Gas Key

Description

PRIORITY CLAIM AND CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit under 35 U.S.C. § 119 (e) (1) of U.S. Provisional Application No. 63/661,696, filed Jun. 19, 2024, which is hereby incorporated by reference in its entirety.

BACKGROUND

Cycling of a semi-automatic or automatic firearm can use the combustion gases produced during a triggering event of the firearm. A gas tube key can be mounted to the surface of the bolt carrier of the firearm. The gas tube key receives combustion gas from the barrel via a gas tube during the triggering event. Combustion gas entering the bolt carrier from the gas tube key forces the bolt carrier backwards within the upper receiver of the firearm to cycle the action of the firearm.

In some rifles, the bolt carrier may travel approximately 4.5″ backwards during the cycle, as it is forced backwards by the combustion gas. The gas tube key generally becomes separated from the stationary gas tube after approximately 0.75″ of backwards bolt carrier travel. However, combustion gases are still existing from the gas tube after separation from the gas tube key. The resulting gap between the gas tube key and the gas tube can cause combustion gases to be forced into the upper receiver and also into the shooter's face.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description is set forth with reference to the accompanying figures. The use of the same reference numbers in different figures indicates similar or identical items.

For this discussion, the devices and systems illustrated in the figures are shown as having a multiplicity of components. Various implementations of devices and/or systems, as described herein, may include fewer components and remain within the scope of the disclosure. Alternately, other implementations of devices and/or systems may include additional components, or various combinations of the described components, and remain within the scope of the disclosure. Shapes and/or dimensions shown in the illustrations of the figures are for example, and other shapes and or dimensions may be used and remain within the scope of the disclosure, unless specified otherwise.

FIG. 1 shows an example AR styled rifle, which is an environment wherein the disclosed embodiments may be practiced.

FIGS. 2 and 3 show right and left side perspective views of an example AR style upper receiver.

FIGS. 4 and 5 show right and left side perspective views of an example AR style bolt carrier with a gas tube key.

FIG. 6 shows a left side perspective view of an example novel gas tube key with extension, according to an embodiment.

FIG. 7 shows a left side perspective view of an example novel gas tube key with extension, according to another embodiment.

FIG. 8 shows a left side perspective view of an example novel gas tube key with extension, according to another embodiment.

FIG. 9 shows a left side perspective view of an example novel gas tube key with

extension, according to another embodiment.

FIG. 10 shows a cutaway view of an example novel gas tube key with extension, according to an embodiment.

FIG. 11 shows a cutaway view of an example novel gas tube key with extension, according to another embodiment.

FIG. 12 shows a left side perspective view of an example novel bolt carrier with a novel gas tube key with extension, according to an embodiment.

FIG. 13 shows a right side perspective view of an example novel upper receiver, having a novel bolt carrier with a novel gas tube key with extension, according to an embodiment.

DETAILED DESCRIPTION

Overview

Representative implementations of devices and techniques provide novel AR style rifle upper receiver components, including a novel upper receiver 110, a novel bolt carrier 102, and a novel gas tube key 600. The incorporation of a novel gas tube key 600 comprises novel upper receiver components (i.e., upper receiver 110 and/or bolt carrier 102) and/or a novel AR styled rifle 100. The novel gas tube key 600 is an exact fit for most if not all AR style rifles (e.g., AR-15, M-16, M4, etc.). For instance, the novel gas tube key 600 can be seamlessly interchanged with the standard gas tube key 46 of an AR style rifle, and allow the reliable use of the AR style rifle.

In various embodiments, the novel gas tube key (hereinafter “key 600”) includes a gas tube key extension (hereinafter “extension 602”) that is integral to the key 600 or coupled to the key 600. The extension 602 can be coupled to the key 600 using various techniques discussed herein. The key 600 with the extension 602 has a length that can be substantially longer than the length of a standard gas tube key 46, depending on the length of the extension 602.

