Modifications For M16 R15 Rifle
Modifications For M16 R15 Rifle
200 N
202
US 9,121,614 B2
Page 2
(56) References Cited JGS, Rimless or Rebated Rifle Minimum Chamber, SAAMI 223
REM (5.56MM), Print #0517, May 8, 2002.
U.S. PATENT DOCUMENTS Johnston, Gary Paul “The 6.8mm Remington SPC.” Internet article
dated Apr. 18, 2004, XP-002548838, <http://www.rifleshootermag.
6,625,916 B1 9, 2003 Dionne com/ammunition/remington 0303/>, pp. 1-4.
6,964,232 B2 11/2005 Eberhart et al. Johnston, Gary Paul “The 6.8mm Rem SPC.” Guns & Ammo Book
7,739,939 B2 6, 2010 Adams of the AR-15, 2004, pp. 46-50, 52, 54, 56, and 57.
7,779,743 B2 8/2010 Herring Mushial, Gregory J.-223 Remington, Copyright 1997-2006.
7.971,382 B2 7, 2011 Robinson et al. Nischalke, Mike, Editor in Chief “The R-15 and the .30 RAR,
7.971,518 B2 7, 2011 Adams Remington Reinvents the Black Rifle.” Shooting Times, Jun. 2009,
7,975,595 B2 7, 2011 Robinson et al. pp. 34-41.
8,069,600 B2 12/2011 Rousseau et al. Roberts, Gary K.—"Time for a Change.” U.S. Military Small Arms
8,096,074 B2 1/2012 Robinson et al. Ammunition Failures and Solutions, NDIA Dallas, Texas, May 21,
2003/0101891 A1 6, 2003 Amick 2008.
2003/O131751 A1 7/2003 MacKerell et al.
2003/0213396 A1 1 1/2003 Dippold S.A.A.M.I.Technical Committee Manual, Section I-Characteris
2004/OO74412 A1 4/2004 Kightlinger tics, Center Fire Rifle, p. 1468.2, Jul. 6, 1962.
2004/O2555O2 A1 12/2004 Jamison SAAMI Maximum Cartridge / Minimum Chamber 223 Remington
2005/0066845 A1 3/2005 Eberhart et al. Technical Drawings (date unknown).
2005/0211126 A1 9/2005 Hurley Sierra Bullets, L.P. “7mm TCUSSP.” Sierra Reloading Manual, 5th
2005/0262752 A1 12/2005 Robinson et al. Edition, 2003, pp. 884, 887, 889, and 890.
2006, OO37464 A1 2/2006 Moore Sierra Bullets, L.P.—Rifle Reloading Data: 6x45mm and 6x47mm,
2006, OO65112 A1 3/2006 Kuczynko et al. Sierra Reloading Manual 5th Edition, published by Sierra Bullets,
2006/0248773 A1 11/2006 Kightlinger Sedalia, Missouri, 2003, pp. 281 and 285.
2007/O199435 A1 8, 2007 Hochstrate et al.
2009, 0211483 A1 8, 2009 Kramer SSK Industries, “300 Whisper.” SSK Industries, Wintersville, Ohio,
2010/0281734 A1 11/2010 Rousseau et al. date unknown, 4 pages.
2011/0094.373 A1 4/2011 Cassels The Reload Bench "7mm TCU.” Internet article dated May 8,
2011, <http://www.reloadbench.com/cartridges/w7mmtcu.html>.
OTHER PUBLICATIONS Williams, Anthony G. "More Punch for the AR-15.” Internet article
dated Feb. 1996, XP-002548730. http://www.quarry nildram.co.uk/
AR15bigbore.htm. pp. 1-3.
