Patent Grant
11118851
The modern sporting rifle (MSR), based on the AR-15 platform, is one example of a gas operated firearm. An MSR appears cosmetically similar to military rifles, such as the M-16, but function like other semi-automatic civilian sporting firearms, firing only one round with each pull of the trigger. Gas operated firearms are also used by law enforcement and military organizations. Examples of gas operated firearms include, but are not limited to, AR10, AK-47, AK-74, M14 M16, M16A2, M4, FN SCAR family, M110, MK11, and others. These gas operated rifles have been produced by numerous manufacturers. These weapons, typically shoot, but are not limited to, 5.45 mm, 5.56 mm, 6.8 mm, and 7.62 mm bullets which provide very high bullet velocities.
These gas operated type rifles utilize either a direct gas impingement system or a gas and push rod system for operating their ejection and loading mechanisms, in an automatic mode and a semi-automatic mode. The expanding gas from the cartridge propellant is tapped from a port in the barrel intermediate the chamber and the muzzle end of the barrel. In the direct gas impingement system, a conduit extends from the port to the upper receiver and into the region of the bolt carrier. In the gas and pushrod system, the gas impinges against the push rod which extends to the upper receiver and into the region of the bolt carrier. During the initial firing of the cartridge, the bolt is locked into the barrel extension, the gas forces the bolt carrier backward a short distance to unlock the bolt. As the bolt carrier moves toward the butt of the gun, a bolt cam pin, forces the bolt to rotate, by this time the bullet has left the barrel. The inertia of the bolt and bolt carrier continues the rearward motion causing the bolt to extract the fired empty cartridge. A spring absorbs the rearward motion of the bolt and bolt carrier forcing the bolt and bolt carrier forward to engage the next cartridge in the magazine and push same into the chamber ready for firing.
The gas pressures for operating the gas operated style weapons are significant and with the 5.56 mm cartridges the exit velocities, typically in excess of 2700 feet per second (fps), substantially exceeding the sound barrier (about 1,126 fps). Associated with these velocities are high bullet travel distances, in excess of 2 miles, and high noise levels, including from the bullet breaking the sound barrier and generating shock waves that cannot be effectively suppressed.
Modifications have been developed for these gas operated weapons to shoot low mass rounds at low velocities that utilize telescoping cartridges-practice ammunition. Typically the cartridges have very low mass, compared to lethal rounds, and may also have frangible projectiles with marking media. The modifications include a bolt and bolt carrier modification that allows the bolt to retract entirely by the propulsion of the expanding telescoping cartridge with no assist from the gas port, effectively changing the function of the weapon from a direct gas impingement system to a direct blowback system. The bolt does not lock into place rearward of the chamber. The energetics in these cartridges is low compared to a normal lethal round and the rounds are relatively expensive.
A need remains for a system that implements a cartridge that fires projectiles at subsonic muzzle velocities, to be used with a modern sporting rifle that has energy levels in a mid energy range that may be used for hunting small game or target practice, that is not supersonic, and that does not have the distance range or energy levels of conventional cartridges, but still allows the modern sporting rifles to reliably cycle.
In various embodiments of the disclosure, a rifle system is disclosed suitable for delivery of projectiles at a reduced energy level relative to standard cartridges used in MSR systems. Standard cartridges deliver projectiles at muzzle energies typically in a range of 1200 foot-pounds force (ft-lbf) to 1400 ft-lbf. Herein, unless otherwise stated, a “reduced” energy level less than 70% of the standard energy level. Such energy levels include a so-called “mid energy” level, which, unless otherwise stated, is defined herein as delivering a projectile at a muzzle energy that is in a range from 50 foot-pounds force (ft-lbf) to 400 ft-lbf inclusive. Reduced energy levels also include mid- to low-energy level, which is herein defined as a projectile muzzle energy in a range of 15 ft-lbf to 250 ft-lbf inclusive. Herein, a range that is said to be “inclusive” includes the end point values of the range as well as all values between the end point values. Such reduced energy levels include both lethal and non-lethal rounds.
The mid energy and mid- to low-energy levels may be tailored to produce subsonic muzzle velocities of the projectile. Subsonic velocities can substantially reduce the noise associated with discharge of a firearm because of the absence of shock waves that are generated by the projectile at sonic or supersonic muzzle velocities. Accordingly, in some embodiments of the disclosure, the sound generated by the MSR can be effectively suppressed so that, in combination with standard silencer technology, the MSR can be operated without hearing protection.
In embodiments, a conversion kit is provided for a gas operated modern sporting rifle that is originally built to fire centerfire rimless necked cartridges to fire rimless necked cartridges of the same exterior casing form factor but utilizing a rimfire propellant unit that is fixed in a recess in the rear face of the cartridge and that is spaced forward in the recess. In embodiments such cartridges have a projectile that weighs from 40 grains to 100 grains. In embodiments, the entirety of the propellant for firing the cartridge projectile and for cycling the modern sporting rifle by direct blowback is provided by the rimfire propellant unit. In embodiments, the conversion kit includes a conversion bolt assembly to replace the original bolt and bolt carrier. The bolt assembly including a non-locking bolt with a bolt face that confronts and abuts the rearwardly most circular face of the rimless necked cartridges and that further has a rigid projection that extends into the recess to confront and engage the rearward surface of the rimfire propellant unit. An offset firing pin extends through a hole positioned near a periphery of the projection such that actuation of the firing pin engages the rim of the rimfire propellant unit. The conventional bolt assembly cannot fire the new ammunition in that the projection on the bolt precludes the bolt from going into an in-battery position with conventional centerfire necked cartridges and the offset firing pin precludes the firing pin from striking a centerfire primer.
In embodiments, the bolt may be formed of stainless steel by way of metal injection molding, providing an economical manufacturing method that is significantly less expensive than the conventional machining of the bolt. Utilization of a polymer bolt carrier accommodates the lack of close tolerances typically inherent in metal injection molding. The polymer to metal engagement of the bolt carrier and bolt does require the close tolerances of a metal bolt to metal bolt carrier. In embodiments, the bolt may be press fit into an injection molded polymer bolt carrier and may be retained therein by, for example a conventional roll pin extending transverse to the axis of travel of the bolt assembly.
