Handguard Assembly, Systems for Handguard Sleeve Attachments, and Related Firearms and Methods

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation application and claims priority under 35 U.S.C. § 120 to U.S. non-provisional Ser. No. 17/901,637 filed Sep. 1, 2022, which claims the benefit under 35 U.S. C. § 119(e) to U.S. Provisional Patent Application Ser. No. 63/240,109, filed Sep. 2, 2021, the entire disclosures of which eare incorporated herein by reference.

BACKGROUND OF THE INVENTION

Handguards, sometime called “forends” or “forearms” are devices to cover a forearm's barrel. As a primary matter the handguard serves a safety purpose, enabling the user to grip the front area of the gun during use without danger of burning his/her hand as the barrel heats up. In addition, the handguard may be used as a carrier for various other firearm accessories or secondary weapons which can be attached to the handguard, for example, bipods, tactical lights, laser sights, night-vision devices, foregrips/handstops, slings and the like.

In general, handguards are manufactured and sold to firearms users as accessories. As an accessory or “extra” it is desirable that the handguard does not add too much additional weight to the overall weight of the firearm. Therefore, lighter-weight handguards are preferred. Moreover, as an accessory, an individual user can periodically switch out his/her current handguard for a different type or model when and as he wishes. Thus, the ease with which a given handguard can be installed is also a significant selling point to the user.

BRIEF SUMMARY OF THE INVENTION

The invention as described herein includes a handguard assembly for attachment to an upper receiver of a firearm. Included in the invention is a barrel nut. The barrel nut extends from a first end to second end and has a convexly curving outer surface that defines an annular groove extending around at least a portion of the circumference of the barrel nut. The handguard sleeve has a first end and a second end.

The adapter is structured to be capable of mechanical attachment to the handguard sleeve at the handguard sleeve's first end and had a first end that has an internal diameter that is dimensioned so that the second end of the barrel nut is insertable into the first end of the adapter. The adapter further includes an adapter body comprising a wall having an outer surface and at least one wedge pocket is disposed on the outer surface of the adapter body wall, the wedge pocket comprising an upper portion and a lower portion, wherein the lower portion comprises a slot in the outer surface of the wall having a bottom in the adapter body, and the upper portion comprises an aperture defined by the adapter body wall.

Included also is at least one locking wedge having an upper section and a lower section, wherein the upper section is dimensioned to be insertable into and through the aperture of the upper portion of the wedge pocket and the lower section is dimensioned to be biased into the slot of the lower portion of the wedge pocket, and wherein the upper section bears an upper surface that includes a concavely curving surface and a center-placed tab extending from the upper surface, the tab being dimensioned to be insertable into the annular groove of the barrel nut and the concavely curving surface having a slope substantially the same as the slope of the convexly curving outer surface of the barrel nut so that when the tab is inserted into the annular groove of the barrel nut the concavely curving surface is positioned concentrically adjacent to the convexly curving outer surface of the barrel nut.

Also within the scope of the invention are related systems and methods of mounting the systems and/or the assemblies of the invention.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The foregoing summary, as well as the following detailed description of preferred embodiments of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there is shown in the drawings embodiments which are presently preferred. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. In the drawings:

FIG. 1 is perspective view of the handguard assembly of an embodiment of the invention;

FIG. 2 is an exploded view of an embodiment of the assembly of the invention including a barrel nut, two locking wedges, an adapter, a handguard sleeve body, rail and associated screws, and end cap;

FIG. 3 shows an exploded, top view of an embodiment of the invention assembled on a firearm;

FIG. 4 shows an exploded, side view of an embodiment of the invention assembled on a firearm;

FIG. 5A shows a first end elevational view of a barrel nut of an embodiment of the invention;

FIG. 5B shows a longitudinal cross-sectional view taken along line 5B-5B of FIG. 5A;

FIG. 5C shows a side elevational view of the barrel nut of FIG. 5A;

FIG. 5D shows a transverse cross-sectional view taken along line 5D-5D of the barrel nut of FIG. 5A;

FIG. 6A shows a front end elevational view of an adapter of the invention in an embodiment;

FIG. 6B shows an enlarged cross-sectional view taken along line 6B-6B of FIG. 6A;

