EP-4735822-A2 - ADDITIVE METAL RIFLE SYSTEMS AND MANUFACTURING METHODS

EP4735822A2EP 4735822 A2EP4735822 A2EP 4735822A2EP-4735822-A2

Abstract

A rifle system and methods for construction thereof is provided. The rifle system is formed using alternative production methods, such as advanced additive manufacturing ("AM") technologies – also called 3D printing. Also included is an improved trigger housing, an improved bolt hold detent system configured to be operated ambidextrously, an improved magazine-well, an improved trunnion, and an ambidextrous release assembly.

Inventors

RENICK, JR., James Phillip
JARBOE, MICHAEL BRENT

Assignees

SAABR LLC

Dates

Publication Date: 20260506
Application Date: 20240701

Claims (20)

1. A firearm comprising: a single piece receiver body formed with additive metal during an additive material process, the receiver body defining a horizontal channel and a mag well extending vertically therefrom; a barrel extending from the horizontal channel of the receiver body; and a multi-piece trunnion assembly for securing said barrel to said receiver body, said trunnion assembly being positioned at least partially within said horizontal channel of said receiver body, wherein said trunnion assembly comprises a trunnion plate and a trunnion block selectively secured therewith.
2. The firearm of claim 1, further comprising: a bolt head engaged with said trunnion plate; and a retaining nut securing said barrel to said trunnion block.
3. The firearm of claim 2, wherein said trunnion plate is coupled directly to said receiver body, wherein said trunnion block is coupled directly to said receiver body, and wherein said trunnion block and said trunnion plate are coupled directly to each other.
4. The firearm of claim 2, wherein said trunnion block is formed with additive metal during an additive material process.
5. The firearm of claim 2, further comprising: first and second magazine release buttons coupled to said receiver body and positioned on respective first and second sides of the firearm to facilitate selective independent user engagement therewith, each of said first and second magazine release buttons being moveable between respective engaged and disengaged configurations; and a magazine catch plate extending from said first magazine release button and being moveable from a retaining position to a retracted position by moving said first magazine release button from its disengaged configuration to its engaged configuration, wherein holding said second magazine release button in its engaged configuration inhibits said first magazine release button from moving away from its engaged configuration.
6. The firearm of claim 5, further comprising: a first pin for securing said first magazine release button to said receiver, wherein moving said first magazine release button between its engaged and disengaged configurations comprises rotating said first magazine release button about said first pin, and wherein moving said second magazine release button from its disengaged configuration towards its engaged configurations comprises moving said second magazine release button linearly towards said first pin, thereby causing said first magazine release button to rotate away from its disengaged configuration.
7. The firearm of claim 6, further comprising first and second springs in communication with respective first and second magazine release buttons, said first and second springs being configured to bias respective first and second magazine release buttons towards respective disengaged configurations.
8. The firearm of claim 7, wherein each of said first and second magazine release buttons comprises a user engagement member and a flange extending therefrom, respective distal ends of said flanges defining corresponding first and second angled noses.
9. The firearm of claim 8, wherein moving said first release button towards its engaged configuration while said second release button remains in its disengaged configuration causes said first angled nose to rotate away from said second angled nose, and wherein moving said second release button towards its engaged configuration while said first release button is in its disengaged configuration causes said second angled nose to drive into said first angled nose, thereby generating a lateral force biasing said first release button away from its disengaged configuration.
10. The firearm of claim 6, wherein said first and second magazine release buttons are in communication via overlapping of respective first and second angled noses.
11. A magazine release assembly for a firearm, the release assembly comprising: a magazine catch plate; a first magazine release button connected to the magazine catch place, wherein said first magazine release button is configured to move rotationally about an axis when engaged, thereby moving said magazine catch plate; a second magazine release button in communication with said first magazine release button, wherein said second magazine release button is configured to move linearly when engaged.
12. The release assembly of claim 11, wherein said second magazine release button is further configured to impact said first magazine release button upon engagement, thus causing the rotation of said first magazine release button.
13. The release assembly of claim 11, further including a first spring in communication with said first magazine release button and a second spring in communication with said second magazine release button, the first and second spring being configured to return the first and second magazine release buttons to their original positions after being engaged.
14. The release assembly of claim 11, wherein the first and second magazine release buttons each comprise a flange, a distal end of each flange defining an angled nose.
15. The release assembly of claim 14, wherein the first and second magazine release buttons are in communication via overlapping of their respective angled noses.
16. The release assembly of claim 15, wherein said second magazine release button is further configured to impact said first magazine release button upon engagement, thus causing rotating of said first magazine release button.
17. The release assembly of claim 16, further including first spring in communication with the first magazine release button and second spring in communication with the second magazine release button, wherein said first and second springs are configured to return the first and second magazine release buttons to their original positions after being engaged.
18. A method of changing the caliber of a firearm, the firearm comprising: a receiver body, the receiver body defining a horizontal channel and a mag well extending vertically therefrom; and a multi-piece trunnion assembly positioned at least partially within said horizontal channel of said receiver body, said multi-piece trunnion assembly comprising: a trunnion plate engaged with a first bolt head; and a trunnion block engaged with a first barrel, wherein the method comprises: decoupling the trunnion block from the receiver body; removing the trunnion block from the receiver body while the trunnion plate remains secured to the receiver body; decoupling the first barrel from the trunnion block; coupling a second barrel with the trunnion block; positioning the trunnion block relative to the receiver body and the trunnion plate; and securing the trunnion block to the receiver body, wherein the first and second barrels are associated with respective first and second calibers.
19. The method of claim 18, further comprising: decoupling the trunnion plate of the trunnion assembly from the receiver body; removing the trunnion plate from the receiver body; replacing the first bolt head with a second bolt head; positioning the trunnion plate relative to the receiver body; and securing the trunnion plate to the receiver body, wherein the first and second bolt heads are associated with the respective first and second calibers.
20. The method of claim 19, wherein the receiver body is a single piece receiver body formed with additive metal during an additive material process.

Description

ADDITIVE METAL RIFLE SYSTEMS AND MANUFACTURING METHODS Cross-Reference to Related Applications [0001]This application claims priority to U.S. Provisional Application Serial No. 63/524,571 , filed June 30, 2023, the entire disclosures of which are incorporated herein by reference. Field of the Invention [0002] The present invention relates generally to firearms. Specifically, the present invention relates to additive metal rifles systems and methods for manufacturing additive metal rifles. Background [0003] The G36 rifle platform was first prototyped in the early 90s as a cold war era replacement for the aging roller rocker G3k and G3A1. The G36 is made of plastic and light polymers to create a lightweight assault rifle. Use of plastic and light polymers in firearm construction, especially in the receiver body, creates durability and tolerance issues. These firearms also wear down quickly, especially in heat, and can be difficult to service or repair. [0004] The scope of the G36’s operation was to be used in cold weather climates, such as for potential battles between the USSR and NATO block countries. Therefore, the G36 design is based on German and NATO requirements of the cold war, which are now decades out of date. The design is for cold climate, and low cycle rates of rounds fired, or 3-5 magazines in full-auto. The shortcomings of the plastic and light polymer construction were not felt as strongly in these conditions. But today's typical war fighter operates in 100-degree heat, extreme altitudes (whether high or low), and in sand and mountains, usually in the middle east or Afghanistan, where these shortcomings become highly problematic. [0005] The construction of the original G36 rifle was only achievable by means of injection molding. No other type of standard grade manufacturing process could work to create the main receiver body formation. Therefore, the original G36 is made from plastic injection molded Nylon66 which overheats and becomes weak allowing the “potted” cast iron trunnion unit to build rotating latency, making the firearm inaccurate. The plastic G36 started to fail in typical modern war conditions rapidly. In fact, a report released by the German Fraunhofer Ernst Mach Institut and Wehrtechnische Dienststelle in 2015 observed the hit rate of the predominantly plastic G36 weapon drops down to a mere 7% at 100 meters when the temperature increases by 30 °C or more. A far cry from the German Bundeswehr required hit rate of 90% at that distance. Such issues are nearly ubiquitous with plastic firearms. Nonetheless, many firearms have continued to be made from plastic due to the low cost and ease of production. [0006] In addition to the problematic materials used in its construction, the G36 has many other downsides. The trigger housing/fire control of the G36 is proprietary to the manufacturer, rather than using NATO standards. Despite being labeled as a “modular rifle system,” the original G36 only used its own special 5.56 magazine rather than a standard STANAG NATO m16 mag. Furthermore, the grip is not interchangeable. And the rifle is not serviceable by the normal soldier. Even further, the bolt detent is a safety obstruction in the down position while wearing gloves. The detent only functions when the bolt is open and needed to be closed. Creating another safety issue. The gas block is not adjustable for suppressed or maritime environments leaving more malfunctions to exist. The G36 has a non-NATO weapons optics system with a mounting area not locked in place. Allowing for no real Minute of Angle (“MOA”) or accuracy basis to be established. This interface between the plastic receiver body and the dual optic carry handle creates a weak point on the firearm. Finally, the aging G36 is difficult to service and there is a lack of parts in stock. [0007] It would be advantageous to provide a new rifle that solves the problems of the G36 platform and similar weapons platforms. It would be advantageous to provide a new rifle capable of performing in modem combat settings. To that end, it would be advantageous to provide a rifle constructed from more durable metal materials. Additionally, it would be advantageous to provide a method for constructing such rifles in an efficient and cost-effective manner. Summary [0008] The instant invention includes a rifle system and methods for construction thereof. The rifle system is formed using alternative production methods, such as advanced additive manufacturing (“AM”) technologies - also called 3D printing. In some embodiments, the rifle system is a 5.56 NATO caliber, gas-piston, semi-automatic rifle. Some embodiments of the present invention include an improved trigger housing. Some embodiments of the present invention include an improved bolt hold detent system configured to be operated ambidextrously. Some embodiments of the present invention include an improved magazine-well. Some embodiments of the present invention include an improved trunnion