Monolithic Upper Receiver Assembly Alignment

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Solution Overview

Problem

Existing firearms designs with separate handguards attached to the upper receiver are difficult to install, costly to manufacture, and can limit accuracy due to misalignment.

Innovation Solution

A monolithic upper receiver assembly that combines features of both the upper receiver and handguard, featuring an outer member with an upper rail and an inner member with pivot and takedown pin lugs, allowing for a single, integrated component that simplifies manufacturing and installation while maintaining accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If separate handguards are attached to the upper receiver, then the firearm can be equipped with handholds and accessory mounting capability, but the installation becomes difficult, manufacturing cost increases, and alignment accuracy decreases

Engineering Contradiction:

Improvehandhold and accessory mounting capabilityVSAvoidinstallation complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines the handguard and upper receiver into a single monolithic component, eliminating the need for separate attachment. The handguard features are integrated directly into the upper receiver structure, providing handholds and accessory mounting capability while simplifying installation to a single-piece assembly process.

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If separate handguards are attached to the upper receiver, then the firearm can be equipped with handholds and accessory mounting capability, but manufacturing cost increases

Engineering Contradiction:

Improvehandhold and accessory mounting capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The monolithic design consolidates two separate manufacturing processes into one, reducing material costs, manufacturing complexity, and assembly operations. The single-component structure eliminates the need for separate handguard fabrication and attachment hardware, thereby reducing overall manufacturing cost while maintaining all necessary handhold and accessory mounting features.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If separate handguards are attached to the upper receiver, then the firearm can be equipped with handholds and accessory mounting capability, but alignment accuracy with the upper receiver decreases

Engineering Contradiction:

Improvehandhold and accessory mounting capabilityVSAvoidalignment accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

By integrating the handguard features directly into the upper receiver as a monolithic component, the patent eliminates alignment misregistration between separate parts. The handholds and accessory mounting interfaces are precisely positioned during the single manufacturing process, ensuring optimal alignment accuracy with the upper receiver's bore axis and other critical features.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS12018908B2Monolithic upper receiver assembly

Publication Date: 2024.06.25 UNDERWOOD JAMES MATTHEW

AI summary

An upper receiver assembly includes an outer member with an upper rail and an inner member with at least one of a pivot pin lug and a takedown pin lug. The inner member is disposed at least partially inside the outer member. The outer member includes an ejection port, and the inner member includes an ejection port. The ejection port of the inner member is at least partially aligned with the ejection port of the outer member.