A coupler having a support provided through the body of the coupler and a plurality of openings in the coupler which are configured as open cavities. The coupler structure includes a shank that has a vertical support as well as lateral support. The coupler may be configured with a double I-beam structure with openings into the shank. Cores that may be fixed to the mold may be used to form the coupler and produce the openings in the shank.

A coupler having a support provided through the body of the coupler and a plurality of openings in the coupler which are configured as open cavities. The coupler structure includes a shank that has a vertical support as well as lateral support. The coupler may be configured with a double I-beam structure with openings into the shank. Cores that may be fixed to the mold may be used to form the coupler and produce the openings in the shank.

A process for producing a coupler knuckle and an improved coupler knuckle design are provided. The process produces a coupler knuckle by constructing a mold having the shape of the coupler knuckle. The mold is coated with a material that is resistant to melting at the molten melt temperatures of the molten metal used to form the knuckle. With the mold coated, the cavities in the mold interior are filled by placing an inert material therein. The molten metal used for forming the knuckle contacts the mold and consumes it, while the coating serves to provide a shape for the knuckle.

A process for producing a coupler knuckle and an improved coupler knuckle design are provided. The process produces a coupler knuckle by constructing a mold having the shape of the coupler knuckle. The mold is coated with a material that is resistant to melting at the molten melt temperatures of the molten metal used to form the knuckle. With the mold coated, the cavities in the mold interior are filled by placing an inert material therein. The molten metal used for forming the knuckle contacts the mold and consumes it, while the coating serves to provide a shape for the knuckle.

An energy absorption system for a railcar having an elongated sill with front and rear stops defining a pocket therebetween. To facilitate use of known railcar structures, the energy absorption system can be used in combination with a railcar also having a sill with center stops disposed between the front and rear stops. A coupler having a head portion and a shank portion is arranged in operable combination with the energy absorption system. The energy absorption system also includes a first cushioning assembly positioned in the sill pocket. A first follower is urged toward and engageable with the front stops under the influence of the first cushioning assembly and is operably engageable with a free end of the shank portion of the coupler. A second cushioning assembly is positioned in generally axial alignment with first cushioning assembly. A second follower is positioned and normally urged by the energy absorption system toward and configured to engage with the center stops. An axially elongated yoke encompasses the first and second cushioning assemblies, terminates in an open forward end, and is coupled to the shank portion of the coupler. The first and second cushioning assemblies act in series relative to each other to absorb and cushion impact forces directed against them when the energy absorption system operates in a buff direction. Advantageously, the second follower acts in concert with the center stops and the second cushioning assembly to minimize excessive system cycles while better dissipating train action energy when the energy absorption system operates in a draft direction.

A method for manufacturing railcar coupler headcores includes providing a first corebox having internal walls defining at least in part perimeter boundaries of at least one rotor core cavity. The method further comprises at least partially filling the at least one rotor core cavity with a first sand resin to form at least one rotor core. The method also includes providing a second corebox having internal walls defining at least in part perimeter boundaries of at least one headcore cavity. The at least one rotor core is positioned within the second corebox. The method also comprises at least partially filling the at least one headcore cavity with a second sand resin to form at least one headcore.

A method for manufacturing railcar coupler headcores includes providing a first corebox having internal walls defining at least in part perimeter boundaries of at least one rotor core cavity. The method further comprises at least partially filling the at least one rotor core cavity with a first sand resin to form at least one rotor core. The method also includes providing a second corebox having internal walls defining at least in part perimeter boundaries of at least one headcore cavity. The at least one rotor core is positioned within the second corebox. The method also comprises at least partially filling the at least one headcore cavity with a second sand resin to form at least one headcore.

A railcar end unit is operable to be mounted in a center sill between buff and draft sill stops. The buff and draft end bodies are configured to be shiftably mounted relative to the center sill to engage the respective sill stops and to shift axially relative to one another along a unit axis. The end unit includes a buff spring pack operably mounted between the end bodies and compressible along the unit axis from a neutral condition to a compressed condition.

An adapter component for adapting a coupling head of a first construction type with a coupling head of a second construction type. The adapter component is constructed, in place of the articulated jaw of the coupling head of the first construction type which is intended to be adapted, to be releasably connected to the coupling head of the first construction type and in particular to the coupling head body of the coupling head of the first construction type.

An adapter component for adapting a coupling head of a first construction type with a coupling head of a second construction type. The adapter component is constructed, in place of the articulated jaw of the coupling head of the first construction type which is intended to be adapted, to be releasably connected to the coupling head of the first construction type and in particular to the coupling head body of the coupling head of the first construction type.