FIG. 6C shows a side elevational view of FIG. 6A;

FIG. 6D shows a bottom elevational view of FIG. 6A;

FIG. 6E shows a rear elevational view of an adapter of adapter of FIG. 6A;

FIG. 6G shows a side elevational view on a side opposite that of FIG. 6C of the adapter of FIG. 6A;

FIG. 6H shows a cross-sectional view taken along line 6H-6H of FIG. 6G;

FIG. 6I shows a cross-sectional view taken along line 6I-6I of FIG. 6G;

FIG. 6J shows a cross-sectional view taken along 6J-6J of FIG. 6G;

FIG. 6K shows an enlarged portion designated as G of FIG. 6G;

FIG. 6L shows a further front elevational view of an adapter of FIG. 6A;

FIG. 6M shows a side elevational view taken along lines 6M-6M on FIG. 6L;

FIG. 6N shows a cross-sectional view taken along line 6N-6N of FIG. 6L;

FIG. 6O shows an enlarged view of a portion of FIG. 6G designated as 6O;

FIG. 7A shows a right hand side elevational view of a first locking wedge of FIGS. 9D and 9E of the invention;

FIG. 7B shows a top elevational view of the locking wedge of FIGS. 9D, 9E, and 7A;

FIG. 7C shows a side elevational view of a second threaded locking wedge for fastening in the opposite side of the barrel as demonstrated in FIG. 9C;

FIG. 7D shows a side elevational view of FIG. 7C on a side perpendicular to that of FIG. 7C;

FIG. 8A shows a right facing perspective view of the embodiment of a handguard sleeve (sleeve body and rail) as shown in FIG. 1;

FIG. 8B shows a side elevational view of the embodiment of the handguard sleeve of FIG. 8A having a countersunk locking wedge according to FIG. 7A;

FIG. 8C shows a top elevational view of the embodiment of the handguard sleeve of FIG. 8A;

FIG. 8D shows an end elevational view of the second end of the handguard sleeve of FIG. 8A;

FIG. 8E shows a left facing perspective view of the embodiment of the handguard sleeve of FIG. 8A;

FIG. 8F shows a side elevational view of the opposite side of FIG. 8D of the handguard sleeve of FIG. 8A;

FIG. 9A shows a firearm where a torque barrel nut is threaded onto a rifle upper receiver, and the gas block and muzzle device are replaced;

FIG. 9B shows the handguard assembly sliding over the barrel in the direction of the arrow shown, adapter end first, wherein the handguard adapter slides over the top of the barrel nut, with the anti-rotation tabs on either side of the upper receiver;

FIG. 9C shows the two locking wedges inserted in the direction of the respective arrow on either side of the adapter into the wedge pockets, so that the tabs on the locking wedges face inward and upward toward the barrel;

FIG. 9D is a closeup enlarged view of insertion of a locking wedge in FIG. 9C;

FIG. 9E shows passing the screw in the direction of the arrow, through the countersunk locking wedge of FIG. 9C on the right-hand side of the receiver and threading the screw into the threaded locking wedge on the left-hand side of the receiver where the torque is a specified value in the manual; and

FIG. 10 shows a portion of the adapter bearing a wedge pocket in an embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

The invention described herein includes a handguard assembly for use on a firearm, particularly an AR 15 platform sporting rifle, as well as related methods, such as methods of installing the assembly and the like. The assembly includes a barrel nut, a handguard sleeve, an adapter having at least one wedge pocket, and at least one corresponding locking wedge. Also included is a system for mounting a handguard sleeve to a firearm that includes a barrel nut, an adapter having at least one wedge pocket, and at least one corresponding locking wedge.

Firearms mounted with such assemblies or systems are contemplated as within the invention's scope, as are methods of attaching and/or mounting the assemblies or systems.

The assemblies of the invention are advantageous at least because they are lightweight, yet ridged and durable, and can be installed quickly and easily to the firearm by an average firearms user. The assemblies of the invention employ an attachment mechanism that is located within the handguard sleeve, not cluttering up the external surface of the sleeve. Moreover, unlike prior art assemblies, the attachment mechanism of the assemblies of the invention utilizes locking wedges (described herein, infra) that are designed to form an enduring lock so compression force alone is not relied upon for pullout strength, and a single screw is used, thereby substantially eliminating the possibility of installation bias.

