Holster With Muzzle End Cap

Description

BACKGROUND AND SUMMARY OF THE INVENTION

This invention relates to a holster, and specifically to a holster for a weapon such as a handgun or an electrical discharge weapon. Such weapons come in various different sizes and shapes. A holster must be configured to closely accommodate the weapon, for various reasons including limiting movement and enabling locking features. In addition, the holster must be configured to closely accommodate a light that might be mounted on the weapon, typically at a location under the barrel.

A typical holster body is designed as two pieces or halves, left and right side (or body side and face side), that are joined together to form the holster body. The holster body as thus formed has an end portion that encloses and protects the muzzle, the front sight if present, and the front end of the light if one is present. The holster body end portion also provides a muzzle stop or forward stop for the muzzle end of the weapon.

Some weapon brands/models are available with different muzzle (barrel) lengths. In addition, different length lights may be available for any one weapon with a given muzzle length. There is a need to accommodate all these variations and combinations in the holster, for weapons with and without lights. Making a different holster body for each such variation or combination is not feasible. A result may be that a user obtains a holster that does not properly accommodate their weapon while keeping it securely contained.

To address this problem, the present invention provides a holster with a muzzle end cap that is formed separately from the remainder of the holster body. The muzzle end cap is customized when formed in order to accommodate a specific weapon, or weapon/light combination. The length and configuration of the muzzle end cap are selected to accommodate the length and configuration of the weapon's muzzle, and also of the light if one is mounted on the weapon. As a result, both the weapon and any included light are securely contained in the holster, against rattling, securely protected. Also, a properly positioned forward stop is provided for the recoil rod.

Providing the muzzle end cap as a different piece from the holster body produces numerous advantageous results. This modular design allows the holster to be of minimal size and volume (i.e., size specific) for the length of the weapon. Specifically, the holster body itself is typically designed for a particular weapon type or family, for example a Glock. But weapons within one family can vary in muzzle length. As such, any one holster for a particular weapon type or family would need to be long enough accommodate the longest model, in which case it would be too long for a smaller model. Then, the holster is oversized, which is not desirable from a functional point of view as there would be no reachable forward stop for the recoil rod. Also, this is not desirable because the user typically wants the smallest possible holster for their weapon.

In addition, many weapons are adapted to carry a light, and these lights are of different lengths that can be selected by the user. A holster in accordance with the present invention, having the changeable (modular) muzzle end cap, can fit various sizes of weapons, with and without a selected light, with the same holster body.

A manufacturer can make a unique muzzle end cap for each specific combination of muzzle length and light, while using the same holster body. When that is done, the user has the smallest package holster that will fit whatever weapon(s) they are purchasing. There is no need for the holster manufacturer to make an entirely different holster for each combination. The manufacturer can easily create and implement customer specific design requests such as additional weapon fits (length); out of the ordinary light model lengths; closed bezel and/or muzzle openings; or the addition of a barrel plug.

The muzzle end cap also provides the forward stop for the weapon. When the weapon is being inserted into the holster (holstered), it is important to provide a hard point that stops that movement. That forward stop must be positioned correctly.

In the illustrated embodiment, this forward stop is a cross-bar on the interior of the muzzle end cap. The cross-bar is a strong, integral part of the muzzle end cap, which is securely held on the holster body. In typical prior art two piece holsters, a separate muzzle stop element must be added inside the assembled end wall of the holster; this construction is not as strong. Being able to customize the modular end cap provides the ability to always have a properly positioned forward stop, regardless of muzzle length. The holster surrounds the weapon keeping it in place; however, the forward stop determines how far into the holster the weapon travels before it settles. The weapon while being holstered should travel far enough to activate any locking mechanism in the holster, but not so far that the gun jumps around as the user walks.

As described above, the muzzle end cap is easily installed. In some embodiments, it may require special tools to remove the muzzle end cap it from the holster body. This would prevent accidental removal or dislodgement of the muzzle end cap.

The one piece design of the muzzle end cap provides increased strength and robustness to the overall holster design. Specifically, when installed, the muzzle end cap can serve to clamp two holster body halves together at the front end. This can allow for a reduction in the amount of hardware (fasteners, such as external fasteners) needed to hold the two holster halves together, further reducing the overall footprint, weight and volume of the holster.

One or more optional openings in the muzzle end cap allow for debris, spent shell casings, and liquids to easily pass through the holster, reducing the likelihood of such substances interfering with the proper operation of the holster. Again, these can be customized to the user's preference and needs.

The custom cap easily slides onto the holster body, holds the two holster body pieces together, and allows the manufacturer to fit many different weapons (and lights) into one holster.

In some embodiments, internal surfaces on the muzzle end cap may engage the gun and/or light to hold them and prevent them from rattling around in the holster.

In another aspect, the invention enables and is embodied in an improved manufacturing process. One step is identifying the weapon make/model for which a holster is to be provided. Another step is selecting the appropriate holster body for the weapon. Another step is determining the length of the muzzle and needed position for the forward stop. Another step is determining the dimensions of the light to be used, if any. Another step is includes determining the configuration of the end cap needed. Another step is manufacturing the needed end cap. Another step is assembling the end cap to the holster body.

Thus, there may be provided a holster for a weapon that has a muzzle with a muzzle opening, the weapon having a forward end surface, the holster comprising a holster body substantially enclosing the weapon when the weapon is holstered, the holster body having a back portion defining an entranceway of the holster for holstering the weapon, the holster body having a cap support portion at its forward end opposite the entranceway, and a muzzle end cap formed separately from the holster body and secured on the cap support portion of the holster body during assembly of the holster in a position surrounding the cap support portion, the muzzle end cap having an inside surface that forms a forward stop for engagement by the forward end surface of the weapon when holstering the weapon.

There may be provided a holster as set forth above wherein the holster body is made from a first holster body half and a second holster body half that are joined along a seam to form the holster body, the cap support portion of the holster body comprises projecting portions of the respective holster body halves, and the muzzle end cap fits over the projecting portions of the holster body halves and clamps them together.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be embodied in various ways. Some are described below.

Others are apparent to one of ordinary skill in the art. Further features of the invention will become apparent to one of ordinary skill in the art to which the invention pertains, from a reading of the following specification together with the accompanying drawings, in which:

FIG. 1 is a face side perspective view of a holster that is a first embodiment of the invention, shown with an attached holster mount in the form of a belt loop, and including a muzzle end cap assembled on the holster body;

FIG. 2 is a view similar to FIG. 1 but showing the muzzle end cap prior to assembly with the holster body;

FIG. 3 is a view similar to FIG. 2 from the opposite perspective;

FIG. 4 is a face side elevational view of the holster of FIG. 1, showing the muzzle end cap assembled on the holster body;

FIG. 5 is a perspective view of the muzzle end cap alone;

FIG. 6 is an opposite perspective view of the muzzle end cap alone;

FIG. 7 is a longitudinal sectional view of the holster of FIG. 1 with a weapon and light therein;

FIG. 8 is a transverse sectional view taken along line 8-8 of FIG. 7;

FIG. 9 is a transverse sectional view taken along line 9-9 of FIG. 7;

FIG. 10 is a face side perspective view of a holster that is a second embodiment of the invention, with a second, different, muzzle end cap assembled on the holster body;

FIG. 11 is a view of the holster of FIG. 11 showing the muzzle end cap prior to assembly with the holster body;

FIG. 12 is a face side perspective view of a holster that is a third embodiment of the invention, with a third, different, muzzle end cap assembled on the holster body;

FIG. 13 is a view of the holster of FIG. 12 showing the muzzle end cap prior to assembly with the holster body;

FIG. 14 is a face side perspective view of a holster that is a fourth embodiment of the invention, with a fourth, different, muzzle end cap assembled on the holster body;

FIG. 15 is a view of the holster of FIG. 14 showing the muzzle end cap prior to assembly with the holster body; and

FIG. 16 is a flow chart illustrating a method of manufacturing a holster in accordance with the invention.

DESCRIPTION OF EMBODIMENTS

The present invention relates to a holster for a weapon such as a handgun. The invention is applicable to holsters of different and varying configurations and uses. The illustrated embodiments are only representative of some of these constructions. As representative of the invention, FIGS. 1-9 illustrate a holster 10 that is a first embodiment of the invention.

