STANDARDIZED OUTER HOLSTER SYSTEM AND CORRESPONDING FIREARM SPECIFIC INNER HOLSTER INSERTS

Abstract

Provided in this disclosure is a customizable holster including a first inner holster component and a second inner holster component, configured in a mating arrangement into an inner holster. Internal contact surfaces are formed on an interior of each of the first and second inner holster components. The internal contact surfaces are conformed to the shape of a predetermined firearm design, in order to securely receive and retain the firearm within the inner holster. An external mating surface defines an exterior of the inner holster. An outer holster has an interior defined by an internal mating surface for receiving and engaging with the external mating surface of the inner holster. The internal and external mating surfaces are configured to encircle the first and second holster components, and thereby securely receive and retain the inner holster within the outer holster.

Description

I. BACKGROUND

A. Technical Field

This invention pertains to the field of holsters for receiving and carrying firearms. The invention has particular relevance to the field of customizable holsters which can be specially designed to suit the needs of a particular user.

B. Description of Related Art

It is known in the art to have holsters for carrying firearms and various other hand-held items or carried gear. Holsters are typically mounted on the user's belt, duty vest, thigh rig, backpack etc. Oftentimes holsters are mounted to surfaces such as vehicle dashboards, nightstands, desks, and other suitable locations.

It is common in the art to manufacture holsters from molded plastic parts. A variety of methods are known in the art fabricating such molded holsters.

In a two-piece construction method, each half of a holster is molded (or thermoformed) separately, and then fastened together to make one holster unit. Due to manufacturing limitations, the holster walls need to be of relatively consistent thickness or use rib features. Such rib features can impede functionality or cause unsightly protrusions. Ribs on the inside reduce contact area with the firearm, and ribs on the outside collect dirt and can be uncomfortable.

A principal problem with the two-piece construction method is that the fasteners holding the halves together are often the weak link in the holster's construction. Stitching, screws, rivets, eyelets, etc. will generally pull through the holster material, which can result in the holster material failing entirely. Another problem with two-piece construction is that the fasteners require a fair amount of space, often deeming it necessary to make the holster larger than it needs to be to make room for the fasteners.

In a one-piece construction method, a holster can be manufactured in different ways, including: 1) injection molding using a hydraulic core pull; 2) molded with living hinges and secured together at the side opposite of the hinge with fasteners; and 3) thermoformed, heated, and folded, and secured with fasteners.

The most durable product formed by the above methods is injection molding using a hydraulic core pull. However, this manufacturing method is quite limiting from a design standpoint regarding the types and characteristics of features a designer is able to use inside the holster while maintaining the ability to strip the part off of the core during manufacturing. These design limitations are especially hindering in more complicated designs that require internal moving parts.

Designs using living hinges are inexpensive to manufacture but inherit the same problem with fasteners. This design also is limited to certain material choices and results in an inherently weak section along the living hinges where the material needs to be very thin.

Thermoformed and folded methods are very limited in terms of design options, material selections, and overall construction due to their lack of surface precision. Even still, this method requires one end of the material to be fastened to the other, and this is generally where failures will occur when rigorously tested. Thus, the existing holster molding techniques tend to result in a product lacking in mechanical strength.

With one piece and two-piece molded designs, multiple different mold configurations are required to accommodate different firearm designs. The entire holster product is molded, resulting in a large, intricate mold and therefore an expensive fabrication process.

II. SUMMARY

Provided in this disclosure is a customizable holster that includes a first inner holster component and a second inner holster component. The first and second inner holster components are configured in a mating arrangement into an inner holster. Internal contact surfaces are formed on an interior of each of the first and second inner holster components. The internal contact surfaces are conformed to the shape of a predetermined firearm design, in order to securely receive and retain the firearm within the inner holster. An external mating surface defines an exterior of the inner holster. An outer holster has an interior defined by an internal mating surface for receiving and engaging with the external mating surface of the inner holster. The internal and external mating surfaces are configured to encircle the first and second holster components, and thereby securely receive and retain the inner holster within the outer holster.

