Patent Publication Number: US-11385027-B2

Title: Modular dovetail rail clamping assembly

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. application Ser. No. 16/848,875, filed Apr. 15, 2020, which is a continuation-in-part of U.S. application Ser. No. 16/430,062, filed Jun. 3, 2019, now U.S. patent Ser. No. 10/648,776, issued May 12, 2020, which is a continuation of U.S. application Ser. No. 15/828,469, filed Dec. 1, 2017, now U.S. patent Ser. No. 10/352,657, issued Jul. 16, 2019, which is a continuation of U.S. application Ser. No. 15/273,835, filed Sep. 23, 2016, now U.S. Pat. No. 9,841,258, issued Dec. 12, 2017. 
    
    
     BACKGROUND OF THE INVENTION 
     (1) Field of the Invention 
     The instant invention relates to weapon accessories for commercial and combat weapons, and more particularly to dovetail rail clamping assemblies for securing weapon accessories to a weapon. 
     (2) Description of Related Art 
     As the field of commercial and combat weaponry expands, numerous add-on accessories have become available and are commonly mounted on various firearms. In order to mount these accessories, most weapons now include, or are modified to include, one or more dovetail attachment rails. Many of the semi-automatic rifle systems include rail systems having four separate rails surrounding the barrel for maximum mounting surface area. Pistols often include a single dovetail rail extending forwardly from the trigger guard below the barrel. The accessories are typically mounted to the dovetail rails using clamping assemblies which are part of a mount or which are incorporated directly into the accessory housing. Many varieties of clamping arrangements are known in the art. 
     There are two main types of dovetail attachment rails, the Weaver rail (or universal rail) and the newer MIL-STD 1913 rail, both of which have a virtually identical cross-sectional profile. The key difference lies in the placement of the recoil grooves and in the width of the grooves. MIL-STD-1913 grooves are 0.206″ wide and have a center-to-center width of 0.394″. The placement of these grooves has to be consistent in order for it to be a true MIL-STD system. Weaver (universal) system grooves are 0.180″ wide and are not necessarily consistent in a center-to-center measurement from one groove to the next. 
     As is well known in this art, user configurable mounting arrangements are highly desirable as there are many different types of accessories and many different preferences for their mounting and operation. Sighting accessories are typically mounted on an upper rail. However, electronic accessories, such as flashlights, IR illuminators and lasers can be mounted in many different locations around the barrel. The ability of the user to mount an accessory in a particular location on a weapon is paramount to ease of use, user effectiveness and most importantly, user safety. Customization is critical to every soldier and law enforcement officer. 
     SUMMARY OF THE INVENTION 
     The invention relates to dovetail rail mounting systems for removably securing weapon accessories to a dovetail rail. A modular dovetail rail clamping assembly includes a body having a longitudinal axis and a rail engaging surface extending parallel to the longitudinal axis. The body may be formed as a mount for receiving and securing a weapon accessory to the dovetail rail, or the body may be integrated directly into the housing of an accessory, such as a flashlight. 
     A fixed clamp component has a longitudinal rail groove and a threaded fastener extends transversely through the body and is received into the fixed clamp component to draw the fixed clamp component into firm engagement with the body. The fixed clamp component and the body have longitudinal ridge and groove mating structures which rigidly fix alignment of the fixed clamp component relative to the body when assembled. In the exemplary embodiments, the threaded fastener is permanently fixed in place once the fixed clamp component is assembled with the body. 
     A movable clamp component opposes the fixed clamp and also has a longitudinal rail groove. A threaded clamping fastener extends transversely through the movable clamp component and the body and is removably received into the fixed clamp component whereby the threaded clamping fastener draws the movable clamp component into engagement with the body. The head of the clamping fastener is exposed on the outer surface of the movable clamp component so that the user may remove the fastener when mounting or unmounting the accessory. 
     A removable, reversible crossbar extends transversely across the rail engaging surface between the fixed clamp component and the movable clamp component. In this regard, the body includes a crossbar spline channel extending transversely through the body and across the rail engaging surface. The crossbar spline channel has a retaining ridge flush with the rail engaging surface and an angled undercut beneath the retaining ridge. The crossbar is formed so that it can be inserted into the spline in two different orientations. More specifically, the crossbar has a generally rectangular cross-section with a universal rail bar on one side thereof and a wider MIL-STD 1913 rail bar on an opposing side thereof. A retaining groove which mates with the spline channel retaining ridge is formed on a side surface therebetween. The crossbar can be reversibly mounted in the spline channel wherein the crossbar is slidably received in a first orientation within spline channel with the universal rail bar side slidably received in the spline channel and the MIL-STD 1913 rail bar side exposed above the rail engaging surface for engagement with the dovetail rail, and a second orientation with the MIL-STD 1913 rail bar side slidably received in the spline channel and the universal rail bar side exposed above the rail engaging surface for engagement with the dovetail rail. 
