Methods of making heat-insulated railway tank car bodies

Claim 1

THE METHOD OF MAKING A RAILWAY CAR BODY INCLUDING A METAL OUTER SHELL AND A METAL INNER LINER AND AN INTERMEDIATE LAYER OF RESILIENT CELLULAR MATERIAL INTIMATELY BONDED TO THE INNER SURFACE OF SAID OUTER SHELL AND TO THE OUTER SURFACE OF SAID INNER LINER, WHEREIN EACH OF SAID OUTER SHELL AND SAID INNER LINER AND SAID INTERMEDIATE LAAYER INCLUDES AN ELONGATED TUBULAR SIDE WALL AND A PAIR OF END WALLS RESPECTIVELY JOINING THE OPPOSITE ENDS OF THE SIDE WALL THEREOF; SAID METHOD COMPRISING PRODUCING AN ASSEMBLY OF SAID OUTER SHELL AND SAID INNER LINER WITH SAID INNER LINER SIDE WALL SPACED RADIALLY INWARDLY SUBSTANTIALLY CONCENTRICALLY WITH RESPECT TO SAID OUTER SHELL SIDE WALL AND WITH SAID INNER LINER END WALLS SPACED INWARDLY SUBSTANTIALLY EQUALLY WITH RESPECT TO THE RESPECTIVELY ADJACENT ONES OF SAID OUTER SHELL END WALLS, FOAMING WITHINERT GAS FIRST UNCURED INGREDIENTS OF A POLYURETHANE RESIN INTO THE SPACE BETWEEN SAID OUTER SHELL SIDE WALL AND SAID INNER LINER SIDE WALL, WHEREIN SAID FIRST INGREDIENTS ARE CHARACTERIZED BY SETTING-UP TO PRODUCE A FIRST BODY OF CELLULAR RESIN HAVING A RELATIVELY LOW DENSITY AND PROVIDING WITH CLOSED CELLS ENTRAPPING A SUBSTANTIAL AMOUNT OF THE INERT GAS, FOAMING WITH AN INERT GAS SECOND UNCURED INGREDIENTS OF A POLYURETHANE RESIN INTO THE SPACE BETWEEN ONE OF SAID OUTER SHELL END WALALS AND THE ADJACENT ONE OF SAID INNER LINER END WALLS, WHEREIN SAID SECOND INGREDIENTS ARE CHARACTERIZED BY SETTING-UP TO PRODUCE A SECOND BODY OF CELLULAR POLYURETHANE RESIN HAVING A RELATIVELY HIGH DENSITY AND PROVIDED WITH CLOSED CELLS ENTRAPPING A SUBSTANTIAL AMOUNT OF THE INERT GAS, AND FOAMING WITH AN INERT GAS THIRD UNCURED INGREDIENETS OF A POLYURETHANE RESIN INTO THE SPACE BETWEEN THE OTHER OF SAID OUTER SHELL END WALLS AND THE ADJACENT OTHER OF SAID INNER LINER END WALLS, WHEREIN SAID THIRD INGREDIENTS ARE CHARACTERIZED BY SETTING-UP TO PRODUCE A THIRD BODY OF CELLULAR POLYURETHANE RESIN HAVING A RELATIVELY HIGH DENSITY AND PROVIDED WITH CLOSED CELLS ENTRAPPING A SUBSTANTIAL AMOUNT OF THE INERT GAS, WHEREIN THE INERT GAS EMPLOYED IN SAID FOAMING STEPS CNSISTS ESSENTIALLY OF A CHLORINE-FLUORINE SUBSTITUTED ALKANE, WHEREBY EACH OF SAID BODIES NAMED OF CELLULAR POLYURETHANE RESIN HAS A K-FACTOR AT LEAST AS LOW AS ABOUT 0.15 B.T.U./ IN./SQ. FT./HR.*F. IN ORDER TO HEAT-INSULATE FROMEACH OTHER SAID OUTER SHELL AND SAID INNER LINER IN THE RESULTING RAILWAY TANK CAR BODY.

