Patent Publication Number: US-9835399-B1

Title: Monocore silencer with integral conical flash hider

Description:
RELATED APPLICATIONS 
     This application claims benefit of U.S. Provisional Application No. 62/142,241, titled MUZZLE END ACCESSORY MOUNT FOR A FIREARM filed Apr. 2, 2015, the contents of which are hereby incorporated by reference herein. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates to an accessory for a firearm that includes features of a flash suppressor and of a sound suppressor that are incorporated into a common structure. 
     BACKGROUND 
     Accessories are available for attachment to the muzzle of a firearm to accomplish various effects when the firearm is operated. Sound suppressors or silencers are an example of such an accessory and that include one or more chambers through which a bullet passes, when fired. The chambers receive rapidly expanding gases that propel the bullet, as the bullet passes, and slow the release of the gases to the external environment. The slowed release of propellant gases and the corresponding slowed reduction in pressure results in a reduced report when the bullet exits the firearm through the sound suppressor. 
     Flash suppressors or flash hiders are another type of accessory that includes features to promote the dispersion and/or mixing of unburnt gunpowder and propellant gases and air in a manner that reduces the overall magnitude of a muzzle flash that may occur with firing of a firearm. In this respect, any impact that such a flash might have on vision of an operator of the firearm may be reduced. Conventional flash hiders or suppressors include prong-like structures that are cantilevered from a muzzle end of a firearm. Such structures are prone to breakage and/or interference with the external environment. 
     SUMMARY 
     According to one example embodiment, an accessory for a firearm is disclosed. The accessory includes a housing mountable to the firearm in alignment with a firing axis of the firearm. A core structure is positionable within the housing in alignment with the firing axis. The core structure includes a proximal bullet receiving portion and a distal bullet discharge portion. A series of baffles at least partially define a series of suppression chambers in the core structure that extend from the proximal bullet receiving portion and towards the distal bullet discharge portion. A flash suppression structure that defines a cross section that lies orthogonal to the firing axis and that expands in area at positions further away from the proximal bullet receiving portion of the core structure to promote dispersion of propellant gases existing the distal bullet discharge portion. 
     According to one embodiment, the housing includes a housing base that is mountable to a muzzle of the firearm and a housing body that is securable to the housing base. The housing base includes an alignment feature to align the core structure with the firing axis of the firearm. The housing body includes a tapered cylinder constructed and arranged to secure the core structure in alignment with the firing axis of the firearm when secured to the housing base. 
     At least some of the series of suppression chambers progressively decrease in volume from the proximal bullet receiving portion and toward the distal bullet discharge portion, according to some embodiments. The series of suppression chambers may be defined, in cooperation, by portions of the core structure and the housing body. Each baffle of the series of baffles may define an aperture about the firing axis that is constructed and arranged to allow passage of a bullet. At least some the series of baffles may define the aperture with portions of the baffle that are axially offset along the firing axis. 
     According to some embodiments, the core structure defines at least a portion of a distal face of the accessory, with the distal face defining a bullet discharge opening of the distal bullet discharge portion. The distal bullet discharge opening may include a distal most portion of the flash suppression structure. The flash suppression structure includes a truncated cone structure that expands in area at positions further away from the proximal bullet receiving portion of the core structure. The truncated cone structure may extend from one of the series of baffles toward the distal face of the accessory. According to some embodiments, the core structure is a unitary structure. 
     The subject matter of this application may involve, in some cases, interrelated products, alternative solutions to a particular problem, and/or a plurality of different uses of a single system or article. 
     The present disclosure is not intended to be limited to a system or method that must satisfy one or more of any stated objects or features. Modifications and substitutions by one of ordinary skill in the art are considered to be within the scope of the present disclosure. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
       In the drawings, different embodiments of the invention are illustrated in which: 
         FIG. 1  is a perspective view of an accessory that includes sound and flash suppression features, according to one embodiment. 
         FIG. 2  is an exploded assembly view of the embodiment of  FIG. 1 . 
         FIG. 3  is a perspective side view of the embodiment of  FIG. 1 , with a portion of the housing removed to show internal features. 
         FIG. 4  is a perspective view of a core structure of the embodiment of  FIG. 1 . 
