CA3171780A1 - Handguard assembly, systems for handguard sleeve attachments, and related firearms and methods - Google Patents

Abstract

The invention as described herein includes a handguard assembly for attachment to an upper receiver of a firearm It includes a barrel nut hat 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 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.

Description

TITLE OF THE INVENTION
Handguard Assembly, Systems for Handguard Sleeve Attachments, and Related Firearms and Methods BACKGROUND OF THE INVENTION
[0001] 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.

[0002] 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

[0003] 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.

[0004] 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 Date Recue/Date Received 2022-09-01 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.

[0005] 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.

[0006] 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

[0007] 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:

[0008] Fig. 1 is perspective view of the handguard assembly of an embodiment of the invention;

[0009] 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;

[0010] Fig. 3 shows an exploded, top view of an embodiment of the invention assembled on a firearm;

[0011] Fig. 4 shows an exploded, side view of an embodiment of the invention assembled on a firearm;

[0012] Fig. 5 shows several views of a barrel nut of the invention in an embodiment;

Date Recue/Date Received 2022-09-01

[0013] Fig. 6 (two sheets) shows several views of an adapter of the invention in an embodiment;

[0014] Fig. 7 shows several view of the locking wedge of the invention in an embodiment;

[0015] Fig. 8 shows several view of an embodiment of the handguard sleeve (sleeve body and rail);

[0016] Fig. 9 shows a step by step process for mounting the an embodiment of the assembly of the invention to a firearm; and

[0017] Fig. 10 shows a portion of the adapter bearing a wedge pocket in an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION

[0018] The invention described herein includes a handguard assembly for use on a firearm, particularly an AK 15 platform sporting rifle, as wells 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.

[0019] 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.

[0020] For convenience, the assemblies are described herein in the contest of a standard AK
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.

Date Recue/Date Received 2022-09-01

[0021] 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.

[0022] With reference to Figures 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.

[0023] 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.

[0024] Looking to Figure 3 and 4, an embodiment of the assembly of the invention is shown assembled on a firearm 102. In the exploded view of Figure 3, one can see the barrel nut 106 that has been threaded along the length of the firearm barrel 176, flowed 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 Figure 3 are a first locking wedge 136a and a second locking wedge 136b and corresponding mechanical fasteners 162a and 162b, which is this embodiment are screws, that are inserted in corresponding hole (not shown in Figures 3 and 4; see Figure 7) in the lower sections 140 of the locking wedges 136.

[0025] Referencing Figures 1 to 4, in an embodiment, the barrel nut 106 includes a substantially cylindrical interior channel 184 and having a length dimension 114 that extends from a first end 108 to a second end 110. An outer surface 112 has a convex curve 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.

[0026] The annular groove 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 Date Recue/Date Received 2022-09-01 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 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 body wall 182, that is, for example without limitation, if the body wall 182 is 1 centimeter thick, than the depth of the groove may be about 2mm to about 8mm.

[0027] In practice of the assembly of the invention, the barrel nut is attached to the upper receiver of a forearm as discussed above. Such attachment may include mechanical or chemical fastenings. In an embodiment, 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 Figure 6.

[0028] The assembly further includes a handguard sleeve 118, with reference to Figures 1-4 .. and 8, 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.

[0029] In the embodiment shown herein, the channel 183 is defined by the eight sidewalls 188a-f of the sleeve body 168 thereby providing a channel that is hexagonal-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., septagonal, 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) 188 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.

[0030] In an embodiment, the upper most sidewall 118a 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.

Date Recue/Date Received 2022-09-01

[0031] The assembly further includes an adapter 124, with reference to Figures 1-4, 6 and 10. The adapter 124 is structured to be mechanically attached to the handguard sleeve 118 at, preferably, at or near the first end 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 136 the channel has an interior diameter dimension 130 that is sized so that the second end of the of the barrel nut is at least partially insertable into the second end of the adapter. Thus, when assembled, the end 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 of barrel nut.

[0032] In an embodiment, the adapter further includes an adapter body 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.

[0033] 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.

[0034] 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 is shaped to receive the lower section 140 of the locking wedge 136 as described below.

[0035] 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 center of bore when assembled on the firearm.

[0036] With reference to Figure 7, the assembly further includes one or more locking wedge(s) that correspond to the wedge pocket(s). The locking wedge 136 includes an upper section 138 and a lower section 140. 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 upper portion 144 of the locking wedge 136 has a concavely curving upper surface 152.
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.

Date Recue/Date Received 2022-09-01

[0037] 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 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.

[0038] 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.

[0039] Firearms bearing either the system or the assembly of the invention, each as described herein are further contemplated within the scope of the invention.