In various embodiments, the length of the key 600 (including the length of the extension 602) can be tuned to determine a gap distance (if any) between the extension 602 and the gas tube 16 of the rifle 100 when the bolt carrier 102 is at its fully retracted state during cycling. Tuning these lengths also tunes the duration of time that there exists a gap (if any) when the bolt carrier 102 is at its fully retracted state. In this way, tuning the overall length of the key 600 (including tuning the length of the extension 602) can mitigate or eliminate the potential for combustion gases to be forced into the upper receiver 110 and also into the shooter's face during cycling of the rifle 100.

In various embodiments, the novel gas tube key 600 includes different (e.g., greater) interior diameter dimensions at various portions of the key 600. Changing the interior diameter dimensions of the various portions of the key 600 allows for tuning the volume of gases moving through the key 600 as well as tuning the pressure of the gases. In this way, tuning the pressure and volume of gases moving through the key 600 (including tuning the interior diameter dimension of various portions of the key 600, including the extension 602) can provide control of cycling of the action while mitigating or eliminating the potential for combustion gases to be forced into the upper receiver 110 and also into the shooter's face during cycling of the rifle 100.

Referring to FIGS. 1-11, the following part number designations are used throughout for prior art or novel components:

Part number	Description

1	Upper Receiver
2	Lower Receiver
3	Buttstock
4	Grip
5	Trigger guard and trigger
6	Magazine well
7	Magazine
8	Handguard
9	Barrel
10	Flash Suppressor
11	Front Sight
12	Barrel Nut
13	Accessory Rail
14	Rear Sight
15	Gas Block (inside Handguard)
16	Gas Tube (inside Handguard)
20	Charging Handle
21	Forward Assist
22	Bolt Carrier
23	Ejection Port Cover
24	Ejection Port
25	Barrel Attachment with Index
26	Rear Takedown Pin Opening
27	Front Pivot Pin Opening
28	Firing Pin
29	Magazine Well Access
30	Trigger Group Opening
31	Gas Tube Access
32	Bolt
33	Bolt Lug
34	Ejector
35	Guide Rivets
36	Rail Rivets
37	Front Pivot Pin Bushing
38	Rail Recess
39	Rail
40	Upper Guide
41	Charging Handle Groove
42	Extractor
43	Firing Pin Opening
44	Bolt Guide Lug
46	Gas Tube Key
47	Bolt Carrier Boss
48	Cam Opening
49	Cam Pin
50	Firing Pin Keeper
51	Rail Groove
52	Forward Assist Detents
53	Cartridge Guide Rail
54	Gas Vents
55	Guide Rail Leading Surface
56	Carrier Grooves
61	Gas Seal Rings
62	Cam Pin Opening
63	Bolt Stabilizer
64	Firing Pin Entry
65	Bolt Stabilizer Opening
66	Firing Pin Tip
67	Firing Pin Upper Shaft
68	Firing Pin Stop
69	Firing Pin Heel
70	Bearing
71	Firing Pin Lower Shaft
72	Firing Pin Toe
73	Bearing Groove
74	Cam Pin Head
75	Cam Pin Shaft
76	Firing Pin Alignment Hole

Note that the use of a part number in the discussion (including the drawings) may refer to the part without necessarily indicating whether the part is a novel part or a prior art part. The discussion will provide details regarding novel aspects of the novel parts indicated.

FIG. 1 references an example AR style rifle, which is an environment wherein the disclosed techniques and devices may be employed. Referring to FIG. 1, an example AR styled rifle is illustrated, however, the incorporation of novel upper receiver components, such as a novel gas key 600, a novel bolt carrier 102, or a novel upper receiver 110, comprises a novel AR style rifle 100.

There are tens of millions of common AR styled rifles (including the AR-15, M16, M4, etc.) in America today. With the western-trained allies also using the AR styled rifles, this makes the AR styled rifle one of, if not the most prolific rifle in the world. For instance, this represents a 10 billion dollar per year industry, with most firearms manufacturers around the world producing and/or marketing a version of an AR styled rifle.