The inventors have recognized that retention between the polymer bolt carrier and metal bolt may be enhanced by utilization of a series of recesses or divots along lengthwise extending surfaces of the bolt. The divots advantageously can also reduce the weight of the bolt. Such divots may form serrations that enhance the robustness of the interface between the polymer bolt carrier and the bolt. The enhancement of the robustness of the interface is applicable particularly where there is an interference fit between the polymer bolt carrier and the bolt and the bolt is forced into the polymer bolt carrier. The serrations and/or divots providing gripping teeth engaging the polymer of the bolt carrier. The enhancement of the robustness of the interface is further applicable where the polymer bolt is overmolded onto the bolt such that the molten polymer will fill the divots or serrations locking the polymer bolt carrier to the bolt.
In embodiments, a flange extends radially outward from the metal bolt to abuttingly engage a forward face of the polymer bolt carrier. This flange may provide further fixation of the polymer bolt carrier with respect to the bolt and enhance the robustness of the engagement between the bolt carrier and the bolt. The flange may absorb forward forces of the bolt carrier as the bolt assembly cycles into an in-battery position. The flange minimizes or eliminates shear forces between the bolt and bolt carrier along axially extending interfaces between the bolt and bolt carrier as the bolt assembly cycles that could otherwise affect a loosening of the bolt and bolt assembly interface after many cycles. The flange and receiver may cooperate to provide a surface that the forward face of the flange engages with a portion of the receiver or a barrel extension simultaneously as the front face of the bolt engages the barrel face. The flange may be configured as a tab extending outwardly at only an upper portion of the bolt. Such a tab configuration facilitates the metal injection molding of the bolt minimizing complexity of the mold.
Other components of the bolt assembly, for example the ejector and extractor, may also be formed by metal injection molding.
In conventional prior art conversion kits for converting modern sporting rifles to fire practice ammunition, the recoil spring is replaced by a spring with a lesser spring constant. In embodiments, a conversion kit can include components allowing “tuning” of the bolt assembly for reliable cycling without replacing the original recoil spring. Such components may include and assortment of weights that may be added to the bolt assembly, in particular, such weights may be added to the bolt carrier by the end user to adjust the reciprocating mass and to facilitate reliable cycling with the existing spring. In embodiments, a conversion kit may include an assortment of such weights and one or more replacement springs allowing the conversion of different brands and models of modern sporting rifles.
The inventors have recognized that conventional bolt assemblies utilize metal to metal bearing surfaces between the bolt assembly and the upper receiver and converting the metal bolt carrier to a polymer then provides a polymer to metal bearing surface with differing characteristics. Depending on the specific polymer, the engagement surface areas, and the amount of usage, that is the number or rounds fired, the bolt carrier polymer bearing surfaces may wear faster than the conventional metal bolt carriers and may provide different friction characteristics. A feature and advantage of embodiments is a bearing insert in the polymer bolt carrier that provides a bearing surface of a material other than the primary injection molded polymer of the polymer bolt carrier. Such inserts may be formed of a metal, for example, that will provide better wear surface and a similar or same friction characteristics as metal bolt carriers. The inserts may be attached to the polymer bolt carrier after molding or they may be placed in the polymer bolt carrier mold prior to injecting the molten polymer into the bolt carrier mold. In embodiments, the bearing inserts may have an adjustment capability such as a threaded member to vary engagement pressure between the bearing insert and receiver bearing surfaces. Such adjustment can provide adjustment of a “tuning” variable to optimize the smooth and reliable cycling of the firearm. In embodiments bearing surface adjustments may also be made to polymer pieces for adjusting the friction and spacing with respect to the bolt assembly and receiver. In embodiments, the bearing inserts can be a replaceable component. In embodiments, tuning may be a slidability adjustment at the receiver for adjusting the relative engagement force between the bolt assembly and the receiver thereby adjusting the relative friction and the slidability.
In conventional bolt assemblies for modern sporting rifles, specifically the AR15, the bolt assembly may be disassembled, in embodiments the conversion bolt and bolt carrier can be integrated to discourage or prevent any such disassembly minimizing consumer issues associated with incorrect reassembly.
The conversion kit may also include instructions for accomplishing the conversion and also instructions for the “tuning” of the new bolt assembly for obtaining reliable cycling of the mechanism. For example, utilizing attachable weights to attach to the bolt carrier, different springs, and bolt carrier bearing inserts, and adjustment of bearing inserts where adjustable.
In embodiments the rimless, necked cartridges utilizing exclusively a 22 caliber projectile weighs 28 grains to 85 grains. In embodiments the projectile weighs 25 grains to 65 grains.
In the disclosed embodiments, the reduced energy cartridges includes a polymer case. The polymer case provides a substantial reduction in the weight relative to conventional metallic casings. The reduction in weight is a substantial factor when considering the shipping and handling of bulk supplies of the cartridges, for example for shipping from supplier to user, in construction of storage and display facilities at the point of purchase, or in the consideration of supply logistics for military applications. Material costs (polymer vs. metals) may also be substantially reduced.
A consideration in the design of polymer-based cartridges is material strength. The firing chambers of many firearms do not support the perimeter of the cartridge near the base, in order to allow clearance for bolt operation and extraction mechanisms. (The unsupported region of the base of the cartridge is illustrated, for example, at
To address this concern, some embodiments of the disclosure include a reinforcement liner that provides support to the unsupported region of the cartridge. In some embodiments, the reinforcement liner lines the inner diameter of the cartridge case at the base. In some embodiments, a portion of the reinforcement liner is imbedded within an annular region of the polymer wall of the cartridge. The length of the reinforcement liner may be tailored to provide the necessary overlap with the supported regions of the cartridge, based on the power level of the cartridge. That is, the reinforcement liners for higher power rounds may have a greater length than for lower power rounds, to provide more overlap with the supported portion of the cartridge which enhances the strength of the bridging of the unsupported portion.
The reinforcement liner may be secured within the polymer casing by a process wherein the polymer case is overmolded onto the reinforcement liner. Various features and geometries also secure the reinforcement liner within the overmolded polymer case.
