WO2022271952A1

WO2022271952A1 - Composite firearm charging handle

Info

Publication number: WO2022271952A1
Application number: PCT/US2022/034729
Authority: WO
Inventors: Joshua Sensinger; James TORGERSEN; Mark Hillis
Original assignee: Silencerco, Llc
Priority date: 2021-06-25
Filing date: 2022-06-23
Publication date: 2022-12-29

Abstract

A composite charging handle having a charging handle shaft which has one or more durable metal pieces that are overmolded with a durable polymer, the polymer comprising the exterior surface that will contact the rest of the firearm, and charging handles which are comprised of two pieces, with the portion that interfaces with the charging handle body being made from a durable metal and the portion that the user touches being made of a polymer or other durable material such as aluminum or steel, in a separate operation, whereby the two pieces are then mechanically attached to prevent easy separation in use, yet facilitate interchangeability in the future

Description

COMPOSITE FIREARM CHARGING HANDLE

CROSS REFERENCE

[0001] The present Application for Patent claims priority to U.S. Patent Application No. 17/847,726 by Sensinger et al., entitled “COMPOSITE CHARGING HANDLE” filed June 23, 2022, which claims priority to and the benefit of U.S. Provisional Patent Application No. 63/215,323 by Sensinger et al., entitled “COMPOSITE CHARGING HANDLE” filed June 25, 2021, assigned to the assignee hereof, and each of which is expressly incorporated by reference in its entirety herein.

TECHNICAL FIELD

[0002] The present disclosure relates generally to charging handles. More particularly, the disclosure relates to a composite charging handle with improved mechanical and performance properties that is manufactured at a reduced cost.

BACKGROUND

[0003] A firearm charging handle is used to manually cycle the action of the firearm by retracting the carrier bolt group to allow a bullet into the chamber. Traditionally, charging handle bodies are machined or cast from aluminum. However, such manufacturing techniques fails to take advantage of modern materials and techniques. Therefore a need exists for a charging handle that combines new materials, such as stainless steel, polymers and carbon fiber where it is best suited. A need further exists to provide a charging handle that is a reduced weight. A further need exists for a charging handle manufactured with alternative manufacturing techniques. A further need exists for a charging handle that utilizes materials to provide improved performance in both the charging handles action in the receiver and with the user’s manipulation of the charging handle. A need exists for a charging handle that utilizes modern materials and techniques in the manufacture to meet or exceed the strength needs of the mechanism while improving consistency of manufacturing dimensions and processes and decreasing production time and effort. Thus an apparatus is needed to improve charging handles. BRIEF SUMMARY

[0004] The general purpose of the apparatus and methods disclosed herein is to provide an improved charging handle that allows for the improved performance of charging handle function and manufacture.

[0005] The charging handle shaft would have one or more durable metal pieces that are held in a mold in an injection molding machine and then overmolded with a durable polymer, the polymer comprising the exterior surface that will contact the rest of the firearm. This will permanently bond them together with the resulting combination having extremely consistent dimensions while maintaining the requisite strength and durability for the application. In the instance that two of more metal pieces are used, the second plate adds rigidity and strength for the shaft component as well as for the pins securing the charging handles/latches.

[0006] The charging handles/latches are comprised of two pieces, with the portion that interfaces with the charging handle body being made from a durable metal and the portion that the user touches being made of a polymer or other durable material such as aluminum or steel, in a separate operation. The two pieces are then mechanically attached to prevent easy separation in use, yet facilitate interchangeability in the future.