         FIG. 5  is a close up view showing flash suppression features of the core structure of the embodiment shown in  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION 
     Disclosed herein are example embodiments of a muzzle end accessory for a firearm that includes features to both suppress sounds and flashes associated with firing of the firearm. The features that provide sound and flash suppression may be formed, at least partially, in a core structure that is interior to the accessory and thus protected from damage by contact with external elements. The core structure may be of a unitary structure, promoting structural integrity and ease of manufacturing. The baffles and/or end cap of the sound suppressor may directly support the flash suppressor. 
     Turn now to the figures and initially  FIGS. 1 and 2  that show a perspective view of an assembled muzzle end accessory and an exploded assembly view of the accessory, respectively. The accessory  10  includes a housing having a housing base  21  and a housing body  22  and that supports a core structure  30  that includes portions of the sound suppressing features and flash suppressing features. The housing base  21  includes a mount  23  that secures the accessory  10  to the muzzle end of a firearm (not shown) such that a firing axis (i.e., central axis along which the firearm discharges a bullet, when fired) is aligned with a firing axis  11  of the accessory. A housing body  22  assembles to the housing base  21  in a manner that secures and aligns the core structure  30  within the accessory  10 . 
     The core structure includes features that define at least portions of sound suppression chambers that suppress the report associated with firing of a firearm. As may be seen in  FIGS. 2-4 , the core structure includes a series of baffles  34 ,  35 ,  36 ,  37 ,  37 ,  38  that at least partially define sound suppression chambers. A first sounds suppression chamber  39  is formed between the housing base  21  and a proximal most baffle  34  of the core structure  30 . A bullet, when fired from the firearm, enters the first sound suppression chamber  39  through of the accessory immediately after exiting the muzzle of the firearm. Propellant gases follow the bullet into the accessory and are initially allowed to expand within the volume of the first sound suppression chamber  39 . The volume of the first sounds suppression chamber  39  lies within the interior of the housing base  21  and the first baffle  34 , with the accessory in an assembled state. The first sound suppression chamber may additionally include volumes  40  that lie between the housing body  22  and lateral portions of the core structure  41 , with fluid communication provided to between these volumes via the core structure openings  42  shown in  FIGS. 2-4 . 
     Apertures between sound suppression chambers may include features to accomplish various desirable effects. By way of example,  FIG. 4  shows an aperture  44  formed in a “V” shaped structure of the first baffle  34  that may promote vortex shedding as a bullet passes through the aperture  44 . The “V” shaped baffle may additionally direct propellant gases and airflow through the openings  42  and into the volumes  40  of the first suppression chamber that lies between the housing body and lateral portions  41  of the core structure. 
     A second suppression chamber is defined, in the illustrated example embodiment, between first  34  and second  35  baffles of the core structure  30  in cooperation with portions of the housing body  22 . The second chamber  45  extends from opposed, internal curved walls of the housing body along a generally rectangular cross section defined by the core structure  30  between the first  34  and second  35  baffle, with the second baffle  35  having a convex shape facing into the second suppression chamber  45 . The convex shape may promote some degree of vortex shedding, similar to the “V” shaped first baffle. The internal volume of the second suppression chamber  45  is less than the overall internal volume of the first suppression chamber  39 , although other arrangements are possible and are contemplated. The apertures  44 ,  50  in each of the first and second baffles are centered about the firing axis  11  and are shaped to generally conform to the size and shape of a bullet with which the accessory is designed to be used. 
     The subsequent third, fourth, fifth, and sixth suppression chambers  46 ,  47 ,  48 , and  49  lie downstream of the second suppression chamber  45 , along the firing axis  11 . Each of the subsequent suppression chambers has a progressively smaller volume, although other arrangements are possible and contemplated. The subsequent chambers extend between opposite, internal curved walls of the housing body and are further defined by third, fourth, fifth, and sixth baffles  36 ,  37 ,  38 , and  43  of the core structure  30 , among other features. Although the illustrated embodiment includes a series of six suppression chambers of decreasing volume along the firing axis, it is to be appreciated that other embodiments may have any number of suppression chambers, formed with volumes that are similar to one another or that may even increase along the firing axis. 
     Baffles may define different types of apertures between suppression chambers, according to various embodiments. By way of example, each of the third, fourth, and fifth baffles  36 ,  37 , and  38  of the core structure  30  define apertures  51  between suppression chambers that have portions  53 ,  55  spaced from one another along the firing axis  11 . That is, different parts of a baffle that are separated from one another along the firing axis, and that each define a portion of a circle or other arcuate shape by which a bullet will pass when moving through the accessory. Apertures constructed in this manner may prevent the passage of propellant gases, when the bullet is present in the aperture, while promoting a greater rate of passage and pressure decay once the bullet has passed the aperture. 
