Multi-flow path firearm noise suppressor

Abstract

Disclosed herein is a suppressor for a firearm having separate flow paths for receiving and directing exhaust gas resulting from discharge of the firearm. In embodiments, the suppressor may have a baffle system that defines two or more separate flow paths for receiving and directing the exhaust gas. The baffle system may have inner baffles that define a primary flow path and outer baffles that define a secondary flow path. The primary flow path and secondary flow paths may each define a tortuous flow path to increase the distance exhaust gas flows as compared to a linear path.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of and priority to U.S. Provisional Ser. No. 63 / 746,426 filed Jan. 17, 2025, the disclosure of which is hereby incorporated by reference in its entirety.TECHNICAL FIELD

[0002] This invention relates to a firearm noise suppressor, colloquially referred to as a silencer.BACKGROUND

[0003] Firearm noise suppressors reduce the actual volume and perceived sound of a firearm's report in several ways. Some of these ways operate to remove energy from the high pressure, high velocity gas flow that propels the projectile and creates a loud report as it escapes form the muzzle of the barrel. One of the ways a suppressor reduces the energy of the muzzle blast is by removing and dissipating heat from the gas flow. Typically, a suppressor will absorb heat into the material of the suppressor body, reducing the temperature of the gas, and then radiate that heat to the atmosphere. This radiation of heat can cause a mirage effect above the suppressor, which is typically directly in the shooter's line of sight. Also, the material of the suppressor body can become heat-saturated, unable to radiate heat faster than it absorbs heat, and no longer effectively remove heat from the propellant gas flow.

[0004] The total interior volume of a suppressor is a significant factor of performance. In designs made by traditional subtractive manufacturing methods where the suppressor body is symmetrical around the bore axis (i.e., round in cross-section), enlarging the volume often is achieved by enlarging the diameter of the body. This can be detrimental when the height above the bore axis increases enough to interfere with the sighting line above the barrel. Other asymmetrical designs have increased volume only by increasing the area below the bore axis, generally shifting the geometric longitudinal axis below the bore axis. Accordingly a need exists for a larger internal volume suppressor with improved energy reduction capabilities.SUMMARY OF THE INVENTION

[0005] The present invention provides a firearm noise suppressor system (or suppressor) for a firearm with multiple gas flow paths and that can be axially asymmetric (non-round).

[0006] According to some embodiments, the suppressor includes a tubular body extending along an axis between a forward end and a rear end, the tubular body having a forward wall at the forward end and defining an interior volume; and a baffle system arranged in the interior volume, wherein the baffle system comprises: an interior sidewall extending rearward from the forward wall of the body; a plurality of inner baffles disposed within the interior sidewall, the plurality having inner baffles defining a projectile passageway for receiving a projectile fired from the firearm and a primary flow path for directing a portion of exhaust gas resulting from discharge of the firearm; and a plurality of outer baffles extending between the interior sidewall and body, wherein the plurality of outer baffles define a secondary flow path for directing any remaining exhaust gas resulting from discharge of the firearm.

[0007] In some embodiments, the interior volume includes an initial blast chamber, and the baffle system is positioned forward of the initial blast chamber.

[0008] In some embodiments, the primary flow path and the secondary flow path are each configured such that exhaust gas flowing through the primary flow path is unable to mix with exhaust gas flowing through the secondary flow path.

[0009] In some embodiments, the forward wall comprises a primary outlet in communication with the primary flow path and a plurality of secondary outlets in communication with the secondary flow path.

[0010] In some embodiments, each of the plurality of inner baffles includes a port. In some of these embodiments, the plurality of inner baffles includes a first interior baffle and a second interior baffle positioned next to the first interior baffle, wherein the port of the first interior baffle is an upper port positioned above the projectile passageway, and wherein the port of the second interior baffle is a lower port positioned below the projectile passageway. In some of these embodiments, the port on one of the inner baffles is not in axial alignment with the port on another one of the inner baffles.

[0011] In some embodiments, each of the plurality of outer baffles includes a series of discrete ports. In some of these embodiments, the plurality of outer baffles includes a first outer baffle and a second outer baffle positioned next to the first outer baffle, wherein the series of discrete ports of the first outer baffle are positioned circumferentially around the first outer baffle and the series of discrete ports of the second outer baffle are positioned circumferentially around the second outer baffle. In some of these embodiments, the series of discrete ports of the first outer baffle are positioned at a first radial distance from the axis and the series of discrete ports of the second outer baffle are positioned at a second radial distance from the axis that is larger than the first radial distance. In some embodiments, the series of discrete ports on one of the outer baffles are not in alignment with the series of discrete ports on another one of the outer baffles. In some embodiments, the discrete ports on the outer baffles border or touch an inner surface of the body.

[0012] In some embodiments, each of the inner baffles includes a projectile aperture, wherein the projectiles apertures are aligned with each other and together define the projectile passageway. In some of these embodiments, each of the projectile apertures includes a central portion and a radial notch extending radial outward from the central portion, wherein the central portion is aligned with the central portion of other projectile apertures.

[0013] In some embodiments, the forward wall comprises a primary outlet in communication with the primary flow path and a plurality of secondary outlets in communication with the secondary flow path. In some of these embodiments, a plurality of vanes arranged on an exterior of the forward wall and surrounding the primary outlet.

[0014] In some embodiments, the suppressor further includes a tertiary flow path positioned radially outward from the secondary flow path. In embodiments, the tertiary flow path receives and directs at least some of the exhaust gas, and the tertiary flow path also receives ambient air, wherein the tertiary flow path is configured such that the exhaust gas flowing therethrough flows in a turbulent manner that creates a vacuum effect that pulls ambient air into the tertiary flow path to help cool the suppressor.

[0015] Other aspects, features, benefits, and advantages of the present invention will become apparent to a person of skill in the art from the detailed description of various embodiments with reference to the accompanying drawing figures, all of which comprise part of the disclosure.BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Like reference numerals are used to indicate like parts throughout the various drawing figures, wherein:

[0017] FIG. 1 is a first isometric view of a firearm sound suppressor, according to one embodiment of the present invention;

[0018] FIG. 2 is a second isometric view thereof;

[0019] FIG. 3 is an isometric longitudinal sectional view taken substantially along line 3-3 of FIG. 2;

[0020] FIG. 4 is another isometric longitudinal sectional view taken substantially along line 4-4 of FIG. 9;

[0021] FIG. 5 is a side sectional view also taken substantially along line 3-3 of FIG. 2;

[0022] FIG. 6 is a rear end view thereof;

[0023] FIG. 7 front end view thereof;

[0024] FIG. 8 is a cross-sectional view taken substantially along line 8-8 of FIG. 1;

[0025] FIG. 9 is a cross-sectional view taken substantially along line 9-9 of FIG. 5;

[0026] FIG. 10 is an isometric view of a firearm sound suppressor, according to one or more alternate embodiments of the present invention;

[0027] FIG. 11 is a side sectional view taken along line 11-11 of FIG. 10;

[0028] FIG. 12A is a perspective of the suppressor of FIG. 10;

[0029] FIG. 12B is a front perspective sectional view of the suppressor along section line 12-12 in FIG. 12A;

[0030] FIG. 12C is a rear perspective sectional view of the suppressor along section line 12-12 in FIG. 12A;

[0031] FIG. 13 is another side cross-sectional view of the suppressor taken along line 11-11 of FIG. 10 depicting the primary flow path and secondary flow path, according to one or more embodiments; and

[0032] FIG. 14 an isometric view of a firearm sound suppressor, according to one or more other alternate embodiments of the present invention; and

[0033] FIG. 15 sectional view of the suppressor along section line 15-15 in FIG. 14.DETAILED DESCRIPTION

[0034] With reference to the drawing figures, this section describes particular embodiments and their detailed construction and operation. Throughout the specification, reference to “one embodiment,”“an embodiment,” or “some embodiments” means that a particular described feature, structure, or characteristic may be included in at least one embodiment. Thus, appearances of the phrases “in one embodiment,”“in an embodiment,” or “in some embodiments” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the described features, structures, and characteristics may be combined in any suitable manner in one or more embodiments. In view of the disclosure herein, those skilled in the art will recognize that the various embodiments can be practiced without one or more of the specific details or with other methods, components, materials, or the like. In some instances, well-known structures, materials, or operations are not shown or not described in detail to avoid obscuring aspects of the embodiments. “Forward” will indicate the direction of the muzzle and the direction in which projectiles are fired, while “rearward” will indicate the opposite direction. “Lateral” or “transverse” indicates a side-to-side direction generally perpendicular to the axis of the barrel. Although firearms may be used in any orientation, “left” and “right” will generally indicate the sides according to the user's orientation, “top” or “up” will be the upward direction when the firearm is gripped in the ordinary manner.

[0035] FIGS. 1 and 2 depict a firearm sound suppressor 1, according to one or more embodiments. The firearm sound suppressor 1 includes a tubular body 10 that extends along an axis A and includes a front end 11 and a rear end 13. The body 10 includes a forward end wall 12 at the front end 11, wherein a primary opening 14 is defined in the forward end wall 12. Stated differently, the forward end wall 12 includes the primary opening 14. As shown, the primary opening 14 is in alignment with the axis A, and, as will be appreciated, the axis A is in alignment with a firearm barrel (not shown) to which the suppressor body 10 may be attached and through which a fired projectile passes to exit the suppressor body 10.

[0036] Also shown in FIG. 2, the forward end wall 12 includes secondary gas outlets 16 and tertiary gas outlets 16, 18. The secondary gas outlets 16 are a series of outlets that are arranged around the axis A and are spaced radially outward from the axis A by a first distance. The tertiary gas outlets 18 are a series of outlets that are arranged around the axis A and are spaced radially outward from the axis A by a second distance that is greater than the first distance, such that the tertiary gas outlets 18 are spaced radially outward from the secondary gas outlets 16 and such that the tertiary gas outlets 18 surround the secondary gas outlets 16. n

[0037] As shown in FIG. 1, the rear end wall 20 includes a series of atmospheric gas inlet ports 22. The atmospheric gas inlet ports 22 are a series of inlet ports that are arranged around the axis A and are spaced radially outward from the axis A. As further described herein, the atmospheric gas inlet ports 22 are in communication with the tertiary gas outlets 18 such that ambient air entering the atmospheric gas inlet ports 22 may eventually exit the body 10 via tertiary gas outlets 18.

[0038] A means for mounting the suppressor body 10 to the barrel of a firearm may be arranged at the rear end 13 of the body 10. While the illustrated embodiment does not show such means for mounting the suppressor body 10 to the muzzle of a firearm barrel, such mounting means or mechanism can be any traditional or novel mounting device or mechanism utilizable to attach the suppressor body 10 to the barrel. Such mounting means or mechanism may be integral to the suppressor body 10 or separable from the suppressor body 10.

[0039] In the illustrated embodiment, the suppressor body 10 has an asymmetric cross-sectional shape that increases the cross-sectional area (and, thereby, the internal volume) without increasing the height of the device relative to the bore axis, which could interfere with the shooter's line of sight. Rather than just lowering the geometric center, the profile can be widened laterally at a top side 15 of the body 10 relative to a bottom side 17 of the body 10. In the illustrated embodiment, the body 10 includes a generally triangular shape when viewed in cross-section, such that a pair of vertices 19a, 19b are provided at the top side 15 of the body 10 and a single vertice 19c is provided at the bottom side 17 of the body 10. With this arrangement, the upper side 15 of the body 10 is a sidewall extending between the vertices 19a and 19b, a left side wall extends between vertices 19b and 19c, and a right sidewall extends between the vertice 19a and 19c, with the left and right sidewalls meeting each other at the lower vertice 19c. In the illustrated embodiment, each of the vertices 19a, 19b, and 19c are rounded such the body 10 has a generally smooth outer surface without sharp or pointed edges on its sides. Stated differently, the vertices 19a, 19b, 19c define smooth transitions between the upper sidewall, the left sidewall, and the right sidewall.

[0040] In the illustrated embodiment, the suppressor 1 has multiple flow paths for gas flow resulting from firing of the firearm. In the embodiment depicted in FIGS. 1-9, the suppressor 1 has three flow paths: a primary flow path 24, a secondary flow path 26, and a tertiary flow path 28. These three flow paths are best shown in at least FIGS. 3-5. As shown in the cross-sectional views, a initial blast chamber 30 is defined inside the tubular body 10 proximate the rear end 13, and the suppressor 1 includes a baffle system 31 forward of the initial blast chamber 30 that extends between the initial blast chamber 30 and the front end 11.

[0041] The baffle system 31 includes a series of asymmetrical inner conical baffles 32 joined together via an inner sidewall 35. Baffle chambers 34 are defined between neighboring baffles 32 and the inner surface of the inner sidewall 35. Each of the asymmetrical conical baffles 32 includes a projectile aperture through which the projectile may pass, and the apertures 36 of the asymmetrical conical baffles 32 are aligned with each other and together define projectile passageway 36′ that extends through the baffle system 31 and through the body 10 along the axis A. More specifically, the apertures 36 include an aligned central portion that together define the projectile passageway 36′. In the illustrated embodiment, the apertures 36 each include a radial notch 38 that extend radially outward from the central portion, such that the apertures 36 may be considered asymmetric due to the presence of the radial notches 38.

[0042] Further, the baffles 32 may each include one or more by-pass ports 40 that is / are not in full alignment with the by-pass port(s) 40 of neighboring baffles 32. Stated differently, the by-pass ports 40 are not fully aligned with each other, but are instead at least partially misaligned with each other. In the illustrated embodiment, the by-pass ports 40 are located and positioned in an alternating arrangement, for example, wherein the by-pass port 40 formed in one of the baffles 32 is misaligned (or not in alignment with) the by-pass ports 40 of the immediately adjacent / neighboring baffle(s) 32. More specifically, in the illustrated embodiment, the asymmetrical inner conical baffles 32 includes baffles 33a-33e, and the by-pass port 40 of the rear-most (or first) baffle 33a is formed in an upper portion of the baffle 33a above the aperture 36, the by-pass port 40 of the second rear-most (or second) baffle 33b is formed in a lower portion of the baffle 33b below the aperture 36 such that it is not in alignment with the by-pass port 40 of the first baffle 33a, the by-pass port 40 of the third rear-most (or third) baffle 33c is formed in an upper portion of the baffle 33c above the aperture 36 such that it is not in alignment with the by-pass port 40 of the second baffle 33b (but is in alignment with the by-pass port 40 of the first baffle 33a), the by-pass port 40 of the fourth rear-most (or fourth) baffle 33d is formed in a lower portion of the baffle 33d below the aperture 36 such that it is not in alignment with the by-pass ports 40 of the third baffle 33c and the first baffle 33a (but is in alignment with the by-pass port 40 of the second baffle 33b), and the by-pass port 40 of the fifth rear-most (or fifth) baffle 33e is formed in an upper portion of the baffle 33e above the aperture 36 such that it is not in alignment with the by-pass ports 40 of the second baffle 33b and fourth baffle 33d (but is in alignment with the by-pass ports 40 of the first baffle 33a and the third baffle 33c). Thus, in the illustrated embodiment, the by-pass ports 40 have an alternating aligned arrangement, wherein the by-pass ports 40 alternate between positions above and below the central aperture 36. Furthermore, the baffles 33a-33e may have textures on surfaces thereof which can increase flow turbulence and internal surface area that comes into contact with gas flow to help decrease temperature.