[0007] Specifically, a system of one or more composite materials can be configured to perform particular operations or actions by mechanically engaging a bolt carrier group that in operation causes or cause the firearm to perform the actions. One or more mechanical members programs can be configured to perform particular operations or actions by virtue of including structures that, when manipulated, cause the apparatus to perform the actions. One general aspect includes a composite charging handle assembly 10. The composite also includes a primary component 15 which may include a body 20 as an integrated structure made from a first material 25 and extending a first axial direction from a head portion 30 at the first end 35 to a second end 40, where the primary component further may include a first lateral side 45 and a second lateral side 50 extending along the axial length of the body from the second end and terminating at the start of the head portion, a top side 55, and a bottom side 60 opposite the top side; where the primary component further may include a member 65 extending from the second end 70; where the head portion may include a substantially planar stamped portion; where the perimeter of the head portion is scalloped 75; where the head portion may include a first pivot 80 hole formed in a first rounded protuberance 85 and a second pivot 90 hole formed in a second rounded protuberance 95; where the first and second lateral sides are distally coined 100 to distally extend the distance between the lateral sides; where a plurality of plastic connecting holes 105 are formed in the primary component; where the head portion may include a plurality of plastic connecting holes 110. The composite also includes a secondary component 200 which substantially covers the primary head portion at the first end, the second end, the first lateral side, the second lateral side the top side, and the bottom side opposite the top side where the secondary component is made from a second material, where the secondary component is a skin 205 over the first component, where the secondary component may include a bilateral receiving slot 210 formed in the head portion covering, where the receiving slot is below 215 a primary plane formed by the top side of the primary member, where the secondary component may include a mating cup 220 extending continuously above the primary plane formed by the top side of the primary member, where the secondary component may include a first rib 225 fixed to the distal side of the first lateral side and a second rib 230 fixed to the distal side of the second lateral side. The composite also includes a primary latch member 300 mated into the receiving slot where the primary latch member may include a latch 305 extending along the first axial direction and terminating in a hook 310, where the primary latch may include a hinge lever 315 coupled to the head portion by a first hinge pin 320 at the primary member first 80 or second 90 pivot hole, where the primary latch may include a first stamped tab 325 extending distally from the head portion, where the primary latch member may include a first insert 330, where the first stamped tab extends from the first hinge pin. The composite also includes a secondary latch activator 335 mated into the receiving slot and articulated to the primary latch member 300 where the activation of the secondary latch 335 manipulates the hook 310; where the secondary latch activator 335 is coupled to the head portion by a second pin 340 at the first 80 or second 90 pivot hole, where the secondary latch activator may include a second stamped tab 345 extending distally from head portion, where the second stamped tab extends from the second hinge pin. The composite also includes a backing plate 350 may include insert pilots 355, plate connecting holes 360 and an O-ring receiving relief cut 365; where the backing plate allows the polymer to create a slot that may further include an O-ring 370, where the insert pivot holes align with the primary component pivot holes. The composite also includes a first stamped tab cover 375 fixed to the primary latch member tab and a second stamped tab cover 380 fixed to the second stamped tab; where the first stamped tab cover or the second stamped tab cover is configured to selectively reconfigured without being separated from the tab to which it is fixed where the stamp cover is configured to screwedly reconfigure and distally extend to lengthen the functional length of the stamped tab, where the stamp cover is configured unfold to increase the functional surface area 385 of the stamp cover where the stamp cover is adhesively fixed to the stamped tab, where the stamp cover is mechanically fixed to the stamped tab with a pin 390, where the stamp cover is slid 395 over the stamped tab. Other embodiments of this aspect include corresponding structures and apparatus, each configured to perform the actions of the methods.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] In order to describe the manner in which the advantages and features of the invention can be obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

[0009] Figure 1 A shows a top view of the primary component.

[0010] Figure IB shows a profile view of the primary component.

[0011] Figure 1C shows a cross-sectional view of the primary component.

[0012] Figure ID shows a top view of the backing plate.

[0013] Figure 2A shows a top view of the secondary component.

[0014] Figure 2B shows a side view of the secondary component.

[0015] Figure 2C shows an end view of the head portion primary, secondary and backing plate components combined.

[0016] Figure 2D shows a side view of the head portion primary, secondary and backing plate components combined.

[0017] Figure 2E shows primary, secondary and backing plate components combined.

[0018] Figure 3 A shows an exploded view of the composite charging handle.

[0019] Figure 3B shows a detailed view of the primary latch member.

[0020] Figure 3C shows a detailed view of the secondary latch member.

[0021] Figure 3E shows a partial view of the composite charging handle assembly.

[0022] Figure 3F shows an end view of the composite charging handle. [0023] Figure 3G shows an alternative plan view of the composite charging handle assembly.

[0024] Figure 4 shows a perspective view of the composite charging handle assembly.

[0025] Figure 5 shows a top view of the composite charging handle assembly.

[0026] Figure 6 shows a transparent view of the charging handle assembly.

DETAILED DESCRIPTION OF THE INVENTION

[0027] The present embodiments of the present invention will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. It will be readily understood that the components of the present invention, as generally described and illustrated in the figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed descriptions of the embodiments of the apparatus, as represented in Figures 1 through 6 are not intended to limit the scope of the invention, as claimed, but are merely representative of present embodiments of the invention.

[0028] In general, the figures disclose an invention that provides a composite charging handle configured to improve the performance and function of the charging handle. In some embodiments comprise a metal core with an overmolded polymer for a permanent bond. In some embodiments the metal core could be comprised of one or more parts and could be made of a number of different metal alloys.

[0029] In some embodiments the charging handles/latches are each comprised of two or more separate pieces that are not permanently bonded or attached. In some embodiments the first piece is made of metal and is attached to the body of the charging handle by common fastening methods. In some embodiments a second piece would be polymer or other durable material such as aluminum or steel and would be mechanically attached by pins, screws or other common fastening method and would offer interchangeability or user serviceability.

