Firearm frame and a method of manufacturing it

A receiver and a method for manufacturing it are disclosed. The receiver contains a first material at least partially surrounded by a second material, wherein the first material has a first melting and the second material has a second melting point, wherein the first melting point is lower than the second melting point. The method disclosed teaches how to manufacture the receiver.

FIELD

The present invention relates to firearm manufacture. More particularly, the present invention relates to a firearm frame and a method of manufacturing it.

BACKGROUND

Firearm frame/receiver is a part of a firearm that provides housing for a hammer, a bolt and/or a firing mechanism. Unfinished frames/receivers, also referred to as 80% frames/receivers, are only about 80% completed. It is up to a customer to finish manufacturing a firearm by performing the remaining 20% of the drilling and/or milling. Due to complexities involved, many customers do not have the equipment and/or knowledge to properly manufacture the last 20% of the firearm frame/receiver.

Therefore, there is a need for a firearm frame/receiver and a method of manufacturing it such that a customer can easily finish manufacturing the last 20% of the firearm.

DETAILED DESCRIPTION

Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,” “coupled,” and “mounted,” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings. In addition, the terms “connected” and “coupled” and variations thereof are not restricted to physical or mechanical connections or couplings.

Referring toFIGS.1-2, an 80% receiver/frame10for a firearm is shown according to the present disclosure. The 80% receiver10comprises an insert15at least partially filling a cavity20(shown inFIG.2). The cavity20is configured to house a firing mechanism (i.e. trigger group). According to some embodiments presently disclosed, the insert15completely fills the cavity20. It is to be understood that the receiver10may be an AR-style lower receiver or any other type of a firearm receiver.

According to some embodiments presently disclosed, the insert15comprises a first material having a first melting point and the receiver10comprises a second material having a second melting point.

According to some embodiments presently disclosed, the first material is steel, aluminum, metal, polymer, and/or sintered metal powder. According to some embodiments presently disclosed, the second material is steel, aluminum, metal, polymer, and/or sintered metal powder. According to some embodiments presently disclosed, the first melting point is lower than the second melting point.

According to some embodiments, the first material comprises a low density polyethylene with a melting point of about 200° F. and the second material comprises glass filled nylon material with a melting point above 200° F. Referring toFIG.3, a method40of manufacturing the 80% receiver10is shown according to the present disclosure. At50, forming the insert15. The insert15may be machined, stamped or molded. The insert15may comprise one or more protrusions25. At55, forming the receiver10around the insert15. According to some embodiments, the insert15is at least partially covered by the receiver10. According to some embodiments, the receiver10is formed around the insert15using, for example, an overmold process.

Referring toFIG.4, a method45of removing the insert15from the receiver10is shown according to the present disclosure. At60, an oven is preheated to a first temperature. According to some embodiments, the first temperature is between the first melting point and a second melting point. The oven may be a common household oven used for cooking food. At65, the receiver10with the insert15are placed into the preheated oven for a first period of time. The first period of time is time required for at least a portion of the insert15to melt away from the receiver10and to form the cavity20. According to some embodiments presently disclosed, the first period of time is time required for most of the insert15to melt away from the receiver10and to form the cavity20. At70, the receiver10is removed from the oven and allowed to cool down. According to some embodiments, a firing mechanism (not shown) may be inserted into the cavity20after the receiver10is removed from the oven and is allowed to cool down.

According to some embodiments, melting away of the at least a portion of the insert15reveals one or more openings30through the sidewalls of the receiver10as shown inFIG.2. The one or more openings30may be formed by the one or more protrusions25. The one or more openings30may allow for installation of pins (not shown) used to secure the firing mechanism (not shown) in the cavity20. The one or more openings30may be used for mounting a selector (not shown) that enables a user to engage and disengage the safety of the firearm. The one or more openings30may allow for installation of at least one pin (not shown) used for coupling an upper receiver (not shown) to the receiver10.

Referring toFIGS.5-6, an 80% receiver100for a firearm is shown according to the present disclosure. The 80% receiver100comprises an insert cover110and an insert150at least partially covered by the insert cover110(shown inFIGS.5-6). The receiver100comprises a receiver cavity115for housing the insert cover110. The insert cover110forms a insert cover cavity120for housing a firing mechanism (i.e. trigger group). According to some embodiments presently disclosed, the insert150completely fills the insert cover cavity120. It is to be understood that the receiver100may be an AR-style lower receiver or any other type of a firearm receiver.

According to some embodiments presently disclosed, the insert150comprises a first material having a first melting point, the receiver100comprises a second material having a second melting point, and the insert cover110comprises a third material having a third melting point.

According to some embodiments presently disclosed, the first material is steel, aluminum, metal, polymer, and sintered metal powder. According to some embodiments presently disclosed, the second material is steel, aluminum, metal, polymer, and sintered metal powder. According to some embodiments presently disclosed, the third material is steel, aluminum, metal, polymer, and/or sintered metal powder. According to some embodiments presently disclosed, the first melting point is lower than the second melting point. According to some embodiments presently disclosed, the first melting point is lower than the third melting point. According to some embodiments presently disclosed, the first melting point is lower than the second melting point and the third melting point.

According to some embodiments, the first material comprises a low density polyethylene with a melting point of about 200° F., the second material comprises glass filled nylon material with a melting point above 200° F., and the third material is metal with a melting point above 200° F.

Referring toFIG.7, a method122of manufacturing the 80% receiver100is shown according to the present disclosure. At125, providing the insert cover110. The insert cover110may be machined, stamped or molded. At130, forming the insert150inside the insert cover110. According to some embodiments, the insert150is at least partially covered by the insert cover110. The insert150may be molded. At135, forming the receiver100around the insert cover110. According to some embodiments, the receiver100is formed around the insert cover110using, for example, an overmold process.

Referring toFIG.8, a method124of removing the insert150from the insert cover110is shown according to the present disclosure. At155, an oven is preheated to a first temperature. According to some embodiments, the first temperature is above the first melting point, below the second melting point, and below the third melting point. The oven may be a common household oven used for cooking food. At160, the receiver100with the insert cover110and the insert150are placed into the preheated oven for a first period of time. The first period of time is time required for at least a portion of the insert150to melt away from the insert cover110and to form the cavity120. According to some embodiments presently disclosed, the first period of time is time required for most of the insert150to melt away from the insert cover110and to form the cavity120. At165, the receiver100and the insert cover110are removed from the oven and allowed to cool down. According to some embodiments, a firing mechanism (not shown) may be inserted into the cavity120after the receiver100is removed from the oven and is allowed to cool down.

According to some embodiments, one or more openings (not shown) may be formed through the sidewalls of the receiver100and the insert cover110. The one or more openings (not shown) may be formed to allow for installation of pins (not shown) used to secure the firing mechanism (not shown) in the cavity120. The one or more openings may be used for mounting a selector (not shown) that enables a user to engage and disengage the safety of the firearm. The one or more openings may allow for installation of at least one pin (not shown) used for coupling an upper receiver (not shown) to the receiver100.

Referring toFIGS.9-10, an 80% frame200for a firearm is shown according to the present disclosure. The 80% frame200comprises an insert215at least partially filling a cavity220(shown inFIG.10). The cavity220is configured to house a firing mechanism (i.e. trigger group). According to some embodiments presently disclosed, the insert215completely fills the cavity220. It is to be understood that the frame200may be a frame for a handgun.

According to some embodiments presently disclosed, the insert215comprises a first material having a first melting point and the frame200comprises a second material having a second melting point.

According to some embodiments presently disclosed, the first material is steel, aluminum, metal, polymer, and/or sintered metal powder. According to some embodiments presently disclosed, the second material is steel, aluminum, metal, polymer, and/or sintered metal powder. According to some embodiments presently disclosed, the first melting point is lower than the second melting point.

According to some embodiments, the first material comprises a low density polyethylene with a melting point of about 200° F. and the second material comprises glass filled nylon material with a melting point above 200° F. Referring toFIG.11, a method204of manufacturing the 80% frame200is shown according to the present disclosure. At250, forming the insert215. The insert215may be machined, stamped or molded. The insert215may comprise one or more protrusions225. At255, forming the frame200around the insert215. According to some embodiments, the insert215is at least partially covered by the frame200. According to some embodiments, the frame200is formed around the insert215using, for example, an overmold process.

Referring toFIG.12, a method205of removing the insert215from the frame200is shown according to the present disclosure. At260, an oven is preheated to a first temperature. According to some embodiments, the first temperature is between the first melting point and a second melting point. The oven may be a common household oven used for cooking food. At265, the frame200with the insert215are placed into the preheated oven for a first period of time. The first period of time is time required for at least a portion of the insert215to melt away from the frame200and to form the cavity220. According to some embodiments presently disclosed, the first period of time is time required for most of the insert15to melt away from the receiver10and to form the cavity20. At270, the frame200is removed from the oven and allowed to cool down. According to some embodiments, a firing mechanism (not shown) may be inserted into the cavity220after the frame200is removed from the oven and is allowed to cool down.

According to some embodiments, melting away of the at least a portion of the insert215reveals one or more openings230through the sidewalls of the frame200as shown inFIG.10. The one or more openings230may be formed by the one or more protrusions225. The one or more openings230may allow for installation of pins (not shown) used to secure the firing mechanism (not shown) in the cavity220.

While several illustrative embodiments of the invention have been shown and described, numerous variations and alternative embodiments will occur to those skilled in the art. Such variations and alternative embodiments are contemplated, and can be made without departing from the scope of the invention as defined in the appended claims.

As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. The term “plurality” includes two or more referents unless the content clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the disclosure pertains.