Monolithic rail platform and bolt assemblies for a firearm

Abstract

A firearm assembly for a firearm can include a monolithic rail platform with a handguard portion and an upper receiver portion. The barrel of the firearm can be positioned through the bandguard portion and secured with the upper receiver portion. A firearm assembly can also include a bolt assembly with a bolt carrier having minimized land area and a forward end sized for receipt in the barrel extension at the rearward end of the barrel.

Description

BACKGROUND

The use of automatic and semi-automatic rifles is commonly known to be prevalent in the military. Such weapons typically employ an upper receiver and bolt action operating system. One standard weapon for the U.S. Military is the M-16 rifle. Semi-automatic rifles such as the AR15 type are used in the civilian sector. Such rifles can be further adapted for single shot action. The structure and mechanisms of semi-automatic and automatic rifles have been the subject of much refinement and variation over the years.

While there have been advances in the designs of prior art rifles, there remains room for additional improvements. The present invention is directed toward providing various improvements to semi-automatic and automatic rifles.

SUMMARY

The present invention is directed to monolithic rail plate platforms and bolt assemblies for rifles.

According to one aspect, there is provided a monolithic rail platform that includes a handguard portion and an upper receiver portion integrally formed with one another as a single component.

According to another aspect, there is provided an improved bolt carrier for a semi-automatic or automatic rifle.

According to a further aspect, there is provided an improved operating system for a semi-automatic or automatic rifle.

According to yet another aspect, there is provided an improved rifle assembly for attachment of peripheral components thereto.

These and other aspects will also be apparent from the following description of the illustrated embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded view of an upper portion of a firearm.

FIG. 2 is a top view of an monolithic rail platform comprising the upper portion of FIG. 1.

FIG. 3 is a side view of the monolithic rail platform of FIG. 2.

FIG. 4 is a bottom view of the monolithic rail platform of FIG. 2.

FIG. 5 is an inverted side view of the monolithic rail platform of FIG. 2 looking at the side opposite the side shown in FIG. 3.

FIG. 6 is a right end view of the monolithic rail platform of FIG. 2.

FIG. 7 is a left end view of the monolithic rail platform of FIG. 2.

FIG. 8 is a top view of a bolt carrier comprising a portion of the upper portion of FIG. 1.

FIG. 9 is a side view of the bolt carrier of FIG. 8.

FIG. 10 is a right end view of the bolt carrier of FIG. 8.

FIG. 11 is a bottom view of the bolt carrier of FIG. 8.

FIG. 12 is a left end view of the bolt carrier of FIG. 8 as oriented in FIG. 11.

FIG. 13 is a section view through line 13-13 of FIG. 12.

DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any such alterations and further modifications in the illustrated device, and any such further applications of the principles of the invention as illustrated herein are contemplated as would normally occur to one skilled in the art to which the invention relates.

An assembly 20 for an upper portion of a firearm is shown in FIG. 1 in an exploded view. The lower receiver assembly, butt stock and magazine are not shown in FIG. 1, it being understood that the lower receiver, butt stock and magazine can be provided in any configuration suitable for an automatic M16/AR15 type rifle or other type or caliber semi-automatic or automatic rifle. Assembly 20 includes a barrel assembly 21 that includes a barrel 22 having a gas block 24 attachable to a forward end thereof. A gas tube 26 extends rearwardly from gas block 24 to the weapon operating system. A barrel extension 28 is attachable to the rearward end of barrel 22 adjacent cartridge chamber 30. Barrel extension 28 is configured to interlock with the bolt, such as bolt 102. Further details regarding one embodiment bolt 102 and barrel extension 28 are provided in U.S. Pat. No. 6,182,389, which is incorporated herein by reference in its entirety. Assembly 20 further includes an monolithic rail platform 50 that includes a handguard portion 52 integrally formed with an upper receiver portion 70.

Referring now further to FIGS. 2-7, when assembly 20 is assembled, a bolt carrier 120 housing bolt 102 is positioned in and movably received along the longitudinal axis of bore 70a of upper receiver portion 70, and barrel assembly 21 is positioned in bore 52a of handguard portion 52. Barrel assembly 21 is secured to monolithic rail platform 50 with fasteners 54a, 54b and clamping nuts 55a, 55b. Fasteners 54a, 54b extend through respective ones of the holes 56a, 56b through monolithic rail platform 50. Clamping nuts 55a, 55b are coupled to the threaded ends of fasteners 54a, 54b to clamp monolithic rail platform 50 around enlarged portion 22a of barrel 22 at the forward end of upper receiver portion 70. It is further contemplated that fastener 54b can act as a locating and retaining pin by interacting with enlarged portion 28a of barrel extension 28 to ensure that barrel 22 is properly positioned and located in monolithic rail platform 50. For example, fastener 54b can be received in a recess formed in an outer surface of enlarged portion 28a of barrel extension 28 when barrel 22 is at the proper locating in bore 52a of handguard portion 52. Fastener 54b can resist any forward movement of barrel 22 and barrel extension 28 that might be created b contact of the bolt carrier therewith.

