Curved insulated rail joint bar and methods for making same

1. A rail joint bar, comprising:

a first side and a second side;

wherein the first side has a longitudinal axis and outer surface curved convexly along the longitudinal axis and wherein the first outer surface define a rounded shape conforming to and fitting within a concavely curved channel of a side of a curved railroad rail joint, wherein the concavely curved channel is defined by a web, a head and a foot of the railroad rail joint; and

wherein the second side has a second outer surface having approximately the same radius of curvature as the first side.

2. The rail joint bar of claim 1 , wherein the first outer surface has a radius of curvature of 82′ (25 m) feet.

3. The rail joint bar of claim 1 , wherein the first outer surface has a radius of curvature of 75 to 85 feet.

4. The rail joint bar of claim 3 , wherein the rail joint bar defines a plurality of bolt holes.

5. The rail joint bar of claim 3 , wherein the rail joint bar defines six or eight bolt holes disposed along a longitudinal center line of the rail joint bar.

6. The rail joint bar of claim 5 , wherein the two or three outermost bolt holes on each side of the longitudinal center line of the rail joint bar were produced prior to, and the two innermost bolt holes thereon were produced after, the bending of the rail joint bar to produce the convexly curved first outer surface.

7. A rail joint bar, comprising:

a first side and a second side; wherein the first side has a longitudinal axis and a first outer surface curved concavely along the longitudinal axis and wherein the first outer surface defines a shape conforming to and fitting within a convexly curved channel of a side of a curved railroad rail joint, wherein the convexly curved channel is defined by a web; a head and a foot of the railroad rail joint;

wherein the second side has a second outer surface having approximately the same radius of curvature as the first side.

8. The rail joint bar of claim 7 , wherein the first outer surface has a radius of curvature of 82′ (23 m) feet.

9. The rail joint bar of claim 7 , wherein the first outer surface has a radius of curvature of 75 to 85 feet.

10. The rail joint bar of claim 9 , wherein the rail joint bar defines a plurality of bolt holes.

11. The rail joint bar of claim 9 , wherein the rail joint bar defines six or eight bolt holes disposed along a longitudinal center line of the rail joint bar.

12. The rail joint bar of claim 11 , wherein the two or three outermost bolt holes on each side of the longitudinal center line of the rail joint bar were produced prior to, and the two innermost bolt holes thereon were produced after, the bending of the rail joint bar to produce the concavely curved first outer surface.

13. A method of making a curved rail joint bar having a plurality of bolt holes disposed along a longitudinal center line of the rail joint bar, wherein half of the plurality of bolt holes are equally-spaced on a first half of the rail joint bar and the other half of the plurality of bolt holes are equally-spaced on a second half of the rail joint bar, comprising:

providing a blank rail joint bar without bolt holes, wherein the blank rail joint bar has a first side and a second side; wherein the first side has a longitudinal axis and a first outer surface defining a rounded shape conforming to and fitting within a channel of a side of a railroad rail joint, wherein the channel is defined by a web, a head and a foot of the railroad rail joint; and wherein the second side of the blank rail joint bar has a second outer surface that is flat; drilling all but the two innermost of the plurality of bolt holes into the blank rail joint bar;

straightening the blank rail joint bar;

immobilizing first and second ends of the blank rail joint bar;

pushing on a center of the second outer surface to place the blank rail joint bar under load;

releasing the load to produce a convex curve along the longitudinal axis of the first Outer surface;

and drilling the two innermost of the plurality of bolt holes into the blank rail joint bar.

14. The method of making a curved rail joint bar of claim 13 wherein, prior to drilling the two innermost of the plurality of bolt holes, the center of the second outer surface is pushed by 0.75″ to 0.85″ and then released to allow the blank rail joint bar to spring back to where the convex curve of the first outer surface has a radius of curvature of 82′ (25 m) along its longitudinal axis.

15. The method of making a curved rail joint bar of claim 14 , further comprising:

molding the blank rail joint bar, in a mold having a concave curvature equal to that of the convexly bent rail joint bar, with cloth and adhesive after the drilling of the two innermost of the plurality of bolt holes.

16. The method of making a curved rail joint bar of claim 13 , wherein the blank rail joint bar is 36 inches or 48 inches long.

17. A method of making a curved rail joint bar having a plurality of bolt holes disposed along a longitudinal center line of the rail joint bar, wherein half of the plurality of bolt holes are equally-spaced on a first half of the rail joint bar and the other half of the plurality of bolt holes are equally-spaced on a second half of the rail joint bar, comprising:

providing a blank rail joint bar without bolt holes, wherein the blank rail joint bar has a first side and a second side, wherein the first side has a longitudinal axis and a first outer surface defining a rounded shape conforming to and fitting within a channel of a side of a railroad rail joint, wherein the channel is defined by a web, a head and a foot of the railroad rail joint; and wherein the second side of the blank rail joint bar has a second outer surface that is flat; drilling all but the two innermost of the plurality of bolt holes into the blank rail joint bar;

straightening the blank rail joint bar;

immobilizing first and second ends of the blank rail joint bar;

pushing on a center of the first outer surface to place the blank rail joint bar under load;

releasing the load to produce a concave curve along the longitudinal axis of the first outer surface; and

drilling the two innermost of the plurality of bolt holes into the blank rail joint bar.

18. The method of making a curved rail joint bar of claim 17 wherein, prior to drilling the two innermost of the plurality of bolt holes, the center of the first outer surface is pushed 0.84″ to 0.94″ and then released to allow the blank rail joint bar to spring back to where the concave curve of the first outer surface has a radius of curvature of 82′ (25 m) along its longitudinal axis.

19. The method of making a curved rail joint bar of claim 18 , further comprising:

molding the blank rail joint bar, in a mold having a convex curvature equal to that of the concavely bent rail joint bar, with cloth and adhesive after the drilling of the two innermost of the plurality of bolt holes.

20. The method of making a curved rail joint bar of claim 17 , wherein the blank rail joint bar is 36 inches of 48 inches long.