For convenience, the assemblies are described herein in the context of a standard AR 15 platform firearm. However, they could also be employed with minimal and routine modifications on numerous other types of firearms, e.g., without limitation, firearms of the M-16 style, the AR-10 style, the M-4 style, various other hunting and sporting rifles, and sniper-type rifles.

Use of the reference to “one embodiment,” “an embodiment,” “some embodiments,” or similar as used herein in intended to mean that a particular described feature, structure, or characteristic may be included in at least one embodiment. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” or “in some embodiments” in various places throughout this specification do not necessarily all refer to the same embodiment. Furthermore, any of the described features, structures, and characteristics may be combined or omitted in any suitable manner in one or more embodiments “mix and match”style.

With reference to FIGS. 1 and 2 (a perspective view and an exploded view, respectively, of the handguard assembly of an embodiment of the invention), the invention includes a handguard assembly that can be used to attach a handguard to an upper receiver of a firearm. The handguard assembly 90 includes an attachment system 100 that is a subset of the assembly, as described further below.

The handguard assembly includes a barrel nut 106, an adapter 124, and a handguard sleeve 118, that itself may include a handguard body 168, rail 166, and end cap 160.

FIGS. 3 and 4 are embodiments of the assembly of the invention is shown assembled on a firearm 102. In FIG. 3, and 2, which is the exploded view of the handguard assembly, one can see the barrel nut 106 that has been threaded along the length of the firearm barrel 176, followed by the adapter 124 and the handguard sleeve 118 (which, in this view having been pre-attached). Flanking the assembly in the exploded view of FIG. 3 are a first locking wedge 136a and a second locking wedge 136b and corresponding mechanical fasteners 162, which in this embodiment is a screw, that is inserted through corresponding holes 179a, 179b (not shown in FIGS. 3 and 4; see FIG. 7) in the lower sections 140 of the locking wedges 136a and 136b.

Referencing FIGS. 1-4, in an embodiment, the barrel nut 106 includes a substantially cylindrical interior channel 184 and has a length dimension l₁ of 2.000 inches that extends from a first end 108 to a second end 110 of the barrel nut 106. An outer surface 112 has a convex curve 161 owing to the cylindrical structure of the barrel nut with a curve slope 178. The outer surface 112 of the barrel nut 106 defines annular groove 180 that is positioned substantially midway between the first end 108 and the second end 110 of the barrel nut 106. In various embodiments, the position of the annular groove may be varied to be closer or farther from the first end as desired.

The annular groove 180 may have dimensions adapted to pair with the dimensions of the particular adapter and/or locking wedges to which it is paired. As an illustration, in an embodiment of the invention, the annular groove 180 extends partially through the body wall 182 of the barrel nut 106; in some embodiments, it may extend all the way through. In an embodiment, the annular groove 180 as shown in FIGS. 5A-5D, extends longitudinally at a length l₂ of 0.653 inches from the first end 108 of the barrel nut 106 to length l₆ which is 0.928±0.001 inches from the first end 108 of the barrel nut 106. The inner diameter D₂ of the barrel nut is 1.055 inches in FIG. 5B. The outer diameter D₃ of the barrel nut at the annular groove measures 1.200 inches. In an embodiment the depth dimension of the annular groove (as measured from the outer surface 112 to the bottom of the groove) is about 20% to about 80% of the depth dimension of the barrel nut body wall 182, that is, for example without limitation, if the barrel nut body wall 182 is 1 centimeter thick, then the depth of the groove may be about 2 mm to about 8 mm.

In the practice of the assembly of the invention, the barrel nut 106 is attached to the upper receiver of a firearm as discussed above. Such attachment may include mechanical or chemical fastenings. In an embodiment of FIGS. 5A-5D, it may be preferred that the first end 108 of the barrel nut 106 includes a female threaded surface 116 that corresponds to a male threaded surface (not shown) present on the end of the upper receiver. The barrel nut can then be attached by engaging the two threaded surfaces. Other details of the barrel nut in a specific embodiment are shown in FIG. 5A-5D.