     In another exemplary embodiment, the crossbar spline channel extends only partially inwardly from the fixed clamp component side of the body wherein the crossbar is fully captured between the body and the fixed clamp component. This makes removal of the crossbar more difficult in embodiments where the fixed clamp component is not permanently secured. Moreover, this arrangement provides flexibility in manufacturing to easily provide either of two different dedicated mounting options when the fixed clamp component is secured in place permanently. 
     In order to provide maximum flexibility in the manufacturing process, the body may be molded from a polymer material. This allows the body to be molded as a custom mount shape, or directly integrated into the housing of an accessory. In other exemplary embodiments, the crossbar may also be formed from a polymer material. However, to also provide maximum strength and fixation on the dovetail rail, the fixed clamp component, the moveable clamp component and the crossbar are preferably formed from a metal, such as aluminum. This hybrid material arrangement provides the best features from both types of materials. 
     Accordingly, it can be seen that the present disclosure provides a unique and novel clamping assembly for any weapon accessory. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       While the specification concludes with claims particularly pointing out and distinctly claiming particular embodiments of the instant invention, various embodiments of the invention can be more readily understood and appreciated from the following descriptions of various embodiments of the invention when read in conjunction with the accompanying drawings in which: 
         FIG. 1  is a perspective view of a pistol mounted flashlight incorporating the hybrid modular dovetail rail clamping assembly of the present disclosure; 
         FIG. 2  is a perspective view of a dovetail rail; 
         FIG. 3  is an exploded perspective view of the hybrid modular dovetail rail clamp assembly; 
         FIG. 4  is another exploded view thereof from a different angle; 
         FIG. 5  is a cross-sectional view taken along line  5 - 5  of  FIG. 1 ; 
         FIG. 6  is another cross-sectional view taken along line  6 - 6  of  FIG. 1 ; 
         FIG. 7  is still another a cross-sectional view taken along line  7 - 7  of  FIG. 1 ; 
         FIG. 8  is a cross-sectional view of the crossbar spline channel; 
         FIG. 9  is a cross-sectional view thereof with the crossbar received therein in a first orientation with the MIL-STD 1913 rail bar side exposed for engagement; 
         FIG. 10  is another cross-sectional view thereof with the crossbar received therein in a second orientation with the universal rail bar side exposed for engagement; 
         FIGS. 11-12  are exploded assembly views showing assembly of the crossbar in the first orientation with the universal rail bar side received into the spline channel and the MIL-STD 1913 rail bar side exposed for engagement; 
         FIGS. 13-14  are exploded assembly views showing assembly of the crossbar in the second orientation with the MIL-STD 1913 rail bar side received into the spline channel and the universal rail bar side exposed for engagement; 
         FIG. 15  is an exploded perspective view of another exemplary embodiment of the clamping assembly where the spline channel only partially extends into the body; and 
         FIG. 16  is a partially assembled view thereof showing the crossbar locking in the channel; 
         FIG. 17  is a perspective view of another exemplary embodiment of a pistol mounted flashlight incorporating the modular dovetail rail clamping assembly of the present disclosure; 
         FIG. 18  is a cross-sectional view taken along line  18 - 18  of  FIG. 17 ; 
         FIG. 19  is another cross-sectional view taken along line  19 - 19  of  FIG. 17 ; and 
         FIGS. 20-21  are exploded assembly views thereof showing assembly of the crossbar in one exemplary orientation with the MIL-STD 1913 rail bar side received into the spline channel and the universal rail bar side exposed for engagement. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to the drawings, an exemplary embodiment of the invention is generally indicated at  10  in  FIGS. 1-14 . The invention relates to dovetail rail mounting systems for removably securing a weapon accessory, such as a flashlight to a dovetail rail  12  ( FIG. 2 ). As described above, there are two main types of dovetail attachment rails, the Weaver rail (or universal rail) and the newer MIL-STD 1913 rail, both of which have a virtually identical cross-sectional profile. The key difference lies in the placement of the recoil grooves  13  and in the width of the grooves  13 . MIL-STD-1913 grooves  13  are 0.206″ wide and have a center-to-center width of 0.394″. The placement of these grooves  13  has to be consistent in order for it to be a true MIL-STD system. Weaver (universal) system grooves (not illustrated) are 0.180″ wide and are not necessarily consistent in a center-to-center measurement from one groove to the next. 
