Re-Moldable Holsters

Abstract

A gun holster is disclosed. The holster includes a first layer, a second layer, and a third layer sandwiched between the first layer and the second layer. The first layer is made of a first material and defines an outer surface of the holster. The second layer is made of a second material and defines an inner surface of the holster. The third layer is made of a thermoplastic composite material containing fibers embedded in a thermoplastic resin. Heating the holster within a predetermined temperature range softens the third layer, thereby facilitating molding of the holster.

Description

Technical Field

[0001] The present disclosure relates generally to moldable articles. More particularly, the present disclosure relates to a moldable casing or covering, such as a holster for a firearm, and methods of making the same. Background Art

[0002] Typically, each different type of gun carry style typically requires a separate holster optimized for that style. Within a single category of holsters, there may be different cant configurations; for example, a holster configured to be worn in the three / nine o'clock position may require no cant, while a holster configured to be worn in the four o'clock position may require a moderate cant to position the handle in an ideal position when the user's arm is articulated in such a position.

[0003] The above illustrates only a few examples of variations in holster configurations. Holsters are worn for significant periods of time every day, so comfort is highly desirable while maintaining adequate concealment. These design goals are often mutually exclusive, and any given design is a compromise of one to the other. The ideal balance can appear elusive because the wearer may not be able to fully feel the desired balance, and the desired balance may change over time based on experience and training. For this reason, it is common for those who regularly carry a concealed firearm to frequently search for and purchase a new holster that may meet their needs, even if only for a short time.

[0004] Therefore, there is a need in the art for a holster that can be reconfigured for a variety of carrying situations and items. There is also a need in the art for a holster that can be custom molded by the user to accommodate a variety of different firearms or other items specific to the intended self-defense requirements. Additionally, there is a need for a holster that is made of a material that provides optimal comfort while also securing the item contained therein. Summary of the invention

[0005] One aspect of the present disclosure relates to a holster. The holster may include a first layer, a second layer, and a third layer sandwiched between the first layer and the second layer. The first layer may be made of a first material and define an outer surface of the holster. The second layer may be made of a second material and define an inner surface of the holster. In addition, the third layer may be made of a thermoplastic composite material containing a plurality of fibers embedded in a thermoplastic resin. In addition, heating the holster within a predetermined temperature range may soften the third layer, thereby facilitating molding of the holster.

[0006] Another aspect of the present invention relates to a method for molding a holster. The method may include heating a holster blank and maintaining the holster blank at a predetermined temperature range to soften the holster blank. The holster blank may include a first layer of a first material defining an outer surface of the holster, a second layer of a second material defining an inner surface of the holster, and a third layer sandwiched between the first layer and the second layer. The third layer may be made of a thermoplastic composite material containing a plurality of fibers embedded in a thermoplastic resin. In addition, heating the holster at a predetermined temperature range may soften the third layer. The method also includes placing a firearm in the holster blank and applying pressure on the holster blank so that the holster blank can be molded into the shape of a firearm. The method may also include hardening the holster blank by cooling the holster blank, wherein the firearm is disposed in the holster blank. In one embodiment, the holster blank may be formed by adhering the first layer to the second layer.

[0007] According to another aspect, an article is disclosed. The article may include a first layer of a first material defining an outer surface of the article and a second layer of a second material defining an inner surface of the article. The article may also include a third layer sandwiched between the first layer and the second layer. The third layer may be made of a thermoplastic composite material containing a plurality of fibers embedded in a thermoplastic resin. In addition, heating the article within a predetermined temperature range may soften the third layer to facilitate molding of the article.

[0008] The present disclosure relates to additional details of the aforementioned holsters, methods of molding holsters, and articles. In one embodiment, the plurality of fibers may be ultra high molecular weight polyethylene fibers. In another embodiment, the first material is a leather material, and in another embodiment, the second material may be a leather material. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] These and other features and advantages of the various embodiments disclosed herein will be better understood from the following description and accompanying drawings, in which like numerals represent like parts, and in which:

[0010] Figure 1 shows a perspective view of an exemplary holster for housing a firearm according to one embodiment of the present disclosure;

[0011] Figure 2 According to one embodiment of the present disclosure, Figure 1 A cross-sectional view of a holster;

[0012] Figure 3 According to one embodiment of the present disclosure, Figure 1 The method for manufacturing a holster of the present invention comprises steps wherein the third layer is located above the first layer;

[0013] Figure 4 shows a perspective view of a holster sheet for making a holster according to one embodiment of the present disclosure; and

[0014] Figure 5 According to one embodiment of the present disclosure, by folding Figure 4 A perspective view of a holster blank formed from holster pieces. DETAILED DESCRIPTION

[0015] The detailed description described below in conjunction with the accompanying drawings is intended to describe the presently preferred embodiments of the moldable holster and is not intended to represent the only forms of the present embodiments that may be developed or utilized. It should also be understood that the use of relational terms such as first and second, etc., are merely used to distinguish one entity from another entity and do not necessarily require or imply any actual such relationship or order between such entities.

