U.S. patent application number 16/706890 was filed with the patent office on 2020-04-16 for firearm sound suppressor.
The applicant listed for this patent is Benjamin R. Ellison. Invention is credited to Benjamin R. Ellison, Tyler Jepson, Matthew Martin.
Application Number | 20200116450 16/706890 |
Document ID | / |
Family ID | 66815841 |
Filed Date | 2020-04-16 |
United States Patent
Application |
20200116450 |
Kind Code |
A1 |
Ellison; Benjamin R. ; et
al. |
April 16, 2020 |
FIREARM SOUND SUPPRESSOR
Abstract
A firearm noise suppressor attachable to the muzzle of a barrel
having a longitudinal bore axis. It includes a housing with an
outer wall, a forward end wall, and a rearward end wall. The
rearward end wall attaches to a firearm barrel and the forward end
wall includes an outlet opening aligned with the longitudinal bore
axis. A blast chamber is defined at least in part by the rearward
end wall, the outer wall, and a blast baffle. At least a second
baffle is situated forward of the blast baffle and supported at a
periphery by the outer wall. A plurality of circumferentially
spaced apart helical blast vanes in the blast chamber impart a
rotational flow to propellant gas.
Inventors: |
Ellison; Benjamin R.;
(Maineville, OH) ; Jepson; Tyler; (Cincinnati,
OH) ; Martin; Matthew; (Cincinnati, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Benjamin R. Ellison |
Mason |
OH |
US |
|
|
Family ID: |
66815841 |
Appl. No.: |
16/706890 |
Filed: |
December 9, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
16225104 |
Dec 19, 2018 |
10502513 |
|
|
16706890 |
|
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|
|
62608101 |
Dec 20, 2017 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F41A 21/30 20130101;
F41A 21/325 20130101 |
International
Class: |
F41A 21/30 20060101
F41A021/30 |
Claims
1. A firearm noise suppressor attachable to the muzzle of a barrel,
the barrel having a longitudinal bore axis, comprising: a housing
having an outer wall, a forward end wall, and a rearward end wall,
the rearward end wall including means for attachment to a firearm
barrel, and the forward end wall including an outlet opening
substantially aligned with the longitudinal bore axis to allow
passage of a projectile; a blast chamber defined at least in part
by the rearward end wall, the outer wall, and a blast baffle, the
blast baffle including an opening substantially aligned with the
longitudinal bore axis to allow passage of the projectile; at least
a second baffle situated forward of the blast baffle, supported at
a periphery by the outer wall, and defining at least a secondary
chamber between it and the blast baffle; and a plurality of
circumferentially spaced apart helical blast vanes in the blast
chamber that impart a rotational flow to propellant gas.
2. The suppressor of claim 1, wherein the rearward end wall
includes a substantially conical portion.
3. The suppressor of claim 1, wherein the forward end wall is
substantially flat.
4. The suppressor of claim 1, wherein the attachment means includes
threads that engage a threaded muzzle end of the barrel.
5. The suppressor of claim 1, wherein the second baffle is
substantially conical.
6. The suppressor of claim 5, wherein the blast baffle is supported
on the second baffle.
7. The suppressor of claim 5, wherein the annular forward space of
the blast chamber is situated between at least a portion of the
blast baffle and the outer wall.
8. The suppressor of claim 1, wherein the vanes are supported on
the blast baffle.
9. The suppressor of claim 8, wherein the vanes direct gas into the
annular outer space of the blast chamber.
10. The suppressor of claim 8, wherein the blast baffle includes a
substantially conical portion on which the vanes are at least
partially supported.
11. The suppressor of claim 10, wherein the vanes have leading
edges disposed toward the rearward wall
12. The suppressor of claim 1, wherein a tertiary chamber is
defined between the second baffle and the forward end wall.
13. The suppressor of claim 12, further comprising at least a third
baffle, the third baffle supported by the forward end wall and
including an opening substantially aligned with the longitudinal
bore axis to allow passage of the projectile, the tertiary chamber
being between the second baffle and third baffle, and a fourth
chamber between the third baffle and the forward end wall.
14. The suppressor of claim 13, wherein the volume of the blast
chamber is greater than that of the secondary chamber, the volume
of the secondary chamber is greater than that of the tertiary
chamber, and the volume of the tertiary chamber is greater than
that of the fourth chamber.
Description
RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application
Ser. No. 16/225,104, filed Dec. 19, 2018, and claims priority to
U.S. Provisional Patent Application No. 62/608,101, filed Dec. 20,
2017, and incorporates the same herein by reference.