[0043] The suppressor 1 may include a funnel-shaped wall 42 that extends into a least a rear portion of the initial blast chamber 30 to converge high pressure / velocity propellant gas toward the first or rear most baffle 33a of the conical baffles 32. In the illustrated embodiment, the funnel-shaped wall 42 is connected to the baffle system 31 and extends rearward from the rear most baffle 33a into the initial blast chamber. The funnel-shaped wall 42 includes a rear end 43 that is spaced away from an inner surface 45 of the initial blast chamber 30, such that a gap is defined between the rear end 43 and the inner surface 45. In the illustrated embodiment, an annular shaped gap 44 is defined between the rear end 43 and the inner surface 45, and a receiving chamber 46 is defined between an outer surface 47 of the funnel wall42 and the inner surface 45. As described below, exhaust gas entering into the funnel shaped wall 42 is directed towards the primary flow path 24, while exhaust gas entering receiving chamber 46 through the annular shaped gap 44 is directed towards either the secondary flow path 26 and the tertiary flow path 28.

[0044] As will be appreciated, the baffle system 31 is operable for reducing the pressure, velocity, and temperature of propellant gas expelled from the muzzle of the firearm barrel, and the baffle system 31 slows the release of propellant gas, allowing pressure to reduce before it is released to the atmosphere.

[0045] The primary flow path 24 is akin to a traditional suppressor flow path, and includes the projectile passageway 36′, but also includes the path defined by the aligned radial notches 38 as well as the tortuous path defined by the alternating aligned by-pass ports 40. In the illustrated embodiment, the primary flow path 24 begins inside the tubular body 10 at a rear end 43 of the funnel shaped wall 42 and ends at the primary opening 14. Thus, upon firing of the firearm, both the projectile and propellant gas enters the initial blast chamber 30 and then both enter the primary flow path 24, where they travel through a space defined within the funnel shaped wall 42 and through the baffle system 31, and then exit the suppressor at the primary opening 14, wherein the gas flows through the projectile passageway 36′, the radial notches 38, and the alternating aligned by-pass ports 40 as it travels through the primary flow path 24.

[0046] The secondary flow path 26 is generally annular in shape and situated radially outward of the primary flow path 24. As described herein, the secondary flow path 26 handles a portion of the high pressure gas separate from the primary flow path 24 to be exhausted through ports 16 in the forward end wall 12 of the suppressor body 10. For example, the secondary flow path 26 is configured such that at least some of the high pressure gas that enters the initial blast chamber 30 is able to flow into the receiving chamber 46 and then into the secondary flow path 26. The secondary path 26 includes inlets 48 arranged inside of the body 10 and, in the illustrated embodiment, the inlets 48 are arranged in the receiving chamber 46. Thus, to access the secondary flow path 26 in the illustrated embodiment, such high pressure exhaust gas will not enter the funnel shaped wall 42, but will instead pass through the annular shaped gap 44 and thereby enter the receiving chamber 46, where it can enter the secondary flow path 26 (or the tertiary flow path 28, detailed below) via the inlets 48. The exhausted through ports 16 are in communication with the secondary flow path 26 such gas entering and flowing through the secondary flow 26 will exit the suppressor 1 via the exhausted through ports 16.

[0047] The tertiary flow path 28 is also generally annular in shape and situated radially outward of the secondary flow path 26. The tertiary flow path 28 is in communication with both the initial blast chamber 30 and the ambient environment, and uses another portion of the high pressure / velocity gas flow to create a venturi effect to draw in outside (atmospheric) air to help cool the suppressor body 10, exhausting through separate ports 18 in the forward wall 12 without contaminating either the primary or secondary flow paths 24, 26 with oxygen rich fresh air. To access the tertiary flow path 28 in the illustrated embodiment, such high pressure exhaust gas will not enter the funnel shaped wall 42, but will instead enter the receiving chamber 46 through the annular shaped gap 44 and, once in the receiving chamber 46, the exhaust gases can enter the tertiary flow path 28. In the illustrated embodiment, the tertiary flow path 28 is in communication with the atmospheric gas inlet ports 22 in the rear end wall 20 and the tertiary gas outlets 18 in the forward wall 12. The outside (atmospheric) air is drawn into the suppressor 1 via the atmospheric gas inlet ports 22 and discharged out of the suppressor 1, together with some high pressure / velocity firearm exhaust gas, via the tertiary gas outlets 18. As further described below, the tertiary flow path 28 also includes tertiary inlets 56 arranged inside the body 10, and at least some of the high pressure / velocity gas entering the initial blast chamber 30 and the receiving chamber 46 may enter pass through the tertiary inlets 56 to enter the tertiary flow path 28, where such high pressure / velocity gas may mix with cooler ambident air pulled into the tertiary flow path 28 via the atmospheric gas inlet ports 22, and then such combined gas may exit the tertiary flow path 28 via the tertiary gas outlets 18 in the forward wall 12. Thus, the tertiary flow path 28 includes a pair of different sets of inlets (i.e., atmospheric gas inlet ports 22 and the tertiary inlets 56) and single set of outlets (i.e., tertiary gas outlets 18).

[0048] The structure of this suppressor design is particularly suited for construction by additive manufacturing methods (e.g., 3-D printing). Inconel® alloy 718, a superalloy made by Huntington Alloys Corporation of Huntington, West Virginia, renowned for its heat resistance, durability, corrosion resistance, and fatigue resistance, is one material ideal for such structure. It has excellent weight-to-strength ratio, which allows for thin-walled construction without compromising performance.

[0049] In the illustrated embodiment, the baffle system 31 is positioned forward of the initial blast chamber 30, such that the initial blast chamber 30 defines a substantially empty chamber, except for the funnel shaped wall 42 extending rearward into initial blast chamber 30. However, as mentioned above, the funnel shaped wall 42 defines a large interior space within which a portion of the firearm may extend without contacting the suppressor 1. In this manner, the initial blast chamber 30 and / or the interior space of the funnel shaped wall 42 may receive a feature of a muzzle mount device (not shown), such as a flash hider or brake, without interference between such muzzle mount device and an internal structure of the suppressor 1.

[0050] Thus, the funnel 42 is configured to separate or bifurcate the high pressure exhaust gas received by the suppressor 1 into a first stream, that can flow through the primary path 24, and a second stream that can flow through the secondary or tertiary flow paths 26, 28, wherein the receiving chamber 46 directs a portion of the exhaust gas flow into inlet openings 48 of the secondary flow path 26 and another portion of the exhaust gas into the inlets 56 of the tertiary flow path 28.

[0051] The baffle system 31 also includes an outward inner sidewall 37 that is positioned radially outward from and surrounds the inner sidewall 35, such that an annular space is defined between the inner sidewalls 35 and 37, and such that the inner sidewall 35 may be referred to as the inward inner sidewall 35. As shown, both the inner sidewalls 35 and 37 are connected to the front wall 12 and extend rearward therefrom toward the rear end 13. In addition, the baffle system 31 includes secondary baffles 52 that extend radially outward from the inward inner sidewall 35 towards and into the outward inner sidewall 37, such that the secondary baffles 52 extend between the inner sidewalls 35 and 37. The secondary baffles 52 divide the annular space defined between the inner sidewalls 35 and 37 into a series of chambers 50, and one or more ports 54 are formed in each of the secondary baffles 52 such that the chambers 50 are interconnected and in communication with each other via the ports 54. Also in the illustrated embodiment, the secondary inlets 48 of the secondary flow path 26 are the ports 54 formed in a proximal most (or first) secondary baffle 53a of the secondary baffles 52. Thus, in the illustrated embodiment, the secondary flow path 26 includes the series of chambers 50, such that when the high pressure / velocity exhaust gas enters the secondary flow path 26 via the ports 54 in the proximal most secondary baffle 53a (i.e., the secondary inlet 48), the high pressure / velocity exhaust gas enters a distal most chamber 50a (of the chambers 50) via the ports 54 in the proximal most secondary baffle 53a. Thereafter, the high pressure / velocity exhaust gas passes through the ports 54 in a next, neighboring secondary baffle 53b (that is distal of the first secondary baffle 53a) of the secondary baffles 52 and into the next chamber 50b, and then the high pressure / velocity exhaust gas passes through the ports 54 in a next neighboring secondary baffle 53c (that is distal of the second secondary baffle 53b) of the secondary baffles 52 and into the next chamber 50c, and so on, until such exhaust gas enters a proximal-most chamber 50g of the chambers 50, where such exhaust gas may exit the secondary path 26 (and the suppressor) via the secondary outlet ports 16 in the forward wall 12. The chambers 50 of the secondary flow path 26 can include irregular internal surfaces that increase surface area (for heat transfer) and generate turbulence in the secondary flow of gas as it passes through the secondary flow path 26. Also, the ports 54 in one of the secondary baffles 52 may be mis-aligned with the ports 54 in a neighboring one of the secondary baffles 52. Here, for example, the ports 54 in the second secondary baffle 53b are not in alignment with the ports 54 in the proximal most secondary baffle 53a and the ports 54 in the third secondary baffle 53c; however, the ports 54 of the first secondary baffle 53a and the ports 54 of the third secondary baffle 53c may be in alignment with each other. In this manner, the secondary path 26 includes a tortuous flow path, which is defined by the series of chambers 50 and the interconnecting ports 50.

[0052] The tertiary inlets 56 are positioned within the annular receiving chamber 46 at locations outwardly adjacent to the secondary inlets 48. As mentioned, the high pressure, high velocity propellant gas stream entering the receiving chamber 46 flows into either the secondary flow path 26 or the tertiary flow path 28. Thus, a first portion of the high pressure, high velocity propellant gas stream enters the secondary flow path 26 via the secondary inlets 48 (i.e., the ports 54 in the proximal most secondary baffle 53a) while the tertiary inlets 56 receive another portion of the high pressure, high velocity propellant gas stream.

[0053] As mentioned, the tertiary flow path 28 includes the fresh air inlets 22 and the high velocity gas flow that enters the tertiary flow path 28 via the tertiary inlets 56 creates a venturi effect within the tertiary flow path 28, which in turn causes fresh or ambient air to be drawn or sucked into the tertiary flow path 28 from outside the body 10 via the ambient air inlets 22 located adjacent the rear end 20. The cooler outside air entering the tertiary flow path 28 via the ambient air inlets 22 will absorb heat from the suppressor body 10 and the ambient air, together with the exhaust gas flow entering the tertiary flow path 28 via the tertiary inlets 56 will be exhausted out of the body 10 through outlet ports 18 in the forward wall 12.

[0054] As shown in FIG. 3 and FIG. 5, the body 10 defines an outer sidewall 39, and an annular space 55 is defined between the inner sidewall 37 and the outer sidewall 39, and this annular space 55 defines at least a portion of the tertiary flow path 28. As best shown in FIG. 5, the tertiary inlets 56 lead direction into the annular space 55 such that pressured exhaust gas flowing through the tertiary inlets 56 is directly enters the annular space 55. Also in the illustrated embodiment, one or more channels 57 are formed in the body 10 proximate the rear end 13 and in communication with the fresh air inlets 22, wherein the channel 57 extends forward from the fresh air inlets 22 into the annular space 55, such that the annular space 55 is in communication with the ambient environment via the channel 57 and the fresh air inlets 22. In this manner, ambient air may enter the suppressor via the fresh air inlets 22, travel through the channel 57 and into the annular space 55, where it is comingled with exhaust gas, before exiting the suppressor 1 via the outlet ports 18 in the forward wall 12. Thus, the tertiary flow path 28 also includes the fresh air inlets 22 and the channel 57. In the illustrated embodiment, the channel 57 is an annular shaped channel that extends substantially continuously around the body 10; however, in other embodiments, the channel 57 comprises a plurality of discrete channel pathways extending between the inlets 22 and the annular space 55.

[0055] The tertiary flow path 28 can include nonlinear longitudinal separation partitions 58. In the illustrated embodiment, the separation partitions 58 are arranged in the annular space 55; however, in other embodiments, the separation partitions are also arranged in the channel 57, for example, when the channel 57 is an annular shaped space as shown in the illustrated embodiment. In the illustrated embodiment, these partitions 58 have a zig-zag configuration to disrupt flow, create turbulence, and increase surface area for heat transfer. Alternatively, the tertiary flow path 28 could include helical vanes (not shown) to swirl the air flow around the annular space 55 so that such air contacts the outer inner side wall 37 that separates the tertiary flow path 28 from the secondary flow path 26, and thus borders the secondary flow path 26, to provide additional heat transferring surface area. The partitions 58 extend between the inner sidewall 37 and the outer sidewall 39 defined by the body 10, wherein a portion of the outer sidewall 39 has been removed in FIG. 4 to depict the partitions 58.

[0056] The tertiary flow path 28 allows the suppressor body 10 to absorb and dissipate more heat energy from the propellant gases and reduces the heat signature (and mirage effect) of the suppressor 10. The tertiary flow path 28 is designed not to “contaminate” the primary flow path 24 or secondary flow path 26 with oxygen-rich fresh outside air. Oxygen in the primary flow path 24 contributes to “first round pop,” a phenomenon in which the first round fired through a suppressor is louder than subsequent rounds fired in close succession thereafter because the amount of oxygen-rich fresh air inside the device has been displaced by residual, oxygen-poor propellant gases.

[0057] As shown in FIG. 2 and FIG. 7, one or more exterior vanes 62 may be arranged on the forward wall 12. The exterior vanes 62 may help dilute gases exiting the outlets 14, 16, 18, which in turn will help to reduce flash signature.

[0058] The suppressor 1 of FIGS. 1-9 has three separate flow paths (i.e., flow paths 24, 26, and 28) and may thus be referred to as a three-layer design, wherein an outer layer includes the tertiary flow path 28 defined between the body 10 and the outer inner sidewalls 37, a middle layer includes the secondary flow path 26 defined between the inward inner sidewalls 35 and the outer inner sidewalls 37, and an inner-most layer includes the primary flow path 24 defined inside the inward inner sidewalls 35. As mentioned above, the tertiary flow path 128 is configured to pull ambient air into the suppressor 1 to facilitate cooling of the suppressor 1 during use.

[0059] FIGS. 10-13 depict a suppressor 100 according to one or more alternate embodiments. As further discussed below, the suppressor 100 differs from the suppressor 1 as the suppressor 100 is a two-layer design that incorporates two layer (i.e., two flow paths: a primary flow path and a secondary flow path) without utilizing an outer layer configured to pull ambient air into the suppressor body.

[0060] The suppressor 100 includes a body 102 having a front end 104 and a rear end 106 opposite the front end 104. The body 102 is tubular and extends along an axis A′. As with the suppressor 1 detailed above, the body 102 of the suppressor 100 is not perfectly round, but is instead triangular in shape with rounded vertices. In the illustrated embodiment, the suppressor body 100 has an asymmetric cross-sectional shape (i.e., non-round) that increases the cross-sectional area (and, thereby, the internal volume) without increasing the height of the device relative to the bore axis, which could interfere with the shooter's line of sight.

[0061] The front end 104 of the body 102 includes a forward wall 110. In the illustrated embodiment, the forward wall 110 includes a recessed wall portion 112 surrounded by a peripheral wall portion 114. A primary outlet or aperture 116 (hereinafter, the primary outlet 116) is formed in the recessed wall portion 112 and a plurality of secondary outlets or apertures 118 (hereinafter, the secondary outlets 118) are formed in the peripheral wall portion 114.

[0062] In the illustrated embodiment, the recessed wall portion 112 is a sloped surface that is sloped inward into the body 102, away from the front end 104 and toward the rear end 106. In the illustrated embodiment, the front end 104 of the body 102 also includes a plurality of vanes 120 arranged on the forward wall 110 and, in particular, on an exterior surface of the forward wall 110 of the body. Here, the vanes 120 surround the primary opening 116, are arranged on the recessed wall portion 112 and extend forward therefrom, toward the front end 104, such that a front surface of the vanes 120 is substantially continuous with a front surface 122 of the peripheral portion 110 that surrounds the vanes 120 and the recessed wall portion 112.

[0063] During use, a projectile fired by the firearm to which the suppressor 100 is attached will exit the suppressor 100 via the primary outlet 116 thereof. Thus, the primary outlet 116 is at least partially aligned with the axis A′ or arranged over. Stated differently, the axis A′ extends through the primary outlet 116. Discharging the firearm will also produce high pressure and high velocity exhaust gas that accompanies and propels the projectile, and, as further detailed below, at least some of this exhaust gas exits the suppressor 100 via the primary outlet 116 and the rest of this exhaust gas exits the suppressor 100 via the secondary outlets 118.

[0064] As will be appreciated, the rear end 106 is configured to be attached to the muzzle of a firearm barrel. In the illustrated embodiment, threads 108 are provided at the rear end 106, and the threads can be configured for receiving a nut 124. The nut 124 is operable to rotationally position (i.e., “clock”) the suppressor 100 to any type of muzzle mount / device such that the flat top side of the body 102 is positioned upward. The nut 124 provides an adjustable shoulder for the mount on the barrel's muzzle to be installed against in order to correctly orient the silencer 100 vertically.

[0065] The body 102 is hollow and includes an interior volume 126. FIG. 11 is a cross-sectional view of the suppressor 100 of FIG. 10 taken along section line 11-11, and depicts the interior volume 126 defined within the body 102, according to one or more embodiments. As shown, the interior volume 126 extends between the forward end 104 and the rear end 106 along the axis A′.

[0066] In the illustrated embodiment, the interior volume 126 includes an initial blast chamber portion or segment 128 and a baffle portion or segment 130 positioned forward of the initial blast chamber portion 128. As shown, the initial blast chamber 128 begins at the rear end 106 of the body 102 and extends forward therefrom, toward the front end 104 of the body 102, and terminates at (or transitions into) the baffle portion 130. The baffle system chamber 130 begins at the end of the initial blast chamber 128 and extends forward therefrom toward the front end 104 and terminates at the forward wall 110. Here, the initial blast chamber portion 128 defines a blast chamber 132 and a baffle system 134 is arranged within the baffle portion 130.

[0067] The baffle system 134 is operable for reducing the pressure, velocity, and temperature of propellant gas expelled from the muzzle of the firearm barrel, and the baffle system 134 slows the release of such exhaust gas, thereby allowing the pressure of the exhaust gas to reduce before the exhaust gas is released out of the suppressor 100 and into the ambient environment outside of the suppressor 100. During use, high pressure exhaust gas enters the initial blast chamber 128 upon discharge of the firearm, and such high pressure exhaust gas may then enter the baffle system 134 after passing through the initial blast chamber 128. As hereinafter described, the baffle system 134 is configured to separate (or bifurcate) the exhaust gas into separate gas flows or streams, which in turn will help reduce pressure, temperature, and velocity of the exhaust gas. The blast chamber 128 allows the exhaust gas to expand, reducing the pressure felt by the baffle system 130 and allowing the baffle system 130 to be more effective. However, with traditional suppressors, as the firearm moves through its firing cycle the blast chamber becomes a pressurized reservoir sending toxic gas and debris back through the barrel towards the action and shooter. With the presently disclosed suppressor 100, however, the volume of exhaust gas that can enter the action of the firearm is greatly reduced, all without increasing the dB of the shot, due to the presence of the primary and secondary flow paths (180, 182), which function to reduce the energy of the exhaust gas.

[0068] The baffle system 134 includes an interior sidewall 136, inner baffles 140, and outer baffles 142. In the illustrated embodiment, the interior sidewall 136 is a hollow tubular member that is disposed within (or nested inside of) the body 102 and extends rearward from the forward wall 110 of the body 102, such that an annular space is defined between an outer surface 144 of the interior sidewall 136 and an inner surface 146 of the body 102. Also, the interior sidewall 136 is substantially hollow and the inner baffles 140 are disposed or mounted within the interior sidewall 136 (i.e., the inner baffles 140 are arranged within an inner bore defined of the interior sidewall 136).

[0069] In the illustrated embodiment, the interior sidewall 136 is corrugated and thus includes alternate ridges and grooves. The outer baffles 142 extend in a generally radial direction (i.e., outward relative to the axis A), between an outer surface 144 of the interior sidewall 136 and an inner surface 146 of the body 102. The outer baffles 142 may thus substantially surround the interior sidewall 136. In the illustrated embodiment, the outer baffles 142 includes seven outer baffles 148a-148g; however, more or less may be utilized in other embodiments.

[0070] The inner baffles 140 are arranged inside of the interior sidewall 136. As shown, the inner baffles 140 extend radially inward from an inner surface 150 of the interior side wall 136. In the illustrated embodiment, the inner baffles 140 includes a series of five inner baffles 152a-152e; however, more or less may be utilized in other embodiments. Also, interior baffle chambers 154 are defined between each of the inner baffles 140, with a first interior baffle chamber 154 defined between the first inner baffle 152a and the second inner baffle 152b, a second interior baffle chamber 154 defined between the second inner baffle 152b and the third inner baffle 152c, a third interior baffle chamber 154 defined between the third inner baffle 152c and the fourth inner baffle 152d, and fourth interior baffle chamber 154 defined between the fourth inner baffle 152d and the fifth inner baffle 152e, and a fifth interior baffle chamber 154 defined between the fifth inner baffle 152e and the forward wall 110.

[0071] The inner baffles 140 may be similar to the baffles 32, detailed above. Thus, the inner baffles 140 are each an asymmetrical conical baffle structure / member. Also, each of the inner baffles 140 includes a projectile aperture 156 through which the projectile may pass, and the apertures 156 of the asymmetrical conical inner baffles 140 are aligned with each other and with the primary outlet 116, and the apertures 156 and the primary outlet 116 together define a projectile passageway or pathway 158 that extends through the baffle system 134 and through the body 102 along the axis A′.

[0072] The apertures 156 include an aligned central portion 160 that align with the primary outlet 116 along the axis A′ and all together define the projectile passageway or pathway 158. Stated differently, the apertures 156 (i.e., the central portions 160 thereof) and the primary outlet 116 together define the projectile passageway or pathway 158 through which the projectile / bullet will travel upon discharging the firearm. In the illustrated embodiment, the apertures 156 each include a radial notch 162 that extend radially outward from the central portion 160, such that the apertures 156 may be considered asymmetric due to the presence of the radial notches 162. In the illustrated embodiment, the radial notches 162 of each of the apertures 156 are in alignment with each other.

[0073] The inner baffles 140 each include at least one by-pass port 170. The by-pass port 170 of one of the inner baffles 140 is at least partially misaligned (i.e., not fully aligned or not in alignment) with the by-pass port 170 of the neighboring inner baffle(s) 140. In the illustrated embodiment, the by-pass ports 170 of the inner baffles 140 are located and positioned in an alternating arrangement, for example, wherein the by-pass port 170 formed in one of the inner baffles 140 is at least partially misaligned (or not in alignment) with the by-pass ports 170 of the immediately adjacent / neighboring baffle(s) 140. More specifically, in the illustrated embodiment, the by-pass port 170 of the rear-most (or first) inner baffle 152a is formed in an upper portion of the inner baffle 152a above the aperture 156, the by-pass port 170 of the second rear-most (or second) inner baffle 152b is formed in a lower portion of the inner baffle 152b below the aperture 156 such that it is not in alignment with the by-pass port 170 of the first inner baffle 152a, the by-pass port 170 of the third rear-most (or third) inner baffle 152c is formed in an upper portion of the inner baffle 152c above the aperture 156 such that it is not in alignment with the by-pass port 170 of the second inner baffle 152b (but is in alignment with the by-pass port 170 of the first inner baffle 152a), the by-pass port 170 of the fourth rear-most (or fourth) inner baffle 152d is formed in a lower portion of the inner baffle 152d below the aperture 156 such that it is not in alignment with the by-pass ports 170 of the third inner baffle 152c and the first inner baffle 152a (but is in alignment with the by-pass port 170 of the second inner baffle 152b), and the by-pass port 170 of the fifth rear-most (or fifth) inner baffle 152e is formed in an upper portion of the inner baffle 152e above the aperture 156 such that it is not in alignment with the by-pass ports 170 of the second inner baffle 152b and fourth inner baffle 152d (but is in alignment with the by-pass ports 170 of the first inner baffle 152a and the third inner baffle 152c). Here, the by-pass ports 170 of the first, third, and fifth inner baffles 152a, 152c, and 152e arranged on the upper portion of the inner baffle 140 are referred to as upper (or first) by-pass ports 172a, while the by-pass ports 170 of the second and fourth inner baffles 152b and 152d arranged on the lower portion of the inner baffle 140 are referred to as lower (or second) by-pass ports 172b which are not in axial alignment with the upper (or first) by-pass ports 172a of the first, third, and fifth inner baffles 152a, 152c, and 152e. Thus, in the illustrated embodiment, the by-pass ports 170 have an alternating arrangement, wherein the by-pass ports 170 alternate between positions above and below the aperture 156. Furthermore, the inner baffles 152a-152d may have textures on surfaces thereof which can increase flow turbulence and internal surface area that comes into contact with gas flow to help decrease temperature.

[0074] The outer baffles 142 extend radially outward from the interior sidewall 136 towards and into the body 102, such that the outer baffles 142 extend between the interior sidewall 136 and the body 102. The outer baffles 142 divide the annular space that is defined between the outer surface 144 of the interior sidewall 136 and the inner surface 146 of the body 102 into a series of exterior baffle chambers 174. As shown, the exterior baffle chambers 174 are positioned radially outward from the interior baffle chambers 154, and the interior sidewall 136 separates the interior baffle chambers 154 and the exterior baffle chambers 174.

[0075] The outer baffles 142 are configured similar to the secondary baffles 52 detailed above. Thus, as shown, the outer baffles 142 each include one or more ports 176 (i.e., one or more ports 176 are formed in each of the outer baffles 142). The one or more ports 176 formed in the outer baffles 142 interconnect the neighboring outer baffle chambers 174, such that the series of outer baffle chambers 174 are in communication with each other via the ports 176. Also, the ports 176 in one of the outer baffles 142 may be mis-aligned with the ports 176 in the neighboring outer baffle(s) 142, such that exhaust gases follow / travel a tortuous path when flowing in-between the outer baffle chambers 174. Here, for example, the ports 176 in the second outer baffle 148b are not in alignment with the ports 176 in the distal most (or first) outer baffle 148a; the ports 176 in the third outer baffle 148c are not in alignment with the ports 176 in the second outer baffle 148b (but are in alignment with the ports 176 in the first outer baffle 148a); the ports 176 in the fourth outer baffle 148d are not in alignment with the ports 176 in the first and third outer baffles 148a and 148c (but are in alignment with the ports 176 in the second outer baffle 148b); the ports 176 in the fifth outer baffle 148e are not in alignment with the ports 176 in the fourth outer baffle 148d and the second outer baffle 148b (but are in alignment with the ports 176 in the first outer baffle 148a and the third outer baffle 148c); the ports 176 in the sixth outer baffle 148f are not in alignment with the ports 176 in the first, third, and fifth outer baffles 148a, 148c, and 148e (but are in alignment with the ports 176 in the second outer baffle 148b and the fourth outer baffle 148d); and the ports 176 in the seventh outer baffle 148g are not in alignment with the ports 176 in the second, fourth, and sixth outer baffles 148b, 148d, and 148f (but are in alignment with the ports 176 in the first outer baffle 148a, the third outer baffle 148c, and the fifth outer baffle 148e). Thus, in this embodiment, the ports 176 in the first outer baffle 148a, the third outer baffle 148c, the fifth outer baffle 148e, and the seventh outer baffle 148g are all in alignment with each other but not in alignment with the ports 176 of the second outer baffle 148b, the fourth outer baffle 148d, and the sixth outer baffle 148f. Similarly, the ports 176 of the second outer baffle 148b, the fourth outer baffle 148d, and the sixth outer baffle 148f are all in alignment with each other but not in alignment with the ports 176 the first outer baffle 148a, the third outer baffle 148c, the fifth outer baffle 148e, and the seventh outer baffle 148g.

[0076] In the illustrated embodiment, the ports 176 the first outer baffle 148a, the third outer baffle 148c, the fifth outer baffle 148e, and the seventh outer baffle 148g are positioned radially inward from (and relative to) the ports 176 of the second outer baffle 148b, the fourth outer baffle 148d, and the sixth outer baffle 148f; and conversely, the ports 176 of the second outer baffle 148b, the fourth outer baffle 148d, and the sixth outer baffle 148f are positioned radially outward of (and surround) the ports 176 the first outer baffle 148a, the third outer baffle 148c, the fifth outer baffle 148e, and the seventh outer baffle 148g. Thus, the ports 176 of the first, third, fifth, and seventh outer baffles 148a, 148c, 148e, and 148g may be referred to as the radially inward ports 178a, while the ports 176 of the second, fourth, and sixth outer baffles 148b, 148d, and 148f may be referred to as the radially outward ports 178b.

[0077] Here, the radially inward ports 178a (i.e., the ports 176 the first outer baffle 148a, the third outer baffle 148c, the fifth outer baffle 148e, and the seventh outer baffle 148g) are a series of discrete ports arranged / formed circumferentially around their respective outer baffle structure (and around the axis A′) at positions closer to the interior sidewall 136 as compared to the radially outward ports 178b (i.e., the ports 176 of the second outer baffle 148b, the fourth outer baffle 148d, and the sixth outer baffle 148f). In this manner, the series of discrete ports 178a of the first outer baffle 148a, the third outer baffle 148c, the fifth outer baffle 148e, and the seventh outer baffle 148g are positioned or spaced at a first radial distance R1 from the axis A′. Also, the radially outward ports 178b are a series of discrete ports arranged / formed circumferentially around their respective outer baffle structure (and around the axis A′) at positions closer to the body 102 as compared to the radially inward ports 178a. In this manner, the series of discrete ports 178b of the second outer baffle 148b, the fourth outer baffle 148d, and the sixth outer baffle 148f are positioned or spaced at a second radial distance R2 from the axis A′, wherein the second radial distance R2 is greater or larger than the first radial distance R1. Thus, as to any particular outer baffle 142, the ports 176 formed thereon have an alternating relationship with respect to the ports 176 on the neighboring outer baffle 142 as they will be closer to either the inner sidewall 136 or the body 102 as compared to the neighboring outer baffle 142.

