Adaptable Handguard

The present invention is a continuation of U.S. Utility patent application Ser. No. 18/417,154 filed on Jan. 19, 2024, the entirety which is hereby incorporated by reference.

The present invention relates to a system and method for changing handguards and barrels on a firearm.

There are multiple barrel sizes for firearms. Different barrels serve different purposes. Consequently, there is a need to be able to quickly and easily change barrels on a firearm.

Several embodiments of Applicant's invention will now be described with reference to the drawings. Unless otherwise noted, like elements will be identified by identical numbers throughout all figures. The invention illustratively disclosed herein suitably may be practiced in the absence of any element which is not specifically disclosed herein.

is a perspective exploded view of an adaptable barrel system in one embodiment.is a perspective view of an assembled adaptable barrel system in one embodiment.

As shown is a barrel. The barrelcan comprise various lengths, calibers, etc. The barrel can comprise various calibers including 223 or 556. The barrelcan also have various lengths. In one embodiment the user wants to change the type of barrelassociated with a specific firearm. The user can want to change the length of the barrel, the caliber, etc. In one embodiment the system and method discussed herein allows the swapping or replacing of a barrel without any additional tools or permanent alterations to the firearm. In one embodiment, the system requires minimal tools to install. However, once installed, no tools are required to switch barrels. As an example, various tools may be needed to install the system onto the firearm. However, once installed, the user can switch from a 300 Blackout to a 556 barrel without requiring any tools.

As depicted is the upper receiverof a firearm with an AR-15 platform. While an AR-15 platform is discussed, this is for illustrative purposes only and should not be deemed limiting. Virtually any firearm platform which has a removable barrel can utilize the system discussed herein.

The system, as shown, includes a handguard. The handguardcovers the barrel. The handguard, can have various accessories such as a rail as depicted. The handguardcouples to the receiver with a housing, which will be discussed in more detail below herein.

Coupled to the barrelis the barrel adapter, which will be discussed in more detail in. The barrel adaptercouples to the receivervia a handguard receiver adapter.

Turning to,is a perspective view of a handguard receiver adapter in one embodiment. As depicted, the upper receiverhas threading. The threadingallows various items to be coupled to the receiver. In one embodiment, the handguard adapter receiverdoes not have threads. Instead, it slides as far upstream as possible. Upstream and downstream refer to relative locations on a firearm. The end closer to the trigger is an upstream end whereas the end closes to the end of the barrel where the projectile exits is the downstream end. Once the handguard adapter receiverhas been positioned as upstream as possible, then the threadingof the receivercouples to threading on the adapter nut. The adaptermaintains the handguard receiver adapterin the desired location. Furthermore, this scenario maintains the precise location, not just along the upstream/downstream axis but also up/down, and left/right, because of a tapered surface on both the nutand the adapter receiver.

In one embodiment the handguard adapter receiverhas earson the upstream end which prevent the adapter receiverfrom rotating. The ears are best shown inwhich shows the reverse side of the receiver adapter. The earsfit within the void of the upper receiverwhich prevents the receiver adapterfrom rotating. Further, as shown, the adapter receivercomprises adapter hookspositioned along the periphery of the adapter receiver. As shown, these are equally spaced about 120 degrees removed from one another. This allows engagement with the housingas will be discussed in more detail.

Turning back to, as shown, the adapter nutcomprises wrench couplerswhich allow a wrench to engage, rotate, and tighten the adapter nut. In one embodiment the adapter nut, like the receiver adapter, comprises a tapered inner wall. This allows the two components to properly align in proper fit. When a tight fit is achieved, as a result of compression, the result is a snug and tight fit with interplay and movement between parts minimized or eliminated

Turning to,is a front perspective view of the receiver adapterbeing positioned on the upper receiver. As noted, the upper receiverhas threads, whereas, as depicted, the receiver adapterdoes not. As can be seen, there is a void between the receiverand the receiver adapter. This results in play as the receiver adaptercan be moved relative to the receiver. The fixed diameter barrel extensionfits within the fixed diameter of the bore of the receiver. The clearance between these parts can be as large or larger than 0.0013 inches. Taking the 0.0013 inches and dividing by 2 to obtain a radius, this is about 0.00065 inches in any direction surrounding the barrel can move within the bore of the receiver. This undesirable distance results is play of the barrel. This play is reduced by the tapering of the adapterand the adapter nut, as described below. In other embodiments the gap can be as large as 0.0041 inches, resulting in considerable play. As noted, this can be reduced with the system discussed herein.

The receiver adapter, as noted, has a tapered inner wall. The adapter nuthas a tapered outer wall. Thus, when the adapter nutis tightened along the threadsof the receiver, the tapers of the receiver adapterand the adapter nutmeet and align. This ensures proper centering of the receiver adapterrelative to the receiverand reduces play between the components. This results in a structurally complete and sound assembled product.

