FIREARM STOCK WITH ACCESSORY RAIL MOUNTING SYSTEM

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of priority to U.S. Provisional Application No. 63/727,334 filed Dec. 3, 2024, which is incorporated herein by reference in its entirety.

BACKGROUND

The present invention generally relates to firearms, and more particularly to panel inserts of various configurations with accessory rails for synthetic stocks used in long guns such as rifles, carbines, and shotguns.

Traditional wooden stocks provided for long guns have elongated and generally smoothly contoured/profiled stocks comprising a rear buttstock for bracing against a shooter's shoulder and a forestock which supports the receiver. Some stocks formed of synthetic polymeric materials such as nylon reinforced plastics or others replicate the smooth contouring and profiles of the traditional wooden stock, but provide enhanced durability and weather resistance in addition to weight reduction. In contrast to AR type long guns having an industrial, military type appearance, many users favor the aesthetics of the smoothly contoured traditional stocks whether made of wood or synthetics.

Numerous firearm accessories are available to the user today to customize and augment the firearm to their needs. This includes items such as flashlights, bipods/tripods, laser sighting systems, grips, and others. To accommodate such accessories, some long guns such as AR type rifles allow the user to readily mount sections of accessory rails of various styles via screws to the metallic handguard or other parts of the firearm chassis to which the accessories can be detachably mounted. Such is not the case for more traditional long guns with smoothly contoured traditional stocks.

There are also numerous commercially-available rail system designs having different mounting interfaces for coupling accessories to the firearm (e.g., Picatinny rails, dovetail rails including ARCA type rails, Weaver rails, M-LOK® rails, etc.). Users generally have specific preferences for which type of rail system they favor for mounting accessories. Accordingly, versatility to employ different types of rail systems is desirable.

A need exists for a user interchangeable accessory rail system for long guns having traditional smoothly contoured synthetic stocks which do not substantially detract from the appearance of the firearm but enables the user to mount various accessories to the firearm.

SUMMARY

The present disclosure provides an accessory rail mounting system usable with firearms such as long guns (e.g., rifles, carbines, or shotguns) having a more traditional appearance with relatively smoothly contoured and curved stocks formed of synthetic materials such as plastic, fiberglass, and carbon fiber. In one embodiment, the stock may be plastic. The stock includes a rear buttstock configured for bracing against the user's shoulder when shooting, and a forestock extending forward therefrom for mounting the receiver and barrel. The forestock may be substantially hollow in some preferred embodiments for weight reduction with an internal lateral bracing structure to add strength and stiffness for handling and enduring repeated firing of the firearm since the forestock provides the bedding for the barrel. In other less preferred but acceptable embodiments, the forestock may have a solid body.

In one non-limiting embodiment, the accessory rail mounting system comprises multiple interchangeable stock panel inserts of different configurations which are mountable on and form a bottom surface of the forestock at a longitudinal aperture configured to accept the inserts without substantially deviating from the appearance of the stock. The inserts act to occupy and enclose the aperture. Each of the stock panel inserts form an integral part of the firearm forestock itself when mounted thereto such that the forestock is not completely closed at least on the bottom if the insert is not mounted to the forestock. The insert therefore forms a part of the forestock to supply the missing piece such that the forestock has a negative space on bottom and lacks a normal finished appearance for use without the insert in place. These “panels” are thus distinguishable from merely mounting a section of accessory rail on a stock with fasteners.

At least some of the stock panel inserts comprise an accessory rail for mounting various types of commercially-available firearm accessories thereto. Such accessories include but are not limited to firearm support devices such as for example without limitation a bipod or tripod, flashlights, laser sights, vertical grips, sling mounts for carrying the firearm, and others. At least one stock panel insert may be provided which is plain without an accessory rail to simply enclose the longitudinal aperture in a manner which blends into the contours of forestock. The plain insert without rails retain the original profile for use of the firearm without any accessories mounted to the panel insert.

In some embodiments, a group of panel inserts may be provided in a kit which may comprise a plain insert for use when accessories will not be used, in addition to one or more inserts with various different rail configurations. The rails provided with the insert may include but are not limited to Picatinny rails, Weaver rails, dovetail rails including ARCA type photographic rails sometimes used with bipods/tripods, and M-LOK® rails. These rail configurations are all well known in the art without further elaboration necessary.

Although the stock panel inserts have different configurations, the inserts share a common mounting configuration compatible with a singular mounting interface defined by the forestock at the longitudinal aperture so as to be interchangeably mountable to the forestock. This defines a modular interchangeable system comprising a plurality of stock panel insert configurations to suit the needs of the user for augmenting the firearm with various accessories. The stock panel inserts advantageously are configured and contoured in profile to closely approximate the existing contour and profile of the firearm forestock at the point of attachment to preserve the aesthetic appearance of the stock to greatest extent possible with exception of the presence of the rail.

It bears noting that the forestock of a long gun as disclosed herein is generally a structure with a majority of solid surfaces at least on the sides and particularly bottom. This is clearly distinguishable from largely open structured handguards found on AR-type rifles which extend forward from the forestock or chassis to encircle the otherwise exposed barrel of the firearm therein.

The present disclosure also provides a related method of using the accessory rail mounting system.