Handguard portion 52 includes a number of rails 58 extending therealong separated by recesses 60 therebetween. Rails 58 include transverse grooves 59 formed therein to facilitate gripping of handguard portion 52. A number of threaded holes 63 are spaced along each rail 58 to allow attachment of peripheral devices, such as a grenade launcher, site, sling and/or scope, for example. Recesses 60 each include a number of holes 62 formed therein along handguard portion 52 to allow air flow and heat from barrel 22 to vent therethrough.

Handguard portion 52 further includes a rearward extension 58a for the upper rail 58 that extends along upper receiver portion 70. The rearward extension 58a includes a passage 64 formed therethrough that communicates gas tube 26 to provide a path for delivering gas to the operating system of the rifle. The forward end 52b of handguard portion 52 includes a triangular shaped opening 52c adapted to receive the upper extension 24a of gas block 24. Gas tube 26 is coupled to upper extension 24a of gas block 24.

Upper receiver portion 70 includes a forward end 70b integrally formed with handguard portion 52 and a rearward end 70c. Forward end 70b can comprise a clamping portion having clamping members 70e, 70f positioned on opposite sides of slot 70d to facilitate clamping of upper receiver portion 70 about barrel 22. A cut-out 65 is formed in forward end 70b to reduce weight. Upper receiver portion 70 further includes a forward lug 72a and a rearward lug 72b extending downwardly from a bottom side thereof. The lower receiver assembly (not shown) is attachable to lugs 72a, 72b. Upper receiver portion 70 further includes ejection port opening 74 and ejection port cover receptacles 76a, 76b on opposite sides thereof. Ejection port receptacles 76a, 76b receive pins that pivotally couple an ejection port cover (not shown) over opening 74. A deflector 78 extends outwardly from upper receiver portion 70 adjacent the rearward end of ejection portion opening 74 to deflect ejected cartridges away from the shooter. Upper receiver portion 70 further includes a forward assist port 80 that receives a forward assist mechanism (not shown) to assist in positioning the bolt carrier assembly 100 in its forward battery position in upper receiver portion 70 if needed.

Opposite ejection port receptacle 74 there is a lip of material 84 to support a cam pin cut-out in the upper receiver portion 70. Upper receiver portion 70 further includes in the bottom side thereof a first opening 82a along a rearward portion thereof for receiving the trigger assembly of the lower receiver assembly. Upper receiver portion 70 also includes a second opening 82b along a forward portion thereof communicating with the magazine receptacle of the lower receiver assembly for receiving cartridges therethrough from the magazine of the rifle. Second opening 82b is wider than first opening 82a and first and second openings 82a, 82b are in communication with one another along the bottom portion of upper receiver portion 70. The rearward end 70c of upper receiver portion 70 is positionable adjacent the lower receiver extension assembly and buttstock assembly of the lower receiver assembly when the rifle is assembled.

With barrel 22 secured to the coupling portion at forward end 70b of upper receiver portion 70, handguard portion 52 can extend around barrel 22, but need not be supported by, or in contact with, or coupled to barrel 22. Accordingly, barrel 22 can float in bore 52a of handguard portion 52. Monolithic rail platform 50 allows the hoop strength of handguard portion 52 to be maximized since, in one embodiment, it is provided as a single continuous ring extending along barrel 22. The integral unitary construction of upper receiver portion 70 and handguard portion 52 provide a stronger, reliable rifle assembly since there are fewer parts that require assembly. Peripheral devices, such as scope mounts, sites, slings, and grenade launchers, for example, that are mounted on handguard portion 52 do not apply load on or influence barrel 22, improving rifle accuracy. Rather, such loads and other influences created by these peripherals are transmitted from handguard portion 52 to upper receiver portion 70. Furthermore, in one embodiment, any threaded connection between barrel 22 and upper receiver portion 70 is eliminated, allowing rapid attachment and detachment of barrel 22 via fasteners 54a, 54b. The integral upper receiver and handguard portions and means of attaching the barrel allow for rapid assembly and disassembly of rifle components, which can be critical in the field.

