Firearm sound suppressor

A sound suppressor for a firearm includes an enclosure enclosing at least a portion of a barrel of the firearm. An intermediate member is coupled to an outer end of the barrel and includes a base member, ring member and a plurality of extension members therebetween. The base member is positioned proximate the intermediate member inner end and includes a through-hole extending longitudinally therethrough. The ring member is positioned proximate the intermediate member outer end. A space between the plurality of extension members forms a chamber. The sound suppressor also includes a flash hider coupled to the intermediate member outer end. The flash hider includes a plurality of baffles extending radially and spaced apart longitudinally from the flash hider inner end to the flash hider outer end, and a plurality of open channels formed between the plurality of baffles. The intermediate member and flash hider are enclosed within the enclosure.

FIELD

The present disclosure relates generally to systems and methods for suppressing noise, and more particularly, to systems and methods for suppressing noise of a firearm.

BACKGROUND

Suppressors for firearms, also known as silencers, generally operate to reduce the audible noise or sharp report of a firing weapon by means of reducing and controlling the energy level of attendant propellant gases. A firearm sound suppressor typically mounts to the end of the muzzle of a firearm and is usually a hollow metal cylinder which has expansion chambers therein and which attaches to the muzzle of a firearm. This type of sound suppressor is readily attached to the end of a firearm barrel and may be used on different firearms of the same caliber.

Firearm sound suppressors work by trapping and delaying the exit of the high pressure muzzle gases from a firearm when the firearm is discharged. Creation of turbulence is one technique used to enhance the trapping of the gases with a subsequent delay in the exit of the gases from a sound suppressor. If a sound suppressor is very effective at trapping and delaying the exit of the gases, this results in a lower sound level coming from the firearm.

Known silencers for firearms can be generally classified into two groups. In one group, the discharge and propellant gases that follow the bullet into the silencer are stored for a short period of time in a plurality of successive chambers which are closed to the outside environment. This produces a controlled expansion of the propellant gases through each chamber, thereby reducing their temperature and pressure.

In a second group, at least a portion of the propellant gases are diverted to exterior coaxial chambers through a plurality of passages between inner and outer walls. Although such arrangements can be complex, these arrangements can provide more capacity to delay and cool the gases, and hence reduce the sound level.

Generally, the techniques include the provision of a series of baffles which control and delay the flow, expansion, and discharge of propellant gases, forcing the propellant gases to pass through various temperature absorbent materials to reduce the temperature and abrupt discharge of propellant gases. The result achieved is a corresponding reduction in the noise produced by the discharged propellant gases.

A firearm suppressor suppresses noise by allowing the rapidly expanding gases from the firing of a cartridge to be diverted or trapped inside a series of chambers. The trapped gas expands and cools, reducing its pressure and velocity before it exits the suppressor. The suppressor chamber may be a single large expansion chamber located at the muzzle end of a firearm to allow the propellant gas to expand considerably and slow before it encounters the baffles therein. Baffles used in sound suppressors are usually circular metal dividers which separate the expansion chamber with each baffle having a hole therethrough to permit passage of gas through the baffle. The aperture in each baffle and the passageway through the sound suppressor are generally slightly larger than the bullet caliber to reduce the risk of a bullet hitting the sides of the housing in the sound suppressor. A sound suppressor housing can become heated to a very high temperature because of the collection of rapidly expanding gases from firing of multiple cartridges, especially in rapid fire weapons.

For typical suppressors, it may become difficult to remove the suppressor from the suppressor housing for cleaning. Tough residue from the discharge gases can build up quickly in and around crevices, creating a bond between the suppressor components which can be difficult to break. Moreover, baffles closer to the muzzle end of the firearm are subjected to greater pressure, contaminants, and heat from the firearm flash during discharge, than baffles located further away from the muzzle end, thereby causing premature wear and failure of the suppressor.

Another disadvantage of current firearm suppressor use is the problem of suppressor instability that results from the use of a threaded connection of the suppressor to the barrel of a firearm. The barrel of a firearm that is designed for attachment of a suppressor is typically provided with a reduced diameter externally threaded section that is of fairly short length. An internally threaded section of a typical suppressor is fairly short, thus causing the threaded connection to have minimal stability due to the typical length of the threaded connection of the suppressor with the firearm barrel.