[0016] refer to Figure 1 , an article 100 is shown, for example, a holster 102 adapted to hold or receive a handheld firearm (i.e., a pistol (not shown), such as an automatic loading pistol or a revolver). Although the article 100 is described as a holster 102, it should be understood that the article 100 of the disclosed construction may be a holster for handcuffs, a holster for a non-lethal weapon (such as a stun device, a pepper spray can, a baton, etc.), and a holster for other general tools (such as a knife, a flashlight, a multi-tool, etc.) that the wearer of the article 100 may prefer to keep on the person and have easy access to. In fact, the article 100 may be adapted to hold any other object, and a person of ordinary skill in the art will understand that the internal shape and size of the article 100 are necessary to hold such an object.

[0017] Holster 102 is adapted to facilitate a user to wear a gun. As shown, holster 102 may include a housing 104 defining an inner cavity 108 for receiving at least a portion of a gun. A pistol typically has a barrel, a trigger, a frame containing action / shooting control components, and a grip for a user to hold the pistol. An automatic loading pistol may also include an action slide that surrounds the barrel and reciprocates along the longitudinal axis of the frame. In the example shown, housing 104 is defined by a first opening 110a and an opposing second opening 110b.

[0018] To secure the firearm in the holster 102, the muzzle / slide of the barrel is inserted through the first opening 110a and toward the second opening 110b. The barrel can reach the second opening 110b and extend outward from there when fully inserted, but this is optional. The length of the housing 104 can correspond to the length of the barrel so that it does not extend beyond the second opening 110b. In other embodiments, the second opening 110b can be omitted, that is, the housing 104 can be closed at the muzzle end. This may be to prevent debris from entering the barrel, or to protect the top of the barrel from damage, among other reasons. The first opening 110b is understood to be higher in order to accommodate the width and height of the barrel and / or slide, as well as the trigger guard that is partially enclosed in the trigger cover area 111. Embodiments in which almost the entire firearm is exposed are possible, but the holster 102 is understood to cover at least the trigger and trigger guard to prevent accidental discharge when the firearm is in the holster.

[0019] Figure 1 The holster 102 is shown as being secured to the wearer by a belt clip 50, which is generally characterized by a base claw 52 and a free claw 54. The claws 52, 54 are understood to be connected to a belt. In the example shown, the holster 102 is configured for use inside the waistband, that is, the holster 102 is tucked inside the wearer's pants and the belt clip 50 is clipped to the belt above the waistband. The belt clip 50 can be made of a flexible / bendable metal that can apply pressure to the pants and belt. However, alternatively, the belt clip 50 can be constructed of any suitable plastic or polymer material that exhibits similar properties.

[0020] The belt clip 50 can be attached to a platform 56 that acts as a spacer between the housing 104 and the base jaw 52. As shown, the platform 56 has a raised pill-shaped configuration and has fixing hardware 58 that mounts the base jaw 52 to the platform 56. In one embodiment, the fixing hardware 58 can include a screw or bolt that is threaded onto a nut that is coupled to a hole in the platform 56. Thus, the screw extends a sufficient depth into the nut without extending into the inner cavity 108. The fixing hardware 58 can also include various washers, grommets, etc.

[0021] same, Figure 1The embodiment of the holster 102 shown is an internal belt type, but the present disclosure also relates to alternative embodiments for other types of carry methods. For example, an external belt holster may include extension wings with belt loops to allow belts to pass through. A separate paddle-like attachment may also be mounted to the housing 104. One of ordinary skill in the art will recognize that the features of the presently disclosed holster 102 may be applicable to other types of holsters, including shoulder holsters, straight leg holsters, inner thigh holsters, ankle holsters, optic ready holsters, and the like.

