Patent Publication Number: US-8991550-B2

Title: Baffle for use in a sound suppressor for a firearm

Description:
BACKGROUND 
     The present application is directed to a baffle for use in a suppressor for a firearm and, more specifically, to a baffle with a stepped design. 
     Suppressors are devices that attach to the barrel of a firearm to reduce the amount of noise and amount of muzzle flash that occurs when the firearm is fired. Sound suppressors normally include a metal tube with a number of interior baffles that form expansion chambers. The suppressor is designed to divert the rapidly expanding gases that are expelled from the end of the firearm into the expansion chambers. The trapped gases expand and cool and the pressure and velocity decreases as it moves through and exits the suppressor. 
     Existing suppressors use a variety of different constructions in attempts to reduce the amount of noise that occurs during firing of the firearm. These may include a wide variety of baffle configurations, lengths and sizes of the metal tube, and attachment mechanisms for attached to the end of the firearm. 
     Existing suppressors are often not adequate to reduce the sound that emanates from a fired firearm. This results in the level of sound that emanates from the firearm remaining too high for use by the shooter. Existing suppressors may also include intricate and/or extensive internal mechanisms positioned within the interior of the metal tube. These internal mechanisms are designed to reduce the sound. However, these mechanisms often result in excessive costs for the suppressor. The mechanisms may also be unacceptably heavy or bulky thus lessening the effectiveness of the firearm. Each of these various drawbacks may result in the shooter not using the suppressor or reluctantly using the suppressor. 
     Therefore, there is a need for a suppressor that is effective in reducing the sound and muzzle flash that emanates from the firearm. 
     SUMMARY 
     The present application is directed to a baffle for use in a sound suppressor for a firearm. 
     One embodiment is directed to a baffle that includes a back section with a first side configured to face towards the firearm and an opposing second side, and a conical section that extends outward at the second side of the back section and includes an outer side and an inner side. The conical section includes a tapered shape that enlarges away from the back section. An opening extends through the back section and has an inlet at the first side and an outlet at the second side. A central bore extends through the back section and the conical section. Steps extend around the outer side of the conical section and along a length of the outer section. The steps face the outlet of the opening and each of the steps includes a flat riser section that extends away from the central bore, a flat tread section, and a curved intermediate portion that connects the riser and tread sections. 
     In the baffle, the riser section may be perpendicular with the central bore. 
     The tread section may be parallel with the central bore. 
     The baffle may include a single opening that extends through the back section. 
     The opening may intersect with the central bore within an interior of the back section between the first and second sides. 
     The first side of the back section may include a concave indent that extends around the central bore. 
     The baffle may also include a second series of steps that extend around and along the inner side of the conical section. Each of the second series of steps may include a riser section and a tread section. 
     Each of the steps of the baffle may include a common shape and size. 
     Another embodiment is directed to a baffle that includes a central bore, and a conical section that includes an inner side that faces towards the central bore and an outer side that faces away from the central bore. The conical section has a tapered shape with a first axial end having a smaller outer diameter than a second axial end. Steps extend along each the inner and outer sides of the conical section with each of the steps including a riser section that extends away from the central bore, a tread section, and an intermediate portion that connects the riser and tread sections. The intermediate portion has a constant radius. 
     The baffle may include that each of the intermediate portions of the steps is aligned along a straight line that is positioned at an acute angle relative to the central bore. 
     Each of the tread sections and the riser sections may be flat. 
     Each step may include the tread section and the riser section being aligned at a 90° angle. 
     The riser section may be perpendicular with the central bore. 
     Each of the steps may include a common shape and size. 
     Another embodiment is directed to a baffle that includes a central bore, a back section that extends around the central bore with a first side configured to face towards the firearm and an opposing second side, and a conical section that extends around the central bore and is integral with and extends outward from the back section along the central bore. The conical section includes an inner side that faces towards the central bore and an outer side that faces away from the central bore. The conical section has a tapered shape that enlarges away from the back section. An opening extends through the back section with an inlet at the first side that is in communication with the central bore and an outlet at the second side. A centerline of the opening is parallel with the tapered conical section. Steps extend along each the inner and outer sides of the conical section with each including a riser section that extends away from the central bore, a tread section, and an intermediate portion that connects the riser and tread sections. 
     The intermediate section of each step along the outer side may include a constant radius. 
     The riser section of each step may be perpendicular with the central bore. 
     The tread section of each step may be parallel with the central bore. 
     Each of the steps along the outer side may include a common shape and size. 
     The first side of the back section may include a concave indent that extends around the central bore. 
     These various aspects may be used together in a single procedure. Alternatively, the various aspects may be used separately to include just the use of the subsequent middle region reaming, and just the use of the dummy implant. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front perspective view of a baffle for use in a sound suppressor for a firearm. 
         FIG. 2  is a back perspective view of a baffle for use in a sound suppressor for a firearm. 
         FIG. 3  is a side schematic view of a baffle. 
         FIG. 4  is a sectional view cut along line IV-IV of  FIG. 1 . 
         FIG. 5  is a schematic view of a series of steps on a conical section of a baffle. 
         FIG. 6  is a schematic view of a sound suppressor. 
     
    
    
     DETAILED DESCRIPTION 
     The present application is directed to a baffle for use in a sound suppressor. The baffle is designed to minimize the sound that emanates from a fired firearm. The baffle generally includes a back section and a conical section. A bore extends through each of the sections and is sized for a fired projectile to pass through. The sides of one or both of the sections are configured to reduce the sound. Further, a second hole extends through the back section at the bore to allow for the passage of gases. 
       FIGS. 1 and 2  illustrate a baffle  10  that includes a back section  20  and a conical section  30 . The sections  20 ,  30  may be formed as a unitary, single piece, or may be constructed from separate pieces that are attached together. A cylindrical bore  40  extends along a centerline C of the baffle  10  and through the center of each section  20 ,  30 . The bore  40  is sized to allow passage of the fired projectile. An opening  50  extends through the back section  20  at the bore  40  to allow the passage of gases. The baffle  10  is designed to be positioned within a tube of a sound suppressor with the back section  20  facing towards the firearm and the conical section  30  facing away from the firearm. The surfaces of the sections  20 ,  30  are configured to reduce the noise caused by the fired projectile. 
     The back section  20  includes a first side  21  that faces away from the conical section  30 , and a second side  22  that faces towards the conical section  30 . An outer edge  24  extends between the sides  21 ,  22  and is substantially flat. The thickness of the outer edge  24  measured between the first and second sides  21 ,  22  may vary. One embodiment includes a thickness of 0.1875 inches. The back section  20  includes a circular shape when viewed axially along the centerline C and is designed to fit within a tube of the suppressor with the outer edge  24  contacting against an inner side of the tube as will be explained in detail below. 
     The first side  21  includes a concave indent  23  that extends around the central bore  40 . The concave indent may include a continuous curve, and may be uniform around the central bore  40 . In one embodiment as illustrated in  FIG. 4 , the concave indent  23  includes a radius R of 0.5625 inches. In one embodiment, the maximum depth measured inward from the first side  21  is positioned at a center point between the central bore  40  and the outer edge  24 . 
     The first side  21  also includes a neck  25  that extends axially outward along the bore  40 . In one embodiment, the neck  25  includes a length along the bore  40  of 0.10 inches. As illustrated in  FIGS. 3 and 4 , the neck  25  extends outward along the bore  40  beyond the first side  21  of the back section  20 . The neck  25  includes a thickness measured radially outward from the bore  40 . The neck  25  includes a thickness measured radially from the bore  40 . In one embodiment, the thickness of the neck  25  is 0.2225 inches. 
     The opening  50  extends through the back section  20  and provides for gases that are emitted from the firearm to pass to the conical section  30 . The opening  50  may include a variety of cross-sectional shapes with one embodiment including a circular shape about a centerline C1. The opening  50  intersects with the bore  40  within the interior of the back section  20 . When viewed from the front, the combined bore  40  and opening  50  form an elongated shape along the back section  20 . 
     As illustrated in  FIG. 4 , the opening  50  includes a centerline C1 that forms an acute angle α with the centerline C of the bore  40 . The angle α may vary with embodiments falling within a range of between 30° to 60°, with one specific embodiment including an angle α of 45°. In one embodiment as illustrated in  FIG. 4 , the centerline C1 intersects the centerline C at a point outward from the neck  25  (i.e., in front of the neck  25 ). 
     The opening  50  is configured to direct the gases from the firearm against the conical section  30 . The opening  50  may be parallel with the conical section  30 . This provides for the gases to move across the outer surface of the conical section  30 . In one embodiment, the centerline C1 of the opening  50  is parallel with a centerline C2 that extends through the body of the conical section  30 . In another embodiment, the centerline C1 is parallel with a line L that extends along the valleys of ridges along the conical section  30 . The centerline C1 may also be parallel with other lines that extend through various sections of the body of the conical section, including the peaks of the ridges, or a center of the ridges. 
     The second side  22  of the back section  20  faces towards the conical section  30 . In one embodiment, the second side  22  is flat. 
     The conical section  30  extends outward from the back section  20  and is centered around the bore  40 . In one embodiment, the conical section  30  includes an outwardly tapered shape that enlarges away from the back section  20 . The conical section  30  includes a first side  31  that faces outward away from the bore  40  and a second side  32  that faces inward towards the bore  40 . The end  34  of the conical section  30  is open and faces away from the back section  20 . 
     A band  35  extends around the end  34  at the first side  31 . The band  35  is configured to contact against the inner side of the suppressor tube. In one embodiment as illustrated in  FIG. 3 , the length of the band  35  is 0.25 inches. The band  35  may include a circular shape when the baffle  10  is viewed axially. In one embodiment as illustrated in  FIG. 3 , the end  34  of the conical section  30  and the outer edge  24  of the back section  20  include the same outer diameter to both contact against the inner side of the suppressor tube. In one embodiment, each has an outer diameter of 1.712 inches. 
     Each of the first and second sides  31 ,  32  include a series of steps  33  to dissipate the gases that emanate from the firearm. Each step  33  includes a first side  36  and a second side  37  that intersect at a ridge  38 . The steps  33  may be evenly spaced apart along one or both of the first and second sides  31 ,  32  of the conical section  30  as illustrated in  FIG. 4 , or may be unequally spaced apart. Further, each of the steps  33  may include the same shape and size as illustrated in  FIG. 4 , or different shapes and sizes. 
       FIG. 5  is a schematic view of a series of steps  33 . Each step  33  includes a first riser side  36 , a second tread side  37 , and an intermediate ridge  38 . The first and second sides  36 ,  37  may be arranged at various angles relative to one another. In one embodiment, the first side  36  is perpendicular to the centerline C of the bore  40 . In one embodiment, the second side  37  is parallel with the centerline C. In the embodiment of  FIG. 5 , each of the sides  36 ,  37  is flat. One or both sides  36 ,  37  may also include different shapes and/or sizes. 
     The ridge  38  is formed at the intersection of the first and second sides  36 ,  37 . The ridge  38  includes a curved shape that extends between the sides  36 ,  37 . In one embodiment, the ridge  38  is radiused to smoothly transition between the sides  36 ,  37 . In one specific embodiment, the radius R is 0.045 inches. The ridges  38  along the steps  33  may each be the same, or the different steps  33  may include ridges of different shapes and/or sizes. The sides  36 ,  37  further include valleys on opposing sides from the ridges  38 . The valley may be the same shape and size of as the ridge  38 , including a smooth radius. Alternatively, the valleys may include different shapes and/or sizes than the ridges. 
     In one embodiment, steps  33  are positioned along both the first and second sides  31 ,  32  as illustrated. In another embodiment, the steps  33  are positioned along just the first side  31 . 
     The bore  40  extends through the length of the baffle  10 . As illustrated in  FIG. 4 , the bore  40  includes a first section with a cylindrical shape that extends through the bodies of the back and conical sections  20 ,  30 . The bore  40  also has a tapered shape through a remainder of the conical section  30  that expands towards the end  34 . 
       FIG. 6  illustrates a suppressor  60  that includes a number of separate baffles  10 . The suppressor  60  includes an exterior sleeve  70  that has a cylindrical shape. The sleeve  70  includes an open interior space and opposing ends. The sleeve  70  may be constructed from various materials, including aluminum. 
     A first endcap  71  is mounted at the first end of the sleeve  70  and is configured to attach to the firearm, and an opposing second endcap  72  at the second end. Each of the endcaps  71 ,  72  includes a bore sized to allow passage of the fired projectile. The endcaps  71 ,  72  may be constructed from a variety of materials. In one embodiment, the endcaps  71 ,  72  are constructed from aluminum. The first endcap  71  may also include a threaded insert for attachment to the firearm. In one embodiment, the insert is constructed from steel which is able to withstand the heat. 
     One or more baffles  10  are positioned along the interior space of the sleeve  70 . The baffles  10  may include the same or different shapes and/or sizes.  FIG. 6  includes each having the same shape and size. The baffles  10  are aligned with the back sections  20  positioned towards the first end of the sleeve  70  that attaches to the firearm and the conical sections  30  facing in an opposing direction. The baffles  10  are further abutted together with the end  34  of the conical section  30  of a first baffle  10  in contact against the first side  21  of the back section  20  of an adjacent baffle  10 . The back section  20  and conical section  30  are further sized to contact against the inner wall of the sleeve  70 . Specifically, the outer edge  24  of the back section  20  and the band  35  of the conical section  30  contact against the inner wall. 
     The baffles  10  may be constructed from a variety of different materials, including but not limited to aluminum and steel. In one embodiment, the first baffle (i.e., the baffle nearest to the firearm) is constructed from steel and the remaining baffles  10  are constructed from aluminum. The first steel baffle  10  may be exposed to greater amounts of heat than the other baffles  10 . The aluminum baffles  10  help to reduce the overall weight of the suppressor  60 . 
     Spatially relative terms such as “under”, “below”, “lower”, “over”, “upper”, and the like, are used for ease of description to explain the positioning of one element relative to a second element. These terms are intended to encompass different orientations of the device in addition to different orientations than those depicted in the figures. Further, terms such as “first”, “second”, and the like, are also used to describe various elements, regions, sections, etc. and are also not intended to be limiting. Like terms refer to like elements throughout the description. 
     As used herein, the terms “having”, “containing”, “including”, “comprising” and the like are open ended terms that indicate the presence of stated elements or features, but do not preclude additional elements or features. The articles “a”, “an” and “the” are intended to include the plural as well as the singular, unless the context clearly indicates otherwise. 
     The present invention may be carried out in other specific ways than those herein set forth without departing from the scope and essential characteristics of the invention. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive, and all changes coming within the meaning and equivalency range of the appended claims are intended to be embraced therein.