BRIEF DESCRIPTION OF THE DRAWINGS

The features of the preferred embodiments will be described with reference to the following drawings where like elements are labeled similarly, and in which:

FIG. 1 is a right side elevation view of a firearm in the form of a long gun including an accessory rail mounting system comprising stock panel inserts according to the present disclosure;

FIG. 2 is a top exploded perspective view of the forestock of the firearm with a stock panel insert;

FIG. 3 is a bottom exploded perspective view thereof showing aspects of one embodiment of a coupling system for coupling the stock panel insert to the forestock;

FIG. 4A is a bottom perspective view of the forestock showing a first embodiment of a stock panel insert without a firearm accessory rail;

FIG. 4B is a bottom perspective view of the forestock showing a second embodiment of a stock panel insert including a firearm accessory dovetail rail;

FIG. 4C is a bottom perspective view of the forestock showing a third embodiment of a stock panel insert including a firearm accessory Picatinny rail;

FIG. 4D is a bottom perspective view of the forestock showing a fourth embodiment of a stock panel insert including a firearm accessory M-LOK® rail;

FIG. 5 is an inverted side cross sectional view of the forestock showing additional details of mounting the stock panel insert to the forestock;

FIG. 6 is a top perspective view of the stock panel insert of FIG. 4C showing a rear locking tab feature of the insert;

FIG. 7 is a partial bottom perspective view of the stock panel insert of FIG. 4C showing an enlarged detail of the rear locking tab;

FIG. 8 is a bottom perspective view of the forestock of the stock showing an internal lateral bracing structure disposed in a longitudinal cavity of the forestock;

FIG. 9 is a top perspective view of the forestock showing a longitudinal concavity for receiving the firearm barrel at least partially therein;

FIG. 10 is a transverse cross sectional view through the forestock showing the barrel nested in the concavity at top and a stock panel insert coupled at bottom to the forestock;

FIG. 11 is a front view of an upper portion of a rail-mountable firearm accessory comprising a firearm support device in the form of an adjustable bipod usable with the system of stock panel inserts disclosed herein and schematically showing an accessory rail of the stock panel insert coupled to the bipod;

FIG. 12 is partial perspective view thereof without the accessary rail present;

FIG. 13 is a cross-sectional perspective view of a known traditional or standard forestock design; and

FIG. 14 is a cross-sectional perspective view of a forestock design according to the present disclosure.

All drawings are schematic and not necessarily to scale. Parts given a reference numerical designation in one figure may be considered to be the same parts where they appear in other figures without a numerical designation for brevity unless specifically labeled with a different part number and described herein. Any reference herein to a whole figure number which may comprise multiple figures with the same whole number but different alphabetical suffixes shall be construed to be a general reference to all those figures sharing the same whole number, unless otherwise indicated.

DETAILED DESCRIPTION

The features and benefits of the invention are illustrated and described herein by reference to exemplary (“example”) embodiments. This description of exemplary embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. Accordingly, the disclosure expressly should not be limited to such exemplary embodiments illustrating some possible non-limiting combination of features that may exist alone or in other combinations of features.

In the description of embodiments disclosed herein, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present invention. Relative terms such as “lower,” “upper,” “horizontal,” “vertical,”, “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivative thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description only and do not require that the apparatus be constructed or operated in a particular orientation. Terms such as “attached,” “affixed,” “connected,” “coupled,” “interconnected,” and similar refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise.

As used throughout, any ranges disclosed herein are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range.

FIG. 1 is a right side view of a firearm in the form of a long gun including an accessory rail mounting system according to the present disclosure.

Firearm 20 generally includes a longitudinal axis LA, a synthetic stock 50, receiver 21 coupled to the stock, barrel 22 coupled to the receiver and supported at least in part by the stock, slideably movable bolt 27, and a trigger-actuated firing mechanism 23 including a movable trigger 24. Stock 50 may be formed of a synthetic polymeric material such as a fiber-reinforced or unreinforced plastic formed by injection molding or 3D printing in various embodiments.

The axial central bore 22a of barrel 22 which extends from a front muzzle end 25 to an opposite rear breech end 26 defines a longitudinal axis LA of the firearm (see also FIG. 10). Longitudinal axis LA can be used as a general reference line for convenience in describing features and aspects of the stock 50 and firearm accessory rail mounting system. For convenience of description, an “axial” direction is defined herein as extending in a direction parallel to the longitudinal axis LA. A “transverse” direction is defined as extending in a direction at an acute angle or perpendicularly (i.e. 90 degrees) to the longitudinal axis LA.

The trigger-actuated firing mechanism 23 operates in a conventional manner to discharge firearm 20. Pulling the trigger 24 releases a spring-biased pivotable hammer (internal and not visible in FIG. 1) operably connected to the trigger via a mechanical linkage to contact a firing pin (not shown) which in turn strikes an ammunition cartridge chambered in the rear breech end 26 of the barrel 22 to fire the firearm in a known manner. The firing pin is carried by an axially moveable bolt 27 which moves rearward to open the breech and forward to close the breech when the bolt is in battery with the rear breech end of the barrel. This construction and operation of a firearm action is conventional and known in the art.

Referring generally to FIGS. 1-10 and 14 as applicable, stock 50 has an axially elongated body 50a including a rear buttstock 51 configured for bracing against the user's shoulder when shooting, and a forestock 52 extending forward therefrom for mounting and supporting the receiver and barrel. In one embodiment as shown, the buttstock and forestock may be formed an integral and inseparable unitary parts of a single monolithic stock body. In such an embodiment, both the entire stock including the buttstock and forestock may therefore be injection molded (or 3D printed) as a single part. In other possible embodiments, the buttstock and forestock may be separate parts which are permanently or detachably coupled together via any suitable coupling means used in the art.

Forestock 52 is axially elongated in structure extending along longitudinal axis LA of the firearm. In one embodiment, the forestock includes an open bottom 52a, top 52b, rear end 52c, front end 52d, and pair of opposing lateral sides 52e. Forestock 52 in one embodiment may be a substantially hollow structure including an internal axially-extending longitudinal cavity 53. Longitudinal cavity 53 is defined and formed in a forward portion of the forestock by opposed lateral sidewalls 75 and a solid top wall 76 which extends laterally and bridges between the tops of the sidewalls to form a closed top of forestock (best shown in FIGS. 10 and 14). Sidewalls 75 are contiguous in structure with the top wall 76 being molded or 3D printed from a monolithic piece of polymeric material as shown. The top of longitudinal cavity 53 is therefore closed by the top wall 76 which physically isolates the cavity below from an axially elongated longitudinal concavity 65 defined by the top wall there above. At bottom however, the longitudinal cavity 53 is downwardly open defining an elongated bottom longitudinal aperture 58 of the forestock, as further described herein. Longitudinal aperture 58 therefore is in communication with longitudinal cavity 53 being formed by the cavity. These foregoing structural features and aspects give the forestock body a generally inverted U-shaped cross-sectional configuration (see, e.g., FIG. 10).

