Abstract:
A holster blank and holster for a handgun formed from a unitary molded body portion having two side holster portions joined to opposite edges of an elongate narrow spine intermediate portion by parallel living hinges. The side holster portions have outer edges brought together by pivoting the side holster portions towards each other via the living hinges so as to form the holster. The body portion includes interfacing elongate male and female locking portions which engage and lock the outer edges together. A method of producing the holster includes molding the body portion and pivoting the sides via the living hinges 90 degrees and providing a lock to interconnect the side portions adjacent the trigger guard of a handgun.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims an invention that was disclosed in part in U.S. Design Patent Application  29 / 443 , 047 , filed Jan. 11, 2013, entitled “Holster Blank and Holster Body”, and claims priority to Provisional Patent Application 61/773,537, filed on Mar. 06, 2013. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not Applicable. 
       REFERENCE TO MICROFICHE APPENDIX. 
       [0003]    Not Applicable. 
       BACKGROUND OF THE INVENTION 
       [0004]    1. Field of the Invention 
         [0005]    The present invention relates to firearm holsters. More particularly, the invention pertains to a holster formed by folding a molded holster blank such that its two clam-like halves/sides come together and can be joined to form a holster configuration that is capable of withstanding the type of “snatch” test necessary to qualify as a law enforcement duty pistol or handgun holster. Specifically, the holster has an Automatic Locking System (ALS). 
         [0006]    2. Relevant Art 
         [0007]    In general, weapon retention is of critical importance for law enforcement personnel. Recent developments in this field focus on the inclusion of locking/retention systems for holstered handguns that must be released by a lever, button or other means in order to release the handgun from the holster, Representative and/or exemplary applications and/or patents related to this field include: U.S. Ser. No. 111672,826 filed Feb. 8, 2007 (Pub. No. 2007/0181619), for a “Modular Holster for Handguns and the Like”, invented by Seyfert et al.; and more especially, U.S. Pat. No. 7,694,860 for a “Handgun Locking Device” issued Apr. 13, 2010, to Clifton. Another patent, U.S. Pat. No. 2,987,229, issued in 1958 for a “Molded Plastic Pistol Holster” by LeClerc is of more limited applicability, but serves to provide some insight into the field of one-piece molded plastic holster construction. 
         [0008]    However, none of these systems and inventions provides or renders obvious the features taught and embodied in the instant invention. The LeClerc patent provides some general insight into the primitive level of unitary molded holster construction, but does not deal with issues of weapon retention. The Seyfert application describes a holster (including a locking system) formed from multiple pieces and alludes to the possibility of a one pieced unitary molded component being used to form such a holster. Nonetheless, it provides no teaching or insight as to how this might be accomplished, particularly in a manner that is capable of withstanding a snatch test. 
         [0009]    The Clifton Automatic Locking System (“ALS”) holsters are also made by joining separate sections together. Thus, this patent also fails to deal with issues related to molding/construction of the holster body from a single work piece in the context of weapon retention. However, the Clifton ALS holster has been able to pass the type of “Snatch Test” required by most Law Enforcement units. The “Snatch Test” is meant to stimulate a handgun being forcibly taken from the holster of a Law Enforcement officer by, e.g., a suspect or assailant. The ability of a holster to retain a holstered handgun against this form of action/attack is important for the safety of the Law Enforcement Officer, and could very well mean the difference between life and death. 
         [0010]    The current design and manufacture of the aforesaid thermoformed ALS holsters results in a holster body having zero points of separation, and results in a “double-wrap” of plastic material in the areas of greatest force during a snatch test: the trigger guard. However, due to manufacturing and cost constraints, development and production of a unitary injection molded holster body that can achieve the same results as a holster body formed from separate thermoformed sections has been elusive. Almost every design that will allow a holster to be injection molded has resulted in joints and mating separations which cannot withstand the force of a snatch test, most notably in the area of the trigger guard, which receives the lion&#39;s share of the forces applied during a snatch test. Efforts to create a uni-body design for a holster/holster blank that is suitable for injection molding has resulted in either an unacceptably bulky holster, or in mold tooling that is so expensive and complex that it is impractical. 