In one aspect of the present holster, the first and second holster components include internal contact surfaces that conform to a left and a right portion of a firearm. The predetermined firearm design is preferably selected from one of a plurality of different firearm designs, each having a respective plurality of different internal contact surfaces. In this manner, different inner holsters can be manufactured corresponding to different firearm designs which can be interchangeably switched out into the same outer holster. The internal contact surfaces also include internal extensions for contacting and supporting the firearm.

In another aspect of the present holster, a front plate is configured to receive at least one detachable accessory. The internal contact surfaces further comprise internal extensions for contacting and supporting the firearm.

In yet another aspect of the present holster, a bottom cap is attached to a bottom periphery of the outer holster to further receive and retain the inner holster within the outer holster. The outer holster includes an exterior surface configured to accept a material covering. The bottom cap is configured to protect edges of the material covering along the exterior surface of the outer holster. The bottom cap is further attached to a first peripheral edge of the first inner holster component and a second peripheral edge of the second inner holster component.

In still another aspect of the present holster, the inner holster includes first and second opposing sides each having attachment mounting holes for securing the holster to a mounting structure. The mounting structure is configured to be received onto one or both of a firearm belt or a vehicle dashboard. The mounting structure is configured for selecting attachment mounting holes of either of the first and second opposing sides to accommodate a right—or left—handed user. The exterior surface of the outer holster includes first and second exterior opposing sides configured to selectively receive external mounting holes on one of the first or second external opposing sides formed thereon at corresponding positions to align with the attachment mounting holes, to respectively accommodate a right or left-hand user.

In a further aspect of the present holster, the external mating surface includes ribs formed thereon to provide structural strength to the inner holster while enabling the internal contact surfaces to have maximum contact area with the firearm. The first and second inner holster components respectively include mechanical engagement components configured for engaging at least one firearm retention mechanism to the holster. The firearm retention mechanism includes one or both of a hood or an ejector port auto-locking mechanism.

In another further aspect of the present holster, an optic shroud is rotatably mounted to the external surface of the outer holster and configured to rotatably cover and protect an optic mounted on the firearm from impact or debris. Detents are located on the inner holster onto which the optic shroud engages to retain the optic shroud into the closed position.

According to an aspect, the present invention generally overcomes problems associated with holsters manufactured by one piece and two-piece construction.

According to another aspect, the present invention specifically overcomes problems with designs including living hinges, preventing problems with weak sections where material needs to be very thin.

According to yet another aspect, the present invention results in a product having mechanical strength, not prone to the known failures resulting from fasteners.

According to still another aspect, the present invention reduces manufacturing costs associated with multiple different mold configurations.

Other benefits and advantages of this invention will become apparent to those skilled in the art to which it pertains upon reading and understanding of the following detailed specification.

III. BRIEF DESCRIPTION OF THE DRAWINGS

The disclosed customized holster may take physical form in certain parts and arrangement of parts, embodiments of which will be described in detail in this specification and illustrated in the accompanying drawings which form a part hereof and wherein:

FIGS. 1A and 1B are respective exterior and interior views of a first inner holster component in accordance with an embodiment of the present invention.

FIGS. 2A and 2B are respective exterior and interior views of a second inner holster component in accordance with an embodiment of the present invention.

FIGS. 3A and 3B are respective overhead and perspective views of an inner holster in accordance with an embodiment of the present invention.

FIG. 4 is a perspective view of an outer holster in accordance with an embodiment of the present invention.

FIGS. 5A and 5B are perspective views of the assembled holster in accordance with an embodiment of the present invention.

FIGS. 6A and 6B are respective side and perspective views of a firearm engaged in the holster whereas FIGS. 6C and 6D are respective side and perspective views of a firearm partially removed from its engagement position in accordance with an embodiment of the present invention.