Structurally, in various embodiments of the disclosure, a reduced energy cartridge comprises a polymer case including: a sleeve portion defining a first outer diameter, the body portion including a base portion defining a base lumen; a neck portion defining a second outer diameter that is less than the first outer diameter, the neck portion defining a neck lumen; and a frustoconical portion extending between the body portion and the neck portion. A projectile includes a first portion disposed within the neck lumen and a second portion extending forwardly beyond the polymer case. A reinforcement liner is disposed within the base lumen, the reinforcement liner defining a sleeve lumen. A propellant unit is disposed in within the sleeve lumen, the propellant unit including: a housing defining a cavity; a propellant charge disposed inside the cavity for producing a quantity of propellant gas; and a priming material disposed inside the cavity for igniting the propellant.
In various embodiments of the disclosure, a reduced energy cartridge, comprises a polymer case having a polymer case wall, the polymer case including: a sleeve portion defining a first outer diameter, the body portion including a base portion defining a base lumen; a neck portion defining a second outer diameter that is less than the first outer diameter, the neck portion defining a neck lumen; and a frustoconical portion extending between the body portion and the neck portion. A projectile includes a first portion disposed within the neck lumen and a second portion extending forwardly beyond the neck portion of the polymer case. A reinforcement liner includes a sleeve portion at least partially imbedded annularly within the polymer case wall of the body portion and a flange portion extending rearwardly beyond the base portion of the polymer case. A propellant unit is disposed in within the base lumen, the propellant unit including: a housing defining a cavity; a propellant charge disposed inside the cavity for producing a quantity of propellant gas; and a priming material disposed inside the cavity for igniting the propellant.
In some embodiments, the polymer case is an injection molded case that is simultaneously overmolded onto the reinforcement liner and the projectile. An outer surface of the sleeve portion of the reinforcement liner may include texturing for enhanced coupling between the polymer case and the reinforcement liner. In some embodiments, the propellant unit is a rim fire blank, for example a .22 caliber power load. In some embodiments, the polymer case defines a forward cavity portion having a first diameter and a rearward cavity portion having a second cavity diameter that is smaller than the first cavity diameter so that polymer case wall includes a step portion where the rearward cavity portion meets the forward cavity portion. The polymer case may define a plurality of longitudinal flutes. In various embodiments, a tangentially extending relief groove is defined on an inner surface of the base portion adjacent the propellant unit. The tangentially extending relief groove is continuous.
In various embodiments of the disclosure, a method of fabricating a cartridge having a polymer case comprises: disposing a projectile in a first aperture defined by a mold; disposing a reinforcement liner in a second aperture defined by the mold; and, after disposing the projectile and the reinforcement liner into the mold, injecting a polymer into the mold. In some embodiments, prior to injecting the polymer into the mold, a pull core is inserted through the second aperture to register against a base of the projectile that is disposed in the first aperture. During the step of inserting the pull core through the second aperture, the pull core may be inserted through the reinforcement liner. In some embodiments, the pull core is removed after the polymer is set. In some embodiments, the pull core is removed after the polymer is cured. In various embodiments, prior to injecting the polymer into the mold, a fitting is positioned at a proximal end of the pull core, the fitting and the pull core cooperating to define a diaphragm gate, wherein the step of injecting the polymer is performed through the diaphragm gate. In some embodiments, the pull core includes a protrusion that forms a relief groove on an interior wall of the polymer case upon injection of the polymer. The relief groove may extend tangentially, and may be continuous. The relief groove may be formed on the polymer case distal to the reinforcement liner.
In various embodiments of the disclosure, a system comprises a gas operated modern sporting rifle (MSR), at least one reduced energy cartridge sized to conform to one of the .223 Remington, a 5.56×45 mm NATO cartridge, 7.62×51 mm NATO cartridge, and a 7.62×39 mm cartridge size having a polymer case and a .22 caliber rim fire power load for a propellant, and a replacement bolt assembly configured to allow a plurality of the reduced energy cartridges to be fired from the modern sporting rifle and cycled through the modern sporting rifle by blowback operation of the replacement bolt assembly. In an embodiment, the replacement bolt assembly moves the low energy cartridge into the chamber and extracts a casing of the low energy cartridge from the chamber after a projectile of the low energy cartridge has been fired through a barrel of the modern sporting rifle. In an embodiment, the modern sporting rifle comprises a upper receiver and a barrel extending forwardly from a forward end of the upper receiver, and the reduced energy cartridge comprises a projectile that is dimensioned to be received in a bore of the barrel.
In various embodiments of the disclosure, a reduced energy cartridge comprises a polymer case having a polymer case wall. The polymer case has a sleeve portion having a first outer diameter, a neck portion having a second outer diameter that is less than the first diameter, and a frustoconical portion extending between the body portion and the neck portion. A projectile of the cartridge has a first portion disposed inside a lumen defined by the neck portion of the polymer case and a second portion extending forwardly beyond the polymer case. A propellant unit is disposed in a lumen defined by a base of the polymer case. The propellant unit comprises a housing defining a cavity, a propellant charge disposed inside the cavity for producing a quantity of propellant gas and a priming material disposed inside the cavity for igniting the propellant. The propellant unit may be a rim fire blank, such as a .22 caliber power load, such as used in construction. In an embodiment, the propellant charge is sized to fire the projectile at a velocity of less than 1125 feet per second. The polymer case defines a forward cavity portion having a first diameter and a rearward cavity portion having a second cavity diameter that is smaller than the first cavity diameter so that polymer case wall includes a step portion where the rearward cavity portion meets the forward cavity portion. The step portion of the polymer case wall has an annular surface that is substantially orthogonal to a longitudinal axis of the polymer case so that propellant gas produced upon ignition of the propellant charge acts on the annular surface to produce a substantially rearward ejecting force on the polymer case. In an embodiment, the first cavity diameter is between 4.0 mm and 8.0 mm. In an embodiment, the second cavity diameter is between 2.0 mm and 7.0 mm. In an embodiment, the first outer diameter is between 8.9 mm and 9.1 mm. In an embodiment, the second outer diameter is between 6.2 mm and 6.4 mm.