The holster 10 includes a holster body 12. The holster 10 also includes a muzzle end cap 40 that is separate from but attached to the holster body 12, and that forms a significant part of the completed holster.

The holster body 12 defines a main body chamber 14 for receiving the weapon (in this first embodiment, a Glock 19 is illustrated), shown schematically at 16. The weapon 16 has an attached light, in this case a TLR-7 light, shown schematically at 17.

The holster body 12 is made from two pieces 20 and 22, or halves, which abut along a laterally central seam or joining line 24. (The term “halves” is used descriptively, as the two pieces 20 and 22 are not exactly 50% each of the holster body 12. Also, the invention is applicable to a holster body 12 that is one piece.) There may be some overlap, not described herein in detail.

In assembly of the second piece 22 with the first piece 20 (FIGS. 4 and 5), the two pieces are moved together laterally toward and into engagement with each other, as in FIG. 5. The two pieces 20 and 22 substantially form the chamber 14 for receiving the weapon 16 in a holstered position in the chamber 14. An open entranceway 26 is formed at a first longitudinal end 30 of the holster (to the left as viewed in FIG. 7) for holstering the weapon 16. The muzzle 19 of the weapon 16 when holstered is at the second longitudinal end 32 of the holster.

The holster 10 includes several elements for securing the two pieces 20 and 22 together. One of them, the muzzle end cap 40, is described herein in detail. The muzzle end cap 40 is located at the front end 32 of the holster 10, which is the lower end typically when the holster is being worn by a user with grip upwards. In the drawings, this is illustrated at the right for example as viewed in FIGS. 1 and 2.

The muzzle end cap 40 is a separate member or element that is positioned on the holster body 12 and that closes the front end of the chamber 14. That is, the muzzle end cap 40 is a separate member or element that is positioned on the two holster body pieces 20 and 22. The particular muzzle end cap 40 that is illustrated in FIGS. 1-9 is configured for use with the particular weapon/light combination 16/17 which is illustrated in those Figures. As described below in detail, and in accordance with the invention, other, different, muzzle end caps are and can be provided by the invention, for use with other weapon/light combinations having different dimensions and/or configurations.

For receiving and supporting the muzzle end cap 40, the holster body 12 has a cap support portion 60. The cap support portion 60 of the holster body 12 is formed as a projecting portion, or forward end portion, of the holster body. In the embodiment illustrated in FIGS. 1-9, since the holster body 12 is made of two pieces 20 and 22, the cap support portion 60 comprises two projecting portions 62 and 64 of the two holster body pieces, respectively. These projecting portions 62 and 64 engage each other in an abutting relationship at the seam 24.

The cap support portion 60 is sleeve shaped, and has a hollow interior space 65 that is an extension of, or part of, the main weapon chamber 14. As illustrated, and typical though not essential, the cap support portion 60 has a relatively large vertical extent to accommodate both the muzzle 19 and the light 18 below the muzzle, and a relatively smaller lateral extent. In this aspect, other muzzle end caps can be configured differently, of course.

The cap support portion 60 of the holster body 12 includes a top wall 66, an inner side wall 68, an outer side wall 70, and a bottom wall 72. The top wall 66 and the bottom wall 72 are formed as adjoining parts of the inner and outer holster body pieces 20 and 22, respectively. The inner side wall 68 of the cap support portion 60 is formed as a part of the inner holster body piece 20. The outer side wall 70 of the cap support portion 60 is formed as a part of the outer holster body piece 22. The four walls together form the cap support portion 60 of the holster body 12, and encircle and define the cap support portion chamber 65.

The cap support portion 60 has a cap engagement surface 74 on its exterior. The cap engagement surface 74 is formed on the four walls 66-72 of the cap support portion 60 of the holster body 12. In the illustrated embodiment, the cap engagement surface 74 is recessed inwardly on all sides from the outer surface 76 of the remainder of the holster body 12 that is directly behind the cap support portion 60. The dimension (depth) of this recess is selected so the outer surface of the muzzle end cap 40, when the muzzle end cap is installed on the cap support portion 60, is flush with the outer surface 76 of the holster body 12. This recess is optional, and in other embodiments, may be varied or may not be provided.

The cap support portion 60 of the holster body 12 supports and locks in place the muzzle end cap 40. For that purpose, the cap support portion 60 of the holster body 12 includes four locking tabs 80. Two locking tabs 80 are disposed on the inner side wall 68, on the cap engagement surface 64. Two locking tabs 80 are disposed on the opposite outer side wall 70, on the cap engagement surface 74.

In addition, the cap support portion 60 has a fastener receiving portion as shown at 82. In this embodiment, the fastener receiving portion 82 includes a recess with therein a T-nut that is secured in the inner side wall of the cap support portion 60 of the holster body 12.

The muzzle end cap 40 is preferably molded from one piece of plastic material, which may be the same material that forms the holster body 12. The muzzle end cap 40 has a shape that is complementary to the shape of the cap support portion 60 of the holster body 12. The muzzle end cap 40 is adapted and configured to fit closely over the cap support portion 60 of the holster body 12.

The dimensions of the muzzle end cap 40, including the front to back length of the muzzle end cap, are selected to fit the particular weapon/light that is being holstered. As described below with respect to other embodiments, a weapon with a longer muzzle and/or longer light may require a longer muzzle end cap 40, while a weapon with a shorter muzzle and/or shorter light may require a shorter muzzle end cap 40, for example, as well as other possible changes.

The muzzle end cap 40 has a side wall 90 that fits closely over the cap support portion 60 of the holster body 12, and also has an outer end wall 92. The side wall 90 in this embodiment can be said to include an overlap portion 94 that overlaps (overlies) and is secured to the cap support portion 60 of the holster body 12; and, in at least some embodiments, an overhang portion 95 that extends outward from the overlap portion, away from the cap support portion 60. In the first embodiment illustrated in FIGS. 1-9, the overhang portion 95 is very short. A longer overhang portion might be provided for use with a weapon having a relatively longer muzzle or light, for example. Such an embodiment is illustrated and described below.

The overlap portion 94 of the side wall 92 of the muzzle end cap 40 has locking slots 96 for receiving the locking tabs 80 of the cap support portion 60 of the holster body 12. As a result, the muzzle end cap 40 is configured and positioned to interlock with the holster body 12 when assembled as described below. In this embodiment the overlap portion 94 of the side wall 92 of the muzzle end cap 40 also has a fastener opening 98 for receiving therethrough a fastener that can be secured in the T-nut 82.

The end wall 92 of the muzzle end cap 40 may include one or more optional openings, for example in the embodiment illustrated herein. The invention is applicable also to muzzle end caps that do not include openings. The size and placement of the opening(s) can vary, depending on the particular weapon/light combination that is being holstered, and on the user's preferences. In this exemplary embodiment, one such opening 100 is aligned with the muzzle 19 of the weapon, the other opening 102 with the light 18.

The muzzle opening 100 can allow for the use of a threaded barrel, and a compensator, that could project outward past the slide of the weapon. The openings 100 and 102 can allow water and debris to exit from the holster. The openings 100 and 102 can also allow stray shell casings to exit from the holster 10 before reholstering the weapon. The end wall 92 can be solid (closed) if that is the user's preference.

The muzzle end cap 40 has a portion that forms a muzzle stop or forward stop for the weapon 16. In this embodiment, that portion is a cross bar 106 that is molded integrally with the muzzle end cap 40. This cross bar 106 is positioned to be engaged by a forward end portion of the weapon 16, for example the outer end of the recoil rod of a semiautomatic handgun. The muzzle stop 106 acts to stop forward or downward movement of the weapon 16 in the holster, which is an important function. For receiving the cross bar 106, the cap support portion 60 of the holster body 12 has two notches 108, best seen in FIG. 9.

The holster 10 is configured optionally for use with a holster mount-that is, a device that will mount the holster on a surface or device, such as a user's belt, a user's vest, a car, etc. The particular mount that is shown in the embodiment illustrated in FIGS. 1-9 is a belt mount (belt loop) 110. This particular piece available commercially as the Safariland brand CUBL Cantable Belt Loop. The invention is not limited to the use of a belt loop as the mount. Other types of mounts are usable. For example, a Safariland brand QLS system mount can be used as the mount; and there are many others that are known.

