluminum-plastic composite bags with strong sealing performance. Sufficient desiccant is placed inside the bags, and the bag openings are sealed using a heat sealing machine to ensure a dry internal environment.

The sealed composite bags are then placed into custom-sized plywood wooden crates. The inner walls of the crates are lined with waterproof asphalt paper, and any gaps inside are filled with foam blocks. The crate lids are fastened with bolts, and the exterior edges of the crates are reinforced with galvanized iron strips, further enhancing the waterproof and impact-resistant capabilities of the packaging.

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GNEE RAILWAY RAILWAY specializes in the manufacture of railway fasteners and standard parts, and is a certified enterprise licensed by the Chinese Ministry of Railways. Our quality control system runs through the entire production chain. The railway fasteners we produce comply with international rail industry standards, combining connection stability with insulation and chemical resistance, and are widely used in railway projects in chemical industrial parks and acid-alkali environments. GNEE RAILWAY can provide precise customization according to customer drawings or samples, strictly controlling from raw material procurement traceability to finished product inspection before shipment. We adhere to the principle of providing high-cost-effective products and professional technical consulting to solve fastener system compatibility challenges for global rail transit customers.

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