TECHNICAL FIELD
[0002] The present invention relates to various embodiments of an
apparatus for suppressing the muzzle blast and attendant noise of a
discharging firearm and to methods of manufacturing the same. In
particular, the methods relate to uses of additive manufacturing,
also known as 3D printing.
BACKGROUND
[0003] Firearm sound suppressing devices, often referred to simply
as "suppressors" or "silencers," that may be integral with the
barrel or attached to the muzzle end of a barrel are well known. In
general, such devices reduce the sound produced by high pressure
gasses rapidly escaping the muzzle when fired by trapping the burst
of gas pressure in an enclosed housing to slow the release to the
atmosphere (to attenuate the pressure wave), consuming energy of
the muzzle blast by creating turbulence and redirecting the flow of
gas pressure, and/or absorbing heat energy. The most common types
of sound suppressing devices include a housing whose interior
volume is divided into multiple chambers by baffles, having a
longitudinal passageway axially aligned with the bore of the barrel
to allow a fired projectile to pass unencumbered.
[0004] The design of an effective suppressor must address its
exposure to both high internal pressure and heat. Traditionally,
suppressors have been made by providing a metallic tubular or
cylindrical housing with attached endcaps and milling or turning
metallic baffles to be held inside the tubular housing. The advent
of additive manufacturing (also known as 3D printing) has expanded
the range of designs that are possible to produce. At the same
time, new issues must be addressed in this alternate form of
manufacturing.
SUMMARY OF THE INVENTION
[0005] The present invention provides a firearm noise suppressor
that can be made by additive manufacturing processes. It includes
integral concentric conical baffles and can include helical vanes
in the blast chamber.
[0006] More specifically, it can include a housing having an outer
wall, a forward end wall, and a rearward end wall. The rearward end
wall will include means for attachment to a firearm barrel, and the
forward end wall will include an outlet opening substantially
aligned with the longitudinal bore axis to allow passage of a
projectile. A blast chamber is defined at least in part by the
rearward end wall, the outer wall, and a blast baffle. The blast
baffle includes an opening substantially aligned with the
longitudinal bore axis to allow passage of the projectile. At least
a second baffle is situated forward of the blast baffle, is
supported at a periphery by the outer wall, and defines at least a
secondary chamber between it and the blast baffle. A plurality of
circumferentially spaced apart helical blast vanes in the blast
chamber impart a rotational flow to the propellant gas.
[0007] The method of manufacturing can include printing by additive
manufacturing a precursor part having a housing with a center axis,
side walls, a forward end wall, a rearward end wall, and defining
an internal volume. The housing has internal baffles separating the
internal volume into chambers, and has temporary internal support
structure along at least a portion of the center axis. A central
bore passageway along the center axis is bored to remove the
temporary internal support structure and to form openings of
predetermined size in the baffles and forward wall and to form an
interim opening in the rearward wall. Internal manufacturing debris
is removed from the chambers through at least one of the interim
opening and the forward wall opening. A larger opening is bored in
the rearward wall to form an attachment opening, and attachment
means is provided in the attachment opening.
[0008] 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
[0009] Like reference numerals are used to indicate like parts
throughout the various drawing figures, wherein:
[0010] FIG. 1 is an isometric external view of a firearm sound
suppressor according to a first embodiment of the present
invention;
[0011] FIG. 2 is an isometric longitudinal sectional view thereof
taken substantially along line 2-2 of FIG. 1;
[0012] FIG. 3 is a cross sectional view thereof taken substantially
along line 3-3 of FIG. 1;
[0013] FIG. 4 is a different isometric view thereof with rear and
side parts of the exterior housing cut away; and
[0014] FIGS. 5-9 are side sectional views thereof showing a series
of manufacturing stages.
DETAILED DESCRIPTION
[0015] 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.
[0016] As used herein, "axial" and "longitudinal" refer to the
direction of the length of a firearm barrel and the path of a
projectile fired therefrom. "Forward" refers to the direction a
projectile is fired and distal from the shooter; "rear" or "aft"
refers to the direction toward and proximal to the shooter.
"Lateral" refers to a direction offset to a side from the
longitudinal axis and "transverse" refers to a direction
substantially perpendicular to or crossing the longitudinal
direction. "Side wall" and "side walls" are used interchangeably
herein to include a cylindrical and/or polygonal shape.