The belt loop 110 has three fastener openings 112, 114, and 116 for use in securing the holster 10 to the belt loop 110. Three fasteners in the form of externally threaded bolts 118, 120, and 122 are provided, capable of threadedly engaging T-nuts in the holster body 12. One of these T-nuts 82, as described above, is located in the cap support portion 60 of the holster body 12.

In assembly of the holster 10, the muzzle end cap 40 is installed on the holster body 12 after the two holster body pieces 20 and 22 are placed adjacent to each other. Specifically, the muzzle end cap 40 is moved from a position off the holster body 12, as shown in FIG. 12, to a position on the cap support portion 60 of the holster body as shown in FIG. 1.

The overlap portion 94 of the muzzle end cap 40 slides onto the cap engagement surface 74 of the cap support portion 60 of the holster body 12. The cross bar 106 on the muzzle end cap 40 engages in the notches 108 in the cap support portion 60 of the holster body 12. As this movement occurs, the locking tabs 80 on the holster body 12 pivot back, then pivot into and engage in the locking slots 96 of the muzzle end cap 40. This engagement holds the muzzle end cap 40 on the holster body 12.

In addition, the fastener opening 98 in the side wall of the muzzle end cap 40 comes into a position overlying the fastener receiving portion 82 of the holster body 12. When the muzzle end cap 40 is thus in place on the holster body 12, the fastener 118 at the bottom of the belt loop 110 can be inserted through a through hole in the belt loop, and through the fastener opening 98 in the muzzle end cap 40, and threaded into the T-nut 82 in the holster body 12. This engagement helps to secure the muzzle end cap 40 on the holster body 12 while simultaneously securing the belt loop 110 on the holster body.

The mount 110 and fastener 118 are optional for securing the muzzle end cap 40 on the holster body 12. As well, the particular configuration and placement of the locking tabs and openings may be changed. This is only one way among known ways, of securing together the holster body pieces 20 and 22. The combination of this fastener together with the locking tabs provides a very strong connection for the muzzle end cap 40 onto the holster body 12. The parts will not come apart in ordinary usage of the holster. The muzzle end cap 40 can be removed only with one or more special tools that are used to, for example, disengage the locking tabs. This connection also helps to hold the two holster body pieces 20 and 22 together, as described further below.

Because the muzzle end cap 40 is a different piece from the holster body 12, the dimensions and configuration of the muzzle end cap 40 are selected to fit the particular weapon and/or light that is being holstered. The muzzle end cap needs to cover both the end of the muzzle and also the end of the light if a light is present. A weapon with a longer muzzle may require a relatively longer muzzle end cap, while a weapon with a shorter muzzle may call for a relatively shorter muzzle end cap. Similarly, a weapon with a longer light may require a longer muzzle end cap, while a weapon with a shorter light may call for require a shorter muzzle end cap. These differences are apparent in a comparison of the muzzle end cap 40 and weapon that are shown in FIGS. 1-9 with the embodiments that are shown in FIGS. 10-15 and described below.

In a second embodiment, FIGS. 10-11 illustrate a longer Glock 17 handgun 130 that is paired with the same TLR-7 light 17 as in the first embodiment. It is apparent that the muzzle of the weapon 130 projects farther forward. Thus, the muzzle end cap 40a illustrated in this embodiment has an overhang portion that is longer, especially in its upper portion. The side walls and the end wall are configured differently to accommodate the longer muzzle.

In a third embodiment, FIGS. 12-13 illustrate the shorter Glock 19 handgun 16 paired with a longer TLR-1 light 132. It is apparent that the end of the light 132 projects farther forward. Thus, the muzzle end cap 40b illustrated in this embodiment has an overhang portion that is longer, especially in its lower portion. The side walls and the end wall are configured differently to accommodate the longer muzzle.

In a fourth embodiment, FIGS. 14-15 illustrate the longer Glock 17 handgun 130 with the larger TLR-7 light 132. It is apparent that both the muzzle of the weapon 130 and the forward end of the light 132 project farther forward. Thus, the muzzle end cap 40c illustrated in this embodiment has an overhang portion that is longer. The side walls and the end wall are configured differently to accommodate the longer muzzle.

