FIREARM HANDGUARD ATTACHMENT SYSTEM

BACKGROUND

During the operation of a firearm, heat is generated by the expansion of gases used to propel a bullet forward out of the barrel of the firearm. A substantial amount of heat is transferred to the barrel during the firing of the firearm, particularly with larger caliber rounds or when firing is repeated or sustained. Consequently, in order to protect the user and anything in the immediate environment from burns sustained by making contact with the heated barrel, one of the benefits of a handguard is to serve as a barrier that prevents direct contact with the barrel.

In addition to protecting a user's hands from barrel heat while allowing the user to hold the firearm, firearm handguards, particularly handguards used with rifles, allow for free floating of barrels for accuracy (e.g. the barrel does not make contact with the handguard so that it can vibrate at its natural frequency) and the attachment of additional firearm accessories, such as stands (e.g. bipods and monopods), foregrips, weights, slings, lights, optics and others. Many of these accessories require mounting with proper alignment to the barrel or handguard. For example, sights generally need to be properly mounted so that they are aligned with the barrel axially, in order for effective use of the sight when aiming the firearm at targets of varying distances. For long range shots, it is important for accuracy that a handguard does not interfere with the barrel.

Therefore, the attachment of a handguard to a firearm particularly for long range shooting or when accessories are being used benefits from a tight alignment with the receiver of the firearm, such that once properly mounted the handguard does not interfere with the barrel and cannot shift out of alignment. Maintaining axial alignment helps maximize accuracy. Maintaining rigid attachment to the receiver and prevents the handguard from unintentionally, moving or detaching from the firearm when fired or handled.

A popular mechanism for securely attaching handguards to rifles in particular is to attach the handguard to the rifle via the barrel nut of the rifle. The barrel nut secures the breech end of the barrel to the rifle receiver. This method of attachment allows a barrel to be free floated for accuracy. However, securely attaching a handguard to the barrel nut of the rifle can present problems. The barrel nut, if smooth on its exterior, may allow for the attachment and alignment with a handguard. Often times a clamping mechanism with a split in the handguard, as shown in FIG. 10, is used to clamp the handguard around the barrel nut. However, due to the smooth nature of such a barrel nut, the handguard may make a poor or weak connection to the barrel nut, causing the handguard to slip or rotate. This can affect alignment or even allow the handguard to detach. Consequently, some barrel nuts are not smooth, but instead have one or more angular facets, detents or other features upon which the handguard can interface and grip. These handguards can still rotate if the clamping mechanism loosens. Even when if they maintain their connection more readily once the connection is made, making the connection can still be more difficult particularly for those rifles that require proper barrel nut “timing.”

When attaching a barrel nut to a rifle receiver to secure a rifle barrel, the barrel nut often requires “timing” due to the manner in which the rifle operates—e.g. the type of gas system used. In this case, a barrel nut is “timed” so that markings on or openings/channels/passages/holes in the barrel nut are considered oriented or positioned against a clock (e.g. a channel in the barrel nut is positioned at 12 o′clock relative to the barrel or receiver position (the top of the barrel or receiver)). Timing a barrel nut involves first tightening the barrel nut around the barrel to within a torque value acceptable for the firearm. For example on an ArmaLite-15 (AR-15) style rifle, that torque value may range between 30 and 80 foot-pounds. Next, the barrel nut must be tightened or loosened such that the angular facets which the handguard will attach to are aligned with the rifle receiver such that when the handguard is attached to the barrel nut, the handguard will also be aligned to the rifle receiver. This can be further complicated if the barrel nut includes a pass-through channel for a gas tube such as a direct-impingement gas tube: the barrel nut must be “timed” to allow the gas tube of the rifle to pass through that channel, and be simultaneously timed to align with the rifle receiver to allow for the handguard to be properly aligned-all while remaining secured to the receiver at a tightness within the established torque value.

SUMMARY

Hence, there is room for improvement in the systems and methods for attaching a handguard to a firearm. The systems and methods of the present invention allow for securing a handguard to a firearm such that the handguard will not become unaligned either radially or axially, without having to time the barrel nut of that firearm for the purposes of aligning and maintaining the alignment of the handguard. The present invention allows for indexing systems, such as barrel nut screws and set screws, in order to assist a user in aligning the handguard to the remainder of the rifle, or to assist in aligning a barrel nut for the purposes of allowing a gas tube of the firearm to pass through a passage in the barrel nut.

Exemplary embodiments provide a handguard system for a firearm having a receiver, a barrel and a barrel nut for attaching the barrel to the receiver. The handguard system includes a handguard component, a first fastener, a second fastener 110B, and a plate. The plate is configured to accept the first fastener and the second fastener. The plate is further configured to apply pressure to the barrel nut of the firearm.