AR styled rifles are produced to use various sizes of cartridges, including 0.223/5.56 mm NATO, 0.22-LR, 9×19 mm Parabellum, various shotgun calibers, as well as others, including 7.62×39 mm rounds. The 7.62×39 mm cartridge is a rimless cartridge that was designed by the Soviet Union during World War II for the SKS and AK-47 rifles and others, and has since proliferated throughout the world, being widely used by civilians and militaries nearly everywhere.

Rather than having a single-application receiver as found on some rifles, the AR styled rifles include a modularly designed receiver with separate upper 1 and lower 2 receivers. The lower receiver 2 includes a trigger guard and houses the trigger group 5. The lower receiver 2 also includes a means (e.g., screw-type fitting) for coupling the buttstock 3 and a pistol grip 4. The lower receiver 2 also includes a magazine well 6 for coupling and interchanging various cartridge magazines 7. The upper receiver 1 attaches to the lower receiver 2 using front and rear pins. With the rear takedown pin removed, the upper receiver 1 can be pivoted at the front pin location, or it can be removed by removing the front pin.

Referring also to FIGS. 2 and 3, the upper receiver 1 includes a coupler 25 for coupling the barrel 9, and the handguard 8. The upper receiver 1 also houses the bolt carrier 22 with the bolt 32 and the firing pin 28 (see FIGS. 4 and 5). An ejection port 24 is located at the upper receiver 1 for expelling spent casings.

EXAMPLE EMBODIMENTS

Embodiments of rifles 100 are disclosed herein, as embodiments with various novel enhancements. Devices, systems, and techniques are also disclosed herein for enhancing rifles. Accordingly, the devices, systems, and techniques may be integral to a disclosed rifle 100, or they may be retrofit to a pre-existing rifle (individually or in various combinations).

For example, this document discloses novel upper receiver components, including a novel gas tube key 600 (a.k.a. bolt carrier key). The novel gas tube key 600 is visually and tactilely differentiable from a common AR style gas tube key 46, but is operated without the need for specialized training. The novel gas tube key 600 is assembled to and disassembled from a bolt carrier 22 in a similar way to a standard AR style gas key 46. However, the shape, size and operation of the novel gas tube key 600 is distinguishable from a standard gas tube key 46.

With the novel gas tube key 600 installed at the bolt carrier 22 (forming a novel bolt carrier 102), the upper receiver assembly 110 is a direct fit on a standard AR style rifle. The novel gas tube key 600 is designed for added strength, reliability, safety, and durability. As mentioned, the addition of a novel gas tube key 600 to a bolt carrier body 45 comprises a novel bolt carrier 102 (see FIG. 10). Further, the addition of a novel bolt carrier 102 to an upper receiver 1 comprises a novel upper receiver 110 (see FIG. 11).

Referring to FIGS. 2 and 3, an example AR style upper receiver 1 assembly is shown. The upper receiver 1 assembly includes a housing for a standard AR style rifle. The upper receiver 1 is constructed to enclose and contain the bolt carrier 22 and related components, and to allow their smooth and reliable movement within the upper receiver 1 during use.

Referring to FIGS. 4 and 5, the bolt carrier 22 is constructed to hold the bolt 32 and firing pin 28 and related components. The bolt 32 is inserted into the front end of the bolt carrier 22 and is held there by the cam pin 49. When the bolt 32 is locked to the barrel extension in preparation for firing, and is rotated and retracted into the bolt carrier 22 by the cam action of the cam pin 49 in the cam pin opening 48, the cam pin 49 may bottom out within the cam pin opening 48 of the bolt carrier 22.

The gas tube key 46 is mounted to the surface of the bolt carrier 22, over a gas opening in the bolt carrier 22 (not shown in the drawings). The gas tube key 46 receives combustion gases from the barrel 9 via the gas tube 16 during a triggering event. Combustion gas entering the bolt carrier 22 from the gas tube key 46 forces the bolt carrier 22 backwards within the upper receiver 1 to cycle the action of the rifle.

