Patent Application
20240151493
The present invention relates to modular modern sporting firearms, and more particularly, to free-floating handguard for use with a modular modern sporting shotgun or rifle. Specifically, the present invention relates to a hybrid free-floating handguard comprising a polymer-based handguard body and including one or more embedded metal substructures strategically positioned at points of stress within the handguard.
There are a number of available automatic and semi-automatic firearms for use by military personnel and civilians. While fully automatic firearms are generally illegal for use by the civilian population, many of the components which constitute an automatic firearm are the same as those found within legal semi-automatic models. Arguably the most popular semi-automatic modern sporting firearm used by civilians, particularly within the United States, is the AR-15. The AR-15 is the semi-automatic variant of the fully automatic M16 firearm used by United States military personnel. While AR-15 is a registered trademark of Colt Industries, a number of additional manufacturers manufacture clones of the AR-15 and market these clones under separate trademarks. While used throughout the specification, it is to be understood that the term AR-15 is meant to include not only those firearms manufactured by Colt Industries, but also those additional clones and any variants thereof.
The AR-15 and M16 are designed as modular rifles generally comprising a buttstock, lower receiver, upper receiver and barrel assembly configured to fire 0.223 Remington or 5.56×45 mm NATO military ammunition. Each component is separable from one another which affords firearm owners the opportunity to customize the firearm with after-market components such as barrels of differing lengths, upper receivers designed to handle different calibers of ammunition, flashlights, handguards, grenade or flare launchers, flash or sound suppressors, grips, front or rear sights, and others.
One common accessory equipped on most automatic and semi-automatic firearms, like the AR-15, is a handguard. Handguards generally shield a user's hand from the firearm's barrel which may become hot during repeated firing of rounds. A handguard may also provide various mounting features designed to allow further accessorizing of the firearm to include such things as forward and rear sights, flashlights, carry handles and sling mounts, scopes and scope mounts, bipod and tripod supports, and the like.
Currently, handguards are generally constructed of metal, such as aluminum, which provides the structural integrity to support the weight of the various accessories mounted onto the handrail, while also being able to withstand the cyclical heating/cooling of the handguard as the firearm alternates between active firing and rest. Polymer-based handguards are also available, but these handguards suffer part failures due to the weight/heat subjected to the polymer material. Polymer handguards are also not available as free-floating handguards and therefore do not provide for the improved accuracy, comfort and aesthetics offered by a free-floating handguard.
Thus, there is a need for a lighter weight and less expensive free-floating handguard that meets and/or exceeds the performance of presently available free-floating metal handguards. The present invention addresses these and other needs.
In accordance with an aspect of the present invention, an exemplary embodiment may be directed to a free-floating handguard configured to be mounted onto a modular sporting firearm. The free-floating handguard comprises a tubular polymer-based handguard body configured to allow passage of a barrel therethrough. The handguard body has an open free-floating muzzle end and an opposing clamping end configured to detachably engage a barrel nut that secures the barrel to the firearm. A downwardly extending lobe is integrally formed on the tubular polymer-based handguard body proximate the clamping end of the handguard body and a first metal insert is embedded within a bottom wall of the downwardly extending lobe. The first metal insert is adapted to releasably couple with a corresponding mounting feature on a firearm sling. The first metal insert may be a swivel socket.
In another aspect, the downwardly extending lobe may include a vertical slot defined therein which extends from the clamping end to adjacent to but a spaced distance from the first metal insert. The downwardly extending lobe includes at least one horizontal through bore proximate the clamping end. A second metal insert is embedded within the downwardly extending lobe and defines a threaded bore. The threaded bore is aligned with the at least one horizontal through bore. The at least one horizontal through bore is configured to receive a threaded fastener therein and the threaded fastener is configured to threadably engage the threaded bore of the second metal insert whereby the vertical slot is at least partially closed so as to clamp the clamping end of the handguard body on the barrel nut to secure the handguard body on the firearm.
In still further aspects, the tubular polymer-based handguard body may be comprised of one or both of nylon and ABS and further impregnated with one or more of carbon fiber, glass or aramid. The tubular polymer-based handguard body may also include a mounting feature defined thereon and the mounting feature may be a picatinny rail.
In yet another aspect, the tubular polymer-based handguard body includes a top wall defining first and second gas regulator apertures configured to receive a selectively adjustable gas regulator assembly coupled to the barrel. The first gas regulator aperture is configured to allow passage of a gas regulator shaft to pass through the top wall and the second gas regulator aperture includes a third metal insert embedded therein. The third metal insert may be configured to threadably receive a detent therein.
In a further aspect of the present invention, an alternative exemplary embodiment may be directed to a free-floating handguard configured to be mounted onto a modular sporting firearm and include a tubular polymer-based handguard body configured to allow passage of a barrel therethrough. The handguard body may have an open free-floating muzzle end and an opposing clamping end configured to detachably engage a barrel nut that secures the barrel to the firearm. A downwardly extending lobe may be integrally formed on the tubular polymer-based handguard body proximate the clamping end of the handguard body. The downwardly extending lobe may define a horizontal through bore therein and a first metal insert may be embedded within the downwardly extending lobe. The first metal insert defines a threaded bore and wherein the threaded bore is aligned with the horizontal through bore such that the horizontal through bore is configured to receive a threaded fastener therein with the threaded fastener configured to threadably engage the threaded bore of the first metal insert so as to clamp the clamping end of the handguard body on the barrel nut to secure the handguard body on the firearm.