FIGS. 7A, 7B, and 7C are respective exploded, partially exploded, and assembled perspective views depicting stages of assembly of the holster in accordance with an embodiment of the present invention.

FIGS. 8A and 8B are respective exploded and assembled perspective views of external accessory components to the holster in accordance with an embodiment of the present invention.

IV. DETAILED DESCRIPTION

Reference is now made to the drawings wherein the showings are for purposes of illustrating embodiments of the article only and not for purposes of limiting the same, and wherein like reference numerals are understood to refer to like components.

FIGS. 1A, 1B, 2A, 2B, 3A, 3B, 4, 5A, and 5B depict the basic configuration of a customizable holster 10 in accordance with the present invention. In particular, FIGS. 1A and 1B show respective exterior and interior views of a first inner holster component 12. FIGS. 2A and 2B show respective exterior and interior views of a second inner holster component 14. As shown in FIGS. 3A and 3B, the first and second inner holster components 12, 14 are configured in a mating arrangement to form a complete inner holster 20.

As especially evident from FIGS. 1A, 1B, 2A, and 2B, there are internal contact surfaces 12a, 14a formed on an interior of each of the first and second inner holster components 12, 14. The internal contact surfaces 12a, 14a are conformed to the shape of a predetermined firearm design, in order to securely receive and retain a firearm 16 according to the respective predetermined firearm design within the inner holster 20 upon assembly.

As particularly visible in FIGS. 3A and 3B, the exterior of the assembled inner holster 20 defines an external mating surface 22. As depicted in FIGS. 4A and 4B, an outer holster 30 is provided which has an interior defined by an internal mating surface 32 for receiving and engaging with the external mating surface 22 of the inner holster 20. As is evident from FIGS. 1A, 2A, and 3B, the first and second inner holster components 12, 14 have certain surface features formed on their respective exterior surfaces 12b, 14b which form the external mating surface 22 upon mating of the first and second inner holster components 12, 14 to form the inner holster 20. It is to be understood and appreciated that corresponding surface features are also formed on the internal mating surface 32 of the outer holster so that these respective surface features fit together in a mating fashion. Thus, the internal mating surface 32 of the outer holster 30 is configured so as to encircle the first and second holster components 12, 14 and to be received within the external mating surface 22 of the inner holster 20, and thereby securely receive and retain the inner holster 20 within the outer holster 30.

As shown in FIGS. 1A, 1B, 2A, and 2B, the first and second inner holster components 12, 14 are respectively right and left sections that also include internal contact surfaces 12a, 14a that respectively conform to a right left and a right portion of a firearm 16. The internal contact surfaces 12a, 14a also include internal extensions 15 for contacting and supporting the firearm 16. The internal extensions 15 are positioned in such a way that they do not interfere with a weapon mounted light 46 (FIG. 6C). In this manner, the internal extensions 15 are configured for contacting and supporting the firearm in 16 order to house various components such as lights and optics (described in detail hereinbelow) via securing surfaces of the internal extensions 15 that are placed into contact with the firearm 16. The external mating surface 22 also includes ribs 17 formed on the exterior surfaces 12b, 14b to provide structural strength to the inner holster 20 while enabling the internal contact surfaces 12a, 14a to have maximum contact area with the firearm. The dual-layer design of the present holster 10 allows for the ribs 17 to be hidden between the outer and inner holsters 20, 30, leaving the exterior surface of the holster 10 to remain aesthetically pleasing and easy to clean, and the internal contact surfaces 12a, 14a to have maximum contact area with the firearm 16.

As is shown in FIGS. 1A, 1B, 2A, and 2B, the internal contact surfaces 12a, 14a can be formed in a variety of different configurations, so that the predetermined firearm design can be selected from one of a plurality of different firearm designs. Each respective different firearm design can have a respective plurality of different internal contact surfaces 12a, 14a in order that a particular shape of contact surface can be formed to conform with a respective shape and size of a specific firearm design. In this manner the holster 10 can be optimally designed in order to accommodate the specific firearm design. Moreover, a plurality of different holster designs can be fabricated by creating respective different inner holster components 12, 14 corresponding to each firearm design to create respective inner holsters 20. These different inner holsters 20 correspond to the different firearm designs that can be interchangeably switched out into the same outer holster 30.

As shown in FIGS. 1A, 1B, 2A, 2B, 3A, 3B, 4, 5A, and 5B, a three-piece “inner and outer holster construction” has superior advantages to the one-piece and two-piece construction methods known in the prior art. The three-piece “inner and outer holster construction” utilizes three components that work together to create a finished holster 10 that has superior strength and function as compared to other holster construction methods. As disclosed hereinabove, the inner holster 20 is made from the first and second inner holster components 12, 14 having the contact surfaces 12a, 14a to securely hold the firearm 16, as well as other features that perform essential duties within the holster. The first and second inner holster components 12, 14 can be plastic molded components created by known plastic molding techniques such as injection molding, or by the thermoformed and folded method, etc.

With continued reference to FIGS. 1A, 1B, 2A, 2B, 3A, 3B, 4, 5A, and 5B, the outer holster 30 is of a one-piece construction (also formed by either injection molding with hydraulic core pull or the thermoformed and folded method) and encircles the inner holster 20, providing the strength to hold the inner holster components 12, 14 together and in position. The inner holster halves 12, 14 are paired and located together, and then inserted into the outer holster 30, which acts to bind the two inner holster components 12, 14 together. In addition to providing superior strength, this technique allows the designer to make better contact with the firearm for a higher quality end product. As explained hereinabove, providing multiple inner holster 20 models can be made to fit with the same outer holster 30 and its accessories, allowing for a cost savings during manufacturing and development.

In the components shown in FIGS. 1A, 1B, 2A, 2B, 3A, 3B, 4, 5A, 5B, 6A, 6B, 6C, 6D, 7A, 7B, 7C, 8A, and 8B, fasteners 43 are preferably used to bind together the inner holster 20 to the outer holster 30. Such fasteners 43 can be used for securing exterior covers 29, mountings, caps, and attachments to the holster In a majority of cases, the fasteners 43 are under a shear load rather than a tensile load in respect to binding the inner and outer holsters, with the binding post aligning the inner and outer holsters 20, 30 much like a dowel pin. In practical experience, this has been found to enhance the strength of the assembly, as the heads of the fasteners will not be loaded in such a way that they will be pulled through the polymer substrate. A method of manufacturing a holster 10 in accordance with the present invention is described in co-pending patent application U.S. Ser. No. 18/453,583 entitled METHOD FOR MANUFACTURING A STANDARDIZED OUTER HOLSTER SYSTEM WITH FIREARM SPECIFIC INNER HOLSTER INSERTS, filed Aug. 22, 2023, the entirety of the disclosure of which is hereby incorporated by reference.

As shown in FIGS. 1A, 1B, 2A, 2B, 3A, 3B, 4, 5A, and 5B, the outer holster 30 can also include an exterior surface 36 defined by an opposite surface from the internal mating surface 32. A material covering (i.e., a fabric covering) can be optionally placed atop the exterior surface 36 of the holster 10, for decorative or other finishing purposes. In this manner, the bottom cap 33 is configured to protect the edges of the material covering along the exterior surface 36 of the outer holster 30.

As shown especially in FIG. 8A, a bottom cap 33 can be attached to a bottom periphery 38a of the holster 10 to further receive and retain the inner holster 20 within the outer holster 30. The bottom cap 33 is attached to the bottom periphery 38a which is defined by a first peripheral edge 38a of the first inner holster component 12 and a second peripheral edge 38c of the second inner holster component 14. The bottom portion 38a is opposite on the body of the holster 10 from an opening 40 that receives the firearm 16. The bottom cap 33 is provided for protecting ends of the covering material, to keep them from fraying or otherwise showing wear during normal use of the holster, as well as further binding the inner holster components 12, 14 together and in proper relation to the outer holster 30.