In some rifles, the bolt carrier 22 may travel approximately 4″ to 4.5″ backwards during the cycle, as it is forced backwards by the combustion gases entering the gas tube key 46. In some cases, the gas tube key 46 becomes separated from the stationary gas tube 16 after approximately 0.75 inches of backwards travel of the bolt carrier 22. However, combustion gases are still likely to be exiting the gas tube 16 when the gas tube key 46 is separated from the gas tube 16. This can be more likely when sub sonic cartridges are used, and with rifles utilizing suppressors that offer back pressure into the system.

The resulting gap between the gas tube key 46 and the gas tube 16 can cause combustion/propellant gases to be forced into the upper receiver 1 and also into the shooter's face. This is a timing issue-since the bolt carrier 22 is quickly returned to the forward firing position by the biasing effect (e.g., spring action) from the buffer tube at the buttstock 3. The forward motion of the bolt carrier 22 reunites the gas tube 16 with the gas tube key 46 at the end of the cycle, closing the gap. However, it can be undesirable for combustion gases to be released into the upper receiver 1 and into the shooter's face while the gap is present.

Novel Gas Tube Key

Referring to FIGS. 6 and 7, a novel gas tube key 600 is disclosed. The novel gas tube key 600 reduces the time duration that a gap exists between the gas tube key 600 and the gas tube 16, and thereby reduces the time duration and the amount of combustion gas that is released into the upper receiver 1 and into the shooter's face. The novel gas tube key 600 can also increase a volume of gas moving through the gas tube key 600 and lower the pressure of the gas. Further, the novel gas tube key 600 can reduce the debris released into the upper receiver 1 and the shooter's face during a triggering event.

In various embodiments, the novel gas tube key 600 includes a key extension 602 that reduces the time duration that a gap exists between the gas tube key 600 and the gas tube 16. The key extension 602 can also be oversized to catch debris during cycling. Further, the interior diameter dimensions of various portions of the novel key 600 can be increased as compared to a standard gas tube key 46 to increase volume and lower pressure of combustion gases traversing the gas tube key 600.

The increased length of the key extension 602 of the novel gas tube key 600 functions to maintain the connection between the gas tube key 600 and the gas tube 16 for a longer duration, thereby containing the propellant gases longer, and reducing the debris released into the upper receiver 1 and into the shooter's face. In some cases, the key extension 602 can reduce the time period that the gas tube 16 dumps combustion gases into the upper receiver 1 by ¼ to ½ of the time. In other cases, the time period can be less or greater. In various embodiments, the key extension 602 can reduce the distance of separation of the gas tube key 600 from the gas tube 16 from about 3″ to about 2″ or less. Accordingly, the key extension 602 can reduce the volume of combustion gases escaping the gas tube 16 during separation of the gas tube key 600 from the gas tube 16, and reduce the exposure to the gases.

As shown at FIGS. 6 and 7, the novel gas tube key 600 comprises a tube-shaped key body 604 with an offset base 606 for mounting the gas tube key 600 to the bolt carrier 22. The offset base 606 includes a port or opening 614 (not shown) that is positioned over a like port or opening in the body 45 of the bolt carrier 22. The offset portion 612 of the gas tube key 600 couples the key body 604 to the base 606, and terminates with the port 614. There are one or more screw openings 608 in the base 606 for securing the gas tube key 600 in place on the surface of the bolt carrier 22.

Referring also to FIGS. 8-11, the key extension 602 is a tube-shaped component that is coupled to or integral with the body 604 of the gas tube key 600. The key extension 602 includes a first end 802 that is configured to mate with the body 604 of the gas tube 600 (or is integral to the body 604) and a second end that comprises a tube port 610 configured to slide over and mate with the free end of the gas tube 16. The key extension 602 is arranged to mate with the free end of the gas tube 16 when the bolt carrier 22 is moved into the forward position in preparation for a triggering event. The key extension 602 is also arranged to mate with the free end of the gas tube 16 when the bolt carrier 22 is pushed forward by the biasing spring within the buttstock 3, after a triggering event that propels the bolt carrier 22 backwards.