In some embodiments of the disclosure, the polymer case has a plurality of longitudinal flutes. The flutes provide a reduced surface contact area in the chamber for reduced extraction force.
Additionally, the flutes provide a thin-walled casing section that may deform with the expansion of the forward portion of a .22 caliber power load inserted in the rearward end of the casing, thus locking the power load into the casing, preventing the power load from moving rearwardly with respect to the casing upon firing. The casing may otherwise be thinned at the region corresponding to the region of the power load that expands to receive and facilitate the radial expansion of the power load and to allow deformation of the polymer at said region effecting the locking of the polymer casing to the power load.
In some embodiments of the disclosure, a rim fire propellant unit expands upon firing to lock the primer to the polymer casing.
In embodiments utilizing a rimfire primer as a propellant unit, such as a power load, the exterior of the propellant unit is secured to the inwardly facing wall of the polymer casing with an adhesive.
A feature and advantage of some embodiments of the disclosure is a round which is quieter and does not create a sonic boom when fired to provide superior covert and stealth capabilities.
A feature and advantage of some embodiments of the disclosure is reduced projectile energy allowing for use in backyards, basements, training facilities, hunting small game, and the like.
A feature and advantage of some embodiments of the disclosure is low cost conversion of a modern sporting rifle to fire the cartridges described in the detailed description.
A feature and advantage of some embodiments of the disclosure is reduced wear to a modern sporting rifle firing the cartridges described in the detailed description.
A feature and advantage of some embodiments of the disclosure is reduced recoil (compared to standard cartridges) when the cartridges described in the detailed description are fired from a modern sporting rifle.
A feature and advantage of some embodiments of the disclosure is the suitability of a modern sporting rifle firing the cartridges described in the detailed description for use when hunting small game.
A feature and advantage of some embodiments of the disclosure is that standard modern sporting rifle magazines may be used in combination with the replacement bolt assemblies and cartridges described in the detailed description.
A feature and advantage of some embodiments of the disclosure is the ability to fire low energy cartridges having an amount of propellant that would not create sufficient gas pressure for operation of gas-operated reloading mechanism of a modern sporting rifle.
A feature and advantage of embodiments is providing a low-cost cartridge capable of cycling modern sporting rifles, that has providing economical
A feature and advantage of some embodiments of the disclosure is the ability to quickly and easily convert a modern sporting rifle back to firing regular full energy ammunition.
Referring to
Orientations are keyed from a firearm in a normal firing position and are applicable throughout this application. The various directions are illustrated in
Herein, the reduced energy cartridges are referred to collectively and generically by reference character 108, with specific configurations referred to by the reference character 108 followed by a letter suffix (e.g., reduced energy cartridge 108a at
In some embodiments, standard modern sporting rifle magazines may be used in combination with the replacement bolt assembly 120 and the reduced energy cartridges 108. The system 100 may include and be used with various firearms without deviating from the spirit and scope of the present detailed description. Embodiments of system 100 may include and be used with handguns and/or rifles. Embodiments of system 100 may include and be used with gas operated firearms and/or non-gas-operated firearms. Examples of gas operated firearms include, but are not limited to, AR10, AK-47, AK-74, M14, M16, M16A2, M4, FN SCAR family, M110, MK11, and others.
Referring to
A propellant unit 138 is disposed in a base lumen 140, the base lumen 140 being defined by a base 146 of the polymer case 104. The propellant unit 138 includes a housing 148 having an anvil 151 and defining a cavity 142. A propellant charge 106 is disposed inside the cavity 142, and a priming material 144 disposed inside the cavity 142 for igniting the propellant charge 106. In some embodiments, supplemental propellant 106′ is disposed within the polymer case 104 outside the propellant unit (
In some embodiments, the propellant charge 106, 106′ is sized to fire the projectile 122 at a velocity of less than 1125 feet per second. In certain embodiments, the propellant unit 138 contains the entire energetic load for launching the projectile 122 and operating the ejection mechanism of the modern sporting rifle 102. In some embodiments, the reduced energy cartridge 108 may include supplemental propellant 106′ disposed in one or more cavities defined by the polymer case 104 (e.g., as depicted for polymer cases 104a, 104c, and 104d of
Referring to
In the depicted embodiments, the polymer case wall 128 is unitary (i.e., formed as a single component) from the body lumen 155 to the first outer diameter D1 of the polymer case 104c, 104d. In some embodiments, the reduced energy cartridge 108c, 108d may include supplemental propellant 106′ that fills the forward cavity 150 and the body lumen 155 to eliminate air pockets between the propellant unit 138 and the projectile 122a. A primary distinction between polymer cases 104c and 104d is the volume (e.g., axial length) of the forward cavity 150. That is, the polymer case 104c defines a longer forward cavity 150, with space between the annular surface 156 and the projectile 122a. The polymer case 104d provides essentially no space, with the projectile 122a being proximate or in contact with the annular surface 156. In some embodiments, the diameter d3 of the forward cavity 150 and neck lumen 134 is in a range of 4.0 mm to 8.0 mm inclusive, with, the diameter d2 of the body lumen 155 is in a range between 2.0 mm and 7.0 mm inclusive. In some embodiments, the third outer diameter d3 is in a range of 8.9 mm and 9.1 mm inclusive, with the second outer diameter d2 in a range of 6.2 mm and 6.4 mm inclusive.
Functionally, the ability to size the forward cavity 150 and body lumen 155 enables tailoring the desired amount of supplemental propellant 106′ to be used to match the volume of the forward cavity 150 and body lumen 155, where the desired amount of supplemental propellant 106′ produces a desired energy level of the projectile in flight. By matching the volume of the supplemental propellant 106′ to the void volumes of the body lumen 155 and the forward cavity 150 that exists between the projectile 122 and the propellant unit 138, the supplemental propellant 106′ can be effectively packed or contiguous without substantial air pockets. Elimination of air pockets mitigates detonation or explosion of the propellant in favor of a rapid burning discharge. Upon ignition of the propellant charge 106, 106′, the initial pressure buildup of the propellant gas behind the projectile 122a acts on the annular surface 156 to produce a substantially rearward ejecting force on the polymer case 104c.
Referring to Table 1, muzzle velocities and muzzle energies for reduced energy cartridges 108 (and for reinforced reduced energy cartridges 308 described below) of various cartridge forms at various projectile weights are presented according to embodiments of the disclosure. The energy levels for 40 grain projectiles fall within a mid energy range of 50 ft-lbf to 450 ft-lbf inclusive. The reduced energy cartridges 108, 308 with 55 grain, 77 grain, and 100 grain projectiles may also be configured to deliver muzzle energies that fall within this range. Likewise, various embodiments of the reduced energy cartridges 108, 308 may be tailored to deliver subsonic velocities (i.e., less than about 1126 fps) for noise abatement.
Referring to
In an embodiment, the replacement bolt assembly weighs less than about 330 grams. In an embodiment, the replacement bolt assembly weighs less than about 300 grams. In an embodiment, the replacement bolt assembly weighs less than about 250 grams. In an embodiment, the replacement bolt assembly weighs less than about 200 grams. In an embodiment, the replacement bolt assembly weighs less than about 150 grams. In an embodiment, the replacement bolt assembly weighs less than about 120 grams.
In one or more embodiments, the modern sporting rifle 102 includes a gas-operated reloading mechanism comprising a piston that reciprocates longitudinally within a cylinder between a forward position and a rearward position when exposed to high-pressure gases from the firing of rounds. In one or more embodiments, the replacement bolt assembly 120 moves the reduced energy cartridges 108 into the chamber and extracts a casings of the reduced energy cartridges 108 from the chamber after the projectile 122 of the reduced energy cartridge 108 has been fired through a barrel of the modern sporting rifle 102. In one or more embodiments, the modern sporting rifle 102 comprises a upper receiver and a barrel extending forwardly from a forward end of the upper receiver, and the reduced energy cartridge comprises a projectile that is dimensioned to be received in a bore of the barrel.
In one or more embodiments, the modern sporting rifle 102 comprises a recoil spring disposed in a lumen defined by a receiver extension, the receiver extension extending in a rearward direction from the upper receiver and the recoil spring acts to bias the replacement bolt assembly in a forward direction. In one or more embodiments, the replacement bolt assembly 120 is biased in a forward direction by a recoil spring and translates in a rearward direction upon firing of the modern sporting rifle 102 to effect cycling of the modern sporting rifle 102 through blowback operation. In embodiments, the recoil spring is the original recoil spring supplied with the modern sporting rifle before installation of the replacement bolt assembly. In embodiments the spring may be replaced
The replacement bolt assembly 120 comprises a bolt 170. In one or more embodiments, the bolt 170 has a first portion disposed inside a cavity 200 defined by the bolt carrier 168 and a second portion extending forwardly beyond the bolt carrier 168. In one or more embodiments, the bolt carrier 168 comprises a body portion 220 and a key member 222 extending upward from the body, the key member does not generally engage the gas tube 221, see
In one or more embodiments, the replacement bolt assembly comprises an extractor 178 pivotally coupled to the bolt. In one or more embodiments, the extractor comprises 17-4 stainless steel. In one or more embodiments, the bolt comprises 17-4 stainless steel. In one or more embodiments, the replacement bolt assembly 120 comprises a firing pin 174. In one or more embodiments, the firing pin 174 is offset from a central longitudinal axis of the bolt 170. In one or more embodiments, the firing pin is positioned to strike a rim of a rim fire blank that is part of a reduced energy cartridge. In one or more embodiments, the firing pin 174 comprises 17-4 stainless steel.
Elevation and plan views of three sides of a replacement bolt assembly 120 are depicted in
Referring to
The bolt may have recesses or divots 181 defining serrations 182 that may be utilized for reducing the weight of the bolt and also for securing the bolt within the bolt carrier. In a press fit arrangement with a polymer carrier, the serrations will resist a sliding disengagement of the bolt and bolt carrier. The bolt may be secured in the bolt carrier with a roll pin 183 that also constrains the firing pin within the bolt. Where the polymer carrier is overmolded over the bolt, the serrations will fill with polymer and the bolt will be locked therein. Additionally, the bolt may have a flange 184 that the polymer bolt carrier may abut against, the flange serving as a stop with respect to the positioning of the polymer bolt carrier on the bolt. The bolt may have a forward projection 189 that fits into recesses of embodiments of reduced energy cartridges. The projection assuring that only the proper ammunition is fired with the replacement bolt and also providing a means of holding a rimfire propellant unit secure in the cartridge being fired, discussion below.
Referring to
The key 222 may also be a separate removable piece that can be a material other than the material of the bolt carrier body and may be secured by fasteners and otherwise adjusted by using different sizes, weights, shape, or materials to further facility tuning for reliable operation of the firearm.
In embodiments the bolt assembly may further be tuned by adjusting the inserts, the key member, or the weights, by changing their size, their position, or their radial projection distance to “tune” the operation of the replacement bolt assembly for use with reduced energy ammunition and for proper reliable cycling.
Referring to
Referring to
In the depicted embodiment of the reinforced reduced energy cartridge 308a, the radial protrusion 320 of the reinforcement liner 310a is provided by a flared portion 322 at a distal end 324 of the reinforcement liner 310a. The radial protrusion 320 may be provided by other means, for example a bead (not depicted) at the distal end 324 of the reinforcement liner 310a, or a radially extending band 326 that projects radially outward relative to the outer surface 314 of the sleeve portion 312 (depicted in
The reinforcement liner 310a includes a shoulder portion 332 that extends from a proximal end 334 of the sleeve portion 312, the shoulder portion 332 defining a radiused inner surface 336. A flange portion 338 extends from a proximal end 335 of the shoulder portion 332 and radially outward, beyond the shoulder portion 332, the flange portion 338 defining a proximal face 342 of the reinforcement liner 310a and also defining a radial extremity 344 of the reinforcement liner 310a. In the depicted embodiment, the flange portion defines a minimum inner diameter that is the same as an inner diameter of the proximal end 335 of the shoulder portion 332.