In some examples, the handguard component can include an interior surface. The barrel nut includes an exterior surface. The plate includes first and second surfaces. The first fastener and the second fastener are configured to apply pressure to the first surface of the plate to drive the second surface of the plate against the exterior surface of the barrel nut.

In some examples, the first fastener is a first threaded screw having a first drive and the second fastener is a second threaded screw having a second drive. The plate has first and second threaded passages with threading corresponding to the threading of the first and second screws, respectively.

In some examples, the first screw is driven into the plate when the first drive is engaged by a first driver, and the second screw is driven into the plate when the second drive is engaged by a second driver.

In some examples, the handguard system is aligned to the firearm independently of a timing of the barrel nut. Alternatively or additionally, the firearm can include a gas tube, and the handguard system can be aligned to the firearm independently of a position of the gas tube.

In some examples, the handguard component further includes a recess, configured to hold the plate, the first fastener, and the second fastener. The first fastener, the second fastener, and the plate reside partially or fully within the recess. the first fastener can include a first fastener tip and a first fastener shaft. the second fastener can include a second fastener tip and a second fastener shaft. In such examples, a first tip diameter of the first fastener tip can be larger than a first shaft diameter of the first fastener shaft.

In some examples, the handguard component includes an interior handguard curved surface. The plate includes first and second surfaces. The second surface is curved. The second surface is parallel to the interior handguard curved surface. The second surface can remain generally parallel to the interior handguard curved surface when the first fastener and the second fastener are driven into the plate.

The plate has a length and a width. In some examples, the length is longer than the width.

In some examples, the handguard system further includes a threaded set screw, where the plate includes a threaded passage corresponding to the threading of the threaded set screw. The barrel nut can include a groove. In such examples, the set screw is configured to mate with the groove when the barrel nut is fixedly attached to the barrel.

The first fastener includes a first fastener tip and a first fastener shaft. The second fastener includes a second fastener tip and a second fastener shaft. In such examples, a first tip diameter of the first fastener tip can be larger than a first shaft diameter of the first fastener shaft. The second tip diameter of the second fastener tip can be larger than a second shaft diameter of the second fastener shaft.

The handguard component can include a first fastener hole, the first fastener hole having a first hole diameter larger than the first shaft diameter of the first fastener and smaller than the first tip diameter of the first fastener. The handguard component can also include a second fastener hole, the second fastener hole having a second hole diameter larger than the second shaft diameter of the second fastener, and smaller than the second tip diameter of the second fastener.

The first fastener tip of the first fastener can reside in the recess, between the handguard component and the plate. The second fastener tip of the second fastener can reside in the recess, between the handguard component and the plate. The first fastener shaft of the first fastener can extend through the first fastener hole, and the second fastener shaft of the second fastener can extend through the second fastener hole.

In some examples the handguard system can further include a barrel nut screw, where the barrel nut is configured to accept the barrel nut screw. The handguard component can include a handguard barrel nut screw hole, and the barrel nut screw passes through the handguard barrel nut screw hole into the barrel nut. The barrel nut can include one or more gas tube channels. the barrel nut can include one or more barrel nut screw holes for accepting the barrel nut screw. The handguard component could then be aligned when a gas tube is able to pass through the one or more gas tube channels and function properly, and the barrel nut screw is able to pass through the handguard barrel nut screw hole into a respective barrel nut screw hole of the one or more barrel nut screw holes. The one or more barrel nut screw holes can be non-intersecting with the one or more gas tube channels.

Variations and other exemplary embodiments are described in more detail in the following description.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is best understood from the following detailed description when read in connection with the accompanying drawings, with like elements having the same reference numerals. When a plurality of similar elements is present, a single reference numeral may be assigned to the plurality of similar elements with a small letter designation referring to specific elements. When referring to the elements collectively or to a non-specific one or more of the elements, the small letter designation may be dropped. According to common practice, the various features of the drawings are not drawn to scale unless otherwise indicated. To the contrary, the dimensions of the various features may be expanded or reduced for clarity. Embodiments of inventions will now be described, strictly by way of example and not limitation, with reference to the accompanying figures, in which:

FIG. 1A shows an exploded view of an exemplary handguard system, including a handguard component, a barrel nut, a plate, and two fasteners;

FIG. 1B shows a cutaway view of the handguard system of FIG. 1A at the angle of the view of FIG. 1A;

FIG. 1C shows a cutaway view of the handguard system of FIG. 1A at a second angle of view;

FIG. 1D shows an assembled view of the handguard system of FIG. 1A at the angle of the view of FIG. 1C.

FIG. 2A shows an exploded view of a second exemplary handguard system, including the handguard component, a barrel nut, a plate, two fasteners, and a set screw;

FIG. 2B shows the exemplary handguard system of FIG. 2A as axially bisected by a plane passing through the bore end of the handguard component to the breech end of the handguard component;

FIG. 2C shows the exemplary handguard system of FIG. 2A connected to a receiver of a firearm;

FIG. 3 shows further detail of an exemplary barrel nut, particularly the barrel nut of FIG. 2A;

FIG. 4A and FIG. 4B show further detail of an exemplary plate, particularly the plate of FIG. 2A;

FIG. 5A shows further detail of an exemplary fastener;

- FIG. 5B shows further detail of an exemplary set screw;
- FIG. 6A is a rendering of the handguard component of FIG. 2A;

FIG. 6B is a cutaway view of the rendering of the handguard component of FIG. 6A;

FIG. 7A is an assembled view of a third exemplary handguard system, including a barrel nut, a plate, two fasteners, and two handguard barrel nut screw holes;

FIG. 7B is an exploded view of the breech end of the handguard system of FIG. 7A;

FIG. 7C is an exploded view of the breech end of the handguard system of FIG. 7A from a lower viewing angle;

FIG. 8A shows the plate of the handguard system of FIG. 7A;

FIG. 8B shows the plate of FIG. 8A including two fasteners and a barrel nut;

FIG. 8C shows the plate and barrel nut of FIG. 8B within the handguard component;

FIG. 8D shows the handguard system of FIG. 8C, including two handguard barrel nut screw holes from a higher viewing angle;

FIG. 9A shows a radial cross-sectional view of the handguard system of FIG. 8D;

FIG. 9B shows an axial cross-sectional view of the handguard system of FIG. 9A;

FIG. 10 shows an exploded view of a handguard system in the prior art, including a handguard component, a barrel nut, a plate, and two fasteners.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

Examples of embodiments are described herein with reference to the accompanying drawings, in which like reference numbers represent like features of different embodiments. In some cases, like features are not indicated by reference numbers, so as to make the drawings less complicated and easier to comprehend.

Certain embodiments may be used with a variety of firearms, such as bolt-action rifles, semi-automatic rifles, automatic rifles, shotguns, carbines, pistols, and so on, as will be understood by a person of skill in the art.

FIG. 1A shows an exploded view of an exemplary handguard system 100, including a handguard component 105, a barrel nut 120, a plate 115, and two fasteners 110A-B.

Handguard system 100 is configured to connect to a firearm. In this exemplary embodiment, handguard system 100 is attached to barrel nut 120, which is typically threaded, surrounds a portion of the breech end of the barrel and secures the barrel to a correspondingly threaded member of the receiver (such as receiver 299 shown in FIG. 2C) of the firearm. The barrel is a component of a firearm with a breech end which is attached to and extends from a receiver of the firearm, and directs the fired projectile of that firearm to travel axially through the bore of the barrel and exit through the muzzle end of the barrel.

Barrel nut 120 serves to rigidly attach a barrel to a receiver. As an example, a receiver such as receiver 299 shown in FIG. 2C typically includes internal functional components of the firearm, and an attachment mechanism to securely align and secure the barrel to the receiver. An example of an attachment mechanism includes a mating opening in which the breach end of the barrel can be properly inserted into a receiver and threads to allow a threaded barrel nut 120 to secure the barrel to the receiver. However, for purposes of this invention, a receiver can also be considered any portion of the firearm which is able to receive the barrel of the firearm, or is a component coupled to a portion of the firearm able to receive the barrel of the firearm.

Exemplary handguard component 105 is designed to prevent a person or external object from making direct contact with the barrel itself. The protection is at least partially motivated to protect the person or external object from heat radiating from the barrel when firing the firearm. The protection may also be motivated to protect the barrel from damage or misalignment while the firearm is being handled or fired.

Handguard component 105 includes one or more mounting or rail systems (such as Picatinny or weaver rail systems and M-LOK or KeyMod mounting systems,). Such mounting/rail systems and components are commonly used to mount optics, lights, grips, bipods/monopods, slings, and other accessories. However, handguard component 105 does not require accessory mounts or mounting/rail systems to perform the core function of protection of and from the barrel of the firearm.

Any accessories or mounts on handguard component 105 may be separate parts that are secured in place directly to the handguard, or secured via an intermediate accessory mount. For example, it is known to secure one type of accessory mount to another type of accessory mount that is already on the firearm (e.g., installing a dovetail-type rail onto a Picatinny-type rail or a Picatinny rail piece onto an M-Lok mount, or one optic attached to another optic). An accessory mount or mounting system also may be integrally formed with other parts of the firearm. For example, handguard component 105 may comprise an extruded and/or machined structure having Picatinny rails or M-LOK attachments integrally formed as a part of handguard component 105.

Handguard component 105 maintains an unbroken circumference where handguard component 105 encircles barrel nut 120. The unbroken circumference reduces the amount of deformation handguard component 105 experiences when attached to barrel nut 120.

Exemplary barrel nut 120 shown in FIG. 1A has a relatively featureless outer surface 122. However, barrel nut 120 may have facets or features as shown in FIG. 2A or an irregular or high-friction outer surface 122. Handguard system 100 may take advantage of any facets or features of barrel nut 120 in order to improve the connection between barrel nut 120 and handguard component 105. Alternatively handguard system 100 may ignore or not require variations in the surface of barrel nut 120. Barrel nut 120 may have been designed to attach a handguard component other than handguard component 105 to the firearm, or barrel nut 120 may be purpose-built to attach handguard component 105 to the firearm.

Exemplary plate 115 is a component designed to be pressed against outer surface 122 of barrel nut 120, which also result in pressing outer surface 122 of barrel nut 120 against an interior surface 106 of handguard component 105. In particular, when securing handguard component 105 with plate 115, outer surface 122 of barrel nut 120 is pushed against interior surface 106 of handguard component 105. Plate 115 has a first surface 121 and a second surface 116 with first surface 121 for receiving one or more fasteners to apply pressure to plate 115 and a second surface 116 for contacting a corresponding surface of barrel nut 120. In an exemplary embodiment, second surface 116 makes contact with outer surface 122 of barrel nut 120. In an exemplary embodiment, interior surface 106 and second surface 116 are both a generally concave surfaces with each configured to compliment and make contact with outer surface 122 of barrel nut 120. However, in some examples interior surface 106 and interior second surface 116 may have concavities of different depths, such that either or both do not make full contact with barrel nut 120. In some examples, it may be advantageous to use a concavity depth that is shallower than the curvature of the exterior surface of barrel nut 120, or to even use a flat or convex shape on interior surface 106 or interior second surface 116. In particular, shallow concave or non-concave surface 106, 116 may be used if the curvature, diameter, and surface features of barrel nut 120 are unknown at the time of manufacturing handguard component 105 or plate 115.

In an exemplary embodiment, first surface 121 has receptacles 117A-B to accept fasteners 110A-B or fastener tips 113A-B. However, it is contemplated that receptacles 117A-B are not required, particularly if fasteners 110A-B are held in place by fastener holes 111A-B, and plate 115 is captured within handguard component 105, placing fasteners tips 113A-B between first surface 121 of plate 115 and base 107 of handguard component 105. Plate 115 has plate length 118 and plate width 119. Plate 115 may be of various dimensions, however in this exemplary embodiment plate length 118 is has approximately the same “length” as barrel nut 120, and plate width 119 is approximately as wide as base 107 of handguard component 105. It will be understood that a sufficient amount of contact between second surface 116 and barrel nut 120 is necessary to secure handguard component 105 to barrel nut 120 and may vary between firearms.

Plate 115 resides in recess 125 in handguard component 105. Recess 125 may be designed with edges or lips (not shown) in order to capture plate 115. Recess 125 may also capture fastener tips 113A-B within recess 125, between plate 115 and handguard base 107, thereby capturing fasteners 110A-B.

Exemplary fasteners 110A-B are components designed to provide force, pushing plate 115 against barrel bolt 120, and maintain this position of plate 115 once selectively set by a user. In this example, fasteners 110A-B are screws, but other fasteners that can provide the necessary force to secure attach handguard 105 to barrel bolt 120 could be used. Fasteners 110A-B in this example are also captured/captive fasteners or captured screws, with fastener tips 113A-B of a wider diameter than fastener channels/holes 111A-B through which fasteners 110A-B pass. In an exemplary embodiment, fastener channels 111A-B are threaded to correspond to the threading of fasteners 110A-B. Fastener shafts 114A-B of fasteners 110A-B are a smaller diameter than that of fastener holes 111A-B so that they can move within fastener holes 111A-B. Fasteners 110A-B each include drive 112A-B in the heads of fastener 110A-B, which engage with a driver having a driver tip (e.g. flathead, Philips, torx, hex, square) in order to drive fasteners 110A-B into or away from plate 115

Fasteners 110A-B are shown as identical with each other, but non-identical fasteners could also be used so long as sufficient force is applied to securely mount handguard component 105 to barrel nut 120. This may include fasteners having different diameters, shapes, lengths or drive types relative to one another. Fasteners 110A-B may recess into fastener holes 111A-B, or may extend out through fastener holes 111A-B, even when barrel nut 120 is captured between interior second surface 116 and opposing interior surface 106.

Components of handguard system 100 may be lubricated with a lubricant to aid in movement, such as an oil on the threads of fasteners 110A-B or in the threaded channels 111A-B, and components of handguard system 100 may be additionally secured from slipping, such as by the use of thread lock adhesive. Some components may be both lubricated as well as thread locked, for the purpose of lubricated installation and a resulting thread locked connection.

Fastener holes 111A-B are configured to receive fasteners 110A-B and allow fasteners 110A-B to transfer force from outside handguard component 105 to plate 115 in order to secure handguard component 105 to barrel nut 120. Fastener holes 111A-B may be threaded to complement the threading of fasteners 110A-B. The thread pitch of fastener holes 111A-B and fasteners 110A-B is sufficiently sized to ensure that fasteners 110A-B do not unintentionally rotate out of fastener holes 111A-B.

FIG. 1B shows a cutaway view of handguard system 100 of FIG. 1A. In particular, the contact between barrel nut 120, opposing interior surface 106, and plate 115 can be seen, securing handguard component 105 to barrel nut 120. As handguard component 105 is secured to barrel nut 120 via a clamping force constituted by opposing interior surface 106 and plate 115, handguard component 105 is aligned to the firearm without respect for the orientation or tightness of barrel nut 120, reducing or obviating the need for barrel nut 120 timing.

Fasteners 110A-B are depicted as captured between plate 115 and handguard base 107, and are captured by their respective fastener tips 113A-B. Fasteners 110A-B are screwed into fastener holes 111A-B, preventing fasteners 110A-B from retreating away from plate 115. Fastener tips 113A-B are pressing up into exterior face 121, thereby driving plate 115 and interior second surface 116 into barrel nut 120. Fasteners 110A-B via engagement with fastener shafts 114A-B also push handguard base 107 down. Due to the low elasticity and high resistance to deformity of handguard component 105, handguard base 107 being pushed down pulls down opposing interior surface 106 of handguard component 105. Opposing interior surface 106 presses down into exterior face 121 of barrel nut 120. The upward pressure of plate 115 and the downward pressure of opposing interior surface 106 clamp down on exterior first surface 121 of barrel nut 120 on opposite sides of barrel nut 120, securing handguard component to barrel nut 120.

FIG. 1C shows a cutaway view of handguard system 100 of FIG. 1A at a second angle of view, and FIG. 1D shows an assembled view of handguard system 100 of FIG. 1A at the angle of the view of FIG. 1C.

Therefore, FIGS. 1A-D depicts handguard system 100 for a firearm having receiver (such as receiver 299 shown in FIG. 2C), a barrel and barrel nut 120 for attaching the barrel to a receiver. Handguard system 100 includes handguard component 105, first fastener 110A, second fastener 110B, and plate 115. Plate 115 is configured to accept first fastener 110A and second fastener 110B. Plate 115 is further configured to apply pressure to barrel nut 120 of the firearm.

In some examples, handguard component 105 includes interior surface 106. Barrel nut 120 includes outer surface 122. Plate 115 includes first surface 121 and second surface 116. First fastener 110A and second fastener 110B are configured to apply pressure to first surface 121 of plate 115 to drive second surface 116 of plate 115 against outer surface 122 of barrel nut 120. Interior surface 106 presses against a corresponding outer surface 122 of barrel nut 120 when fasteners 110A-B are tightened. Second surface 116 of plate 115 presses against a corresponding outer surface 122 of barrel nut 120. First fastener 110A and second fastener 110B are driven with a drive tool to securely and accurately mount handguard 105 against barrel nut 120 when first fastener 110A or second fastener 110B are driven into plate 115.

In some examples, first fastener 110A is a first threaded screw having first drive 112A, and second fastener 110B is a second threaded screw having second drive 112B. Plate 115 has optional first and second receptacles 117A-B for receiving the tips of first and second screws 110A-B, respectively.

In some examples, first screw 110A is driven into plate 115 when first drive 112A is engaged by a first driver or drive tool, and second screw 110B is driven into plate 115 when second drive 112B is engaged by a second driver or drive tool.

In some examples, handguard system 100 is aligned to the firearm independently of a timing or orientation of barrel nut 120. Typically when the firearm includes a gas tube, handguard system 100 will be aligned to the firearm dependent upon the position of the gas tube.

In some examples, handguard component 105 further includes recess 125 configured to hold plate 115, first fastener 110A, and second fastener 110B. First fastener 110A, second fastener 110B, and plate 115 reside partially or fully within recess 125. First fastener 110A can include first fastener tip 113A and first fastener shaft 114A. Second fastener 110B can include second fastener tip 113A and second fastener shaft 114A. In such examples, first tip diameter of first fastener tip 113A can be larger than first shaft diameter of first fastener shaft 114A.

In some examples, handguard component 105 includes interior handguard curved surface 130. Plate 115 includes first surface 121 and second surface 116. Second surface 116 is generally parallel to interior handguard curved surface 130. Second surface 116 can remain generally parallel to interior handguard curved surface 130 when first fastener 110A and second fastener 110B are driven into plate 115.

Plate 115 has length 118, width 119, and a thickness. In some examples, measurement of length 118 is greater than that of width 119.

FIG. 2A shows second exemplary handguard system 200, including handguard component 105, barrel nut 120, plate 115, two fasteners 110A-B, and set screw 210. Handguard system 200 is substantially similar to handguard system 100, barring some explicit differences.

Interior second surface 116 of plate 15 is curved, and recess 125 in handguard component 105 is complementarily curved. Plate 115 includes a third recess, and handguard component includes a third fastener hole in order to accommodate set screw 210.

Set screw 210 is designed to improve a user's ability to reliably align handguard component 105 on barrel nut 120, without requiring timing of barrel nut 120 with respect to handguard component 105. Proper alignment of handguard component 105 in an example rifle would result in breech end 265 of handguard component 105 abutting receiver 299 of the firearm, though other alignments are contemplated. Barrel nut 120 includes groove 220, which encircles barrel nut 120 at a particular position around barrel nut 120. The depth and profile of groove 220 is such that the tip of set screw 210 will mate with groove 220 when driven into groove 220. When set screw 210 is driven through handguard component 105 into groove 220, the mating between groove 220 and set screw 210 is such that handguard component should less readily move axially, allowing for more convenient setting of fasteners 110A-B with minimal or no further corrective alignment of handguard component 105 on barrel nut 120. Set screw 210 may also prevent radial movement of handguard component 105 in some examples, if driven sufficiently into groove 220. Once fasteners 110A-B are driven appropriately into plate 115, in some examples set screw 210 may optionally be removed. Set screw 210 may full pass through plate 115, and align handguard component 105 with groove 220, or set screw 210 may have a beveled design such that once set screw 210 is at full proper depth within groove 220, further attempts to drive set screw 210 further into groove 220 instead push the bevel of set screw 210 into plate 115, thereby pressing plate 115 into barrel nut 120. The hole in plate 115 which accommodates set screw 210 is threaded but in an alternate embodiment may be smooth using a friction fit or another manner of fixation.

Groove 220 in barrel nut 120 is at a position such that, when barrel nut 120 is properly attached to receiver 299 of the firearm, handguard component 105 is fitted around barrel nut 120, and set screw 210 passes through handguard component 105 and mates with groove 220.

Handguard 105 can also be aligned by utilizing an alignment pin. A first end of the alignment pin can be inserted into alignment pin hole 290. A second end of the alignment pin can then be inserted into an alignment pin hole in receiver 299, or the alignment pin can be fused, welded, or otherwise incorporated into receiver 299. By seating alignment pin hole 290 over an alignment pin coupled to and aligned with receiver 299, handguard 105 is radially aligned. In combination with set screw 210 aligning handguard 105 axially, handguard 105 is fully aligned, and fasteners 110A-B can be used to secure handguard 105 to barrel nut 120.

Handguard 105 can further be aligned by a gas block of receiver 299. Handguard 105 has a small area on the interior surface 106 capable of accommodating a gas block. If space tolerance between the gas block and the small area on the interior surface is sufficiently small, handguard 105 will be aligned when seated on barrel nut 120 and the gas block of receiver 299.

FIG. 2B shows exemplary handguard system 200 of FIG. 2A as bisected by plane 250 passing through bore end 260 of handguard component 105 and breech end 265 of handguard component 105.

In some embodiments, the distribution of fasteners 110A-B and their respective fastener holes 111A-B is immaterial, as the force driven from fasteners 110A-B into plate 115 is sufficiently distributed throughout interior second surface 116 to provide sufficient engagement with barrel nut 120 to secure handguard component 105. However, in some examples to reduce any uneven distribution of force, fasteners 110A-B may be aligned either radially or axially to barrel nut 120. In this example, fasteners 110A-B are aligned axially to barrel nut 120. Generally, firearm recoil causes bore end 260 to rise, thereby creating a shear force in an axial direction along the connection between handguard component 105, barrel nut 120, and plate 115. Therefore, placing fasteners 110A-B along the axial direction of handguard component 105 reduces the torsion and shearing experienced by handguard component 105 when the firearm is fired. However, some firearms may not experience recoil in an upward radial direction. In such examples, recoil is experienced in some radial direction, or along some radial vector emanating from the barrel within handguard component 105.

FIGS. 2A-B depicts handguard system 200 for a firearm having receiver 299, a barrel and barrel nut 120 for attaching the barrel to receiver 299. Handguard system 200 includes handguard component 105, first fastener 110A, second fastener 110B, and plate 115. Plate 115 is configured to accept first fastener 110A and second fastener 110B. Plate 115 is further configured to apply pressure to barrel nut 120 of the firearm.

