Down sprue core for use in casting railcar coupler knuckles

Abstract

A core for use in railcar coupler part casting processes is provided. The core has a hollow body, a top with a first opening defined therein, a bottom having a generally rounded wall, and second and third openings defined in the side wall of the body.

1 . A core for use in railcar coupler part casting processes, said core comprising:
 a hollow body;   a top with a first opening defined therein;   a bottom having a generally rounded wall; and   second and third openings defined in the side wall of the body.   
     
     
         2 . The core of  claim 1 , wherein said second and third openings are defined opposite each other in said side wall of said body. 
     
     
         3 . The core of  claim 1 , further comprising a fourth opening defined in said side wall of said body. 
     
     
         4 . The core of  claim 3 , further comprising a fifth opening defined in said side wall of said body. 
     
     
         5 . The core of  claim 4 , wherein said fourth and fifth openings are defined opposite each other in said side wall of said body. 
     
     
         6 . The core of  claim 1 , wherein said first opening matches a down sprue defined in a cope portion of a mold. 
     
     
         7 . The core of  claim 2 , wherein said second and third openings are designed to feed into first and second risers defined in a mold. 
     
     
         8 . The core of  claim 5 , wherein said fourth and fifth openings are designed to feed into third and fourth risers defined in a mold. 
     
     
         9 . The core of  claim 7 , wherein said outer wall of said bottom of said core includes a first extension defined thereon. 
     
     
         10 . The core of  claim 7 , wherein said side wall has a second extension defined thereon. 
     
     
         11 . The core of  claim 9 , wherein said first extension is designed to match an opening defined in said drag portion of said mold. 
     
     
         12 . The core of  claim 11 , further comprising a second extension defined on said side wall of said core. 
     
     
         13 . The core of  claim 12 , wherein said first extension is cylindrical. 
     
     
         14 . The core of  claim 12 , wherein said second extension is a cylindrical trough. 
     
     
         15 . The core of  claim 12 , wherein said first extension extends at least about 1″ from said outer wall of said bottom of said core. 
     
     
         16 . The core of  claim 12 , wherein said second extension extends about 1″ from said side wall of said core. 
     
     
         17 . The core of  claim 12  wherein, said first extension is about 2″ in diameter. 
     
     
         18 . The core of  claim 12 , wherein said first extension has a radius of between about 0.5″ and 1.5″. 
     
     
         19 . The core of  claim 12 , wherein said second extension has a radius of between about 0.5″ and 1.5″. 
     
     
         20 . The core of  claim 7 , wherein said outer wall of said bottom of said core substantially matches a rounded wall in said drag portion of said mold. 
     
     
         21 . The core of  claim 6 , further comprising a first hollow cylindrical wall extending from said side wall around said second opening and a second hollow cylindrical wall extending from said side wall around said third opening. 
     
     
         22 . The core of  claim 21 , wherein said first and second hollow cylindrical walls are between about 0.25″ and 0.75″ in thickness. 
     
     
         23 . The core of  claim 22 , wherein said first and said second hollow cylindrical walls extend between about 0.5″ and 1.5″ from said side wall. 
     
     
         24 . The core of  claim 22 , wherein said first and second hollow cylindrical walls have a uniform thickness. 
     
     
         25 . The core of  claim 7 , wherein said core is a no-bake blown core. 
     
     
         26 . The core of  claim 7 , wherein said second and third openings have diameters of between about 1″ and 3″. 
     
     
         27 . The core of  claim 1 , wherein said core has a sand grain fineness value of between about 75-80. 
     
     
         28 . The core of  claim 1 , wherein said core is a 2 piece core. 
     
     
         29 . A core for use in railcar coupler part casting processes, said core comprising:
 a hollow body;   a top with a first opening defined therein;   a bottom wall; and   a plurality of openings defined in a side wall of said body.   
     
