FIREARM WITH ADJUSTABLE GAS BLOCK REGULATOR

Field of the Present Disclosure

[0001] The present disclosure relates to firearms, and more particularly to a semi-automatic firearm with an adjustable gas block regulator configured to change back flow pressure depending on a suppressed or an unsuppressed configuration of the firearm. The present disclosure also relates to a gas piston assembly that is less sensitive to gas block to upper receiver hole angular or concentricity deviation.

Background of the Present Disclosure

[0002] Gas-operated semi-automatic rifles use a portion of high-pressure combustion gas from a cartridge being fired to power a bolt assembly to eject the cartridge and feed a subsequent cartridge. Many existing gas systems consist of a gas block rigidly attached to the barrel, where the gas block incorporates an integral gas cylinder and a gas piston housed within the gas cylinder that acts upon a bolt assembly to cycle to load a new round after a previous round was fired. Many existing gas systems also include an orifice communicating with a bore of a barrel and a gas cylinder. Gas pressure entering a gas block may vary depending on the presence or absence of a suppressor on a muzzle of a semi-automatic rifle. Use of a suppressor may impede the exit of gas from a muzzle, resulting in higher back flow pressure into a gas block relative to unsuppressed operation of a semi-automatic rifle.. If a gas block is tuned for unsuppressed operation, gas pressure may cause a gas piston to exert excessive force on a bolt assembly during unsuppressed operation, resulting in excessive wear. If a gas block is tuned for suppressed operation, gas pressure may be insufficient to enable a gas piston to reliably act upon a bolt assembly during unsuppressed operation. Many existing adjustable rotary-type gas regulators may be difficult to change between settings when installed on a semi-automatic rifle.

[0003] Many existing gas piston assemblies may be vulnerable to inappropriate operation in the event of excessive gas block to upper receiver hole angular or concentricity deviation that could cause the back flow pressure to fluctuate. Many existing gas piston assemblies may also be vulnerable to longitudinal loads exceeding their limit of flexure if they are not designed with a sufficient length-to-diameter ratio. This requirement poses challenges with rifles firing higher caliber cartridges that require a longer distance between the upper receiver and the orifice communicating with the bore of the barrel to obtain the correct gas pressure to cycle the action reliably without causing excessive wear. [0004] Therefore, a need exists for a new and improved semi-automatic firearm with a switch-type adjustable gas block regulator to change the back flow pressure depending on suppressed or unsuppressed operation of the firearm that is more ergonomic for the user. A need also exists for a new and improved semi-automatic firearm that includes a gas piston assembly that is less sensitive to gas block to upper receiver hole angular or concentricity deviation.

[0005] This Background is provided to introduce a brief context for the Detailed Description that follows. This Background is not intended to be an aid in determining the scope of the claimed subject matter nor be viewed as limiting the claimed subject matter to implementations that solve any or all of the shortcomings or problems presented above.

Summary of the Present Disclosure

[0006] The present disclosure provides an improved semi-automatic firearm with an adjustable gas block regulator.

[0007] A firearm comprises a receiver. The receiver defines a passage configured to receive a reciprocating bolt assembly. The firearm comprises a barrel defining a barrel axis. The barrel extends from the receiver and defines a barrel gas aperture. The firearm comprises a gas block connected to the barrel. The gas block comprise a gas block inlet registered with the barrel gas aperture. The gas block defines a gas block bore transverse to the barrel axis and in communication with the gas block inlet. The gas block bore defines a gas block bore axis. The gas block defines a gas block outlet in communication with the gas block bore. The firearm comprises a regulator closely received in the gas block bore and operable to reciprocate along the gas block bore between at least a first position and a second position, the second position different from the first position. The regulator defines a first gas path communicating between the gas block inlet and the gas block outlet when the regulator is in the first position. The regulator defines a second gas path communicating between the gas block inlet and the gas block outlet when the regulator is in the second position. The first gas path and the second gas path have different gas flow characteristics.