     The modular dovetail rail clamping assembly  10  includes a body  14  having a longitudinal axis A ( FIG. 1 ) and a planar rail engaging surface  16  extending parallel to the longitudinal axis A. The body  14  may be integrated directly into the housing of an accessory, such as a flashlight as illustrated. In the exemplary embodiment, the body  14  is molded as part of the elongated housing of a flashlight having a light  18  at the head end thereof and switches  20  at the tail end. The longitudinal axis A extends between the head  18  and the tail  20  of the flashlight housing (body)  14 . 
     Alternately, the body  14  may be formed as a separate mount body for receiving and securing a weapon accessory to the dovetail rail  12 . When formed as a mount body, the body may include an opposing mount surface contoured to receive the housing of a weapon accessory, which may comprise any of a variety of lights, laser, IR illuminators, sighting devices or magnifiers. 
     Turning to  FIGS. 3 and 4 , a fixed clamp component  22  has a longitudinal rail groove  24  for engaging the dovetail rail  12 . A first threaded fastener  26  extends transversely through the body  14  and is received into a threaded opening  28  in the fixed clamp component  22  to draw the fixed clamp component  22  into firm engagement with the body  14 . Referring briefly to  FIG. 5 , it can be seen that the fixed clamp component  22  and the body  14  have longitudinal ridge  30  and groove  32  mating structures which rigidly fix alignment of the fixed clamp component  22  relative to the body  14  when assembled. Moving to  FIG. 7 , the head of the threaded fastener  26  is recessed into the body  14 , and in the exemplary embodiments, the threaded fastener  26  is permanently fixed in place with an epoxy plug  34 , once the fixed clamp component  22  is assembled with the body. 
     Turning back to  FIGS. 3 and 4 , a movable clamp component  36  opposes the fixed clamp component  22  and also has a longitudinal rail groove  38  for engaging the opposing side of the dovetail rail  12 . A threaded clamping fastener  40  extends transversely through the movable clamp component  36  and the body  14  and is removably received into a second threaded opening  42  in the fixed clamp component  22  whereby the threaded clamping fastener  40  draws the movable clamp component into engagement with the body (See  FIG. 6 ). The head of the clamping fastener  40  is exposed on the outer surface of the movable clamp component  36  so that the user may remove the fastener  40  when mounting or unmounting the assembly. A snap ring washer  44  is received in a groove  46  in the shank of the fastener  40  to retain the movable clamp component  36  and the fastener  40  together as a unit. 
     A removable, reversible crossbar  48  extends transversely across the rail engaging surface  16  between the fixed clamp component  22  and the movable clamp component  36 . In this regard, the body  14  includes a crossbar spline channel  50  extending transversely through the body  14  and across the rail engaging surface  16 . Referring to  FIGS. 8-10 , the crossbar spline channel  50  has a retaining ridge  52  flush with the rail engaging surface  16  and an angled undercut  54  beneath the retaining ridge  52 . The crossbar  48  is formed so that it can be inserted into the spline channel  50  in two different orientations ( FIGS. 9 and 10 ). More specifically, the crossbar  48  has a generally rectangular cross-section with a universal rail bar  56  on one side thereof and a wider MIL-STD 1913 rail bar  58  on an opposing side thereof. A retaining groove  60  which mates with the spline channel retaining ridge  52  is formed on a side surface therebetween. 
     Turning to  FIGS. 11-14 , the crossbar  48  can be reversibly mounted in the spline channel  50  wherein the crossbar  48  is slidably received in a first orientation ( FIGS. 11-12 ) within spline channel  50  with the universal rail bar side  56  slidably received in spline channel  50  and the MIL-STD 1913 rail bar side  58  exposed above the rail engaging surface  16  for engagement with the dovetail rail  12  (See also  FIG. 9 ), and a second orientation ( FIGS. 13-14 ) with the MIL-STD 1913 rail bar side  58  slidably received in the spline channel  50  and the universal rail bar side  56  exposed above the rail engaging surface  16  for engagement with the dovetail rail  12  (See also  FIG. 10 ). 
     Referring to  FIGS. 15 and 16 , another exemplary embodiment is illustrated and generally indicated at  100 . In this embodiment, the crossbar spline channel  50 A extends only partially inwardly from the fixed clamp component  22  side of the body  14 A. The crossbar  48 A is made slightly shorter in length and is fully captured between the body  14 A and the fixed clamp component  22 , rather than the two clamping components  22  and  36 . This arrangement provides flexibility in manufacturing to easily provide either of two different dedicated mounting options when the fixed clamp component  22  is secured in place permanently. 
     In order to provide maximum flexibility in the manufacturing process, the body  14 , 14 A may be molded from a polymer material. This allows the body  14 , 14 A to be molded as a custom mount shape, or directly integrated into the housing of an accessory as described above. In other exemplary embodiments, the crossbar  48 ,  48 A may also be formed from a polymer material. However, to also provide maximum strength and fixation on the dovetail rail  12 , the fixed clamp component  22 , the moveable clamp component  36 , the crossbar  48 ,  48 A and the threaded fasteners  26 ,  40  are preferably formed from a metal, such as aluminum. This hybrid material arrangement provides the best features from both types of materials. 
     Referring now to  FIGS. 17-21 , another exemplary embodiment of the invention is generally indicated at  200 . 
     The modular clamping assembly  200  is in almost all aspects the same as illustrated and described for clamping assembly  10  in  FIGS. 1-14 . The one noted difference in the construction is an all metal body  214  which includes the integrated formation of the earlier plastic body  14  and metal fixed clamp component  22 . In certain embodiments of the flashlight construction it has been shown to be desirable to provide an all metal body construction, but one which can also utilize the reversible crossbar  48 . 
     The modular dovetail rail clamping assembly  200  includes a body  214  having a longitudinal axis A ( FIG. 1 ) and a planar rail engaging surface  16  extending parallel to the longitudinal axis A. The body  214  may be integrated directly into the housing of an accessory, such as a flashlight as illustrated. In the exemplary embodiment, the body  214  is milled as part of the elongated housing of a flashlight having a light  18  at the head end thereof and switches  20  at the tail end. The longitudinal axis A extends between the head  18  and the tail  20  of the flashlight housing (body)  214 . 
     Alternately, the body  214  may be formed as a separate mount body for receiving and securing a weapon accessory to the dovetail rail  12 . When formed as a mount body, the body may include an opposing mount surface contoured to receive the housing of a weapon accessory, which may comprise any of a variety of lights, laser, IR illuminators, sighting devices or magnifiers. 
     Turning to  FIGS. 18-21 , the fixed clamp component  222  is now milled or otherwise formed as an integrated part of the  214  body and still has a longitudinal rail groove  24  for engaging the dovetail rail  12 . 
     The movable clamp component  36  is the same as previously described and opposes the fixed clamp component  222  and also has a longitudinal rail groove  38  for engaging the opposing side of the dovetail rail  12 . Threaded clamping fastener  40  extends transversely through the movable clamp component  36  and into the body  214  and is removably received into a threaded opening  242  ( FIG. 19 ) in the body  214  whereby the threaded clamping fastener  40  draws the movable clamp component into engagement with the body (See also  FIG. 19 ). The head of the clamping fastener  40  is exposed on the outer surface of the movable clamp component  36  so that the user may remove the fastener  40  when mounting or unmounting the assembly. A snap ring washer  44  is received in a groove  46  in the shank of the fastener  40  to retain the movable clamp component  36  and the fastener  40  together as a unit. 
     A removable, reversible crossbar  48  as previously described above, extends transversely across the rail engaging surface  16  between the fixed clamp component  222  and the movable clamp component  36 . In this regard, the body  214  includes a crossbar spline channel  50  extending transversely across the rail engaging surface  16 . Referring to  FIGS. 20-21 , the crossbar spline channel  50  has a retaining ridge  52  flush with the rail engaging surface  16  and an angled undercut  54  beneath the retaining ridge  52 . The crossbar  48  is formed so that it can be inserted into the spline channel  50  in two different orientations ( FIGS. 9 and 10 ). More specifically, the crossbar  48  has a generally rectangular cross-section with a universal rail bar  56  on one side thereof and a wider MIL-STD 1913 rail bar  58  on an opposing side thereof. A retaining groove  60  which mates with the spline channel retaining ridge  52  is formed on a side surface therebetween. 
     As described above, the crossbar  48  can be reversibly mounted in the spline channel  50  wherein the crossbar  48  is slidably received in the same first and second orientations, i.e. a first orientation within spline channel  50  with the universal rail bar side  56  slidably received in spline channel  50  and the MIL-STD 1913 rail bar side  58  exposed above the rail engaging surface  16  for engagement with the dovetail rail  12  (not shown), and a second orientation ( FIGS. 20-21 ) with the MIL-STD 1913 rail bar side  58  slidably received in the spline channel  50  and the universal rail bar side  56  exposed above the rail engaging surface  16  for engagement with the dovetail rail  12  (See also  FIG. 10 ). 
     It can therefore be seen that the exemplary embodiments provide unique and novel modular clamping assemblies for any weapon accessory. 
     While there is shown and described herein certain specific structures embodying various embodiments of the invention, it will be manifest to those skilled in the art that various modifications and rearrangements of the parts may be made without departing from the spirit and scope of the underlying inventive concept and that the same is not limited to the particular forms herein shown and described except insofar as indicated by the scope of the appended claims