[0078] In the illustrated embodiment, the radially inward ports 178a are spaced, at least a short distance, from the surface 144 of the inner sidewall 136, such that a portion of the outward baffle 142 is present between the port 176 and the inner sidewall 136; however, in other embodiment, one or more of the radially inward ports 178a are positioned such that it / they touch or border the surface 144 of the inner sidewall 136. Also in the illustrated embodiment, the radially outward ports 178b are positioned on their respective outward baffle 142 such that they each touch or border the inner surface 146 of the body 102; however, in other embodiments, one or more of the radially outward ports 178b are positioned such that it / they are spaced, at least a small distance, from the inner surface 146 of the body 102. Also in the illustrated embodiment, the radially inward ports 178a each have a chevron shape while the radially outward ports 178b each have a truncated chevron shape.

[0079] Thus, as exhaust gas flows from the initial blast chamber 132 into the distal most outer baffle chamber 174 (i.e., defined between the first and second outer baffles 148a and 148b) via the inward ports 178a of the first outer baffle 148a, such exhaust gas is unable to flow in a straight path into the next outer baffle chamber 174 (i.e., defined between the second and third outer baffles 148b and 148c), but instead must travel radially outward within such outer baffle chamber 174 to the radially outward ports 178b of the second outer baffle 148b so that it can enter that next outer baffle chamber. Then, once the exhaust gas is in that second outer baffle chamber 174 (i.e., defined between the second and third outer baffles 148b and 148c), the exhaust gas must flow radially inward towards the inner sidewall 136 and the radially inward ports 178a of the third outer baffle 148c so that the exhaust gas may flow into the next (third) outer baffle chamber 174 (i.e., defined between the third outer baffle 148c and the fourth outer baffle 148d), and so on. Eventually the exhaust gas will travel into the proximal most (or, here, the seventh) outer baffle chamber 174 (i.e., defined between the seventh outer baffle 148g and the forward wall 110), where such exhaust gas may flow out of (or exit) the suppressor 100 via the secondary outlets 118 that are in communication with such seventh outer baffle chamber 174. In this manner, the exhaust gas travels a tortuous path defined by the alternating nature of the radially inward and outward ports 178a and 178b, which is substantially longer than if all of the ports 176 were aligned along an axis. By forcing the exhaust gas to travel along such a tortuous path, the exhaust gas is slowed down and given a greater amount of time to cool, and also forces the exhaust gas into contact with a greater extent of the interior surface area of the suppressor 100. In embodiments, the outer baffle chambers 174 can include irregular internal surfaces that increase surface area (for heat transfer) and generate turbulence in the exhaust gas flow as it passes there-through.

[0080] FIG. 12A is a perspective view of the suppressor 100, while FIGS. 12B and 12C are cross-sectional front and rear perspective views of the suppressor 100 taken along section line 12-12 in FIG. 12A. FIGS. 12B and 12C further depict the positioning of the ports 170 (i.e., the upper ports 172a and the lower ports 172b) of the inner baffles 140, the ports 176 (i.e., the radially inward ports 178a and the radially outward ports 178b) of the outer baffles 142. FIGS. 12B and 12C further depict the configuration of the apertures 156 formed in the inner baffles 140 and, in particular, the configuration of the central 160 and the radial notch 162 of the apertures 156. As shown, the upper ports 172a and the lower ports 172b are positioned on opposite sides of the projectile pathway 158 (or on opposite sides of the axis A′). In this manner, the upper ports 172a may be considered to be positioned above the projectile pathway 158 (or the axis A′), while the lower ports 172b may be considered to be positioned below the projectile pathway 158 (or the axis A′).

[0081] Accordingly, as detailed herein the suppressor 100 includes two discrete flow paths that exhaust gas entering the suppressor 100 may travel upon discharge of the firearm. As described herein, the two discrete flow paths are defined by the baffle system 134 for receiving and directing exhaust gas after such exhaust gas has entered the initial blast chamber 132 upon firearm discharge, wherein such exhaust gas may travel through either the first flow path or the second flow path before exiting the suppressor 100. As best shown in FIG. 13, which is a cross-sectional view similar to FIG. 11, the suppressor 100 includes a first or primary flow path 180 and a second or secondary flow path 182, wherein the first flow path 180 and the second flow path 182 are the two discrete flow paths mentioned above. As shown, both the first flow path 180 and the second flow path 182 begin in the initial blast chamber 132 where, upon discharge of the firearm, resultant exhaust gases 184 enter. After discharging the firearm, the projectile / bullet will travel through the projectile pathway 158 along a projectile path 186. The projectile / bullet is propelled by exhaust gases 184, which accompanies firearm discharge and propels the projectile / bullet as will be appreciated and, upon discharge, that exhaust gas 184 enters the initial blast chamber 132. From there, the exhaust gas 184 may flow along either the secondary flow path 182, the primary flow path 180, or the projectile path 186. The secondary flow path 182 is constrained in the outer baffle chambers 174 formed in the annular space that is defined between the outer surface 144 of the interior sidewall 136 and the inner surface 146 of the body 102, and the exhaust gas 184 passes through the ports 176 of the outer baffles 142 (i.e., the radially inward and outward ports 178a, 178b) to travel distally through the outer baffle chambers 174 to the secondary outlets 118, which the exhaust gas 184 passes through to exit the body 102. The primary flow path 180, which includes exhaust gas 184 flowing through the projectile pathway 158 along the projectile path 186, is constrained within the interior baffle chambers 154, such that the exhaust gas 184 passes through the ports 170 of the inner baffles 140 (i.e., the upper and lower ports 172a, 172b) to travel distally through the interior baffle chambers 154 to the primary outlet 116, which the exhaust gas 184 passes through to exit the body 102.

[0082] Exhaust gas 184 entering the initial blast chamber 132 of the suppressor 100 may then enter either the primary flow path 180 or the secondary flow path 182, with some or a portion of the exhaust gas 184 entering the primary flow path 180 and a remaining portion of the exhaust gas 186 entering the secondary flow path 182. As to the primary flow path 180, such exhaust gas 186 will enter the and flow through the various ports 170 of the inner baffles 140. In particular, in the illustrated embodiment, the primary flow path 180 is defined by path that the exhaust gas 186 travels or flows as it flows through the upper port 172a of the first inner baffle 152a, then passes through the inner baffle chamber 154 between the first inner baffle 152a and the second inner baffle 152b, then flows through the lower port 172b of the second inner baffle 152b, then passes through the inner baffle chamber 154 between the second inner baffle 152b and the third inner baffle 152c, then flows through the upper port 172a of the third inner baffle 152c, then passes through the inner baffle chamber 154 between the third inner baffle 152c and the fourth inner baffle 152d, then flows through the lower port 172b of the fourth inner baffle 152d, then passes through the inner baffle chamber 154 between the fourth inner baffle 152d and the fifth inner baffle 152e, then flows through the upper port 172a in the fifth inner baffle 152e, then flows through the inner baffle chamber 174 defined between the fifth inner baffle 152e and the forward wall 110, and then flows through the primary outlet 116 in the forward wall 110 to exit the suppressor 100. Due to the alternating nature of the ports 170 in the inner baffles 140, the primary flow path 180 defines a tortuous path for the exhaust gas 186 to travel rather than being a linear flow path.

[0083] The primary flow path 180 can also include the central portion 160 and the radial notch 162 of the projectile apertures 156, as exhaust gas 186 may also flow through there after discharging the firearm. The radial notches 162 may be referred to as “clippings” or “baffle clippings” which help to force the jet of gas traveling through the projectile pathway 158 to be diverted off the axis A′ of the suppressor 100, causing more exhaust gas to be trapped in each baffle chamber 154 rather than being forced straight through the bore (i.e., just through smaller central portions 160 of the apertures 156).

[0084] The remaining portion of the exhaust gas 186 in the blast chamber that has not entered the primary flow path 180 will embark on the secondary flow path 182. As to the secondary flow path 182, such remaining exhaust gas 186 will enter the and flow through the various ports 176 of the outer baffles 142. In particular, in the illustrated embodiment, the secondary flow path 182 is defined by path that the exhaust gas 186 travels or flows as it flows through the radially inward ports 178a in the first outer baffle 148a, then through the outer baffle chamber 174 between the first outer baffle 148a and the second outer baffle 148b, then through the radially outward ports 178b in the second outer baffle 148b, then passes through the outer baffle chamber 174 between the second outer baffle 148b and the third outer baffle 148c, then through the radially inward ports 178c in the third outer baffle 148c, then through the outer baffle chamber 174 between the third outer baffle 148c and the fourth outer baffle 148d, then through the radially outward ports 178b in the fourth outer baffle 148d, then through the outer baffle chamber 174 between the fourth outer baffle 148d and the fifth outer baffle 148e, then through the radially inward ports 178b in the fifth outer baffle 148e, then through the outer baffle chamber 174 between the fifth outer baffle 148e and the sixth outer baffle 148f, then through the radially outward ports 178b in the sixth outer baffle 148f, then passes through the outer baffle chamber 174 between the sixth outer baffle 148f and the seventh outer baffle 148g, then through the radially inward ports 178a in the seventh outer baffle 148f, then through the baffle chamber 174 defined between the seventh outer baffle 148f and the forward wall 110, and then through the secondary outlets 118 in the forward wall 110 to thereby exit the suppressor 100. Due to the alternating nature of the ports 176 in the outer baffles 142, with ports 176 of one outer baffle 142 being positioned at a different (larger or smaller) radial distance from the axis A relative to the ports 176 of another (e.g., neighboring) outer baffle 142, the secondary flow path 182 defines a tortuous path for the exhaust gas 186 to travel rather than being a linear flow path.

[0085] Because the exhaust gas flowing along the secondary flow path 184 is traveling through the ports 176 (i.e., the inward and outwardly radial ports 178a, 178b) which are located radially outward from the ports 170 of the primary flow path 180, relative to the axis A′, the secondary flow path 182 is oriented radially outward from the primary flow path 180.

[0086] Also, with this construction of the primary flow path 180 and the secondary flow path 182, mixing of the separate exhaust gas streams is inhibited. Here, for example, the primary flow path 180 and the secondary flow path 182 are each configured such that exhaust gas flowing through the primary flow path 180 is unable to mix with exhaust gas flowing through the secondary flow path 182 and vice versa.

[0087] FIG. 14 depicts yet another suppressor 1000, according to one or more other embodiments. The suppressor 1000 is similar to the suppressor 100 described above, as the suppressor 1000 is also a two layer design having the primary flow path 180 and the secondary flow path 182. However, the primary flow path 180 and the secondary flow path 182 of the suppressor 100 are completely partitioned and sealed relative to each other, such that there is no mixing of exhaust gas flowing through the primary flow path 180 and the secondary flow path 182 of the suppressor 100 (i.e., exhaust gas flowing through the primary flow path 180 of the suppressor 100 does not mix with exhaust gas flowing through the secondary flow path 182 of the suppressor 100, and vice versa).

[0088] The suppressor 1000 differs from the suppressor 100 in that the suppressor 1000 is configured to permit mixing of exhaust gas flowing through the primary flow path 180 and the secondary flow path 182. In the illustrated embodiment, the suppressor 1000 includes a plurality of mixing ports 1002 that permit mixing between the primary flow path 180 and the secondary flow path 182. Here, the mixing ports 1002 are formed in the interior sidewall 136, to provide fluid communication between at least some of the interior baffle chamber 154 and outer baffle chambers 174, such that exhaust gas in the interior baffle chamber 154 may flow into the outer baffle chambers 174 and vice versa. In the illustrated embodiment, the mixing ports 1002 are provided at locations on the interior sidewalls 136 associated with each of the corresponding pairs of interior and exterior baffle chambers 154, 174; however, in other embodiment, a corresponding pair of interior and exterior baffle chambers 154, 174 may not include any such mixing ports 1002 so that exhaust flowing through that particular corresponding pair of interior and exterior baffle chambers 154, 174 is not able to comingle, but may later or prior be mixed when flowing through other corresponding pairs of interior and exterior baffle chambers 154, 174 distally or proximally located therefrom.

[0089] Other aspects, features, benefits, and advantages of the present invention will be apparent to a person of skill in the art from the drawing figures.

[0090] While one or more embodiments of the present invention have been described in detail, it should be apparent that modifications and variations thereto are possible, all of which fall within the true spirit and scope of the invention. Therefore, the foregoing is intended only to be illustrative of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not intended to limit the invention to the exact construction and operation shown and described. Accordingly, all suitable modifications and equivalents may be included and considered to fall within the scope of the invention, defined by the following claim or claims.

Examples

Embodiment Construction

[0034]With reference to the drawing figures, this section describes particular embodiments and their detailed construction and operation. Throughout the specification, reference to “one embodiment,”“an embodiment,” or “some embodiments” means that a particular described feature, structure, or characteristic may be included in at least one embodiment. Thus, appearances of the phrases “in one embodiment,”“in an embodiment,” or “in some embodiments” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the described features, structures, and characteristics may be combined in any suitable manner in one or more embodiments. In view of the disclosure herein, those skilled in the art will recognize that the various embodiments can be practiced without one or more of the specific details or with other methods, components, materials, or the like. In some instances, well-known structures, materials, or operations are not shown ...

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of and priority to U.S. Provisional Ser. No. 63 / 746,426 filed Jan. 17, 2025, the disclosure of which is hereby incorporated by reference in its entirety.TECHNICAL FIELD

[0002] This invention relates to a firearm noise suppressor, colloquially referred to as a silencer.BACKGROUND

[0003] Firearm noise suppressors reduce the actual volume and perceived sound of a firearm's report in several ways. Some of these ways operate to remove energy from the high pressure, high velocity gas flow that propels the projectile and creates a loud report as it escapes form the muzzle of the barrel. One of the ways a suppressor reduces the energy of the muzzle blast is by removing and dissipating heat from the gas flow. Typically, a suppressor will absorb heat into the material of the suppressor body, reducing the temperature of the gas, and then radiate that heat to the atmosphere. This radiation of heat can cause a mirage effect above the suppressor, which is typically directly in the shooter's line of sight. Also, the material of the suppressor body can become heat-saturated, unable to radiate heat faster than it absorbs heat, and no longer effectively remove heat from the propellant gas flow.

[0004] The total interior volume of a suppressor is a significant factor of performance. In designs made by traditional subtractive manufacturing methods where the suppressor body is symmetrical around the bore axis (i.e., round in cross-section), enlarging the volume often is achieved by enlarging the diameter of the body. This can be detrimental when the height above the bore axis increases enough to interfere with the sighting line above the barrel. Other asymmetrical designs have increased volume only by increasing the area below the bore axis, generally shifting the geometric longitudinal axis below the bore axis. Accordingly a need exists for a larger internal volume suppressor with improved energy reduction capabilities.SUMMARY OF THE INVENTION

[0005] The present invention provides a firearm noise suppressor system (or suppressor) for a firearm with multiple gas flow paths and that can be axially asymmetric (non-round).

[0006] According to some embodiments, the suppressor includes a tubular body extending along an axis between a forward end and a rear end, the tubular body having a forward wall at the forward end and defining an interior volume; and a baffle system arranged in the interior volume, wherein the baffle system comprises: an interior sidewall extending rearward from the forward wall of the body; a plurality of inner baffles disposed within the interior sidewall, the plurality having inner baffles defining a projectile passageway for receiving a projectile fired from the firearm and a primary flow path for directing a portion of exhaust gas resulting from discharge of the firearm; and a plurality of outer baffles extending between the interior sidewall and body, wherein the plurality of outer baffles define a secondary flow path for directing any remaining exhaust gas resulting from discharge of the firearm.

[0007] In some embodiments, the interior volume includes an initial blast chamber, and the baffle system is positioned forward of the initial blast chamber.

[0008] In some embodiments, the primary flow path and the secondary flow path are each configured such that exhaust gas flowing through the primary flow path is unable to mix with exhaust gas flowing through the secondary flow path.

[0009] In some embodiments, the forward wall comprises a primary outlet in communication with the primary flow path and a plurality of secondary outlets in communication with the secondary flow path.

[0010] In some embodiments, each of the plurality of inner baffles includes a port. In some of these embodiments, the plurality of inner baffles includes a first interior baffle and a second interior baffle positioned next to the first interior baffle, wherein the port of the first interior baffle is an upper port positioned above the projectile passageway, and wherein the port of the second interior baffle is a lower port positioned below the projectile passageway. In some of these embodiments, the port on one of the inner baffles is not in axial alignment with the port on another one of the inner baffles.

[0011] In some embodiments, each of the plurality of outer baffles includes a series of discrete ports. In some of these embodiments, the plurality of outer baffles includes a first outer baffle and a second outer baffle positioned next to the first outer baffle, wherein the series of discrete ports of the first outer baffle are positioned circumferentially around the first outer baffle and the series of discrete ports of the second outer baffle are positioned circumferentially around the second outer baffle. In some of these embodiments, the series of discrete ports of the first outer baffle are positioned at a first radial distance from the axis and the series of discrete ports of the second outer baffle are positioned at a second radial distance from the axis that is larger than the first radial distance. In some embodiments, the series of discrete ports on one of the outer baffles are not in alignment with the series of discrete ports on another one of the outer baffles. In some embodiments, the discrete ports on the outer baffles border or touch an inner surface of the body.

[0012] In some embodiments, each of the inner baffles includes a projectile aperture, wherein the projectiles apertures are aligned with each other and together define the projectile passageway. In some of these embodiments, each of the projectile apertures includes a central portion and a radial notch extending radial outward from the central portion, wherein the central portion is aligned with the central portion of other projectile apertures.

[0013] In some embodiments, the forward wall comprises a primary outlet in communication with the primary flow path and a plurality of secondary outlets in communication with the secondary flow path. In some of these embodiments, a plurality of vanes arranged on an exterior of the forward wall and surrounding the primary outlet.

[0014] In some embodiments, the suppressor further includes a tertiary flow path positioned radially outward from the secondary flow path. In embodiments, the tertiary flow path receives and directs at least some of the exhaust gas, and the tertiary flow path also receives ambient air, wherein the tertiary flow path is configured such that the exhaust gas flowing therethrough flows in a turbulent manner that creates a vacuum effect that pulls ambient air into the tertiary flow path to help cool the suppressor.

[0015] Other aspects, features, benefits, and advantages of the present invention will become apparent to a person of skill in the art from the detailed description of various embodiments with reference to the accompanying drawing figures, all of which comprise part of the disclosure.BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Like reference numerals are used to indicate like parts throughout the various drawing figures, wherein:

[0017] FIG. 1 is a first isometric view of a firearm sound suppressor, according to one embodiment of the present invention;

[0018] FIG. 2 is a second isometric view thereof;

[0019] FIG. 3 is an isometric longitudinal sectional view taken substantially along line 3-3 of FIG. 2;

[0020] FIG. 4 is another isometric longitudinal sectional view taken substantially along line 4-4 of FIG. 9;

[0021] FIG. 5 is a side sectional view also taken substantially along line 3-3 of FIG. 2;

[0022] FIG. 6 is a rear end view thereof;

[0023] FIG. 7 front end view thereof;

[0024] FIG. 8 is a cross-sectional view taken substantially along line 8-8 of FIG. 1;

[0025] FIG. 9 is a cross-sectional view taken substantially along line 9-9 of FIG. 5;

[0026] FIG. 10 is an isometric view of a firearm sound suppressor, according to one or more alternate embodiments of the present invention;

[0027] FIG. 11 is a side sectional view taken along line 11-11 of FIG. 10;

[0028] FIG. 12A is a perspective of the suppressor of FIG. 10;

[0029] FIG. 12B is a front perspective sectional view of the suppressor along section line 12-12 in FIG. 12A;

[0030] FIG. 12C is a rear perspective sectional view of the suppressor along section line 12-12 in FIG. 12A;

[0031] FIG. 13 is another side cross-sectional view of the suppressor taken along line 11-11 of FIG. 10 depicting the primary flow path and secondary flow path, according to one or more embodiments; and

[0032] FIG. 14 an isometric view of a firearm sound suppressor, according to one or more other alternate embodiments of the present invention; and

[0033] FIG. 15 sectional view of the suppressor along section line 15-15 in FIG. 14.DETAILED DESCRIPTION

[0034] With reference to the drawing figures, this section describes particular embodiments and their detailed construction and operation. Throughout the specification, reference to “one embodiment,”“an embodiment,” or “some embodiments” means that a particular described feature, structure, or characteristic may be included in at least one embodiment. Thus, appearances of the phrases “in one embodiment,”“in an embodiment,” or “in some embodiments” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the described features, structures, and characteristics may be combined in any suitable manner in one or more embodiments. In view of the disclosure herein, those skilled in the art will recognize that the various embodiments can be practiced without one or more of the specific details or with other methods, components, materials, or the like. In some instances, well-known structures, materials, or operations are not shown or not described in detail to avoid obscuring aspects of the embodiments. “Forward” will indicate the direction of the muzzle and the direction in which projectiles are fired, while “rearward” will indicate the opposite direction. “Lateral” or “transverse” indicates a side-to-side direction generally perpendicular to the axis of the barrel. Although firearms may be used in any orientation, “left” and “right” will generally indicate the sides according to the user's orientation, “top” or “up” will be the upward direction when the firearm is gripped in the ordinary manner.

[0035] FIGS. 1 and 2 depict a firearm sound suppressor 1, according to one or more embodiments. The firearm sound suppressor 1 includes a tubular body 10 that extends along an axis A and includes a front end 11 and a rear end 13. The body 10 includes a forward end wall 12 at the front end 11, wherein a primary opening 14 is defined in the forward end wall 12. Stated differently, the forward end wall 12 includes the primary opening 14. As shown, the primary opening 14 is in alignment with the axis A, and, as will be appreciated, the axis A is in alignment with a firearm barrel (not shown) to which the suppressor body 10 may be attached and through which a fired projectile passes to exit the suppressor body 10.

[0036] Also shown in FIG. 2, the forward end wall 12 includes secondary gas outlets 16 and tertiary gas outlets 16, 18. The secondary gas outlets 16 are a series of outlets that are arranged around the axis A and are spaced radially outward from the axis A by a first distance. The tertiary gas outlets 18 are a series of outlets that are arranged around the axis A and are spaced radially outward from the axis A by a second distance that is greater than the first distance, such that the tertiary gas outlets 18 are spaced radially outward from the secondary gas outlets 16 and such that the tertiary gas outlets 18 surround the secondary gas outlets 16. n

[0037] As shown in FIG. 1, the rear end wall 20 includes a series of atmospheric gas inlet ports 22. The atmospheric gas inlet ports 22 are a series of inlet ports that are arranged around the axis A and are spaced radially outward from the axis A. As further described herein, the atmospheric gas inlet ports 22 are in communication with the tertiary gas outlets 18 such that ambient air entering the atmospheric gas inlet ports 22 may eventually exit the body 10 via tertiary gas outlets 18.

[0038] A means for mounting the suppressor body 10 to the barrel of a firearm may be arranged at the rear end 13 of the body 10. While the illustrated embodiment does not show such means for mounting the suppressor body 10 to the muzzle of a firearm barrel, such mounting means or mechanism can be any traditional or novel mounting device or mechanism utilizable to attach the suppressor body 10 to the barrel. Such mounting means or mechanism may be integral to the suppressor body 10 or separable from the suppressor body 10.

[0039] In the illustrated embodiment, the suppressor body 10 has an asymmetric cross-sectional shape that increases the cross-sectional area (and, thereby, the internal volume) without increasing the height of the device relative to the bore axis, which could interfere with the shooter's line of sight. Rather than just lowering the geometric center, the profile can be widened laterally at a top side 15 of the body 10 relative to a bottom side 17 of the body 10. In the illustrated embodiment, the body 10 includes a generally triangular shape when viewed in cross-section, such that a pair of vertices 19a, 19b are provided at the top side 15 of the body 10 and a single vertice 19c is provided at the bottom side 17 of the body 10. With this arrangement, the upper side 15 of the body 10 is a sidewall extending between the vertices 19a and 19b, a left side wall extends between vertices 19b and 19c, and a right sidewall extends between the vertice 19a and 19c, with the left and right sidewalls meeting each other at the lower vertice 19c. In the illustrated embodiment, each of the vertices 19a, 19b, and 19c are rounded such the body 10 has a generally smooth outer surface without sharp or pointed edges on its sides. Stated differently, the vertices 19a, 19b, 19c define smooth transitions between the upper sidewall, the left sidewall, and the right sidewall.

[0040] In the illustrated embodiment, the suppressor 1 has multiple flow paths for gas flow resulting from firing of the firearm. In the embodiment depicted in FIGS. 1-9, the suppressor 1 has three flow paths: a primary flow path 24, a secondary flow path 26, and a tertiary flow path 28. These three flow paths are best shown in at least FIGS. 3-5. As shown in the cross-sectional views, a initial blast chamber 30 is defined inside the tubular body 10 proximate the rear end 13, and the suppressor 1 includes a baffle system 31 forward of the initial blast chamber 30 that extends between the initial blast chamber 30 and the front end 11.

[0041] The baffle system 31 includes a series of asymmetrical inner conical baffles 32 joined together via an inner sidewall 35. Baffle chambers 34 are defined between neighboring baffles 32 and the inner surface of the inner sidewall 35. Each of the asymmetrical conical baffles 32 includes a projectile aperture through which the projectile may pass, and the apertures 36 of the asymmetrical conical baffles 32 are aligned with each other and together define projectile passageway 36′ that extends through the baffle system 31 and through the body 10 along the axis A. More specifically, the apertures 36 include an aligned central portion that together define the projectile passageway 36′. In the illustrated embodiment, the apertures 36 each include a radial notch 38 that extend radially outward from the central portion, such that the apertures 36 may be considered asymmetric due to the presence of the radial notches 38.

[0042] Further, the baffles 32 may each include one or more by-pass ports 40 that is / are not in full alignment with the by-pass port(s) 40 of neighboring baffles 32. Stated differently, the by-pass ports 40 are not fully aligned with each other, but are instead at least partially misaligned with each other. In the illustrated embodiment, the by-pass ports 40 are located and positioned in an alternating arrangement, for example, wherein the by-pass port 40 formed in one of the baffles 32 is misaligned (or not in alignment with) the by-pass ports 40 of the immediately adjacent / neighboring baffle(s) 32. More specifically, in the illustrated embodiment, the asymmetrical inner conical baffles 32 includes baffles 33a-33e, and the by-pass port 40 of the rear-most (or first) baffle 33a is formed in an upper portion of the baffle 33a above the aperture 36, the by-pass port 40 of the second rear-most (or second) baffle 33b is formed in a lower portion of the baffle 33b below the aperture 36 such that it is not in alignment with the by-pass port 40 of the first baffle 33a, the by-pass port 40 of the third rear-most (or third) baffle 33c is formed in an upper portion of the baffle 33c above the aperture 36 such that it is not in alignment with the by-pass port 40 of the second baffle 33b (but is in alignment with the by-pass port 40 of the first baffle 33a), the by-pass port 40 of the fourth rear-most (or fourth) baffle 33d is formed in a lower portion of the baffle 33d below the aperture 36 such that it is not in alignment with the by-pass ports 40 of the third baffle 33c and the first baffle 33a (but is in alignment with the by-pass port 40 of the second baffle 33b), and the by-pass port 40 of the fifth rear-most (or fifth) baffle 33e is formed in an upper portion of the baffle 33e above the aperture 36 such that it is not in alignment with the by-pass ports 40 of the second baffle 33b and fourth baffle 33d (but is in alignment with the by-pass ports 40 of the first baffle 33a and the third baffle 33c). Thus, in the illustrated embodiment, the by-pass ports 40 have an alternating aligned arrangement, wherein the by-pass ports 40 alternate between positions above and below the central aperture 36. Furthermore, the baffles 33a-33e may have textures on surfaces thereof which can increase flow turbulence and internal surface area that comes into contact with gas flow to help decrease temperature.

[0043] The suppressor 1 may include a funnel-shaped wall 42 that extends into a least a rear portion of the initial blast chamber 30 to converge high pressure / velocity propellant gas toward the first or rear most baffle 33a of the conical baffles 32. In the illustrated embodiment, the funnel-shaped wall 42 is connected to the baffle system 31 and extends rearward from the rear most baffle 33a into the initial blast chamber. The funnel-shaped wall 42 includes a rear end 43 that is spaced away from an inner surface 45 of the initial blast chamber 30, such that a gap is defined between the rear end 43 and the inner surface 45. In the illustrated embodiment, an annular shaped gap 44 is defined between the rear end 43 and the inner surface 45, and a receiving chamber 46 is defined between an outer surface 47 of the funnel wall42 and the inner surface 45. As described below, exhaust gas entering into the funnel shaped wall 42 is directed towards the primary flow path 24, while exhaust gas entering receiving chamber 46 through the annular shaped gap 44 is directed towards either the secondary flow path 26 and the tertiary flow path 28.

[0044] As will be appreciated, the baffle system 31 is operable for reducing the pressure, velocity, and temperature of propellant gas expelled from the muzzle of the firearm barrel, and the baffle system 31 slows the release of propellant gas, allowing pressure to reduce before it is released to the atmosphere.

[0045] The primary flow path 24 is akin to a traditional suppressor flow path, and includes the projectile passageway 36′, but also includes the path defined by the aligned radial notches 38 as well as the tortuous path defined by the alternating aligned by-pass ports 40. In the illustrated embodiment, the primary flow path 24 begins inside the tubular body 10 at a rear end 43 of the funnel shaped wall 42 and ends at the primary opening 14. Thus, upon firing of the firearm, both the projectile and propellant gas enters the initial blast chamber 30 and then both enter the primary flow path 24, where they travel through a space defined within the funnel shaped wall 42 and through the baffle system 31, and then exit the suppressor at the primary opening 14, wherein the gas flows through the projectile passageway 36′, the radial notches 38, and the alternating aligned by-pass ports 40 as it travels through the primary flow path 24.

[0046] The secondary flow path 26 is generally annular in shape and situated radially outward of the primary flow path 24. As described herein, the secondary flow path 26 handles a portion of the high pressure gas separate from the primary flow path 24 to be exhausted through ports 16 in the forward end wall 12 of the suppressor body 10. For example, the secondary flow path 26 is configured such that at least some of the high pressure gas that enters the initial blast chamber 30 is able to flow into the receiving chamber 46 and then into the secondary flow path 26. The secondary path 26 includes inlets 48 arranged inside of the body 10 and, in the illustrated embodiment, the inlets 48 are arranged in the receiving chamber 46. Thus, to access the secondary flow path 26 in the illustrated embodiment, such high pressure exhaust gas will not enter the funnel shaped wall 42, but will instead pass through the annular shaped gap 44 and thereby enter the receiving chamber 46, where it can enter the secondary flow path 26 (or the tertiary flow path 28, detailed below) via the inlets 48. The exhausted through ports 16 are in communication with the secondary flow path 26 such gas entering and flowing through the secondary flow 26 will exit the suppressor 1 via the exhausted through ports 16.

[0047] The tertiary flow path 28 is also generally annular in shape and situated radially outward of the secondary flow path 26. The tertiary flow path 28 is in communication with both the initial blast chamber 30 and the ambient environment, and uses another portion of the high pressure / velocity gas flow to create a venturi effect to draw in outside (atmospheric) air to help cool the suppressor body 10, exhausting through separate ports 18 in the forward wall 12 without contaminating either the primary or secondary flow paths 24, 26 with oxygen rich fresh air. To access the tertiary flow path 28 in the illustrated embodiment, such high pressure exhaust gas will not enter the funnel shaped wall 42, but will instead enter the receiving chamber 46 through the annular shaped gap 44 and, once in the receiving chamber 46, the exhaust gases can enter the tertiary flow path 28. In the illustrated embodiment, the tertiary flow path 28 is in communication with the atmospheric gas inlet ports 22 in the rear end wall 20 and the tertiary gas outlets 18 in the forward wall 12. The outside (atmospheric) air is drawn into the suppressor 1 via the atmospheric gas inlet ports 22 and discharged out of the suppressor 1, together with some high pressure / velocity firearm exhaust gas, via the tertiary gas outlets 18. As further described below, the tertiary flow path 28 also includes tertiary inlets 56 arranged inside the body 10, and at least some of the high pressure / velocity gas entering the initial blast chamber 30 and the receiving chamber 46 may enter pass through the tertiary inlets 56 to enter the tertiary flow path 28, where such high pressure / velocity gas may mix with cooler ambident air pulled into the tertiary flow path 28 via the atmospheric gas inlet ports 22, and then such combined gas may exit the tertiary flow path 28 via the tertiary gas outlets 18 in the forward wall 12. Thus, the tertiary flow path 28 includes a pair of different sets of inlets (i.e., atmospheric gas inlet ports 22 and the tertiary inlets 56) and single set of outlets (i.e., tertiary gas outlets 18).

[0048] The structure of this suppressor design is particularly suited for construction by additive manufacturing methods (e.g., 3-D printing). Inconel® alloy 718, a superalloy made by Huntington Alloys Corporation of Huntington, West Virginia, renowned for its heat resistance, durability, corrosion resistance, and fatigue resistance, is one material ideal for such structure. It has excellent weight-to-strength ratio, which allows for thin-walled construction without compromising performance.

[0049] In the illustrated embodiment, the baffle system 31 is positioned forward of the initial blast chamber 30, such that the initial blast chamber 30 defines a substantially empty chamber, except for the funnel shaped wall 42 extending rearward into initial blast chamber 30. However, as mentioned above, the funnel shaped wall 42 defines a large interior space within which a portion of the firearm may extend without contacting the suppressor 1. In this manner, the initial blast chamber 30 and / or the interior space of the funnel shaped wall 42 may receive a feature of a muzzle mount device (not shown), such as a flash hider or brake, without interference between such muzzle mount device and an internal structure of the suppressor 1.

[0050] Thus, the funnel 42 is configured to separate or bifurcate the high pressure exhaust gas received by the suppressor 1 into a first stream, that can flow through the primary path 24, and a second stream that can flow through the secondary or tertiary flow paths 26, 28, wherein the receiving chamber 46 directs a portion of the exhaust gas flow into inlet openings 48 of the secondary flow path 26 and another portion of the exhaust gas into the inlets 56 of the tertiary flow path 28.

[0051] The baffle system 31 also includes an outward inner sidewall 37 that is positioned radially outward from and surrounds the inner sidewall 35, such that an annular space is defined between the inner sidewalls 35 and 37, and such that the inner sidewall 35 may be referred to as the inward inner sidewall 35. As shown, both the inner sidewalls 35 and 37 are connected to the front wall 12 and extend rearward therefrom toward the rear end 13. In addition, the baffle system 31 includes secondary baffles 52 that extend radially outward from the inward inner sidewall 35 towards and into the outward inner sidewall 37, such that the secondary baffles 52 extend between the inner sidewalls 35 and 37. The secondary baffles 52 divide the annular space defined between the inner sidewalls 35 and 37 into a series of chambers 50, and one or more ports 54 are formed in each of the secondary baffles 52 such that the chambers 50 are interconnected and in communication with each other via the ports 54. Also in the illustrated embodiment, the secondary inlets 48 of the secondary flow path 26 are the ports 54 formed in a proximal most (or first) secondary baffle 53a of the secondary baffles 52. Thus, in the illustrated embodiment, the secondary flow path 26 includes the series of chambers 50, such that when the high pressure / velocity exhaust gas enters the secondary flow path 26 via the ports 54 in the proximal most secondary baffle 53a (i.e., the secondary inlet 48), the high pressure / velocity exhaust gas enters a distal most chamber 50a (of the chambers 50) via the ports 54 in the proximal most secondary baffle 53a. Thereafter, the high pressure / velocity exhaust gas passes through the ports 54 in a next, neighboring secondary baffle 53b (that is distal of the first secondary baffle 53a) of the secondary baffles 52 and into the next chamber 50b, and then the high pressure / velocity exhaust gas passes through the ports 54 in a next neighboring secondary baffle 53c (that is distal of the second secondary baffle 53b) of the secondary baffles 52 and into the next chamber 50c, and so on, until such exhaust gas enters a proximal-most chamber 50g of the chambers 50, where such exhaust gas may exit the secondary path 26 (and the suppressor) via the secondary outlet ports 16 in the forward wall 12. The chambers 50 of the secondary flow path 26 can include irregular internal surfaces that increase surface area (for heat transfer) and generate turbulence in the secondary flow of gas as it passes through the secondary flow path 26. Also, the ports 54 in one of the secondary baffles 52 may be mis-aligned with the ports 54 in a neighboring one of the secondary baffles 52. Here, for example, the ports 54 in the second secondary baffle 53b are not in alignment with the ports 54 in the proximal most secondary baffle 53a and the ports 54 in the third secondary baffle 53c; however, the ports 54 of the first secondary baffle 53a and the ports 54 of the third secondary baffle 53c may be in alignment with each other. In this manner, the secondary path 26 includes a tortuous flow path, which is defined by the series of chambers 50 and the interconnecting ports 50.

[0052] The tertiary inlets 56 are positioned within the annular receiving chamber 46 at locations outwardly adjacent to the secondary inlets 48. As mentioned, the high pressure, high velocity propellant gas stream entering the receiving chamber 46 flows into either the secondary flow path 26 or the tertiary flow path 28. Thus, a first portion of the high pressure, high velocity propellant gas stream enters the secondary flow path 26 via the secondary inlets 48 (i.e., the ports 54 in the proximal most secondary baffle 53a) while the tertiary inlets 56 receive another portion of the high pressure, high velocity propellant gas stream.

[0053] As mentioned, the tertiary flow path 28 includes the fresh air inlets 22 and the high velocity gas flow that enters the tertiary flow path 28 via the tertiary inlets 56 creates a venturi effect within the tertiary flow path 28, which in turn causes fresh or ambient air to be drawn or sucked into the tertiary flow path 28 from outside the body 10 via the ambient air inlets 22 located adjacent the rear end 20. The cooler outside air entering the tertiary flow path 28 via the ambient air inlets 22 will absorb heat from the suppressor body 10 and the ambient air, together with the exhaust gas flow entering the tertiary flow path 28 via the tertiary inlets 56 will be exhausted out of the body 10 through outlet ports 18 in the forward wall 12.

[0054] As shown in FIG. 3 and FIG. 5, the body 10 defines an outer sidewall 39, and an annular space 55 is defined between the inner sidewall 37 and the outer sidewall 39, and this annular space 55 defines at least a portion of the tertiary flow path 28. As best shown in FIG. 5, the tertiary inlets 56 lead direction into the annular space 55 such that pressured exhaust gas flowing through the tertiary inlets 56 is directly enters the annular space 55. Also in the illustrated embodiment, one or more channels 57 are formed in the body 10 proximate the rear end 13 and in communication with the fresh air inlets 22, wherein the channel 57 extends forward from the fresh air inlets 22 into the annular space 55, such that the annular space 55 is in communication with the ambient environment via the channel 57 and the fresh air inlets 22. In this manner, ambient air may enter the suppressor via the fresh air inlets 22, travel through the channel 57 and into the annular space 55, where it is comingled with exhaust gas, before exiting the suppressor 1 via the outlet ports 18 in the forward wall 12. Thus, the tertiary flow path 28 also includes the fresh air inlets 22 and the channel 57. In the illustrated embodiment, the channel 57 is an annular shaped channel that extends substantially continuously around the body 10; however, in other embodiments, the channel 57 comprises a plurality of discrete channel pathways extending between the inlets 22 and the annular space 55.

[0055] The tertiary flow path 28 can include nonlinear longitudinal separation partitions 58. In the illustrated embodiment, the separation partitions 58 are arranged in the annular space 55; however, in other embodiments, the separation partitions are also arranged in the channel 57, for example, when the channel 57 is an annular shaped space as shown in the illustrated embodiment. In the illustrated embodiment, these partitions 58 have a zig-zag configuration to disrupt flow, create turbulence, and increase surface area for heat transfer. Alternatively, the tertiary flow path 28 could include helical vanes (not shown) to swirl the air flow around the annular space 55 so that such air contacts the outer inner side wall 37 that separates the tertiary flow path 28 from the secondary flow path 26, and thus borders the secondary flow path 26, to provide additional heat transferring surface area. The partitions 58 extend between the inner sidewall 37 and the outer sidewall 39 defined by the body 10, wherein a portion of the outer sidewall 39 has been removed in FIG. 4 to depict the partitions 58.

[0056] The tertiary flow path 28 allows the suppressor body 10 to absorb and dissipate more heat energy from the propellant gases and reduces the heat signature (and mirage effect) of the suppressor 10. The tertiary flow path 28 is designed not to “contaminate” the primary flow path 24 or secondary flow path 26 with oxygen-rich fresh outside air. Oxygen in the primary flow path 24 contributes to “first round pop,” a phenomenon in which the first round fired through a suppressor is louder than subsequent rounds fired in close succession thereafter because the amount of oxygen-rich fresh air inside the device has been displaced by residual, oxygen-poor propellant gases.

[0057] As shown in FIG. 2 and FIG. 7, one or more exterior vanes 62 may be arranged on the forward wall 12. The exterior vanes 62 may help dilute gases exiting the outlets 14, 16, 18, which in turn will help to reduce flash signature.

[0058] The suppressor 1 of FIGS. 1-9 has three separate flow paths (i.e., flow paths 24, 26, and 28) and may thus be referred to as a three-layer design, wherein an outer layer includes the tertiary flow path 28 defined between the body 10 and the outer inner sidewalls 37, a middle layer includes the secondary flow path 26 defined between the inward inner sidewalls 35 and the outer inner sidewalls 37, and an inner-most layer includes the primary flow path 24 defined inside the inward inner sidewalls 35. As mentioned above, the tertiary flow path 128 is configured to pull ambient air into the suppressor 1 to facilitate cooling of the suppressor 1 during use.

[0059] FIGS. 10-13 depict a suppressor 100 according to one or more alternate embodiments. As further discussed below, the suppressor 100 differs from the suppressor 1 as the suppressor 100 is a two-layer design that incorporates two layer (i.e., two flow paths: a primary flow path and a secondary flow path) without utilizing an outer layer configured to pull ambient air into the suppressor body.

[0060] The suppressor 100 includes a body 102 having a front end 104 and a rear end 106 opposite the front end 104. The body 102 is tubular and extends along an axis A′. As with the suppressor 1 detailed above, the body 102 of the suppressor 100 is not perfectly round, but is instead triangular in shape with rounded vertices. In the illustrated embodiment, the suppressor body 100 has an asymmetric cross-sectional shape (i.e., non-round) that increases the cross-sectional area (and, thereby, the internal volume) without increasing the height of the device relative to the bore axis, which could interfere with the shooter's line of sight.

[0061] The front end 104 of the body 102 includes a forward wall 110. In the illustrated embodiment, the forward wall 110 includes a recessed wall portion 112 surrounded by a peripheral wall portion 114. A primary outlet or aperture 116 (hereinafter, the primary outlet 116) is formed in the recessed wall portion 112 and a plurality of secondary outlets or apertures 118 (hereinafter, the secondary outlets 118) are formed in the peripheral wall portion 114.

[0062] In the illustrated embodiment, the recessed wall portion 112 is a sloped surface that is sloped inward into the body 102, away from the front end 104 and toward the rear end 106. In the illustrated embodiment, the front end 104 of the body 102 also includes a plurality of vanes 120 arranged on the forward wall 110 and, in particular, on an exterior surface of the forward wall 110 of the body. Here, the vanes 120 surround the primary opening 116, are arranged on the recessed wall portion 112 and extend forward therefrom, toward the front end 104, such that a front surface of the vanes 120 is substantially continuous with a front surface 122 of the peripheral portion 110 that surrounds the vanes 120 and the recessed wall portion 112.

[0063] During use, a projectile fired by the firearm to which the suppressor 100 is attached will exit the suppressor 100 via the primary outlet 116 thereof. Thus, the primary outlet 116 is at least partially aligned with the axis A′ or arranged over. Stated differently, the axis A′ extends through the primary outlet 116. Discharging the firearm will also produce high pressure and high velocity exhaust gas that accompanies and propels the projectile, and, as further detailed below, at least some of this exhaust gas exits the suppressor 100 via the primary outlet 116 and the rest of this exhaust gas exits the suppressor 100 via the secondary outlets 118.

[0064] As will be appreciated, the rear end 106 is configured to be attached to the muzzle of a firearm barrel. In the illustrated embodiment, threads 108 are provided at the rear end 106, and the threads can be configured for receiving a nut 124. The nut 124 is operable to rotationally position (i.e., “clock”) the suppressor 100 to any type of muzzle mount / device such that the flat top side of the body 102 is positioned upward. The nut 124 provides an adjustable shoulder for the mount on the barrel's muzzle to be installed against in order to correctly orient the silencer 100 vertically.

[0065] The body 102 is hollow and includes an interior volume 126. FIG. 11 is a cross-sectional view of the suppressor 100 of FIG. 10 taken along section line 11-11, and depicts the interior volume 126 defined within the body 102, according to one or more embodiments. As shown, the interior volume 126 extends between the forward end 104 and the rear end 106 along the axis A′.

[0066] In the illustrated embodiment, the interior volume 126 includes an initial blast chamber portion or segment 128 and a baffle portion or segment 130 positioned forward of the initial blast chamber portion 128. As shown, the initial blast chamber 128 begins at the rear end 106 of the body 102 and extends forward therefrom, toward the front end 104 of the body 102, and terminates at (or transitions into) the baffle portion 130. The baffle system chamber 130 begins at the end of the initial blast chamber 128 and extends forward therefrom toward the front end 104 and terminates at the forward wall 110. Here, the initial blast chamber portion 128 defines a blast chamber 132 and a baffle system 134 is arranged within the baffle portion 130.

