Patent ID: 12253329

DETAILED DESCRIPTION

The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described.

Although the illustrated embodiments shown inFIGS.1-5illustrate components of various semi-automatic or automatic firearms, the features, concepts, and functions described herein are also applicable (with potential necessary alterations for particular applications) to handguns, rifles, carbines, shotguns, or any other type of firearm. Furthermore, the embodiments may be compatible with various calibers including rifle calibers such as, for example, 5.56×45 mm NATO, .223 Remington, 7.62×51 mm NATO, .308 Winchester, 7.62×39 mm, 5.45×39 mm; pistol calibers such as, for example, 9×19 mm, .45 ACP, .40 S&W, .380 ACP, 10 mm Auto, 5.7×28 mm; and shotgun calibers such as, for example, 12 gauge, 20 gauge, 28 gauge, 0.410 gauge, 10 gauge, 16 gauge. The illustrated embodiments focus on components of the AR-15 variant (civilian) or M16/M4 (military) firearm platform (i.e., AR-15 style firearms); however, the concepts and features described herein are also applicable (with potential necessary alterations for particular applications) to other components of the AR-15 style firearm platform and to components of other firearms.

In some cases, a firearm1includes a lower receiver10, an upper receiver11, a stock12, a pistol grip13, a delta ring14, a handguard endcap15, a front sight16, a barrel17, and at least one handguard assembly100(seeFIG.1). The firearm1may include multiple handguard assemblies100including, as shown inFIG.1, a first handguard assembly100and a second handguard assembly100. In some cases, the first handguard assembly100is an upper handguard assembly100and the second handguard assembly100is a lower handguard assembly100. Accordingly, in some cases, an entire handguard may include two handguard assemblies100. In some embodiments, the upper handguard assembly100and the lower handguard assembly100are identical. The handguard assemblies100illustrated are carbine length but all of the features described herein are applicable and can be included for handguard assemblies for mid-length, rifle length, pistol length, and/or any other appropriate size or style handguard assembly. The handguard assembly100may include an outer member101and an inner member201(seeFIGS.2A-3). The illustrated embodiments focus on components of an AR-15 style firearm with a traditional (in outer appearance) A2 handguard, however, the concepts and features described herein are also applicable (with potential necessary alterations for particular applications) to other components of the AR-15 style firearm platform and to components of other firearms.

As shown inFIG.1, the firearm1may be formed such that an operator can hold the firearm1with his/her shooting hand holding the pistol grip13such that the operator's index finger (of the shooting hand) can reach the trigger. In some embodiments, the configuration of the at least one handguard assembly100provides a location for an operator to grip the firearm1with his/her off hand. The operator may hold the firearm1with his/her off hand primarily on the lower handguard assembly100with his/her fingers wrapping around to the upper handguard assembly100. In other cases, the operator may hold the firearm1with his/her off hand primarily from a lateral direction such that the operator approximately equally grips the upper handguard assembly100and the lower handguard assembly100.

The handguard assembly100may include an installed configuration for the inner member201and an uninstalled configuration for the inner member201. An example of the installed configuration is shown inFIG.2Awhere the inner member201is installed and secured within the outer member101.FIG.3shows an example of the uninstalled configuration where the inner member201is separate and uninstalled relative to the outer member101.

As shown inFIG.1, in some embodiments, the handguard assembly100extends forward in a direction approximately parallel to the barrel17. In some embodiments, the outer member101includes a forward end105, a rear end106, and an outer surface111(seeFIGS.2A and2B). The outer surface111of the handguard assembly100may have an approximately cylindrical shape (or semi-cylindrical external shape) that extends between the forward end105and the rear end106. In some cases, the shape of the outer surface111of the handguard assembly100is conical (or partially conical) such that the forward end105has a smaller size (and/or diameter) than the rear end106. As shown inFIGS.2A and2B, the outer surface111may include at least one rib112, at least one channel109, and at least one hole113. In some cases, the at least one channel109is centrally located at the bottom (or top, depending on orientation) of the outer member101. The at least one rib112may extend in a direction that is perpendicular to the direction of the at least one channel109. The rib(s)112may follow a curved contoured path around the outer surface of the outer member101. The outer surface of the outer member101may include a cross-section that is at least partially round, oval, elliptical, and/or any other appropriate shape. The at least one hole113may be located in or on the at least one channel109. The outer member101may include at least one standoff114(seeFIG.4). Although the at least one standoff114is shown with a cylindrical shape (circular cross-section), the at least one standoff114may have a cross-sectional shape that is circular, square, oval, elliptical, polygonal, or any other appropriate shape. The forward end105may include an attachment feature107that interfaces with the handguard endcap15and is located rearward and/or approximately adjacent to the front sight16. The rear end106may include an attachment feature108that interfaces with the delta ring14and is located forward and/or approximately adjacent to one or both of the lower receiver10and the upper receiver11. In some embodiments, the at least one channel109may include a rail. The rail may be a Picatinny rail (MIL-STD-1913 rail or STANAG 2324 rail), a Weaver rail, or any other appropriate rail.

To arrange multiple handguard assemblies100together (e.g., seeFIG.1), the outer member101may also include at least one feature for securing a second outer member101. For example, in some embodiments, the outer member101may include at least one first securing member103and at least one second securing member104. As shown inFIGS.2A,3, and4, the at least one first securing member103may be a female recess, and the at least one second securing member104may be a male protrusion with a corresponding shape. In some embodiments, the securing members103,104have an approximately rectangular cross-sectional shape. Each end of the rectangular shape may be rounded or curved. The at least one first securing member103may be a single securing member (as illustrated) while in other embodiments, the at least one first securing member103may be a series of securing members. Similarly, the at least one second securing member104may be a single securing member (as illustrated) while in other embodiments, the at least one second securing member104may be a series of securing members. The securing members103,104may have a cross-sectional shape that is circular, square, oval, elliptical, polygonal, or any other appropriate shape. In some embodiments, the securing members103,104may extend along approximately 55%-95% of the length of the respective edges of the outer member101. In some cases, the securing members103,104may extend along approximately 70%-90% of the length of the respective edges of the outer member101. In some embodiments, the securing members103,104may extend along approximately 80% of the length of the respective edges of the outer member101.

The inner member201may extend in the forward/aft direction within the outer member101surrounding and approximately parallel to the barrel17(as shown inFIGS.2A-3). The inner member201may be a heat shield. In some embodiments, the inner member201includes a forward end205, a rear end206, an outer surface211, and at least one hole213(seeFIGS.2A and3). Each of the at least one hole213may be aligned with a corresponding hole113of the outer member101. In other embodiments, the inner member201includes fewer or more holes than the outer member101where some or all of the hole(s)213of the inner member201are not aligned with the hole(s)113of the outer member101. In other words, the holes may be arranged to slow the heat transfer out of the firearm1(away from the barrel17) and/or to create a longer path for heat to escape through the handguard assembly100. In some embodiments, the inner member201is metallic. In some cases, the inner member201is stamped sheet metal. For example, the inner member201may include a flat plate that is formed or bent to the shape shown inFIGS.3and5. In other cases, the inner member201is a non-metallic material.

In some embodiments, the handguard assembly100includes engagement features for engaging the inner member201relative to the outer member101. The handguard assembly100may include two, four, six, eight, or any other appropriate number of engagement features. For example, the outer member101may include at least one protrusion115a,116a,117a,118aand the inner member201may include at least one recess215a,216a,217a,218athat corresponds to the relevant protrusion. Each protrusion115a,116a,117a,118amay include an inboard surface (facing the interior of the outer member101), an outboard surface (facing away from the interior of the outer member101), and an offset surface. For example, protrusion116aincludes an inboard surface116b, an outboard surface116c, and an offset surface116d(seeFIGS.2A,3, and4) and protrusion118aincludes an inboard surface118b, an outboard surface118c, and an offset surface118d(seeFIGS.2A and3). Each recess215a,216a,217a,218amay include a tab and an edge. For example, recess216aincludes a tab216band an edge216c(seeFIGS.2A,3, and5) and recess218aincludes a tab218band an edge218c(seeFIGS.2A and3). In some embodiments, each recess215a,216a,217a,218amay include a shape that is approximately “L” shaped. As an exemplary case, the interaction between protrusion118aand recess218ais described below. The other portions of the assembly (e.g., protrusions115a,116a,117aand recesses215a,216a,217a) may function in a similar manner and are not duplicated in the description.

Although the illustrated examples of the protrusions115a,116a,117a,118ainclude a rectangular cross-section with distinct surfaces (as described above), the protrusions115a,116a,117a,118amay include any appropriate cross-sectional shape including, for example, circular, elliptical, oval, square, pentagonal, hexagonal, heptagonal, octagonal, etc. The recesses215a,216a,217a,218awill have the corresponding appropriate shape.

As illustrated inFIGS.2A-3, each handguard assembly100may include multiple engagement features at the forward end105,205and multiple engagement features at the rear end106,206for securing the inner member201relative to the outer member101. In some embodiments, there may be a first engagement feature located approximately halfway between the channel109and a first outer edge (i.e., at the first securing member(s)103) and a second engagement feature located approximately halfway between the channel109and a second outer edge (i.e., at the second securing member(s)104). The first engagement feature and the second engagement feature may be mirrored relative to one another.

As shown inFIGS.2A and3, the inner member201may be pressed into the interior of the outer member101such that at least a portion of the protrusion118apasses through recess218a. In particular, part of the protrusion118amay pass between tab218band edge218cof recess218a. The protrusion118amay include an inboard surface118b(facing the interior of the outer member101) and an outboard surface118c(facing away from the interior of the outer member101). The shape of the recess218adictates that tab218bextends from a relatively narrow neck. The recess218aof the inner member201may be designed such that the distance between the tab218band the edge218cis smaller than the dimension of the protrusion118a(i.e., the distance between the inboard surface118band the outboard surface118c). Accordingly, as the inner member201is pressed into the interior of the outer member101and the edge218cof the recess218amakes contact with the outboard surface118cof the protrusion118a, the tab218bpresses against the inboard surface118bsuch that the tab218bdeflects inward. Due to the contour/shape of the inner member201, the deflection of the tab218bcaused by the interaction with the inboard surface118bdictates that the tab218bengages and locks itself against the surface of the inboard surface118b. The inner member201may be pressed into the interior of the outer member101until the outer surface211of the inner member201contacts (i) the offset surface118dand/or (ii) the top of the standoff114(seeFIG.4). In addition to the offset surface118d, the outer member101may include analogous offset surfaces for each of the protrusions118a,118b,118c. For example, the offset surface116dis shown inFIG.4.

In some embodiments, the handguard assembly100is designed such that the inner member201is to be pressed into the interior of the outer member101(as described above) without provisions for removal. In other words, the inner member201is not designed to be removable from the outer member101. In some cases, the inner member201can be removed from the outer member101by prying or bending the tab(s) (e.g., tab216band tab218b) away from the corresponding protrusion (e.g., protrusion116aand118a). For example, an operator may use a tool (e.g., a flat head screwdriver) to deform or bend at least one of the tabs away from the corresponding protrusion.

The components of any of the handguard assemblies100and/or firearms1described herein may be formed of materials including, but not limited to, thermoplastic, carbon composite, plastic, nylon, glass-filled nylon, steel, aluminum, stainless steel, high strength aluminum alloy, other plastic or polymer materials, other metallic materials, other composite materials, or other similar materials. Moreover, the components of the firearms may be attached to one another via suitable fasteners, which include, but are not limited to, screws, bolts, rivets, welds, co-molding, injection molding, or other mechanical or chemical fasteners.

Different arrangements of the components depicted in the drawings or described above, as well as components and steps not shown or described, are possible. Similarly, some features and sub-combinations are useful and may be employed without reference to other features and sub-combinations. Embodiments of the invention have been described for illustrative and not restrictive purposes, and alternative embodiments will become apparent to readers of this patent. Accordingly, the present invention is not limited to the embodiments described above or depicted in the drawings, and various embodiments and modifications may be made without departing from the scope of the claims below.