As particularly shown in FIGS. 3A and 3B, the inner holster 20 includes first and second opposing sides 41a, 41b each having attachment mounting holes 44 for securing the holster 10 to a mounting structure 45. The mounting structure 45 can be configured to be received onto a firearm belt or a vehicle dashboard. The mounting structure 45 is configured for selecting attachment mounting holes 44 of one of the first and second opposing sides 41a, 41b to accommodate a right—or left—handed user. In one embodiment, as especially indicated in FIG. 8A, the mounting structure 45 can be an “insert plate” for engaging a “receiver platform” or other suitable component as described in co-pending application U.S. Ser. No. 17/729,361, filed Apr. 26, 2022, entitled INTERCHANGEABLE, MULTI LOCATION, MULTI CANT, AUTO LOCKING, QUICK MOUNT FOR HOLSTERS, HANDHELD DEVICES, AND CARRIED GEAR the entirety of the disclosure of which is hereby incorporated by reference.

As particularly shown in FIGS. 5A and 5B, the exterior surface 36 of the outer holster 30 also includes first and second exterior opposing sides 42a, 42b which are made planar and injection molded without mounting holes to allow the addition of external mounting holes 44a in a secondary operation on one of the first or second external opposing sides 42a, 42b. The external mounting holes 44a are formed on one of the first or second external opposing sides 42a, 42b at corresponding positions to align with the attachment mounting holes 44, to respectively accommodate a right or left-hand user. This results in an outer holster 30 that can be made to accommodate either a right or left-handed user before pairing with an inner holster 20, resulting in the holster 10 able to be configured during manufacturing to satisfy the needs of either right or left-handed users quickly and efficiently.

As especially visible in FIGS. 1A, 1B, 2A, and 2B, the inner holster components 12, 14 also respectively include mechanical engagement components 18a, 18b configured for the addition of firearm retention mechanisms to the holster 10 including a strap or hood 60 around the rear of the slide of the firearm and/or an ejector port auto-locking mechanism 50. Both of these mechanisms serve to block rearward movement of the firearm 16 and retain the firearm 16 in an engagement position within the holster 10. These firearm retention mechanisms can be used individually or in combination together. Moreover, while the mechanical engagement components 18a, 18b are shown on the inner holster components 12, 14, they can optionally be attached to the outer holster 30 without departing from the invention. The firearm retention mechanisms including the hood 60 and ejector port auto-locking mechanism 50 are particularly described in greater detail in co-pending patent application U.S. Ser. No. 18/463,398 entitled FIREARM RETENTION MECHANISM FOR A HOLSTER, filed Sep. 8, 2023, the entirety of the disclosure of which is hereby incorporated by reference.

As shown in FIGS. 6A, 6B, 6C, 6D, 8A, and 8B, the holster 10 can include a front plate 34b configured to receive at least one detachable accessory (i.e., a tourniquet carrier or other detachable accessory 48). In another aspect, the front plate can be configured as a minimalistic front plate 34a to protect the seam edges of the material covering applied to the exterior surface 36 of the outer holster 30. In this manner, the front plate 34a conceals and protects the edges of the material covering where the edge seam of the covering is located.

As shown in FIGS. 4, 6A, 6B, 6C, and 6D, holster 10 can include an optic shroud 24, rotatably mounted to the external surface 36 of the outer holster 30. The optic shroud 24 is for rotatably covering and protecting from impact or debris a firearm mounted optic 47 attached to a user's firearm 16 once the firearm is fully placed into an engagement position within the holster 10. This optic shroud 24 mounts onto the holster 10 by means of the mounting structures 25 on opposing sides of the exterior surface 36 of outer holster 30. The mounting structures 25 serve to provide an axis of rotation to the optic shroud 24 as well as limit its rotational travel to a functional and practical range of motion. The optic shroud 24 engages with detents 26a, 26b located on the exterior surfaces 12b, 14b of the respective inner holster components 12, 14 upon closing to detent itself into the closed position to prevent unwanted rotation into the open position. The optic shroud 24 can be rotated into the open position by the hood 60 being rotated to its disengaged position, by rearward movement of the firearm 16 and/or mounted optic or sight in cases where the hood 60 is not used, or manually by the user. The detents 26a, 26b are located on a portion of the inner holster 20 onto which the optic shroud 24 engages to retain the optic shroud 24 into the closed position.

