Main body core set assembly and core box for a coupler body

Abstract

A main body core box assembly for creating coupler head cores which are attachable to various shank cores includes a main body core box including two halves, each half including a pattern configured to form the outer walls of a first head core having a first shank core. A plug is insertable into an end of respective patterns to form a second, alternative head core having a first half of a connection joint attachable to a second shank core that includes a second half of the connection joint, the second shank core being different than the first shank core. The first half of the connection joint may be a male connector, where the plug includes a recess having an angled surface to create a notch on the male connector. The second half of the connection joint may be a female connector with a raised surface corresponding to the notch.

1 . A main body core box assembly for creating head cores which are attachable to various different shank cores for use in casting a coupler body, comprising:
 a main body core box including two halves, each half including a pattern configured to form the outer walls of a first head core having a first shank core; and   a plug insertable into an end of respective patterns of the main body core box such as to form a second, alternative head core having a first half of a connection joint attachable to a second shank core that includes a second half of the connection joint, the second shank core being different than the first shank core.   
     
     
         2 . The main body core box assembly of  claim 1 , where the plug comprises a pair of plugs insertable into patterns of respective halves of the main body core box. 
     
     
         3 . The main body core box assembly of  claim 1 , where the plug includes a recess that forms a male connector as at least part of the first half of the connection joint. 
     
     
         4 . The main body core box assembly of  claim 3 , where the recess includes at least one angled surface so as to create a notch in the male connector, where the second half of the connection joint comprises a female connector including a raised surface corresponding to the notch to ensure proper orientation of the second shank core relative to the second head core when connected. 
     
     
         5 . The main body core box assembly of  claim 1 , where the first half of the connection joint comprises a female connector and the second half of the connection joint comprises a male connector corresponding to the female connector. 
     
     
         6 . The main body core box assembly of  claim 1 , where the first and second shank cores comprise Type-E and Type-F shank cores, the first and second shank cores being of different lengths. 
     
     
         7 . The main body core box assembly of  claim 1 , where a cold box process is used to make the head core within the main body core box. 
     
     
         8 . The main body core box assembly of  claim 1 , further comprising an insert piece to form an aperture for a lock guide, the insert piece slidable along a slot formed on each half of the pattern. 
     
     
         9 . The main body core box assembly of  claim 8 , where the insert piece is inserted in and withdrawn from the inside of the pattern at approximately a 90-degree angle with respect to an axis formed through a longitudinal center of the pattern. 
     
     
         10 . The main body core box assembly of  claim 8 , where the insert piece fits within about a 0.005 inch tolerance of the dimensions of the slot. 
     
     
         11 . The main body core box assembly of  claim 1 , further comprising an insert piece to form an aperture for a thrower lug, the insert piece slidable along a slot formed on each half of the pattern. 
     
     
         12 . The main body core box assembly of  claim 11 , where the insert piece is inserted in and withdrawn from the inside of the pattern at approximately a 45-degree angle with respect to an axis formed through a longitudinal center of the pattern. 
     
     
         13 . The main body core box assembly of  claim 11 , where the insert piece fits within about a 0.005 inch tolerance of the dimensions of the slot. 
     
     
         14 . The main body core box assembly of  claim 1 , where the connection joint begins between about 14 and 17 inches from a front face of the second head core. 
     
     
         15 . A main body core set for casting a coupler body of a railcar coupler, comprising:
 a shank core configured with a female connector; and   a head core configured with a male connector attachable to the female connector of the shank core to form a tight-fitting connection joint, where the head core is adaptable for multiple types of shank cores, each type of shank core having a substantially identical female connector.   
     
     
         16 . The main body core set of  claim 15 , where the multiple types of shank cores comprise shank cores of different lengths. 
     
     
         17 . The main body core set of  claim 15 , where the male connector comprises a notched portion on a side thereof, and where the female connector comprises a raised portion that corresponds to the notched portion to ensure proper orientation of the shank core relative to the head core when connected. 
     
     
         18 . The main body core set of  claim 17 , where the notched portion and the raised portion have corresponding curved surfaces. 
     
     
         19 . The main body core of  claim 15 , where the shank and head cores are for a Type-F coupler. 
     
     
         20 . The main body core of  claim 15 , where the shank and head cores are for a Type-E coupler. 
     
     
         21 . The main body core set of  claim 15 , where a cold box process is used to make the head core and the shank core before interconnecting the head and shank cores. 
     
     
         22 . The main body core set of  claim 15 , where a mid-point of the connection joint is located between about 16 and 18 inches from a front face of the second head core. 
     
     
         23 . A method of creating a main body core for casting a coupler body of a railcar coupler, the method comprising:
 inserting a plug into a pattern of a main body core box, the plug configured to adapt an end of the pattern of the main body core box so that a head core formed within the pattern includes a first half of a connection joint attachable to a second shank core, the second shank core different than a first shank core formed integral with the head core when the plug is not used;   blowing sand into the main body core box;   curing the sand to form a head core including the first half of the connection joint; and   attaching the first half of the connection joint to a corresponding second half of the connection joint of the second shank core.   
     
     
         24 . The method of  claim 23 , where a cold box process is used for curing the sand. 
     
     
         25 . The method of  claim 23 , where the plug comprises a pair of plugs, one insertable into a cope mold portion of the pattern and the other insertable into a drag mold portion of the pattern. 
     
     
         26 . The method of  claim 23 , where the plug includes a recess that forms a male connector as at least part of the first half of the connection joint. 
     
     
         27 . The method of  claim 26 , where the recess includes an angled surface so as to create a notch in the male connector, where the second half of the connection joint comprises a female connector including a raised surface corresponding to the notch to ensure proper orientation of the second shank core relative to the head core when connected. 
     
     
         28 . The method of  claim 23 , where the first half of the connection joint comprises a female connector and the second half of the connection joint comprises a male connector corresponding to the female connector. 
     
     
         29 . The method of  claim 23 , where the second shank core is selected from multiple types of shank cores of different lengths. 
     
     
         30 . A main body core box assembly for creating head cores for use in casting a coupler body, comprising:
 a main body core box including cope and drag mold halves defining respective patterns configured to form a head core having a shank core integral therewith;   a first insert piece to form a first aperture for a lock guide, the first insert piece slidable along a first slot formed on each half of the pattern; and   a second insert piece to form a second aperture for a thrower lug, the second insert piece slidable along a second slot formed on each half of the pattern.   
     
     
         31 . The main body core box assembly of  claim 30 , where the second slot is oriented at approximately a 45-degree angle with respect to the first slot. 
     
     
         32 . The main body core box assembly of  claim 30 , where the first insert piece is inserted in and withdrawn from the inside of the pattern at approximately a 90-degree angle with respect to an axis formed through a longitudinal center of the pattern. 
     
     
         33 . The main body core box assembly of  claim 30 , where the second insert piece is inserted in and withdrawn from the inside of the pattern at approximately a 45-degree angle with respect to an axis formed through a longitudinal center of the pattern. 
     
     
         34 . The main body core box assembly of  claim 30 , where the first insert piece fits within about a 0.005 inch tolerance of the dimensions of the first slot. 
     
     
         35 . The main body core box assembly of  claim 30 , where the second insert piece fits within about a 0.005 inch tolerance of the dimensions of the second slot. 
     
     
         36 . The main body core box assembly of  claim 30 , further comprising:
 a plug insertable into an end of respective patterns of the main body core box such as to form a second head core with a connector attachable to a second shank core different than the integral shank core.   
     
     
         37 . The main body core box assembly of  claim 36 , where the plug comprises a pair of plugs insertable into respective patterns of the cope and drag mold halves of the main body core box. 
     
     
         38 . The main body core box assembly of  claim 36 , where the connector comprises a male connector insertable into a female connector of the second shank core to form a secure connection joint between the male and female connectors. 
     
     
         39 . A main body core set for casting a coupler body of a railcar coupler, comprising:
 a shank core configured with a male connector; and   a head core configured with a female connector attachable to the male connector of the shank core to form a tight-fitting connection joint, where the head core is adaptable for multiple types of shank cores, each type of shank core having a substantially identical male connector.