Turning back to, the handguard adapter receiver, as shown, has an exhaust hole. The exhaust holecan align with other holes in other components to provide a path for the exhaust. Further, this exhaust hole provides an additional opportunity to secure and hold the receiver adapterin the desired location. Thus, the adapter receiveracts as a brace for the gas tube which can become jostled and loose. The adapter receiver, when it includes an exhaust hole, eliminates the need for a separate gas tube brace. While a gas tube has been described, this is for illustrative purposes only. The adapter receivercan accommodate other items or configurations depending upon the specific firearm.

Turning to,is a perspective view of the barrel adapter assembly in one embodiment. The barrel adapterattaches to the barrel extension. As noted (and shown in), the barrel has a barrel extensionlocated on the downstream end of the barrel.

The assembly, as shown in one embodiment, comprises a depth ring, a lock ring, and barrel adapter. As shown, and in one embodiment, the depth ringand the lock ringboth thread onto the barrel adapter. When installed together, the depth ring, lock ring, and the barrel adapterare referred to collectively as the barrel adapter assembly. The barrel adapteralso has outer threads on the upstream post of the barrel adapter. The depth ringand the lock ring, in one embodiment, comprise internal threads which engage and couple with the external threads on the barrel adapter. The internal edge of the depth ringmakes contact with the barrel extension. The width of the barrel adapter assembly can be adjusted by manipulating the depth ringand the lock ringrelative to the barrel adapter. When tightened as tight as possible, the width of the barrel adapter assembly is tight and compact. As used in this example, width is measured as the upstream and downstream axis. The width can be increased by loosening the depth ringand or the lock ringrelative to the barrel adapter. A more compact barrel adapter assembly occupies less space within the housing. If the resulting coupling has too much play or slack, the barrel adapter assembly can be manipulated to increase the width. Increasing the width of the barrel adapter assembly results in more space being occupied within the housing. This results in less play and less slack. Thus, the ability to increase the size of the barrel adapter assembly, and thus the amount of space it occupies within the handguard, allows for controlling the slack and play within the handguard.

To install, the barrel adapter assembly is placed the furthest upstream possible on the barrel. In one embodiment, the barrel adapter assembly is placed adjacent the barrel adapter.

Once a desirable position of the rings has been set it is slid onto the barrel as far upstream as possible, the adapter can be set in the location. Initially the rings,are loose in relation to the post on the barrel adapter assembly. They can be tightened, in one embodiment, via wrenches. As noted, the adapter assemblyis placed as far upstream as possible on the barrelor barrel extension. In one embodiment, and as depicted, the barrel adapterhas screw portslocated within the barrel adapter. In one embodiment the screw portsare equally spaced along the barrel adapter. As shown, they are approximatelydegrees separated along the barrel adapter. Screws, or the like, can be inserted via the screw ports, and tightened to fix the adapterto the barrelin the desired location. Once this occurs, compression is set. No further tools are necessary for the installation at this point.

In one embodiment, the downstream face of the barrel adapteris tapered. This creates a neutral position for the handguard to match up to, which once under compression, removes any error from tolerances of the two mating parts. Additionally, this likely positions the barrel where it was previously. Further, it allows for a natural self-centering concept.

In one embodiment the downstream faceis tapered along the entire periphery of the barrel adapter's outer wall. As shown, the taper begins inwardly at a larger diameter and expands to a reduced diameter at the end of the taper. As noted, the taper allows the barrel adapter, and thus the barrel adapter assembly, to find a centered and neutral position within the handguard.

Turning to,is a perspective view of the adaptable barrel system in one embodiment. As can be seen the barrel, and the barrel adapterare properly aligned with the handguard receiver adapter. The barrel extensionwill be received by the receiver.

is a perspective view of the assembled adaptable barrel system in one embodiment. As can be seen, the adapter assembly is brought adjacent to the handguard receiver adapter.

It should be noted that while one embodiment has been shown for a variable-width barrel adapter assembly, this is for illustrative purposes only and should not be deemed limiting. In other embodiments, the system utilizes a fixed width barrel adapter assembly. In one such embodiment, rather comprising adjustable pieces which can expand or shorten the width, the barrel adapter assembly comprises a single piece which is not adjustable. In some embodiments, and some handguards, a specific width will suffice. Thus, in such embodiments the fixed barrel adapter assembly need not be adjustable. In some embodiments, however, the downstream end still has a tapered shape to allow it to be received within the housing.

Turning to,is a perspective view of the housing in one embodiment. As shown the housinghas a plurality of coupling holes to connect to the handguard. This can be accomplished via any method or device known in the art including screws. The handguardhas not been illustrated into highlight the housing.

As shown, the housinghas three over center compression toggle latches. While three is shown, this is for illustrative purposes only and should not be deemed limiting. The three are spread equally along the outer periphery of the housing. This allows the latchesto be equally spaced at about 120 degrees from one another. This orientation, in some embodiments, provides for an even spread of compression. Many AR-15 barrels are hand slide-in fit and have a lot of undesirable vertical play. Two latches, for example, without more and oriented on the side of the embodiment, do not decrease the vertical play problem. However, by having three latchesspread evenly, there is compression in the vertical dimension as well, and the play in the vertical dimension is reduced. In one embodiment, the latchesmove up and down on the pin as it rotates, this makes the latcheswant to move to the same location every time. Additionally, because the surfaces are tapered, the internal tapering of the housingmatches with the tapering of barrel adapter. If the internal surface of the housingwere not tapered, regardless of the amount of compression, the position might be microns off compared to the location of the previous removal. The interior tapering of the housingreduces this problem since it matches with the barrel adapter.

In one embodiment, the latchesmate with the adapter hookon the handguard receiver adapter. In one embodiment, and as shown, the latchespivot. If an inward force is applied on a downstream end of the latches, the upstream end of the latchespivot outwardly, disengaging from the adapter hook. In one embodiment the latchescomprises a biasing mechanism such as a spring. The latches can also pivot outwardly if they were not hooked into the receiver adapter.

Turning to,is a perspective view of an assembled housing in one embodiment. As can be seen, the housingis coupled to the handguard receiver adaptervia the latches. This secures the barrelin its desired, and operational, location. Thereafter, the handguardcan be positioned around the housingand secured.

Now that a system has been described, a method of installing an adaptable handguard will be discussed. The method involves removing the existing barrel. This may involve the use of tools. Next, the receiver adapteris coupled to a receiver such as via the adapter nut as described. The receiver adapter can have a tapered inner wall which mates with a tapered outer wall o the adapter nut. If necessary, a wrench or other device can be used to secure the adapter nutto the receiver. In one embodiment, as noted, the receiver adapterhas earswhich keep the receiver adapterin the desired location while the adapter nutis tightened.

Next, the barrel adapter assembly is coupled to a new barrel, as previously described. It should be noted that any such barrel does not have a gas block on it yet. Any applicable AR15 gas block for the barrel in use will need to be installed after the barrel adapter, for example. In one embodiment the barrel adapter assembly is pushed as far upstream as possible. The width of the barrel adapter assembly, if adjustable, can be adjusted to determine a first width. Once set, set screws within the barrel adapter assembly can secure the barrel adapter assembly relative to the barrel.

Thereafter, the housing is secured over the barrel adapter assembly and coupled to the receiver adapter. The housing, in some embodiments, is already coupled to the handguard. In other embodiments, the handguard is coupled to the housingsubsequently. In some embodiments screws are used to couple the housingto the handguard. When the housing was already secured to the handguard, there are no further steps which require a tool. The user can simply decouple the barrel adapter assembly from the receiver adapter and install a different barrel.

Once secured, the user can determine if the barrelis properly and securely held within the handguard. If there is too much slack and play, or too much movement of the barrelwithin the handguard, the user can decouple the housing. The user would then adjust the width of the barrel adapter assembly. If there was too much movement of the barrel, the width of the barrel adapter assembly can be increased. This results in more contact and more compression of the barrel adapter assembly within the housing. This results in less play. This process can be repeated until the barrelis properly held and secured within the handguard.

In some embodiments due to the trial-and-error nature of adjusting the barrel adapter assembly, the housingis repeatedly coupled and de-coupled. In doing so, the user must move the latchesout of the way to couple the housing. As such, in one embodiment the latchescomprise a spring or other biasing mechanism which moves the latchesout of the way when not engaged. When the latchesare out of the way, the user can move easily couple and position the housingas necessary. Otherwise, the latches, which can be in the way must be manually moved and positioned so the housingcan be coupled.

The system and method discussed herein provides for the ability to swap barrelswithout any permanent modifications to the firearms. The tools necessary are minimal—namely screw drivers for screws, and perhaps a wrench for the adapter nut. Furthermore, due to the tapering, the various components allow for precise placement and coupling. As noted, once the system is installed, no tools are necessary for removing the barrel. Instead, the housingis removed, without the use of tools, and the barrelcan be removed.

The user can go from a full length rifle to a short closer quarter rifle. The user can also switch handguards to one with a larger inner diameter that can fit a suppressor underneath it, for example.

It should be noted that the housinghas been depicted as a separate component from the handguard. This is for illustrative purposes only and should not be deemed limiting. In one embodiment the handguardand the housingcomprise a single component. In some embodiments the handguard and housingare integrally made.

While the invention has been particularly shown and described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention.