U.S. patent application number 13/599815 was filed with the patent office on 2013-03-07 for payload delivery system with forward folding stabilizer for cartridges.
The applicant listed for this patent is James Y. Menefee, III. Invention is credited to James Y. Menefee, III.
Application Number | 20130055916 13/599815 |
Document ID | / |
Family ID | 46970398 |
Filed Date | 2013-03-07 |
United States Patent
Application |
20130055916 |
Kind Code |
A1 |
Menefee, III; James Y. |
March 7, 2013 |
PAYLOAD DELIVERY SYSTEM WITH FORWARD FOLDING STABILIZER FOR
CARTRIDGES
Abstract
This disclosure provides for payload delivery systems and
cartridges and methods that incorporate the payload delivery
systems. The payload delivery system can comprise a stabilizer
having a longitudinally cut side wall defining a series of vanes
that are folded forward in the pre-launched configuration. Other
aspects combine a payload cup nested within the forward folding
stabilizer. Still other aspects integrate the payload portion and
the stabilizer portion into a single piece that constitutes a
stabilized payload cup. The disclosed cartridges can be used to
deliver payloads such as solid projectiles, shot of all sizes,
powders, gels, liquids, and other payloads to exploit their
specific function.
Inventors: |
Menefee, III; James Y.;
(Macon, GA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Menefee, III; James Y. |
Macon |
GA |
US |
|
|
Family ID: |
46970398 |
Appl. No.: |
13/599815 |
Filed: |
August 30, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61530116 |
Sep 1, 2011 |
|
|
|
Current U.S.
Class: |
102/334 ;
102/336; 102/364; 102/370; 102/439; 102/448; 102/473; 102/502;
102/506; 102/513; 102/517; 102/524 |
Current CPC
Class: |
F42B 7/08 20130101; F42B
12/76 20130101 |
Class at
Publication: |
102/334 ;
102/517; 102/524; 102/439; 102/336; 102/502; 102/513; 102/364;
102/473; 102/506; 102/370; 102/448 |
International
Class: |
F42B 12/00 20060101
F42B012/00; F42B 14/00 20060101 F42B014/00; F42B 10/06 20060101
F42B010/06; F42B 12/42 20060101 F42B012/42; F42B 12/40 20060101
F42B012/40; F42B 12/38 20060101 F42B012/38; F42B 12/02 20060101
F42B012/02; F42B 12/20 20060101 F42B012/20; F42B 12/22 20060101
F42B012/22; F42B 12/46 20060101 F42B012/46; F42B 7/04 20060101
F42B007/04; F42B 12/04 20060101 F42B012/04; F42B 10/02 20060101
F42B010/02; F42B 12/44 20060101 F42B012/44 |
Claims
1-67. (canceled)
68. A payload delivery system comprising, in its pre-launched
configuration: a) a payload cup having an open fore end, a closed
aft end, and a cylindrical side wall defining a cavity; and b) a
stabilizer coaxially aligned with the payload cup, having an open
fore end, a closed aft end, and a side wall comprising a plurality
of forward folding vanes defined by a plurality of cuts in the side
wall; wherein the payload cup is nested within the stabilizer, and
the payload cup aft end is adjacent and attached to the stabilizer
aft end.
69. A payload delivery system according to claim 68, wherein the
payload cup and the stabilizer are attached with a connector.
70. A payload delivery system according to claim 68, further
comprising: c) an obturating component adjacent the aft end of the
stabilizer, comprising a pre-formed gas seal or an obturating
medium.
71. A payload delivery system according to claim 68, further
comprising: c) a pre-formed gas seal adjacent the aft end of the
stabilizer and coaxially aligned with the payload cup and the
stabilizer; wherein the payload cup and the stabilizer are attached
with a connector.
72. A payload delivery system according to claim 71, wherein the
connector further attaches the gas seal with the payload cup and
the stabilizer.
73. A payload delivery system according to claim 68, wherein the
payload cup and the stabilizer are attached with a connector, the
connector comprising an integral pre-formed gas seal.
74. A payload delivery system according to claim 68, wherein the
plurality of cuts in the side wall are longitudinal or
substantially longitudinal.
75. A payload delivery system according to claim 68, wherein the
stabilizer comprises paper, polymer, polymer coated paper,
composite, laminate, or textile.
76. A payload delivery system according to claim 68, wherein the
stabilizer comprises at least 3 radial fins.
77. A payload delivery system according to claim 68, wherein the
stabilizer inverts during flight.
78. A payload delivery system according to claim 68, wherein the
stabilizer comprises an even number of radial fins, and wherein
alternating radial fins are removed from the stabilizer.
79. A payload delivery system according to claim 68, wherein at
least a portion of the vanes extend greater than 85% the length of
the cylindrical side wall of the payload cup.
80. A payload delivery system according to claim 68, wherein the
aft end portion of the payload cup is recessed in an annular
fashion from the fore end portion, wherein the aft end portion has
a smaller diameter than the fore end portion, and the vanes extend
the length of the recessed aft end portion of the payload cup.
81. A payload delivery system according to claim 68, wherein the
closed aft end of the payload cup is crimped.
82. A payload delivery system according to claim 68, wherein the
payload cup and the stabilizer are attached with a connector
selected from a rivet, a screw, a staple, a pin, a bolt, a brad, an
anchor, an adhesive, a tack, or a nail.
83. A payload delivery system according to claim 82, wherein the
connector is a rivet, a screw, a staple, a pin, a bolt, a brad, an
anchor, a tack, or a nail and comprises an integral pre-formed gas
seal.
84. A payload delivery system according to claim 68, wherein the
payload cup comprises polyethylene, polypropylene, or poly(vinyl
chloride).
85. A cartridge comprising a payload delivery system according to
claim 68, wherein the cartridge is an ammunition cartridge, a flare
cartridge, a smoke flare cartridge, a signaling device cartridge, a
chemical cartridge, a distraction device cartridge, a pyrotechnic
launching device cartridge, a marking cartridge, a grenade launcher
cartridge, an incendiary cartridge, an explosive cartridge, a
tracer cartridge, an armor-piercing cartridge, or a non-lethal
cartridge.
86. A cartridge comprising a payload delivery system according to
claim 68, further comprising at least one of a frangible
projectile, a non-frangible projectile, a lead projectile, a
non-lead metal projectile, a steel projectile, a rubber projectile,
a bean bag projectile, a tear gas-containing projectile, an
oleoresin capsicum-containing projectile, a liquid-containing
projectile, a powder-containing projectile, a gel-containing
projectile, a marking projectile, a tracer projectile, a penetrator
projectile, a flechette projectile, an armor-piercing projectile,
an explosive projectile, an incendiary projectile, a flare
projectile, or any combination thereof.
87. A cartridge comprising a payload delivery system according to
claim 68 and at least one projectile selected from birdshot,
buckshot, and slug projectiles.
88. A cartridge comprising: a) a cartridge case having a fore end
and an aft end, and comprising a primer situated at the aft end; b)
a propellant adjacent the primer; c) an obturating component
adjacent the propellant; d) a payload delivery system according to
claim 68 adjacent the obturating component, and e) a payload at
least partially contained within the cavity of the payload cup.
89. A cartridge according to claim 88, wherein obturating component
comprises a pre-formed gas seal or an obturating medium.
90. A payload delivery system comprising, in its pre-launched
configuration: a) a stabilizer having an open fore end, a closed
aft end, and a side wall defining a cavity, the side wall
comprising a plurality of forward folding vanes defined by a
plurality of longitudinal cuts in the side wall; b) an obturating
component adjacent the stabilizer aft end; and c) at least one
payload contained within the cavity of the stabilizer.
91. A payload delivery system according to claim 90, wherein: the
stabilizer comprises paper, polymer, polymer coated paper,
composite, laminate, or textile; and the obturating component
comprises a pre-formed gas seal or an obturating medium.
92. A cartridge comprising a payload delivery system according to
claim 90.
93. A cartridge comprising a payload delivery system according to
claim 90, further comprising at least one additional wad.
94. A cartridge comprising a payload delivery system according to
claim 90, further comprising at least one of a frangible
projectile, a non-frangible projectile, a lead projectile, a
non-lead metal projectile, a steel projectile, a rubber projectile,
a bean bag projectile, a tear gas-containing projectile, an
oleoresin capsicum-containing projectile, a liquid-containing
projectile, a powder-containing projectile, a gel-containing
projectile, a marking projectile, a tracer projectile, a penetrator
projectile, a flechette projectile, an armor-piercing projectile,
an explosive projectile, an incendiary projectile, a flare
projectile, or any combination thereof.
95. A payload delivery system comprising, in its pre-launched
configuration: a stabilized payload cup comprising a tube with an
open fore end, an open aft end, and a cylindrical side wall
defining a cavity that terminates at a fore edge and an aft edge;
the open aft end comprising a plurality of longitudinal slits
defining a plurality of vanes extending from the aft edge along a
portion of the length of the cylindrical side wall, the vanes being
forward folded along the cylindrical side wall, thereby defining a
derivative aft end and a derivative aft edge.
96. A payload delivery system according to claim 95, further
comprising a pre-formed gas seal coaxially aligned with the
stabilized payload cup and adjacent the derivative aft end.
97. A unitary pre-formed gas seal comprising: a) a gas seal portion
having a side wall that defines a gas-sealing skirt; and b) a
connector portion integral to the gas seal portion; wherein the gas
seal portion and the connector portion are coaxially aligned and
oppositely directed.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 61/530,116, filed Sep. 1, 2011, the disclosure of
which is incorporated herein by reference in its entirety.
TECHNICAL FIELD OF THE INVENTION
[0002] This disclosure relates to cartridges for launching a
payload and the cartridge components themselves, including
cartridges and components for launching a payload comprising solid
projectiles, liquid- or gel-containing projectiles, or powders.
BACKGROUND
[0003] Cartridge systems constitute extremely practical
constructions and methods for deploying almost any payload or
projectile downrange. Typical cartridge systems incorporate the
desired payload, a propellant, and some priming composition all
within a self-contained unit. While ammunition cartridges are
prototypical of cartridge devices, cartridge systems have been used
to launch chemical, pyrotechnic, marker, tracer, signaling,
non-lethal, explosive, smoke, and other payloads to exploit their
specific function. These more complex payloads often require
additional complex and expensive components beyond the nominal
propellant, projectile, and primer for their effective use in
cartridges.
[0004] Shotshell cartridges are also complex cartridge systems
because shotshells require intricate components beyond those
necessary in rifle or pistol rounds. Many of the principles of
payload delivery systems developed in shotshell cartridges are
applicable to launching chemical, pyrotechnic, signaling,
non-lethal, and other complex payloads in their respective
cartridges. For example, a shotshell "wad" is the general term
applied to the collection of components in a shotshell other than
the projectile(s), the propellant, and the primer, which is used
for effective delivery of the projectiles. Shotshell wads may be
designed for various functions such as providing a seal against
expanding propellant gases, containing and stabilizing the
projectile(s) for a desired distance downrange, and/or cushioning
and barrel protection. Components having similar functions are
often required to launch chemical, pyrotechnic, non-lethal, and
other complex payloads in a cartridge. In all these cases, the
expense and complexity of construction, tooling, and manufacture of
these components and the cartridges themselves can be
challenging.