A rear portion of the forestock 52 behind longitudinal cavity 53 defines vertically deep receiver cavity 53a beginning proximate the rear end 52c of the forestock 52 adjoining buttstock 51 and extending forward to but not intersecting longitudinal cavity 53 in one embodiment. Vertical partition wall 53b separates receiver cavity 53a from longitudinal cavity 53 (see, e.g., FIG. 5). Cavity 53a is configured to receive the receiver 21 at least partially therein (see, e.g., FIG. 1).

The top wall 76 the forestock 52 defines and comprises elongated longitudinal concavity 65 extending from the front end of receiver 21 to the front end 52d of the forestock. The concavity 65 intersects the receiver cavity 53a at the rear portion of the forestock for coupling firearm barrel 22 to the front end of the receiver. Concavity 65 is recessed into the top of forestock 52 and configured to receive the lower portion or half of the firearm barrel 22 which becomes partially nested therein (see, e.g., FIGS. 9 and 10). The sides and bottom of the concavity formed by the forestock top wall 76 are essentially solid with exception of penetrations by through holes 55a such that the concavity for all intents and purposes is substantially physically isolated from the internal longitudinal cavity 53 of the forestock (particularly when the fasteners 70 are installed in the through holes).

Longitudinal concavity 65 of the forestock 52 is arcuately curved from side to side having a semi-circular cross-sectional shape in one embodiment formed by an arcuately curved section 65a of top wall 76 which is complementary configured to the round cross-sectional shape of the lower portion of barrel 22.

It bears noting that the barrel 22 is detachably coupled to the front of the receiver 21 for primary support and to allow the axially movable bolt 30 of the firearm action within the receiver to contact the rear breech end of the barrel and close the breech in a conventional manner.

As previously described herein, the forestock may be substantially hollow in some embodiments due to the presence of longitudinal cavity 53 for weight reduction. To make the forestock structure more durable and robust, an internal lateral bracing structure 54 comprising a plurality of flat bracing members 54a is provided to add strength and stiffness for handling and enduring repeated firing of the firearm (see, e.g., FIG. 3). The bracing members 54a are vertically oriented and extend from lateral side to side of forestock 52 inside the longitudinal cavity 53 and axially for a majority of front portion 53b of the buttstock which underlies the barrel of the firearm. The bracing members may be arranged in a suitable intersecting pattern. In one embodiment, the bracing members 54a may be arranged in a crisscross pattern as shown in which the members intersect non-orthogonally at acute angles (see, e.g., FIG. 8). Some of the bracing members may be arranged for form a longitudinal spine 54b extending axially down the center of the longitudinal cavity 53 as shown. The spine provides additional support for a plurality of mounting bosses 55 with through holes 55a as further described herein. In one embodiment, the bracing members 54a may be injection molded (or 3D printed) features as unitary structural parts of the entire monolithic stock body 50a rather than separate components added later which creates a stronger forestock structure.

Longitudinal aperture 58 extends from a rear stepped shoulder portion of the forestock 52 formed by an angled shoulder 59 to a point proximate and adjacent to the front end 52d of the forestock. The longitudinal aperture 58 further may extend completely from lateral side to opposing lateral side 52e of the forestock (i.e. from bottom edge of one lateral sidewall 75 to the opposite lateral sidewall as shown). The sidewalls 75 therefore define a peripheral edge 52g on bottom 52a of forestock 52 circumscribing the longitudinal aperture 58 (see, e.g., FIG. 8). Peripheral edge 52g extends from the rear of the angled shoulder 59 along both lateral sides of the forestock and to and around the front end 52d thereof. The longitudinal aperture 58 renders a majority of the bottom 52a of the forestock 52 forward of the receiver (i.e. a front portion) completely open at bottom such that there is no solid bottom surface of the forestock per se unless one of the stock panel inserts is installed.

According to one aspect of the invention therefore, a plurality of interchangeable stock panel inserts 60 are provided of different configuration (some with or without accessory rails) which are detachably coupled to the bottom of the forestock 52 to completely enclose the longitudinal aperture 58 in some embodiments as shown in FIG. 4. The solid bottom surface of the panel inserts themselves when coupled to the forestock therefore define part of the bottom of the forestock forming the solid bottom surface 52f of the forestock as depicted in FIG. 3. Accordingly, the forestock may alternatively be viewed as having a detachable bottom section that defines the solid bottom surface of the stock which is provided by the interchangeable stock panel inserts. A plurality of differently configured stock panel inserts for different uses are shown in FIGS. 3-5 and further described herein.

It bears noting that the stepped shoulder 59 and longitudinal aperture 58 creates an axially elongated negative space “N” on the bottom of the forestock 52 which is filled by the stock panel insert 60 when the insert is coupled to the forestock. Negative space N is open forwardly, laterally, and downwardly. The negative space N is created by and extends from stepped shoulder 59 forward to front end 52d of the forestock 52 and may occupy at least half of the bottom of the forestock in some embodiments. Accordingly, without the insert in place, rear portions of the forestock behind the stepped shoulder are lower and vertically offset by an offset distance D1 from front portions of the forestock at the bottom longitudinal aperture 58 creating a stepped appearance of the forestock as shown. The bottom of the forestock therefore lacks a uniform normal appearance without a stock panel insert 60 in place. With the stock panel insert 60 in place on the forestock, forestock has a relatively continuous straight bottom line or profile in which there is no appreciable offset between the front and rear portions of the forestock. Notably, this differentiates the stock panel inserts which form part of the forestock when in place from common accessory attachments including protruding rail sections which are merely attached to the bottom of the forestock which do not have a negative space with or without the attachment. Such common accessory attachments do not form an integral portion of the forestock when mounted to the firearm.

Each stock panel insert 60 comprises an axially elongated and generally flattened body 60f having a length L1 and width W1 which completely enclose the downwardly open longitudinal aperture 53 of the forestock 52. Length L1 is thus substantially larger than its width W1 (e.g., at least 2 times or more). In one embodiment, length L1 may be greater than 4 times W1. The panel insert 60 has a width W1 which may extend from lateral side to lateral side 52e of the forestock 52 when the insert is coupled thereto.

Referring specifically now to FIGS. 3 and 6-7, each panel insert 60 includes front end 60a, rear end 60b, pair of lateral sides 60c, top 60d and bottom 60e. Top 60d defines a top surface 60d-1 which lies in a horizontal plane from side to side and front to rear. Lateral sides 60c do not project upwards beyond top surface 60d-1 of the insert in one embodiment. Bottom 60e defines the bottom surface 52f of the forestock 52 as noted above. The body 60f of each stock panel insert further is configured to define a rear locking portion 61 and forward coupling portion 62 extending forwardly therefrom to the front end of the insert. Locking portion 61 is configured to form a mechanical interlock with the forestock 52 to better secure the rear end of the insert in place on the forestock. In one embodiment, locking portion 61 includes a first locking feature which may be a male or female locking feature that is complementary configured to mate with a corresponding other one of a male or female locking feature of the forestock 52 (i.e. one locking feature is male and the other female). For example in the illustrated embodiment, panel insert 60 includes a male locking tab 57 which protrudes rearwardly from the rear end of the insert in a cantilevered manner. The forestock 52 includes a mating forwardly open female locking recess 56 configured to receive the locking tab 57 therein to form a mechanical interlock between the rear end of the stock panel insert and the forestock. The locking recess is formed on the bottom 52a of forestock 52 at the stepped shoulder 59 located at the rear of the open longitudinal aperture 53 and negative space “N” of the forestock which is filled and enclosed by coupling the panel insert 60 to the forestock. Locking tab 57 may be laterally broadened/widened in comparison to its height (i.e. width greater than height) to ensure positive and secure engagement with the locking recess 56. The locking tab 57 is slideably received in the recess 56 when the stock panel inserts 60 are mounted to the forestock of the firearm. The recess 56 defines a forward protruding lip 56a which traps locking tab 57 in the recess (see, e.g., FIG. 5).

In other embodiments, it will be appreciated and understood by those skilled in the art that the male and female features (e.g., locking tab 57 and locking recess 56) may be switched on the panel insert 60 and forestock 52. Accordingly, the forestock may include a forwardly projecting locking tab formed at stepped shoulder 59 of the forestock which slideably receives a rearwardly open locking recess formed on the rear end of the stock panel insert 60. Since the forestock is a larger structure in contrast to the panel insert which has a relatively thin flattened body, it is preferable to locate the locking tab on panel insert in lieu of the locking recess. However, the reverse construction noted above is acceptable and would function equivalently for creating a mechanical interlock between the rear end of the panel insert and the forestock.

The forward coupling portion 62 of the stock panel inserts 60 has a greater axial length than the rear locking portion 61. Both the coupling portion 62 and optionally the locking portion 61 may each include a plurality of fastener holes 63 (see, e.g., FIG. 6) which receive threaded fasteners 70 therethrough for detachably coupling the panel insert 60 to the forestock 52 at the longitudinal aperture 53 to at least partially but preferably fully enclose the aperture. Fasteners holes 63 may be formed by mounting bosses 63a formed integrally as a unitary structural part of each stock panel insert 60. Forestock 52 may include a plurality of corresponding mounting bosses 55 with through holes 55a therein (see, e.g., FIG. 8) which coincide in location to the location of each fastener hole 63 in the panel insert 60 so that holes 55a and 63 become concentrically aligned to receive the fasteners when the panel insert is mounted to the forestock.

In one embodiment, the stock panel inserts 60 may include an upwardly open longitudinal recess 64. An internal lateral bracing structure 64a may be disposed in the recess 64 which comprises a plurality of flat bracing members 64b. Bracing members 64b may be arranged in a crisscross pattern as shown in which the members intersect non-orthogonally at acute angles. Bracing structure 64a may be complementary configured to bracing structure 54 in the forestock 52 in some embodiments as shown in FIGS. 6 and 8 so that exposed linear edges of each bracing member in the stock panel insert aligns with and engages a corresponding bracing member in the longitudinal cavity of the forestock. When one of the stock panel inserts is coupled to the forestock 52 via the fasteners 70, tightening the fasteners draws the insert to the forestock and compresses bracing members 64b of the insert into abutting engagement with the mating bracing members 54a in the forestock which advantageously contributes to a strong and robust coupling since the bracing members of the insert act as a continuation of the bracing members of the forestock. In addition, the aligned bracing members 54a and 64b provide structural support for the bosses 55 and 63a of the forestock and stock panel inserts when the fasteners are tightened.

In one embodiment, the fastener bosses 55 in forestock 52 may be integrally formed as a unitary part of the forestock 52 and the bracing members 54a of the internal bracing structure in the forestock. Because rear locking portion 61 of the panel insert 60 includes a locking feature (e.g., locking tab 57 described above), fasteners are not necessarily required to secure this rear portion of the insert to the forestock. However, to enhance securement of the panel insert to the forestock, at least one or a pair of laterally spaced fastener holes 63 as shown may be provided in the rear locking portion to also receive fasteners 70. This ensures the locking tab 57 of the panel insert will remain inserted in the locking recess 56 when the firearm is fired which induces vibration in the stock. Threaded nuts 71 may be used to secure each threaded fastener 70 in place. In one embodiment, nuts 71 may be hex nuts which are inserted into complementary configured nut recesses 72 formed in the lower portion of the longitudinal concavity 65 in which firearm barrel 22 is partially nested and mounted (see, e.g., FIGS. 9-10). Nuts 71 are inserted into their respective recesses 72 before the barrel is mounted to the forestock 52. Once installed, the barrel holds and traps the nuts in place on the forestock within the recesses and concavity. The recesses having a polygonal shape as shown prevent the nuts 71 from rotating when the fasteners 70 are threaded into each nut.