Referring to FIG. 6, a gas tube key 600 can be formed with a key extension 602 as an integral component of the gas tube key 600. Alternately, as shown at FIG. 7, the key extension 602 can be coupled to the end of a specially prepared gas tube key 600 that has been formed to receive the key extension 602.

Referring to FIGS. 8 and 9, the key extension 602 can be formed with a first end that comprises a fitting 802 configured to mate with the body 604. In one embodiment, as shown at FIG. 8, the key extension 602 can include a fitting 802 configured to be pressed into or onto the body 604 of the gas tube key 600. In the embodiment, the body 604 may include a recessed portion 804 (e.g., fitting) either on an outer surface of the mating end of the body 604 or an inner surface of the mating end of the body 604 as applicable to receive the key extension 602.

In another embodiment, as shown at FIG. 9, the key extension 602 can include a threaded fitting 802 configured to be screwed into or onto the body 604 of the gas tube key 600. In the embodiment, the body 604 may include a threaded portion 804 either on an outer surface of the mating end of the body 604 or an inner surface of the mating end of the body 604 as applicable.

In other embodiments, the key extension 602 can include a different fitting 802 configured to mate with a matching fitting 804 on the key body 604, or be otherwise configured to be affixed thereon. For instance, the fitting 802 of the key extension may include a bayonet-style coupler, or one of other twist-to-fit couplers. In that case, the fitting 804 of the key body 604 includes a mating bayonet receiver, twist-to-fit receiver, or the like. In any of the above examples, or other examples, coupling the key extension 602 to the key body 604 can be augmented using heat, pressure, cooling, or other means.

The key extension 602 can be formed of a hardened steel or other material that is durable and able to withstand high temperatures. The key extension 602 includes a tube port 610 (i.e., opening) that is configured (i.e., size and shape) to receive the end of the gas tube 16 during cycling. In some cases, the port 610 may be enlarged in diameter to capture debris being expelled from the gas tube 16. In other cases, the entire key extension 602 may be enlarged in diameter to capture debris and to increase the volume of gas traversing the key 600.

The key extension 602 comprises a tube that can be between 0.5″ and 1.0″ in length. In alternate embodiments, the key extension 602 may be shorter or longer. The length of the key extension 602 determines the length of the resulting gap between the key extension 602 and the gas tube 16 during cycling of the action and the corresponding time duration that a gap between the gas tube key 600 and the gas tube 16 is present. Thus, the length of the gap and the time duration of the gap can be tuned by using extensions 602 of different lengths. A key extension 602 with a greater length results in a shorter gap duration, and vice versa. In an embodiment, a length of the key extension 602 is proportional to a predetermined time duration for the gap during cycling of the action of the firearm. Thus a particular length of key extension 602 can be used to achieve a predetermined gap time and/or gap distance.

In one illustrative example, the cycle time of a common AR styled rifle is between 0.1 and 0.2 seconds for one complete cycle. In the example, the bolt carrier 22 moves 4″ backward, followed by 4″ forward during one cycle. After 0.5″ of backward movement, or about ⅛ portion of the backward travel, a standard gas key 46 separates from the gas tube 16, forming a gap. Combustion gases are still exiting the gas tube 16, at least during this first backward portion of the cycle. That means that during the remaining ⅞ portion of backward travel, or about 3.5″ and 0.044 to 0.088 seconds, combustion gases and debris are entering the upper receiver 1 and being propelled into the shooter's face.

The gap remains between the gas tube key 46 and the gas tube 16 through another ⅞ portion of the forward travel, which includes 3.5″ and another 0.044 to 0.088 seconds, for a total gap time of between 0.088 to 0.176 seconds. In some cases, gases and debris may continue to be expelled from the gas tube 16 through at least part of the forward portion of the cycle.