Referring now to FIGS. 8-13, further details regarding bolt carrier 120 of bolt assembly 100 will be provided. Bolt carrier 120 includes a forward end 120a and an opposite rearward end 120b. Forward end 120a is oriented toward barrel 22 when bolt carrier 120 is positioned in upper receiver portion 70. A passage 120d extends between forward end 120a and rearward end 120b along a longitudinal axis of bolt carrier 120. Passage 120d has a minimum diameter portion 120c sized to receive the reduced diameter end portion 102a of bolt 102 when positioned therein. Passage 120d further includes a bolt receiving portion 120e extending forwardly from minimum diameter portion 120c to forward end 120a to receive the remaining portion of bolt 102. Bolt 102 is mounted in bolt carrier 120 for axial sliding movement in forward portion 120e. Bolt 102 includes a cartridge extractor 104 pivotally coupled thereto, and includes lugs 106 at the forward end thereof that releasably interlock with barrel extension 28. A firing pin (not shown) extends through a central bore through bolt 102. A cam slot 124 is formed adjacent forward end 120a which receives a cam member therethrough for contacting bolt 102 to rotate it as it moves rearwardly and forwardly for engagement with barrel extension 28.

Bolt carrier 120 includes a slot 134 therethrough that receives the hammer from the lower receiver assembly to strike the firing pin in bolt 102. Bolt carrier 120 further includes gas key mounting holes 136 formed in an upper mounting surface 131 of bolt carrier 120. Gas key mounting holes 136 communicate with passage 120d. A gas port 138 is further provided in mounting surface 131 and includes ports extending therefrom in communication with passage 120d. One side of bolt carrier 120 is provided with forward assist notches 144 which are engageable by a forward assist mechanism (not shown) in forward assist port 80 of upper receiver portion 70. Bolt carrier 120 further includes a door opener 122 that is recessed in the body of bolt carrier 120 to provide room for the door latch to close. Bolt carrier 120 includes a charging handle contact portion 146 adjacent forward end 120a.

Rearward end portion 130 includes a groove 132 cut therein along the longitudinal axis of bolt carrier 120 to maintain alignment of bolt carrier 120 as it axially reciprocates in upper receiver portion 70. Bolt carrier 120 further includes forward lands 126a, 126b, 126c, and 126d extending along the forward half of bolt carrier 120. Lands 126a, 126b extend along the upper portion of bolt carrier 120 along mounting surface 131 and terminate at contact portion 146. Lands 126c and 126d extend along the bottom portion of bolt carrier 120 and terminate at forward end 120a. The lands 126a, 126b 126c, 126d contact the inner wall of bore 70a of upper receiver portion 70 to maintain alignment of bolt carrier 120 centrally therein and also in alignment with the centerline of barrel 22. The land area along bolt carrier 120 and also along forward end portion 148 is minimized by reducing the land area in the range from one-half to one twenty-fifth of that of prior art bolt carriers.

The portion of bolt carrier 120 along which each of the lands 126a, 126b, 126c, 126d extends has a surface area, and lands 126a, 126b, 126c, 126d occupy a portion of that surface area. In one embodiment, a section of bolt carrier 120 including lands 126a, 126b, 126c, 126d occupies a surface area that ranges from 1% to 12% of the surface area of the occupied portion of the bolt carrier 120. In another embodiment, lands 126a, 126b, 126c, 126d occupy a surface area that ranges from 1% to 8% of the surface area of the occupied portion of the bolt carrier. In another embodiment, lands 126a, 126b, 126c, 126d occupy a surface area that ranges from 1% to 4% of the surface area of the occupied portion of the bolt carrier.

By minimizing the land area, the contact surface area between bolt 120 and the wall of bore 70a of upper receiver portion 70. This allows greater ease of movement of bolt carrier 120 in upper receiver portion 70. The reduced contact area also provides greater clearance between bolt carrier 120 and any particles in bore 70a of upper receiver portion 70, allowing bolt carrier 120 to deposit such particles and debris in the recessed areas between the lands to provide a self-cleaning action that reduces malfunction in harsh environments and with prolonged usage.