In some embodiments, the forestock 52 may be overmolded onto the threaded nuts 71 when the synthetic stock is injection molded to then become an integral fixedly attached and inseparable part of the forestock. In yet other possible embodiments contemplated, the through holes 55a of the mounting bosses 55 may include threads to engage the threaded shanks of the fasteners 70, thereby eliminating the need for the threaded nuts 71 provided secure enough purchase is possible between the bosses and fasteners. The threads in the mounting bosses may be provided by cylindrical metal inserts onto which the synthetic stock is overmolded. Other means for mounting the nuts or threading the bosses may be provided.

If a carrying sling is to be used with the firearm, a threaded sling bolt 70a may be provided to replace one of the fasteners 70 (e.g., the forward-most one) as shown in FIG. 3.

As shown in FIGS. 4A-C, a plurality of different interchangeable stock panel inserts 60 with different configurations (some with or without accessory rails) may be provided with the firearm accessory mounting system according to the present disclosure. To provide a modular user-interchangeable system or kit of panel inserts 60, each panel insert is provided with a common mounting configuration collectively formed by the locking tab 57 and fastener holes 63 previously described herein which are compatible and coordinated with the singular panel insert mounting interface of the forestock 52 collectively formed by the locking recess 60 and mounting bosses 55 with holes 55a of the forestock in layout and configuration. This forms a modular system of interchangeable panel inserts 60 which allows the user to employ different panel inserts to fill and enclose the longitudinal aperture 58 and bottom axially elongated negative space N of the forestock 52 (see, e.g., FIG. 5) while providing various options for mounting different insert configurations with or without accessory rails. Accordingly, the configuration of the locking tabs 57 and the fastener holes 63 (e.g., shape, dimension, and location) on each different panel insert are identical to provide the required interchangeability.

FIG. 4A shows a first example of a stock panel insert 60 in the form of a plain panel insert designated by reference numeral 80 which does not have an accessory rail configured for detachable mounting a firearm accessory thereto. This panel insert is smoothly contoured in configuration to substantially match the contour of the bottom of the forestock 52 and enclose the longitudinal aperture 58 on the bottom of the forestock. This insert may be provided as part of the firearm manufacturer's original equipment for example and maintains the original aesthetics of the firearm. The term “plain” as used above connotes that the insert 80 does not have an accessory mounting rail.

FIG. 4B shows a second example of a stock panel insert 60 which includes an integrally formed firearm accessory rail 86 configured for detachable mounting a firearm accessory thereto. This stock panel insert is designated by reference numeral 85. Rail 86 may be formed as a monolithic unitary part of the stock panel insert body in preferred embodiments, but may be a separate part coupled to the body in other possible embodiments. In this embodiment, the accessory rail 86 extends for the entire length L1 of the stock panel insert from front to rear end thereby extending axially along both lateral sides 60c of the insert body. Rail 86 shown is a dovetail rail, which in some embodiment may be an ARCA rail (or ARCA Swiss rail) having a 45 degree dovetail cut. ARCA rails have grown in popularity for secure mounting of firearm support devices such as tripods or bipods (the latter shown in FIG. 11 and further described herein).

FIG. 4C shows a third example of a stock panel insert 60 which is a hybrid panel insert including two different integrally formed sections of firearm accessory rails 86 and 91 each configured for detachable mounting a firearm accessory thereto. This hybrid stock panel insert is designated by reference numeral 90. Rails 86 and 91 may be formed as a monolithic unitary part of the stock panel insert body in preferred embodiments, but may be a separate part coupled to the body in other possible embodiments. In this embodiment, one section of an accessory rail 91 is disposed only on a front portion of the stock panel insert 90 and extend for part of the length L1 of the stock panel insert. Rail 91 shown is configured as a section of a Picatinny rail well known and commonly used in the art for mounting various firearm accessories thereto. The rear portion of stock panel insert 90 includes a section of the dovetail rail 86 shown in FIG. 4B. The locations of rails 86 and 91 on the stock panel insert may be reversed in some embodiments. This stock panel insert 90 advantageously allows a user to couple firearm accessories thereto which are compatible with either a Picatinny or dovetail rail. In yet another example embodiment, the dovetail rail 86 section may be omitted and the stock panel insert 90 may include only a section of Picatinny rail 91 which may be limited to only the forward portion of the insert, or optionally may extend farther rearward for a majority of the length of the stock panel insert.

FIG. 4D shows a fourth example of a stock panel insert 60 which includes an integrally formed firearm accessory rail 101 configured for detachable mounting a firearm accessory thereto. This stock panel insert is designated by reference numeral 100. Rail 101 may be formed as a monolithic unitary part of the stock panel insert body in preferred embodiments, but may be a separate part coupled to the body in other possible embodiments. In this embodiment, the accessory rail 101 extends longitudinally for a majority of the length L1 of the stock panel insert 100 from front to rear. Rail 101 shown is configured as a section of an M-LOK® rail well known and commonly used in the art for mounting various firearm accessories thereto. M-LOK® rails have longitudinal openings 102 (e.g., slots) which define mounting locations for coupling accessories to the rails. The openings receive T-shaped nuts on the firearm accessory which are then rotated and locked in place on the rail.

Other embodiments of stock panel inserts 60 may include other types and configurations of rails as previously notes herein (e.g., Weaver rails, other types of dovetail rails, etc.).

The stock panel inserts 60 may be formed of a suitable material for their intended purpose and use. The inserts may be formed of the same or different material than the synthetic material of which the stock 80 including the forestock 82 are made in preferred embodiments. For example, stock panel inserts which include firearm accessory rails may have a monolithic body formed of metal for added durability and strength to survive mounting and dismounting firearm accessories over time thereto and therefrom. Aluminum, steel, or titanium are some examples of suitable metallic materials. However, suitable strong polymeric materials such as nylon reinforced plastics may also be used for panel inserts 60 with accessory rails due to their added strength. For plain inserts such as stock panel insert 80 previously described herein which are used aesthetically to simply enclose the bottom longitudinal aperture 58 of forestock and fill the negative space N at the bottom of the forestock to provide a completed and finished firearm appearance, a lightweight material such as a polymeric material (e.g., plastic) may be used (e.g., nylon reinforced or unreinforced) which may be the same as or different than the material used to form the rest of the stock. Accordingly, the stock panel inserts 60 may be made of various materials appropriate for the intended use and is not limited in this regard.