In another aspect of the alternative embodiment, the downwardly extending lobe may include a vertical slot defined therein. The horizontal through bore is in communication with the vertical slot insert whereby the vertical slot is at least partially closed upon the threaded engagement of the threaded fastener within the horizontal through bore with the threaded bore. The tubular polymer-based handguard body may also include a top wall defining first and second gas regulator apertures configured to receive a selectively adjustable gas regulator assembly coupled to the barrel. The first gas regulator aperture may be configured to allow passage of a gas regulator shaft to pass through the top wall and the second gas regulator aperture may include a second metal insert embedded therein, wherein the second metal insert is configured to threadably receive a detent therein.
Yet another exemplary embodiment is directed to a free-floating handguard configured to be mounted onto a modular sporting firearm and including a tubular polymer-based handguard body configured to allow passage of a barrel therethrough. The handguard body has an open free-floating muzzle end and an opposing clamping end configured to detachably engage a barrel nut that secures the barrel to the firearm. A top wall defines first and second gas regulator apertures configured to receive a selectively adjustable gas regulator assembly coupled to the barrel. The first gas regulator aperture is configured to allow passage of a gas regulator shaft to pass through the top wall of the handguard body, and the second gas regulator aperture includes a first metal insert embedded therein. The first metal insert is configured to threadably receive a detent therein.
Additional objects, advantages and novel features of the present invention will be set forth in part in the description which follows, and will in part become apparent to those in the practice of the invention, when considered with the attached figures.
The accompanying drawings form a part of this specification and are to be read in conjunction therewith, wherein like reference numerals are employed to indicate like parts in the various views, and wherein:
Most modern sporting firearms are configured to be operated as rifles and include a rifled barrel and are chambered to receiver and fire rifle cartridges. By way of example, the most ubiquitous civilian modern sporting weapon, the AR-15 style firearm, is generally chambered for standardized rounds such as the Remington 0.223 cartridge or the 5.56×45 mm NATO military cartridge. The major components of AR-15 style firearms have been standardized, with such standardization being generally referred to as meeting United States Military Standards or, more commonly as being “mil-spec”. Specifically, as used herein, the terms “mil-spec” and “mil-spec M16/AR-15” shall refer to the structural specificities defined by the United States Department of Defense as of the date of filing of the instant United States patent application. Modern sporting weapons, such as the AR-15 style firearm, have also been modified to chamber and fire 0.410 bore shotgun shells as generally shown and described within commonly owned U.S. Pat. Nos. 10,578,381 and 11,125,516, the entirety of which are hereby incorporated by reference.
Referring to the drawings in detail, and specifically to
With reference to
Handguard body 130 may further include an integrally formed, downwardly extending lobe 136 proximate clamping end 134. In one embodiment of the present invention, downwardly extending lobe 136 may include a first metal insert 138, such as a female quick disconnect/detach (QD) fitting or mount, or a swivel socket embedded within the polymer base material of downwardly extending lobe 136. First metal insert 138 may open to either the side wall (e.g. outer surface 136a) or, more preferably, toward the bottom wall 136b of downwardly extending lobe 136. First metal insert 138 may then releasably couple with a corresponding mounting feature on a firearm sling, such as a male QD fitting.
Additionally or alternatively and with particular reference to
With reference to
Turning now to
As shown in
As shown most clearly in
Turning now to
As can be seen, each of the free-floating handguards includes a common portion 111-111c, respectively and a variable portion 113-113c, respectively. Common portions 111-111c may be formed by a common mold having a nominal length of about 5 inches. Common portions 111-111c are constructed to include one or both of first and second metal inserts 138/238 and 142/242 therein. Variable portions 113-113c may be used to extend the free-floating handguard to a required or user-selected length, with variable portions 113-113c having any desired length, and as shown by example only, can be either 2 inches, 4 inches, 6 inches or 8 inches, although other lengths are envisioned.
Common portions 111-111c may be formed as separate subunits than subunits comprising variable portions 113-113c, with the subunits coupled together to form a completed handguard, or more preferably, a respective common portion 111-111c and a respective variable portion 113-113c may be fabricated as a monolithic unit. When used with the 410 upper receiver and barrel assembly described in the commonly owned '516 Patent, variable portions 213-213c are configured to include the first and second gas regulator apertures 260, 262 and third metal insert 264 (see e.g.,
It should be noted that while described throughout the description and claims as being a “metal insert”, each of first, second and/or third inserts 138, 144, 264 may be any suitable material, including and without limitation thereto, a metal, an alloy, a composite metal or any combination thereof. In one embodiment, inserts 138, 144, 264 may be stainless steel, brass or copper. Inserts 138, 144, 264 may all be comprised of the same material or be of different materials, as desired or necessary. It should be further noted that fastener (compressing bolt) 145 may be fabricated of a material identical to second insert 144 to avoid the possibility of corrosion or pitting.
Although the present invention has been described in considerable detail with reference to certain aspects thereof, other versions are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the aspects contained herein.
All features disclosed in the specification, including the claims, abstract, and drawings, and all the steps in any method or process disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. Each feature disclosed in the specification, including the claims, abstract, and drawings, can be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.