The addition of the key extension 602 to the gas tube key 600 reduces the duration that a gap between the gas tube key 600 and the gas tube 16 is present, as well as reducing the gap distance itself. For example, the end of the gas tube 16 remains within the gas tube key 600, or the key extension 602, for a longer duration than with a prior art gas tube key 46 alone. Considering the example above, the addition of a 1″ key extension 602 to a gas key 600 means that the backward travel gap time is reduced to about 0.031 to 0.0625 seconds, and the total gap time is reduced to between 0.0625 to 0.125 seconds. This significant reduction can be further tuned by applying gas key extensions 602 of predetermined lengths, as discussed herein.

Referring to FIGS. 10 and 11, the gas tube key 600 and its constituent portions (602, 604, 612) can be further tuned by enlarging an interior diameter of one or more of the portions (602, 604, 612). The illustrations of FIGS. 10 and 11 show two examples of using predetermined interior dimensions A, B, and C with a gas key 600 to tune the key 600. Tuning the key 600 can be performed relative to using various types of ammunition with different charges and combustion characteristics. In each case, desired goals can include a reduction (or minimizing) of combustion gas expelled into the upper receiver 110 paired with a desired bolt 102 cycle that is reliable and predictable. Using (or tuning) novel gas keys 600 with different dimensions, including different lengths of key extension 602 and various interior diameter dimensions at various portions of the key 600 with the various types of ammunition can lead to achieving the desired goals.

For instance, a predetermined key 600 with specific dimensions can be paired with specific ammunition to be used in the rifle 100. In some cases, the dimensions of an existing gas key (46 or 600) installed on a bolt carrier 102 may be designed to work with ammunition that was used in the past, but will not be used with the rifle going forward. In other cases, the combustion gases of a desired type of ammunition to be used with the rifle 100 may not be fully utilized with the existing gas key (46 or 600).

Replacing the gas key (46 or 600) with a different gas key 600 having different predetermined dimensions, can improve or maintain the cycle performance of the bolt carrier 102, while reducing the gas and debris expelled into the upper receiver 110 and into the shooter's face. Replacing the gas key (46 or 600) on the bolt carrier 102 is a simple matter of unscrewing the base 606 of the existing gas key (46 or 600) from the bolt carrier 102, and attaching the base 606 of the replacement gas key 600 to the bolt carrier 102. The fit of the various gas keys (46 or 600) is the same, since the gas keys (46 or 600) are interchangeable.

Referring to FIGS. 10 and 11, the interior diameter dimension “C” of the offset portion 612 can be enlarged on a novel key 600 to reduce the restriction to gas flow and increase the volume of gas traversing through the key 600 to the bolt carrier 102. Increasing the volume of gas traversing through the key 600 lowers the pressure of the traversing gas, while maintaining the cycling functionality. The interior diameter dimension “B” of the key body 604 can remain as in a stock configuration, or it can be adjusted up or down as desired to tune the volume and pressure of the gas traversing through the key 600.

Further, the diameter “A” of the extension 602 can also be enlarged to tune the volume and pressure of the gas traversing through the key 600, as well as to capture a greater volume of the debris being expelled from the gas tube 16 during a greater portion of the bolt 102 cycle. A greater volume of gas captured and/or moving through the key 600 can translate to a greater volume of gas that is functioning to cycle the action of the rifle 100, and a lesser volume of gas and debris that is available to be expelled into the upper receiver 110 and into the shooter's face. Accordingly, the interior diameter dimension “A” may be greater than the interior diameter dimension “B” or the interior diameter dimension “C”.

Various increments of the interior dimensions A, B, and C can be made when a gas key 600 is formed, so that gas keys 600 having any desired dimensions can be available. In other words, gas keys 600 with various combinations of different dimensions A, B, and C can be formed and used to tune bolt carriers 102, upper receivers 110, and rifles 100 as desired. Any and all gas keys 600 with the various dimension combinations can include extensions 602 of various lengths as well, providing fully customizable performance.

Although various implementations and examples are discussed herein, further implementations and examples may be possible by combining the features and elements of individual implementations and examples.

CONCLUSION

Although the implementations of the disclosure have been described in language specific to structural features and/or methodological acts, it is to be understood that the implementations are not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as representative forms of implementing the claims.