FIGS. 11 and 12 show one non-limiting example of a firearm accessory usable with the accessory rail mounting system provided by the stock panel inserts according to the present disclosure. This figure shows the upper portion of a bipod 200 (a firearm support device) used to steady the firearm from an available support surface to improve aiming and shooting.

Bipod 200 includes a coupling mechanism and interface configured to mate with the dovetail rail 86 of stock panel insert 85 shown in FIG. 4 previously described herein as an example. Such bipods are commercially-available such as for example are available from Magpul Industries Corporation or other suppliers. Bipod 200 includes a pair of adjustable legs (spreadable and extendible/retractable) 201 which engage an available support surface to in turn support the firearm. The legs are coupled to a central swivel mechanism 202 which in turn includes rail coupling mechanism 203 including a pair of opposing jaws 204a, 204b. An adjustable opening 206 is formed by and between the jaws which is configured to receive and retain the coupling rail of the stock panel insert 60 therein via a pressure clamping action. Jaws 204a, 204b are closeable and openable via rotating adjustment screws 205 which are coupled to each of the jaws. When and after the coupling rail is inserted into opening 206 with the jaws spread apart, the jaws may then be moved together to lockingly engage the rail via clamping action by tightening the screws to detachably couple the stock panel insert and attached firearm to the bipod. Other clamping mechanisms may be used in other types of bipods, tripods, or other firearm support devices with the stock panel inserts 60 having accessory rails disclosed herein, or with firearm accessories other than support devices examples of which have been described herein.

A process or method for coupling a firearm accessory to the forestock of a firearm using the stock panel insert accessory mounting system according to the present disclosure in one embodiment comprises: providing a first stock panel insert comprising a front end, rear end, opposing lateral sides, and an accessory rail; locating the first stock panel insert at an open longitudinal aperture formed in a bottom of the forestock; inserting a locking tab projecting from the rear end of the first stock panel insert into a forwardly open locking recess on the forestock; and coupling the first stock panel insert to the forestock using a plurality of fasteners. FIG. 5 is a longitudinal cross section view with the locking tab of the first stock panel insert engaged in the locking recess of forestock 52 at rear of the stock panel insert and longitudinal aperture. The coupling step includes completely enclosing the longitudinal aperture of the forestock with the first stock panel insert. The coupling step further includes inserting a plurality of fasteners through the first stock panel insert, and coupling a nut (or metal threaded insert) inside the forestock to each of the fasteners inside a longitudinal cavity of the forestock.

The method may further comprise steps including: uncoupling the first stock panel insert from the forestock; providing a second stock panel insert comprising a front end, rear end, and opposing lateral sides; locating the second stock panel insert at the open longitudinal aperture formed in the bottom of the forestock, the second stock panel insert having a different configuration than the first stock panel insert; inserting a locking tab projecting from the rear end of the second stock panel insert into the forwardly open locking recess on the forestock; and coupling the second stock panel insert to the forestock using a plurality of fasteners.

Variations of the method are possible within the scope of the present disclosure.

Although the firearm accessory mounting system using the stock panel inserts has been described in relation to use on long guns, it will be appreciated that the system may be used in the same manner with some pistols having OEM or after-market stocks of sufficient length. Accordingly, the invention is not necessarily limited in its applicability to long guns alone.

According to another aspect of the invention, the design of the forestock 52 with open bottom (i.e. longitudinal aperture 58) provides distinct injection molding benefits resulting in an improved final monolithic synthetic stock structure which is superior to past approaches for injection molded synthetic stocks. Reference is made to FIGS. 13 and 14 for comparison. When designing a part for injection molding, the best practice is to have a uniform wall thickness achieved with the practice of “coring.” If the wall is too thick it can cause sink or voids that can weaken the strength of the stock. In injection molding, “coring” is a term of art that refers to the process of intentionally removing excess material from thick sections of a plastic part by designing mold features that create internal cavities, resulting in a more uniform wall thickness throughout the part, which helps to prevent warping, sink marks, and reduces raw polymer resin usage and overall weight. The term “coring” therefore refers to creation of hollow areas within a molded piece to optimize cost, design, and function.

In molding traditional or standard synthetic stocks formed of polymer as shown in FIG. 13, the “coring” is performed from the top down into the stock resulting in a forestock with an open top. This results some degree of manufacturing and cost efficiencies since the bottom of the forestock comes out closed right from the mold and the barrel covers the otherwise open top of the stock as seen. However, this conventional injection molding approach typically results in sections of the walls of the stock having non-uniform thicknesses as can be seen which is undesirable. The “coring” (internal cavity or hollow) of stock can only be as wide as the barrel channel when coring is made from the top surface downwards leading to thicker sections of the stock wall and wasted polymer resin base material.

By contrast, the inventor has discovered that “coring” in the mold from the bottom surface of stock upwards according to the present disclosure as shown in FIG. 14 allows for wider coring, thereby resulting in the ability to create more uniform wall thicknesses in the molded stock. The bottom longitudinal aperture 58 of the present forestock 52 advantageously facilitates formation of a wider internal cavity 53 from side to side in the mold which results in substantially uniform thicknesses in the sidewalls of the forestock. The top of the forestock is closed as previously described herein. Although this approach leaves an open bottom in the forestock even after the barrel is installed, the open longitudinal aperture 58 on the bottom can be closed by attaching any of the stock panel inserts 60 disclosed herein. Although this is an additional fabrication and material cost even if a plain insert is used (i.e. without an accessory rail), the tradeoff is desirable to achieve more uniform wall thicknesses and improved strength of the molded stock.

Example Embodiments

The following are non-limiting example embodiments demonstrating various features and possible combinations of features and aspects according to the present invention.