Barnes, F. C. "Cartridges of the World, Passage.” Cartridges of the Chastain, R., “Homady's New Ammo Loadings for 2007 a Mixture of
World, Jan. 1, 1972, XP-002049245, pp. 8, 10, 20, 46, 59, 66, 125 New and Old Cartridges' about.com: hunting and shooting Apr. 5,
157, 177, 178. 2007 online, retrieved on Oct. 14, 2009. Retrieved from the
Crist, Stan “SSK6.5mm MPC.” Gun Buyer's Annual Presents #44, Internet <URL:http://hunting...about.com/od/ammo?a?
Special Weapons for Military and Police 2006, published by Harris newhdyammo2007.htm>.
Publications, Inc., New York, New York, 2006, pp. 64-67 and 89.
Gary's U.S. Infantry Weapons Reference Guide, Copyright 2004. * cited by examiner
U.S. Patent Sep. 1, 2015 Sheet 1 of 20 US 9,121,614 B2
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U.S. Patent Sep. 1, 2015 Sheet 2 of 20 US 9,121,614 B2
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U.S. Patent Sep. 1, 2015 Sheet 6 of 20 US 9,121,614 B2
U.S. Patent Sep. 1, 2015 Sheet 8 of 20 US 9,121,614 B2
U.S. Patent Sep. 1, 2015 Sheet 9 of 20 US 9,121,614 B2
U.S. Patent Sheet 10 of 20 US 9,121,614 B2
U.S. Patent Sep. 1, 2015 Sheet 11 of 20 US 9,121,614 B2
FIG. 5A
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1. 2
CARTRIDGES AND MODIFICATIONS FOR United States Military Needs
M16/AR15 RFLE The existing standard cartridge or chambering for the mili
tary's M16 rifle is the .223 Remington or 5.56 mm NATO
BACKGROUND OF THE INVENTION (military designation) cartridge. It fires a .224 caliber bullet
weighing 62 grains in the military issue M855 ammunition.
1. Field of the Invention Bullets weighing as much as 77 grains are currently in use by
Embodiments of the present invention relate generally to the US military to increase the performance of the 5.56 mm
cartridges and modifications for an M16/AR15 rifle. NATO cartridge and have increased the terminal performance
2. Description of the Related Art of the cartridge, but its terminal effects are still less than
10 desirable for what is considered an adequate combat car
Domestic Law Enforcement Needs
Most domestic law enforcement agencies in the United tridge. The shortcomings in the performance of the 5.56 mm
States utilize the AR15/M16 rifle platform in the course of NATO cartridge are well documented in current and past
their daily duties, as patrol officers out on the street; it is often military conflicts, and the cartridge's ineffectiveness is more
referred to as a “patrol carbine” and is carried by individual pronounced when the enemy combatants are under the influ
15 ence of drugs that affect the central nervous system.
officers. These rifles are also used by SWAT teams for room An alternative for heavier machine guns is the .308 or 7.62
entry or close quarter's battle (CQB) for close in shooting, mm caliber bullet. The most common military caliber utiliz
and are used by some departments as short range Sniper rifles. ing the .308 or 7.62mm caliber bullet is the 308Winchesteror
The reasons for the selection of this rifle platform are that they 7.62 mm NATO cartridge. The performance of the 7.62
are readily available in many configurations and are fairly NATO is also well documented in combat and is known for its
reasonably priced to Law Enforcement agencies, the AR15's increased stopping power. The U.S. M14 rifle fires the 7.62
weight and size are also attractive features of the AR15 as they mm NATO cartridge as does the U.S. M240 machinegun, as
are easily operable by large men and Smaller stature women. well as several aircraft mounted machineguns and the mini
The limiting factor is the cartridge that it fires, the 223 Rem gun. The AK47 also utilizes a 7.62 mm bullet.
ington, most commonly using a 55 grain bullet. Domestic law 25 What is needed is a cartridge that will provide improved
enforcement is not held to the military restriction of using full stopping power without over penetrating, and is compatible
metaljacket projectiles and therefore can choose from a wide with the standard size M16/AR15 rifle platform.