In this embodiment or any other embodiment, the muzzle end cap may easily be configured so that internal surfaces on the muzzle end cap engage the gun and light to hold them and prevent them from rattling around in the holster.

It can be seen that providing the muzzle end cap as a different piece from the holster body produces numerous advantageous results. This modular design allows the holster to be of minimal size and volume (i.e., size specific) for the length of the weapon. Specifically, the holster body itself is typically designed for a particular weapon type or family, for example a Glock. But weapons within one family can vary in muzzle length. As one example, a Glock 17 has a relatively long muzzle, while a Glock 19 with a similar body has a shorter muzzle. Thus, a holster body that is long enough to accommodate a Glock 19, for example, may not accommodate a Glock 17.

As such, any one holster for a particular weapon type or family would need to be long enough accommodate the longest model, in which case it would be too long for a smaller model. Then, the holster is oversized, which is not desirable from a functional point of view as there would be no reachable forward stop for the weapon, e.g., the recoil rod. Also, this is not desirable because the user typically wants the smallest possible holster for their weapon.

In addition, many weapons are adapted to carry a light, and these lights are of different lengths that can be selected by the user.

A holster in accordance with the present invention, having the changeable (modular) muzzle end cap, can fit various sizes of weapons, with and without a selected light, by using the same holster body.

A manufacturer can make a unique muzzle end cap for each specific combination of muzzle length and light, while using the same holster body. When that is done, the user has the smallest package holster that will fit whatever weapon(s) they are purchasing. There is no need for the holster manufacturer to make an entirely different holster for each combination. The manufacturer can easily create and implement customer specific design requests such as additional weapon fits (length); out of the ordinary light model lengths; closed bezel and/or muzzle openings; or, the addition of a barrel plug. This increases manufacturing efficiency and can lower customer cost.

The muzzle end cap also provides the forward stop for the weapon. When the weapon is being inserted into the holster (that is, when the weapon is being holstered), it is desirable and important to provide a hard point that stops that movement. If the outer end portion of the recoil rod of a semi-automatic weapon is selected as the part of the weapon to engage the holster in this manner, then the forward stop that it engages must be positioned correctly. In the illustrated embodiment, this forward stop is the cross-bar on the interior of the muzzle end cap. The cross-bar is a strong, integral part of the muzzle end cap, which is securely held on the holster body. lin typical prior art two piece holsters, a separate muzzle stop element must be added inside the assembled end wall of the holster; this construction is not as strong and durable. Being able to customize the modular end cap provides the ability to always have a properly positioned forward stop, regardless of muzzle length.

As described above, the muzzle end cap is easily installed. In the illustrated embodiment, though, it requires special tools to remove the muzzle end cap it from the holster body, as the locking tabs are one way. This prevents accidental removal or dislodgement of the muzzle end cap.

The one piece design of the muzzle end cap provides increased strength and robustness to the overall holster design. Specifically, when installed, the muzzle end cap clamps the two holster body halves together at the front end. This feature can allow for a reduction in the amount of hardware (fasteners, such as external fasteners) needed to hold the two holster halves together, further reducing the overall footprint, weight and volume of the holster.

The openings in the muzzle end cap allow for debris, spent shell casings, and liquids to easily pass through the holster, reducing the likelihood of such substances interfering with the proper operation of the holster.

The custom cap easily slides onto the holster body, holds the two holster body pieces together, and allows the manufacturer to fit many different weapons (and lights) into one holster.

In another aspect, the invention thus enables and is embodied in an improved and advantageous manufacturing process. FIG. 16 is a flow chart illustrating one possible manufacturing process in accordance with the present invention.

At 201, the process includes the step of identifying the weapon make/model for which a holster is to be provided.

At 202, the process includes the step of selecting the appropriate holster body for the weapon.

At 203, the process includes determining the length of the muzzle and needed position for the forward stop.

At 204, the process includes determining the dimensions of the light to be used, if any.

At 205, the process includes determining the configuration of the end cap needed.

At 206, the process includes manufacturing the needed end cap.

At 207, the process includes assembling the end cap to the holster body.