[0030] In some embodiments the charging handle shaft may have a stainless steel core for strength and corrosion resistance. In some embodiments the core may be stamped. In some embodiments the polymer used for the overmolding would have high temperature resistance, low friction, good UV light resistance and high rigidity.

[0031] In some embodiments the charging handles/latches would ideally have a stainless steel plate for corrosion resistance and strength. In some embodiments if made from polymer, the handles would have high rigidity, high strength and good UV light resistance. In some embodiments if made from aluminum or steel, the handles would have high rigidity, high strength and excellent corrosion resistance.

[0032] In the following description, references will be made to firearms, bullets, bolt carrier groups and receivers, but these items are not shown in detail in the figures. However, it should be understood that one of ordinary skill in the art and in possession of this disclosure, would readily understand how the present invention and firearms and firearm components can be incorporated. [0033] Detailed references will now be made to the preferred embodiments of the present invention, examples of which are illustrated in FIG. 1 a primary component 15 comprising a body 20 as an integrated structure made from a first material 25 and extending a first axial direction from a head portion 30 at the first end 35 to a second end 40. In some embodiments the primary component further comprises a first lateral side 45 and a second lateral side 50 extending along the axial length of the body from the second end and terminating at the start of the head portion, a top side 55, and a bottom side 60 opposite the top side. In some embodiments the primary component further comprises a member 65 extending from the second end 70. In some embodiments the head portion comprises a substantially planar stamped portion. In some embodiments the perimeter of the head portion is scalloped 75. In some embodiments the head portion comprises a first pivot 80 hole formed in a first rounded protuberance 85 and a second pivot 90 hole formed in a second rounded protuberance 95. In some embodiments the first and second lateral sides are distally coined 100 to distally extend the distance between the lateral sides. In some embodiments a plurality of plastic connecting holes 105 are formed in the primary component. In some embodiments the head portion comprises a plurality of plastic connecting holes 110.

[0034] Referring now to Figure 2, in some embodiments a secondary component 200 which substantially covers the primary head portion at the first end, the second end, the first lateral side, the second lateral side the top side, and the bottom side opposite the top side. In some embodiments the secondary component is made from a second material. In some embodiments the secondary component is a skin 205 over the first component. In some embodiments the secondary component comprises a bilateral receiving slot 210 formed in the head portion covering. In some embodiments the receiving slot is below 215 a primary plane formed by the top side of the primary member. In some embodiments the secondary component comprises a mating cup 220 extending continuously above the primary plane formed by the top side of the primary member. In some embodiments the secondary component comprises a first rib 225 fixed to the distal side of the first lateral side and a second rib 230 fixed to the distal side of the second lateral side

[0035] Referring now to Figures 3A-3F, in some embodiments a primary latch member 300 mated into the receiving slot. In some embodiments the primary latch member comprises a latch 305 extending along the first axial direction and terminating in a hook 310. In some embodiments the primary latch comprises a hinge lever 315 coupled to the head portion by a first hinge pin 320 at the primary member first 80 or second 90 pivot hole. In some embodiments the primary latch comprises a first stamped tab 325 extending distally from the head portion. In some embodiments the primary latch member comprises a first insert 330. In some embodiments the first stamped tab extends from the first hinge pin.

[0036] In some embodiments a secondary latch activator 335 mated into the receiving slot and articulated to the primary latch member 300 . In some embodiments the activation of the secondary latch 335 manipulates the hook 310. In some embodiments the secondary latch activator 335 is coupled to the head portion by a second pin 340 at the first 80 or second 90 pivot hole. In some embodiments the secondary latch activator comprises a second stamped tab 345 extending distally from head portion. In some embodiments the second stamped tab extends from the second hinge pin.

[0037] Some embodiments comprise a backing plate 350 comprising insert pilots 355, plate connecting holes 360 and an O-ring receiving relief cut 365. In some embodiments the backing plate further comprises an O-ring 370. In some embodiments the insert pivot holes align with the primary component pivot holes.

[0038] In some embodiments the top stamping and bottom/back stamping are both encased in the composite. In some embodiments the xy plane cross section of the charging handle show both the larger stamping on top and the bottom/back plate. In some embodiments both the top and bottom/back plate are both encased in the composite, with a cut out in the back plate to allow for the O-ring channel to be deep enough to retain the O-ring while not having the bottom/back plate protruding out into the lever channel.

[0039] In some embodiments the backing plate, colored blue in the pictures, will be completely covered with polymer in the final product. It will sit close to the bottom surface and the polymer will flow around it and inside the U-slot to form the dovetail for the o-ring. The o-ring diameter is about 70% as wide as the slot in the backing plate, so there is space for the polymer to completely encase the plate. The polymer will flex as the dovetail portion of the mold is retracted and keep the original shape, while the backing plate provides rigidity to the polymer.

[0040] In some embodiments the composite charging handle comprises a first stamped tab cover 375 fixed to the primary latch member tab and a second stamped tab cover 380 fixed to the second stamped tab. In some embodiments the first stamped tab cover or the second stamped tab cover is configured to selectively reconfigured without being separated from the tab to which it is fixed. In some embodiments the stamp cover is configured to screwedly reconfigure and distally extend to lengthen the functional length of the stamped tab. In some embodiments the stamp cover is configured unfold to increase the functional surface area 385 of the stamp cover. In some embodiments the stamp cover is adhesively fixed to the stamped tab. In some embodiments the stamp cover is mechanically fixed to the stamped tab with a pin 390. The mechanically attached covers, whether polymer or other durable materials, allow for user configurability without disassembling the functional parts of the charging handle. In some embodiments the stamp cover is slid 395 over the stamped tab.

[0041] In closing, it is to be understood that the embodiments of the disclosure disclosed herein are illustrative of the principles of the present disclosure. Other modifications that may be employed are within the scope of the disclosure. Thus, by way of example, but not of limitation, alternative configurations of the present disclosure may be utilized in accordance with the teachings herein. Accordingly, the present disclosure is not limited to that precisely as shown and described.

Claims

CLAIMS:

1. A composite charging handle assembly 10 comprising: a primary component 15 comprising a body 20 as an integrated structure made from a first material 25 and extending a first axial direction from a head portion 30 at the first end 35 to a second end 40, wherein the primary component further comprises a first lateral side 45 and a second lateral side 50 extending along the axial length of the body from the second end and terminating at the start of the head portion, a top side 55, and a bottom side 60 opposite the top side; wherein the primary component further comprises a member 65 extending from the second end 70; wherein the head portion comprises a substantially planar stamped portion; wherein the perimeter of the head portion is scalloped 75; wherein the head portion comprises a first pivot 80 hole formed in a first rounded protuberance 85 and a second pivot 90 hole formed in a second rounded protuberance 95; wherein the first and second lateral sides are distally coined 100 to distally extend the distance between the lateral sides; wherein a plurality of plastic connecting holes 105 are formed in the primary component; wherein the head portion comprises a plurality of plastic connecting holes 110; a secondary component 200 which substantially covers the primary head portion at the first end, the second end, the first lateral side, the second lateral side the top side, and the bottom side opposite the top side wherein the secondary component is made from a second material; wherein the secondary component is a skin 205 over the first component; wherein the secondary component comprises a bilateral receiving slot 210 formed in the head portion covering; wherein the receiving slot is below 215 a primary plane formed by the top side of the primary member; wherein the secondary component comprises a mating cup 220 extending continuously above the primary plane formed by the top side of the primary member; wherein the secondary component comprises a first rib 225 fixed to the distal side of the first lateral side and a second rib 230 fixed to the distal side of the second lateral side; a primary latch member 300 mated into the receiving slot wherein the primary latch member comprises a latch 305 extending along the first axial direction and terminating in a hook 310; wherein the primary latch comprises a hinge lever 315 coupled to the head portion by a first hinge pin 320 at the primary member first 80 or second 90 pivot hole; wherein the primary latch comprises a first stamped tab 325 extending distally from the head portion; wherein the primary latch member comprises a first insert 330; wherein the first stamped tab extends from the first hinge pin; a secondary latch activator 335 mated into the receiving slot and articulated to the primary latch member 300 wherein the activation of the secondary latch 335 manipulates the hook 310; wherein the secondary latch activator 335 is coupled to the head portion by a second pin 340 at the first 80 or second 90 pivot hole; wherein the secondary latch activator comprises a second stamped tab 345 extending distally from head portion; wherein the second stamped tab extends from the second hinge pin; a backing plate 350 comprising insert pilots 355, plate connecting holes 360 and an O-ring receiving relief cut 365; wherein the backing plate further comprises an O-ring 370; wherein the insert pivot holes align with the primary component pivot holes; and a first stamped tab cover 375 fixed to the primary latch member tab and a second stamped tab cover 380 fixed to the second stamped tab; wherein the first stamped tab cover or the second stamped tab cover is configured to selectively reconfigured without being separated from the tab to which it is fixed wherein the stamp cover is configured to screwedly reconfigure and distally extend to lengthen the functional length of the stamped tab; wherein the stamp cover is configured unfold to increase the functional surface area 385 of the stamp cover wherein the stamp cover is adhesively fixed to the stamped tab; wherein the stamp cover is mechanically fixed to the stamped tab with a pin 390; wherein the stamp cover is slid 395 over the stamped cover.