[0008] The regulator is operable to reciprocate along the gas block bore without rotation.

[0009] The gas block bore is cylindrical.

[0010] One of the first gas flow path and the second gas flow path has a greater gas flow restriction than the other of the first gas flow path and the second gas flow path.

[0011] The first gas flow path including a first orifice with a first size and the second gas flow path having a second orifice having a second size different from the first size.

[0012] The regulator is a cylindrical body. [0013] The regulator defines a manifold in communication with the first gas path and the second gas path.

[0014] The gas block bore axis is perpendicular to the barrel axis.

[0015] The gas block defines a piston bore in communication with the gas block bore. The gas block is configured to receive a gas piston operably engaged to the reciprocating bolt assembly.

[0016] The regulator includes first indicia associated with the first position.

[0017] The regulator includes second indicia associated with the second position.

[0018] The first indicia includes a symbol associated with an operative mode.

[0019] The gas block defines a window. The first indicia is visible in the window based on the regulator position.

[0020] The second indicia includes a symbol associated with an operative mode.

[0021] The gas block defines a window. The second indicia is visible in the window based on the regulator position.

[0022] There has thus been outlined, rather broadly, the more important features presented in order that the detailed description thereof that follows may be better understood and in order that the present contribution to the art may be better appreciated.

Brief Description of the Drawings

[0023] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several embodiments and, together with the description, serve to explain the disclosed principles. In the drawings:

[0024] Fig. 1 is a top isometric view of an example embodiment of a firearm with an adjustable gas block regulator constructed in accordance with the principles of the present disclosure.

[0025] Fig. 2 is an exploded view of the example piston assembly of Fig. 1.

[0026] Fig. 3 is a side sectional view of the example receiver and example barrel of Fig. 1.

[0027] Fig. 4 is a side sectional view of the example receiver and example barrel of Fig. 1.

[0028] Fig. 5 is an exploded view of the example regulator of the example firearm of Fig. 1.

[0029] Fig. 6A is a top sectional view of the example gas block of Fig. 1 showing the example regulator in the position suitable for unsuppressed operation of the example firearm.

[0030] Fig. 6B is a top sectional view of the example gas block of Fig. 1 showing the example regulator in the position suitable for suppressed operation of the example firearm.

[0031] Fig. 7 A is an isometric sectional view of the example regulator of Fig. 5 cutaway through the example orifice for suppressed operation of the example firearm.

[0032] Fig. 7B is an isometric sectional view of the example regulator of Fig. 5 cutaway through the example orifice for unsuppressed operation of the example firearm. [0033] Fig. 8 is an isometric sectional view of the example gas block of Fig. 1.

[0034] Fig. 9 is a top view of the example gas block of Fig. 1.

[0035] The same reference numerals refer to the same parts throughout the various figures.

Detailed Description of Embodiments

[0036] Many example embodiments of a firearm with an adjustable gas block regulator are shown and generally designated by the reference numeral 10.

[0037] Fig. 1 illustrates an example improved firearm with an adjustable gas block regulator 10 with the trigger hidden.

[0038] Fig. 2 illustrates an exploded view of an example piston assembly 48.

[0039] Figs. 3 & 4 are side sectional views of an example receiver 12 and an example barrel 18.

[0040] Fig. 5 is an exploded view of an example regulator 34.

[0041] Fig. 6 A is a top sectional view of an example gas block 24 showing an example regulator in the position suitable for unsuppressed operation of an example firearm.

[0042] Fig. 6B is a top sectional view of an example gas block showing an example regulator in the position suitable for suppressed operation of an example firearm.

[0043] Fig. 7 A is an isometric sectional view of an example regulator cutaway through the orifice for suppressed operation of an example firearm.

[0044] Fig. 7B is an isometric sectional view of an example regulator cutaway through the orifice for unsuppressed operation of an example firearm.

[0045] Fig. 8 is an isometric sectional view of an example gas block.

[0046] Fig. 9 is a top view of an example gas block.

[0047] In some embodiments, a firearm may comprise a receiver 12 defining a passage 14 receiving a reciprocating bolt assembly 16. A barrel 18 may define a barrel axis 20 which extends from the receiver in a forward direction and defines a barrel gas aperture 22. A gas block 24 may be connected to the barrel. The gas block may comprise a gas block inlet 26 registered with the barrel gas aperture. The gas block may define a gas block bore 28 transverse to the barrel axis and in communication with the gas block inlet. The gas block bore may define a gas block bore axis 30. The gas block may also define a gas outlet 32 in communication with the gas block bore. A regulator 34 may be closely received in the gas block bore. The regulator may be operable to reciprocate along the gas block bore between at least a first position shown in Fig. 6 A and a different second position shown in Fig. 6B. The regulator may define a first gas path 36 shown in Figs. 7A & 8 communicating between the gas block inlet and gas block outlet when the regulator is in the first position. The regulator may define a second gas path 38 shown in Fig. 7B communicating between the gas block inlet and gas block outlet when the regulator is in the second position. The first gas path and the second gas path may have different gas flow characteristics.

[0048] In some embodiments, a first gas path and a second gas path may have different gas flow characteristics, with one being suitable for suppressed operation of a firearm and one being suitable for unsuppressed operation of the firearm. This may be accomplished by one of the first gas flow path and the second gas flow path having a greater gas flow restriction than the other of the first gas flow path and the second gas flow path. The varying gas flow restriction may result from the first gas flow path including a first example orifice 40 with a first size and the second gas flow path having a second example orifice 42 having a second size different from the first size. In the current embodiment, the second orifice is smaller than the first orifice so the increased gas pressure resulting from suppressed operation of the firearm relative to unsuppressed operation of the firearm does not result in excessive force being exerted upon an example piston assembly 48.

[0049] In some embodiments, a regulator 34 may be operable to reciprocate along a gas block bore 28 without rotation. The gas block bore may be cylindrical, and the regulator may comprise a cylindrical body. However, the regulator could be any shape. A cylindrical shape may be employed to facilitate machining of the matching gas block bore. The regulator may define a manifold 44 in communication with a first gas path 36 and a second gas path 38. A gas block bore axis 30 may be perpendicular to a barrel axis 20. A gas block 24 may define a piston bore 46 open in a rearward direction and in communication with the gas block bore. The piston bore may be configured to receive a piston assembly 48. The piston assembly may comprise a forward end operably engaged to the piston bore and a rear end operably engaged to a reciprocating bolt assembly 16, which is shown in Fig. 3.

[0050] In some embodiments, a regulator 34 may include first and second indicia 50, 52, each associated with a respective one of a first and second position. The first and second indicia may be positioned to provide the user with better visibility of them when in the shooting position. The first and second indicia may each include a symbol associated with an operative mode. For example, “N” may represent a regulator position for normal, unsuppressed operation of a firearm 10, and “S” may represent a regulator position for suppressed operation of the firearm. Symbols may include alphanumeric symbols and icons. Operative modes may include suppressed, standard (unsuppressed), and fault override (for example, usage of the suppressed setting without a suppressor attached to the muzzle of the firearm to apply additional force to a reciprocating bolt assembly 16 in the event of a malfunction). [0051] In some embodiments, a gas block may define a window 54. One of a first indicia and a second indicia may be visible in the window based on a regulator position (for example, “N” as shown in Fig. 9).

[0052] In some embodiments, a regulator plunger 56 may be received in a gas plug 58. The regulator plunger may be biased by a regulator plunger spring (not visible) into one of two notches 62, 64 in a regulator as shown in FIGs 6A and 6B. Each notch may correspond to one of a first position and a second position to releasably retain the regulator in a selected position while providing tactile feedback when changing the regulator between positions.

[0053] In some embodiments, a piston assembly 48 may comprise a gas piston 66 closely received in a piston bore 46 and having a piston rear end 68. The piston assembly may include an elongated intermediate rod 70 having an intermediate rod forward end 72 registered with the piston rear end and an intermediate rod rear end 74. The piston assembly may also include a rear portion 76 having a forward end 78 registered with the intermediate rod rear end and a rear portion 80 operably connected to a reciprocating bolt assembly 16.

[0054] In some embodiments, a firearm with an adjustable gas block regulator 10 may include a handguard 80 located between a receiver 12 and a barrel gas aperture 22. The handguard may define a handguard rod bore 82 that closely receives an elongated intermediate rod 70 in a close slip fit manner. An intermediate rod forward end 72 may extend forward of the handguard rod bore. An intermediate rod rear end 74 may extend rearward of the handguard rod bore. The elongated intermediate rod may be longer than the handguard rod bore. The elongated intermediate rod may include a plurality of full diameter portions 84 closely received by the handguard rod bore. The elongated intermediate rod may also include a reduced diameter portion 86 between the full diameter portions. The elongated intermediate rod may have a largest diameter that is less than the handguard rod bore diameter.

[0055] In some embodiments, a spring 88 may be located forward of a portion of a gas piston 66. When a reciprocating bolt assembly 16 is in a forward battery position, the spring may be configured to bias piston assembly 48 components together and against the reciprocating bolt assembly. The spring may be configured to compress in response to movement of the reciprocating bolt assembly to the battery position.

[0056] In some embodiments, each of piston assembly 48 components may be free of connection to each other except for an abutting connection. In this example, each of the piston assembly components are disconnected and separable from each other.

[0057] In some embodiments, piston assembly components may be easily adjusted for use with a firearm having a larger caliber, which requires more distance between a receiver 12 and a barrel gas aperture 22 to obtain the correct gas pressure to cycle a reciprocating bolt assembly 16 reliably without causing excessive wear. The piston assembly components may be easily adjusted by replacing a handguard 80 and an elongated intermediate rod 70 with longer versions. [0058] Piston assembly 48 has numerous benefits including ease of manufacturing by simple turning components, an overall length being spread over multiple components, and a modular design enabling usage of different materials. Elongated intermediate rod 70 may be fully guided within handguard rod bore 82, so any longitudinal loads could exceed the limit of flexure without disrupting operation. As a result, the elongated intermediate rod may be designed with a higher length-to-diameter ratio. Because the elongated intermediate rod may be operating and being guided directly within the handguard rod bore, a substantially lower adapter-rail-to-bore-axis may be achieved. The separated gas operation design of the piston assembly may be less sensitive to gas block 24 to receiver hole angular or concentricity deviation. Furthermore, because the elongated intermediate rod may be disconnected from gas piston 66 after the initial impulse transfer, barrel 18 may be left freely floating afterwards for increased accuracy of firearm 10. Spring 88 may provide positive contact between the gas piston, the elongated intermediate rod, rear portion 76, and reciprocating bolt carrier 16. No gap between the piston assembly components exists. Therefore, the impulse transfer, when operating the reciprocating bolt carrier, may be realized shock- free, unlike many traditional gas piston designs.

[0059] According to an embodiment, a firearm may comprise a receiver. The receiver may define a passage configured to receive a reciprocating bolt assembly. The firearm may comprise a barrel defining a barrel axis. The barrel may extend from the receiver. The barrel may define a barrel gas aperture. The firearm may comprise a gas block connected to the barrel. The gas block may comprise a gas block inlet registered with the barrel gas aperture. The gas block may define a gas block bore transverse to the barrel axis and in communication with the gas block inlet. The gas block bore may define a gas block bore axis. The gas block may define a gas block outlet in communication with the gas block bore. The firearm may comprise a regulator closely received in the gas block bore and operable to reciprocate along the gas block bore between at least a first position and a second position, the second position different from the first position. The regulator may define a first gas path communicating between the gas block inlet and the gas block outlet when the regulator is in the first position. The regulator may define a second gas path communicating between the gas block inlet and the gas block outlet when the regulator is in the second position. The first gas path and the second gas path may have different gas flow characteristics.

[0060] According to an embodiment, a regulator may be operable to reciprocate along a gas block bore without rotation.

[0061] According to an embodiment, a gas block bore may be cylindrical. [0062] According to an embodiment, one of a first gas flow path and a second gas flow path may have a greater gas flow restriction than the other of the first gas flow path and the second gas flow path.

[0063] According to an embodiment, a first gas flow path may include a first orifice with a first size and a second gas flow path may include a second orifice with a second size different than the first size.

[0064] According to an embodiment, a regulator may comprise a cylindrical body.

[0065] According to an embodiment, a regulator may define a manifold in communication with a first gas path and a second gas path.

[0066] According to an embodiment, a gas block bore axis may be perpendicular to a barrel axis.

[0067] According to an embodiment, a gas block may define a piston bore in communication with a gas block bore. The gas block may be configured to receive a gas piston operably engaged to a reciprocating bolt assembly.

[0068] According to an embodiment, a regulator may include a first indicia associated with a first position.

[0069] According to an embodiment, a regulator may include a second indicia associated with a second position.

[0070] According to an embodiment, a first indicia may include a symbol associated with an operative mode.

[0071] According to an embodiment, a gas block may define a window. A first indicia may be visible in the window based on a regulator position.

[0072] According to an embodiment, a second indicia may include a symbol associated with an operative mode.

[0073] According to an embodiment, a gas block may define a window. A second indicia may be visible in the window based on a regulator position.

[0074] In the context of the specification, the terms “rear” and “rearward,” and “front” and “forward” have the following definitions: “rear” or “rearward” means in the direction away from the muzzle 90 of the firearm while “front” or “forward” means it is in the direction towards the muzzle of the firearm.

[0075] In this specification, “a” and “an” and similar phrases are to be interpreted as “at least one” and “one or more.” References to “a”, “an”, and “one” are not to be interpreted as “only one”. In this specification, the term “may” is to be interpreted as “may, for example.” In other words, the term “may” is indicative that the phrase following the term “may” is an example of one of a multitude of suitable possibilities that may, or may not, be employed to one or more of the various embodiments. References to "an" embodiment in this disclosure are not necessarily to the same embodiment. [0076] In this specification, various embodiments are disclosed. Limitations, features, and/or elements from the disclosed example embodiments may be combined to create further embodiments within the scope of the disclosure.

[0077] In addition, it should be understood that any figures that highlight any functionality and/or advantages, are presented for example, purposes only. The disclosed architecture is sufficiently flexible and configurable, such that it may be utilized in ways other than that shown.

[0078] Furthermore, many features presented above are described as being optional through the use of “may” or the use of parentheses. For the sake of brevity and legibility, the present disclosure does not explicitly recite each and every permutation that may be obtained by choosing from the set of optional features. However, the present disclosure is to be interpreted as explicitly disclosing all such permutations. For example, a rifle stock described as having three optional features may be embodied in seven different ways, namely with just one of the three possible features, with any two of the three possible features or with all three of the three possible features.

[0079] While various embodiments of a firearm with an adjustable gas block regulator have been described in detail, it should be apparent that modifications and variations thereto are possible, all of which fall within the true spirit and scope of the present disclosure. With respect to the above description, it is to be realized that the optimum dimensional relationships for parts of various embodiments, to include variations in size, materials, shape, form, function and manner of operation, assembly, and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present disclosure.

[0080] Therefore, the foregoing is considered as illustrative only of the principles of the present disclosure. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the claimed invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the claimed invention.