In some embodiments, the radiused inner surface 336 of the shoulder portion 332 and the flange portion 338 define an internal axial dimension 346 that is greater than the axial dimension 153 of the hollow rim portion 149 of the propellant unit 138. As such, in combination, the propellant unit 138 and the reinforcement liner 310a define a recess 352 between the proximal face 342 of the reinforcement liner 310a and the anvil 151 of the hollow rim portion 149, the recess 352 defining an axial dimension 354. In some embodiments, the axial dimension 354 is in a range of 0.02 inches to 0.07 inches inclusive. In some embodiments, the axial dimension 354 is in a range of 0.03 inches to 0.06 inches inclusive. In some embodiments, the axial dimension 354 is in a range of 0.04 inches to 0.05 inches inclusive.
Referring to
For the depicted embodiment of the reinforced reduced energy cartridge 308b, a proximal portion 358 of the reinforcement liner 310b extends rearwardly beyond the base 146 of the polymer case 104. A proximal end 362 of the base 146 may define the radiused inner surface 336. In some embodiments, the radiused inner surface 336 of the base 146 and a rearwardly-extending portion 364 of the reinforcement liner 310b define the internal axial dimension 346 that is greater than the axial dimension 153 of the hollow rim portion 149 of the propellant unit 138. As such, in combination, the propellant unit 138, the radiused inner surface 336, and the reinforcement liner 310b define the recess 352 between the proximal face 342 of the reinforcement liner 310b and the anvil 151 of the hollow rim portion 149, the recess 352 defining the axial dimension 354.
The propellant unit 138 is disposed within the base lumen 140 of the polymer case 104. In some embodiments, the base lumen 140 defines a tangentially extending relief groove 366 adjacent the propellant unit 138. The tangentially extending relief groove 366 may surround the propellant unit 138, i.e., be continuous.
Functionally, the reinforcement liner 310 reinforces the base 146 of the reinforced reduced energy cartridge 308 to withstand the forces incurred during discharge of the propellant unit 138, so that the polymer case wall 128 of the reinforced reduced energy cartridge 308 does not rupture during the discharge. The texturing of the outer surface 314, when implemented, enhances the coupling between the polymer case wall 128 and the reinforcement liner 310.
The axial dimension 354 of the recess 352 may be sized so that the reinforced reduced energy cartridges 308 is beyond the reach of center firing pins or rimfiring pins of certain weapons. In this way, the reinforced reduced energy cartridges 308 can be prevented from being discharged in various weapons.
For the reinforcement liner 310a, the radial protrusion 320, when implemented, extends radially into the polymer case wall 128 to secure the reinforcement liner 310a within the base 146 of the reinforced reduced energy cartridge 308a. The radiused inner surface 336 of the shoulder portion 332 of the reinforced reduced energy cartridge 308a may be substantially conformal to the hollow rim portion 149 of the propellant unit 138 to prevent deformation of the hollow rim portion 149 when inserted into the reinforcement liner 310a. The inner diameter 319 of the sleeve lumen 318 may be dimensioned for a slight interference fit with the propellant unit 138, requiring a light press fit of the propellant unit 138 into the reinforcement liner 310a, thereby securing the propellant unit 138 to the reinforcement liner 310a during shipping and handling.
For the reinforcement liner 310b, a distal end portion 368 of the sleeve portion 312 extends axially into the polymer case wall 128 to secure the reinforcement liner 310b within the base 146 of the reinforced reduced energy cartridge 308b. Imbedding the distal end portion 368 within the polymer case wall 128 prevents expanding gasses from leaking between the reinforcement liner 310b and the polymer case 104, thereby preventing failure of the polymer case wall 128 at the base 146.
The radiused inner surface 336 of the base 146 may be substantially conformal to the hollow rim portion 149 of the propellant unit 138 to prevent deformation of the hollow rim portion 149 when inserted into the base 146. The inner diameter of the base lumen 140 may be dimensioned for a slight interference fit with the propellant unit 138, requiring a light press fit of the propellant unit 138 into the polymer case 104, thereby securing the propellant unit 138 to the reinforcement liner 310b during shipping and handling.
The tangentially extending relief groove 366 provides relief for the expansion of the housing 148 of the propellant unit 138. Upon discharge of the propellant unit 138, the housing 148 may expand radially into the tangentially extending relief groove 366, thereby capturing and preventing the spent housing 148 from being propelled rearwardly within or out of the polymer case 104.
The reinforcement liners 310 may be fabricated by techniques known to the artisan, for example by stamping, milling, injection molding (including metals), or casting. The reinforcement liners 310 may be fabricated from any material strong enough to withstand the forces incurred during discharge of the propellant unit 138, such as metals or high strength epoxies.
Referring to
Accordingly, in some embodiments, a ratio of the length LS of the sleeve portion 312 of the reinforcement liner 310 to an overall length LA of the polymer case 104 is in a range of 5% to 20% inclusive. In some embodiments, the ratio of the length LS of the sleeve portion 312 of the reinforcement liner 310 to an overall length LA of the polymer case 104 is in a range of 20% to 40% inclusive. In some embodiments, the ratio of the length LS of the sleeve portion 312 of the reinforcement liner 310 to an overall length LA of the polymer case 104 is in a range of 30% to 50% inclusive.
The reinforcement liners 310c, 310d, and 310e also depict a radiused corner 372 at the inner diameter of the flange portion 338. The reinforced reduced energy cartridge 308e also depicts a body lumen 374 of reduced diameter relative to the base lumen 140 for increased thickness of the unitary polymer case wall 128 relative to wall thickness about the rearward cavity 152, in combination with a rim fire blank power load 138. It is noted that the increased thickness of the unitary polymer case wall 128 may be implemented in any of the reinforced reduced energy cartridges 308, as well as reduced energy cartridges 108. It is further noted that it is not necessary to implement the increased thickness of the unitary polymer case wall 128 in the reinforced reduced energy cartridge 308e.