Claim 2

THE METHOD OF MAKING A RAILWAY CAR BODY INCLUDING A METAL OUTER SHELL AND A METAL INNER LINER AND AN INTERMEDIATE LAYER OF RESILIENT CELLULAR MATERIAL INTIMATELY BONDED TO THE INNER SURFACE OF SAID OUTER SHELL AND TO THE OUTER SURFACE OF SAID INNER LINER, WHEREIN EACH OF SAID OUTER SHELL AND SAID INNER LINER AND SAID INTERMEDIATE LAAYER INCLUDES AN ELONGATED TUBULAR SIDE WALL AND A PAIR OF END WALLS RESPECTIVELY JOINING THE OPPOSITE ENDS OF THE SIDE WALL THEREOF; SAID METHOD COMPRISING PRODUCING AN ASSEMBLY OF SAID OUTER SHELL AND SAID INNER LINER WITH SAID INNER LINER SIDE WALL SPACED RADIALLY INWARDLY SUBSTANTIALLY CONCENTRICALLY WITH RESPECT TO SAID OUTER SHELL SIDE WALL AND WITH SAID INNER LINER END WALLS SPACED INWARDLY SUBSTANTIALLY EQUALLY WITH RESPECT TO THE RESPECTIVELY ADJACENT ONES OF SAID OUTER SHELL END WALLS, FOAMING WITHINERT GAS FIRST UNCURED INGREDIENTS OF A POLYURETHANE RESIN INTO THE SPACE BETWEEN SAID OUTER SHELL SIDE WALL AND SAID INNER LINER SIDE WALL, WHEREIN SAID FIRST INGREDIENTS ARE CHARACTERIZED BY SETTING-UP TO PRODUCE A FIRST BODY OF CELLULAR RESIN HAVING A RELATIVELY LOW DENSITY AND PROVIDING WITH CLOSED CELLS ENTRAPPING A SUBSTANTIAL AMOUNT OF THE INERT GAS, FOAMING WITH AN INERT GAS SECOND UNCURED INGREDIENTS OF A POLYURETHANE RESIN INTO THE SPACE BETWEEN ONE OF SAID OUTER SHELL END WALALS AND THE ADJACENT ONE OF SAID INNER LINER END WALLS, WHEREIN SAID SECOND INGREDIENTS ARE CHARACTERIZED BY SETTING-UP TO PRODUCE A SECOND BODY OF CELLULAR POLYURETHANE RESIN HAVING A RELATIVELY HIGH DENSITY AND PROVIDED WITH CLOSED CELLS ENTRAPPING A SUBSTANTIAL AMOUNT OF THE INERT GAS, AND FOAMING WITH AN INERT GAS THIRD UNCURED INGREDIENETS OF A POLYURETHANE RESIN INTO THE SPACE BETWEEN THE OTHER OF SAID OUTER SHELL END WALLS AND THE ADJACENT OTHER OF SAID INNER LINER END WALLS, WHEREIN SAID THIRD INGREDIENTS ARE CHARACTERIZED BY SETTING-UP TO PRODUCE A THIRD BODY OF CELLULAR POLYURETHANE RESIN HAVING A RELATIVELY HIGH DENSITY AND PROVIDED WITH CLOSED CELLS ENTRAPPING A SUBSTANTIAL AMOUNT OF THE INERT GAS, WHEREIN THE INERT GAS EMPLOYED IN SAID FOAMING STEPS CNSISTS ESSENTIALLY OF A CHLORINE-FLUORINE SUBSTITUTED ALKANE, WHEREBY EACH OF SAID BODIES NAMED OF CELLULAR POLYURETHANE RESIN HAS A K-FACTOR AT LEAST AS LOW AS ABOUT 0.15 B.T.U./ IN./SQ. FT./HR.*F. IN ORDER TO HEAT-INSULATE FROMEACH OTHER SAID OUTER SHELL AND SAID INNER LINER IN THE RESULTING RAILWAY TANK CAR BODY.