[0017] Referring first to FIG. 1, therein is shown a firearm noise
suppressor 10 according to a first embodiment of the present
invention. The suppressor 10 includes an outer wall that 12 may
provide a substantially cylindrical housing having a circular
(shown) or other polygonal cross-sectional shape, a rear end wall
14, and a forward end wall 16. The rear and forward end walls 14,
16 may be substantially flat, rounded, tapered, and/or
frustoconical in shape. The rear end wall 14 may include means for
attachment to the muzzle of a firearm barrel (not shown). The
attachment may be any of several well-known means, such as a direct
threaded engagement (shown) or a quick disconnect mount (not
shown). The illustrated embodiment includes a neck portion 18
having a threaded bore surface 20 to engage corresponding threads
on the muzzle end of the barrel and may include exterior wrench
flats 22 or other means for engaging a tool to apply torque for
attaching or removing the suppressor 10 from a firearm barrel. The
forward end wall 16 includes an exit opening 24 that is coaxially
aligned with the bore of the firearm barrel, when attached, and is
sized to allow a projectile fired from the barrel to pass
unimpeded.
[0018] Referring now in particular to FIG. 2, the outer wall 12 and
end walls 14, 16 define an inner volume 26 that may be
substantially completely enclosed, except for the exit opening 24
in the forward end wall 16, when the suppressor 10 is attached to a
firearm barrel. The inner volume 26 may be divided into separate
chambers by a series of integral coaxial, substantially conical
baffles 28, 30, 32, 34, 36, 37. A first or blast chamber 38 is
defined within the inner volume by the rear end wall 14, a portion
of the outer wall 12, and a first baffle 28. Because this first
baffle 28 is directly impinged upon by the blast of propellant gas
exiting the muzzle, it is sometimes referred to as a "blast
baffle." A second chamber 40 is defined between the first and
second baffles 28, 30, a third chamber 42 is defined between the
second and third baffles 30, 32, a fourth chamber 44 is defined
between the third and fourth baffles 32, 34, a fifth chamber 46 is
defined between the fourth and fifth baffles 34, 36, a sixth
chamber 48 is defined between the fifth baffle 36 and the sixth
baffle 37, and a seventh chamber 47 is defined between the sixth
baffle 37 and the forward end wall 16. The number of baffles and
chambers may vary, as desired, depending upon the caliber and
velocity of the projectile to be fired therethrough, which largely
determines the pressure and volume of propellant gas to be
contained and/or controlled by the suppressor 10. In the
illustrated embodiment, the volume of each of the chambers 38, 40,
42, 44, 46, 47, 48 is successively reduced in the order through
which the projectile and propellant gas will pass before passing
through the exit opening 24. When the outer wall 12 has a diameter
that is large relative to the projectile diameter (as in the
illustrated embodiment), the axial spacing of the baffles 28, 30,
32, 34, 36, 37 can be relatively closer together while maintaining
the desired volume of the chambers 40, 42, 44, 46, 47, 48.
[0019] In the illustrated embodiment, for example, the first (or
blast) baffle 28 connects to and is supported by the second baffle
30, rather than by the outer wall 12. This construction defines a
forward annular extension portion 49 of the blast chamber 38
between the first baffle 28 and outer wall 12 that may be partially
defined at its forward end by an outer portion of the second baffle
30. A like structure would result from considering the first baffle
28 to be supported by the outer wall 28 and the second baffle 30 to
be supported on the interior or forward side of the first baffle
28. Also in the illustrated embodiment, the second and third
baffles 30, 32 extend to and are supported by the outer wall 12,
the fourth baffle is supported at the intersection of the outer
wall 28 and forward end wall 16, while the fifth and sixth baffles
36, 37 are supported by the forward end wall 16.
[0020] Each of the baffles 28, 30, 32, 34, 36, 37 includes a
passageway 50, 52, 54, 56, 58, 59 that is axially aligned with the
bore of the barrel and exit opening 24 to allow unimpeded passage
of a projectile (labeled as axis a in FIG. 2). The diameter of each
baffle passageways 50, 52, 54, 56, 58, 59 may be selected to allow
passage of a projectile of the largest caliber expected to be used
with the suppressor 10. These can be enlarged to ensure that there
is no contact with the path of the projectile, but enlargement can
affect sound-suppressing performance of the device 10. If desired,
the shape of the baffle passageways 50, 52, 54, 56, 58, 59 may be
asymmetrical or irregular to disrupt or otherwise affect the flow
of expanding propellant gas from one chamber to the next.
[0021] As previously described, the highest pressure and velocity
of rapidly expanding propellant gas exiting the muzzle will enter
the blast chamber 38 and be directed toward the first baffle 28.
Likewise, the greatest amount of sound-reduction performance may be
achieved in the blast chamber 38. The longer the propellant gas is
retained in the blast chamber 38, and the greater the amount of
kinetic and heat energy removed in the blast chamber 38, the
greater is the sound-reducing performance of the subsequent
chambers 40, 42, 44, 46, 47, 48 and of the suppressor 10 overall.