variety of available bullet styles and designs, which makes the
223 Remington more effective. SUMMARY OF THE INVENTION
30
Even with the proper selection of ammunition, the 223
Remington is still substandard for most law enforcement Embodiments of the present invention relate generally to
applications and has a well known reputation for "over pen cartridges and modifications for an M16/AR15 rifle. In one
etration' with its small-fast bullet. This can result in embodiment, a modified M16/AR15 rifle or carbine includes
extremely dangerous situations for patrol officers working in a bolt having a maximum outside diameter greater than that of
a built up urban environment. The small weight or mass of the
35 a standard M16/AR15 bolt; and a bolt extractor pivoted to the
bolt. The bolt and the bolt extractor are operable to: transport
bullet makes it less effective and more prone to deflection on a cartridge from a magazine to a barrel, and eject a spent
vehicles when engaged by police, especially when engaging cartridge from the barrel. The rifle or carbine further includes
thick windshield glass. Although there are a few “alternate’ a barrel extension configured to receive the bolt; a standard
cartridges available that will function in the AR15 rifle, they 40 M16/AR15 upper receiver coupled to the barrel extension; a
do not offer enough of an improvement over the existing .223 standard M16/AR15 lower receiver coupled to the upper
Remington cartridge chambering to justify the cost in Switch receiver.
ing over to them, mainly cost and availability of ammunition In another embodiment, a cartridge includes a bullet hav
and magazines. Thus the agencies are limited on their choices ing a diameter greater than or equal to 0.224 inch; and a case
of cartridge choices if they maintain the AR15/M16 rifle 45 having a case head diametergreater than or equal to 0.45 inch.
platform as their weapon of choice. A length of the cartridge is substantially equal to 2.26 inches.
The other choice for law enforcement agencies is the larger In another embodiment, a firearm includes a barrel. The
and more costly AR15 “style” rifle made by various compa firearm further includes a bolt operable to transport a car
nies that fire the .308Winchester cartridge. The .308 Win tridge from a magazine to the barrel and eject the spent
chester is a powerful cartridge and offers a substantial 50 cartridge from the barrel. The firearm further includes a
improvement over the much smaller .223 Remington cham spring biasing the bolt toward the barrel and a piston system
bering. Most police sniper rifles are chambered in the .308 in fluid communication with the barrel. The piston system
Winchester and are bolt action guns, which do not allow for includes a body and a piston disposed in the body and oper
quick follow up shots if needed. able to move the bolt away from the barrel in response to
When quick follow up shots are required the larger AR15 55 firing of the cartridge and force exhaust gas from the body and
style rifles are sometimes used, they are heavier and have into the barrel in response to the spring returning the bolt to
more recoil than the smaller rifles, but deliver ample fire the barrel.
power when needed. These heavier and larger rifles are not the
preferred option for SWAT teams for use in room entry and BRIEF DESCRIPTION OF THE DRAWINGS
building clearing operations because the power of the 308 60
Winchester is too much for inside building operations, due to So that the manner in which the above recited features of
muzzle blast, recoil, and over penetration. the present invention can be understood in detail, a more
These two calibers represent not only the two most popular particular description of the invention, briefly summarized
calibers used in law enforcement but are the two extremes, above, may be had by reference to embodiments, some of
with the 223 Remington not providing enough performance 65 which are illustrated in the appended drawings. It is to be
or power and the 308 Winchester providing too much or noted, however, that the appended drawings illustrate only
excessive power. typical embodiments of this invention and are therefore not to
US 9,121,614 B2
3 4
be considered limiting of its scope, for the invention may 440 KINETIC military, law enforcement, door & wall
admit to other equally effective embodiments. breeching, hunting
FIGS. 1A-1C illustrate cartridges, according to embodi 440 ENTRY (buckshot)—military, law enforcement, door
ments of the present invention. & wall breeching, room entry (CQB), hunting. The barrel
FIG. 2 is an exploded assembly of a bolt, bolt extractor, and 5 may be smooth bore or rifled for the 440 ENTRY.
barrel extension usable with the cartridges of FIGS. 1A-1C. The bullets may have hollow points and may have full
FIGS. 3A-3E illustrate details of the bolt of FIG. 2. metal jackets or be semi-jacketed (lead tip).
FIGS. 4A-4E illustrate details of the bolt extractor of FIG. FIGS. 7A-7D illustrate details of a bolt usable with the
2. cartridges of FIGS. 1A-1C and a modified gas piston system
FIGS. 5A-5D illustrate details of the barrel extension of 10 (see FIG. 8), according to another embodiment of the present
FIG 2. invention. All dimensions are in inches.
FIGS. 6A-6G illustrate details of a magazine usable with FIG. 8 is a cross section of a gas piston system 800, accord
the cartridges of FIGS. 1A-1C. ing to another embodiment of the present invention.
FIGS. 7A-7D illustrate details of a bolt usable with the The use of gas piston systems in weapons to cycle the
cartridges of FIGS. 1A-1C and a modified gas piston system, 15 action is used in weapons such as the Russian AK47 (1947),
according to another embodiment of the present invention. the U.S. M1 Garand (1939) and the U.S. M14 (1957). There
FIG. 8 is a cross section of a gas piston system, according areas many as five gas piston systems currently manufactured
to another embodiment of the present invention. for the AR15 rifle by various companies. They use a gas piston
FIG. 9 is an exploded assembly of a prior art M16/AR15. actuated by "tapped gas” from the fired cartridge via a small
2O hole or 'gas port in the barrel, the expanding gas forces the
DETAILED DESCRIPTION piston to move. As such, the gas from a fired cartridge is
utilized to cycle the action and load the next cartridge. The
FIGS. 1A-1C illustrate cartridges, according to embodi expanding gas from the fired cartridge, once utilized to cycle
ments of the present invention. the piston, is then vented out of the gas manifold at the end of
The 308 ERC was designed to maximize the performance 25 the piston operating stroke before the piston returns to the
of the AR15/M16 rifle, give it more stopping or incapacitation starting position.
power and increase its performance in self defense, law The standard design gas system used in AR15 and M16
enforcement, and military combat applications. The 308 ERC rifles utilizes a “direct gas impingement system’ which
is based on the .308Winchester or 7.62 mm NATO cartridge, directs expanding gas from the fired cartridge out of the barrel
utilizes the 308 caliberbullet, and is designed to operate in the 30 through a “gas port” or hole in the barrel. The expanding
existing standard issue sized AR15/M16 rifle platform. "tapped gas” is then directed through a “gas tube' which
Cartridge Details; “directs” the gas back into the upper receiver. The gas then
Case head diameter, 0.473" inches (a 25% increase over enters the “bolt carrier key” forcing the carrier to the rear and
the 223 Remington/5.56 NATO) unlocking the bolt of the rifle, beginning the cycling process.
NL is an abbreviation for neck length. NW is an abbrevia- 35 The gas piston system 800 may include a barrel 805, a
tion for neck wall. COL is an abbreviation for cartridge over piston/rod assembly 810, a gas block 815, and a gas block cap
all length 820. The gas block 815 may have a bore formed therethrough,
Powder capacity: 52% increase over the 223 Remington/ may be disposed around the barrel 805, and secured to the
5.56 NATO & 18% less than the 308 Winchester barrel 805 with fasteners (not shown), such as screws or pins.
Projected design performance data; 40 The gas block 815 may have a piston chamber formed therein.
Bullet weight: 135-140 grains A piston 810p of the piston/rod assembly 810 may be dis
Muzzle velocity: 2650 feet per second (fps) (16" barreled posed in the piston chamber. The piston 810p may divide the
AR15/M16 carbine) chamber into an air Sub-chamber and an exhaust Sub-cham
Muzzle energy: 2106 foot pounds ber. The piston 810p may be longitudinally coupled to a rod
Muzzle energy increase: 82% (compared to military cur- 45 810r of the piston/rod assembly 810, such as by being formed
rent issue M855 62 grain FMJBTWC(a 2900 fps fired from a integrally therewith or welded thereto. The piston 810p may
16" barreled AR15/M16 carbine) include an array of carbon grooves (not shown) formed
FIG. 2 is an exploded assembly of a bolt, bolt extractor, and around an outer surface thereof. The cap 820 may be coupled
barrel extension usable with the cartridges of FIGS. 1A-1C. to the gas block 815 by a threaded connection. The rod 810r
Although the cartridge is designed to operate in the AR15/ 50 may extend through a bore formed through the cap 820. The
M16 platform, the following design changes were required cap may have one or more ports 820p formed therethrough
(in addition to modification of the barrel); and providing air communication between air Sub-chamber
204-ERC redesigned bolt and the atmosphere. The gas block 815 may have a channel
206-ERC redesigned bolt extractor 815c formed between the chamber and the bore and providing
202-ERC redesigned barrel extension 55 fluid communication between the exhaust sub-chamber and a
FIG. 6A-6G-ERC redesigned magazines, 25 round capac port 805p formed through a wall of the barrel 805. The port
ity 805p may provide fluid communication between a bore 805b
Additional ERC cartridges: of the barrel 805 and the channel 815c. The bore 805b barrel
Although any of these cartridges utilizing the ERC case can may be rifled (not shown) to impart rotation to a bullet (not
be used for self defense or law enforcement applications, their 60 shown) fired therethrough. The piston 810p may include a
projected use is listed below: recess formed therein in fluid communication with the
224 caliber/5.7 mm—varmint hunting, rifle competition exhaust sub-chamber. One or more ports 810h may beformed
243 caliber/6 mm—varmint hunting, rifle competition through a wall of the piston 810p and may provide fluid
264 caliber/6.5 mm—varmint hunting, rifle competition communication between the channel 815c and the piston
270 caliber/6.8 mm military, law enforcement, hunting 65 CCCSS.
308 caliber/7.62 mm military, law enforcement, hunting In operation, as the bullet passes the gas port 805p in the
338 caliber/8.6 mm military, law enforcement, hunting barrel 805, and before the bullet exits the barrel, the exhaust
US 9,121,614 B2
5 6
Sub-chamber becomes pressurized from the expanding gas of 2. The kit of claim 1, wherein:
the fired cartridge via (port 805p, channel 815c, and ports the case head diameter is greater than or equal to 0.4 inch,
810h). The pressurized exhaust gas forces the piston 810p to and
the rear of the piston chamber or “full stroke' position. The the bullet diameter is greater than or equal to 0.243 inch.
operating rod810rpushes on the bolt carrier key (see FIG.9), 5 3. The kit of claim 1, wherein the case head diameter is
which then moves the bolt carrier to the rear, unlocking the greater than or equal to 0.425 inch.
bolt and cycling the rifles action. As the bolt carrier is forced 4. The kit of claim 1, wherein the case head diameter is
to the rear, it compresses the rifles main operating spring greater than or equal to 0.45 inch.
(buffer spring). Air in the air sub-chamber is vented to the 5. The kit of claim 1, further comprising the magazine
atmosphere via the ports 820p. 10
configured to hold a plurality of the cartridges.
Once the bullet has exited the muzzle or flash suppressor 6. The kit of claim 1, further comprising the barrel config
and the pressure in the rifle bore decreases, the piston/rod ured to receive the cartridge and connected to the barrel
assembly 810 is pushed back to the forward or “resting posi extension.
tion by the expanding buffer spring. As the bolt and bolt 7. The kit of claim 1, wherein the bolt has an inside diam
carrier continue forward, the bolt carrier is returned all the 15
way to the forward position, locking the bolt. The residual gas eter (I in FIG. 3C) greater than that of the standard M16/M4
bolt.
in the piston chamber is exhausted back into the barrel 8. The kit of claim 7, wherein the barrel extension has a
through the gas channel 815c and gas port 805p. The firing
sequence is now complete, and the rifle is now ready to fire maximum inside diameter (I in FIG.5C) greater than that of
again. The gas piston system 800 keeps exhaust gas near the a standard M16/M4 barrel extension (existing M16A1-A4
front end of the gun and in the barrel instead of discharging versions and M4 and M4A1 versions).
the gas into the upper receiver as the conventional M16/AR15 9. The kit of claim 8, wherein:
gas impingement system does. the bolt has an outer diameter (H in FIG. 3C) greater than
Alternatively, the gas piston system may be incorporated that of the standard M16/M4 bolt, and
into the front sight. Alternatively, the ports 810h may be 25 the barrel extension has an inner diameter (J in FIG.5C)
omitted and the channel 815c may be in direct fluid commu greater than that of the standard M16/M4 barrel exten
S1O.
nication with the piston recess. Alternatively, the ports 810h 10. A kit for modifying an M16 rifle, M4 carbine, or AR15
may be omitted, a primary channel may be in direct fluid rifle or carbine, comprising:
communication with the piston recess and an auxiliary gas a bolt having a maximum outside diameter (Kin FIG. 3C)
channel may be in fluid communication with the exhaust 30
and an inside diameter (I in FIG. 3C) greater than those
sub-chamber when the piston is in the full stroke position, of a standard M16/M4 bolt (existing M16A1-A4 ver
thereby aiding venting of the exhaust gas into the barrel and
accelerating return of the piston to the at-rest position. sions and M4 and M4A1 versions);
While the foregoing is directed to embodiments of the an ejector carried by the bolt;
present invention, other and further embodiments of the 35 a bolt extractor pivoted to the bolt,
wherein:
invention may be devised without departing from the basic the bolt, the ejector, and the bolt extractor operable to:
scope thereof, and the scope thereof is determined by the transport a cartridge from a magazine to a barrel, and
claims that follow.
The invention claimed is: eject a spent cartridge from the barrel,
1. A kit for modifying an M16 rifle, M4 carbine, or AR15 40 a length of the cartridge is equal to or slightly less than
rifle or carbine, comprising: 2.26 inches, and
a bolt having a maximum outside diameter (Kin FIG. 3C) the cartridge comprises:
greater than that of a standard M16/M4 bolt (existing a case having a case head diameter greater than 0.378
M16A1-A4 versions and M4 and M4A1 versions); inch; and
an ejector carried by the bolt; 45 a bullet having a diameter greater than or equal to
a bolt extractor pivoted to the bolt and having a maximum 0.224 inch; and
width (F in FIG. 4D) greater than that of a standard a barrel extension having a maximum inside diameter (I in
M16/M4 bolt extractor (existing M16A1-A4 versions FIG.5C) greater than that of a standard M16/M4 barrel
and M4 and M4A1 versions), extension (existing M16A1-A4 versions and M4 and
wherein: 50 M4A1 versions) for receiving the bolt.
the bolt, the ejector, and the bolt extractor operable to: 11. The kit of claim 10, wherein:
transport a cartridge from a magazine to a barrel, and the bolt has an outer diameter (H in FIG. 3C) greater than
eject a spent cartridge from the barrel, that of the standard M16/M4 bolt, and
a length of the cartridge is equal to or slightly less than the barrel extension has an inner diameter (J in FIG.5C)
2.26 inches, and 55 greater than that of the standard M16/M4 barrel exten
the cartridge comprises: sion.
a case having a case head diameter greater than 0.378 12. The kit of claim 10, wherein:
inch; and the case head diameter is greater than or equal to 0.4 inch,
a bullet having a diameter greater than or equal to and
0.224 inch; and 60 the bullet diameter is greater than or equal to 0.243 inch.
a barrel extension configured to receive the bolt. ck ck ck ck ck