In FIG. 5B, the length l₄ of the barrel nut portion having the threaded surface is 0.550 inches. A depth of the thread l₅ is 0.450 inches.

In an embodiment of FIG. 5D, the inner diameter D₄ at the location of line 5D-5D is 1.150 inches. A taper of 0.03 inches at an angle α of 60° is shown at the outer surface 112 at the second end 110 of the barrel nut 106 shown in FIG. 5C.

A radius R₁ of the curve 161 of the surface 112 of the barrel nut 106 is 0.125 inches. A length l₈ of each curve 161 is 0.350 inches as shown in FIG. 5C and there are six curves. The curve has an angle β of 60° with the wall 112 as shown in FIG. 5D. The length l₉ represents a narrow outer diameter of the curve of 1.240 inches at three locations.

The flat area in the curve 161 is shown in FIG. 5C as 0.350 inches in length l₈, each of 6 curves which are positioned a length l₇, of 1.343 inches from the first end of the barrel nut. The length l₃ of the barrel nut in FIG. 5B at the location of the diameter D₂ is 0.950 inches.

The assembly further includes a handguard sleeve 118, with reference to FIGS. 1-4 and 8A to 8F, which in an embodiment may include a sleeve body 168, a rail 166, and an endcap 160. The handguard sleeve 118 extends from a first end 120 to a second end 122 and contains a channel 186 of a sufficient dimension to permit passage of the firearm's barrel and/or muzzle through the channel.

In the embodiment shown herein, the channel 186 is defined by the eight sidewalls 188a-h of the sleeve body 168 as shown in FIGS. 2 and 8D thereby providing a channel that is octagonal shaped when viewed in cross-section. In other embodiments, the channel may have a cross-section of any shape; however, it may be preferred that the cross-section is a shape that permits the handguard sleeve to present external flat outer sidewall surfaces (e.g., hexagonal heptagonal, square, triangular, etc.). This facilitates attachment to the sleeve of various firearm accessories or secondary weapons can be attached to the handguard, for example, bipods, tactical lights, laser sights, night-vision devices, foregrips/handstops, slings, and the like. In addition, in an embodiment, the sidewall(s) 188a-h of sleeve body 168 may include various cutouts 172 that may act as vents to permit ventilation, decorative elements, and/or to provide attachment points.

In an embodiment, the uppermost sidewall 188a of the sleeve body 168 is attached to a rail 166 which extends along a length of the sleeve body 168. The rail may be attached to the sleeve body via, for example, a series of screws 170, as is shown herein. Also, to the sleeve body 168, at its second end 122 may be attached an endcap 160.

The assembly further includes an adapter 124, with reference to FIGS. 1-4, 6A-6O, and 10. In an embodiment of FIG. 6A, the height h₁ of the adapter 124 is 2.213 inches. The upper end 129 of the adapter 124 has a curve with a radius R₂ of 0.188 inches. About 0.120 inches below the curve of the adapter 124 of FIG. 6A, there is a transversely extruding cut out 117 of length measured longitudinally of 0.063±0.002 inches. The distance l₁₉ from the upper end of the cut out 117 to the center c of the adapter 124 is 1.080±0.002 inches. The angle δ between a vertical side and an angled upper side of the outer surface 134 of the adapter 124 is 43°±1.0°.

The adapter 124 is structured to be mechanically attached to the handguard sleeve 118 at, preferably, or near the first end 120 of the sleeve 118. The adapter 124 is substantially cylindrical and includes a channel 190 extending from a first end 126 to a second end 128 and defined by an adapter body 132. At the first end 126 the channel 190 has an interior diameter dimension that is sized so that the second end 110 of the barrel nut 106 is at least partially insertable into the second end 128 of the adapter 124. Thus, when assembled, the end 126 of the adapter is slid overtop of the barrel nut so that the upper portion 144 of the wedge pocket 142 (described below) of the adapter directly overlays the annular channel 184 of barrel nut 106.

