Firearm Sound Suppressor

This U.S. patent application is a continuation of, and claims priority under 35 U.S.C. § 120 from, U.S. patent application Ser. No. 18/667,230, filed on May 17, 2024, which is a continuation of, and claims priority under 35 U.S.C. § 120 from, U.S. patent application Ser. No. 18/524,183, filed on Nov. 30, 2023, which is a continuation of, and claims priority under 35 U.S.C. § 120 from, U.S. patent application Ser. No. 17/217,771, filed on Mar. 30, 2021, which is a continuation of, and claims priority under 35 U.S.C. § 120 from, U.S. patent application Ser. No. 16/887,137, filed on May 29, 2020, which is a continuation of, and claims priority under 35 U.S.C. § 120 from, U.S. patent application Ser. No. 16/266,843, filed on Feb. 4, 2019, which claims the benefit under 35 U.S.C. § 119(e) to U.S. Provisional Application No. 62/626,871, filed on Feb. 6, 2018. The disclosures of these prior applications are considered part of the disclosure of this application and are hereby incorporated by reference in their entireties.

The present disclosure relates generally to a sound suppressor for a firearm.

This section provides background information related to the present disclosure and is not necessarily prior art.

Sound is generated by numerous sources when a firearm is discharged or otherwise fired. For example, high-temperature and high-pressure propellant gases escaping and expanding from the muzzle of the firearm can generate a shockwave that produces a loud muzzle blast. Sound suppressors are often used with firearms to slow or cool down the escaping propellant gas, thereby reducing the amount of noise (e.g., sound intensity or volume) generated when the firearm is discharged. Such suppressors often employ baffles, spacers, or packing material to affect the slowing or cooling down of the escaping propellant gas.

While known firearm sound suppressors have proven acceptable for their intended purposes, a continuous need for improvement in the relevant art remains.

This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

One aspect of the disclosure provides a sound suppressor for a firearm. The sound suppressor may include a housing, an outer shell, an inner shell, and an intermediate member. The housing may extend along, and be disposed about, a central axis. The outer shell may be concentrically disposed within the housing. The inner shell may be concentrically disposed within the outer shell and define a plurality of first apertures. The intermediate member may be disposed between the inner shell and the outer shell and formed at least in part from an acoustic metamaterial.

Implementations of the disclosure may include one or more of the following optional features. In some implementations, each of the first apertures defines a maximum dimension extending across the first aperture. The maximum dimension may be less than one millimeter. In some implementations, the maximum dimension is less than a half millimeter. Each of the first apertures may extend through a thickness of the inner shell. The thickness may be greater than two hundred percent of the maximum dimension.

In some implementations, at least one of the inner shell or the outer shell is formed from one of aluminum or an aluminum alloy.

In some implementations, the sound suppressor includes a sleeve disposed within the inner shell and including a plurality of undulations defining a plurality of second apertures. The sleeve may define a central passage in fluid communication with the plurality of first apertures and the plurality of second apertures. Each of the second apertures may define a second maximum dimension extending across the second aperture. The second maximum dimension may be less than one millimeter. In some implementations, the second maximum dimension is less than a half millimeter. In some implementations, each of the second apertures extends through a thickness of the sleeve. The thickness may be greater than two hundred percent of the second maximum dimension. The sleeve may be formed from one of aluminum or an aluminum alloy. In some implementations, each of the plurality of undulations defines a U-shape or a V-shape.

Another aspect of the disclosure provides a sound suppressor for a firearm. The sound suppressor may include a housing and a door. The housing may extend from a proximal end to a distal end along a central passage. The proximal end may be configured to receive the firearm. The distal end may define an exit opening. The door may be pivotally supported by the housing for rotation between an open position and a closed position. The door may at least partially block the exit opening in the closed position and be configured to rotate from the open position to the closed position upon passage of a projectile through the exit opening.

Implementations of this aspect of the disclosure may include one or more of the following optional features. In some implementations, the sound suppressor includes a biasing member operable to rotate the door from the closed position to the open position after passage of the projectile through the exit opening.

In some implementations, the sound suppressor includes an outer shell, an inner shell, and an intermediate member. The outer shell may be concentrically disposed within the housing. The inner shell may be concentrically disposed within the outer shell and defining a plurality of apertures. The intermediate member may be disposed between the inner shell and the outer shell and formed at least in part from an acoustic metamaterial. Each of the apertures may define a maximum dimension extending across the aperture. The maximum dimension may be less than one millimeter.

In some implementations, the sound suppressor includes a sleeve disposed within the housing. The sleeve may include a plurality of undulations defining a plurality of apertures in fluid communication with the central passage. Each of the plurality of undulations may define a U-shape or a V-shape. Each of the apertures may define a maximum dimension extending across the aperture. The maximum dimension may be less than one millimeter.

Yet another aspect of the disclosure provides a sound suppressor for a firearm. The sound suppressor may include a housing and a first sleeve. The housing may extend along, and be disposed about, a central axis. The first sleeve may be concentrically disposed within the housing and may define a plurality of first undulations disposed about the central axis. Each first undulation may define a plurality of first apertures.

Implementations of this aspect of the disclosure may include one or more of the following optional features. In some implementations, each of the first apertures defines a first maximum dimension extending across the first aperture. In some implementations, the first maximum dimension is less than one millimeter. In some implementations, the first maximum dimension is less than a half millimeter.

In some implementations, the sound suppressor includes a second sleeve. The second sleeve may be concentrically disposed within the first sleeve and may define a plurality of second undulations disposed about the central axis. Each second undulation may define a plurality of second apertures. Each of the second apertures may define a second maximum dimension extending across the second aperture. In some implementations, the second maximum dimension is less than one millimeter. Each of the first apertures may extend through a thickness of the first sleeve. The thickness may be greater than two hundred percent of the first maximum dimension.

In some implementations, at least one of the first sleeve or the second sleeve is formed from one of aluminum or an aluminum alloy.

In some implementations, each of the plurality of first undulations defines a U-shape or a V-shape.

A further aspect of the disclosure provides a sound suppressor for a firearm. The sound suppressor may include a housing and a first sleeve. The housing may define a first central passage. The first sleeve may be disposed within the first central passage and may include a plurality of first undulations defining a second central passage. Each first undulation may define a plurality of first apertures in fluid communication with the first central passage and the second central passage.

Implementations of this aspect of the disclosure may include one or more of the following optional features. In some implementations, each of the first apertures defines a first maximum dimension extending across the first aperture. The first maximum dimension may be less than one millimeter. In some implementations, the first maximum dimension is less than a half millimeter.

In some implementations, the sound suppressor includes a second sleeve. The second sleeve may be disposed within the second central passage and may include a plurality of second undulations defining a third central passage. Each second undulation may define a plurality of second apertures in fluid communication with the second central passage and the third central passage. Each of the second apertures may define a second maximum dimension extending across the second aperture. In some implementations, the second maximum dimension is less than one millimeter.

Each of the first apertures may extend through a thickness of the first sleeve. The thickness may be greater than two hundred percent of the first maximum dimension.

In some implementations, at least one of the first sleeve or the second sleeve is formed from one of aluminum or an aluminum alloy.

In some implementations, each of the plurality of first undulations defines a U-shape or a V-shape.

Yet another aspect of the disclosure provides a sound suppressor for a firearm. The sound suppressor may include a housing and a first sleeve. The first sleeve may be disposed within the housing and may include a first inner surface and a first outer surface. At least one of the first inner surface or the first outer surface may define a plurality of first undulations. Each first undulation may define a plurality of first apertures extending through the first inner surface and the first outer surface.

Implementations of this aspect of the disclosure may include one or more of the following optional features. In some implementations, each of the first apertures defines a first maximum dimension extending across the first aperture. The first maximum dimension may be less than one millimeter. In some implementations, the first maximum dimension is less than a half millimeter.

In some implementations, the sound suppressor includes a second sleeve. The second sleeve may be disposed within the first sleeve and may include a second inner surface and a second outer surface. At least one of the second inner surface or the second outer surface may define a plurality of second undulations. Each second undulation may define a plurality of second apertures extending through the second inner surface and the second outer surface. Each of the second apertures may define a second maximum dimension extending across the second aperture. In some implementations, the second maximum dimension is less than one millimeter.

Each of the first apertures may extend through a thickness of the first sleeve. The thickness may be greater than two hundred percent of the first maximum dimension.

In some implementations, at least one of the first sleeve or the second sleeve is formed from one of aluminum or an aluminum alloy.

In some implementations, each of the plurality of first undulations defines a U-shape or a V-shape.

Another aspect of the present disclosure provides a sound suppressor kit for a firearm. The sound suppressor kit includes a housing, a first shell assembly, and a second shell assembly. The first shell assembly is configured to be removably coupled to the housing and configured to reduce a volume of a first sound having a first frequency. The second shell assembly is configured to be removably coupled to the housing and configured to reduce a volume of a second sound having a second frequency that is different than the first frequency.

Implementations of this aspect of the disclosure may include one or more of the following optional features. In some implementations, the housing defines an opening and a passage in fluid communication with the opening. The first shell assembly and the second shell assembly may each be configured to be removably inserted through the opening and into the passage.

Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

Corresponding reference numerals indicate corresponding parts throughout the drawings

Example configurations will now be described more fully with reference to the accompanying drawings. Example configurations are provided so that this disclosure will be thorough, and will fully convey the scope of the disclosure to those of ordinary skill in the art. Specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of configurations of the present disclosure. It will be apparent to those of ordinary skill in the art that specific details need not be employed, that example configurations may be embodied in many different forms, and that the specific details and the example configurations should not be construed to limit the scope of the disclosure.

The terminology used herein is for the purpose of describing particular exemplary configurations only and is not intended to be limiting. As used herein, the singular articles “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. Additional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,” “connected to,” “attached to,” or “coupled to” another element or layer, it may be directly on, engaged, connected, attached, or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” “directly attached to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

The terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections. These elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example configurations.

With reference to, a firearm system, including a firearmand a sound suppressor, is shown. While the firearmis shown as being a pistol-type firearm, it will be appreciated that the firearm systemmay include other types of firearmswithin the scope of the present disclosure.