Reinforcement liners 310f and 310 g of reinforced reduced energy cartridge 308f and 308g (
The radial protrusion 382 may be continuous. The radial protrusion 382 defines a radial protrusion dimension 384 relative to an inner diameter 386 of the sleeve portion 312 at a distal end 388 of the sleeve portion 312 (
Reinforcement liner 310h of reinforced reduced energy cartridge 308h (
Alternatively, or in addition, a reinforcement liner 310i may include an outwardly inclined outer surface 402, as depicted in
Geometries where the sleeve portion 312 of the reinforcement liner 310 defines inner or outer surfaces 392, 402 that are inclined are herein referred to as “tapered-cylindrical.” The tapered-cylindrical geometries depicted in
The reinforcement liners 310h and 310i may be characterized by the magnitude of the incline of the sleeve portion 312. The “magnitude of the incline” is taken as the difference between the proximal end and distal end diameters. Specifically, for the inwardly inclined inner surface 392, the magnitude of the incline is the difference between the proximal inner diameter 394 and the distal inner diameter 396 of the sleeve portion 312. For the outwardly inclined outer surface 402, the magnitude of the incline is the difference between the distal outer diameter 406 and the proximal outer diameter 404 of the sleeve portion 312. In some embodiments, the magnitude of the incline is in a range of 75 micrometers to 250 micrometers inclusive. In some embodiments, the magnitude of the incline is in a range of 75 micrometers to 150 micrometers inclusive. In some embodiments, the magnitude of the incline is in a range of 100 micrometers to 150 micrometers inclusive.
Reinforcement liner 310j of reinforced reduced energy cartridge 308j (
Functionally, the length of the sleeve portions 312 may be dictated by the power level of the respective reinforced reduced energy cartridge 308. That is, as power increases, the length of the sleeve portion 312 may need to increase as well to effectively bridge and prevent failure of the portion of the polymer case 104 that is not supported by the chamber of the firearm. The radiused corner 372 may facilitate ejection of the reinforced reduced energy cartridge 308, as explained in further detail below. Both the inward radial protrusion 382 of (
Referring to
A pull core 416 is inserted through the reinforcement liner 310a and registered against and concentrically with the projectile 122 (
Liquid polymer 410 is injected through the injection port 412 to fill the remaining voids of the mold cavity 405. Displaced gas from the mold cavity 405 is vented through the vent port 414 (
Referring to
Functionally, the raised portion 434 prevents the propellant unit 138 from being displaced rearwardly within the base lumen 140 during discharge. Such displacement may otherwise occur upon contact with the rimfire firing pin 174, causing the anvil 151 of the propellant unit 138 to tear or rupture against the firing pin 174 before the firing pin 174 is withdrawn. Such rupture can cause some of the expanding gases to leak therethrough, reducing the energy imparted to the projectile in an unwanted and unpredictable manner.
Referring to
Referring to
Because of the arcing action, the portion of the flange portion 338 that is adjacent the opposed portion 444 of the bolt 432 moves radially inward, toward the longitudinal axis C. The radiused relief shoulders 436 enable flange portion 338 to clear the bolt 432 without incidental contact with the raised portion 434. To illustrate this effect, a hypothetical squared corner profile 447 for the raised portion 434 is depicted in phantom in
The
Referring to
Functionally, the sloped relief face 449 operates to the same effect as the radiused relief shoulders 436, as depicted in
Alternative relief structures for providing clearance between the reinforced reduced energy cartridge 308 and the raised portion 434 of the bolt 432 are also contemplated. For example, the raised portion 434 could be of a frustoconical shape that tapers toward the longitudinal axis C at the distal face 435. Also, instead of radiused shoulders, chamfered shoulders may be used to the same effect. Also, the radiused, chamfered, or frustoconical relief does not have to be continuous about the periphery of the raised portion 434. Rather, as with the sloped relief face 449, the radiused, chamfered, or frustoconical relief may be localized to the opposed portion 444 of the raised portion 434 of the bolt 432.
Referring to
An injection port 472 is defined in a fitting 474 that is disposed within the reinforcement liner 310b against a proximal end 476 of the pull core 466. In the depicted embodiment, the fitting 474 defines the radiused inner surface 336 of the base 146 during the molding process. Also in the depicted embodiment, the fitting 474 cooperates with the pull core 466 to define a diaphragm gate 478 for injection molding of the polymer case wall 128.
Upon registration of the projectile 122, the reinforcement liner 310b, the core pull 466, and the fitting 474, the exposed surfaces of the mold cavity 454 define the exterior surfaces of the polymer case 104, and the core pull 466 defines the base lumen 140 (
Liquid polymer 410 is injected through the injection port 472 to fill the remaining voids of the mold cavity 454. Displaced gas from the mold cavity 454 is vented through the vent port 464 (
As is known in the art, there is a window of time in the curing process where the shape of the molded article is defined and the polymer is set, but the polymer is still soft and pliable. It is during this time window that the core pull 466 is removable from the tangentially extending relief groove 366 without damaging the polymer case 104. Also known in the art is the proper dimensioning of a protrusion 470 that defines the tangentially extending relief groove(s) 366 that enables removal of the core pull 466 without damage to the polymer case 104.
In the depiction of
The reinforced reduced energy cartridge 308b is depicted as defining a single tangentially extending relief groove 366. Alternatively, a plurality of such relief grooves may be defined, each of reduced radial dimension to reduce the force required to remove the core pull 466. Also, the relief groove 366 may be extended in the axial dimension and reduced in the radial dimension to the same effect. Also in the depicted embodiment, the tangentially extending relief groove 366 is disposed forward of the reinforcement liner 310b. Alternatively, the relief groove(s) 366 can be disposed closer to the proximal end 362 of the base 146, surrounded by the reinforcement liner 310b.
Referring to
Referring to
The external reinforcement sleeve 510k includes an external shoulder portion 532 that extends from a proximal end 534 of the sleeve portion 512, the external shoulder portion 532 including an outer surface 536. A neck portion 533 extends axially from a proximal end 535 of the shoulder portion 532. A flange portion 538 extends radially outward from the neck portion 533, the flange portion 538 defining a proximal face 542 of the external reinforcement sleeve 510k and also defining a radial extremity 544 of the external reinforcement sleeve 510k. In the depicted embodiment, the neck portion 533 defines a minimum inner diameter 545 that is less than the maximum inner diameter 519.