       SUMMARY OF THE INVENTION 
       [0011]    In one aspect of the present invention, there is provided an Automatic Locking System (ALS) Holster that can be injection molded as a single piece as opposed to being produced in separate sections using the thermoforming process in current use. This represents a significant breakthrough as only ALS holsters formed in thermoformed sections have previously been able to pass such a “Snatch Test”. It is accomplished using a “living hinge” holster design. More specifically, the design includes an intermediate spine portion joined on either side by living hinges to separate holster halves/sides. This allows the living hinges to be bent through a lesser angle than would otherwise be needed to join the two halves together by a single hinge. The hinge design is such that it allows the plastic material to bend at 90°, but not fracture along the living hinges. Likewise, in keeping with the overall goals and purposes of the invention, this living hinge design has proved capable of passing the snatch test without fracturing. Using this design has allowed the manufacture of a single-body holster with one tool and a minimal amount of assembly. 
         [0012]    In another aspect of the instant invention, a trigger guard lock is provided that can also pass and survive the stresses imposed by the snatch test. As part of the assembly process, the right and left halves of the holster are folded inward toward each other, via the living hinges described above, until they touch at their edges opposite the edges by which they are joined via living hinges to the spine portion. The trigger guard lock then engages and locks the holster halves together. The trigger guard lock is a vital component of the invention. It locks the two halves of the holster together, and provides an extremely strong connection and reinforcement at the trigger guard where the highest force is applied during the snatch test, The lock is designed to be easy to snap together, but virtually impossible to disengage without the use of a tool. 
         [0013]    The male side of the lock features a U-shaped protrusion. The two upper protrusions that form the “uprights” of the U-shape directly contact the left side of the trigger guard on the handgun. The lower face of the male side of the lock is chamfered to allow easy engagement into the female side of the lock. The back side of the male lock is cleared out at a near right angle cut. The cut away area forms the locking surface against the outside of the female lock, and is primarily responsible for resisting the forces applied in a snatch test. The female lock provides a pocketed area for the neck of the male lock to interface. The female lock also contains an engagement tab that pushes out of the way during install, but then engages into the “U” portion of the male lock preventing the male lock from working its way out of the U-shaped slot in the female lock. This engagement tab must be pried out of the way with a flat blade screwdriver or the like in order to disengage the male lock from the female lock. 
         [0014]    In still other aspects, it will be seen that the ALS holster of the invention has additional means for securing the two sides forming the holster together and other features as explored below that contribute to its purpose and goals as a sturdy, secure, durable and effective duty pistol holster with automatic locking system features. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]    The novel features believed to be characteristic of this invention are set forth with particularity in the appended claims. The invention itself, however, both as to its organization and method of operation, together with further object and advantages thereof, may best be understood by reference to the following description taken in connection with the accompanying drawings in which: 
           [0016]      FIG. 1  is a front, top perspective view of the open holster blank of the invention, showing the outside surfaces of the holster when formed; 
           [0017]      FIG. 2  is a left end elevational view of the holster blank of the invention shown in  FIG. 1 , which end will become the top or pistol insertion end of the holster when formed; 
           [0018]      FIG. 3  is a right end elevational view of the holster blank of the invention shown in  FIG. 1 , which end will become the bottom end of the holster when formed; 
           [0019]      FIG. 4  is a right side elevational view of the holster blank of the invention shown in  FIG. 1 , which right side will be joined to the left side to become the front/outward side of the holster when formed; 
           [0020]      FIG. 5  is a left side elevational view of the holster blank of the invention shown in  FIG. 1 , which left side will be joined to the right side to become the back/belt side of the holster when formed; 
           [0021]      FIG. 6A  is a top plan view of the holster blank of the invention, illustrating portions that will become the outside of the holster when formed; 
           [0022]      FIG. 6B  is a bottom plan view of the holster blank of the invention, illustrating portions that will become the inside of the holster when formed; 
