Method and System for Manufacturing a Coupler Knuckle

Abstract

A method for manufacturing a railcar coupler knuckle includes providing a cope mold portion and a drag mold portion. The cope and drag mold portions have internal walls defining at least in part perimeter boundaries of a coupler knuckle mold cavity. The method includes positioning one or two internal cores within either the cope mold portion or the drag mold portion. The one or two internal cores are configured to define a kidney cavity, a finger cavity and a pivot pin cavity of a coupler knuckle. The method includes closing the cope and drag mold portions with the one or two internal cores therebetween and at least partially filling the mold cavity with a molten alloy, the molten alloy solidifying after filling to form the coupler knuckle.

1 - 19 . (canceled)  
   
   
       20 . A railcar coupler knuckle, comprising: 
 a tail section, a hub section, and a nose section;    the tail, hub and nose sections defining internal cavities comprising a kidney cavity, a finger cavity, and a pivot pin cavity;    the internal cavities formed using one or two internal cores during manufacturing of the coupler knuckle.    
   
   
       21 . The knuckle of  claim 20 , wherein the one or two internal cores comprise: 
 a kidney portion configured to define the kidney cavity of the coupler knuckle;    a finger portion configured to define the finger cavity of the coupler knuckle; and    a pivot pin portion configured to define the pivot pin cavity of the coupler knuckle.    
   
   
       22 . The knuckle of  claim 20 , wherein the one or two internal cores comprise two internal cores.  
   
   
       23 . The knuckle of  claim 22 , wherein the two internal cores comprise: 
 a first internal core comprising a kidney portion configured to define the kidney cavity of the coupler knuckle; and    a second internal core comprising: 
 a finger portion configured to define the finger cavity of the coupler knuckle; and  
 a pivot pin portion configured to define the pivot pin cavity of the coupler knuckle.  
   
   
   
       24 . The knuckle of  claim 22 , wherein the two internal cores comprise: 
 a first internal core comprising a finger portion configured to define the finger cavity of the coupler knuckle; and    a second internal core comprising: 
 a pivot pin portion configured to define the pivot pin cavity of the coupler knuckle; and  
 a kidney portion configured to define the kidney cavity of the coupler knuckle.  
   
   
   
       25 . The knuckle of  claim 20 , wherein the one or two internal cores comprise a single core comprising: 
 a kidney portion configured to define the kidney cavity of the coupler knuckle;    a finger portion configured to define the finger cavity of the coupler knuckle; and    a pivot pin portion configured to define the pivot pin cavity of the coupler knuckle.    
   
   
       26 . The knuckle of  claim 25 , wherein the kidney cavity, the finger cavity, and the pivot pin cavity are joined together.  
   
   
       27 . The knuckle of  claim 20 , wherein the one or two internal cores comprise a sand resin.  
   
   
       28 . A system for manufacturing a railcar coupler knuckle, comprising: 
 a cope mold portion and a drag mold portion having internal walls defining at least in part perimeter boundaries of a coupler knuckle mold cavity;    one or two internal cores configured to be positioned within either the cope mold portion or the drag mold portion;    the one or two internal cores configured to define a kidney cavity, a finger cavity and a pivot pin cavity within a coupler knuckle formed upon: 
 the closing of the cope and drag mold portions with the one or two internal cores therebetween;  
 the at least partial filling of the mold cavity with a molten alloy; and  
 the solidifying of the molten alloy after filling to form the coupler knuckle.  
   
   
   
       29 . The system of  claim 28 , wherein the one or two internal cores comprise: 
 a kidney portion configured to define the kidney cavity of the coupler knuckle;    a finger portion configured to define the finger cavity of the coupler knuckle; and    a pivot pin portion configured to define the pivot pin cavity of the coupler knuckle.    
   
   
       30 . The system of  claim 28 , wherein the one or two internal cores comprise two internal cores.  
   
   
       31 . The system of  claim 30 , wherein the two internal cores comprise: 
 a first internal core comprising a kidney portion configured to define the kidney cavity of the coupler knuckle; and    a second internal core comprising: 
 a finger portion configured to define the finger cavity of the coupler knuckle; and  
 a pivot pin portion configured to define the pivot pin cavity of the coupler knuckle.  
   
   
   
       32 . The system of  claim 30 , wherein the two internal cores comprising: 
 a first internal core comprising a finger portion configured to define the finger cavity of the coupler knuckle; and    a second internal core comprising: 
 a pivot pin portion configured to define the pivot pin cavity of the coupler knuckle; and  
 a kidney portion configured to define the kidney cavity of the coupler knuckle.  
   
   
   
       33 . The system of  claim 28 , wherein the one or two internal cores comprise a sand resin.  
   
   
       34 . A method for manufacturing a railcar coupler knuckle, comprising: 
 providing a cope mold portion and a drag mold portion, the cope and drag mold portions having internal walls defining at least in part perimeter boundaries of a coupler knuckle mold cavity;    positioning two internal cores within either the cope mold portion or the drag mold portion, the two internal cores configured to define a kidney cavity, a finger cavity and a pivot pin cavity within a coupler knuckle;    closing the cope and drag mold portions with the two internal cores therebetween; and    at least partially filling the mold cavity with a molten alloy, the molten alloy solidifying after filling to form the coupler knuckle.    
   
   
       35 . The method of  claim 34 , wherein the two internal cores comprise: 
 a first internal core comprising a kidney portion configured to define the kidney cavity of the coupler knuckle; and    a second internal core comprising: 
 a finger portion configured to define the finger cavity of the coupler knuckle; and  
 a pivot pin portion configured to define the pivot pin cavity of the coupler knuckle.  
   
   
   
       36 . The method of  claim 34 , wherein the two internal cores comprise: 
 a first internal core comprising a finger portion configured to define the finger cavity of the coupler knuckle; and    a second internal core comprising: 
 a pivot pin portion configured to define the pivot pin cavity of the coupler knuckle; and  
 a kidney portion configured to define the kidney cavity of the coupler knuckle.