[0040] Also included are methods of mounting or assembling the system or assembly onto a firearm. With reference to Figure 9, the method in an embodiment includes obtaining a firearm, such as for example without limitation, forearms of an AK 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.

[0041] 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).

[0042] 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).

[0043] 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 Date Recue/Date Received 2022-09-01 curving surface of the bane! 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.

[0044] 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.

[0045] 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.

Date Recue/Date Received 2022-09-01

Claims (17)

What is claimed is:

1. A handguard assembly for attachment to an upper receiver of a firearm comprising:
a barrel nut extending from a first end to second end, wherein a convexly curving outer surface of the barrel nut defines an annular groove extending around at least a portion of the circumference of the barrel nut;
a handguard sleeve having a first end and a second end;
an adapter capable of mechanical attachment to the handguard sleeve at the handguard sleeve's first end, the adapter having 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; wherein the adapter 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;
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.

2. The assembly of claim 1, comprising two wedge pockets and two locking wedges, wherein the wedge pockets are disposed on opposite sides of the adapter.

3. The assembly of claim 1 or claim 2 wherein the wedge pocket(s) on the adapter are each disposed below center of bore when the assembly is mounted on the firearm.

4. The assembly of claim 1, wherein the handguard sleeve further includes an end cap that is disposed at the second end of the sleeve body.

5. The assembly according to claim 1, wherein the first end of the barrel nut has a female threaded surface that is attachable to a counterpart male threaded surface of the upper receiver of the firearm.

6. The assembly according to claim 1, wherein the firearm is selected from a platform selected from an AK 15, an M-16 style, an AR-10 style, an M-4 style, a hunting rifle, a sporting rifles, and a sniper-type rifle.

7. A firearm comprising the assembly of any one of claims 1 to 7.

8. A attachment system for mounting a handguard sleeve to a firearm comprising:
a. a barrel nut extending from a first end to second end, wherein a convexly curving outer surface of the barrel nut defines an annular groove extending around at least a portion of the circumference of the barrel nut;
b. an adapter capable of mechanical attachment to the handguard sleeve at the handguard sleeve's first end, the adapter having 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; wherein the adapter 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 wall, and the upper portion comprises an aperture defined by the adapter body wall;
c. 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.

9. The system of claim 8, comprising two wedge pockets and two locking wedges, wherein the wedge pockets are disposed on opposite sides of the adapter.

10. The system of claim 8 or claim 9 wherein the wedge pocket(s) are each disposed on the adapter below center of bore when the system is mounted on the firearm.

11. The system according to claim 8, wherein the first end of the barrel nut has a female threaded surface that is attachable to a counterpart male threaded surface of the upper receiver of the firearm.

12. The system according to claim 8, wherein the firearm is selected from a platform selected from an AK 15, an M-16 style, an AR-10 style, an M-4 style, a hunting rifle, a sporting rifles, and a sniper-type rifle.

13. A firearm comprising the system of any one of claims 8-12.

14. A method of attaching an attachment system for attaching a handguard sleeve to an upper receiver of a firearm comprising:
a. Providing a firearm;
b. Disassembling the firearm to expose a distal end of the upper receiver;
c. Attaching a barrel nut on to the upper receiver of the firearm, wherein the barrel nut extends from a first end to second end having a convexly curving outer surface that defines an annular groove extending around at least a portion of the circumference of the barrel nut;
d. Reassembling the firearm;
e. Sliding an adapter onto the firearm so that the first end of the adapter slides onto and against an outer surface of the barrel nut, wherein the adapter is capable of mechanical attachment to the handguard sleeve at the handguard sleeve's first end a first end of the adapter that has an internal diameter that is dimensioned so that the first end of the barrel nut is insertable into the first end of the adapter;
wherein the adapter includes an adapter body comprising a wall having an outer surface and a first and a second wedge pocket that are disposed on the outer surface of the adapter and spaced apart from one another, the wedge pockets each comprising an upper portion and a lower portion, wherein the lower portion comprises a slot in the wall extending to a bottom surface within the adapter body, and the upper portion comprises an aperture defined by the adapter body wall;
Inserting a first and a second locking wedge in to the corresponding first and second wedge pockets of the adapter, wherein each locking wedge has 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 is 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.

15. The method of claim 13, wherein the further comprising securing the locking wedge to the to the adapter.

16. The method of claim 15 wherein securing is accomplished by a mechanical fastener attaching the lower section of the locking wedge to the adapter.

17. The method of claim 14 where the firearm is selected from firearm is selected from a platform selected from an AK 15, an M-16 style, an AR-10 style, an M-4 style, a hunting rifle, a sporting rifles, and a sniper-type rifle.