In some examples, handguard system 200 further includes threaded set screw 210, where plate 115 includes a threaded passage corresponding to the threading of threaded set screw 210. Barrel nut 120 can include groove 220. In such examples, set screw 210 is configured to mate with groove 220 when barrel nut 120 is fixedly attached to the barrel.

FIG. 2C shows exemplary handguard system 200 connected to receiver 299 of a firearm. Barrel nut 120 is properly attached to receiver 299 of the firearm, handguard component 105 is fitted around barrel nut 120, and set screw 210 passes through handguard component 105 and mates with groove 220.

5
FIG. 3 shows further detail of barrel nut 120, particularly barrel nut 120 of FIG. 2A. FIG. 4A and FIG. 4B show further detail on plate 115, particularly plate 115 of FIG. 2A. In this example it is shown that set screw 210 will cleanly pass through plate 115.

FIG. 5A shows further detail of fastener 110A. In particular, fastener tip diameter 533 is shown as larger than fastener shaft diameter 534, which in exemplary embodiments allows for more force to be driven into and evenly distributed into plate 115, as well as capturing fastener 110A in handguard component 105 below plate 115. Additionally, fastener threading 540 is shown in further detail, and can be adjusted to increase the frictional hold of fastener 110A in fastener hole 111A.

FIG. 5B shows further detail of set screw 210. The proportions of set screw 210 are not required to confirm with or be proportional to fasteners 110A-B. In an exemplary embodiment, set screw 210 used primarily to aid in alignment and not primarily to attach handguard component 105 to barrel nut 120.

Therefore, FIG. 5 in combination with prior figures depicts handguard system 100 for a firearm having receiver 299, a barrel and barrel nut 120 for attaching the barrel to receiver 299. Handguard system 100 includes handguard component 105, first fastener 110A, second fastener 110B, and plate 115. Plate 115 is configured to accept first fastener 110A and second fastener 110B. Plate 115 is further configured to apply pressure to barrel nut 120 of the firearm. First fastener 110A includes first fastener tip 113A, 513 and first fastener shaft 114A, 514. Second fastener 110B includes second fastener tip 113A, 513 and second fastener shaft 114A, 514. In such examples, first tip diameter 533 of first fastener tip 113A, 513 can be larger than first shaft diameter 534 of first fastener shaft 114A, 514. Second tip diameter 533 of second fastener tip 113B, 513, can be larger than second shaft diameter 534 of second fastener shaft 114B, 514.

Handguard component 105 can include first fastener hole 111A, first fastener hole 111A having a first hole diameter larger than first shaft diameter 534 of first fastener 110A and smaller than first tip diameter 533 of first fastener 110A. Handguard component 105 can also include second fastener hole 111B, second fastener hole 111B having a second hole diameter larger than second shaft diameter 534 of second fastener 110B, and smaller than second tip diameter 533 of second fastener 110B.

First fastener tip 513 of first fastener 110A can reside in recess 125, between handguard component 105 and plate 115. Second fastener tip 513 of second fastener 110B can reside in recess 125, between handguard component 105 and plate 115. First fastener shaft 514 of fastener 110A can extend through first fastener hole 111A, and second fastener shaft 514 of second fastener 110B can extend through second fastener hole 111B.

FIG. 6A is a rendering of handguard component 200 of FIG. 2A, and FIG. 6B is a cutaway view of the rendering of handguard component 200 of FIG. 6A.

FIG. 7A is an assembled view of third exemplary handguard system 700, including barrel nut 120, plate 115, two fasteners 110A-B, and two handguard barrel nut screw holes 705A-B. FIG. 7B is an exploded view of breech end 265 of handguard system 700 of FIG. 7A. FIG. 7C is an exploded view of breech end 265 of handguard system 700 of FIG. 7A from a lower viewing angle. Handguard system 700 is substantially similar to handguard system 100, barring some explicit differences.

Handguard component 105 includes handguard barrel nut screw holes 705A-B. Handguard barrel nut screw holes 705A-B and barrel nut screws 799A-B operate similarly to set screw 210, except handguard barrel nut screw holes 705A-B and barrel nut screws 799A-B lock handguard component 105 in place both axially and radially. Locking handguard component 105 within tolerance of its proper place before affixing handguard component 105 to barrel nut 120 via plate 115 is important when the orientation of barrel nut 120 is relevant. In particular, barrel nut 120 needs to be “timed” when a gas tube for the firearm runs through barrel nut 120, rather than through handguard component 105. “Timing” barrel nut 120 ensures that barrel nut 120 is torqued to specifications, and that one of barrel nut gas tube channels 721A-D is aligned such that the gas tube can pass unaffected through that barrel nut gas tube channel 721A-D. Even when gas tubes run along the top of a firearm, barrel nut gas tube channel 721A must often also be located at the twelve o′ clock position if viewing barrel nut 120 as a clock face.

If barrel nut 120 must be timed to permit passage of a gas tube, handguard system 700 takes advantage of this fact by using barrel nut screw holes 720A-H in alignment with handguard barrel nut screw holes 705A-B to secure barrel nut screws 799A-B. In this example, if barrel nut gas tube channel 721A is at a 12 o' clock position (and other barrel nut gas tube channels 721B-D are consequently at 3 o' clock, 6 o' clock, and 9 o' clock, respectively), then barrel nut screw holes 720A-H can be set at a different location (e.g. 45 degree offset from barrel nut gas tube channels 721A-D) so as not to interfere with any of barrel nut gas tube channels 721A-D.

As an example, assume barrel nut 120 is properly timed, handguard barrel nut screw hole 705A is at a 45-degree offset from the top of handguard component 105, and barrel nut screw hole 720A is also at a 45-degree offset from the top of barrel nut 120. If barrel nut screw 799A is inserted through handguard barrel nut screw hole 705A and barrel nut screw hole 720A at 45 degrees, then handguard component 105 will be timed to barrel nut 120. Because barrel nut 120 is properly timed, then handguard component 105 is properly aligned to receiver 299 of the firearm.

Once aligned, plate 115 can be driven into barrel nut 120 to secure handguard component 105 to barrel nut 120. Like set screw 210, barrel nut screws 799A-B may be relied upon for additional stabilization and security, or in some examples may be removed once handguard component 105 is secured in an aligned state.

This handguard system 700 does not require gas tubes, or the presence of barrel nut gas tube channels 721A-D-handguard component 105 may be designed for precise alignment, facilitated by timing barrel nut 120.

Therefore, FIG. 7A-C depicts handguard system 700 for a firearm having receiver 299, a barrel, and barrel nut 120 for attaching the barrel to receiver 299. Handguard system 700 includes handguard component 105, first fastener 110A, second fastener 110B, and plate 115. Plate 115 is configured to accept first fastener 110A and second fastener 110B. Plate 115 is further configured to apply pressure to barrel nut 120 of the firearm.

In some examples handguard system 700 can further include barrel nut screw 799A-B, where barrel nut 120 is configured to accept barrel nut screw 799A-B. Handguard component 105 can include handguard barrel nut screw hole 705A-B, and barrel nut screw 799A-B passes through handguard barrel nut screw hole 720A-H into barrel nut 120. Barrel nut 120 can include one or more gas tube channels 721A-D. Barrel nut 120 can include one or more barrel nut screw holes 720A-D for accepting barrel nut screw 799A-B. Handguard component 105 could then be aligned when a gas tube is able to pass through the one or more gas tube channels 721A-D and function properly, and barrel nut screw 799A-B is able to pass through handguard barrel nut screw hole 705A-B into a respective barrel nut screw hole 720A-H of one or more barrel nut screw holes 720A-H. One or more barrel nut screw holes 720A-H can be non-intersecting with one or more gas tube channels 721A-D.

FIG. 8A shows plate 115 of handguard system 700 of FIG. 7A. FIG. 8B shows plate 115 of FIG. 8A including two fasteners 110A-B and barrel nut 120. FIG. 8C shows plate 115 and barrel nut 120 of FIG. 8B mounted within handguard component 105. FIG. 8D shows handguard system 700 of FIG. 8C, including two handguard barrel nut screw holes 705A-B from a higher viewing angle.

Handguard 105 can also be aligned by utilizing an indexed rail. An indexed rail can extend from receiver 299. Handguard 105 can include indexing indent 890, which can complement an indexing projection extending from and aligned with receiver 299. By seating the indexing projection within indexing indent 890, handguard 105 is aligned.

FIG. 9A shows a radial cross-sectional view of handguard system 700 of FIG. 8D. FIG. 9B shows an axial cross-sectional view of handguard system 700 of FIG. 9A.

The numbers and counts of various components, such as fasteners 110A-B, fastener holes 111A-B, set screw 210, plate 115, handguard barrel nut screw hole 705A-B, or barrel nut screw hole 720A-H, are exemplary, and any number including a single one of any of those components is contemplated. Further, the holes and fasteners or screws are not perfectly paired, and in particular more holes in handguard system 100, 200, 700 may be placed than fasteners or screws are able to fully fill.

The foregoing are examples of a handguard system for a firearm, secured to the firearm by a plate pressured by fastener or screws. This description and the accompanying drawings are provided as non-exclusive examples, and the claimed invention is not intended to be narrowly construed to require any particular described or illustrated features except as specifically set forth in the claims. It will also be understood that features and configurations described herein can be used interchangeably as desired, without changing the general principle of operation All such modifications are within the scope of the invention, and other alternatives and embodiments will be apparent to persons of ordinary skill in the art in view of the present disclosure.

FIREARM HANDGUARD ATTACHMENT SYSTEM

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CPC

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