For reinforced reduced energy cartridge 308k, the neck portion 533 of the external reinforcement sleeve 510k extends rearwardly beyond the base 146 of the polymer case 104 (
Referring to
Accordingly, in some embodiments, a ratio of the length LS of the sleeve portion 512 of the external reinforcement sleeve 510 to an overall length LA of the polymer case 104 is in a range of 5% to 20% inclusive. In some embodiments, the ratio of the length LS of the sleeve portion 512 of the external reinforcement sleeve 510 to an overall length LA of the polymer case 104 is in a range of 20% to 50% inclusive. In some embodiments, the ratio of the length LS of the sleeve portion 512 of the external reinforcement sleeve 510 to an overall length LA of the polymer case 104 is in a range of 50% to 80% inclusive.
Referring to
In some embodiments, reinforced reduced energy cartridges 308o and 308p utilize an external reinforcement sleeve 510o and 510p, respectively, the reinforcement sleeves 510o, 510p each include a punched retention feature 550o, 550p, respectively (
In some embodiments, a reinforced reduced energy cartridge 308q includes an external reinforcement sleeve 510q having dimple retention features 550q (
In some embodiments, a reinforced reduced energy cartridge 308r includes an external reinforcement sleeve 510r having at least one ribbed retention feature 550r (
In some embodiments, a reinforced reduced energy cartridge 308s includes an external reinforcement sleeve 510s (
In some embodiments, a reinforced reduced energy cartridge 308t includes an external reinforcement sleeve 510t (
Functionally, the external reinforcement sleeve 510 surrounds the base 146 of the polymer case 104 and partially captures the proximal end 362 of the base 146, thereby enabling the reinforced reduced energy cartridge 308 to withstand the forces incurred during discharge of the propellant unit 138 and prevent rupturing of the polymer case wall 128 of the reinforced reduced energy cartridge 308. Because the polymer case wall 128 effectively lines sleeve portion 512, there is no path for expanding gasses to leak between the external reinforcement sleeve 510 and the polymer case wall 128.
The radiused inner surface 336 of the base 146 may be substantially conformal to the hollow rim portion 149 of the propellant unit 138 to prevent deformation of the hollow rim portion 149 when inserted into the base 146. The inner diameter of the polymer case wall 128 may be dimensioned for a slight interference fit with the propellant unit 138, requiring a light press fit of the propellant unit 138 into the polymer case 104, thereby securing the propellant unit during shipping and handling. Embodiments utilizing the external reinforcement sleeve 510 may also include a tangentially extending relief groove (not depicted), akin to the tangentially extending relief groove 366 of the reinforced reduced energy cartridge 308b, for the same function and utility. Embodiments utilizing the external reinforcement sleeves 510 may also incorporate polymer casings with body lumens 374 of reduced diameter (not depicted) relative to the base lumen 140, akin to reinforced reduced energy cartridge 308e (
The external reinforcement sleeves 510 may be fabricated by techniques known to the artisan, for example by stamping, milling, injection molding (including metals), or casting. The external reinforcement sleeve 510 may be fabricated from any material strong enough to withstand the forces incurred during discharge of the propellant unit 138, such as metals or high strength epoxies.
The following United States patents are hereby incorporated by reference herein in their entirety except for patent claims and express definitions contained therein: U.S. Pat. Nos. 9,273,941; 9,261,335; 9,003,973; 8,875,633; 8,869,702; 8,763,535; 8,726,560; 8,590,199; 8,573,126; 8,561,543; 8,453,367; 8,443,730; 8,240,252; 8,146,505; 7,984,668; 7,621,208; 7,444,775; 7,441,504; 7,278,358; 7,225,741; 7,059,234; 6,931,978; 6,845,716; 6,752,084; 6,625,916; 6,564,719; 6,439,123; 6,178,889; 5,677,505; 5,492,063; 5,359,937; 5,216,199; 4,955,157; 4,169,329; 4,098,016; 4,069,608; 4,058,922; 4,057,003; 3,776,095; and 3,771,415. Components illustrated in the incorporated by reference references may be utilized with embodiments herein. Incorporation by reference is discussed, for example, in MPEP section 2163.07(B).
All of the features disclosed, claimed, and incorporated by reference herein, and all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. Each feature disclosed in this specification may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is an example only of a generic series of equivalent or similar features. Inventive aspects of this disclosure are not restricted to the details of the foregoing embodiments, but rather extend to any novel embodiment, or any novel combination of embodiments, of the features presented in this disclosure, and to any novel embodiment, or any novel combination of embodiments, of the steps of any method or process so disclosed.
Although specific examples have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement calculated to achieve the same purpose could be substituted for the specific examples disclosed. This application is intended to cover adaptations or variations of the present subject matter. Therefore, it is intended that the invention be defined by the attached claims and their legal equivalents, as well as the illustrative aspects. The above described embodiments are merely descriptive of its principles and are not to be considered limiting. Further modifications of the invention herein disclosed will occur to those skilled in the respective arts and all such modifications are deemed to be within the scope of the inventive aspects.
This application is a continuation-in-part of U.S. application Ser. No. 16/141,505, filed Sep. 25, 2018, now U.S. Pat. No. 10,466,022, which is a continuation-in-part of International Patent Application No. PCT/US2017/024361, filed Mar. 27, 2017, which claims the benefit of U.S. Provisional Patent Application No. 62/331,563, filed Mar. 25, 2016, U.S. Provisional Patent Application No. 62/348,258, filed Jun. 10, 2016, and U.S. Provisional Patent Application No. 62/413,065, filed Oct. 26, 2016. the disclosures of which are hereby incorporated by reference herein in their entirety. This application also claims the benefit of U.S. Provisional Patent Application No. 62/856,146, filed Jun. 3, 2019, the disclosure of which is hereby incorporated by reference herein in its entirety.
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| Number | Date | Country | |
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| 20200080803 A1 | Mar 2020 | US |
| Number | Date | Country | |
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| 62856146 | Jun 2019 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 16141505 | Sep 2018 | US |
| Child | 16674925 | US | |
| Parent | PCT/US2017/024361 | Mar 2017 | US |
| Child | 16141505 | US |