With reference to, the sound suppressormay include a housing, an endcap, one or more inner sleeves, one or more baffles, an expansion device, and an insulator. The housingmay extend along a longitudinal axis Aand include a proximal end, a distal end, an inner surface, and an outer surface. The distal endmay be opposite the proximal end. The housingmay be formed from one or more of a variety of materials, including, for example, aluminum, steel, or another suitable metal material.

As illustrated in, the inner and outer surfaces,may surround and extend along the longitudinal axis Afrom the proximal endto the distal end, such that the inner and outer surfaces,define a thickness T() extending therebetween in a direction substantially perpendicular to the inner and outer surfaces,. Accordingly, the inner surfacemay define a passageextending through the housingfrom the proximal endto the distal end. The proximal endof the housingmay define an entrance opening, while the distal endof the housingmay define an exit opening. In this regard, the entrance openingmay be in fluid communication with the exit openingthrough the passage.

In some implementations, the inner and outer surfaces,each define a cylinder or a polygonal prism, such that the thickness Tis uniform along and about the longitudinal axis A. It will be appreciated, however, that the inner or outer surface,may define other shapes within the scope of the present disclosure, such that the thickness Tl varies along or about the longitudinal axis A.

A portion of the inner or outer surface,may include a threaded portionfor securing the housingto the endcap. For example, as illustrated in, in some implementations, the outer surfaceincludes a male threaded portionextending from the proximal endalong and about the longitudinal axis A.

As illustrated in, the housingmay define a plurality of perforations or aperturesextending through the inner and outer surfaces,. In some implementations, the aperturesdefine a circular or cylindrical shape extending through the inner and outer surfaces,. In this regard, the aperturesmay define a diameter greater than 0.75 millimeters. In particular, the aperturesmay define a diameter greater than 1.0 millimeter. The aperturesmay collectively define one or more patterns extending along or about the longitudinal axis A. For example, in some implementations, the aperturesmay collectively define a helical pattern extending from the proximal endto the distal end. In some implementations, a plurality of groups of the aperturesmay each collectively define a circle extending about the longitudinal axis A, such that the plurality of groups of the aperturescollectively define (i) a plurality of circular patterns extending about the longitudinal axis Aand (ii) a plurality of linear patterns extending along (e.g., substantially parallel to) the longitudinal axis A.

With reference to, the endcapmay extend along a longitudinal axis Aand include a proximal end, a distal end, an inner surface, and an outer surface. The distal endmay be opposite the proximal end. As illustrated in, the inner surfacemay surround and extend along the longitudinal axis Afrom the proximal endtoward the distal end. Accordingly, the inner surfacemay define a passageextending through the endcapfrom the proximal endtoward the distal end. In some implementations, the distal endof the endcapmay include a counterboredefined in part by a shoulderextending radially outward from the inner surfaceof the endcap. The counterboremay include a threaded portionextending from the distal endtoward the shoulderto threadingly engage the threaded portionof the housingin the assembled configuration.

With reference to, the one or more inner sleevesmay include a first inner sleeveand a second inner sleeveAs illustrated in, in the assembled configuration, the first inner sleevemay be disposed within the housing, and the second inner sleevemay be disposed within the first inner sleeve

The first inner sleevemay define a hollow construct extending along a longitudinal axis Aand having a proximal end, a distal end, an inner surface, and an outer surface. In some implementations, the first inner sleevemay define a polygonal prism extending along the longitudinal axis A. The distal endmay be opposite the proximal end. The first inner sleevemay be formed from one or more of a variety of materials, including, for example, aluminum, steel, or another suitable metal material.

As illustrated in, the inner and outer surfaces,may surround and extend along the longitudinal axis Afrom the proximal endto the distal end, such that the inner and outer surfaces,define a thickness T() extending therebetween in a direction substantially perpendicular to the inner and outer surfaces,. Accordingly, the inner surfacemay define a passageextending through the first inner sleevefrom the proximal endto the distal end. The proximal endof the first inner sleevemay define an entrance opening, while the distal endof the first inner sleevemay define an exit opening. In this regard, the entrance opening may be in fluid communication with the exit opening through the passage.

In some implementations, the inner or outer surface,each define a plurality of undulationsdisposed about the longitudinal axis A. As illustrated in, in some implementations, the undulationsdefine V-shapes or profiles disposed symmetrically about the longitudinal axis A. It will be appreciated, however, that the undulationsmay define other shapes (e.g., U-shape, a square wave shape, etc.) within the scope of the present disclosure. In this regard, the inner surfacemay define a plurality of inner peaksand inner troughscorresponding to, or collectively defining, minimum and maximum diameters, respectively, of the inner surface, while the outer surfacemay define a plurality of outer peaksand outer troughscorresponding to, or collectively defining, minimum and maximum diameters, respectively, of the outer surface. While the inner and outer surfaces,are illustrated to define ten peaks,and ten troughs,, it will be appreciated that the inner and outer surfaces,may define more or less than ten peaks,or ten troughs,within the scope of the present disclosure.