Abstract:
A firearm suppressor includes an outer housing and a baffle stack mounted inside the outer housing. The baffle stack includes baffles and spacers. The baffles and spacers are configured to allow a projectile to pass through while causing exhausted gas to flow through various chambers and channels in different directions.

Description:
FIELD OF THE INVENTION 
     The present invention relates to sound suppression. In particular, the present invention relates to firearm suppressors having baffles separated by spacers that are rotationally oriented around a projectile pathway with respect to each other. 
     BACKGROUND OF THE INVENTION 
     Firearms typically discharge noise and gases into the atmosphere, when fired, which may be harmful or offensive to the shooter and/or to others within the general vicinity. As a result various suppression devices have been devised in order to attempt to solve this problem. These sound suppressor devices may feature baffles that use some form of asymmetry while others may feature the use of baffles that are basically symmetrical. While asymmetrical baffles typically produce high levels of turbulence within the sound suppressor, which aids in producing high levels of sound and flash reduction, asymmetrical baffles may result in some detrimental effects on the accuracy of the host firearm. 
     The concept behind the use of baffles is to divert gases away from a bore axis along which a projectile travels after leaving the muzzle of a firearm. The more effective the diversion, and subsequent creation of turbulence due to the diverting gases impinging upon other surfaces (e.g., spacers, gas flow channels and vent holes) within the suppressor, generally the suppressor is more efficient with regards to sound reduction. 
     SUMMARY OF THE INVENTION 
     In accordance with the present invention, a firearm suppressor may include an outer housing and a baffle stack that may be inserted and/or removed from the outer housing. The baffle stack may include three or more baffles that each have a proximal baffle surface and a distal baffle surface. A baffle bore sized to receive a projectile may extend through each baffle along a longitudinal axis. The firearm suppressor may further include two or more spacers that are each disposed between a respective set of two baffles. One spacer may be positioned along a first surface plane having a first orientation, and another spacer may be positioned along a second surface plane having a second orientation. The second surface plane may intersect the first surface plane along the longitudinal axis, and an acute angle may separate the first surface plane and the second surface plane. Additional spacers may be included, where the additional spacers are disposed between respective sets of two baffles and are oriented along respective surface planes that similarly intersect other surface planes along the longitudinal axis. 
     In accordance with the present invention, a firearm suppressor may include baffle stack including a first baffle, a second baffle, and a third baffle, each baffle including an opening defining a projectile aperture. The first, second, and third baffles may be coaxially positioned along a longitudinal axis defined by the projectile apertures. A first spacer may be connected between the first baffle and the second baffle, and a second spacer may be connected between the second baffle and the third baffle. The second spacer may be rotated about the longitudinal axis at an angle relative to the first spacer. 
     In accordance with the present invention, a method of manufacturing one or more firearm suppressor components includes the steps of forming all or a portion of three baffles with openings defining a projectile aperture. The baffles may be coaxially positioned along a longitudinal axis defined by the projectile apertures. A first spacer may be formed between a first baffle and a second baffle, and a second spacer may be formed between the second baffle and a third baffle. The orientation of the second spacer may be rotated about the longitudinal axis at an angle relative to the orientation of the first spacer. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present application may be more fully appreciated in connection with the following detailed description taken in conjunction with the accompanying drawings. 
         FIG. 1  depicts an isometric view of a baffle stack for one embodiment of a firearm suppressor. 
         FIG. 2  depicts a sectional side view of a baffle stack. 
         FIG. 3  depicts an exploded view of one embodiment of a firearm suppressor. 
         FIG. 4  illustrates different orientations of a baffle in accordance with one or more embodiments. 
         FIG. 5  illustrates different shapes of a spacer in accordance with one or more embodiments. 
         FIG. 6A  illustrates a cross-sectional, side view of a baffle stack. 
         FIG. 6B  illustrates a cross-sectional, isometric view of a baffle stack. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Overview 
     One aspect of the disclosure relates to one or more components of a firearm suppressor. In one embodiment, a firearm suppressor may include three or more baffles, wherein each baffles has a proximal baffle surface and a distal baffle surface, and wherein a baffle bore extends through each baffle along a longitudinal axis. The firearm suppressor may further include two or more spacers. Each spacer may be disposed between a respective set of two baffles. One spacer may be positioned along a first surface plane having a first orientation, and another spacer may be positioned along a second surface plane having a second orientation. The second surface plane may intersect the first surface plane along the longitudinal axis, and an acute angle may separate the first surface plane and the second surface plane. Additional spacers may be included, where the additional spacers are disposed between respective sets of two baffles and are oriented along respective surface planes that similarly intersect other surface planes along the longitudinal axis. 
     Another aspect of the disclosure relates to gas flow through chambers formed by spacers with cut-out portions, through channels formed by surfaces of a spacer and two baffles, through vent holes, and through channels carved into a spacer that allow the gas to flow to/from chambers separated by two baffles and the spacer. 
     Another aspect of the disclosure relates to orientations and shapes of baffles and spacers in a three-dimensional space including a longitudinal axis. 
     Another aspect relates to manufacturing of one or more components of a firearm suppressor. In accordance with one embodiment regarding the manufacture of firearm suppressor components, several baffles may be formed with openings defining projectile apertures, and several spacers are formed, each between a respective set of the baffles. The baffles may be coaxially positioned along a longitudinal axis defined by the projectile apertures, and the orientation of one spacer is rotated about the longitudinal axis at an angle between zero (0) degrees and 360 degrees relative to the orientation of the first spacer. 
     Exemplary Embodiments 
     Certain features of the invention are depicted in the Figures. 
     Turning to  FIG. 1 , for example, an isometric view showing a baffle stack  100  of an embodiment of the present invention is illustrated. The baffle stack  100  may be formed as a single member (e.g., each part is milled from a piece of material or each piece is joined together using various techniques known in the art), or may be comprised of several members that are positioned next to each other. 
     As shown, the baffle stack  100  includes a plurality of baffles  110   a - k , a plurality of relationally-rotated spacers  120   a - h , a plurality of cylindrical spacers  130   a - c , a plurality of venting holes (e.g., venting hole  140   a  and  140   b ), a plurality of bores/apertures sized larger than a projectile (e.g., bores  150   a  and  150   b ) through which a projectile (e.g., a bullet) travels along a longitudinal axis through the baffle stack  100  from a proximal end  160  to a distal end  170 —e.g., through the center of the baffle stack  100  along the longitudinal axis. As will be illustrated in later figures, the any of the baffles  110  and spacers  120  may be formed or positioned at different orientations to those shown in  FIG. 1 . Moreover, any of the baffles  110  and spacers  120  may have different shapes, sizes and designs to those shown in  FIG. 1 . Later figures will illustrate additional features of the components depicted in  FIG. 1  along with illustrations of other components not shown in  FIG. 1 . 
     As shown in  FIG. 1 , spacer  120   b  is positioned between baffle  110   a  and baffle  110   b  at a first orientation with respect to a three-dimensional space defined by the longitudinal axis, a lateral axis and a vertical axis. Spacer  120   c  is positioned between baffle  110   b  and baffle  110   c  at a second orientation with respect to the three-dimensional space. As shown, the second orientation is rotationally-offset around the longitudinal axis from the first orientation by an angle of rotation. The angle of rotation may be any angle from zero (0) degrees to 360 degrees. In a preferred embodiment, the angle of rotation may by approximately 137.5 degrees. In other embodiments, the angle of rotation may be selected from 20 degrees to 160 degrees, or from 200 degrees to 340 degrees. 
     Other spacers  120  are similarly rotated with respect to each other so that some spacers have different orientations than other spacers. Rotation of the spacers is a unique and advantageous feature of the invention, which provides structural strength while further dampening sound as compared to other suppressors. The different orientations of some spacers in relation to other spacers provide different gas flow characteristics over flow characteristics of other suppressors. 
     The spacers  120  in  FIG. 1  are depicted as intersecting the longitudinal axis along respective bores (not labeled) that extend through the spacers from a respective distal end of one baffle to a respective proximal end of another baffle. Each of the spacers may be positioned along a respective surface plane that intersects the longitudinal axis. For example, spacer  120   a  may be positioned along a first surface plane that intersects the longitudinal axis, and spacer  120   b  may be positioned along a second surface plane that intersects the longitudinal axis. The second surface plane may be offset by any angle from the first surface plane (e.g., 137.5 degrees, or any angle between zero (0) degrees and 360 degrees). One of skill in the art will appreciate that the above surface planes, and therefore the spacers  120 , need not intersect the longitudinal axis (i.e., the pathway of the bullet). Instead the spacers  120  may be offset from the bullet pathway, thereby eliminating any need to form the spacers  120  with respective bores to allow a projectile to pass through the spacers  120  as it travels from the proximal end  160  to the distal end  170 . 
       FIG. 1  also illustrates a plurality of cylindrical spacers  130   a - c  that are formed or positioned between baffles  110   h - k . Spacers  130   a - c  encircle the longitudinal axis, thereby creating a bore (not labeled) through which a projectile may travel. Gases emitted from the muzzle of the firearm may flow through channels formed by the outer wall of the spacers  130   a - c  and walls of the baffles  110 - h - k . For example, gas may enter a first channel (not labeled) formed by the outer wall of spacer  130   a , the distal wall of baffle  110   i , and the proximal wall of baffle  110   h . The gas may enter or exit through venting hole  140   b . The same gas may flow through other channels formed by spacers  130   b - c  and baffles  110   i - k , through various bores  150  of baffles  110   a - g , and/or through various bores (not labeled) of spacers  120   a - h.    
     Turning now to  FIG. 2 , which provides a sectional side view of a baffle stack  200 . As shown, the baffle stack  200  includes baffles (e.g., baffles  210   a  and  210   b ) and spacers (e.g., spacer  220   b ). Spacer  220   b  includes a geometric cut-out  225   b  that joins chamber portions  227   b  and  229   b , thereby forming one large chamber into which gas from a firearm may flow. The geometric cut-out  225   b  may take various shapes or combinations of shapes. Shapes may include any geometric shape, letter, number, image, or other design known in the art. 
     Attention is now drawn to  FIG. 3 , which depicts an isometric exploded view of a firearm suppressor in accordance with one embodiment. As shown, the suppressor includes a baffle stack  300 , an outer tube  380  and a muzzle connector  385  with several vent holes  385   a . The baffle stack  300  may slide inside the outer tube  380 , and a portion of the muzzle connector  385  may slide into the proximal end  360  of the baffle stack  300 . 
     The outer tube  380  may be held in compression between one indentation  305  (e.g., a machined indentation) of the baffle stack  300  and one indentation  387  (e.g., a machined indentation) of the muzzle connector  385 . The outer tube  380  may be held in place when the baffle stack  300  (e.g., as a monocore component) screws into the muzzle connector  385  using female threading on the baffle stack near the proximal end  360  of the baffle stack  300 , and male threading on the muzzle connector  385 . The outer tube  380  may spin freely around the baffle stack  300  or may be held in place by a locking method (not shown, e.g., a screw that passes through the cylinder to contact the baffle stack  300  or the muzzle connector  385 ). 
     The muzzle connector  385 , via female threading, may screw onto the end of a firearm barrel (not shown), which would include male threading. 
     Turning now to  FIGS. 4 and 5 , which illustrate different configurations (e.g., orientation, shape, size) for a baffle and spacer, respectively.  FIG. 4  illustrates different orientations of a baffle in accordance with one or more embodiments. In  FIG. 1 , baffles  110  are perpendicular (i.e., at right angles) to the longitudinal axis. However, one of skill in the art will appreciate that other angles (e.g., acute and obtuse angles) are possible. One of skill will also understand that a baffle may have any orientation within a three-dimensional space—e.g., a baffle may be rotated about a lateral axis and/or a vertical axis to achieve a different orientation than that shown in  FIG. 1 . 
     A baffle may also have different shapes beyond the washer shape baffles  110  shown in  FIG. 1 , and may include additional cut-outs beyond the bores  150 . Moreover, either or both of the proximal and distal surfaces of a baffle may be flat, curved, stepped, saw-toothed, or have any geometric surface shape or structure known in the art (e.g., indentations, dimples, grooves, etc). The proximal and distal ends may also be coated with known coatings. 
       FIG. 5  illustrates different shapes of a spacer  520  between two baffles  510  in accordance with one or more embodiments. As shown, a spacer  520  may be parallel with the longitudinal axis (e.g., see A in  FIG. 5 , and as shown in  FIG. 1 ). A spacer  520  may alternatively diagonal to or curved about the longitudinal axis (e.g., see B-C in  FIG. 5 , respectively). A spacer  520  may also be stepped relative to the longitudinal axis (e.g., see D in  FIG. 5 ), or may be helical about the longitudinal axis (not shown). Alternatively, two spacers  520  may be positioned between the same baffles, parallel to each other and at an any shape shown in  FIG. 5  or otherwise described herein (e.g., see E in  FIG. 5 ). Although the baffles  510  are shown to be perpendicular to the longitudinal axis, one of skill in the art will appreciate that the baffles can be in an orientation described herein, including those in  FIG. 4 . 
     Turning now to  FIGS. 6A and 6B , which illustrate side and isometric cross-sectional view of a baffle stack  600 , respectively. As illustrated, the longitudinal axis extends along a bore axis that includes several bores, including bores  650   a  and  650   b . The baffle stack  600  includes several baffles, including baffles  610   a  and  610   h . The baffle stack  600  further includes several spacers, including spacers  620   b  and  620   c . As shown, some or all of the spacers are positioned at different orientations around the longitudinal axis. 
     The components described herein may be made from any suitable material, including metals, metal alloys, plastics, and other materials capable of necessary heat transfer, sound absorption, durability and other factors appreciated by those skilled in the art. Manufacture of embodiments described herein may include milling single pieces of material into the components, molding the components, welding the components together, or other methods appreciated by those skilled in the art. 
     It is understood that the specific order, dimension, shape and other characteristics of components disclosed herein are examples of exemplary apparatuses, methods of manufacturing apparatuses, and methods of assembling apparatuses, among other approaches. Based upon design preferences, it is understood that the specific order components may be rearranged while remaining within the scope of the present disclosure unless noted otherwise. It is further noted that any of the concepts described herein can be used in combination with each other even if that combination is not explicitly described herein. The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present disclosure. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the disclosure. Thus, the present disclosure is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein. 
     The disclosure is not intended to be limited to the aspects shown herein, but is to be accorded the full scope consistent with the specification and drawings, wherein reference to an element in the singular is not intended to mean “one and only one” unless specifically so stated, but rather “one or more.” Unless specifically stated otherwise, the term “some” refers to one or more. A phrase referring to “at least one of” a list of items refers to any combination of those items, including single members. As an example, “at least one of: a, b, or c” is intended to cover: a; b; c; a and b; a and c; b and c; and a, b and c. 
     While various embodiments of the present firearm suppressor and its components have been described in detail, it will be apparent to those skilled in the art that the present invention can be embodied in various other forms not specifically described herein. The innovative structures described herein are applicable to a wide variety of sound suppression apparatuses and circumstances besides a firearm suppressor. Therefore, the protection afforded the present invention should only be limited in accordance with the following claims.