• • 1. An interchangeable stock panel insert system for attaching accessories to a firearm, the system comprising:
  • a longitudinal axis;
  • a longitudinally elongated stock formed of a synthetic material, the stock comprising a forestock;
  • the forestock comprising:
    • a top;
    • an axially elongated internal longitudinal cavity;
    • a downwardly open elongated longitudinal aperture formed in a bottom of the forestock beneath the longitudinal cavity, the longitudinal aperture in communication with the longitudinal cavity; and
    • a singular mounting interface defined at the longitudinal aperture;
  • a first stock panel insert configured for detachable coupling to the forestock to enclose the longitudinal aperture, the first stock panel insert having a first configuration;
  • a second stock panel insert configured for detachably coupling to the forestock to enclose the longitudinal aperture, the second stock panel insert having a second configuration different than the first configuration;
  • wherein the first stock panel insert and the second stock panel insert each have a common mounting configuration compatible with the singular mounting interface of the forestock so as to be interchangeably mountable to the forestock.
  • 2. The system according to Embodiment 1, wherein the first and second stock panel inserts each comprise an elongated flattened body defining a front end, rear end, and opposing lateral sides extending between the ends.
  • 3. The system according to Embodiments 1 or 2, wherein the bottom of the forestock includes a stepped shoulder which creates an axially elongated negative space extending from the stepped shoulder forward to a front end of the forestock when the first or second stock panel inserts are not coupled to the forestock.
  • 4. The system according to Embodiment 3, wherein a majority of the bottom of the forestock is open from the stepped shoulder to the front end of the forestock when the first or second stock panel inserts are not coupled to the forestock.
  • 5. The system according to Embodiment 4, wherein rear portions of the forestock behind the stepped shoulder are lower and vertically offset by an offset distance from front portions of the forestock at the longitudinal aperture creating a stepped appearance when the first or second stock panel inserts are not coupled to the forestock, and wherein the first or second stock panel inserts fill the negative space when coupled to the forestock so as to form a continuous straight bottom profile of the forestock.
  • 6. The system according to any one of Embodiments 1-5, wherein the forestock further comprises a longitudinally extending top wall which defines an axially elongated longitudinal concavity above the longitudinal cavity of the forestock, the longitudinal concavity having a semi-circular cross-sectional shape configured to receive a firearm barrel at least partially therein and physically isolated from the longitudinal cavity below the top wall.
  • 7. The system according to Embodiments 3 or 4, wherein the first and second stock panel inserts each comprise a solid bottom surface which in turn defines a bottom surface of the forestock when the panel inserts are coupled to the forestock.
  • 8. The system according to any one of Embodiments 1-7, wherein at least one of the first and second stock panel inserts comprises an accessory rail configured for mounting a firearm accessory thereto.
  • 9. The system according to Embodiment 8, wherein the first stock panel insert includes an accessory rail and the second stock panel insert is plain without an accessory rail.
  • 10. The system according to Embodiments 8 or 9, wherein the accessory rail is selected from the group consisting of a Picatinny rail, Weaver rail, dovetail rail, and M-LOK® rail.
  • 11. The system according to Embodiments 9 or 10, wherein the first stock panel insert which includes the accessory rail is formed of metal, and the second panel insert which is plain is formed of a polymeric material.
  • 12. The system according to Embodiment 1, wherein the first and second stock panel inserts each have a width which extends from one lateral side to an opposite lateral side of the forestock and from the stepped shoulder to a front end of the forestock when the first and second stock panel inserts are coupled to the forestock.
  • 13. The system according to any one of Embodiments 1-12, wherein the common mounting configuration of the first and second stock panel inserts includes a locking tab projecting from the rear end of the panel inserts which is engageable with a forwardly locking recess defined by the stepped shoulder of the forestock thereby forming a mechanical interlock between the panel inserts and the forestock when the first or second stock panel inserts are coupled to the forestock.
  • 14. The system according to Embodiment 13, wherein the common mounting configuration of the first and second stock panel inserts further includes a plurality fastener holes which receive threaded fasteners to couple the first or second stock panel inserts to the forestock.
  • 15. The system according to Embodiment 14, wherein each of the threaded fasteners is threadably coupled to a threaded nut or threaded insert disposed inside the longitudinal cavity of the forestock.
  • 16. The system according to Embodiment 15, wherein each threaded nut or threaded insert is seated in a complementary configured recess formed in the top of the forestock and located within an arcuately curved longitudinal concavity.
  • 17. The system according to Embodiments 14 or 15, wherein a forward most threaded fastener is a sling screw configured for attaching a firearm sling thereto.
  • 18. The system according to any one of Embodiments 9-11, wherein the accessory rail extends for the entire length of the first stock panel insert.
  • 19. The system according to any one of Embodiments 9-11, wherein the accessory rail is disposed only on a front portion of the first stock panel insert.
  • 20. The system according to Embodiment 9, wherein at least one of the first and second stock panel inserts is a hybrid insert comprising a first accessary rail having a first configuration and a second accessory rail having a second configuration different than the first configuration.
  • 21. The system according to Embodiment 20, wherein the first accessory rail is a Picatinny rail and the second accessory rail is a dovetail rail.
  • 22. The system according to Embodiment 1, wherein the forestock comprises a bracing structure formed by a plurality of bracing members disposed in the longitudinal cavity which are arranged in a crisscross pattern in which the members intersect non-orthogonally at acute angles.
  • 23. The system according to Embodiment 22, wherein at least one of the first and second stock panel inserts comprises a complementary configured bracing structure to the bracing structure of the forestock.
  • 24. A method for coupling a firearm accessory to the forestock of a firearm, the method comprising:
  • providing a first stock panel insert comprising a front end, rear end, opposing lateral sides, and an accessory rail;
  • locating the first stock panel insert at an open longitudinal aperture formed in a bottom of the forestock;
  • interlocking a first locking feature formed on the rear end of the first stock panel with a mating second locking feature formed at a rear end of the longitudinal aperture on the forestock; and
  • coupling the first stock panel insert to the forestock.
  • 25. The method according to Embodiment 24, wherein the coupling step includes completely enclosing the longitudinal aperture of the forestock with the first stock panel insert.