     
         30 . The core of  claim 29 , wherein said plurality of openings defined in said side wall of said body comprises at least four openings, wherein first and second openings are defined on said side wall opposite each other and third and fourth openings are defined on said side wall opposite each other. 
     
     
         31 . The core of  claim 29 , wherein each of said plurality of openings feeds into a separate riser defined in a mold. 
     
     
         32 . The core of  claim 29 , further comprising a first extension defined on an outside surface of said bottom wall. 
     
     
         33 . The core of  claim 32 , further comprising a second extension defined on an outside surface of said side wall. 
     
     
         34 . A core for use in railcar coupler part casting processes, said core comprising:
 a hollow body;   a top wall with a first opening defined therein;   a bottom wall;   a side wall with at least one opening defined therein;   at least one channel defined in the interior of said side wall; and   at least one filter shaped to fit in said channel.   
     
     
         35 . The core of  claim 34 , wherein said channel is arcuate. 
     
     
         36 . The core of  claim 34 , wherein said filter is square. 
     
     
         37 . The core of  claim 35 , wherein said filter is circular. 
     
     
         38 . The core of  claim 34 , wherein said filter is positioned such that material passing through said at least one opening in said at least one side wall must pass through said filter. 
     
     
         39 . The core of  claim 34 , further comprising a second opening defined in said side wall. 
     
     
         40 . The core of  claim 39 , further comprising a second channel defined on the interior of said side wall. 
     
     
         41 . The core of  claim 40 , further comprising a second filter shaped to fit in said second channel. 
     
     
         42 . The core of  claim 34 , wherein said core is comprised of a first and a second half. 
     
     
         43 . The core of  claim 34 , wherein said opening in said top wall matches a down sprue defined in a cope portion of a mold. 
     
     
         44 . The core of  claim 34 , wherein said opening in said side wall is designed to feed into a riser defined in cope and drag portions of a mold. 
     
     
         45 . The core of  claim 34 , further comprising a first extension defined on an outside surface of said bottom wall. 
     
     
         46 . The core of  claim 45 , wherein said first extension is designed to match an opening defined in a drag portion of a mold. 
     
     
         47 . The core of  claim 46 , further comprising a second extension defined on said side wall of said core. 
     
     
         48 . The core of  claim 47 , wherein said second extension is designed to match an opening defined in a drag portion of a mold. 
     
     
         49 . The core of  claim 48 , wherein said first extension is cylindrical. 
     
     
         50 . The core of  claim 47 , wherein said second extension is a cylindrical trough. 
     
     
         51 . A core for use in railcar coupler part casting processes, said core comprising:
 a hollow body;   a top wall with a first opening defined therein;   a bottom having a wall; and   at least one opening defined in a side wall.   
     
     
         52 . The core of  claim 51 , wherein said at least one opening in said side wall is shaped to match a runner that feeds a riser defined in said mold. 
     
     
         53 . The core of  claim 52 , wherein said first opening in said top wall is shaped to match a downsprue defined in a mold. 
     
     
         54 . (canceled) 
     
     
         55 . (canceled) 
     
     
         56 . (canceled) 
     
     
         57 . (canceled) 
     
     
         58 . (canceled) 
     
     
         59 . (canceled) 
     
     
         60 . (canceled) 
     
     
         61 . (canceled) 
     
     
         62 . (canceled) 
     
     
         63 . (canceled) 
     
     
         64 . (canceled) 
     
     
         65 . (canceled) 
     
     
         66 . (canceled) 
     
     
         67 . (canceled) 
     
     
         68 . (canceled) 
     
     
         69 . (canceled) 
     
     
         70 . (canceled) 
     
     
         71 . (canceled) 
     
     
         72 . (canceled) 
     
     
         73 . (canceled) 
     
     
         74 . (canceled) 
     
     
         75 . (canceled) 
     
     
         76 . (canceled) 
     
     
         77 . (canceled) 
     
     
         78 . (canceled) 
     
     
         79 . (canceled) 
     
     
         80 . (canceled)