U.S. Pat. No. 5,136,923 discloses a firearm silencer which includes an outer housing and an interior tube (a central channel) within the housing. The interior tube is spaced from the inside walls of the housing to form an exterior chamber around the interior tube. The interior tube is adapted to receive a projectile discharged from a firearm and extends the entire length of the housing which is attached to a muzzle of a firearm. The interior tube is perforated with a plurality of rows of ports which extend through the wall of the interior tube and discharge into the exterior chamber. The sound suppressing performance of this type of suppressor is considered to be due to the rapid heat exchange between the propellant gases and the surface area of the conductive metal in the suppressor. The efficiency of this type silencer is considered greater on a volume basis for a given projectile clearance than that of baffle silencers. However, because of the limited surface area inherent in this type of design, this type of suppressor is useful only for small fire arms. A sound suppressor of this design having substantially increased surface area for a given volume, for heat dissipation, and that could create greater turbulance of the gases around the length of the interior tube, would be much more effective in suppressing sound and attenuating recoil.

Another problem with prior art suppressors is the large size, especially for suppressors used on rifles which add much overall length to the firearm. Because suppressors for rifles are often long, the length of the rifle is drastically increased, making it inconvenient during use and for storage. For gas impingement rifles and rifles with piston operating systems, such increased length is unavoidable due to the gas tube being positioned directly above the barrel. As such, prior art suppressors are installed on the barrel past the gas block.

It is desirable to provide a suppressor which is conveniently and efficiently assembled to and disassembled from the firearm for convenient cleaning and maintenance. Additionally, it is desirable to provide a suppressor that is exceptionally stable as well as protecting the internal components from the undesirable characteristics of gunpowder residue buildup and fouling. Moreover, it is desirable to provide a suppressor that further suppresses noise and flash discharge, while not unduly increasing the overall length of the firearm. Finally, it is desirable to provide a suppressor that could be integrated with the gas block and gas tube of the firearm.

SUMMARY

The present invention solves the problems of the prior art described above and provides additional advantages. To do so, the present invention provides a suppressor comprising a tube that extends along the entire length of a barrel thus reducing the increased overall length of the fire arm. A tube encloses the barrel and gas tube, and is sealed with rear and front end caps. Within the tube is a main body where a gas block is enclosed; an intermediate member operably coupled to the barrel end; a blast baffle operably coupled to the intermediate member; and a flash hider operably coupled to the intermediate member and blast baffle.

The present invention provides a sound suppressor for a firearm comprising: an enclosure enclosing at least a portion of a barrel of the firearm, the barrel having an inner end and an outer end and extending longitudinally from a receiver of the firearm with the barrel inner end operably coupled to the receiver of the firearm, a space between the enclosure and barrel forming a main body; an intermediate member having an inner end and an outer end, the intermediate member inner end operably coupled to an outer end of the barrel, the intermediate member comprising: a base member positioned proximate the intermediate member inner end, the base member having a first through-hole extending longitudinally therethough, a ring member having an inner surface and an opposing outer surface, the ring member positioned proximate the intermediate member outer end, and a plurality of extension members, each extension member having an inner and an opposing outer end, and an inner surface and an opposing outer surface, the plurality of extension members extending between the base member and the ring member, a space between the plurality of extension members forming a chamber; a flash hider having an inner end and an outer end, the flash hider inner end operably coupled to the intermediate member outer end, the flash hider comprising: a plurality of baffles extending radially and spaced apart longitudinally from the flash hider inner end to the flash hider outer end, and a plurality of open channels formed between the plurality of baffles, each open channel having a longitudinal width; wherein the intermediate member and flash hider are enclosed within the enclosure.

In another aspect, the present invention provides a sound suppressor for a firearm comprising: an enclosure enclosing at least a portion of a barrel of the firearm, the barrel having an inner end and an outer end and extending longitudinally from a receiver of the firearm with the barrel inner end operably coupled to the receiver of the firearm; an intermediate member having an inner end and an outer end, the intermediate member inner end operably coupled to an outer end of the barrel; and a flash hider having an inner end and an outer end, the flash hider inner end operably coupled to the intermediate member outer end; wherein the intermediate member and flash hider are enclosed within the enclosure.

In yet another aspect, the present invention provides a method for suppressing noise in a firearm by providing a sound suppressor having an enclosure enclosing at least a portion of a barrel of the firearm, the barrel having an inner end and an outer end and extending longitudinally from a receiver of the firearm with the barrel inner end operably coupled to the receiver of the firearm; an intermediate member having an inner end and an outer end, the intermediate member inner end operably coupled to an outer end of the barrel, a space within the intermediate member forming a chamber; and a flash hider having an inner end and an outer end, the flash hider inner end operably coupled to the intermediate member outer end, the flash hider having a plurality of baffles extending radially and spaced apart longitudinally from the flash hider inner end to the flash hider outer end such that a plurality of open channels are formed between the plurality of baffles; wherein the intermediate member and flash hider are enclosed within the enclosure. The sound suppressor causes gases formed from a traveling projectile to be displaced within the chamber of the intermediate member substantially in a direction from the intermediate member outer end to the intermediate member inner end. The sound suppressor also causing gases formed from the traveling projectile to be displaced within the flash hider substantially in a direction from the flash hider outer end to the flash hider inner end.

To facilitate an understanding of the invention, identical reference numerals have been used, when appropriate, to designate the same or similar elements that are common to the figures. Further, unless stated otherwise, the features shown in the figures are not drawn to scale but are shown for illustrative purposes only.

DETAILED DESCRIPTION

Certain terminology is used in the following description for convenience only and is not limiting. The article “a” is intended to include one or more items, and where only one item is intended the term “one” or similar language is used. Additionally, to assist in the description of the present invention, words such as top, bottom, side, upper, lower, front, rear, inner, outer, right and left are used to describe the accompanying figures. The terminology includes the words above specifically mentioned, derivatives thereof, and words of similar import.

Referring toFIGS. 1-4, an exemplary embodiment of a suppressor1of the present invention is shown. In general, the suppressor1is configured to enclose a barrel2of a firearm. In this embodiment, the barrel2is of a rifle having a gas impingement system and the suppressor1encloses both the barrel2and gas tube or gas piston4of the firearm, as shown inFIG. 4. Even though the present embodiment shows a suppressor for use on this type of firearm, it can also be used on other types of firearms as well. The suppressor1generally comprises a tube10enclosed by a rear end cap12on one end and a front end cap14on an opposing end of the tube10. The tube10is substantially cylindrical and is constructed of a high-strength material such as stainless steel, 4140 high tensile steel, B7 alloy steel and titanium. One of ordinary skill in the art will recognize that other materials could be used as well. Optionally, a hand guard could be installed on the suppressor1, fully or partially enclosing the same.

Referring toFIGS. 4 and 5, the rear end cap12is fixed to the tube10and is sealed against the barrel2and positioned rearward from a barrel extension portion6of the barrel2and on a base portion8of the barrel2. Although not fully shown inFIGS. 4 and 5, a bore3extends completely through the barrel2. The rear end cap12includes an inner section122having an inner diameter substantially equal to the barrel base8and an outer section124having an outer diameter slightly greater than the diameter of the tube10. The outer section124includes a lip portion126that surrounds an inner end of the tube10. Thus, the rear end cap12is form fit onto the barrel2as well as the tube10. The lip portion126provides a secure seal and prevents gas from exiting the tube10and also protects the rear end cap12from damage, as damage in this area would result in gas leakage and cause the suppressor1to malfunction. The rear end cap12includes an aperture128that is sized substantially the same and aligned with the gas tube4so that the gas tube4extends therethrough, as shown inFIG. 5, while still providing a seal. As such, the gas tube is integrated into the rear end cap12or the piston passes through the rear end cap12and into the upper receiver. Thus, the rear end cap12is capable of being machined onto the barrel2.

Referring toFIGS. 6-8, a gas block20is positioned on the barrel extension6and enclosed by the tube10within a main body11. The gas block20includes an inner section202and an outer section204integrally formed with each other. The inner section202is substantially cylindrical and sized to be positioned on the barrel extension6in a secure form fit. The inner section202includes an opening or aperture (not shown) which coincides with and is aligned with another opening or aperture (not shown) on the barrel extension6. The inner section202could include more than one opening or aperture depending on the number of openings or apertures on the barrel extension6. The outer section204is also substantially cylindrical and is connected integral to the inner section202by upper and lower rib members208,210. The outer section204is shaped and sized substantially similar to an inner surface of the tube10to form a support structure for the main body11to make the tube10less susceptible to damage such as dings and dents. The upper rib member208includes an inner aperture (not shown) which is connected with the aperture of the inner section202and aperture of the barrel extension6. The upper rib member208also includes an outer aperture212which is configured to be coupled with the gas tube4. The outer aperture212is connected with the aperture of inner section202and the aperture of the barrel extension6to form an unimpeded path for gas to travel from the inner barrel2to the gas tube4and to an upper receiver of the firearm.

As shown inFIG. 8, the rib members208,210of the gas block20extend toward the front of the barrel2forming rib extensions208a,210a. The rib extensions208a,210aengage the inner surface of the tube10to provide additional support to the main body11. The outer aperture212extends through the upper rib extension208a, which also includes a side aperture220connected to the outer aperture212. In this configuration, excess gas can be displaced from the gas tube4through the side aperture220, for example during emergency situations when the excess gas is formed in the gas tube4and upper receiver. Alternatively, the side aperture220is used for indexing the gas tube, for example, with a spring pin, so that the gas tube4is properly positioned within the aperture212. The gas block20is configured to accommodate standard gas tubes used in the industry. However, modifications could be made to accommodate other types of gas tubes.

A plurality of open channels214are formed between the inner and outer sections202,204. In this embodiment, two open channels214are provided so that gas can travel within the main body11of the tube10. In the alternative, the open channels214could be eliminated and comprise of a solid material to form a shorter suppressor. Referring toFIGS. 7 and 8, outside edges216of the outer section204are sharp to aid in cleaning carbon exhaust and build up from the inner surface of the tube10. That is, when the tube10is removed from the barrel2, the sharp edges216will naturally scrape residue off of the inner surface of the tube10with little resistance. Inner edges218of the outer section204, being a high-stress area, are chamfered or radiused to prevent distortion of the outer section204and for relieving stress. As described above, the gas block20is capable of being machined onto the barrel2.

Referring toFIGS. 9-15, an intermediate member30is shown attached to the front end of the barrel extension6. The intermediate member30is shaped and sized to fit snugly within the tube10to provide additional support for the tube10. Generally, the intermediate member30includes a base member32and an opposing ring member36with extension members34positioned therebetween, the components of which are integrally formed together.

The base member32includes an engaging section320that is substantially hollow with a threaded portion322therein for engagement with a barrel end3with substantially matching threads. In other embodiments where the barrel end is provided with dimples or indents instead of threads, the inside of the engaging section could instead be provided with matching indents or protrusions, respectively, for engagement. Outer surfaces321of the engaging section320are substantially flat so that open ended tools such as wrenches could be utilized to easily engage the engaging section320for installation and removal of the intermediate member30. The engaging section320extends away from the barrel end3and is positioned between the extension members34. The engaging section320also includes a through hole324which is aligned with a central axis of the barrel2(or bore3) so that a round could pass through. The through hole324is sized such that the round or bullet does not make contact with the intermediate member30. Referring toFIG. 11, an inner portion of the base member32is also provided with gap325for accommodating a washer to provide further security from the intermediate member30and barrel extension6from disengaging. The washer also provides a seal from carbon debris entering the threaded area. In the alternative, set screws could be utilized to further secure the same. The gap325is tightly toleranced so that carbon cannot easily enter, thereby reducing the risk of carbon build up and difficulty in removing the intermediate member30from the barrel extension6.

The base member32also includes opposing base extensions326extending radially from the engaging section320. The base extensions326include apertures328extending therethrough to provide alternative means for removing the intermediate member30from the barrel extension6. That is, in the event a wrench is unavailable, the user could extend other devices through the apertures328such as a screw driver to generate sufficient torque for removal. Edges330formed between the engaging section320and base extensions326are rounded or radiused to eliminate high stress areas and to allow for easier cleaning compared with straight ninety degree edges. The rounded edges330also provide a less restricted path for gas to travel backward towards the main body11. In additional the base extensions326include rounded or radiused pockets332for easily collecting and cleaning accumulated carbon build up or deposits. As shown inFIG. 14, outer edges327of the base extensions326are sharp so that carbon build up on the inner surface of the tube10could be scraped and easily removed when removing the tube10.

As shown inFIG. 9, the extension members34extend from the base extensions326, forming a chamber340between the extension members34. The extension members34have rounded outer surfaces342(best shown inFIG. 15) which conform with the inner surface of the tube10such that the respective surfaces are securely engaged. Inner surfaces346are substantially linear and extend through to the ring member36.

The ring member36is integrally formed on the outer ends344of the extension members14. The ring member36includes an outer surface360and an opposing inner surface (not shown) having an aperture362extending therethrough. A side wall364extends rearwardly from the ring member inner surface. The inner surface of the ring member36includes a linear portion coinciding with the extension member inner surfaces346.

Referring toFIGS. 16-19, a blast baffle40is shown installed on the intermediate member30. The blast baffle40includes an engagement section410integrally formed with an extension section420. The engagement section410is substantially cylindrical except that opposing sides412,414are substantially linear to coincide with the extension member inner surfaces346. As such, the engagement section410is configured to snap fit or form fit into the ring member36. The engagement section410includes a free edge428which is substantially sharp so that carbon debris could be scraped and removed from the inner surface of the tube10when the components are disassembled. The extension section420is substantially tubular with at least the outer diameter being greater at a base portion422. However, the outer diameter of the extension section420could be uniform as well. An aperture424extends through the engagement section410and the extension section420at a substantial center and substantially aligned with the bore3for a round or projectile to pass through. The size of the aperture424is such that the bullet does not make contact with the blast baffle40. The aperture424is threaded on the engagement section410as shown inFIG. 23.

Referring toFIGS. 20-26, a flash hider50is shown. The general shape of the flash hider50is substantially cylindrical and includes a plurality of baffles502positioned between an inner end506and an outer end508. The baffles502form a plurality of open channels512which decrease in width from the inner end506to the outer end508. In this embodiment, five baffles form six channels but this could be varied depending on design requirements. Optionally, a flat surface514is provided on opposing outer sides to provide a means from a tool such as a wrench to be used to install and de-install the flash hider50. In this embodiment, the flat surface514extends 1.5 inches but other dimensions could be used as well. An aperture520extends through the flash hider50at a substantial center and is aligned with the bore3for a round or projectile to pass through. The size of the aperture520is such that the bullet does not make contact with the flash hider50. A flash hider extension530extends from the inner end506at a center position and is threaded for engagement with the threaded portion of the blast baffle40as shown inFIG. 23. The positioning and engagement of the threaded blast baffle40within the ring member36provides the function of a nut for the flash hider50. Furthermore, with this engagement the flash hider50engages the ring member outer surface360. A space426formed between the ring member inner surface and ring member outer surface360shown inFIG. 17(i.e., the thickness of the ring member) adjacent the blast baffle40could be provided with a crush washer to further eliminate any open space between the blast baffle40and the flash hider50. The crush washer would further provide a seal from carbon debris from entering the threaded area. Finally, the outer end508includes internal threads as shown inFIG. 24.

Referring toFIG. 24, the front end cap14is shown engaged with the flash hider50. As with the rear end cap12, the front end cap14is also substantially cylindrical and fixed to the tube10in friction or form fit, as shown inFIG. 26. The front end cap14includes an extension section600integrally formed with a base section610. The extension section600includes a threaded outer surface602for engaging with the threaded portion of the flash hider50. The base section610includes an inner surface612that engages an outer surface516of the flash hider50. This provides a seal so that carbon debris is prevented from entering the threaded portion. This engagement could also be supplemented with a crush washer to further accomplish the same. The base section610also includes a lip portion614having an inner diameter that is substantially equal to the outer diameter of the tube10. As such, a space615is provided so the front end cap14is secured to the tube10to form a substantial seal, as shown inFIG. 26. An aperture620extends through the front end cap14and is centrally positioned and substantially aligned with the bore3. The aperture620is sized such that a bullet is capable of passing through without making direct contact with the front end cap14. Moreover, the base section610is provided with a drive hole630at an outer end for securing the front end cap14to the flash hider50with a rotational tool. In this embodiment, the drive hole630is configured to receive a ⅜ inch hexagonal key but other sizes and shapes could be utilized without departing from the spirit and scope of the invention. As such, the front end cap14is secured to the flash hider50by threaded engagement and to the tube10by form fit.

As shown inFIG. 26, each component is assembled on and around the barrel2to form the suppressor1of the present invention.

Referring toFIG. 25, in operation, a fired round, bullet or projectile B travels through barrel extension6via the bore3, producing exhaust gas. As the bullet B enters the blast baffle40, in the intermediate member30, the blast baffle aperture424is partially sealed and gas is dissipated around the extension section420of the blast baffle40and back toward the rear of the tube10to the main body11as shown by the arrows in the chamber340. This is due to the pressure difference within the suppressor1in that the intermediate member30has a higher pressure than that of the main body11. Due to the length of the blast baffle extension section420, sufficient time is provided for sufficient amount of gas to travel backward instead of through the blast baffle40and flash hider50. After the bullet B exits the suppressor1, in the flash hider50, the gas is dissipated radially outwardly from the flash hider aperture520through the respective channels512as shown by the arrows within the channels512. In addition, excess propellant is burned within each channel512as the bullet B travels forward. With the channels512being larger toward the rear of the flash hider50, more propellent is burned earlier during travel. As well, the larger channels512toward the rear of the flash hider50provide areas of lower pressure than that of the smaller channels in the front so that gas is more susceptible to travel backward. InFIG. 25, each vertical line1A-6A on the flash hider aperture520represents a partial seal that is formed between the bullet B and baffle512as the bullet B travels through the flash hider50. Due to the high pressure in the flash hider50, gas is further dissipated back towards the main body11through the blast baffle40. As such, exhaust gas is pushed backward to within the tube10rather than outward to the ambient air. With this configuration, noise is greatly reduced.

The components of the suppressor1are constructed of a high-strength material such as stainless steel, 4140 high tensile steel, B7 alloy steel and titanium. One of ordinary skill in the art will recognize that other materials could be used as well. For example, certain components could be manufactured with high-grade plastics or composite materials with high melting points to reduce weight of the suppressor1.

The components of the suppressor1described above could be installed on an existing barrel of a firearm. As well, the suppressor1could be manufactured with a barrel and sold as a combination. Modifications to the barrel and suppressor could be made to customize each combination with different types of firearms for optimal performance including but not limited to customization based on harmonics.

The present invention provides a suppressor which is conveniently and efficiently assembled to and disassembled from a firearm for convenient cleaning and maintenance. Additionally, the present invention provides a suppressor that is exceptionally stable and that protects the internal components from the undesirable characteristics of gunpowder residue buildup and fouling. Moreover, the suppressor of the present invention suppresses noise and flash discharge. As well, the suppressor of the present invention is capable of installing on gas impingement and piston operated firearms by enclosing the gas impingement system, thereby eliminating the need for modification of the firearm while not unduly increasing the overall length of the firearm. Additionally, because of the extra area provided by the suppressor, heat dissipation is also improved.

In the embodiments illustrated in the figures, the suppressor of the present invention can be used on AR-15 rifles as well as any other firearms, whether rifles or handguns and whether automatic, semi-automatic or bolt action. Still other variants that are known now or are developed later are intended to be included within the scope of the term “firearm,” as understood by a person of skill in the art.