The present invention maximizes this performance by maximizing the
heat-removing surface area and energy consuming turbulence of the
gas in the blast chamber 38.
[0022] Referring now also to FIG. 3, the first or blast baffle 28
may include a plurality of blast vanes 60 that extend radially and
helically relative to the longitudinal axis a and the projectile
passageway 50 in the blast chamber 38. Each blast vane 60 includes
an inner edge 62, at which it can be attached to or extend from the
first baffle 28, a leading edge 64, which first confronts the
stream of high pressure and velocity propellant gas exiting the
muzzle, and a trailing edge 66, defining a terminus of each vane
60. If desired (as illustrated), the vanes 60 may increase in
height relative to the conical angle of the blast baffle 28 so that
the leading edges 64 are substantially along a plane perpendicular
to the axis a. Helical channels 68 having an increasing radius are
defined between each of the blast vanes 60. As can be seen best in
FIG. 3, this arrangement of blast vanes 60 imparts a rotational
flow to the stream of propellant gas, while increasing the surface
area to be impacted by the stream to increase turbulence and absorb
heat energy. The direction can be chosen to correspond to or
counter the direction of spin given the projectile by the barrel
rifling. The thickness of each vane 60 will be selected as
necessary to withstand the dynamic force and abrading effect of the
high-pressure stream of hot propellant gas. The helical flow
imparted to the stream of propellant gas expanding into the blast
chamber 38 further impedes and delays its eventual escape from the
blast chamber 38, all of which must escape through the passageway
50 of the first baffle 28 and into subsequent chambers 40, 42, 44,
46, 47, 48, which further delaying and allow significant pressure
reduction before passing through the exit opening 24.
[0023] Referring now to FIGS. 5-9, the present invention includes
methods of manufacturing a suppressor 10, such as the one described
above. FIG. 5 shows a cross-sectional view of a precursor part 70
to the suppressor 10 in a condition as it may initially appear when
manufactured by 3D printing. The suppressor 10 is "printed"
beginning with the forward end wall 16 and proceeding to form the
baffles 30, 32, 34, 36, 37 and outer wall 12. The blast baffle 28
and vanes 60 are formed as the outer wall is continued. Finally,
the rear end wall 14 and neck portion are formed. The precursor
part 70 may include internal support structure 72 required during
the additive manufacturing processes. If desired, the forward end
wall 16 can include additional indexing material 71 that is cut or
milled away to provide a finished end surface.
[0024] The support structure 72 can be formed with ports or
passageways 73a, 73b, 73c. Typically, powder material or other
debris encased in the body of the precursor part 70, present in and
a result of many additive manufacturing processes, can be removed
from the conical chambers 40, 42, 44, 46, 47, 48 through the
passageways 52, 54, 56, 58, 59 and opening 24 in the forward wall
and/or the axial passageway 73a in the support structure 72 by
gravity simply by inverting and/or shaking/tapping the part 70.
Powder material or other debris in the blast chamber 26 can be more
difficult to remove by gravity because it will collect in the
forward annular extension portion 49 or (when inverted) in the area
75 defined between the conical rear wall 14 and neck portion 18. To
remove powder material or debris from the blast chamber 26, an
angled nozzle (not shown) can be inserted into the larger
passageway 73b and used to introduce a stream of high velocity air
to create a vortex that will lift (fluidize) the material and force
it to flow out through the other passageway 73c.
[0025] As shown in FIG. 6, a portion of the internal support
structure 72 may be removed by creating an axial bore 74, such as
by drilling, along the center axis a from either end. This drilling
step can define the final diameter of the blast baffle passageway
50, and it may also be used to size the other baffle passageways
52, 54, 56, 58, 59 and the exit opening 24.
[0026] Referring now to FIG. 7, a rear end wall opening 76 may be
formed to a final desired diameter, ready for threading for
attachment to the muzzle of a firearm barrel or for insertion of a
separate threaded bushing (not shown) for the same purpose.
Referring to FIG. 8, additional internal support structure may be
removed to define a final axial length of the rear end wall opening
76 and neck portion 18. This maximizes the volume of the blast
chamber 38, while leaving adequate structural support and axial
length in the neck portion 18 of the rear end wall 14. Referring
finally to FIG. 9, the rear end wall opening 76 may be finished by
cutting the previously described threaded surface 20.
Alternatively, the rear end wall opening 76 may be fitted with a
quick-disconnect mechanism, threaded bushing, or other means for
attachment to a firearm barrel. Other processing steps may be
required to treat the material or portions thereof from which the
suppressor 10 is formed and/or application of one or more surface
coatings in order to provide the desired strength and surface
qualities for a functioning suppressor 10.
[0027] 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.
* * * * *