           [0023]      FIG. 7A  is a top end elevational view of the holster blank of the invention in the process of being folded to form the holster of the invention, with each side bent away from the horizontal and towards each other by 30 degrees; 
           [0024]      FIG. 7B  is a top end elevational view of the holster blank of the invention in the process of being folded to form the holster of the invention, with each side bent away from the horizontal and towards each other by 60 degrees; 
           [0025]      FIG. 7C  is a detailed perspective view of the male portion of the latch that is used to join the two sides/halves of the holster blank together to form the holster of the invention; 
           [0026]      FIG. 7D  provides a detailed perspective view of the female portion of the latch that will be used to join the two sides/halves of the holster blank together to form the holster of the invention; 
           [0027]      FIG. 7E  is a cut-away perspective view of the holster taken through the male and female portions of the latch when snapped together so as to join the two sides/halves of the holster blank together to form the holster of the invention; 
           [0028]      FIG. 7F  is a cross-sectional view of the male and female portions of the latch when snapped together so as to join the two sides/halves of the holster blank together to form the holster of the invention, with the living hinges being bent at 90°; 
           [0029]      FIG. 7G  is a perspective view of a pistol nested in the interior of the holster blank in what will become the front side of the holster when formed, further illustrating how the male portion of the latch interfaces with the trigger guard of a pistol; 
           [0030]      FIG. 7H  provides a cross-sectional detail view of a living hinge of the invention in a partially bent/deflected position; 
           [0031]      FIG. 8  is a rear top perspective view of the holster body of the invention, formed by completing the process of folding the two sides/halves of the holster blank of the invention together, the two clam-like sides/halves which self-connect via the latch portions illustrated in  FIGS. 7C through 7G  to form the holster configuration illustrated; 
           [0032]      FIG. 9  is a left end elevational view of he holster of the invention illustrated in  FIG. 8 , illustrating the bottom of the holster; 
           [0033]      FIG. 10  is a right end elevational view of the holster body of the invention illustrated in  FIG. 8 , illustrating the top, or pistol insertion opening/end, of the holster; 
           [0034]      FIG. 11  is a rear side elevational view of the holster body of the invention illustrated in  FIG. 8 , which faces inward towards the users body/belt adjacent thereto; 
           [0035]      FIG. 12  is a front side elevational view of the holster body of the invention illustrated in  FIG. 8 , which faces outward away from the users body when the holster is mounted adjacent thereto; 
           [0036]      FIG. 13  is a top plan view of the holster body of the invention illustrated in  FIG. 8 , which faces forward towards the user&#39;s front when the holster is mounted in standard fashion; 
           [0037]      FIG. 14  is a bottom plan view of the holster body of the invention illustrated in  FIG. 8 , which faces towards the user&#39;s back when the holster is mounted in standard fashion; 
           [0038]      FIG. 15  is a first perspective view of the interior of the back/belt side of the holster of the invention; and 
           [0039]      FIG. 16  is a second perspective view of the interior of the back/belt side of the holster of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0040]    With respect now to the drawings,  FIGS. 1 through 6B  illustrate the design and configuration of the basic injection molded one-piece holster blank  1  used in forming the holster  10  of the invention, illustrating many of the basic component parts of the invention and otherwise providing an introduction to its features. The sequence of portions initially denoted in the drawing figures will assist in orienting and understanding the various portions of the blank  1 , comprising: the edges that will become the top  2  of the holster  10 , the edges that will become the bottom  3  of the holster  10 , the section/side that will become the back  4  or belt mounting side of the holster  10 , the section/side that will become the front or outward side  5  of the holster  10 , and a generally linear spine portion  6  joining sides  4  and  5 . As will be noted from these drawing figures, the blank  1  (and holster  10 ) is/are primarily defined by the last three basic parts named, i.e., it is comprised of a relatively rigid elongate intermediate narrow spine portion  6  joined by a first living hinge  7  to back side  4  and by a second living hinge  8  to front side  5 , with each of the living hinge being substantially parallel to each other and each being adapted to bend through a 90 degree angle so as to bring back side  4  into contact with front side  5 , The male latch element  9  and female latch element  12  are readily visible in many of the aforesaid drawing figures. 