In an embodiment, the adapter further includes an adapter body that has a wall 192 with an outer surface 134. At least one wedge pocket 142 is disposed on the outer surface 134 of the adapter body 132. In the embodiment of FIG. 6C, the adapter 124 has a length l₆ of 1.708±0.010 inches from the first end 126 to the second end 128. A width w₁ of the lower end 130 of the adapter 124 is 0.800 inches.

In the embodiment of FIG. 6C there is a series of holes that appear on both sides of the adapter body as in FIG. 2, and 6C, 6D, 6G, 6N, and 6O. There are a total of 12 holes in the adapter. FIG. 6C shows on the outer surface 134 of the adapter body 132, four holes 176a, two on either side of the outer surface 134, each with a diameter of 0.129 inches. A first hole is positioned in FIG. 6C, so that it is a length l₁₃ of 0.427 inches from the side 126 of the adapter 124. The second hole is a length l₁₂ of 1.218 inches from side 126 of adapter 124.

These two holes are on either side of the adapter body. A second set of eight holes 176b on the outer surface 134 of the adapter body 132 are also on either side of the adapter body and each has a size of 0.129 inches in diameter. The first hole has a length l₂₃ to the first end 126 of the adapter 124. A second hole is a length l₂₂ of 1.448 inches from the first end 126 of the adapter 124.

The wedge pocket 142 includes an upper portion 144 and a lower portion 146. The upper portion 144 includes an aperture 150 that is defined by the adapter body wall 192 and shaped to receive an upper section 138 of a locking wedge 136, described below.

In an embodiment, the adapter of FIG. 1-3, FIG. 6D, and FIG. 10, as shown has a gap 143 that is a width w₄ of 0.063 inches and two projections 153 which are a distance w₅ of 0.675 inches apart on end 126 of the adapter. In the embodiment of FIGS. 1-10, the adapter includes two wedge pockets 142 disposed on opposite sides of the adapter.

The lower portion 146 of the wedge pocket includes a slot 148 in the outer surface of the adapter body wall 192. The slot 148, which as shown in FIG. 6C has a diameter of 0.177 inches, is shaped to receive the lower section 140 of the locking wedge 136 as described below. As in FIG. 6C, the lower end of the first end 126 of the adapter has a taper, t₁, of 0.125 inches in length at an angle of 45°. The slot 148 is distance l₁₄, 0.808 inches, from the first end 126 of the adapter 124. The slot 148 is longitudinal in length l₁₅ from the center of the holes 176a of 0.775 inches and a distance l₁₄ of 0.808 inches in length from the first end 126 of the adapter body 124.

In an embodiment of FIGS. 1, 2, 6A, 6B, 6C, 6E and 6G, the adapter 124 includes a portion of a rail on the upper end 129 of the adapter 124 which has a width w₂ of 0.132±0.008 inches. The top of the portion of the rail that is on top of the adapter 124, is a distance l₁₁ from the center of the adapter. The distance of l₁₁ in FIG. 6A is 1.300±0.10 inches. Further, the length l₁₆ from the center of the holes 176a to the top of the rail on the adapter is 1.213 inches. In the first end 126 in FIG. 6E, the length l₂₁ from the upper end 129 of the adapter 124 to the center c of the adapter 124 is 1.213 inches±0.002 inches.

In the embodiment of FIG. 6D the lower end 130 of the adapter 124, the adapter 124 has a width w₃ of 1.596±0.002 inches. The pins 153 are on the adapter 124 on the first end 126 thereof a distance w₅ of 0.675 inches apart from one another. The projections 153 of FIG. 6D have a curvature radius R₃ of 0.063°. Each extend 0.10 inches from the first end 126 of the adapter. The adapter pins 153 are 0.125 inches in width w₆. The distance 117 of the pin from the top end 129 is 0.616 inches.

In an embodiment, the adapter includes at least two wedge pockets. Preferably, each wedge pocket is spaced apart a distance from the other. In an embodiment, the adapter includes two wedge pockets disposed on opposite sides of the adapter. In the embodiment, it may be preferred that each of the wedge pockets is positioned on the adapter to be disposed at the center of the bore when assembled on the firearm.