[0067] The baffle system 134 is operable for reducing the pressure, velocity, and temperature of propellant gas expelled from the muzzle of the firearm barrel, and the baffle system 134 slows the release of such exhaust gas, thereby allowing the pressure of the exhaust gas to reduce before the exhaust gas is released out of the suppressor 100 and into the ambient environment outside of the suppressor 100. During use, high pressure exhaust gas enters the initial blast chamber 128 upon discharge of the firearm, and such high pressure exhaust gas may then enter the baffle system 134 after passing through the initial blast chamber 128. As hereinafter described, the baffle system 134 is configured to separate (or bifurcate) the exhaust gas into separate gas flows or streams, which in turn will help reduce pressure, temperature, and velocity of the exhaust gas. The blast chamber 128 allows the exhaust gas to expand, reducing the pressure felt by the baffle system 130 and allowing the baffle system 130 to be more effective. However, with traditional suppressors, as the firearm moves through its firing cycle the blast chamber becomes a pressurized reservoir sending toxic gas and debris back through the barrel towards the action and shooter. With the presently disclosed suppressor 100, however, the volume of exhaust gas that can enter the action of the firearm is greatly reduced, all without increasing the dB of the shot, due to the presence of the primary and secondary flow paths (180, 182), which function to reduce the energy of the exhaust gas.

[0068] The baffle system 134 includes an interior sidewall 136, inner baffles 140, and outer baffles 142. In the illustrated embodiment, the interior sidewall 136 is a hollow tubular member that is disposed within (or nested inside of) the body 102 and extends rearward from the forward wall 110 of the body 102, such that an annular space is defined between an outer surface 144 of the interior sidewall 136 and an inner surface 146 of the body 102. Also, the interior sidewall 136 is substantially hollow and the inner baffles 140 are disposed or mounted within the interior sidewall 136 (i.e., the inner baffles 140 are arranged within an inner bore defined of the interior sidewall 136).

[0069] In the illustrated embodiment, the interior sidewall 136 is corrugated and thus includes alternate ridges and grooves. The outer baffles 142 extend in a generally radial direction (i.e., outward relative to the axis A), between an outer surface 144 of the interior sidewall 136 and an inner surface 146 of the body 102. The outer baffles 142 may thus substantially surround the interior sidewall 136. In the illustrated embodiment, the outer baffles 142 includes seven outer baffles 148a-148g; however, more or less may be utilized in other embodiments.

[0070] The inner baffles 140 are arranged inside of the interior sidewall 136. As shown, the inner baffles 140 extend radially inward from an inner surface 150 of the interior side wall 136. In the illustrated embodiment, the inner baffles 140 includes a series of five inner baffles 152a-152e; however, more or less may be utilized in other embodiments. Also, interior baffle chambers 154 are defined between each of the inner baffles 140, with a first interior baffle chamber 154 defined between the first inner baffle 152a and the second inner baffle 152b, a second interior baffle chamber 154 defined between the second inner baffle 152b and the third inner baffle 152c, a third interior baffle chamber 154 defined between the third inner baffle 152c and the fourth inner baffle 152d, and fourth interior baffle chamber 154 defined between the fourth inner baffle 152d and the fifth inner baffle 152e, and a fifth interior baffle chamber 154 defined between the fifth inner baffle 152e and the forward wall 110.

[0071] The inner baffles 140 may be similar to the baffles 32, detailed above. Thus, the inner baffles 140 are each an asymmetrical conical baffle structure / member. Also, each of the inner baffles 140 includes a projectile aperture 156 through which the projectile may pass, and the apertures 156 of the asymmetrical conical inner baffles 140 are aligned with each other and with the primary outlet 116, and the apertures 156 and the primary outlet 116 together define a projectile passageway or pathway 158 that extends through the baffle system 134 and through the body 102 along the axis A′.

[0072] The apertures 156 include an aligned central portion 160 that align with the primary outlet 116 along the axis A′ and all together define the projectile passageway or pathway 158. Stated differently, the apertures 156 (i.e., the central portions 160 thereof) and the primary outlet 116 together define the projectile passageway or pathway 158 through which the projectile / bullet will travel upon discharging the firearm. In the illustrated embodiment, the apertures 156 each include a radial notch 162 that extend radially outward from the central portion 160, such that the apertures 156 may be considered asymmetric due to the presence of the radial notches 162. In the illustrated embodiment, the radial notches 162 of each of the apertures 156 are in alignment with each other.

[0073] The inner baffles 140 each include at least one by-pass port 170. The by-pass port 170 of one of the inner baffles 140 is at least partially misaligned (i.e., not fully aligned or not in alignment) with the by-pass port 170 of the neighboring inner baffle(s) 140. In the illustrated embodiment, the by-pass ports 170 of the inner baffles 140 are located and positioned in an alternating arrangement, for example, wherein the by-pass port 170 formed in one of the inner baffles 140 is at least partially misaligned (or not in alignment) with the by-pass ports 170 of the immediately adjacent / neighboring baffle(s) 140. More specifically, in the illustrated embodiment, the by-pass port 170 of the rear-most (or first) inner baffle 152a is formed in an upper portion of the inner baffle 152a above the aperture 156, the by-pass port 170 of the second rear-most (or second) inner baffle 152b is formed in a lower portion of the inner baffle 152b below the aperture 156 such that it is not in alignment with the by-pass port 170 of the first inner baffle 152a, the by-pass port 170 of the third rear-most (or third) inner baffle 152c is formed in an upper portion of the inner baffle 152c above the aperture 156 such that it is not in alignment with the by-pass port 170 of the second inner baffle 152b (but is in alignment with the by-pass port 170 of the first inner baffle 152a), the by-pass port 170 of the fourth rear-most (or fourth) inner baffle 152d is formed in a lower portion of the inner baffle 152d below the aperture 156 such that it is not in alignment with the by-pass ports 170 of the third inner baffle 152c and the first inner baffle 152a (but is in alignment with the by-pass port 170 of the second inner baffle 152b), and the by-pass port 170 of the fifth rear-most (or fifth) inner baffle 152e is formed in an upper portion of the inner baffle 152e above the aperture 156 such that it is not in alignment with the by-pass ports 170 of the second inner baffle 152b and fourth inner baffle 152d (but is in alignment with the by-pass ports 170 of the first inner baffle 152a and the third inner baffle 152c). Here, the by-pass ports 170 of the first, third, and fifth inner baffles 152a, 152c, and 152e arranged on the upper portion of the inner baffle 140 are referred to as upper (or first) by-pass ports 172a, while the by-pass ports 170 of the second and fourth inner baffles 152b and 152d arranged on the lower portion of the inner baffle 140 are referred to as lower (or second) by-pass ports 172b which are not in axial alignment with the upper (or first) by-pass ports 172a of the first, third, and fifth inner baffles 152a, 152c, and 152e. Thus, in the illustrated embodiment, the by-pass ports 170 have an alternating arrangement, wherein the by-pass ports 170 alternate between positions above and below the aperture 156. Furthermore, the inner baffles 152a-152d may have textures on surfaces thereof which can increase flow turbulence and internal surface area that comes into contact with gas flow to help decrease temperature.

[0074] The outer baffles 142 extend radially outward from the interior sidewall 136 towards and into the body 102, such that the outer baffles 142 extend between the interior sidewall 136 and the body 102. The outer baffles 142 divide the annular space that is defined between the outer surface 144 of the interior sidewall 136 and the inner surface 146 of the body 102 into a series of exterior baffle chambers 174. As shown, the exterior baffle chambers 174 are positioned radially outward from the interior baffle chambers 154, and the interior sidewall 136 separates the interior baffle chambers 154 and the exterior baffle chambers 174.

[0075] The outer baffles 142 are configured similar to the secondary baffles 52 detailed above. Thus, as shown, the outer baffles 142 each include one or more ports 176 (i.e., one or more ports 176 are formed in each of the outer baffles 142). The one or more ports 176 formed in the outer baffles 142 interconnect the neighboring outer baffle chambers 174, such that the series of outer baffle chambers 174 are in communication with each other via the ports 176. Also, the ports 176 in one of the outer baffles 142 may be mis-aligned with the ports 176 in the neighboring outer baffle(s) 142, such that exhaust gases follow / travel a tortuous path when flowing in-between the outer baffle chambers 174. Here, for example, the ports 176 in the second outer baffle 148b are not in alignment with the ports 176 in the distal most (or first) outer baffle 148a; the ports 176 in the third outer baffle 148c are not in alignment with the ports 176 in the second outer baffle 148b (but are in alignment with the ports 176 in the first outer baffle 148a); the ports 176 in the fourth outer baffle 148d are not in alignment with the ports 176 in the first and third outer baffles 148a and 148c (but are in alignment with the ports 176 in the second outer baffle 148b); the ports 176 in the fifth outer baffle 148e are not in alignment with the ports 176 in the fourth outer baffle 148d and the second outer baffle 148b (but are in alignment with the ports 176 in the first outer baffle 148a and the third outer baffle 148c); the ports 176 in the sixth outer baffle 148f are not in alignment with the ports 176 in the first, third, and fifth outer baffles 148a, 148c, and 148e (but are in alignment with the ports 176 in the second outer baffle 148b and the fourth outer baffle 148d); and the ports 176 in the seventh outer baffle 148g are not in alignment with the ports 176 in the second, fourth, and sixth outer baffles 148b, 148d, and 148f (but are in alignment with the ports 176 in the first outer baffle 148a, the third outer baffle 148c, and the fifth outer baffle 148e). Thus, in this embodiment, the ports 176 in the first outer baffle 148a, the third outer baffle 148c, the fifth outer baffle 148e, and the seventh outer baffle 148g are all in alignment with each other but not in alignment with the ports 176 of the second outer baffle 148b, the fourth outer baffle 148d, and the sixth outer baffle 148f. Similarly, the ports 176 of the second outer baffle 148b, the fourth outer baffle 148d, and the sixth outer baffle 148f are all in alignment with each other but not in alignment with the ports 176 the first outer baffle 148a, the third outer baffle 148c, the fifth outer baffle 148e, and the seventh outer baffle 148g.

[0076] In the illustrated embodiment, the ports 176 the first outer baffle 148a, the third outer baffle 148c, the fifth outer baffle 148e, and the seventh outer baffle 148g are positioned radially inward from (and relative to) the ports 176 of the second outer baffle 148b, the fourth outer baffle 148d, and the sixth outer baffle 148f; and conversely, the ports 176 of the second outer baffle 148b, the fourth outer baffle 148d, and the sixth outer baffle 148f are positioned radially outward of (and surround) the ports 176 the first outer baffle 148a, the third outer baffle 148c, the fifth outer baffle 148e, and the seventh outer baffle 148g. Thus, the ports 176 of the first, third, fifth, and seventh outer baffles 148a, 148c, 148e, and 148g may be referred to as the radially inward ports 178a, while the ports 176 of the second, fourth, and sixth outer baffles 148b, 148d, and 148f may be referred to as the radially outward ports 178b.

[0077] Here, the radially inward ports 178a (i.e., the ports 176 the first outer baffle 148a, the third outer baffle 148c, the fifth outer baffle 148e, and the seventh outer baffle 148g) are a series of discrete ports arranged / formed circumferentially around their respective outer baffle structure (and around the axis A′) at positions closer to the interior sidewall 136 as compared to the radially outward ports 178b (i.e., the ports 176 of the second outer baffle 148b, the fourth outer baffle 148d, and the sixth outer baffle 148f). In this manner, the series of discrete ports 178a of the first outer baffle 148a, the third outer baffle 148c, the fifth outer baffle 148e, and the seventh outer baffle 148g are positioned or spaced at a first radial distance R1 from the axis A′. Also, the radially outward ports 178b are a series of discrete ports arranged / formed circumferentially around their respective outer baffle structure (and around the axis A′) at positions closer to the body 102 as compared to the radially inward ports 178a. In this manner, the series of discrete ports 178b of the second outer baffle 148b, the fourth outer baffle 148d, and the sixth outer baffle 148f are positioned or spaced at a second radial distance R2 from the axis A′, wherein the second radial distance R2 is greater or larger than the first radial distance R1. Thus, as to any particular outer baffle 142, the ports 176 formed thereon have an alternating relationship with respect to the ports 176 on the neighboring outer baffle 142 as they will be closer to either the inner sidewall 136 or the body 102 as compared to the neighboring outer baffle 142.

[0078] In the illustrated embodiment, the radially inward ports 178a are spaced, at least a short distance, from the surface 144 of the inner sidewall 136, such that a portion of the outward baffle 142 is present between the port 176 and the inner sidewall 136; however, in other embodiment, one or more of the radially inward ports 178a are positioned such that it / they touch or border the surface 144 of the inner sidewall 136. Also in the illustrated embodiment, the radially outward ports 178b are positioned on their respective outward baffle 142 such that they each touch or border the inner surface 146 of the body 102; however, in other embodiments, one or more of the radially outward ports 178b are positioned such that it / they are spaced, at least a small distance, from the inner surface 146 of the body 102. Also in the illustrated embodiment, the radially inward ports 178a each have a chevron shape while the radially outward ports 178b each have a truncated chevron shape.

[0079] Thus, as exhaust gas flows from the initial blast chamber 132 into the distal most outer baffle chamber 174 (i.e., defined between the first and second outer baffles 148a and 148b) via the inward ports 178a of the first outer baffle 148a, such exhaust gas is unable to flow in a straight path into the next outer baffle chamber 174 (i.e., defined between the second and third outer baffles 148b and 148c), but instead must travel radially outward within such outer baffle chamber 174 to the radially outward ports 178b of the second outer baffle 148b so that it can enter that next outer baffle chamber. Then, once the exhaust gas is in that second outer baffle chamber 174 (i.e., defined between the second and third outer baffles 148b and 148c), the exhaust gas must flow radially inward towards the inner sidewall 136 and the radially inward ports 178a of the third outer baffle 148c so that the exhaust gas may flow into the next (third) outer baffle chamber 174 (i.e., defined between the third outer baffle 148c and the fourth outer baffle 148d), and so on. Eventually the exhaust gas will travel into the proximal most (or, here, the seventh) outer baffle chamber 174 (i.e., defined between the seventh outer baffle 148g and the forward wall 110), where such exhaust gas may flow out of (or exit) the suppressor 100 via the secondary outlets 118 that are in communication with such seventh outer baffle chamber 174. In this manner, the exhaust gas travels a tortuous path defined by the alternating nature of the radially inward and outward ports 178a and 178b, which is substantially longer than if all of the ports 176 were aligned along an axis. By forcing the exhaust gas to travel along such a tortuous path, the exhaust gas is slowed down and given a greater amount of time to cool, and also forces the exhaust gas into contact with a greater extent of the interior surface area of the suppressor 100. In embodiments, the outer baffle chambers 174 can include irregular internal surfaces that increase surface area (for heat transfer) and generate turbulence in the exhaust gas flow as it passes there-through.

[0080] FIG. 12A is a perspective view of the suppressor 100, while FIGS. 12B and 12C are cross-sectional front and rear perspective views of the suppressor 100 taken along section line 12-12 in FIG. 12A. FIGS. 12B and 12C further depict the positioning of the ports 170 (i.e., the upper ports 172a and the lower ports 172b) of the inner baffles 140, the ports 176 (i.e., the radially inward ports 178a and the radially outward ports 178b) of the outer baffles 142. FIGS. 12B and 12C further depict the configuration of the apertures 156 formed in the inner baffles 140 and, in particular, the configuration of the central 160 and the radial notch 162 of the apertures 156. As shown, the upper ports 172a and the lower ports 172b are positioned on opposite sides of the projectile pathway 158 (or on opposite sides of the axis A′). In this manner, the upper ports 172a may be considered to be positioned above the projectile pathway 158 (or the axis A′), while the lower ports 172b may be considered to be positioned below the projectile pathway 158 (or the axis A′).

[0081] Accordingly, as detailed herein the suppressor 100 includes two discrete flow paths that exhaust gas entering the suppressor 100 may travel upon discharge of the firearm. As described herein, the two discrete flow paths are defined by the baffle system 134 for receiving and directing exhaust gas after such exhaust gas has entered the initial blast chamber 132 upon firearm discharge, wherein such exhaust gas may travel through either the first flow path or the second flow path before exiting the suppressor 100. As best shown in FIG. 13, which is a cross-sectional view similar to FIG. 11, the suppressor 100 includes a first or primary flow path 180 and a second or secondary flow path 182, wherein the first flow path 180 and the second flow path 182 are the two discrete flow paths mentioned above. As shown, both the first flow path 180 and the second flow path 182 begin in the initial blast chamber 132 where, upon discharge of the firearm, resultant exhaust gases 184 enter. After discharging the firearm, the projectile / bullet will travel through the projectile pathway 158 along a projectile path 186. The projectile / bullet is propelled by exhaust gases 184, which accompanies firearm discharge and propels the projectile / bullet as will be appreciated and, upon discharge, that exhaust gas 184 enters the initial blast chamber 132. From there, the exhaust gas 184 may flow along either the secondary flow path 182, the primary flow path 180, or the projectile path 186. The secondary flow path 182 is constrained in the outer baffle chambers 174 formed in the annular space that is defined between the outer surface 144 of the interior sidewall 136 and the inner surface 146 of the body 102, and the exhaust gas 184 passes through the ports 176 of the outer baffles 142 (i.e., the radially inward and outward ports 178a, 178b) to travel distally through the outer baffle chambers 174 to the secondary outlets 118, which the exhaust gas 184 passes through to exit the body 102. The primary flow path 180, which includes exhaust gas 184 flowing through the projectile pathway 158 along the projectile path 186, is constrained within the interior baffle chambers 154, such that the exhaust gas 184 passes through the ports 170 of the inner baffles 140 (i.e., the upper and lower ports 172a, 172b) to travel distally through the interior baffle chambers 154 to the primary outlet 116, which the exhaust gas 184 passes through to exit the body 102.

[0082] Exhaust gas 184 entering the initial blast chamber 132 of the suppressor 100 may then enter either the primary flow path 180 or the secondary flow path 182, with some or a portion of the exhaust gas 184 entering the primary flow path 180 and a remaining portion of the exhaust gas 186 entering the secondary flow path 182. As to the primary flow path 180, such exhaust gas 186 will enter the and flow through the various ports 170 of the inner baffles 140. In particular, in the illustrated embodiment, the primary flow path 180 is defined by path that the exhaust gas 186 travels or flows as it flows through the upper port 172a of the first inner baffle 152a, then passes through the inner baffle chamber 154 between the first inner baffle 152a and the second inner baffle 152b, then flows through the lower port 172b of the second inner baffle 152b, then passes through the inner baffle chamber 154 between the second inner baffle 152b and the third inner baffle 152c, then flows through the upper port 172a of the third inner baffle 152c, then passes through the inner baffle chamber 154 between the third inner baffle 152c and the fourth inner baffle 152d, then flows through the lower port 172b of the fourth inner baffle 152d, then passes through the inner baffle chamber 154 between the fourth inner baffle 152d and the fifth inner baffle 152e, then flows through the upper port 172a in the fifth inner baffle 152e, then flows through the inner baffle chamber 174 defined between the fifth inner baffle 152e and the forward wall 110, and then flows through the primary outlet 116 in the forward wall 110 to exit the suppressor 100. Due to the alternating nature of the ports 170 in the inner baffles 140, the primary flow path 180 defines a tortuous path for the exhaust gas 186 to travel rather than being a linear flow path.

[0083] The primary flow path 180 can also include the central portion 160 and the radial notch 162 of the projectile apertures 156, as exhaust gas 186 may also flow through there after discharging the firearm. The radial notches 162 may be referred to as “clippings” or “baffle clippings” which help to force the jet of gas traveling through the projectile pathway 158 to be diverted off the axis A′ of the suppressor 100, causing more exhaust gas to be trapped in each baffle chamber 154 rather than being forced straight through the bore (i.e., just through smaller central portions 160 of the apertures 156).

[0084] The remaining portion of the exhaust gas 186 in the blast chamber that has not entered the primary flow path 180 will embark on the secondary flow path 182. As to the secondary flow path 182, such remaining exhaust gas 186 will enter the and flow through the various ports 176 of the outer baffles 142. In particular, in the illustrated embodiment, the secondary flow path 182 is defined by path that the exhaust gas 186 travels or flows as it flows through the radially inward ports 178a in the first outer baffle 148a, then through the outer baffle chamber 174 between the first outer baffle 148a and the second outer baffle 148b, then through the radially outward ports 178b in the second outer baffle 148b, then passes through the outer baffle chamber 174 between the second outer baffle 148b and the third outer baffle 148c, then through the radially inward ports 178c in the third outer baffle 148c, then through the outer baffle chamber 174 between the third outer baffle 148c and the fourth outer baffle 148d, then through the radially outward ports 178b in the fourth outer baffle 148d, then through the outer baffle chamber 174 between the fourth outer baffle 148d and the fifth outer baffle 148e, then through the radially inward ports 178b in the fifth outer baffle 148e, then through the outer baffle chamber 174 between the fifth outer baffle 148e and the sixth outer baffle 148f, then through the radially outward ports 178b in the sixth outer baffle 148f, then passes through the outer baffle chamber 174 between the sixth outer baffle 148f and the seventh outer baffle 148g, then through the radially inward ports 178a in the seventh outer baffle 148f, then through the baffle chamber 174 defined between the seventh outer baffle 148f and the forward wall 110, and then through the secondary outlets 118 in the forward wall 110 to thereby exit the suppressor 100. Due to the alternating nature of the ports 176 in the outer baffles 142, with ports 176 of one outer baffle 142 being positioned at a different (larger or smaller) radial distance from the axis A relative to the ports 176 of another (e.g., neighboring) outer baffle 142, the secondary flow path 182 defines a tortuous path for the exhaust gas 186 to travel rather than being a linear flow path.

[0085] Because the exhaust gas flowing along the secondary flow path 184 is traveling through the ports 176 (i.e., the inward and outwardly radial ports 178a, 178b) which are located radially outward from the ports 170 of the primary flow path 180, relative to the axis A′, the secondary flow path 182 is oriented radially outward from the primary flow path 180.

[0086] Also, with this construction of the primary flow path 180 and the secondary flow path 182, mixing of the separate exhaust gas streams is inhibited. Here, for example, the primary flow path 180 and the secondary flow path 182 are each configured such that exhaust gas flowing through the primary flow path 180 is unable to mix with exhaust gas flowing through the secondary flow path 182 and vice versa.

[0087] FIG. 14 depicts yet another suppressor 1000, according to one or more other embodiments. The suppressor 1000 is similar to the suppressor 100 described above, as the suppressor 1000 is also a two layer design having the primary flow path 180 and the secondary flow path 182. However, the primary flow path 180 and the secondary flow path 182 of the suppressor 100 are completely partitioned and sealed relative to each other, such that there is no mixing of exhaust gas flowing through the primary flow path 180 and the secondary flow path 182 of the suppressor 100 (i.e., exhaust gas flowing through the primary flow path 180 of the suppressor 100 does not mix with exhaust gas flowing through the secondary flow path 182 of the suppressor 100, and vice versa).

[0088] The suppressor 1000 differs from the suppressor 100 in that the suppressor 1000 is configured to permit mixing of exhaust gas flowing through the primary flow path 180 and the secondary flow path 182. In the illustrated embodiment, the suppressor 1000 includes a plurality of mixing ports 1002 that permit mixing between the primary flow path 180 and the secondary flow path 182. Here, the mixing ports 1002 are formed in the interior sidewall 136, to provide fluid communication between at least some of the interior baffle chamber 154 and outer baffle chambers 174, such that exhaust gas in the interior baffle chamber 154 may flow into the outer baffle chambers 174 and vice versa. In the illustrated embodiment, the mixing ports 1002 are provided at locations on the interior sidewalls 136 associated with each of the corresponding pairs of interior and exterior baffle chambers 154, 174; however, in other embodiment, a corresponding pair of interior and exterior baffle chambers 154, 174 may not include any such mixing ports 1002 so that exhaust flowing through that particular corresponding pair of interior and exterior baffle chambers 154, 174 is not able to comingle, but may later or prior be mixed when flowing through other corresponding pairs of interior and exterior baffle chambers 154, 174 distally or proximally located therefrom.

[0089] Other aspects, features, benefits, and advantages of the present invention will be apparent to a person of skill in the art from the drawing figures.

[0090] While one or more embodiments of the present invention have been described in detail, it should be apparent that modifications and variations thereto are possible, all of which fall within the true spirit and scope of the invention. Therefore, the foregoing is intended only to be illustrative of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not intended to limit the invention to the exact construction and operation shown and described. Accordingly, all suitable modifications and equivalents may be included and considered to fall within the scope of the invention, defined by the following claim or claims.

Examples

Embodiment Construction

[0034]With reference to the drawing figures, this section describes particular embodiments and their detailed construction and operation. Throughout the specification, reference to “one embodiment,”“an embodiment,” or “some embodiments” means that a particular described feature, structure, or characteristic may be included in at least one embodiment. Thus, appearances of the phrases “in one embodiment,”“in an embodiment,” or “in some embodiments” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the described features, structures, and characteristics may be combined in any suitable manner in one or more embodiments. In view of the disclosure herein, those skilled in the art will recognize that the various embodiments can be practiced without one or more of the specific details or with other methods, components, materials, or the like. In some instances, well-known structures, materials, or operations are not shown ...

Claims

1. A suppressor for a firearm, comprising:a tubular body extending along an axis between a forward end and a rear end, the tubular body having a forward wall at the forward end and defining an interior volume; anda baffle system arranged in the interior volume, wherein the baffle system comprises:an interior sidewall extending rearward from the forward wall of the body;a plurality of inner baffles disposed within the interior sidewall, the plurality having inner baffles defining a projectile passageway for receiving a projectile fired from the firearm and a primary flow path for directing a portion of exhaust gas resulting from discharge of the firearm; anda plurality of outer baffles extending between the interior sidewall and body, wherein the plurality of outer baffles define a secondary flow path for directing any remaining exhaust gas resulting from discharge of the firearm.

2. The suppressor of claim 1, wherein the interior volume includes an initial blast chamber, and the baffle system is positioned forward of the initial blast chamber.

3. The suppressor of claim 1, wherein the primary flow path and the secondary flow path are each configured such that exhaust gas flowing through the primary flow path is unable to mix with exhaust gas flowing through the secondary flow path.

4. The suppressor of claim 1, wherein each of the plurality of inner baffles includes a port.

5. The suppressor of claim 4, wherein the plurality of inner baffles includes a first interior baffle and a second interior baffle positioned next to the first interior baffle, wherein the port of the first interior baffle is an upper port positioned above the projectile passageway, and wherein the port of the second interior baffle is a lower port positioned below the projectile passageway.

6. The suppressor of claim 4, wherein the port on one of the inner baffles is not in axial alignment with the port on another one of the inner baffles.

7. The suppressor of claim 1, wherein each of the plurality of outer baffles includes a series of discrete ports.

8. The suppressor of claim 7, wherein the plurality of outer baffles includes a first outer baffle and a second outer baffle positioned next to the first outer baffle, wherein the series of discrete ports of the first outer baffle are positioned circumferentially around the first outer baffle and the series of discrete ports of the second outer baffle are positioned circumferentially around the second outer baffle.

9. The suppressor of claim 8, wherein the series of discrete ports of the first outer baffle are positioned at a first radial distance from the axis and the series of discrete ports of the second outer baffle are positioned at a second radial distance from the axis that is larger than the first radial distance.

10. The suppressor of claim 9, wherein the series of discrete ports of the second outer baffle border an inner surface of the body.

11. The suppressor of claim 7, wherein the series of discrete ports on one of the outer baffles are not in alignment with the series of discrete ports on another one of the outer baffles.

12. The suppressor of claim 1, wherein each of the inner baffles includes a projectile aperture, wherein the projectiles apertures are aligned with each other and together define the projectile passageway.

13. The suppressor of claim 12, wherein each of the projectile apertures includes a central portion and a radial notch extending radial outward from the central portion, wherein the central portion is aligned with the central portion of other projectile apertures.

14. The suppressor of claim 1, wherein the forward wall comprises a primary outlet in communication with the primary flow path and a plurality of secondary outlets in communication with the secondary flow path.

15. The suppressor of claim 14, further comprising a plurality of vanes arranged on an exterior of the forward wall and surrounding the primary outlet.

16. A suppressor for a firearm, comprising:a tubular body extending along an axis between a forward end and a rear end, the tubular body having a forward wall at the forward end and defining an interior volume, wherein the interior volume includes a blast chamber portion and a baffle portion located forward of the blast chamber portion, the blast chamber portion defining a blast chamber; anda baffle system arranged in the baffle portion of the interior volume, the baffle system having an interior sidewall disposed within the body and extending rearward from the forward wall of the body, a plurality of outer baffles extending between the interior sidewall and body, and a plurality of inner baffles disposed within the interior sidewall, the plurality having inner baffles defining a projectile passageway for receiving a projectile fired from the firearm and a primary flow path for receiving a portion of exhaust gas resulting from discharge of the firearm, wherein the plurality of outer baffles define a secondary flow path for receiving any remaining exhaust gas resulting from discharge of the firearm.

17. The suppressor of claim 1, wherein the forward wall comprises a primary outlet in communication with the primary flow path and a plurality of secondary outlets in communication with the secondary flow path.

18. The suppressor of claim 1, wherein each of the plurality of inner baffles includes a port and the plurality of inner baffles includes a first interior baffle and a second interior baffle positioned next to the first interior baffle, wherein the port of the first interior baffle is an upper port positioned above the projectile passageway, and wherein the port of the second interior baffle is a lower port positioned below the projectile passageway.

19. The suppressor of claim 1, wherein each of the plurality of outer baffles includes a series of discrete ports and the plurality of outer baffles includes a first outer baffle and a second outer baffle positioned next to the first outer baffle, wherein the series of discrete ports of the first outer baffle are positioned circumferentially around the first outer baffle and the series of discrete ports of the second outer baffle are positioned circumferentially around the second outer baffle, andwherein the series of discrete ports of the first outer baffle are positioned at a first radial distance from the axis and the series of discrete ports of the second outer baffle are positioned at a second radial distance from the axis that is larger than the first radial distance.

20. The suppressor of claim 1, wherein each of the inner baffles includes a projectile aperture having a central portion and a radial notch extending radial outward from the central portion, wherein the central portion is aligned with the central portion of other projectile apertures to define the projectile passageway.

Images