# US 9,038,836 B1 · Lightweight coupler > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,038,836 B1 - Document ID: US9038836B1 - Status: Granted - Kind: B1 - Application number: 13/678,203 - Filed: 2012-11-15 - Granted: 2015-05-26 - Earliest claimed: 2012-11-15 - Assignees: Pennsy Corporation - Applicants: Pennsy Corporation - Inventors: Manuel Tavares; Michael J. Schmidt - Web page: https://patentgrep.com/patent/US9038836B1 ## CPC - B61G 3/04: with coupling head having a guard arm on one side and a knuckle with angularly-disposed nose and tail portions pivoted to the other side thereof, the nose of the knuckle being the coupling part, and means to lock the knuckle in coupling position, e.g. "A.A.R." or "Janney" type - B61G: COUPLINGS; DRAUGHT AND BUFFING APPLIANCES (vehicle connections in general B60D) ## 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. ## Claims ### Claim 1 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. ### Claim 2 (depends on 1) The railway vehicle coupler of claim 1, wherein said coupler is constructed from austempered metal. ### Claim 3 (depends on 2) The railway vehicle coupler of claim 2, wherein said austempered metal is austempered alloy steel. ### Claim 4 (depends on 3) The railway vehicle coupler of claim 3, wherein said austempered steel comprises steel alloyed with one or more metals selected from the group consisting of chromium, nickel, magnesium, manganese, copper, molybdenum, and mixtures thereof, wherein said steel alloyed with said one or more metals is austempered to produce said vehicle coupler. ### Claim 5 (depends on 2) The railway vehicle coupler of claim 2, wherein the austempered metal is austempered steel. ### Claim 6 (depends on 2) The railway vehicle coupler of claim 2, wherein said austempered metal is austempered ductile iron. ### Claim 7 (depends on 6) The railway vehicle coupler of claim 6, wherein said austempered ductile iron comprises ductile iron alloyed with one or more metals selected from the group consisting of nickel, molybdenum, manganese, copper and mixtures thereof, wherein said ductile iron alloyed with said one or more said metals is austempered to produce said vehicle coupler. ### Claim 8 (depends on 1) The railway vehicle coupler of claim 1, wherein said coupler has internal or external ribs. ### Claim 9 (depends on 1) The railway vehicle coupler of claim 1, wherein the coupler head portion is configured to couple to a first coupler knuckle for coupling the railcar coupler to a second railcar coupler of an adjacent railcar; 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; and the coupler head portion comprising a guard arm portion extending from the nose portion towards the shank portion. ### Claim 10 (depends on 9) The railway vehicle coupler of claim 9, wherein said coupler has inside surfaces and outside surfaces. ### Claim 11 (depends on 10) The railway vehicle coupler of claim 10, wherein said at least one or more of the coupler inside surfaces and outside surfaces is a shot-peened surface. ### Claim 12 (depends on 1) The railway vehicle coupler of claim 1, including a guard arm portion. ### Claim 13 (depends on 12) The railway vehicle coupler of claim 12, wherein said guard arm portion is integrally provided with said head portion. ### Claim 14 (depends on 13) The railway vehicle coupler of claim 13, wherein said coupler comprises a first casting including said shank portion, said head portion and said guard arm portion. ### Claim 15 (depends on 12) The railway vehicle coupler of claim 12, wherein said guard arm portion is provided as a separate component attached to said head portion. ### Claim 16 (depends on 12) The railway vehicle coupler of claim 12, wherein said coupler comprises a first casting including said shank portion and said head portion. ### Claim 17 (depends on 1) The railway vehicle coupler of claim 1, further comprising a knuckle pivotally carried on the head portion. ### Claim 18 (depends on 17) The railway vehicle coupler of claim 17, wherein said knuckle is constructed from austempered metal. ### Claim 19 (depends on 18) The railway vehicle coupler of claim 18, wherein said knuckle is constructed from austempered ductile iron. ### Claim 20 (depends on 18) The railway vehicle coupler of claim 18, wherein said knuckle is constructed from austempered alloy steel. ### Claim 21 (depends on 17) The railway vehicle coupler of claim 17, wherein said coupler comprises a first casting including said shank portion, said head portion and a second casting comprising said knuckle. ### Claim 22 (depends on 1) The railway vehicle coupler of claim 1, wherein said coupler back end includes a rear portion with an outer surface, wherein said first side weight reduction zone has a plurality of side cores including said at least one side core, wherein spaced apart ribs define said plurality of side cores, wherein said coupler includes an upper wall portion and a lower wall portion, wherein said ribs span between said upper wall portion and said lower wall portion, wherein said plurality of side cores each has a depth relative to the outer surface of the coupler rear portion that is defined by an upstanding wall, and wherein each defining upstanding wall is coextensive with said bore defining wall portion. ### Claim 23 (depends on 22) The railway vehicle coupler of claim 22, wherein said second side weight reduction zone is configured having a plurality of side cores including said at least one side core, wherein spaced apart ribs define said plurality of side cores of said second side weight reduction zone, wherein said coupler includes an upper wall portion and a lower wall portion of said second side weight reduction zone, wherein said ribs of said second side weight reduction zone span between said upper wall portion and said lower wall portion of said second side weight reduction zone, wherein said plurality of side cores of said second side weight reduction zone each has a depth relative to the outer surface of the coupler rear section that is defined by an upstanding wall of said second side weight reduction zone, and wherein each defining upstanding wall of said second side weight reduction zone is coextensive with said bore defining wall portion. ### Claim 24 (depends on 1) The railway vehicle coupler of claim 1, wherein said connecting means for connecting the coupler to a coupler of an adjacent railcar comprises a coupler knuckle. ### Claim 25 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. ### Claim 26 (depends on 25) The railway knuckle coupler of claim 25, wherein said inside surfaces and said outside surfaces define coupler walls having a thickness, and wherein said maximum thickness of said coupler walls is 1.6 inches. ### Claim 27 (depends on 1) The railway knuckle coupler of claim 1, having walls, and wherein the walls have thicknesses substantially less that those walls of AAR standard couplers. ### Claim 28 (depends on 1) The railway knuckle coupler of claim 1, having walls, and wherein the walls have a maximum thickness of 1.6 inches. ### Claim 29 (depends on 1) The railway knuckle coupler of claim 1, wherein the walls have a maximum thickness of 1.15 inches. ### Claim 30 (depends on 1) The railway knuckle coupler of claim 1, wherein the walls have a maximum thickness of 1.0 inches. ### Claim 31 (depends on 1) The railway knuckle coupler of claim 1, wherein the walls have a maximum thickness of 0.65 inches. ### Claim 32 (depends on 25) The railway knuckle coupler of claim 25, wherein said austempered ductile iron comprises ductile iron alloyed with one or more metals selected from the group consisting of nickel, molybdenum, manganese, copper and mixtures thereof, wherein said ductile iron alloyed with said one or more said metals is austempered to produce said vehicle coupler.