The protrusion 125 at the forward end of bolt carrier 120 is sized for receipt in the rearwardly facing opening of barrel extension 28. Protrusion 125 is positioned radially inwardly from the outer perimeter of forward end 120a, and includes a sloped or chamfered outer surface that extends from a first diameter at rearward end 125b adjacent forward end 120a to a reduced diameter forward face 125b at the forward end of protrusion 125. Bore 120d extends through protrusion 125. Protrusion 125 allows bolt carrier 120 to be positioned more forwardly in upper receiver portion 70 as compared to a bolt carrier having the same overall length without protrusion 125. By positioning bolt carrier 120 more forwardly in upper receiver portion 70, the time required to move bolt carrier 120 rearwardly to turn bolt 102 is increased. Protrusion 125 thus increases the stroke length for bolt carrier 120 in upper receiver portion 70. The additional stroke length provided by protrusion 125 increases the dwell time of bolt 102 in barrel extension 28, allowing residual gas pressure in barrel 22 more time to vent before bolt 102 unlocks with barrel extension 28.

In one embodiment, protrusion 125 is sized to extend forwardly a distance of one hundred thousandths of an inch to increase the dwell time of bolt 102 by up to two times that provided in bolt carriers without protrusion 125. It is contemplated that other embodiments may provide other lengths and/or other dwell times associated with protrusion 125. The reduced gas pressure in the blowback operation reduces the load exerted on extractor 104 during the extraction cycle, improving system operation in the extraction and ejection cycles for the spent cartridge. For example, by venting additional gas pressure before extraction, expansion of the spent cartridge casing is reduced facilitating extraction and reducing the extraction loading. The load and forces exerted on bolt 102, barrel extension 28, and upper receiver portion 70 are reduced. Thus, rather than having excess energy from the gas pressure consumed in the recoil cycle, more energy is directed for use in the counter recoil cycle and feeding and chambering of cartridges. The increased stroke length thus increases overall system operability, reliability and the life of the firearm. Operating performance with attachments that affect the gas operation of the rifle are also improved. For example, silencers accumulate gas to muffle the noise. The additional dwell time allows more gas to vent to the breech, reducing load on the barrel and providing longer barrel life when silencers are employed.

While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character. All changes and modifications that come within the spirit of the invention are desired to be protected.

Claims

1. A monolithic rail platform for a firearm, comprising: a handguard portion adapted to receive at least a portion of a barrel assembly of the firearm therein; and an upper receiver portion extending rearwardly from and integrally formed with said handguard portion, said upper receiver portion adapted to receive a bolt carrier therein.

2. The platform of claim 1, wherein said upper receiver portion includes a bore extending along a longitudinal axis thereof, said bolt carrier being movably received in said bore of said upper receiver portion along said longitudinal axis.

3. The platform of claim 1, further comprising a coupling portion at a forward end of said upper receiver portion and integral with said handguard portion, said coupling portion adapted to releasably clamp a rearward end of said barrel assembly extending through said handguard portion to said upper receiver portion.

4. The platform of claim 3, wherein said upper receiver portion includes a longitudinal axis and said coupling portion includes a slot extending in the direction of said longitudinal axis separating said coupling portion into first and second clamping portions positioned on respective sides of said slot.

5. The platform of claim 4, further comprising at least one fastener positionable through said coupling portion transversely to said longitudinal axis, said at least one fastener operable to bring said clamping portions toward one another to clamp said barrel assembly in said coupling portion.

6. The platform of claim 5, further comprising a pair of fasteners positionable through said coupling portion transversely to said longitudinal axis, one of said pair of fasteners positioned against a an enlarged portion of said barrel assembly to resist forward movement of said barrel assembly.

7. The platform of claim 1, wherein said handguard portion includes a number of rails extending therealong separated by recessed portions therebetween.

8. The platform of claim 7, wherein said number of rails includes an upper rail extending rearwardly along said upper receiver portion.

9. The platform of claim 8, wherein said upper rail includes a passage formed therealong for delivering gas from a forward end of said barrel.

10. The platform of claim 1, wherein said handguard portion extends along said barrel assembly to a position adjacent a forward end of said barrel assembly.

11. The platform of claim 1, wherein said upper receiver portion includes a first opening along a bottom side thereof adapted to receive a trigger assembly and a second opening along said bottom side thereof in communication with and forming a forward extension of said first opening, said second opening adapted to receive a magazine therein.

12. The platform of claim 1, wherein said barrel assembly is attachable to said upper receiver portion and extends through said handguard portion in a floating relationship therewith.

13. The platform of claim 1, wherein the monolithic rail platform comprises a portion of a bolt action rifle.

14. The platform of claim 1, wherein: said barrel assembly includes a barrel extension at a rearward end thereof; said upper receiver portion includes a longitudinal bore extending therethrough in communication with said barrel extension; and said bolt carrier including a protrusion at a forward end thereof, said protrusion being sized for receipt in said barrel extension thereby increasing a stroke length of said bolt carrier in said longitudinal bore of upper receiver portion.

15. A firearm assembly, comprising: a handguard portion; a barrel assembly extending through said handguard portion, said barrel assembly including a barrel extension at a rearward end thereof; an upper receiver portion extending from a rearward end of said handguard portion, said upper receiver portion including a longitudinal bore extending therethrough in communication with said barrel extension; and a bolt assembly movably positioned in said longitudinal bore, said bolt assembly including a bolt carrier having a protrusion at a forward end thereof, said protrusion being sized for receipt in said barrel extension thereby increasing a stroke length of said bolt carrier in said longitudinal bore of said upper receiver portion.

16. The platform of claim 15, wherein said handguard portion is integrally formed with said upper receiver portion.

17. The assembly of claim 15, further comprising a coupling portion at a forward end of said upper receiver portion integral with said handguard portion, said coupling portion adapted to releasably clamp a rearward end of said barrel assembly extending through said handguard portion to said upper receiver portion.

18. The assembly of claim 17, wherein said upper receiver portion includes a longitudinal axis and said coupling portion includes a slot extending in the direction of said longitudinal axis separating said coupling portion into first and second clamping portions positioned on respective sides of said slot.

19. The assembly of claim 18, further comprising at least one fastener positionable through said coupling portion transversely to said longitudinal axis, said at least one fastener operable to bring said clamping portions toward one another to clamp said barrel assembly in said coupling portion.

20. The assembly of claim 15, wherein said handguard portion includes a number of rails extending therealong separated by recessed portions therebetween.

21. The assembly of claim 20, wherein said number of rails includes an upper rail extending rearwardly along said upper receiver portion.

22. The assembly of claim 15, wherein said handguard portion extends along said barrel assembly to a position adjacent a forward end of said barrel assembly.

23. The assembly of claim 15, wherein said barrel assembly is attachable to said upper receiver portion and said handguard portion extends around and is separated from said barrel assembly.

24. The assembly of claim 15, wherein said bolt carrier includes a forward end portion and a rearward end portion, said forward end portion including a number of lands extending therealong and spaced thereabout for contacting said upper receiver portion in said bore, said number of lands occupying from about 1% to about 12% of a surface area of said forward end portion along which said number lands extend.

25. The assembly of claim 15, wherein said protrusion extends into said barrel extension for a distance of one hundred thousandths of an inch when said bolt carrier is positioned completely forwardly in said upper receiver portion.

26. A firearm assembly, comprising: a handguard portion; a barrel assembly extending through said handguard portion; an upper receiver portion extending from a rearward end of said handguard portion, said upper receiver portion including a longitudinal bore extending therethrough in communication with said barrel extension; and a bolt assembly movably positioned in said longitudinal bore, said bolt assembly including a bolt carrier including a forward end portion and a rearward end portion, said forward end portion including a number of lands extending therealong and spaced thereabout, said number of lands occupying from about 1% to about 12% of a surface area of said forward end portion along which said number of lands extend.

27. The assembly of claim 26, wherein said number of lands occupy from about 1% to about 8% of said surface area of said forward end portion.

28. The assembly of claim 26, wherein said number of lands occupy from about 1% to about 4% of said surface area of said forward end portion.

29. The assembly of claim 26, wherein said number of lands occupy about 4% of said surface area of said forward end portion.

30. The assembly of claim 26, wherein said barrel assembly includes a barrel extension at a rearward end thereof.

31. The assembly of claim 26, wherein said bolt carrier includes a protrusion at a forward end thereof, said protrusion being sized for receipt in said barrel extension thereby increasing a stroke length of said bolt carrier in said longitudinal bore of said upper receiver portion.

32. The assembly of claim 26, wherein said handguard portion and said upper receiver portion are formed as an integral unit.

33. The assembly of claim 26, further comprising a coupling portion at a forward end of said upper receiver portion and integral with said handguard portion, said coupling portion adapted to releasably clamp a rearward end of said barrel assembly extending through said handguard portion to said upper receiver portion.

34. The assembly of claim 33, wherein said upper receiver portion includes a longitudinal axis and said coupling portion includes a slot extending in the direction of said longitudinal axis separating said coupling portion into first and second clamping portions positioned on respective sides of said slot.

35. The assembly of claim 26, wherein said handguard portion extends along said barrel assembly to a position adjacent a forward end of said barrel assembly.

36. The assembly of claim 26, wherein said barrel assembly is attachable to said upper receiver portion and extends through said handguard portion in a floating relationship therewith.