Abstract:
A system and method for a diffuser muzzle brake. The exhaust ports are upstream of the reaction plate. This allows the deflection and redirection of exhaust gases to reduce recoil. The internal cylinder bore and exhaust ports are manufactured with cost saving methods. The muzzle brake has at least one radial exhaust port pattern. The muzzle brake has at least one longitudinal exhaust port pattern. The muzzle brake has at least one downstream reaction plate.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of and claims priority to U.S. Provisional Application No. 62/210147, filed Aug. 26, 2015. 
     
    
     TECHNICAL FIELD 
       [0002]    A muzzle brake, or recoil compensator, can be used to counter recoil and unwanted rising of a barrel of a firearm during firing. A muzzle brake can be connected to the muzzle of a firearm. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0003]    The features and advantages of certain embodiments will be more readily appreciated when considered in conjunction with the accompanying figures. The figures are not to be construed as limiting any of the preferred embodiments. 
           [0004]      FIG. 1 a    is a side view of a muzzle device according to certain embodiments. 
           [0005]      FIG. 1 b    is a front cross-sectional view of the muzzle device of  FIG. 1 . 
           [0006]      FIG. 2  is a side cross-sectional view of a muzzle device according to certain embodiments. 
           [0007]      FIG. 3  is a side cross-sectional view of the muzzle device showing a center drill for creating exhaust ports. 
           [0008]      FIG. 4  is a top, front perspective view of the muzzle device according to certain embodiments. 
           [0009]      FIG. 5  is a top, front perspective view of the muzzle device according to certain other embodiments. 
           [0010]      FIG. 6 a    is a side view of the muzzle device of  FIG. 5 . 
           [0011]      FIG. 6 b    is a front cross-sectional view of the muzzle device of  FIG. 6 a    taken along lines  6 - 6 . 
           [0012]      FIG. 7 a    is a front cross-sectional view of the muzzle device according to certain other embodiments. 
           [0013]      FIG. 7 b    is a side cross-sectional view of the muzzle device of  FIG. 7 a    taken along lines  7 - 7 . 
           [0014]      FIG. 8  is a top, front perspective view of the muzzle device according to certain other embodiments. 
           [0015]      FIG. 9 a    is a side view of the muzzle device of  FIG. 8 . 
           [0016]      FIG. 9 b    is a front cross-sectional view of the muzzle device of  FIG. 9 a    taken along lines  9 - 9 . 
           [0017]      FIG. 10 a    is a front cross-sectional view of the muzzle device according to certain other embodiments. 
           [0018]      FIG. 10 b    is a side cross-sectional view of the muzzle device of  FIG. 10 a    taken along lines  10 - 10 . 
           [0019]      FIG. 11  is a side cross-sectional view showing a cylindrical bore created with a drill bit. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0020]    It is to be understood that the relative terms, “top,” “bottom,” “front,” “back,” and “sides” are used to describe the drawings and various parts to aid the reader in understanding the various embodiments. 
         [0021]    Muzzle brakes or recoil compensators are devices that are connected to the muzzle of a firearm to redirect gas flow out of exhaust ports on the muzzle brake that functions to counteract recoil and unwanted rising of the barrel during firing. Generally, muzzle brakes are manufactured in multiple stages using multiple techniques and steps, which results in an increased manufacturing cost. Moreover, most exhaust ports are cylindrical in shape thereby decreasing the volume of gas that can be redirected out of the exhaust ports. As such, there is a need for improved exhaust ports and methods of manufacturing a muzzle brake. 
         [0022]    It has been discovered that using of a standard center drill to create exhaust ports and a thread relief cylinder bore to create an internal diameter results in a cost-effective method of manufacture. Additionally, the exhaust ports created with the center drill enhance gas flow out of the ports and greatly increase muzzle brake effectiveness. 
         [0023]      FIG. 1 a    shows a muzzle brake  100  according to certain embodiments. The muzzle brake  100  can include a body  101 . The body  101  can be generally cylindrical in shape and include a first end and a second end. The body  101  can form an outer diameter (OD) of the muzzle brake  100 . The body  101  can be made from a variety of materials, including, but not limited to, a ferrous metal, a non-ferrous metal, a carbon based material, a ceramic material, a composite material, and combinations thereof. The body  101  can also be treated with any surface treatment that may enhance the strength, corrosion resistance, wear resistance, erosion resistance, and fatigue strength of the body  101 . The body  101  may also be treated to reduce thermal signature or treated for coloring and/or identification. The muzzle brake  100  includes one or more exhaust ports  104 . 
