US 9,038,836 B1Granted

Lightweight coupler

AssigneePennsy Corporation

InventorsManuel Tavares, Michael J. Schmidt

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Abstract

The coupler system of a railway car truck is constructed such that basic overall appearance may be maintained, but the actual material of which it is constructed is changed. According to one embodiment, the coupler is constructed from cast austempered ductile iron; whereas cast iron has a density, 0.26 lbs/in^3, which is approximately 8% less than steel, 0.283 lbs/in^3, thereby allowing for a reduction in weight over steel. A suitable austempering process is used to produce the austempered metal coupler and components thereof. A second benefit of embodiments of the present invention provides for a more efficient use of materials, meaning less metal is used to make the same final shape, as a way of reducing the coupler weight. Both factures combined allow for a lighter weight coupler, while utilizing the standard designs. Alternate coupler configurations are disclosed for further reducing coupler weight.

Claims32

Dependent claims

A railway vehicle coupler, comprising:

(a) a shank portion;
(b) a coupler head portion extending from said shank portion;
and
(c) connecting means for connecting the coupler to a coupler of an adjacent railcar;
(d) wherein the coupler shank portion has a front end, a back end, and a weight reduction zone provided at the back end thereof;
(e) including a bore disposed at the back end thereof, said bore being defined by a wall portion,
(f) wherein said wall portion has a thickness;
(g) wherein said weight reduction zone has a core;
and
(h) wherein said wall portion has a first surface on one side of said thickness that defines said bore;
(i) wherein said wall portion has a second surface on the other side of said thickness defining said core of said weight reduction zone;
(j) wherein said weight reduction zone comprises a rear weight reduction zone provided at the back end of said coupler shank portion, and wherein said coupler has a first side weight reduction zone provided on one side of said coupler shank portion and a second side weight reduction zone provided on the other side of said coupler shank portion;
and
(k) wherein said first side weight reduction zone has at least one core with an inner wall, wherein said second side weight reduction zone has at least one core with an inner wall, and wherein said bore defining wall portion second surface defines said first side core inner wall and said second side inner wall.

11 more elements

A railway knuckle coupler comprising:

(a) a shank portion;
(b) a coupler head portion extending from said shank portion,
(c) the coupler head portion configured to couple to a first coupler knuckle for coupling the railcar coupler to a second railcar coupler of an adjacent railcar;
(d) the coupler head portion comprising a nose portion and a gathering face extending from the nose portion for engaging a second coupler knuckle coupled to the second railcar coupler;
(e) the coupler head portion comprising a guard arm portion extending from the nose portion towards the shank portion;
(f) a coupler knuckle;
(g) a pair of pivot lugs disposed on said head portion;
(h) a pivot pin disposed in said pivot lugs and pivotally mounting said knuckle on said head portion;
(i) wherein said coupler shank portion and head portion are constructed from austempered metal selected from the group consisting of austempered ductile iron and austempered steel;
(j) a guard arm portion,
(k) a plurality of cavities,
(j) wherein at least some of said plurality of cavities are provided in said guard arm portion;
(l) wherein said coupler has inside surfaces and outside surfaces,
(m) wherein at least some of said inside surfaces define said cavities;
(n) wherein said coupler is constructed from at least one first casting that includes said coupler shank portion and coupler head portion;
(o) wherein said coupler knuckle is constructed from at least one second casting;
(p) wherein said at least one or more of the coupler inside surfaces and outside surfaces is a shot-peened surface.

14 more elements

Dependencies are inferred from the claim text.