  • 26. The method according to Embodiments 24 or 25, wherein the coupling step includes inserting the plurality of fasteners through the first stock panel insert, and threadably engaging the fasteners with the forestock within a downwardly open axially elongated internal longitudinal cavity of the forestock which forms the longitudinal aperture in the bottom of the forestock.
  • 27. The method according to Embodiment 26, wherein each fastener threadably engages a corresponding threaded nut or threaded insert disposed in a longitudinal cavity of the forestock.
  • 28. The method according to any one of Embodiments 24-27, wherein the forestock comprises a stepped shoulder which defines an elongated negative space on the bottom of the forestock, and the coupling step fills the negative space with the first stock panel insert.
  • 29. The method according to any one of Embodiments 24-28, wherein the first stock panel insert has an elongated flattened body defining opposing lateral sides and a top surface which lies in a horizontal plane in which the lateral sides do not extend upwards beyond the top surface.
  • 30. The method according to Embodiment 24, wherein the first locking feature is a locking tab projecting from the rear end of the first stock panel insert and the mating second locking feature is a forwardly open locking recess formed at the rear end of the longitudinal aperture on the forestock, the interlocking step including inserting the locking tab into the locking recess on the forestock.
  • 31. The method according to any one of Embodiments 24-30, further comprising steps including:
  • uncoupling the first stock panel insert from the forestock;
  • providing a second stock panel insert comprising a front end, rear end, and opposing lateral sides;
  • locating the second stock panel insert at the open longitudinal aperture formed in the bottom of the forestock, the second stock panel insert having a different configuration than the first stock panel insert;
  • interlocking a third locking feature formed on the rear end of the second stock panel with the second locking feature formed at the rear end of the longitudinal aperture on the forestock; and
  • coupling the second stock panel insert to the forestock using a plurality of fasteners.
  • 32. The method according to Embodiment 31, wherein the first stock panel insert and the second stock panel insert each have a common mounting configuration compatible with a singular mounting interface of the forestock so as to be interchangeably mountable to the forestock.
  • 33. The method according to Embodiment 32, wherein the second stock panel insert is plain in configuration and does not have an accessory rail.
  • 34. The method according to Embodiment 32, wherein the second stock panel insert comprises an accessory rail having a different configuration than the accessory rail of the first stock panel insert.
  • 35. A firearm stock for attaching accessories to a firearm, the stock comprising:
  • a longitudinal axis;
  • a longitudinally elongated body formed of a synthetic material, the stock comprising a buttstock configured for bracing against a shoulder of a user, and a forestock configured to support a receiver of the firearm;
  • the forestock comprising a top, and an axially elongated internal longitudinal cavity defining a downwardly open elongated longitudinal aperture in a bottom of the forestock, the longitudinal aperture in communication with the longitudinal cavity; and
  • a stock panel insert detachably coupled to the forestock at the longitudinal aperture, the stock panel insert having an elongated body which encloses the longitudinal aperture;
  • the stock panel insert including an accessory rail configured for mounting a firearm accessory thereto.
  • 36. The firearm stock according to Embodiment 35, wherein the stock panel insert comprises an axially elongated flattened body defining a top surface, a bottom surface, a front end, a rear end, and opposing lateral sides extending between the ends which do not project upwards beyond the top surface.
  • 37. The firearm stock according to Embodiment 36, wherein the stock panel insert has a width which extends from one lateral side of the forestock to an opposite lateral side thereof.
  • 38. The firearm stock according to any one of Embodiments 35-37, wherein a majority of the bottom of the forestock is open when the stock panel insert is not coupled to the forestock.
  • 39. The firearm stock according to Embodiment 38, wherein the bottom of the forestock includes a stepped shoulder which creates an axially elongated negative space extending from the stepped shoulder forward to a front end of the forestock when the stock panel insert is not coupled to the forestock.
  • 40. The firearm stock according to Embodiment 39, wherein rear portions of the forestock behind the stepped shoulder are lower and vertically offset by an offset distance from front portions of the forestock at the longitudinal aperture creating a stepped appearance when the stock panel insert is not coupled to the forestock.
  • 41. The firearm stock according to Embodiment 35, wherein the stock panel insert is a hybrid insert comprising a first accessary rail having a first configuration and a second accessory rail having a second configuration different than the first configuration.
  • 42. The firearm stock according to Embodiment 41, wherein the first accessory rail is a Picatinny rail and the second accessory rail is a dovetail rail.
  • 43. The firearm stock according to any one of Embodiments 35-42, wherein the forestock further comprises an axially elongated longitudinal concavity formed by a solid top wall in the top of the forestock, the longitudinal concavity having a semi-circular cross-sectional shape configured to receive a firearm barrel at least partially therein.
  • 44. The firearm stock according to Embodiment 43, wherein the top wall isolates the concavity from the longitudinal cavity of the forestock below the top wall.

While the foregoing description and drawings represent preferred or exemplary embodiments of the present invention, it will be understood that various additions, modifications and substitutions may be made therein without departing from the spirit and scope and range of equivalents of the accompanying claims. In particular, it will be clear to those skilled in the art that the present invention may be embodied in other forms, structures, arrangements, proportions, sizes, and with other elements, materials, and components, without departing from the spirit or essential characteristics thereof. In addition, numerous variations in the methods/processes as applicable described herein may be made without departing from the spirit of the invention. One skilled in the art will further appreciate that the invention may be used with many modifications of structure, arrangement, proportions, sizes, materials, and components and otherwise, used in the practice of the invention, which are particularly adapted to specific environments and operative requirements without departing from the principles of the present invention. The presently disclosed embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being defined by the appended claims and equivalents thereof, and not limited to the foregoing description or embodiments. Rather, the appended claims should be construed broadly, to include other variants and embodiments of the invention, which may be made by those skilled in the art without departing from the scope and range of equivalents of the invention.