Segmented Composite Barrel for Weapon Thermal Management
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Solution Overview
Problem
Light-weight, high-strength composite barrels for automatic weapons face issues due to high barrel temperatures exceeding the melting point of composite or epoxy resin, particularly around gas ports, where high-pressure gas can degrade or melt the materials, and differing coefficients of thermal expansion cause shear stress.
Innovation Solution
A rifle barrel design featuring a metallic liner with a thermally conductive sleeve and a composite wrap separated from the gas port, using carbon foam for the sleeve to manage heat and maintain structural integrity, and segmenting the composite wrap to avoid direct contact with the gas port, thereby preventing damage from high-pressure gases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a composite wrap is used to reduce weight, then the barrel weight is reduced, but the composite material degrades or melts due to high temperatures from high-pressure gas
Solution Approach 1:
The composite wrap is divided into two separate sections with a gap between them at the gas port location. This segmentation prevents the composite material from directly contacting the high-temperature gas, eliminating the thermal degradation issue while preserving the weight reduction benefits of the composite material in the cooler regions of the barrel.
Solution Approach 2:
The composite wrap is extracted or removed from the immediate vicinity of the gas port where high-temperature gases are present. By creating a gap or separation zone around the gas port, the composite material is taken out from the harmful thermal environment, preventing melting and degradation while maintaining structural integrity.
2Length of moving object
If the composite wrap is placed close to the gas port to reduce barrel length, then the barrel length is reduced, but the high-pressure gas degrades or melts the composite material
Solution Approach 1:
The composite wrap is segmented into two discrete sections with a gap at the gas port location. This allows the barrel to maintain a compact overall length while the composite material itself is separated from the harmful high-temperature gas zone, preventing thermal damage.
Solution Approach 2:
The barrel structure has different material configurations in different regions. The composite wrap is applied in regions away from the gas port where temperatures are lower, while the gas port region has a different construction (metallic liner exposed or protected by heat-resistant materials) to handle the high-temperature gases.
3Strength
If a continuous composite wrap is used for structural strength, then the barrel strength is improved, but the differing coefficients of thermal expansion cause shear stress
Solution Approach 1:
The continuous composite wrap is divided into two separate sections with a gap between them at the gas port. This segmentation eliminates the thermal expansion mismatch issue by removing the composite material from the high-temperature zone, preventing shear stress generation while the composite sections in cooler regions maintain structural strength.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively manages heat and prevents material degradation, ensuring the structural integrity and longevity of the composite barrel by isolating it from high-temperature gases, thus maintaining the barrel's light-weight and high-strength properties even under high-pressure and temperature conditions.
Implementation Method 1
A thermally conductive sleeve circumscribes the liner substantially along the length of the liner
Implementation Method 2
The sleeve can include a carbon foam
Data Source
AI summary
A rifle barrel for a gas-operated rifle includes a metallic liner with a longitudinal bore and a transverse gas port through the liner to the bore intermediate along a length of the liner. A thermally conductive sleeve circumscribes the liner substantially along the length of the liner. A composite wrap circumscribes the sleeve substantially along a length of the sleeve. The composite wrap is separated from the gas port.