     The core structure may define at least portions of a structure that suppress a muzzle flash. As may be seen in  FIGS. 3 and 5 , a conical structure  56  extends from an aperture in the sixth baffle  38  and towards the distal face  58  of the core structure. In this respect, the muzzle flash suppressor is formed of and/or supported by the structure of the flash suppressor. The conical structure is centered along the firing axis and provides an expanding volume at points further from the firearm. The expanding volume of the flash suppressor promotes dispersion of propellant gases and reduction of any muzzle flash, so as to prevent the vision of an operator of the firearm from being impacted. Although the conical structure  56  is illustrated as a truncated cone having a continuous, solid surface, it is to be appreciated that other constructions are also contemplated, including structures having oblong cross sections and/or apertures that provide fluid communication through portions of the flash suppressor structure. 
     The core structure may support the structure of the flash suppressor. By way of example, the distal face  58  of the core structure  30  defines a distal most end and opening  59  of the flash suppressor and a baffle  38  provides the opening through which a bullet enters the flash suppressor. In this respect, each end of the flash suppressor structure is supported by another portion of the core structure that is located further away from the firing axis, in a radial direction. This may help minimize or eliminate cantilevering of the flash suppressor structure itself and, in turn, better support the flash suppressor structure. In the illustrated example embodiment, a single baffle  38  and distal face  58  support the structure of the flash suppressor. It is to be appreciated, however, that additional or alternate arrangements are also contemplated, including an embodiment with additional ribs and/or baffles that support the flash suppressor. 
     The housing, in the illustrated example embodiment, includes a housing base  21  and housing body  22  that may be assembled to enclose the core structure therein. The core structure  30  may be positioned and/or aligned with respect to the housing base  21  by various features.  FIG. 2  shows a shoulder  61  in the base that mates with a corresponding feature  62  on the core structure to align each of the core structure  30  and housing base  21  with one another and the firing axis  11  of the accessory. The housing body  22  may include a slight taper, corresponding to a taper formed into the outermost surfaces of the core structure. Such a taper may serve to promote alignment of the core structure with respect to the housing base and housing body when the housing body is secured to the base. The distal most end of the housing body includes a lip  64 , as shown, that interacts with a corresponding feature of the core structure to prevent the core structure from moving forward within the housing. The lip is constructed to leave at least a portion of the distal face  58  of the core structure exposed to the external environment, although other constructions are also possible. 
     Components of the accessory may be constructed according to different approaches. The core structure, according to some example embodiments, may be formed as a unitary structure. The term “unitary”, as used herein, refers to the structure being manufactured from a single, continuous piece of material. One example of a unitary core structure includes a core structure that is formed by molding or casting, with material removed therefrom after the molding or casting, such as through a machining process. The core structure may be made of different types of materials and is generally constructed of heat resistant materials, including but not limited to steel, aluminum, thermoset plastics, and other types of plastics. 
     It is to be appreciated that a firearm may be operated with or without a first and/or a second accessory assembled to the firearm by an assembly mount. By way of example, according to some approaches, an operator may fire a firearm with a compensator assembled to the first connector of an assembly mount and without any accessories assembled to a second mount. Alternately an operator may operate a firearm with an accessory, such as a silencer, assembled to the firearm via the second connector of an accessory mount. The operator may, additionally or alternately, use the firearm without accessories mounted at either of the first or second connectors of the accessory mount. 
     While several embodiments have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and/or structures for performing the functions and/or obtaining the results and/or one or more of the advantages described herein, and each of such variations and/or modifications is deemed to be within the scope of this disclosure. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the teachings of this disclosure is/are used. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments described herein. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, along with other embodiments that may not be specifically described and claimed. 
     All definitions, as defined herein either explicitly or implicitly through use should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and/or ordinary meanings of the defined terms. 
     The indefinite articles “a” and “an,” as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean “at least one.” 
     The phrase “and/or,” as used herein in the specification and in the claims, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Other elements may optionally be present other than the elements specifically identified by the “and/or” clause, whether related or unrelated to those elements specifically identified, unless clearly indicated to the contrary.