[0005] Therefore, there exists a need for new cartridge components
and structures for the more complex cartridge systems--that is,
beyond the projectile, propellant, and primer--that do not require
new specialty tooling with its associated high capital costs. There
is also a need for cartridge components and cartridges that can be
readily adapted for delivering virtually any complex and
difficult-to-handle payload downrange, such as powders, liquids,
and gels, as well as solids. Such components would be versatile
enough to be used in shotshells, but also for launching chemical,
pyrotechnic, non-lethal, non-lethal, explosive, and other similarly
complex payloads. Desirably, these components would generally avoid
the complicated features that can prohibitively increase costs.
SUMMARY OF THE INVENTION
[0006] The present disclosure relates to cartridges for delivering
payloads, the payload delivering component of the cartridges, and
the associated methods of making and using the components and
cartridges. Typically, this disclosure uses shotshells as exemplary
"complex" cartridge systems and the disclosed components may be
discussed in terms of their shotshell applications or aspects.
However, the principles of payload delivery systems described
herein are applicable to launching chemical, pyrotechnic,
signaling, non-lethal, and other complex payloads in their
respective cartridges. Indeed, it is to be understood that this
disclosure and the appended claims are not limited to shotshells,
because the disclosed structures, components, and methods have a
wide utility and are adaptable to the delivery of any number of
payload types downrange.
[0007] One aspect of this disclosure relates to a payload delivery
system that includes, as its fundamental element, at least one
cup-shaped stabilizer having an open fore end, a closed aft end,
and a side wall comprising a plurality of forward folding vanes
defined by a plurality of cuts in the side wall. Thus, when the
plurality of vanes are forward folded they impart the cup shape to
the stabilizer. In various embodiments, the cup-shaped stabilizer
can be used for its stabilizing function as a "stabilizing
component, or simply "stabilizer", when it is attached to another
component in the cartridge. For example, the cup-shaped stabilizer
can be or can comprise a stabilizing component which assists in
stabilizing the payload during flight to any extent desired. In
this aspect, the cup-shaped stabilizer can be attached to another
component such as a payload or projectile container or "cup" or
attached directly to at least a portion of the payload itself, for
example a single projectile, and thereby function as a means to
impart high stability and drag to that other component, payload, or
projectile. In other various embodiments, the cup-shaped stabilizer
itself can be used as a means to embrace the payload, and therefore
serve as a high-drag component having a sabot effect, until a point
in time or distance after launching at which the cup-shaped
stabilizer separates from the payload and delivers it in free
flight. By way of example, in this configuration of containing the
payload, the cup-shaped stabilizer can assist in launching powders,
gels, liquids, capsules containing powders, gels, or liquids, other
solids, even other payloads such as solid projectiles, to exploit
their specific function.
[0008] In its various aspects and embodiments, the stabilizer of
this disclosure may be described by terms such as cup-shaped
stabilizer, forward folding stabilizer, forward folded stabilizer,
stabilizer cup, stabilizer with cut side wall, or simply,
stabilizer, and similar terms. These terms are used interchangeably
to reflect the same structure, that is, a cartridge component that
is cup-shaped in its pre-launched and forward folded condition,
having an open fore end, a closed aft end, and a side wall
comprising a plurality of vanes that are defined by a plurality of
cuts in the side wall. Thus, the vanes result because some or all
of the plurality of cuts in the side wall extend to the edge of the
cup-shaped "stabilizer" that is defined by its open fore end.
Typically, though not necessarily, the cuts in the side wall are
longitudinal cuts, substantially longitudinal (for example, not
varying more than 30 degrees from longitudinal), and typically,
though not necessarily, parallel cuts. The vanes defined by the
cuts in the stabilizer side wall also may be termed vanes ribbons,
strips, fins, wings, flaps, segments, and the like, and such terms
are used interchangeably. When used in conjunction with a separate
component that functions as a payload cup, this cup-shaped
component is coaxially aligned with the payload cup and is
generally attached to the payload cup in its pre-launched
condition.
[0009] These alternative terms for the cup-shaped component may be
used regardless of any momentary configuration the component may be
in. For example, terms such as forward folding stabilizer, forward
folded stabilizer, and the like may be used to describe this
component even after it has been launched from a cartridge, and the
vanes are not forward folded, even if the vanes have unfolded and
inverted such that the open end of the stabilizer now points
uprange or in the aft direction.
[0010] The cup-shaped stabilizer defines a cavity that can contain
either the payload itself, or the cavity can contain a payload cup
or container in which the payload cup or container contains the
payload. For example, when the cup-shaped stabilizer is attached to
the payload cup, it may be referred to as a stabilizing component
or stabilizer, because it functions to impart stability and
different degrees of drag to the payload cup during flight, for a
desired ballistic performance. The combined and attached cup-shaped
stabilizer and payload cup, which may be referred to as a
"stabilized payload cup", can provide for early or late release of
the payload as desired, because stability is achieved by the
function of the cup-shaped stabilizer. Additional structures and
functions can be incorporated into a stabilized payload cup, such
as a means to puncture or rupture a capsule that houses a gel or
liquid payload contained within the stabilized payload cup.
[0011] In one aspect, the cut side wall of the cup-shaped
stabilizer can be cut in a fashion such that the vanes cover
substantially all the side wall area of the payload cup in the
forward folded or "pre-launched" configuration, because each vane
is flush against a neighboring vane. Alternatively, the cut side
wall of the stabilizer can be structured such that at least some of
the vanes are missing, shaped in different ways, have gaps between
the vanes such that each vane is not flush against a neighboring
vane, and similarly diverse configurations. Still alternatively,
the cut side wall of the stabilizer can be structured such that at
least some of the vanes overlap each other, which can aid in the
sabot function. The common structural theme of the stabilizer is
that it comprises vanes that are forward folding in their
pre-launched configuration, and subsequently unfold after launching
to provide a stabilizing and drag function.
[0012] When constructed of suitable materials, the cup-shaped
stabilizer of this disclosure can contain the payload in its own
cavity. In this aspect, the cup-shaped stabilizer function as its
own type of payload container or payload cup, rather than
functioning as a stabilizer, to achieve the desired performance
with certain payloads, such as powders. For example, a cup-shaped
stabilizer can impart a sabot effect on a projectile that it
contains and be used to fire a projectile that is sub-bore diameter
and to hold that projectile in a more precise position throughout
launching. Also by way of example, using the cup-shaped stabilizer
to contain and launch the payload itself can be useful for imposing
a sudden charge of powder or liquid into a confined space, such as
might be required in chemical, biological, or other encounters.
When used in this fashion, the typical embodiments do not have gaps
between the individual vanes such that each vane is either flush
against a neighboring vane or overlaps a neighboring vane. In this
manner, the barrel protection and sabot function are bolstered.
[0013] Typically, the stabilized payload cup or the cup-shaped
stabilizer itself can be used in conjunction with an obturating
component to provide a seal against expanding propellant gases.
This disclosure provides for use of virtually any obturating
component, including pre-formed gas seals of any type or an
obturating medium. When using a pre-formed gas seal, the pre-formed
gas seal can be loaded into the cartridge as a separate component,
or it can be attached in any manner to the stabilized payload cup
or the cup-shaped stabilizer itself and used as the combination in
a cartridge.
[0014] Accordingly, the present disclosure generally relates to
cartridges for delivering payloads, the payload delivering
components of cartridges, and the associated methods of making and
using the components and cartridges. Among other things, this
disclosure provides for a payload delivery system comprising, in
its pre-launched configuration: [0015] a) a payload cup having an
open fore end, a closed aft end, and a cylindrical side wall
defining a cavity; and [0016] b) a stabilizer coaxially aligned
with the payload cup, having an open fore end, a closed aft end,
and a side wall comprising a plurality of forward folding vanes
defined by a plurality of cuts in the side wall; [0017] wherein the
payload cup is nested within the stabilizer, and the payload cup
aft end is adjacent and attached to the stabilizer aft end. In this
aspect, the cup-shaped stabilizer is attached in some manner to the
payload cup to ensure stability and provide drag for a clean
separation of the payload cup from the payload. The payload cup aft
end and the stabilizer aft end can be connected or attached by any
means, without limitation, and attachment does not require a
connector component. For example, when made of the appropriate
materials, the payload cup and the stabilizer can be attached by a
melting process, by a punching method, by a sonic weld process, and
the like. In various embodiments, the payload cup and the
stabilizer can be attached by a connector component. For example,
the connector can be selected from a rivet, a screw, a staple, a
pin, a bolt, a brad, an anchor, an adhesive, a tack, or a nail, or
in certain embodiments, multiple connectors, or any combination of
these connectors.
[0018] The stabilizer also not limited as to the material from
which it is fabricated. For example, in some aspects, the
stabilizer can be made of any type of paper, plastic,
polymer-coated paper, fabric, and more, depending on the particular
payload and/or cartridge and the properties desired for the
stabilizer with respect to its function.
[0019] Similarly, the payload cup also is not limited to a
particular material, and the material is selected for its
properties of thickness, strength, ease of fabrication, and so
forth. For example, in some aspects, the payload cup can be made of
any type of paper, polymer or plastic, polymer-coated paper, and
the like, depending on the particular payload and cartridge and the
intended launching parameters such as velocity that are needed. In
some embodiments, the closed aft end of the payload cup can be
crimped closed, which simplifies the construction and lowers the
cost of the payload delivery system. This payload delivery system
can further comprise a pre-formed gas seal attached thereto or used
a pre-formed gas seal as a separate element, or this payload
delivery system can employ so-called "wadless" technology which
does not require a pre-formed gas seal of any type.
[0020] In a further aspect, this disclosure provides for a
cartridge comprising a payload delivery system as disclosed herein,
wherein the cartridge is an ammunition cartridge, a flare
cartridge, a smoke flare cartridge, a signaling device cartridge, a
chemical cartridge, a distraction device cartridge, a pyrotechnic
launching device cartridge, a marking cartridge, a grenade launcher
cartridge, an incendiary cartridge, an explosive cartridge, a
tracer cartridge, an armor-piercing cartridge, or a non-lethal
cartridge.
[0021] In a further aspect, this disclosure provides for a payload
delivery system that comprises, in its pre-launched configuration:
[0022] a) a stabilizer having an open fore end, a closed aft end,
and a side wall defining a cavity, the side wall comprising a
plurality of forward folding vanes defined by a plurality of
longitudinal cuts in the side wall; [0023] b) an obturating
component adjacent the stabilizer aft end; and [0024] c) at least
one payload contained within the cavity of the stabilizer. By way
of example, the obturating component can comprise a pre-formed gas
seal coaxially aligned with the payload cup or an obturating
medium. In this aspect, the cup-shaped stabilizer typically is used
as a means to contain, support, or contain the payload until a
point in time or distance after launching the stabilizer separates
from the payload and delivers it in free flight. In this
configuration of containing the payload itself, the stabilizer can
assist in launching powders, gels, liquids, capsules containing
powders, gels, or liquids, other solids, even other payloads such
as solid projectiles, to exploit their specific function.
Therefore, this construction can be adjusted across a range of
applications for launching a number of payloads.
[0025] Moreover, this disclosure also provides for a cartridge
comprising, in its pre-launched configuration, a cup-shaped
stabilizer having an open fore end, a closed aft end, and a side
wall comprising a plurality of vanes defined by a plurality of
longitudinal cuts in the side wall.
[0026] There is further provided a payload delivery system
comprising, in its pre-launched configuration, a cup-shaped
stabilizer having an open fore end, a closed aft end, and a cut
side wall defining a cavity. Accordingly, this disclosure further
provides a method of loading a cartridge comprising charging a
cartridge case with a cup-shaped stabilizer having an open fore
end, a closed aft end, and a side wall comprising a plurality of
vanes defined by a plurality of cuts in the side wall. In
accordance with another aspect, the plurality of cuts in the side
wall of the stabilizer can comprise, or alternatively can be,
longitudinal cuts, substantially longitudinal cuts, or cuts that
are not longitudinal. This novel aspect can include embodiments in
wherein the cut side wall is in contact with the inner wall of the
cartridge case. Various embodiments of this method can further
comprise charging the cartridge case with an obturating component
adjacent the cup-shaped stabilizer aft end.
[0027] While this disclosure is applicable to the construction of
shotshells, flare cartridges, chemical cartridges, signal
cartridges, non-lethal cartridges and the like, it is not necessary
to fire these cartridges from a firearm or a device that includes a
muzzle. To the contrary, certain cartridges such as flare or
chemical cartridges that include the disclosed components can
further incorporate a system for self-firing or self-activation of
the cartridge without a separate firing device like a flare gun.
Optionally, such cartridges with the firing component or trigger
device built in can be protected from accidental firing by a pin or
other type of firing safety.
[0028] Another aspect of this disclosure is provided in the
operation of the payload delivery system upon being launched from
the cartridge, particularly the function of the cup-shaped
stabilizer. The stabilizer is a cup-shaped component having a cut
side wall, which has its open end forward-facing, whether used in
combination with a separate payload cup to which it is attached or
whether used in the absence of a separate payload cup. When
attached to a separate payload cup, the cup-shaped stabilizer is
generally coaxially aligned with the payload cup, and the payload
cup is nested within the stabilizer to which it is attached. In
this configuration, the open ends of both the stabilizer and the
payload cup are directed forward, in a downrange fashion. Upon
launching, the entire payload delivery system comprising the
payload cup, cup-shaped stabilizer, and the selected payload, is
discharged from the cartridge along with the selected payload.
After a certain distance in flight, the stabilizer opens and
inverts, much like an umbrella will invert from a gust of wind, and
the trailing material imparts both high drag and high stability to
the cartridge payload delivery system in this manner.
[0029] This disclosure further provides for a cartridge comprising
a payload delivery system as described herein. If desired, the
cartridge can comprise a conventional pre-formed gas seal in
combination with the disclosed payload delivery system, or the
cartridge can utilize the disclosed payload delivery system with an
obturating medium that is not pre-formed into a gas seal. This
latter, wadless technology provides an extremely versatile system
to launch a range of projectiles downrange. In this aspect, for
example, a cartridge according to this disclosure can comprise:
[0030] a) a cartridge case having a fore end and an aft end and,
comprising a primer situated at the aft end; [0031] b) a propellant
adjacent the primer; [0032] c) an obturating medium adjacent the
propellant; [0033] d) a payload delivery system adjacent the
obturating medium comprising a cup-shaped stabilizer and optionally
further comprising a payload cup, and [0034] e) a payload at least
partially contained within the cavity of the cup-shaped stabilizer
or the payload cup; [0035] wherein the cartridge does not contain a
pre-shaped gas seal. In a further aspect to the above-disclosed
cartridge, the obturating medium can be used in combination with a
pre-formed gas seal or alternatively, can be replaced by a
pre-formed gas seal if desired. By way of example, the cartridge
payload delivery system can be used with an obturating medium such
as a granular polyethylene, polypropylene, or a combination
thereof.
[0036] The fundamental aspects of the payload delivery system, that
is, the payload cup, the cup-shaped stabilizer, and their
embodiments, configurations, and other aspects disclosed herein,
are applicable to launching payloads in any manner known. Thus,
while the payload delivery system and payload can be discharged
using cartridges, the system and payload also can be launched using
compressed gases such as in a CO.sub.2 or air gun, or in a pressure
device that uses a liquid as a reactive mass.
[0037] When taken in conjunction with the accompanying drawings,
detailed description, and the appended claims, the various features
of this disclosure become apparent. Supporting aspects of this
disclosure are found, for example, in the following publications
and patents, each of which is incorporated herein by reference in
its entirety: Thomas J. Griffin, editor, Shotshell Reloading
Handbook, 5.sup.th ed., Lyman Publications, Lyman Products
Corporation, Middletown, Conn., c. 2007; Don Zutz, Hodgdon Powder
Company Shotshell Data Manual, 1.sup.st ed., Hodgden Power Company,
Shawnee Mission, Kans., c. 1996; Bob Brister, Shotgunning: The Art
and the Science, Winchester Press, New Win Publishing, Inc.,
Clinton, N.J., c. 1976; and U.S. Patent Application Publication
Number 2011/0017090. Even though each of these incorporated
references concern shotshells and their components, shotshells are
used herein as exemplary cartridge systems and the disclosed
components, methods, and principles are applicable to launching any
type of payload in a cartridge system. The disclosure and the
appended claims are not limited to shotshells, because the
disclosed structures, components, and methods have a wide utility
and are adaptable to any number of payload delivery systems.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] Various aspects and embodiments of this disclosure are
illustrated in the drawings in which like reference characters
designate the same or similar parts throughout the figures.
[0039] FIG. 1A illustrates a sectional view of a representative
embodiment of a payload delivery system in its pre-launched
configuration showing the payload cup, the forward folded
stabilizer, and in this embodiment a connector, as provided by this
disclosure.
[0040] FIG. 1B illustrates a sectional view of a representative
embodiment of a payload delivery system in its pre-launched
configuration showing the payload cup, the forward folded
stabilizer, and in this embodiment a connector, as provided by this
disclosure, and highlighting an embodiment with a payload cup
having a recessed aft portion.
[0041] FIG. 1C illustrates a perspective view of a representative
embodiment of a payload delivery system in its pre-launched
configuration, corresponding to the embodiment shown in FIG. 1A,
showing the forward folded stabilizer that surrounds the payload
cup, the stabilizing vanes extending the full length of the payload
cup.
[0042] FIG. 1D illustrates a perspective view of a representative
embodiment of a payload delivery system in its pre-launched
configuration, corresponding to the embodiment shown in FIG. 1B,
showing the forward folded stabilizer that surrounds a portion of
the payload cup, the stabilizing vanes extending the length of the
recessed aft portion of the payload cup
[0043] FIGS. 2A-C illustrate perspective views of three different
payload delivery systems according to this disclosure, each having
a different type of forward folded stabilizer, and each stabilizer
extending a substantial portion of the length of the payload cup.
The left side views correspond to a post-launching configuration
showing the stabilizers after they unfold and invert during flight.
The right side views correspond to pre-folded stabilizers prior to
loading into a cartridge, and also demonstrate the stabilizers part
way through the unfolding stage during flight. FIG. 2A illustrates
a payload delivery system with a forward folding stabilizer having
identical vanes, in which no vanes or fins have been removed,
perforated, or shortened. FIG. 2B illustrates a payload delivery
system with a forward folding stabilizer in which alternating vanes
have been removed. FIG. 2C illustrates a payload delivery system
with a forward folding stabilizer in which alternating vanes have
been removed and every other remaining vane has been shortened.
[0044] FIGS. 3A-B illustrate perspective views of two different
payload delivery systems according to this disclosure, each having
a different alternative type of forward folding stabilizer, and
each stabilizer extending a substantial portion of the length of
the payload cup. Each figure corresponds to a post-launching
configuration showing the stabilizer after unfolding and inverting
during flight. FIG. 3A illustrates an alternative forward folded
stabilizer in which the stabilizer side wall comprises a plurality
of vanes defined by a plurality of parallel, but non-longitudinal,
cuts in the side wall. FIG. 3B illustrates an alternative forward
folded stabilizer in which the stabilizer side wall comprises a
plurality of vanes defined by a two types of non-longitudinal cuts
in the side wall in which alternating cuts are parallel.
[0045] FIGS. 4A-C illustrate various embodiments of the forward
folding component of the cartridge system, demonstrating methods by
which cuts can be made in the stabilizer side wall. These
embodiments are representative of those that can be used when the
forward folding component is deployed as a stabilizer in
combination with a separate payload cup to which it is attached and
when it is used as a stand-alone stabilizer cup, itself containing
the payload. FIG. 4A provides a perspective view of a forward
folding component that includes longitudinal slits through the
stabilizer side wall. FIG. 4B provides a perspective view of a
forward folding component that includes perforations through the
stabilizer side wall. FIG. 4C provides a perspective view of a
forward folding component that includes cut-outs through the
stabilizer side wall with different vane lengths.
[0046] FIG. 5A illustrates a sectional view of a representative
embodiment of a payload delivery system in its pre-launched
configuration showing the payload cup, the forward folded
stabilizer, a pre-formed gas seal, and the connector, as provided
by this disclosure.
[0047] FIG. 5B illustrates a perspective view of a representative
embodiment of a payload delivery system in its pre-launched
configuration corresponding to that shown in FIG. 5A, showing the
relative arrangement of a forward folded stabilizer which surrounds
and extends the full length of the payload cup, and including a
pre-formed gas seal. This arrangement represents those payload
delivery systems that either: 1) attach the pre-formed gas seal to
the payload cup and the forward folded stabilizer; or 2) attach
only the payload cup and the forward folded stabilizer, the
combination of which sits atop a pre-formed gas seal.
[0048] FIG. 5C illustrates a sectional view of a representative
embodiment of a payload delivery system in its pre-launched
configuration showing the payload cup having a recessed aft
portion, a forward folded stabilizer extending the length of the
recessed aft portion, a pre-formed gas seal, and the connector, as
provided by this disclosure.
[0049] FIGS. 6A-C illustrate a progression of end-on views of a
downrange observer (left) and perspective views (right) of the
payload delivery system, without showing a particular payload, as
the forward folded stabilizer unfolds and inverts to slow the
payload delivery system in a stabilized manner. The particular
embodiment illustrated has a forward folded stabilizer with eight
vanes, extending a portion of the length of the payload cup, in
which the stabilizer is attached to the payload cup with a
connector. The payload delivery system is illustrated before or
instantly after launching (FIG. 6A, time 1), early in the unfolding
stage (FIG. 6B, time 2), and later in the unfolding and inversion
stage (FIG. 6C, time 3).
[0050] FIGS. 7A-C illustrate a progression of sectional views of
the payload delivery system with an attached pre-formed gas seal,
without showing a particular payload, as the forward folded
stabilizer unfolds and inverts to slow the payload delivery system
in a stabilized manner. The payload delivery system is illustrated
before or instantly after launching (FIG. 7A, time 1), early in the
unfolding stage (FIG. 7B, time 2), and later in the unfolding and
inversion stage (FIG. 7C, time 3).
[0051] FIGS. 8A-D illustrate embodiments of the payload delivery
system prior to folding the attached stabilizer in a forward manner
along the length of the payload cup, and prior to loading the
system into a cartridge. FIG. 8A illustrates an end-on view of a
representative embodiment of a payload delivery system prior to
folding the stabilizer and before loading the system into a
cartridge, showing the payload cup, the stabilizer prior to
folding, and the connector, in which the aft end of the payload cup
is crimped closed using a 6-point star crimp. In the illustrated
embodiment, the connector is a blind rivet that holds the
stabilizer to the crimped end of the payload cup.
[0052] FIG. 8B illustrates a perspective view of a representative
embodiment of a payload delivery system corresponding to that shown
in FIG. 8A, prior to folding the stabilizer and before loading the
system into a cartridge, showing the payload cup and the stabilizer
prior to folding. In this view, the connector is not seen.
[0053] FIG. 8C illustrates a sectional view of a representative
embodiment of a payload delivery system corresponding to that shown
in FIG. 8A, prior to folding the stabilizer and before loading the
system into a cartridge, showing the payload cup, the stabilizer
prior to folding, and the connector, in which the aft end of the
payload cup is crimped closed. In the illustrated embodiment, the
connector is a blind rivet that holds the stabilizer to the crimped
end of the payload cup.
[0054] FIG. 8D illustrates a sectional view of a representative
embodiment of a payload delivery system also corresponding to that
shown in FIG. 8A, prior to folding the stabilizer and before
loading the system into a cartridge, showing the payload cup, the
stabilizer prior to folding, and the connector, in which the aft
end of the payload cup is crimped closed. The embodiment shown
illustrates a unitary pre-formed gas seal that include a gas seal
portion and a connector portion comprising a blind rivet that is
integral to the gas seal portion.
[0055] FIGS. 9A-D illustrate embodiments of the payload delivery
system corresponding to FIGS. 8A-D, respectively, showing the
system after folding the attached stabilizer in a forward manner
along the length of the payload cup, as it would appear in a
pre-launched configuration when loaded into a cartridge. FIG. 9A
provides an end-on view of the representative embodiments of a
payload delivery system in its pre-launched configurations of FIGS.
9C and 9D, viewed perpendicular to the 500-500' line, and showing
the payload cup, the forward folded stabilizer, and the connector,
in which the aft end of the payload cup is crimped closed using a
6-point star crimp. In the illustrated embodiment, the connector is
a "tri-grip" triangular blind rivet that accommodates the 6-point
star crimp to hold the forward folded stabilizer to the crimped end
of the payload cup very tightly.
[0056] FIG. 9B illustrates a perspective view of the payload
delivery system corresponding to that shown in FIG. 9A, showing the
system after folding the attached stabilizer in a forward manner
along the length of the payload cup, as it would appear in a
pre-launched configuration, for example, when loaded into a
cartridge.
[0057] FIG. 9C illustrates a sectional view of a representative
embodiment of a payload delivery system in its pre-launched
configuration showing the payload cup, the forward folded
stabilizer, and the connector, in which the aft end of the payload
cup is crimped closed. In the illustrated embodiment, the connector
is a blind rivet that holds the forward folded stabilizer to the
crimped end of the payload cup.
[0058] FIG. 9D illustrates a sectional view of a representative
embodiment of a payload delivery system in its pre-launched
configuration showing the payload cup, the forward folded
stabilizer, the pre-formed gas seal, and the connector, in which
the aft end of the payload cup is crimped closed. In the
illustrated embodiment, the connector is a blind rivet that holds
the forward folded stabilizer to the crimped end of the payload
cup, in which the pre-formed gas seal forms the head of the rivet
connector and is an integral part thereof, such that the unitary
gas seal-rivet attaches the stabilizer and the stabilizer. This
arrangement can also represent those payload delivery systems in
which the pre-formed gas seal is a separate component that is
attached to the payload cup having a crimped aft end to the
stabilizer with the rivet connector.
[0059] FIG. 10 illustrates a sectional view of one embodiment of a
loaded shotshell using the payload delivery system according to
this disclosure, in which the forward folded stabilizer is
illustrated in its pre-launched and pre-inverted condition in a
loaded cartridge.
[0060] FIGS. 11A-D illustrate perspective views of a stabilized
payload cup 200 before (FIG. 11A), during (FIG. 11B), and after
(FIG. 11C) forward folding the integrated vanes arising from the
longitudinal slits 220 in the tube 215 from which the stabilized
payload cup is formed. The extend of the slits defines the payload
cup portion 205 and the stabilizer portion 210 of the stabilized
payload cup 200. FIG. 11C further illustrates a separate pre-formed
gas seal 250, which can be used along with the stabilized payload
cup 200 to both form the bottom or base of the payload cup on which
the payload will sit and to provide its obturating function. In
FIG. 11D, the gas seal has been inserted to as to fit inside the
folded stabilized payload cup 200.
[0061] FIG. 11E illustrates a sectional view of one type of gas
seal 250 which can be used in various embodiments of this
disclosure, including those shown in FIGS. 11A-D. This gas seal 250
can be shaped to include a recessed forward portion 255 having a
smaller diameter that the gas sealing skirt 260 situated at the aft
portion of the gas seal. Some embodiments of this gas seal include
a concave portion at the fore end, as illustrated in FIG. 11E.
DETAILED DESCRIPTION OF THE INVENTION
[0062] This disclosure provides for a payload delivery system for
use in cartridges or launched in any fashion, the system including
a cup-shaped stabilizer that assists in the discharge, launching,
and ballistic performance of the payload. In some aspects, the
stabilizer can serve as a flight stabilizer for any payload or
payload cup to which it is attached. If desired and in some
embodiments, other components such as spacers can be used along
with the projectiles and the stabilizer. The cup-shaped stabilizer
can be adjusted to achieve different degrees of drag for a desired
ballistic performance. In other aspects, the cup-shaped stabilizer
can contain the payload in its own cavity and function as its own
type of payload container or payload cup. In this aspect, after a
certain distance downrange, the stabilizer can open and peel back
to cleanly separate from its payload. The potential advantages of
this payload delivery system include using relatively low-cost
components, avoiding complicated structures, generally eliminating
the high capital cost of new tooling, and affording an ease of
manufacturing.
[0063] Portions of this disclosure discuss shotshells as exemplary
cartridge systems that can use the disclosed components, and these
components may be discussed in terms of their shotshell
applications. However, this disclosure relates to virtually any
type of launching system such as a cartridge system and components
of such launching systems and cartridge systems for delivering any
number of payload types. For example, the components and methods
disclosed here are equally amenable to constructing shotshell
cartridges which launch their payload at high velocities, as they
are to constructing cartridges for launching liquid, powder or gel
payloads at low velocities. Thus, the disclosed payload delivery
systems are applicable to chemical, pyrotechnic, signaling,
non-lethal, and other complex cartridge systems, as well as
shotshells with bird shot, buck shot, or slug projectiles.
Accordingly, the disclosure and the claims are not limited to any
particular type of cartridge delivery system.
General Structure of the Payload Delivery System
[0064] In one aspect, there is provided a payload delivery system
comprising, in its pre-launched configuration: [0065] a) a payload
cup having an open fore end, a closed aft end, and a cylindrical
side wall defining a cavity; [0066] b) a cup-shaped stabilizer
coaxially aligned with the payload cup, having an open fore end, a
closed aft end, and a side wall comprising a plurality of vanes
defined by a plurality of cuts in the side wall; [0067] wherein the
payload cup is nested within the stabilizer, such that the payload
cup aft end is adjacent and attached to the stabilizer aft end.
[0068] c) optionally, a connector element that unites the payload
cup and the cup-shaped stabilizer. Representative embodiments
illustrated in the figures are generally shown with a connector
element to unite the payload cup and the cup-shaped stabilizer.
[0069] FIG. 1A illustrates a sectional view of a representative
embodiment of a payload delivery system 5 in its pre-launched
configuration, the payload delivery system including a payload cup
10 and a forward folded stabilizer 35, also referred to as a
cup-shaped stabilizer, and in this embodiment a connector, as
provided by this disclosure. Payload cup 10 has an open forward or
fore end 15, a closed rearward or aft end 20, and a cylindrical
side wall 25 defining a cavity that terminates at a rim 30
contiguous with the open fore end 15. The forwarded folding
stabilizer 35 is coaxially aligned with the payload cup 10 and has
an open forward or fore end 40, a closed rearward or aft end 45,
and a side wall 50 defining a cavity that terminates at an edge 55
contiguous with the open fore end 40. The side wall 50 comprises a
series of cut or slits therethrough, which are not shown in this
figure. As illustrated, the payload cup rearward end 20 is located
within the cup-shaped stabilizer cavity and adjacent the stabilizer
rearward end 45, such that the payload cup is nested within the
cup-shaped stabilizer. That is, the bottom of the payload cup 10
generally sits within and at the bottom of the cup-shaped, forward
folded stabilizer 35.
[0070] In FIG. 1A, a connector 60 joins or unites payload cup 10
and cup-shaped stabilizer 35 such that the bottoms of these
components are maintained in this contiguous and adjacent situation
after launch, and are not separated during flight. In this manner,
the stabilizer imparts its stabilizing and drag effect as it
unfolds and inverts during flight. While a simple rivet type
connector 60 is illustrated in FIGS. 1A-D, the payload delivery
system of this disclosure is not so limited, as the connector can
be selected from or alternatively can comprise a rivet, a screw, a
staple, a pin, a bolt, an anchor, an adhesive, a tack, or a nail,
or any similar structure that can unite the payload cup 10 and
cup-shaped stabilizer 35. However, the payload cup aft end and the
stabilizer aft end can be connected or attached by any means, and
attachment does not require a connector component. For example, the
payload cup and the cup-shaped stabilizer could be attached by a
melting process, by a punching method, by a sonic weld process, and
the like. Moreover, additional structures and functions can be
incorporated into the connector 60, such as a point or edge that is
exposed to the inside of the payload cup at the aft end, that
provides a means to puncture or rupture a capsule that houses a gel
or liquid payload contained within the stabilized payload cup.
[0071] FIG. 1B illustrates a sectional view of another
representative embodiment of a payload delivery system 5 in its
pre-launched configuration, showing the payload cup 10, the
cup-shaped stabilizer 35, and in this embodiment a connector 60. In
this embodiment, the payload cup 10 has a recessed aft portion 65,
a non-recessed forward portion 70, and an annular step 75 that
forms the transition between the two portions. The recessed aft
portion 65 has a smaller diameter than forward portion 70, and the
forward portion can remain in contact with the inner wall of the
cartridge when loaded. In some embodiments, the cup-shaped
stabilizer 35 can surround or fit around the recessed aft portion
65 of the payload cup when forward folded, such that the forward
portion 70 of payload cup has approximately the same outer diameter
as the cup-shaped stabilizer 35 when it is installed about the
recessed aft portion 65. The embodiment shown in FIG. 1B shows the
cup-shaped stabilizer edge 55 situated flush against the annular
step 75, which maintains the approximately same outer diameter in
the forward portion 70 as in the recessed aft portion 65 with the
stabilizer side wall 50 installed. In this typical embodiment, the
stabilizer side wall 50 is approximately the same length as the
recessed aft portion 65 side wall, although other embodiments
provide that the cup-shaped stabilizer side wall 50 can be longer
or shorter than the aft portion 65 side wall. The side wall 50
comprises a series of cut or slits therethrough, which are not
shown in this figure. A connector 60 of any type can be employed to
join the payload cup 10 and cup-shaped stabilizer 35, or as
disclosed herein, the payload cup and cup-shaped stabilizer can be
joined without a discrete connector element.
[0072] FIGS. 1C and 1D illustrate perspective views of
representative embodiments of a payload delivery system in its
pre-launched configuration 5, showing the cup-shaped stabilizer 35
and the relative arrangement of the payload cup 10 and stabilizer
35 components. In both FIGS. 1C and 1D, the cup-shaped stabilizer
fore end 40, aft end 45, cut cylindrical side wall 50 comprising
vanes 90, and stabilizer edge 55 are seen in perspective. The vanes
90 are defined by the cuts 80 in the stabilizer side wall 50, and
longitudinal cuts that extend from the stabilizer aft portion 45 to
the forward edge 55 of the stabilizer are particularly illustrated
in FIGS. 1C and 1D. The perspective view shown in FIG. 1C
corresponds to the representative embodiment shown in FIG. 1A,
showing the forward folded stabilizer that surrounds the payload
cup, the stabilizer vanes extending the full length of the payload
cup. The perspective view shown in FIG. 1D corresponds to the
representative embodiment shown in FIG. 1B, showing the forward
folded stabilizer that surrounds a portion of the payload cup, the
stabilizer vanes extending the length of the recessed aft portion
of the payload cup.
[0073] In one aspect, and while not limiting, the cut side wall of
the cup-shaped stabilizer defining the vanes can extend any portion
of the length of the cylindrical side wall of the payload cup and
in some embodiments, can even extend greater than the length of the
cylindrical side wall of the payload cup. Some embodiments include
a cup-shaped stabilizer side wall and vanes that generally can
extend the entire length of the cylindrical side wall of the
payload cup. The use of these substantially full-length stabilizer
side walls and vanes generally allows the use of thinner payload
cups than typically would be required if no double-layer comprising
stabilizer material and payload cup material were used. A
construction in which the stabilizer side wall and the payload cup
overlap in their pre-launched configuration provides the temporary
lamination effect of the forward folded vanes of the stabilizer and
the payload cup for strength and allows relatively thin materials
to be used for both the stabilizer and payload cup if desired.
[0074] By way of example, the cut side wall of the stabilizer and
the vanes defined by the cuts in the side wall can extend about 10%
the length of the cylindrical side wall of the payload cup;
alternatively, about 20%; alternatively, about 30%; alternatively,
about 40%; alternatively, about 50%; alternatively, about 60%;
alternatively, about 70%; alternatively, about 80%; alternatively,
about 90%; alternatively, about 100%; alternatively, about 110% the
length of the cylindrical side wall of the payload cup. In some
embodiments, the cut side wall of the stabilizer and the vanes
defined by the cuts in the side wall can extend at least 5% the
length of the cylindrical side wall of the payload cup. In another
aspect, the cut side wall of the cup-shaped stabilizer can extend
at least 10%, at least 15%, at least 20%, at least 25%, at least
30%, at least 35%, at least 40%, at least 45%, at least 50%, at
least 55%, at least 60%, at least 65%, at least 70%, at least 75%,
at least 80%, at least 85%, at least 90%, at least 95%, or about
100%, the length of the cylindrical side wall of the payload cup.
Typically, the cut side wall of the stabilizer and the vanes
defined by the cuts in the side wall can extend at least 75%, at
least 80%, at least 85%, at least 90%, or at least 95% the length
of the cylindrical side wall of the payload cup. In further
embodiments, the cut side wall of the cup-shaped stabilizer can
extend 100% or greater than 100% the length of the cylindrical side
wall of the payload cup if it is desired to provide additional
material forward of the aft portion of the payload cup that can be
folded over the open fore end of the payload cup.
[0075] FIGS. 1A-D illustrates another aspect of this disclosure,
namely that the payload cup 10 is not required to have slits in its
cylindrical side wall for the wad structure to function. Slits must
be either molded or cut into conventional payload cups and the
consistent molding or cutting of slits in conventional cups can be
difficult. Therefore, the present payload cup, which does not
require slits, affords improvements in ease of manufacturing and
costs as compared to conventional wad structures. Slits are not
required in the present payload cup because drag is provided by the
cup-shaped stabilizer having vanes that unfold and invert during
flight, rather than from the petals of a conventional slit payload
cup that open during flight. Moreover, the absence of slits in the
payload cup component of the present payload delivery system
provides better barrel protection when used in shotshells,
particularly for hard shot such as steel, because there are no cut
or weakened areas that can allow hard pellets to work through as
they are accelerated down the barrel, thereby making contact with
barrel and/or choke. While the disclosed payload delivery system
does not require slits in the payload cup to function, the payload
cup can incorporate slits, cut-outs, perforations, and the like, if
so desired. In this case, structures such as perforations can
impart a greater stabilizing function of the cup-shaped stabilizer
as the vanes open and invert.
[0076] In accordance with one further aspect of this disclosure,
there is provided a payload delivery system comprising, in its
pre-launched configuration: [0077] a) a payload cup having an open
fore end, a closed aft end, and a cylindrical side wall defining a
cavity; [0078] b) a cup-shaped stabilizer coaxially aligned with
the payload cup, having an open fore end, a closed aft end, and a
side wall comprising a plurality of vanes defined by a plurality of
cuts in the side wall, that terminates at an edge contiguous with
the open fore end; [0079] wherein the payload cup is nested within
the stabilizer, such that the payload cup aft end is adjacent and
attached to the cup-shaped stabilizer aft end; and [0080] c)
optionally, a connector that unites the payload cup and the
cup-shaped stabilizer; further comprising: [0081] d) an obturating
component adjacent the aft end of the cup-shaped stabilizer,
comprising a pre-formed gas seal or an obturating medium. In this
aspect, the payload delivery system can further comprise: d) a
pre-formed gas seal adjacent the aft end of the cup-shaped
stabilizer and coaxially aligned with the payload cup and the
stabilizer, wherein the connector further unites the gas seal with
the payload cup and the cup-shaped stabilizer. When the pre-formed
gas seal is further united in this manner, the stabilizer vanes
unfold and invert over the pre-formed gas seal as the entire
delivery system including the gas seal component is launched
downrange. In other aspects, it is not necessary to attach the
pre-formed gas seal to the combined and attached stabilizer and
payload cup, as the combined stabilizer and payload cup simply can
sit or be situated forward of the pre-formed gas seal in a
cartridge. In another aspect, and in contrast to including a
pre-formed gas seal, the payload delivery system can further
comprise: d) an obturating medium adjacent the aft end of the
cup-shaped stabilizer. This so-called "wadless" technology, which
does not employ a pre-formed gas seal, is further described
herein.
Forward Folding Stabilizer Structure
[0082] An aspect of this disclosure is provided in the structure
and composition of the cup-shaped and forward folding stabilizer.
For example, in one aspect, the forward folding stabilizer can be
made of, or alternatively can comprise, paper, at least one
polymer, or fabric. In its pre-launched configuration, the
stabilizer is cup-shaped, and the vanes are forward folded,
somewhat reminiscent of an umbrella, in which the stabilizer has an
open top (fore end), a closed bottom (aft end), and a cut side wall
that can be cylindrical to slightly frustoconical. The stabilizer
sidewall 50 in the pre-launched stabilizer 35 comprises a plurality
of vanes or ribbons defined by a plurality of cuts in the side
wall, generally extending from the aft end 45 of the stabilizer 35
to the stabilizer edge 55. The cup-shaped stabilizer 35 can impart
a stabilizing effect when it is attached to a payload cup, because
the stabilizer structure includes forward folded vanes 90 that open
or unfold and invert in a controlled and symmetric fashion during
flight. As a result, the payload delivery system as a whole can be
decelerated in a highly stable manner and release its payload in a
controlled and tailored manner.
[0083] The stabilizer side wall 50 can include any number, sizes,
and shapes of cuts, including a plurality of longitudinal or
substantially longitudinal cuts therein. By the term substantially
longitudinal, it is intended that the cuts do not vary more than 30
degrees from longitudinal; alternatively, not more than 25 degrees
from longitudinal; alternatively, not more than 20 degrees from
longitudinal; alternatively, not more than 15 degrees from
longitudinal; alternatively, not more than 10 degrees from
longitudinal; or alternatively, not more than 5 degrees from
longitudinal. In one aspect, the cut side wall of the stabilizer
can be cut in a fashion such that the vanes cover substantially all
the side wall area of the payload cup when forward folded, because
each vane is flush against a neighboring vane. Alternatively, the
cut side wall of the stabilizer can be structured such that at
least some of the vanes are missing, shaped in different ways, have
gaps between the vanes such that each vane is not flush against a
neighboring vane, and other configurations. Still alternatively,
the cut side wall of the stabilizer can be structured such that at
least some of the vanes overlap each other, which can aid in the
sabot function.
[0084] The use of forward folding stabilizers having the disclosed
structures can afford certain advantages in manufacturing the
disclosed cartridges. For example and while not intending to be
limiting, the stabilizer component can be manufactured from flat
sheets of suitable materials. The desired shape of the material can
be die cut or punched from flat sheets and subsequently cut in the
appropriate manner using established technology to create the
stabilizing vanes or ribbons. The manufacturing advantages of using
flat sheets include the relative low cost of flat sheet materials
as compared to other forms. Further, using flat sheets avoids the
limitations of injection molding in terms of high cost,
restrictions in compositions suitable for molding, and initial
capital costs for tooling.
[0085] FIGS. 2A-C illustrate perspective views of three different
payload delivery systems according to this disclosure, each having
a different type of forward folded stabilizer 35, and each
stabilizer having vanes 90 extending a substantial portion of the
length of the payload cup 10. The left side views correspond to a
post-launching configuration showing the stabilizers after they
unfold and invert during flight. The right side views correspond to
pre-folded stabilizers prior to loading into a cartridge, and also
demonstrate the stabilizers part way through the unfolding stage
during flight. FIG. 2A illustrates a payload delivery system with a
forward folding stabilizer having identical vanes, in which no
vanes or fins have been removed, perforated, or shortened. FIG. 2B
illustrates a payload delivery system with a forward folding
stabilizer in which alternating vanes have been removed. FIG. 2C
illustrates a payload delivery system with a forward folding
stabilizer in which alternating vanes have been removed and every
other remaining vane has been shortened.
[0086] FIGS. 3A-B illustrate perspective views of two different
payload delivery systems according to this disclosure, each having
a different alternative type of forward folding stabilizer, and
each stabilizer extending a substantial portion of the length of
the payload cup. Each figure corresponds to a post-launching
configuration showing the stabilizer after unfolding and inverting
during flight. FIG. 3A illustrates an alternative forward folded
stabilizer 35 in which the stabilizer side wall comprises a
plurality of vanes 90 defined by a plurality of parallel, but
non-longitudinal, cuts 80 in the side wall 50. That is, the cuts in
FIG. 3A are not parallel to the line of flight. FIG. 3B illustrates
an alternative forward folded stabilizer in which the stabilizer
side wall comprises a plurality of vanes defined by a two types of
non-longitudinal cuts (not parallel to the line of flight) in the
side wall in which alternating cuts are parallel.
[0087] Each of FIGS. 4A-C further illustrate various aspects of the
forward folding component, demonstrating methods by which cuts can
be made in the stabilizer side wall. These aspects and embodiments
are representative of the forward folding component used as a
stabilizer in combination with a separate payload cup to which it
is attached and when it is deployed as stand-alone or "stabilizer
cup", itself containing the payload in the absence of a separate
payload cup component.
[0088] Therefore, in accordance with an aspect, this disclosure
provides a payload delivery system that can comprise, in its
pre-launched configuration: [0089] a) a cup-shaped stabilizer
having an open fore end, a closed aft end, and a side wall
comprising a plurality of vanes defining a cavity and defined by a
plurality of longitudinal cuts in the side wall; [0090] b) an
obturating component adjacent the stabilizer aft end; and [0091] c)
at least one payload contained within the cavity of the stabilizer.
This aspect does not require a separate payload cup and cup-shaped
stabilizer in contrast to that shown FIGS. 1A-D. The FIGS. 4A-C
constructions can be particularly useful for launching certain
projectiles such as powders, gels, liquids contained in a breakable
or rupturable container, and the like, for example, at relatively
low velocities. In these situations, the stabilizer cup can provide
a clean separation of the cup from the payload. Moreover, the FIGS.
4A-C constructions can be used for launching certain solid
projectiles to which they are attached and therefore function as
stabilizing components for the solid projectile. It is also not
necessary to attached the forward folding component of FIGS. 4A-C
to a solid projectile, in which case it can serve a sabot function
and protection function. Again, the particular structural features
cut in the side wall are not limited to simple slits as shown in
FIG. 4A, but can encompass a wide variation in structures.
[0092] While each of FIGS. 4A-5C generally show the cuts,
perforations, and/or cut outs extending from the stabilizer edge 55
to the stabilizer aft end 45, embodiments in which cuts,
perforations, cut outs, and the like that extend a portion of the
distance from the stabilizer edge 55 to the stabilizer aft end 45
are also envisioned and encompassed by this disclosure. Moreover,
features that are longitudinal, that is, parallel to the initial
payload line of flight, and those that are not longitudinal are
also envisioned. FIG. 4A provides a perspective view of a forward
folding component that includes longitudinal slits through the
stabilizer side wall. FIG. 4B provides a perspective view of a
forward folding component that includes perforations through the
stabilizer side wall. FIG. 4C provides a perspective view of a
forward folding component that includes cut-outs through the
stabilizer side wall with different vane lengths. By further
example, variously-shaped and -sized cuts, cut-outs, slits, holes,
perforations, and the like, whether generally longitudinal,
transverse, or otherwise, or combinations thereof, can be used to
impart additional stabilizing influence on payload delivery system
as it is launched. In this aspect, for example, perforations or
cut-outs can be employed to provide various degrees of stability
during flight, as a function of the number, size, and patter of the
perforations or cut-outs. Thus, the features shown in FIGS. 4A-C
are merely illustrative of any number, size, shape, and pattern of
cuts, cut-outs, perforations, and the like that can be included in
the forward folding component for their stabilizing function.
[0093] The cup-shaped and forward folding stabilizer used in any
disclosed embodiments of the payload delivery systems can be made
of, or alternatively can comprise, any material that can be folded
and cut, including for example, paper, coated paper, paper
composites, woven fabric, non-woven fabric, a wide range of
polymers and plastics, various composites, various laminates, and
the like. For example, the forward folding stabilizer can be made
of, or alternatively can comprise, a polyolefin material, such as
homopolymers or copolymers of polyethylene, polypropylene, and/or
other olefin monomers. Paper that is coated on one or both sides
with various polymers, resins, or other materials can also be used.
Further, the stabilizer can be made of, or alternatively can
comprise, various grades and types of paper, including any number
of laminates or composites using such paper. In a further aspect,
the stabilizer can be made of or alternatively can comprise a
material that is from about 0.1 mil to about 25 mil in thickness,
for cartridges that are generally applicable to being discharged
while hand-held. However, this range is merely illustrative, as the
thickness and size of the stabilizer can be altered as necessary to
accommodate the requirements of the cartridge size, desired initial
velocity and/or pressure on launching, and the like. Generally,
there is no limit or restriction on the material thickness or
material type that can be used according to this disclosure, as
long as that sample can be folded and cut into a suitable structure
and used as provided herein.
[0094] While materials such as nonwovens comprising spun polyolefin
fibers such as Tyvek.RTM. can be used as the stabilizer, for most
applications, the cup-shaped stabilizer can be made of paper or a
plastic material of some type, including materials that comprise
paper or plastic. Suitable paper can include a wide range of basis
weights and can be coated or uncoated. By way of example, a paper
stabilizer can be coated to improve functional properties such as
strength or stiffness or rigidity. Numerous paper coatings and
their functional effect on the coated paper properties are
well-understood in the paper art. Typical ingredients used in
formulating a paper coating composition can include water,
inorganic fillers, dispersants for the filler, binders and optional
co-binders, water retention aids, rheology modifier to yield the
proper viscosity profile to apply the coating, and the like.
The Payload Cup
[0095] Generally, the materials used to construct the payload cup
are well known and varied, and the payload delivery system is not
limited to a particular material. For example, the payload cup can
be made of, or alternatively can comprise, a range of polymers or
plastics, paper including paper composites and laminates,
combinations of polymers and paper such as coated paper or
laminates of paper and polymers, and the like. A number of
composite or laminate materials can be used. Unlike the cup-shaped
stabilizer, the payload cup shown as 10 in FIGS. 1-4, retains its
shape upon being launched. By way of example, the payload cup can
be made of or alternatively can comprise a polyolefin material,
such as homopolymers or copolymers of polyethylene, polypropylene,
and/or other olefin monomers. Paper materials that are relatively
stiff such as paper that is coated with various polymers, resins,
or other materials can also be used, as can convoluted paper and
other types of laminated materials.
Payload Delivery System Including an Integral or Separate Gas
Seal
[0096] Many modern cartridges include a gas seal or obturating
component, either as a separate element in the cartridge or formed
as an integral part of projectile or payload container. For
example, modern shotshell cartridges typically include a gas seal
as a separate element in the cartridge or formed as an integral
part of the wad and payload cup (shot cup) itself As appreciated by
the skilled artisan, the payload delivery system of this disclosure
also can use any type of gas seal element known in the art. For
example, a discrete pre-formed gas seal can be used to separate the
powder charge from the payload delivery system and payload.
Alternatively, so-called wadless technology described in U.S. Pat.
No. 7,814,820 and U.S. Patent Application Publication No.
2011/0017090 by Menefee, both of which are incorporated herein by
reference in their entireties, works well with the payload delivery
system of this disclosure. In addition, embodiments having an
integral gas seal component that is part of the payload delivery
system itself also work well and are described here. For example,
the connector that is used to attach the payload cup with the
stabilizer can have a gas seal portion or "head" that is directed
toward the propellant when the connector is attached.
[0097] FIGS. 5A-C illustrate representative aspects and embodiments
of a payload delivery system in its pre-launched configuration,
that includes a pre-formed gas seal 110 as an attached component of
the payload delivery system that further includes the payload cup
10 and the cup-shaped stabilizer 35 as previously described. FIG.
5A illustrates a sectional view of an example of a payload delivery
system in its pre-launched configuration showing the payload cup
10, the forward folded stabilizer 35, a pre-formed gas seal 110,
and the connector 60, as provided by this disclosure. In FIG. 5A,
the pre-formed gas seal 110 is coaxially aligned with and
oppositely directed to the payload cup 10 and the cup-shaped
stabilizer 35, adjacent the rearward or aft end 45 of stabilizer
35. Gas seal 110 has a side wall that generally defines a
gas-sealing skirt 115. If desired, and as illustrated in FIG. 5A,
the payload cup, cup-shaped stabilizer, and gas seal can be united
by a connector 60, for example, the rivet-type connector shown in
FIG. 5A, which is typically a plastic or polymer material. Any type
of connector can be used in this aspect. However, this connection
of the gas seal to the remainder of the payload delivery system is
not required.
[0098] FIG. 5B illustrates a perspective view of representative
aspects of a payload delivery system in its pre-launched
configuration corresponding to that shown in FIG. 5A, showing the
relative arrangement of a stabilizer 35 with its forward folded
vanes 90 which surround and extend the full length of the payload
cup, and further includes a pre-formed gas seal. This arrangement
represents those payload delivery systems that either: 1) attach
the pre-formed gas seal to the payload cup and the forward folded
stabilizer, corresponding to the FIG. 5A arrangement; or 2) attach
only the payload cup and the forward folded stabilizer, the
combination of which sits atop a pre-formed gas seal. Thus, some
embodiments can attach the gas seal to the aft end of the combined
and nested payload cup and stabilizer, while other embodiments can
use a separate gas seal that is not attached or integral the
payload cup and cup-shaped stabilizer combination.
[0099] FIG. 5C illustrates a sectional view of representative
aspects of a payload delivery system in its pre-launched
configuration showing the payload cup 10 having a recessed aft
portion 65, a stabilizer 35 having forward folded vanes 90
extending the length of the recessed aft portion, a pre-formed gas
seal, and the connector, as provided by this disclosure.
[0100] Thus, payload cup 10, cup-shaped stabilizer 35, and gas seal
110 can all be united by a connector 60, for example, the
rivet-type connector shown in FIG. 5A and FIG. 5C, which typically
can be a plastic or polymer material, for cost and ease of
manufacturing and use purposes. As before, connector 60 of any type
can be used to join the payload cup, stabilizer, and gas seal, for
example, a rivet, a screw, a staple, a pin, a bolt, a brad, an
anchor, an adhesive, a tack, or a nail of some type can be
used.
Unfolding and Inversion of the Cup-shaped Stabilizer During
Flight
[0101] With reference to the general structure of the payload
delivery system described herein, FIGS. 6A-C illustrate a
progression of end-on views of a downrange observer (left) and
perspective views (right) of the payload delivery system, without
showing a particular payload, as the forward folded stabilizer
unfolds and inverts to slow the payload delivery system in a
stabilized manner. The particular embodiment illustrated has a
forward folded stabilizer 35 with eight vanes 90, extending a
portion of the length of the payload cup 10, according to various
disclosed embodiments. Also illustrated is a connector 60 by which
the stabilizer 35 is attached to the payload cup 10. The payload
delivery system is illustrated before or instantly after launching
(FIG. 6A, time 1), early in the unfolding stage (FIG. 6B, time 2),
and later in the unfolding and inversion stage (FIG. 6C, time 3).
FIG. 6C also illustrates the vanes trailing from the aft edge of
the payload cup as would occur when a pre-formed gas seal is
attached to the aft end of the stabilizer and the payload cup, such
that the vanes drape over the gas seal and naturally trail from the
payload cup aft edge. While not theory bound, it is believed that
the stabilizer vanes may function in a similar manner as a
shuttlecock in that they add high drag and high stability to the
wad structure as it releases its projectile or payload.
[0102] FIGS. 7A-C illustrate sectional views of the progression of
the payload delivery system, which evolves over time and downrange
distance, with an attached pre-formed gas seal, without showing a
particular payload. These figures demonstrate how the vanes of the
forward folded stabilizer unfold and invert such that they are
rearward folded to slow the payload delivery system in a stabilized
manner. The payload delivery system is illustrated before or
instantly after launching the payload or projectile(s) from the
cartridge (FIG. 7A, time 1), early in the unfolding stage (FIG. 7B,
time 2), and later in the unfolding and inversion stage (FIG. 7C,
time 3). The embodiment shown in FIGS. 7A-C illustrates the vanes
trailing from the aft edge of the payload cup where the pre-formed
gas seal attaches to the aft end of the stabilizer and the payload
cup. Seen in FIGS. 7A-C are payload cup 10, cup-shaped stabilizer
35 in its various stages of unfolding and inverting, pre-formed gas
seal 110, all of which are connected by connector 60. It is
emphasized that this figure is illustrative, and is not intended to
disclose a "snapshot" or limit the exact spatial orientation of the
unfolding stabilizer and vanes at any point in time during the
flight sequence. Moreover, FIG. 7 is not intended to be limiting by
illustrating the symmetric unfolding of a stabilizer.
[0103] As shown in FIGS. 7A-C having an attached pre-formed gas
seal, the vanes drape over the gas seal and naturally trail from
the payload cup aft edge. While not theory bound, it is believed
that the stabilizer vanes may function in a similar manner as a
shuttlecock during flight and add high drag and high stability to
the payload delivery system as it releases its projectile or
payload. In those embodiments that do not have an integral or
attached pre-formed gas seal, such as when using a pre-formed gas
seal that is not attached or when using wadless technology, and
while not intending to be theory bound, it is envisioned that later
in the flight sequence the stabilizer can trail the payload cup and
contact the cup only by way of the connector 60. The high stability
and high drag provided by the cup-shaped stabilizer, in turn,
achieves a clean projectile or payload release from the payload
cup.
[0104] While not intending to be theory bound, the cup-shaped
stabilizer can be used in cartridges that launch their payloads
supersonically such as shotshells, and in cartridges that might
launch their payloads sub-sonically, such as chemical cartridges or
possibly certain signal cartridges. When initial velocity of the
payload system is supersonic, the cup-shaped stabilizer maintains
its forward facing configuration until after it is launched and is
in flight. Again, while not theory-bound, it is expected that once
clear of the constrictions of a cartridge or launching tube, a
supersonically launched payload system will open its cup-shaped
stabilizer rapidly with assistance from sonic shock waves and not
necessarily from drag, whereas in subsonic launching, the opening
of the cup-shaped stabilizer is expected to be more draft and air
resistance influenced.
[0105] When air resistance plays a role in the unfolding mechanism,
partial opening of the vanes of the stabilizer exposes additional
area of the stabilizer vanes to air resistance, a feature made
possible by the cut and forward folded structure that initially
maintained the vanes in a forward folded configuration. As
unfolding progresses, the amount of exposed area of stabilizing
material increases as the payload delivery system moves further
downrange. Moreover, the stabilizer also begins to invert as
unfolding advances, much like an umbrella is inverted by a strong
gust of wind. Late in the trajectory of such a payload delivery
system, it is likely that the stabilizer trails the payload cup and
generally contacts the cup only by way of the point or area of
connection to the payload cup, unless there is also an attached
pre-formed gas seal. Therefore, this opening and reversal of
direction of the stabilizer vanes imparts high stability and high
drag to what it is attached, which, in turn, achieves a clean
projectile or payload release from the payload cup.
[0106] Again, while not intending to be bound by theory, it is
believed that the stabilizer and vanes may function in a similar
manner as a shuttlecock, that is, it adds high drag and high
stability to the wad structure as it releases its projectile or
payload. Because the disclosed design is extremely aerodynamically
stable and tends to re-orient when subjected to destabilizing
forces, the stabilizer will resist the tendency to yaw and pitch
that would degrade flight stability and performance of the payload
as it releases from its delivery system. In the present design and
like the shuttlecock, the stabilizer remains attached to the
payload cup for continual stability and drag and thereby enhancing
ballistic performance.
[0107] The opening of the stabilizer and/or the drag imparted by
the stabilizer vanes to the payload delivery system can be
regulated as desired, for example, by adjusting the longitudinal
length of the vanes 90 of the stabilizer side wall 50 of the
cup-shaped stabilizer and/or by the size, shape, and number of the
slits, perforations, cut-outs, and the like in its side wall. While
not theory bound, it is thought that the location of the stabilizer
on the aft portion of the payload delivery system, that is, on the
bottom (primer end or uprange end), helps impart the shuttlecock
stabilizing effect. This feature contrasts with conventional
one-piece plastic wads having longitudinal slits in the shot cup
which form petals that peel open during flight. Stiff wads such as
used in shotshells for steel shot can have petals that may open up
unevenly and inconsistently, and the resulting instability can
cause the opening wad to tumble, pitch, or yaw before clean
separation of the wad from the shot column has been achieved.
Crimped Payload cups
[0108] Among other things, this disclosure provides for a
cylindrical payload cup having an open fore end and a closed aft
end and a cup-shaped stabilizer that is nested within the payload
cup. According to one aspect, the payload cup can have a closed aft
end that is closed by crimping the aft end. By crimping the aft end
of the payload cup closing, a structure and method of forming the
closed payload cup can be attained at low cost and with minimal
retooling and capital costs. Moreover, by using a simple connector
such as a pop rivet, the entire crimped payload cup, cup-shaped
stabilizer, and connector structure can be obtained easily and at
low cost.
[0109] FIG. 8 illustrates some of the aspects and embodiments of
the crimped payload cup of the present disclosure. Specifically,
FIGS. 8A-D illustrate aspects of the payload delivery system prior
to folding the attached stabilizer in a forward manner along the
length of the payload cup, and prior to loading the system into a
cartridge. FIG. 8A illustrates an end-on view, viewed perpendicular
to the 500-500' line and into the open end of the payload cup of a
representative embodiment of a payload delivery system 5 prior to
folding the stabilizer 35 and before loading the system into a
cartridge. This figures shows the payload cup 10, the stabilizer 35
prior to folding, and the connector 60, in which the aft end 20 of
the payload cup is crimped closed using a 6-point star crimp 120,
although this aspect is not limited to a specific type of crimp.
Also illustrated is the connector 60 extends all the way through
the stabilizer 35 and the crimped aft end 20 of the payload cup 35
to join these elements. In the illustrated embodiment, the
connector is a "tri-grip" triangular blind rivet that accommodates
the 6-point star crimp to holds the cup-shaped stabilizer to the
crimped end of the payload cup very tightly. The vanes 90 of the
stabilizer are illustrated in their pre-folded orientation having a
size and shape that would allow them to fold forward in a manner
that each vane is more-or-less flush or touching a neighboring
vane.
[0110] FIG. 8B illustrates a perspective view of a representative
embodiment of a payload delivery system corresponding to that shown
in FIG. 8A, prior to folding stabilizer vanes forward along the
payload cup side wall and before loading the system into a
cartridge. In this view, the connector is not seen. In both FIGS.
8A and 8B, the presence or absence of an attached pre-formed gas
seal is not seen or illustrated.
[0111] FIG. 8C illustrates a sectional view of a representative
payload delivery system, showing the payload cup 10, the stabilizer
35 prior to folding the stabilizer vanes 90 and before loading the
system into a cartridge, and the connector 60, in which the aft end
20 of the payload cup is crimped closed using a crimp 120. This
view is prior to folding the stabilizer vanes 90 and before loading
the system into a cartridge, corresponding to FIGS. 8A and 8B. In
the illustrated embodiment, the connector is a blind rivet that
holds the stabilizer to the crimped end of the payload cup.
[0112] FIG. 8D illustrates a sectional view of a representative
payload delivery system, also illustrating the payload cup 10, the
stabilizer 35 prior to folding the stabilizer vanes 90 and before
loading the system into a cartridge, and the connector 60, in which
the aft end 20 of the payload cup is crimped closed using a crimp
120. This view is also prior to folding the stabilizer vanes 90 and
before loading the system into a cartridge, corresponding to FIGS.
8A and 8B. The embodiment shown illustrates a "unitary" pre-formed
gas seal and connector 130, also termed a "gas seal connector",
which include a gas seal portion or skirt 115 and a connector
portion comprising a blind rivet that is integral with the gas seal
portion. The illustrated gas seal connector 130 includes a blind
rivet that holds the stabilizer 35 to the crimped end of the
payload cup 10, in which the pre-formed gas seal forms the head of
the rivet and is an integral part thereof, thereby forming a
unitary gas seal-rivet piece with both connector and gas sealing
functions. This FIG. 8D arrangement can also represent those
payload delivery systems in which the pre-formed gas seal is a
separate component that is attached to the payload cup having a
crimped aft end to the cup-shaped stabilizer with the rivet
connector. Therefore, this disclosure further provides for a
unitary pre-formed gas seal comprising: [0113] a) a gas seal
portion having a side wall that defines a gas-sealing skirt; and
[0114] b) a connector portion integral to the gas seal portion;
[0115] wherein the gas seal portion and the connector portion are
coaxially aligned and oppositely directed.
[0116] FIGS. 9A-D illustrate embodiments of the payload delivery
system corresponding to FIGS. 8A-D, respectively, showing the
system after forward folding the vanes 90 of the attached
stabilizer 35 along the length of the payload cup 10, as it would
appear in a pre-launched configuration when loaded into a
cartridge. FIG. 9A provides an end-on view of the representative
embodiments of a payload delivery system in its pre-launched
configurations of FIGS. 9C and 9D, viewed perpendicular to the
500-500' line, and showing the payload cup 10, the forward folded
stabilizer 35, and the connector 60, in which the aft end of the
payload cup is crimped closed using a 6-point star crimp 120. The
exemplary "tri-grip" triangular blind rivet is shown to accommodate
the 6-point star crimp to hold the forward folded stabilizer to the
crimped end of the payload cup very tightly.
[0117] FIG. 9B illustrates a perspective view of the payload
delivery system corresponding to that shown in FIG. 9A, showing the
system after forward folding the vanes of the attached stabilizer
35 along the length of the payload cup 10 such that they cover the
payload cup side wall, as it would appear in a pre-launched
configuration when loaded into a cartridge.
[0118] FIGS. 9C and 9D provide sectional views that correspond to
FIGS. 8C and 8D, showing the payload delivery system after forward
folding the vanes 90 of the attached stabilizer 35 along the length
of the payload cup 10, as it would appear in a pre-launched
configuration when loaded into a cartridge.
[0119] As in FIG. 8D, FIG. 9D also shows a "unitary" pre-formed
"gas seal connector" 130, which combines a gas seal skirt and a
connector comprising a blind rivet that is integral with the gas
seal portion. The pre-formed gas seal forms the head of the rivet
and accomplishes both connector and gas sealing functions. This
FIG. 9D arrangement also can represent those payload delivery
systems in which the pre-formed gas seal is a separate component
that is attached to the payload cup having a crimped aft end to the
cup-shaped stabilizer with the rivet connector.
Wadless Gas Seal Technology with the Payload Delivery System
[0120] As provided in this disclosure, the gas seal that separates
the powder charge from the rest of the payload delivery system and
payload can take on any number of configurations. For example, the
gas seal can be a separate structure that is not attached to the
payload cup and cup-shaped stabilizer combination, it can be an
integral gas seal that is part of the payload cup and wad
structure, or the so-called wadless technology using a granulated
obturating medium can be used to seal the gases from the ejecta.
Wadless materials and methods that are suitable for use with the
payload delivery system of this disclosure are described in U.S.
Pat. No. 7,814,820 and U.S. Patent Application Publication No.
2011/0017090 by Menefee, both of which are incorporated herein by
reference in their entireties. While not intended to be limiting,
wadless technology may be useful in launching powders and gels and
the like relatively short distances, such as in a cartridge
designed for distributing powders indoors or generally within
closed confines.
[0121] As provided in the incorporated references, the wadless
technology provides an extremely versatile system to launch a wide
range of projectiles downrange. In this aspect, for example, the
cartridge can comprise: [0122] a) a cartridge case having a fore
end and an aft end and, comprising a primer situated at the aft
end; [0123] b) a propellant adjacent the primer; [0124] c) an
obturating medium adjacent the propellant; [0125] d) a payload
delivery system adjacent the obturating medium, in which the
payload delivery system comprises [0126] 1) a payload cup having an
open fore end, a closed aft end, and a cylindrical side wall
defining a cavity; [0127] 2) a cup-shaped stabilizer coaxially
aligned with the payload cup, having an open fore end, a closed aft
end, and a side wall comprising a plurality of vanes defined by a
plurality of cuts in the side wall; [0128] wherein the payload cup
is nested within the stabilizer, such that the payload cup aft end
is adjacent and attached to the stabilizer aft end; and [0129] 3) a
connector that unites the payload cup and the cup-shaped
stabilizer. and [0130] e) a payload at least partially contained
within the cavity of the payload cup; [0131] wherein the cartridge
does not contain a pre-shaped gas seal. The obturating medium is
not a pre-formed gas seal, but is usually a finely divided or
granular medium such as a particulate polyolefin, which is
generally contiguous with the propellant and which forms into a
dense obturating mass when subjected to the pressure of firing the
cartridge.
[0132] In one aspect, the material constituting the obturating
medium can be in the form of particles of any shape. For
manufacturing ease, the obturating medium generally can be
free-flowing and non-agglomerated. A range of sizes and size
distributions of particles are useful as obturating medium.
According to one aspect and by way of example, a suitable
obturating medium can be one that generally combines the properties
of irregularly shaped particles and the small particle sizes
disclosed herein. While not intending to be bound by theory, it is
believed that, among other things, irregularly-shaped particles
impart a high critical angle of repose to the obturating medium,
which may also reflected in the ability of the particles to
interlock or bridge. Also while not intending to be bound by
theory, it is thought that under the extreme shear stress of the
rapidly expanding combustion gases, the obturating medium behaves
in a non-Newtonian fashion, conforming to parameters of the chamber
throat or forcing cone and obturating the hot gases, while
protecting and insulating the projectile(s).
[0133] Other features of suitable particles for the obturating
medium can be found in U.S. Pat. No. 7,814,820 and U.S. Patent
Application Publication No. 2011/0017090. For example, there does
not appear to be a lower limit of suitable particle sizes that
work. Combinations of more than one type or material or particle
can be used to form the obturating medium, each of which can have
the same approximate upper limit of useful particle sizes for good
obturating effect. In one aspect, low density polyethylenes such as
the Microthene.RTM. MN 701 series of polyethylenes from Equistar
work well, either alone or in combination with other obturating
media materials.
[0134] In accordance with another aspect of the wadless technology,
a flow control additive can be used in conjunction with the
obturating medium during loading and manufacturing, if desired. A
flow control additive usually takes the form of particles that can
be larger than the obturating medium particles and have antistatic
or non-static properties. Typically, the volume fraction of the
flow control component is less than the volume fraction of the
obturating medium particles. For example, a portion of 2 parts by
volume of obturating medium combined with a portion of 1 part by
volume of a flow control component can be used. The smaller and the
larger particles can have the same composition or can have
different compositions. For example, a combination of small
polyethylene or polypropylene obturating particles with larger
polyethylene or polypropylene flow control particles provides a
useful "combination" obturating material. In this aspect, for
example, a relatively small size of low density polyethylene
obturating material in combination with a larger particle size
polypropylene flow control additive is useful for improved flow
properties.
[0135] The composition of the obturating medium can be selected
from any number of thermoplastics, thermosets, elastomers,
thermoplastic elastomers, and other materials, including
combinations thereof. A suitable obturating medium acts as a good
seal under pressure, while also providing a thermal insulating
effect which insulates and protects the projectile(s) from the
intense heat of the powder combustion. This insulating effect of
the obturating medium of this disclosure is provided without the
obturating medium melting together to form a solid mass from the
intense heat of combustion. This thermal insulating and gas-sealing
effect of the obturating medium also allows a wide range or
projectile types to be launched from a cartridge, and specifically
permits the use of a paper or fabric cup-shaped stabilizer in the
payload delivery system. The obturating medium also provides a
cushion effect on the projectile(s) reducing deformation. In one
aspect, suitable obturating medium compositions include, but are
not limited to, various polyethylenes, polypropylenes, ethylene
alpha-olefin copolymers (for example ethylene-1-hexene copolymers),
propylene alpha-olefin copolymers (for example propylene-1-hexene
copolymers), ethylene vinyl acetate copolymers, and the like,
including any combinations or mixtures thereof, any polymer alloys
thereof, or any copolymers thereof. Useful polyethylenes include
high density polyethylenes, low density polyethylenes, and linear
low density polyethylenes. Readily available and inexpensive
low-density polyethylene, polypropylene, and combinations of
polyethylene and polypropylene are suitable and relatively low cost
obturating medium materials, which can provide a manufacturing
advantage.
Applications to Shotshells
[0136] In one aspect, the disclosed payload delivery system is
applicable to shotshell "wad" designs or muzzle-loading wad designs
for firearms and other types of muzzle-loading payload launchers.
Shotshell wads of various designs have been used in loading
shotshell ammunition to separate the propellant from the shot, to
provide a seal against hot expanding propellant gases, and more
recently, to protect the barrel itself from direct contact with
hard shot. Early shotshell wads were made of cardboard type
materials and were used generally as over-powder wads, often in
combination with fiber, cork, felt, or pressed paper filler wads.
Thin card wads were also used as over shot barriers for the older
roll crimped cartridges. Card wads withstood the heat of combustion
very well and were simple and low cost materials. However, these
early wads required rather precise internal shell dimensions for
proper fit, and even then, their gas sealing properties were only
moderate. Moreover, early wads offered little cushioning effect for
the soft lead shot and provided no protection from direct contact
with the bore; therefore some degree of shot deformation and
inconsistent patterns resulted. Improvements in gas sealing were
realized with Winchester's so-called "bottle cap" cup wad
introduced in the mid-1940s, which helped point the way to further
advances.
[0137] Next generation wads for lead shot were plastic
constructions that incorporated a flanged or slightly flared
over-powder cup to provide an obturating gas seal, which was
integral with a shot cup to contain and protect shot from direct
barrel contact. These structures included a collapsible section
interposed between the over-powder gas seal and the shot cup. Such
one-piece plastic wads improved the gas sealing properties and
enhanced shot integrity by the cushioning effect of the collapsible
section and elimination of direct barrel contact, all of which
afford improved and consistent downrange shot patterns.
Longitudinal slits in the shot cup portion are typical, and these
slits form petals in the cup that open up to peel away the wad from
the shot column after firing. Similar plastic constructions have
been adapted as sabots for single slug projectiles. While one-piece
plastic wads offer certain improvements over earlier materials,
their complexity and the costly tooling requirements for their
manufacture can make these wads less attractive than simpler
designs.
[0138] With the advent of steel and other hard shot, the barrel
protection function of the wad became paramount and its shot
cushioning function of less concern. As a result, steel shot wads
generally dispense with any collapsible section between the gas
seal and the shot cup, and steel shot wads are typically
constructed of much thicker plastic to prevent shot from
penetrating the shot cup itself and contacting the barrel. The
thickness of the plastic wads can be problematic, often leading to
high pressures upon firing and affording inconsistent opening of
any petals that are pre-slit in the shot cup portion. Moreover, the
consistent cutting of slits into the thick plastic walls can itself
present a challenge, and their very presence may allow hard steel
shot to penetrate the side wall and contact the barrel under the
high pressures of firing the cartridge. The aerodynamic stability
of such designs are only fair, and complete separation of the wad
from the shot column may not occur before tumbling ensues and
degrades its subsequent trajectory. Attempts to address these
issues have required complex designs at a substantial increase in
cost. In this aspect, designs with thick petals that expand from
the front and/or rear, or wads with break-away portions or complex
constructions have been claimed, for example, as disclosed in U.S.
Pat. Nos. 4,773,329, 6,260,484, 5,979,330, and 5,874,689.
[0139] When the disclosed payload delivery system is used in
loadings for shot, the stability of the system allows for clean
separation of the wad structure from the shot column and provides
consistent patterns and accurate delivery of the payload. While any
type of shot or other projectile can be used with this payload
delivery system, its performance with steel and other hard shot is
an improvement over the aerodynamic stability of conventional thick
plastic wads used for steel shot. Moreover, the stabilizer and
vanes can be adjusted for the desired load and application, such
that tight patterns can be delivered accurately at ranges that are
difficult to achieve using traditional wads. For example, the
length and number of the vanes of the stabilizer, the vane
structure itself arising from the cut structure of the stabilizer,
the inclusion of cut-outs, additional slits, perforations, and the
like in the stabilizer side wall, the thickness of the stabilizer
material, and the nature of the material itself, all can be
adjusted to "tune" the overall payload delivery system for the
desired performance.
[0140] Typically, when using steel or other hard shot, the side
wall of the payload cup does not include perforations or cut-outs.
Therefore, there are no problems arising from the penetration of
hard shot through the payload cup and stabilizer and contacting the
barrel, even though the stabilizer side wall includes cuts that
define the stabilizer vanes. