Patent Publication Number: US-2022228832-A1

Title: Method of Making a Training Firearm

Description:
FIELD OF THE INVENTION 
     The invention generally relates to a method of making a training firearm that has a replaceable magazine. The training firearm is not an actual firearm but possesses a visual look and tactile fee of an actual firearm, to enable a user to train realistically but safely. 
     BACKGROUND 
     The use of actual firearms during training often results in avoidable injuries. Consequently, it is safer to train in the accessing, handling and holstering of firearms using a training firearm, that is not an actual firearm but possesses a visual look and tactile feel of an actual firearm. This enables one to train realistically but safely. 
     Ideally, such a training firearm replicates the appearance and handling characteristics of an actual firearm, fits perfectly into a trainee&#39;s service weapon holster, and has long-term durability, but also facilitates training for safely handling, transporting, retaining, and presenting firearms. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       While embodiments can take many different forms, specific embodiments are shown in the drawings and will be described with the understanding that the present disclosure is an exemplification of the principles of the present invention and the best mode of practicing it. No limitation to a specific embodiment illustrated is intended. The following drawings are not necessarily drawn to scale. 
         FIG. 1  is a flow chart of an exemplary method of making a training firearm that has a replaceable magazine. 
         FIG. 2  shows an exemplary training firearm with its training magazine removed. 
         FIG. 3  shows part of an exemplary firearm with a disassembled magazine release button. 
         FIG. 4  is an exemplary schematic representation of a cross-section of a magazine well and a magazine release button for a training firearm. 
         FIG. 5  is an exemplary schematic representation of a side view of a training magazine. 
         FIG. 6  is an exemplary schematic representation of part of a left side poured replica of a training firearm, with an inserted weight. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  is a flow chart of an exemplary method of making a training firearm that has a replaceable magazine, Any actual firearm can be replicated by a training firearm, including any number of pistols or other handguns or side arms, rifles or other shoulder weapons, and so forth. 
     An exemplary method of making a training firearm comprises creating ( 1  and  12 ) permanent open cavity molds of the right and left sides of an actual firearm being replicated. Basing the mold on an actual firearm facilitates replicating the details of the original firearm, and makes use of the training firearm more realistic. 
     The illustrated exemplary method comprises positioning ( 13 ) a magazine (or a replica of the magazine) of the actual firearm being replicated in one of the permanent open cavity molds. In a preferred embodiment, a magazine (or replica of the magazine) is positioned in only one of the permanent open cavity molds, and is done so before a material is poured into the mold. The other half of a magazine well is formed when right and left side poured replicas are combined. However, in other embodiments, magazines (or replicas) could be positioned in the open cavity mold of each side of the firearm, and/or a magazine or magazines (or replica(s)) could be positioned in a mold or molds after a material is poured into the molds. 
     The magazine (or replica of the magazine) typically should be pre-hardened, or should be coated (such as with a silicon coating) to inhibit fusing of the magazine (or replica of the magazine) with the material from which the training firearm is being molded. This facilitates withdrawal of the magazine (or replica of the magazine) from the fused replica resulting from fusing of the right and left side poured replicas. 
     The exemplary method comprises pouring ( 14 ) a material into each of the permanent open cavity molds to create right and left side poured replicas, respectively, of the right and left sides of the actual firearm being replicated. Various materials may be used including different polymers, metals or alloys. A preferred material is a high impact polymer which is durable but relatively inexpensive. It also is preferred that the chosen material have a distinctive color, such as red, that provides instant recognition that the fused replica is a safe training firearm rather than an actual firearm. 
     In some embodiments, a weight  32  is inserted into one or both of the permanent open cavity molds.  FIG. 6  is an exemplary schematic representation of part of a left side poured replica  31  of a training firearm, with an inserted weight  32 . The weight  32  can be any heavy material, preferably a metal such as steel, most preferably a steel reinforcing bar. In the case of a polymer fused replica, the weight  32  makes the weight of the training firearm closer to that of the actual firearm being replicated, which enhances the training value. The weight  32  also increases the durability of the training firearm, and may be positioned to move the center of gravity of the training firearm closer to the center of gravity of the actual firearm being replicated. 
     The exemplary method comprises combining ( 15 ) the right and left poured replicas to fuse them together, and letting them harden ( 16 ) to create the fused replica. 
     The exemplary method comprises withdrawing ( 17 ) the magazine (or replica of the magazine) from the combined right and left side pour relicas. This leaves a magazine well  71  in a space where the magazine (or replica of the magazine) had been located before being withdrawn. 
     The exemplary method comprises forming a training magazine for use with the training firearm. This comprises creating ( 21 ) a training magazine mold of the magazine (or replica of the magazine), pouring ( 22 ) a material into the training magazine mold and letting it harden ( 23 ).  FIG. 2  shows an exemplary training firearm  73  with its training magazine  72  removed from its magazine well  71 . The training magazine  72  is dimensioned for insertion into the magazine well  71  of the fused replica resulting from the combining ( 15 ) and hardening ( 16 ) of the right and left poured replicas and the withdrawal ( 17 ) of the magazine (or replica of the magazine). The training magazine  72  is insertable into the magazine well  71 , releasable from the magazine well  71 , and replaceable. Various materials may be used for the training magazine  72  including different polymers, metals or alloys. A preferred material is a polymer which is durable but relatively inexpensive. In addition, a weight (such as a metal, for example) is inserted into the training magazine mold in some embodiments. Interchangeable training magazines  72  are made with or without the weight, to simulate, respectively, a magazine with or without ammunition. 
     The exemplary method comprises inserting ( 18 ) a magazine release button in the fused replica. The magazine release button and the training magazine  72  comprise respective mating features that engage to lock the training magazine  72  in the magazine well  71  unless the magazine release button is activated. 
     One exemplary embodiment is illustrated in  FIGS. 3-5 .  FIG. 3  shows part of an exemplary firearm with a disassembled magazine release button.  FIG. 4  is an exemplary schematic representation of a cross-section of a magazine well  51  and a magazine release button for a training firearm.  FIG. 5  is an exemplary schematic representation of a side view of training magazine  41  for a training firearm. 
     For at least this exemplary embodiment, at least one of steps of creating a permanent open cavity mold of a right or left side of the actual firearm being replicated, in the method of making the training firearm, comprises blocking out a path in the corresponding permanent open cavity mold. That path is dimensioned to create a magazine release button channel into which a magazine release button is inserted. 
     For this exemplary embodiment, the method of making the training firearm comprises the step of creating the right side permanent open cavity mold comprising blocking out a first path in the right side mold that is dimensioned to create a right side of a magazine release button channel; and the step of creating the left side permanent open cavity mold comprising blocking out a second path in the left side mold that is dimensioned to create a left side of the magazine release button channel. The fusing of the right and left side poured replicas results in a fused replica with a magazine release button channel, and the method of making the training firearm comprises inserting ( 18 ) the magazine release button into the magazine release button channel. 
     For at least this exemplary embodiment, the magazine release button comprises a right side  62 , a left side  61 , and a shaft  63  that joins the right and left sides ( 62  and  61 ) of the magazine release button. The inserting step ( 18 ) comprises inserting the right side  62  of the magazine release button into the right side of the magazine release button channel through a right side of the fused replica, inserting the left side  61  of the magazine release button into the left side of the magazine release button channel through a left side of the fused replica, and joining the right and left sides ( 62  and  61 ) of the magazine release button with the shaft  63 . 
     For this exemplary embodiment, the magazine release button also comprises a spring  64  surrounding or adjacent to the shaft  63 . The method of making the training firearm comprises one of the steps of creating the right or left side permanent open cavity molds further comprising leaving an opening across a part of the corresponding first or second path. Whereas the path blocks out the magazine release button channel when material is poured into the mold, the opening across part of the path results in a barrier  65  across the magazine release button channel. The shaft  63  extends through the barrier  65 , but the spring  64  is restrained on one side of the barrier  65 . Consequently, pressing one side of the magazine release button will compress the spring  64 , biasing it to restore the magazine release button to its initial position when the magazine release button is released (as seen in  FIG. 4 ). 
     For at least this exemplary embodiment, the magazine release button comprises a projection  66 , and the training magazine  41  comprises an indentation  42  that is positioned and dimensioned to engage with the projection  66  to lock the training magazine  41  in the magazine well  51  unless the magazine release button is activated. 
     It will be understood that the disclosed methods of making a training firearm can be modified without departing from the teachings of the invention. Accordingly, the scope of the invention is only to be limited as necessitated by the accompanying claims.