         [0041]    By expanding the scope of consideration to include  FIGS. 7A and 7B  it can be seen how the front half  5  and back half  4  of the holster blank  1  can be folded inward toward each other until they touch/lock (forming the holster  10  illustrated in  FIG. 8 ) via the trigger guard lock  11  comprising male lock/latch element  9  and female lock/latch element  12  (including the various subparts thereof discussed below), engages and locks the halves  4 ,  5  together. The various components comprising trigger guard lock  11  can best be seen in  FIGS. 7C through 7G . Trigger guard lock  11  forms a vital component of the injection molded holster  10 . It not only locks the two halves  4 ,  5  of the holster  10  together, it provides an extremely strong connection and reinforcement adjacent a trigger guard  13  of a handgun nested in the trigger guard area  14  of the holster  10  where the highest force is applied during the snatch test. The lock  11  is designed to be easy to snap together, but virtually impossible to disengage without the use of a tool. The male portion  9  of the lock  11  is elongated along a longitudinal axis of the holster  10  and includes a U-shaped protrusion  9 A. The two prongs  9 A 1 ,  9 A 2 , that form the “uprights” of the “U-shape” protrusion  9 A, directly contact the back side of a trigger guard  13  on a handgun inserted into holster  10 . (See,  FIG. 7F ). 
         [0042]    The lower face  9 B of the male portion  9  of the lock  11  is chamfered to allow easy engagement into the female portion  12  of the lock. The back side  9 C of the male portion  9  is cleared out at a near right angle cut. The cut away area of back side  9 C forms the locking surface against the outside of the female lock portion  12 , and is primarily responsible for resisting the forces applied in a snatch test. The female portion  12  provides a pocketed area  12 A for the neck  90  of the male lock element  9  to interface. The female lock portion  12  is elongated along a longitudinal axis of the holster  10  and also contains an engagement tab  12 B that pushes out of the way during install, but then engages into the “U” portion  9 A of the male lock portion  9  preventing the male lock portion  9  from working its way out of the U-shaped slot  12 C in the female lock portion  12  This engagement tab  128  must be pried out of the way with a flat blade screwdriver or the like in order to disengage the male lock portion  9  from the female lock portion  12 . 
         [0043]    The holster  10  of the invention is also secured together at four additional engagement points  15 ,  16 ,  17  and  18 , which assist in maintaining both halves  4 ,  5  of the holster  10  secured and engaged and prevent detachment during a snatch test. There are apertures for two spaced large truss-head screws (engagement points  15 ,  16 ) located along the “keel” of the holster  10  slightly below the trigger guard lock  11  to provide additional reinforcement against forces that are applied to the trigger guard  13  during a snatch test. There are also two spaced plastic threading screw apertures (engagement points  17 ,  18 ) located just below the living hinges  7 ,  8  adjacent the upper end  2  and lower end  3  of the holster  10 . These two plastic threading screw engagement points  17 ,  18  serve two functions. The first is to assist in relieving any load against the living hinges  7 ,  8  during a snatch test. The second is to assist in pulling the spine portion  6  edge/side of the holster  10  together as the living hinges  7 ,  8  resists the halves  4 ,  5  of the holster  10  coming perfectly together. The holster  10  also has a “Grid” of external structural ribs  19  that reinforce the trigger guard area  14  and resists the bending that can lead to failure of the trigger guard lock  11  during a snatch test. The holster  10  uses the same belt loop/accessory mounting platform  20  and screw pattern currently used in thermoformed ALS holsters. 
         [0044]    There are several internal features in the holster that are also important to the functionality of the invention. To begin with, in the ALS lock area there is a socket and a screw mounting hole  21  in the top-inside surface of the holster where the ALS “Lever-Lock” mounts. This ALS “Lever-Lock” is currently used on all of the ALS thermoformed holsters, and will work in the exact same manner in the context of the instant invention. (See, U.S. Pat. No. 7,694,860, which is incorporated herein by reference). A second group of important internal features relate to “contact points” that are important to the support and positioning of a handgun in the holster  10 . The first contact point is an upper slide contact boss  22 . This feature is located on both halves of the holster, below the living hinges  7 ,  8 . The contact bosses  22  protrude toward the inside of the holster  10  and provide contact with the top of the slide of the handgun when inserted therein. The contact bosses  22  do not protrude so far inside the holster  10  as to interfere with the front sight of the handgun. When the holster blank  1  is folded together to form holster  10 , there remains a gap between each of the upper contact bosses  22  to allow a front sight to pass between them when the handgun is inserted into and withdrawn from the holster  10 . 
         [0045]    Another internal feature of note is the trigger guard stop/receiver rest  23 . This feature defines the forward limit of the handgun as it is inserted into the holster  10 . The trigger guard stop  23  provides a barrier that the forward section of the trigger, guard on the handgun butts up against when inserted into holster  10 . The lower receiver rest  24  is the portion of this feature that the bottom of the handgun below the slide (receiver) rests against In addition, contact ribs  25  are present on the inside surfaces of both halves  4 ,  5  of the holster  10 , and contact the handgun along the receiver, slide and grip. The contact ribs  25  allow the manufacturer/producer of the invention to easily add or reduce the pressure on the handgun due to manufacturing variations in the size of the ribs  25 . The contact ribs  25  are small in height, and can be reduced or eliminated if the fit of the handgun is too tight. Conversely, the ribs  2  can be increased in height should the handgun fit be too loose. 
         [0046]    Other features of note include build-ups  26  for the protection of the magazine release from accidental engagement. Finally, the muzzle end of the holster features well rounded corners and edges to protect seat cushions from being scratched or punctured. Also, there are several depressed regions on either side of the holster that don&#39;t serve an operational function. These are there for material removal purposes to maintain a consistent wall thickness, or for cosmetics. 
       PARTS AND FEATURES ILLUSTRATED IN DRAWING FIGURES 
       [0000]    
       
           1  holster blank 
           2  top of the holster 
           3  bottom of the holster 
           4  back/belt mounting side of the holster 
           5  front/outward side of the holster 
           6  linear spine portion joining sides  4  and  5   
           7  first living hinge joining side  4  to spine  6   
           8  second living hinge joining side  5  to spine  6   
           9  male latch portion 
           9 A u-shaped protrusion portion of male latch element  9   
           9 A 1 ,  9 A 2  two prongs that form the “uprights” of the “U-shape” protrusion  9 A 
           9 B lower face of the male portion  9   
           9 C back side of the male portion  9   
           9 D neck of the male lock portion  9   
           10  holster formed from holster blank  1   
           11  trigger guard lock  11 —comprising male lock/latch element  9  and female lock/latch element  12  and subcomponents 
           12  female lock portion 
           12 A pocketed area of female portion  12   
           12 B engagement tab of female lock portion  12   
           12 C U-shaped slot in the female lock portion  12   
           13  trigger guard of pistol 
           14  trigger guard area of the holster  10   
           15 ,  16  engagement points/apertures for large truss-head screws 
           17 ,  18  plastic threading screw apertures/engagement points 
           19  grid of external structural ribs that reinforce the trigger guard area  14   
           20  belt loop/accessory mounting platform 
           21  socket and a screw mounting hole  21  for mounting ALS “Lever-Lock” 
           22  upper slide contact boss 
           23  trigger guard stop 
           24  lower receiver rest 
           25  contact ribs 
           26  build-ups protecting the magazine release from accidental engagement 
       
     
         [0079]    In view of the foregoing, it should be clear that numerous changes and variations can be made without exceeding the scope of the inventive concept outlined. Accordingly, it is to be understood that the embodiment(s) of the invention herein described is/are merely illustrative of the application of the principles of the invention. Reference herein to details of the illustrated embodiment(s) is not intended to limit the scope of the claims, which will recite those features regarded as essential to the invention.