[0022] As will be described in further detail below, the holster 102 of the present disclosure involves fitting the outer shell 104 tightly to the gun, and fixing the gun in the inner cavity 108 by the compression force applied by the outer shell 104. Generally, the holster 102 can be made of a material that is easy to mold according to the shape and size of the gun. A second fixing mechanism can be added to the holster 12, such as a fixing belt that is disengaged only before the gun is pulled out. One or more belts are suitable for moving between an open position and a closed position. In the open position, the belt allows the gun to be removed from the outer shell 104, while one or more belts can help to fix the gun in the outer shell 104. However, the belt is optional and can be omitted. In addition to the belt, other fixing systems that can be disengaged using a thumb break (break) or the like can be utilized, including fixing systems that require a third form (three-level fixation) and above.

[0023] refer to Figure 1 and Figure 2 , the housing 104 (i.e., the holster 102) includes a first layer 112 of a first material defining an outer surface 114 of the housing 104, a second layer 118 of a second material defining an inner surface 120 of the housing 104, and a third layer 124 sandwiched between the first layer 112 and the second layer 118. In one embodiment, the first material and the second material are the same and can be a leather material. The use of leather in the housing 104 is merely exemplary and non-limiting, and any other flexible fabric type material can be substituted without departing from the present disclosure. Examples of such alternative materials include nylon fabrics (e.g., INVISTA's ). The outer surface 114 may include various color patterns, such as camouflage, etc., to enhance the visual appearance of the holster 102. Alternatively, the first material and the second material may be different materials. For example, the first layer 112 may be leather, such as commonly found in the wearer's pants, which has a hard outer shell to prevent wear and tear. However, the second layer 112 may be a softer suede type material to avoid damage to the finish of the firearm.

[0024] The third layer 124 includes a third material that is different from the first material and the second material. Preferably, the third material is a thermoplastic composite material that includes a plurality of fibers embedded in a material matrix. Preferably, the fibers are ultra-high molecular weight polyethylene (UHMWPE) fibers. UHMWPE provides enhanced stiffness to the holster 102. In some embodiments, the fibers may be polyester fibers or Kevlar. TM Fiber. In addition, the fiber is a long fiber to enhance the hardness of the holster 102. In addition, the matrix is ​​a thermoplastic resin and may include an ethylene homopolymer and a 2-oxepanone homopolymer. The thermoplastic composite material is suitable for softening when heated in a predetermined temperature range. In some embodiments, the softening temperature can be as low as 140° Fahrenheit (F), and the fiber will be damaged when it exceeds 190° F. In a preferred embodiment, when the temperature is maintained at 155° F to 175° F, the shell 104 (especially its third layer 124) can be ideally molded and formed into the shape and size of a gun. The thermoplastic composite material has a melting temperature higher than a predetermined temperature range. As will be described in further detail below, any suitable heat source can be used to reach these temperatures, including warm water, hot air from an oven, a hair dryer, a heat gun, etc.

[0025] In one embodiment, the thermoplastic composite material is FORJ TM Thermoplastic tape material in which ultra-high strength thermoplastic fibers are completely wetted by the thermoplastic polymer matrix, i.e., there is complete bonding between the fibers and the matrix material. It is envisioned that this bonding provides the high strength of the fibers and the low temperature formability of the matrix polymer. Once cooled, the thermoplastic composite is understood to retain its fixed shape. To the extent that any adjustments, additions or reuse of the final shape are contemplated, the material can be reheated, reshaped and cooled to its hard solid state.

[0026] Now, the method of manufacturing the holster 102 will be considered. First, the first layer 112 is cut from a first material sheet (e.g., a leather sheet) into a suitable shape and size. The first layer 112 includes a first surface 114 defining an outer surface of a first hole of the holster 102 and a second surface 132 (e.g., a second surface 132 disposed opposite the first surface. Figure 3 1 ). Similar to the first layer 112, the second layer 118 is cut from a second material sheet (e.g., a leather sheet). The second layer 118 has the same shape and size as the first layer 112. In addition, the second layer 118 includes a first surface that defines the inner surface 120 of the holster 102 and a second surface 134 that is disposed opposite to the first surface.

[0027] The third layer 124 is cut from a third material sheet (e.g., the above-mentioned thermoplastic composite sheet) into a shape similar to the first layer 112 and the second layer 118, but with a smaller size. In one example, the first layer 112, the second layer 118, and the third layer 124 can be cut by using a bench press or a laser. The illustrated shape of the third layer 124 is merely exemplary and not restrictive. It is conceivable that the third layer 124 provides structural rigidity for fixing the gun in the shell 104, thereby serving as a frame or pillar (backbone) of the holster 102. The holster 102 is configured to accommodate a variety of pistols, which have the same overall size but have different external profiles and shapes. For example, a "large bracket" pistol may have a variant, a "compact" pistol has another variant, a "super-compact" pistol has another variant, and so on. In this regard, the third layer 124 can be strategically placed in the shell 104 to contact the protruding parts of the pistol (e.g., slide, trigger guard, bracket under the accessory rail, etc.) Those positions.