Numerous embodiments have been described herein. It will be apparent to those skilled in the art that the above methods and apparatuses may incorporate changes and modifications without departing from the general scope of this invention. It is intended to include all such modifications and alterations in so far as they come within the scope of the appended claims or the equivalents thereof.

Having thus described the invention, it is now claimed:

Claims

1. A holster, comprising:

a first inner holster component and a second inner holster component, wherein the first and second inner holster components are configured in a mating arrangement into an inner holster;

internal contact surfaces formed on an interior of each of the first and second inner holster components, wherein the internal contact surfaces are conformed to the shape of a predetermined firearm design, in order to securely receive and retain a respective firearm within the inner holster;

an external mating surface defining an exterior of the inner holster; and

an outer holster having an interior defined by an internal mating surface for receiving and engaging with the external mating surface of the inner holster, wherein the internal and external mating surfaces are configured to encircle the first and second holster components, and thereby securely receive and retain the inner holster within the outer holster.

2. The holster of claim 1, wherein the first and second holster components comprise internal contact surfaces that conform to a left and a right portion of a firearm.

3. The holster of claim 1, wherein the predetermined firearm design is selected from one of a plurality of different firearm designs, having a respective plurality of different internal contact surfaces, wherein different inner holsters corresponding to different firearm designs can be interchangeably switched out into the outer holster.

4. The holster of claim 1, further comprising a front plate configured to receive at least one detachable accessory.

5. The holster of claim 1, wherein the internal contact surfaces further comprise internal extensions for contacting and supporting the firearm.

6. The holster of claim 1, further comprising a bottom cap attached to a bottom periphery of the outer holster to further receive and retain the inner holster within the outer holster.

7. The holster of claim 6, wherein the outer holster comprises an exterior surface configured to accept a material covering.

8. The holster of claim 7, wherein the bottom cap is configured to protect edges of the material covering along the exterior surface of the outer holster.

9. The holster of claim 6, wherein the bottom cap is further attached to a first peripheral edge of the first inner holster component and a second peripheral edge of the second inner holster component.

10. The holster of claim 1, wherein the inner holster further comprises first and second opposing sides each having attachment mounting holes for securing the holster to a mounting structure.

11. The holster of claim 10, wherein the mounting structure is configured to be received onto least one of a firearm belt or a vehicle dashboard.

12. The holster of claim 10, wherein the mounting structure is configured for selecting attachment mounting holes of one of the first and second opposing sides to accommodate a right- or left-handed user.

13. The holster of claim 12, wherein the exterior surface of the outer holster further comprises first and second exterior opposing sides configured to selectively receive external mounting holes on one of the first or second external opposing sides formed thereon at corresponding positions to align with the attachment mounting holes, to respectively accommodate a right or left-hand user.

14. The holster of claim 1, wherein the external mating surface further comprises ribs formed thereon to provide structural strength to the inner holster while enabling the internal contact surfaces to have maximum contact area with the firearm.

15. The holster of claim 1, where the first and second inner holster components further respectively comprise mechanical engagement components configured for engaging at least one firearm retention mechanism to the holster.

16. The holster of claim 15, wherein the firearm retention mechanism comprises at least one of a hood or an ejector port auto-locking mechanism.

17. The holster of claim 1, further comprising an optic shroud rotatably mounted to the external surface of the outer holster and configured to rotatably cover and protect an optic mounted on the firearm from impact or debris.

18. The holster of claim 17, further comprising detents located on the inner holster onto which the optic shroud engages to retain the optic shroud into the closed position.