With reference to FIG. 7, the assembly further includes one or more locking wedge(s) that correspond to the wedge pocket(s). As shown in FIGS. 6C, 6D, 6G, 6K, and 10 the wedge pocket has a side wall 189, a bottom surface of a lower portion of the wedge pocket 191, and a bottom edge defining an aperture 193. The locking wedge 136 includes an upper section 138 a lower section 140. In FIG. 3, of the embodiment is shown with a first locking wedge 136a and a second locking wedge 136b and corresponding mechanical fasteners 162, shown as screws, which insert in a corresponding hole (shown in FIG. 9E) in a lower section 140 of each locking wedge 136. The upper section 138 is dimensioned to be insertable into and through the aperture 150 of the upper portion 144 of the corresponding wedge pocket 142. The locking wedge has a recessed hole 179a as shown with a diameter of 0.177 inches. The wedge 136 also has a hole 179b with a diameter of 0.136 inches on an opposite side. In the embodiment of FIGS. 7A-7D, the distance 120 between the upper section 138 of the wedge and the center hole 179a, 179b of the wedge 142 is 0.245 inches. The holes receive a fastener 162 shown as threaded.

As shown in FIG. 7D, the upper portion 154 of the locking wedge 136 has a concavely curving upper surface 152 with a radius R₆ of 0.680 inches. The concave curve of the upper surface 152 has a curve slope that corresponds to the curve slope of the convex curve of the outer surface of the barrel nut. Thus, in practice when the locking wedge 136 is inserted in the wedge pocket 142, the locking wedge upper surface 152 is nested concentrically against the outer surface 112 of the barrel nut 106.

In the embodiment of the invention shown herein, the upper surface 152 of the upper section 138 of the locking wedge 136 further includes a tab 154 that extends from the upper surface. In an embodiment, it may be preferred that the tab is center-placed, i.e., that it is disposed approximately equidistantly between the lateral edges 194a, 194b, with a width w₆ of 0.750 inches of the locking wedge 136. When this embodiment is assembled the locking wedge is fitted into the wedge pocket so that the tab is engaged within the annular channel of the barrel nut and, as above, the locking wedge upper surface 152 is nested concentrically against the outer surface 112 of the barrel nut 106.

The invention further includes a system for mounting a handguard sleeve to a firearm that includes at minimum, a barrel nut and an adapter, each as described herein.

Firearms bearing either the system or the assembly of the invention, each as described herein are further contemplated within the scope of the invention.

Also included are methods of mounting or assembling the system or assembly onto a firearm. With reference to FIGS. 9A-9D, the method in an embodiment includes obtaining a firearm, such as for example without limitation, forearms of an AR 15 style, an M-16 style, an AR-10 style, an M-4 style, a hunting rifle, a sporting rifles, and a sniper-type rifle.

The firearm is disassembled to expose the male threaded portion of the upper receiver. The bore is then passed through the interior channel of the barrel nut and the female threaded surface of the barrel nut is engaged with the male threaded surface of the upper receiver. The disassembled portions of the firearm are reattached (e.g., gas block, muzzle device).

Separately, the adapter at its second end is fitted to the first end of the handguard sleeve. Such fitting may occur by use of fasteners (e.g., screws), corresponding threaded surfaces or otherwise mechanically engaging surfaces, or chemical adherents (e.g., epoxy).

The adapter-sleeve part is then slid over the barrel of the firearm adapter end first. The first end of the adapter slides overtop the outer surface of the barrel nut with the anti rotation tabs on either side of the upper receiver. The locking wedges are then inserted into the wedge pockets of the adapter, with the tabs of the locking wedges facing inward and upwards towards the barrel. The upper section of the locking wedge is inserted in the wedge pocket so that the at least a portion of it is passed through the aperture of the adapter pocket and it tabs engage with the annular channel of the barrel nut and its at least a portion of its concave surfaces are substantially in contact with at least a portion of the corresponding outer, convexly curving surface of the barrel nut. If desired, the countersunk locking wedges can be secured by passing a screw through the first locking wedge and into the second locking wedge.

In view of the disclosure herein, those skilled in the art will recognize that the various embodiments can be practiced without one or more of the specific details or with other methods, components, materials, or the like. In some instances, well-known structures, materials, or operations are not shown or not described in detail to avoid obscuring aspects of the embodiments.

It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims.