Porous Matrix Sound Suppressor

Abstract

Disclosed is a sound-suppressing device that employs a porous micro-channel diffusion matrix surrounding a hollow core lube that acts to increase the surface area of the suppressor and allow combustion gasses to diffuse and exit the suppressor. Various polymers can fee used to produce the porous micro-channel diffusion matrices. These porous polymer micro-channel diffusion matrices are made by sintering processes. By controlling the polymer type and particle size distribution of the particles that are sintered to create the porous polymer micro-channel diffusion matrix, the suppression can be maximized.

What is claimed is: 
     
         1 . A suppressor for use With a firearm configured to fire a round of ammunition including a projectile along a projectile path, the suppressor comprising:
 a porous micro-channel diffusion polymer matrix having a longitudinal axis, a front end portion and a rear end portion spaced apart along the longitudinal axis, and an interior surface and an exterior surface extending generally along the longitudinal axis, the interior surface defining an internal passage for receiving the projectile through the diffusion polymer matrix; the diffusion polymer matrix being formed of sintered panicles comprising a polymer having a melt flow index of less than about 5 g/10 minutes, the sintered particles being sized and arranged to define pores between adjacent ones of the sintered particles having pore diameters in a range of from about 50 μm to about 400 μm and so that the diffusion polymer matrix has a porosity in a range of from about 30% to about 60%, the pores being fluidly connected to one another to form a network of exhaust flow passages extending through the diffusion polymer matrix from the inferior surface through the exterior surface and from the rear end portion through the front end portion; and   a muzzle connector operatively attached to the diffusion polymer matrix configured for mounting the diffusion polymer matrix on a muzzle of the firearm so that the projectile path is aligned with the internal passage of porous micro-channel diffusion polymer matrix.   
     
     
         2 . A suppressor as set forth in  claim 1  wherein the polymer has a melt flow index of less than about 3 g/10 minutes. 
     
     
         3 . A suppressor as set forth in  claim 2  wherein the polymer has a melt flow index of less than about 1 g/10 minutes. 
     
     
         4 . A suppressor as set forth in  claim 1  wherein the polymer comprises one of a polyethylene, a polypropylene, and a polycarbonate. 
     
     
         5 . A suppressor as set forth in  claim 1  further comprising a core tube received in the internal passage of the diffusion matrix. 
     
     
         6 . A suppressor as set forth in  claim 5  wherein the core tube has a wall and at least one vent hole extending radially through the wall. 
     
     
         7 . A suppressor as set forth in  claim 5  further comprising a containment cap secured to the front end portion of the core tube, the muzzle connector being secured to a rear end portion of the core tube and the diffusion matrix extending along the longitudinal axis between the muzzle connecter and the containment cap. 
     
     
         8 . A suppressor as set forth in  claim 7  further comprising a sheath the diffusion matrix. 
     
     
         9 . A suppressor as set forth in  claim 8  wherein the sheath extends from a rear end portion sealingly engaging the muzzle connector to a front end portion sealingly engaging the containment cap. 
     
     
         10 . A method of making a suppressor, comprising:
 sintering polymer particles to form a porous diffusion matrix having a longitudinal axis, a rear end portion and a front end portion spaced apart along the longitudinal axis, and an exterior surface extending generally along the longitudinal axis, at least about 90% of the particles by mass having diameters in a range of from about 100 μm to about 3000 μm before said step of sintering;   maintaining partial separation between the particles during the step of sintering the particles to define pores between adjacent ones of the particles that are fluidly connected to one another to form a network of exhaust passages extending throughout the diffusion matrix; and   forming an internal passage through the diffusion matrix defined by an interior surface of the diffusion matrix opposite the exterior surface, the internal passage extending generally along the longitudinal axis from the rear end portion through the front end portion and being sized and arranged for receiving a projectile through the diffusion matrix, said stop or forming the internal passage including forming openings in the interior surface of the diffusion matrix that fluidly connect the internal passage to the network of exhaust passages.   
     
     
         11 . A method as set forth in  claim 11  wherein the diameters of at least about 90% of the particles by mass is in a range of from about 100 μm to about 1000 μm before said step of sintering. 
     
     
         12 . A method as set forth in  claim 12  wherein the diameters of at least about 90% of the particles by mass is in a range of from about 100 μm to about 450 μm before said step of sintering. 
     
     
         13 . A method as set forth in  claim 11  wherein the particles have a melt flow index of less than about 5 g/10 minutes. 
     
     
         14 . A method as set forth in  claim 14  wherein the melt flow index of the particles is less than about 3 g/10 minutes. 
     
     
         15 . A method as set forth in  claim 15  wherein the melt flow index of the particles is less than about 1 g/10 minutes. 
     
     
         16 . A method as set forth in  claim 11  wherein the particles comprise one of a polyethylene, a polypropylene, and a polycarbonate. 
     
     
         17 . A method as set forth in  claim 11  wherein the steps of sintering the particles and forming the internal passage are performed simultaneously. 
     
     
         18 . A method as set forth in  claim 18  further comprising positioning the particles in an annular mold cavity. 
     
     
         19 . A method as set forth in  claim 19  wherein the step of sintering the particles comprises heating the particles while the particles are positioned in the annular mold cavity. 
     
     
         20 . A method as set forth in  claim 11  further comprising securing a muzzle connector configured for being mounted on the muzzle of a firearm to the diffusion matrix. 
     
     
         21 . A method as set forth in  claim 21  wherein the step of securing the muzzle connector comprises:
 securing the muzzle connector to a core tube; 
 inserting the core tube into the internal passage of the diffusion matrix; and 
 securing a containment cap to the core tube so that the diffusion matrix is received over the core tube between the muzzle connector and the containment cap. 
 
     
     
         22 . A method as set forth in  claim 22  further comprising inserting the diffusion matrix into a sheath such that the sheath is received between the muzzle connector and the containment cap. 
     
     
         23 . A method of making a suppressor, comprising;
 sintering polymer particles having a melt flow index of less than about 5 g/10 minutes to form a porous diffusion matrix having a longitudinal axis, a rear end portion and a front end portion spaced apart along the longitudinal axis, and an exterior surface extending generally along the longitudinal axis;   maintaining partial separation between the particles during the step of sintering the particles to define pores between adjacent ones of the particles that are fluidly connected to one another to form a network of exhaust passages extending throughout the diffusion matrix; and   forming an internal passage through the diffusion matrix defined by an interior surface of the diffusion matrix opposite the exterior surface, the internal passage extending generally along the longitudinal axis from the rear end portion through the front end portion and being sized and arranged for receiving a projectile through the diffusion matrix, said step or forming the internal passage including forming openings in the interior surface of the diffusion matrix that fluidly couple the internal passage to the network of pores.