[0028] Subsequently, the third layer 124 is placed on the first layer 112 so that the third layer 124 is adjacent to the second surface 132 of the first layer 112. Figure 3 As shown, the third layer 124 is disposed on the first layer 112 so that the edge 140 of the third layer 124 deviates from the edge 142 of the first layer 112. As shown, the edge 142 of the first layer 112 is disposed outwardly and is at a distance from the edge 140 of the third layer 124. In this way, the edge portion 144 of the first layer 112 is defined between the edge 140 and the edge 142. After the third layer 124 is positioned on the first layer 112, an adhesive may be applied to the edge portion 144. In one embodiment, the adhesive may be applied in the form of a layer. As with the shape itself, the positioning of the third layer 124 is presented only by way of example and may be adjusted as described above in the context of the shaping of the third layer 124 to improve the fixation of the firearm.

[0029] Thereafter, the second layer 118 is placed on the third layer 124 and adhered to the edge portion 144 of the first layer 112. In certain embodiments, the third layer 124 may also be adhered to the first layer 112 and the second layer 118. The second layer 118 is positioned so that the edge 148 of the second layer 118 is aligned with the edge 142 of the first layer 112, and the second surface 132 faces the second surface 134 of the second layer 118. In this manner, the edge 148 is offset from the edge 140 of the third layer 124, and the edge 148 is disposed outside the edge 140 and at a distance from the edge 140. In one embodiment, the first layer 112 and the second layer 118 are sewn together using a line along the edge portion 144 to secure the first layer 112 to the second layer 118. In this manner, the first layer 112, the second layer 118, and the third layer 124 are connected to form a holster piece 150 (e.g., Figure 4 shown).

[0030] After the holster piece 150 is formed, the holster piece 150 is folded and the second layer 118 is connected along the edge 148 to form a holster blank 152 (eg, Figure 5 The holster panels 150 are folded and sewn or stitched together such that the first surface of the second layer 118 defines an elongated opening 154.

[0031] According to the shape and size of the gun, the holster blank 152 is molded to form the customized holster 102. The holster blank 152 is heated, and the temperature of the holster blank 152 is maintained at a predetermined temperature range for a predetermined period of time to promote the softening of the holster blank 152 (i.e., the third layer 124). In one example, in order to heat the holster blank 152, the holster blank 152 is placed in a plastic bag and sealed from all sides. The plastic bag is placed in hot water and heated to a temperature in a predetermined temperature range, such as 155°F to 175°F. The temperature of the hot water can be limited to below 190°F to prevent the thermoplastic composite material disposed inside the holster blank 152 from degrading. Depending on the thickness of the plastic bag, the holster blank 152 is kept in the hot water for about 3 to 7 minutes to promote the full softening of the holster blank 152. Thereafter, the plastic bag can be removed from the hot water and the holster blank 152 can be checked to see if it is fully softened by pressing the holster blank 152. If the holster blank 152 is not sufficiently softened, the holster blank 152 may be heated again.

[0032] After the holster blank 152 is sufficiently softened, the heating of the holster blank 152 is stopped and the firearm is placed into the elongated opening 154. Thereafter, the holster blank 152 is pressed around the firearm so that the inner surface of the holster blank 152 has the shape of the firearm. The pressure applied to the holster blank 152 causes the holster blank 152 and the elongated opening 154 to be molded into the holster 102 and the inner cavity 108, respectively. In one embodiment, a control tool can be used to apply pressure on the holster blank 152. The heat-softened plastic of the third layer 124 is understood to be capable of molding a rigid underlying structure of the holster 102. The first layer 112 and the second layer 118 of leather or other fabric do not need to be processed to fit the shape of the firearm.

[0033] The holster blank 152 is cooled to ambient temperature together with the firearm located in the elongated opening 154. Due to the cooling, the thermoplastic composite material of the third layer 124 is hardened, so that the holster blank 152 is molded into a holster according to the shape and size of the firearm, and it is clearly conceivable that the end user of the holster 102 can perform the aforementioned procedures to more specifically mold the holster blank 152 to the firearm. In this way, a customized holster 102 is manufactured or prepared without additional leather processing or polymer (e.g., Kydex) processing tools. In addition, by heating the holster 102 and following the steps of molding the holster 102 as described above, the holster 102 can be re-molded according to the shape of another firearm of similar size. The first layer 112 and the second layer 118 are flexible, and the third layer 124 is also flexible to a lesser extent. However, the third layer 124 can be bent to a sufficient degree to allow the firearm to be pulled out of the inner cavity 108.

[0034] The details shown herein are only examples for the purpose of discussion of the embodiments of the present disclosure, and are intended to provide the description of the principles and concepts believed to be the most useful and easiest to understand. In this regard, no attempt is made to show more specific details than are necessary for a basic understanding of the present disclosure, and the description in conjunction with the accompanying drawings makes it clear to those skilled in the art how to implement several forms of the present disclosure in practice.

Claims

1. An end-user customizable holster for accommodating a firearm selected from a group of firearms each conforming to a predetermined range of shapes and sizes, the holster comprising: a first layer of a first material defining an exterior surface of the holster; a second layer of a second material defining an interior surface of the holster; and A third layer sandwiched between the first layer and the second layer, the third layer being a thermoplastic composite material having ultra-high strength thermoplastic fibers fully wetted in a thermoplastic polymer matrix, the third layer having a size different from the first layer and the second layer, and selectively shaped and positioned at selected locations on the first layer and the second layer corresponding to generally protruding portions common to the gun group, but not at other locations, and the first layer and the second layer having identical edges that are not connected to the third layer but are connected to each other, forming an assembly of the first layer, the second layer and the third layer to define a holster blank that is generally compatible with a predetermined shape and size range of the gun group, heating the holster blank within a predetermined temperature range that can be achieved by an end user via a water bath to soften the third layer to facilitate molding the holster blank around the gun, and when the holster blank is cooled below the predetermined temperature range, the resulting structure conforms to the specific gun and maintains the holding orientation of the gun.

2. The holster of claim 1, wherein the first material is leather.

3. The holster of claim 1 , wherein the second material is leather.

4. The holster of claim 1, wherein the predetermined temperature range is 140 degrees Fahrenheit to 190 degrees Fahrenheit.

5. A method for molding a holster, the method comprising: heating a holster blank and maintaining the holster blank within a predetermined temperature range to soften the holster blank, the holster blank comprising: a first layer of a first material defining an exterior surface of the holster; a second layer of a second material defining an interior surface of the holster; and a third layer sandwiched between the first and second layers, the third layer being a thermoplastic composite material having ultra-high strength thermoplastic fibers fully wetted in a thermoplastic polymer matrix, the third layer having a different size from the first and second layers and selectively shaped and positioned at selected locations on the first and second layers corresponding to substantially protruding portions of a firearm group each of which conforms to a predetermined shape and size range, and not at other locations, and the first and second layers having identical edges not connected to the third layer but connected to each other, forming an assembly of the first, second and third layers to define a holster blank substantially compatible with the predetermined shape and size range of the firearm group, heating the holster within a predetermined temperature range achievable by an end user via a water bath to soften the third layer; placing a firearm within the holster blank and applying pressure to the holster blank to mold the holster blank into the shape of the firearm in a particular holding orientation; and The holster blank is hardened by cooling the holster blank, wherein the firearm is placed within the holster blank.

6. The method of claim 5, wherein the predetermined temperature range is 140 degrees Fahrenheit to 190 degrees Fahrenheit. The method of claim 5 , wherein the first material is leather.

8. The method of claim 5, wherein the second material is leather.

9. The method of claim 5, wherein the holster blank is formed by adhering the first layer to the second layer.

10. An article for containing an object, comprising: a first layer of a first material defining an outer surface of the article; a second layer of a second material defining an interior surface of the article; and A third layer sandwiched between the first layer and the second layer, wherein the third layer is a thermoplastic composite material, the thermoplastic composite material has ultra-high strength thermoplastic fibers fully wetted in a thermoplastic polymer matrix and the third layer has a size different from the first layer and the second layer, and the first layer and the second layer have identical edges that are not connected to the third layer but are connected to each other, and the third layer is softened by heating the article within a predetermined temperature range that can be reached by the end user through a water bath to facilitate molding the article around the shape of the object by selectively positioning the third layer at a position corresponding to the protruding portion of the object, and when the article is cooled below the predetermined temperature range, the resulting structure corresponding to the shape of the object is maintained.

11. The article of claim 10, wherein the predetermined temperature range is 140 degrees Fahrenheit to 190 degrees Fahrenheit.

12. The article of claim 10, wherein the first material is leather.

13. The article of claim 10, wherein the second material is leather.

14. The article of claim 10, wherein the article is a holster for an ammunition magazine.

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