         [0024]    The length and OD of the body  101  can vary based on the desired use, for example, the bullet caliber. According to certain embodiments, the length of the body  101  ranges from about 1.75 inches (in.) (4.4 centimeters (cm)) to about 4 in. (10.2 cm). The OD can range from about 0.75 in. (1.9 cm) to about 3 in. (7.6 cm). It should be understood that larger or smaller calibers may require larger or smaller dimensions. 
         [0025]      FIG. 1 b    is a cross-sectional front view of the muzzle brake  100  according to certain embodiments. According to these embodiments, the muzzle brake  100  can include one or more drain holes  107  for allowing a liquid to drain from the muzzle brake  100 . The drain holes  107  can vary in number and arrangement in the muzzle brake  100  and can be selected based on the anticipated volume of liquid needing to be expelled from the muzzle brake  100 . 
         [0026]    As can be seen in  FIG. 2 , the muzzle brake  100  can include a device coupler  102 . The device coupler  102  couples the muzzle brake  100  to a firearm. The muzzle brake  100  can be coupled by any method or device known in the art including screwing the device coupler  102 , bolts, a threaded barrel muzzle, a pinch bolt clamp, screws, etc. As can be seen, according to certain embodiments, the device coupler  102  is located at a first end of the muzzle brake upstream from a second end of the muzzle brake  100 . As used herein, “upstream” means at a location closer to the barrel of the gun and “downstream” means at a location further away from the barrel. 
         [0027]    The muzzle brake  100  can also include a central bore  103 . The central bore  103  can be generally cylindrical in shape and make up an inner diameter (ID) of the muzzle brake  100 . The central bore  103  can be a thread relief bore. The muzzle brake  100  can also include a projectile exit  108  wherein a projectile can exit the muzzle brake  100 . The muzzle brake  100  can also include a top portion  109  that is oriented at the top of the muzzle brake  100  in relation to the barrel of a firearm and a bottom potion  110  that is oriented at the bottom of the muzzle brake  100  in relation to the barrel of a firearm. 
         [0028]    As can be seen in  FIG. 3 , the muzzle brake  100  can include a reaction plate  105 . The reaction plate  105  can be located at the second end of the muzzle brake  100 , downstream of the device coupler  102 . The reaction plate  105  can be oriented approximately perpendicular to the length of a barrel of a firearm. The reaction plate  105  can redirect the flow of gases from the second end of the muzzle brake  100  and toward the exhaust ports  104 . The reaction plate  105  can include an exit  108  for allowing a projectile to exit the muzzle brake  100 . The size of the projectile exit  108  will depend upon the caliber of the bullet. The reaction plate  105  of  FIG. 3  includes generally flat surface faces. 
         [0029]    The exhaust ports  104  are created using a center drill  106 . The center drill  106  includes a large diameter body, an included angle (e.g., a 60° included angle), and a tapered head. The center drill  106  creates exhaust ports  104  having a cylindrical-shaped portion and a conical-shaped portion. The cylindrical-shaped portion is located at and near the central bore  103 , while the conical-shaped portion is located at and near the OD of the body  101 . Thus, each exhaust port  104  has an exit diameter that is greater than the inlet diameter. The center drill  106  is positioned on the outside of the body  101  and penetrates through the thickness of the body and into the central bore  103  to create the exhaust ports  104 . As a result, gases can be redirected from the central bore  103 , through the exhaust ports  104 , to the outside of the body  101 . 
         [0030]      FIGS. 5-7   b  show a muzzle brake  100  according to certain other embodiments. As can be seen, the muzzle brake  100  according to these other embodiments, includes a radiused reaction plate  105 , a conical-shaped second end of the body  101 , a deeper radial cut by wrench flats to allow for attachment of various accessories, and aesthetic cuts on the second end. 
         [0031]      FIGS. 8-10   b  show a muzzle brake  100  according to certain other embodiments. As can be seen, the muzzle brake  100  according to these other embodiments, has a smaller central bore  103 , a conical-shaped reaction plate  105  formed with a standard drill bit, and a shallow aesthetic cut by wrench flats. 
         [0032]    The exhaust ports  104  according to any of the embodiments can be arranged radially around the body  101  and longitudinally along a longitudinal axis of the body. The number and the dimensions of the exhaust ports  104  can vary and depend on a variety of factors. The factors can include, but are not limited to, the length of the body  101 , the distance between the ID and OD of the body  101 , the OD of the body  101 , thread size, and stress to the body  101 . According to certain embodiments, the exhaust ports  104  are selected and positioned to maximize the total exhaust port  104  area relative to the area of the body  101 . According to certain embodiments, the ODs of the exhaust ports  104  do not touch each other or overlap. These embodiments can be useful to reduce stress to the body  101  of the muzzle brake  100 . For example, as seen in  FIGS. 5-7   b,  8 exhaust ports  104  are arranged radially around the outer circumference of the body and 6 exhaust ports  104  are arranged longitudinally along the outer circumference of the body for a total of 48 exhaust ports. By way of another example, as seen in  FIGS. 8-10   b,  7 exhaust ports  104  are arranged radially around the outer circumference of the body and 5 exhaust ports  104  are arranged longitudinally along the outer circumference of the body for a total of 35 exhaust ports. 
         [0033]    Depending on the thickness of the body  101  between the OD and ID of the body, a larger or smaller center drill  106  may be needed to form the exhaust ports  104 . For example, the larger the body thickness, the larger the center drill  106  needed to create exhaust ports that transverse the entire thickness. This results in exhaust ports  104  having a larger OD compared to exhaust ports that have been created using a smaller center drill. In this example, fewer number of exhaust ports  104  may be required to reduce or prevent stressing the body  101  beyond its stress point. One of the many advantages to using a center drill for creating the exhaust ports  104  is that the overall shape of the exhaust ports  104  means that there is a larger solid surface area on the ID of the body (where the ID of the exhaust ports is smaller) and a smaller solid surface area on the OD of the body (where the OD of the exhaust ports is larger). This can provide increased structural integrity to the muzzle brake  100  while also providing for an increased gas flow through the ports. 
         [0034]    Exhaust ports  104  can be omitted from the top portion  109  of the body  101  to keep the exhaust plume out of the user&#39;s line of sight. In addition to, or instead of, exhaust ports  104  can also be omitted from the bottom portion  110  of the body  101  to eliminate disturbance of the ground below. 
         [0035]    The muzzle brake  100  can also include additional features to accommodate, for example, mounting a silencer, use as a grenade launcher, a bayonet mount, and a castellated glass breaking feature on the second end or downstream end of the device. The additional features can be attached to the muzzle brake  100  via any method or device known in the art. For example, for a barrel launched rifle grenade, the muzzle brake  100  can be of such an OD and length as to accommodate the grenade. A bayonet can include a loop on the bayonet guard that mounts over the muzzle brake  100  diameter. A silencer can utilize grooves, threads, interrupted threads, lugs, timing slots, ratcheting gear/notches, and/or a conical feature for sealing, location, and retention to the muzzle brake  100 . 
         [0036]    Methods of manufacturing the muzzle brake  100  can include: creating an outer diameter (OD) of a body; creating OD features; creating a central bore  103 , for example, via a drill bit  111  as shown in  FIG. 11 ; threading the muzzle brake; creating the exhaust ports  104  with the center drill  106 ; cutting the first and second ends of the muzzle brake  100 ; facing the ends of the muzzle brake off; and creating any OD features, such as applying corrosion resistant coatings. It should be understood that the use of a center drill allows the muzzle brake  100  to be manufactured at lower costs, while also providing for a more effective muzzle brake  100 . Additionally, the use of a standard drill  111  further reduces the manufacturing cost of the muzzle brake. 
         [0037]    Therefore, the present invention is well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is, therefore, evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present invention. 
         [0038]    As used herein, the words “comprise,” “have,” “include,” and all grammatical variations thereof are each intended to have an open, non-limiting meaning that does not exclude additional elements or steps. While compositions and methods are described in terms of “comprising,” “containing,” or “including” various components or steps, the compositions and methods also can “consist essentially of” or “consist of” the various components and steps. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range is specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. Moreover, the indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the element that it introduces. If there is any conflict in the usages of a word or term in this specification and one or more patent(s) or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted.