Patent Publication Number: US-10330409-B2

Title: Worm drive gas regulator

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Patent Application No. 62/447,398 entitled “ULTRA-PRECISION WORM DRIVE GAS REGULATOR” and filed on Jan. 17, 2017 for Ernest Bray, which is incorporated herein by reference. 
    
    
     FIELD 
     This application relates generally to gas regulators for firearms that utilize a gas flow to chamber a new round and rearm a firing mechanism, and in particular, the application relates to an adjustable gas flow volume control device. 
     BACKGROUND 
     Many semi-automatic and automatic rifles utilize a gas-driven reloading system. These systems are often tuned by the rifle manufacturer for optimal performance of the firearm. However, the addition of an accessory (e.g., a suppressor) or the wear of components due to usage alters the firing characteristics of the firearm. 
     To compensate for such changes, adjustable gas regulators were introduced that allow for the metering (i.e., increasing or decreasing) of the gas flow. The majority of adjustable gas regulators use a screw or piston of some type to partially obstruct a round gas hole in the gas block and gas tube of the firearm/rifle, such as an AR-15. The flaw in this design is that as the screw is turned in and begins to obstruct the gas flow, it has little effect and that effect gets more progressive as the screw approaches the apex/center of the gas hole, and then progressively less as the screw advances into the back side of the hole. This causes inconsistent gas metering as one turn or one click has different effect from the previous adjustment and is unpredictable. Additionally, the gasses on some designs cause the screw to work its way out, and the tip of the screw may be eroded by the flow of hot gasses during operation, or, fouling of the threads of the screw with carbon from the burning gasses and gun powder residue. 
     SUMMARY 
     A device and system for the metering of gas into a gas driven reloading system of a rifle is provided. The device, in certain embodiments, is a gas plate that includes a plurality of openings of differing radii, and a plurality of positioning notches formed on an edge of the gas plate. The device also includes, in certain embodiments, a series of teeth formed on a surface of the gas plate, where the series of teeth are formed with a pitch configured to correspond with threads of a worm drive, and where at least a partial rotation of the worm drive slidingly positions the gas plate with respect to the adjustable gas regulator. 
     In certain embodiment, the worm drive further comprises an annular groove positioned adjacent a first end of the worm drive, and the threads of the worm drive are positioned adjacent a second end of the worm drive. In certain embodiments, the adjustable gas regulator includes a worm drive retention plate having a semi-circular ridge configured to engage the annular groove. The worm drive retention plate may be configured to be secured in an opening of the adjustable gas regulator. 
     In certain embodiments, the adjustable gas regulator comprises a bore extending longitudinally from a first end to a second end, and where the bore is configured to receive the worm drive. In certain embodiments, each of the plurality of positioning notches is formed with a semi-circular shape and configured to engage a positioning ball. The positioning ball may be biased by a spring plate coupled to an exterior surface of the adjustable regulator. 
     The system includes, in certain embodiments, the device and a body having an opening configured to receive a movable gas plate and a worm drive. A rifle is also provided that includes the adjustable gas regulator with a moveable gas plate as described above. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A more particular description of the embodiments briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Understanding that these drawings depict only some embodiments and are not therefore to be considered to be limiting of scope, the embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which: 
         FIG. 1  is an exploded view diagram illustrating one embodiment of a worm drive gas regulator (“regulator”) in accordance with embodiments of the present disclosure; 
         FIGS. 2 a  and 2 b    are perspective view diagrams illustrating embodiments of the gas plate and worm drive in accordance with embodiments of the present disclosure; 
         FIG. 3  is a schematic diagram illustrating one embodiment of the gas plate in accordance with embodiments of the present disclosure; 
         FIG. 4  is a perspective view diagram illustrating one embodiment of a worm drive retention plate in accordance with embodiments of the present disclosure; 
         FIG. 5  is a perspective view diagram illustrating one embodiment of the worm drive in accordance with embodiments of the present disclosure; 
         FIG. 6  is a perspective view diagram illustrating one embodiment of the ball retention plate in accordance with embodiments of the present invention; 
         FIG. 7  is a perspective view diagram illustrating one embodiment of the body and the worm drive in accordance with embodiments of the present disclosure; 
         FIG. 8  is a side view diagram illustrating one embodiment of a rifle including an adjustable worm drive gas regulator in accordance with embodiments of the present disclosure; and 
         FIG. 9  is a schematic block diagram illustrating one embodiment of a gas-driven rifle in accordance with embodiments of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     The subject matter of the present application has been developed in response to the present state of the art, and in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available gas regulators. Accordingly, the subject matter of the present application has been developed to provide a firearm suppressor that overcomes at least some shortcomings of the prior art. 
     As will be described in greater detail below, the gas regulator includes an adjustable worm drive that drives a small narrow plate that moves over a gas port in the barrel and contains a series of precise holes for exact and predictable metering. The current disclosure illustrates a gas plate with precise holes in sequence. So, if a rifle barrel has a 0.082 gas port, then the user would obtain a gas plate that has the first hole in the sequence at 0.082 and then following holes in smaller sizes, for example, either 0.001 or 0.002 smaller. In one embodiment, a gas plate may go from 0.082, 0.081, 0.080, 0.079, 0.078, and 0.077. Alternatively, the openings may be reduced by 0.002, or even a custom plate with specific sizes for different ammo or suppressed use, etc. 
     The movable gas plate is narrow and small, therefore there is a much smaller opening for any gas to escape. Also, the opening that receives the worm drive is arranged co-linearly with the barrel (i.e., extending along the same longitudinal axis as the barrel), so that any gasses that might escape are vented in the same direction as the bore and do not affect the shooter. Beneficially, the below described worm drive system can be accessed from the end of the rifle and therefore can be used with almost any handguard. There may be six or more, adjustable positions on the plate. 
     In another embodiment, the depicted gas regulator includes detents or notches to signal when a port on the plate is in alignment with the barrel&#39;s port. In one embodiment, the openings in the gas plate run from largest to smallest, and a user can count the number of clicks to know which opening is in alignment with the port of the barrel. In another embodiment, the block includes indicator notches that coordinate with the worm drive to indicate which port is in use. The worm drive can be driven by hand, by using a coin, a flat blade screwdriver, a hex wrench, ¼″ nut driver, socket, etc. 
     The description of elements in each figure may refer to elements of proceeding figures. Like numbers refer to like elements in all figures, including alternate embodiments of like elements. Similar elements may be referred to with a number and a letter, such as “ 102 a” and “ 102 b”, when identified individually, and when referred to jointly by the number only (i.e., “ 102 ” without that “a” or “b”). 
       FIG. 1  is an exploded view diagram illustrating one embodiment of a worm drive gas regulator (“regulator”)  100  in accordance with embodiments of the present disclosure. The regulator assembly  100 , in one embodiment, includes a body  102  with barrel bores  104  that are configured to engage the barrel of a rifle. The barrel bores  104  are configured to slide over a barrel and be positioned such that the regulator  100  and gas plate  106  are positioned above a gas port (not shown) in a barrel. An upper portion of the body  102  is configured with an opening  109  to receive the adjustable gas plate  106 , and a worm drive  108 . The opening  109 , in one embodiment, comprises a bore that extends longitudinally from one end of the regulator  100  to an opposing end of the regulator  100 . In this embodiment, the worm drive  108  is insertable into one of the ends of the bore, and a gas tube (or other gas driven system) is insertable into the opposite end of the bore. A worm drive retention plate  110  is also provided, and may be secured with a pin  112 . 
     The gas regulator  100  is also configured with an opening  105  for receiving a position indicator, which in one embodiment, may be a ball  114  that engages a series of detents  107  or notches in the gas plate  106 . A spring plate  116  provides a biasing force to the ball  114  and maintains the ball  114  at least partially within the opening. The spring plate  116  may be rigidly mounted at one end to the regulator  100 . The spring plate  116  may be formed of a thing sheet of metal that is capable of flexing enough to allow the ball  114  to move in to and out of position within the detents  107 . 
       FIGS. 2 a  and 2 b    are perspective view diagrams illustrating embodiments of the gas plate  106  and worm drive  108  in accordance with embodiments of the present disclosure. In the depicted embodiments, the worm drive  108  rests on the worm-drive retention plate  110 . The worm-drive retention plate  110 , in one embodiment, includes a ridge  111  (see  FIG. 1 ) that extends into an annular groove  202  formed on the shaft of the worm drive  108 . The ridge maintains the position of the worm drive  108  with respect to the body  102 . As the threads of the worm drive  108  shaft engage corresponding threads or grooves of the gas plate  106 , the gas plate  106  either moves toward to the worm drive or away from the worm drive  108 . 
     Also depicted is the engagement of the ball  114  to the notches or detents  107  formed in the side of the gas plate. The ball moving in to and out of engagement with the notches causes the ball retention plate  116  to move in and out. This visual indication allows a user to know the position of the gas plate  106  within the body  102 . Stated differently, a user is able to identify that an opening in the gas plate is properly aligned with the gas port of the barrel. In another embodiment, an aural click may be heard, also indicative of the position. 
       FIG. 3  is a schematic diagram illustrating one embodiment of the gas plate  106  in accordance with embodiments of the present disclosure. The gas plate  106 , in one embodiment, includes grooves  302  formed in the gas plate  106  that correspond with a gear pitch and tooth profile of the worm drive. In one embodiment, the gear pitch and tooth profile may be altered to increase the movement of the gas plate with respect to the worm drive. Stated differently, faster or slower adjustments of the gas plate when the worm drive is turned may be implemented by providing different gear pitches and tooth profiles. In such an example, the pitch may be altered such that a quarter turn, for example, advances the gas plate enough to align an adjacent opening with the gas port. Accordingly, visual indicators on the body  102  may be positioned to correspond with the position of the gas block, as will be described below in greater detail with reference to  FIG. 7 . 
     The gas plate  106  also includes a series of openings  302  with varying radii, as depicted. The radii may be modified to suit a particular application. In one embodiment, the sizes of the openings sequentially increase or decrease, as described above. This beneficially aids in adjustment, as the user will know that the next opening will be either slightly larger or slightly smaller than the currently positioned opening. Notches may be formed in one edge of the gas plate to indicate a position. Counting the “clicks” or number of times the ball engages the notch allows the user to take note of the position of the gas plate. Alternatively, the visual indicator of  FIG. 7  may indicate the position. 
       FIG. 4  is a perspective view diagram illustrating one embodiment of a worm drive retention plate  110  in accordance with embodiments of the present disclosure. As described above, the worm drive retention plate  110 , in one embodiment, includes a semi-circular ridge  402  configured to engage an annular groove or notch in the worm drive. The ridge allows for the rotation of the worm drive while maintaining the longitudinal position of the worm drive with respect to the regulator  100 . Stated differently, the ridge fixes the position of the worm drive and cause a rotation of the worm drive to move the gas plate, instead of the other way around. An opening  404  may also be provided to allow the retention pin to secure the retention plate  110  within the body  102 . This, consequently, locks the retention plate  110  and the worm drive within the body  102 . 
       FIG. 5  is a perspective view diagram illustrating one embodiment of the worm drive  108  in accordance with embodiments of the present disclosure. As discussed above, the worm drive  108  includes threads  502  positioned near a first end of the worm drive, and a turnable head  504  positioned at the second end of the worm drive. The threads  502  are configured to engage the teeth or grooves formed in the surface of the gas plate. Turning the worm drive  108  cause the gas plate to slide longitudinally with respect to the body  102 . The turnable head  504 , in one embodiment, has a hexagonal nut that may be turned with a socket or wrench. Additionally, a slot in the turnable head  504  allows the worm drive to be turned with a coin. Alternative turnable heads  504  are contemplated, including but not limited to, thumb screws, etc. 
       FIG. 6  is a perspective view diagram illustrating one embodiment of the ball retention plate  116  in accordance with embodiments of the present invention. In the depicted embodiment, the ball retention plate  116  includes multiple openings. Some of these openings allow fasteners to secure the ball retention plate  116  to the body  102 . The smaller opening is configured to engage the ball and maintain the ball within its opening in the body  102 . The ball retention plate  116  is formed of a material that is capable of providing a biasing force to the ball, such as metal, or a composite of metal. The biasing force pushes the ball against the notches formed in the side of the gas plate. As the gas plate is moved, the ball pushes outward on the ball retention plate  116  until the ball engages the next notch. Because the ball retention plate  116  is always pushing on the ball, the ball makes an audible click as it engages the next notch and indicates to the user that the next opening has been aligned with the gas port. 
       FIG. 7  is a perspective view diagram illustrating one embodiment of the body  702  and the worm drive  704  in accordance with embodiments of the present disclosure. The body  702 , in one embodiment, may include visual indicators  706  formed in a surface of the body  702 . The visual indicators  706 , for example, are dots positioned on the body  702  so as to be radially adjacent an outer surface of the turnable head of the worm drive  704  when the worm drive  704  is inserted in the body  702 . An indicator  708  formed in the outer surface of the turnable head is configured to indicate a position of the gas plate. 
     As described above, the pitch of the worm drive may be selected to advance the gas plate with a small turn of the turnable head. In the depicted embodiment, a sixth of a full rotation will advance the gas plate from one position to the adjacent position. Also depicted are the different mechanisms that may be used for turning the turnable head, such as a hex-shaped opening for receiving a hex drive, a slot for receiving a screwdriver, or a knurled outer surface for engaging a user&#39;s thumb and index finger. 
       FIG. 8  is a side view diagram illustrating one embodiment of a rifle  800  including an adjustable worm drive gas regulator  100  in accordance with embodiments of the present disclosure. As described above, the regulator  100  is configured to couple to the barrel of the rifle  800 . The worm drive  108  is accessible from the barrel end of the rifle, beneficially, for ease of adjustment. The regulator  100  is configured to be mounted over the gas port of the barrel so as to align one of the openings of the gas plate with the gas port. 
       FIG. 9  is a schematic block diagram illustrating one embodiment of a gas-driven rifle  900  in accordance with embodiments of the present disclosure. As known to those of skill in the art, semi-automatic and automatic rifles are often driven by the flow of gasses that result from the firing of a round of ammunition. After the initial round of ammunition is loaded, the gasses may drive the expulsion of the spent round and the loading of the next round. Examples of common gas-driven systems are gas-piston and gas-impingement. 
     If a silencer  902  is attached to the barrel  904 , gas flow (indicated by the arrows) exiting the barrel may be inhibited causing back pressure that creates a greater or less than optimal pressure on the gas-driven system. Beneficially, the different diameter openings in the gas plate  106  can increase or decrease the gas pressure on the gas-driven system. A receiver  906  (graphically depicting an upper and lower receiver) houses all of the components necessary to fire a round of ammunition. The barrel  904  couples to the receiver  906 , and the regulator  100  couples to the barrel to align with the gas port  910  of the rifle  900 . 
     A gas tube  912  (or gas piston, depending upon the system utilized by the rifle) is fluidly coupled with the gas port  910 . As a round of ammunition travels down the barrel  904 , gasses are forced through the gas port  910  and in to the gas tube  912 . The gasses travel through the gas tube  912  back to the receiver  906  and cause the rifle to eject the spent ammunition casing and load a new round, as is known to those of skill in the art. The worm drive  108 , as is described above in greater detail, may be rotated to position the gas plate  106  such that one of the openings of the gas plate  106  aligns with the gas port  910  to meter the flow of gas through the gas tube  912 . In one embodiment, a channel is formed in the interior of the regulator  100  to fluidly couple the gas port  910  with the gas tube  912 . 
     Reference throughout this specification to features, advantages, or similar language does not imply that all of the features and advantages that may be realized with the subject matter of the present disclosure should be or are in any single embodiment. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an embodiment is included in at least one embodiment of the present disclosure. Thus, discussion of the features and advantages, and similar language, throughout this specification may, but do not necessarily, refer to the same embodiment. 
     Furthermore, the described features, advantages, and characteristics of the subject matter of the present disclosure may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize that the subject matter may be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments. These features and advantages will become more fully apparent from the following description and appended claims, or may be learned by the practice of the subject matter as set forth hereinafter. 
     Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment. The terms “including,” “comprising,” “having,” and variations thereof mean “including but not limited to” unless expressly specified otherwise. An enumerated listing of items does not imply that any or all of the items are mutually exclusive and/or mutually inclusive, unless expressly specified otherwise. The terms “a,” “an,” and “the” also refer to “one or more” unless expressly specified otherwise. 
     Additionally, instances in this specification where one element is “coupled” to another element can include direct and indirect coupling. Direct coupling can be defined as one element coupled to and in some contact with another element. Indirect coupling can be defined as coupling between two elements not in direct contact with each other, but having one or more additional elements between the coupled elements. Further, as used herein, securing one element to another element can include direct securing and indirect securing. Additionally, as used herein, “adjacent” does not necessarily denote contact. For example, one element can be adjacent another element without being in contact with that element. 
     The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.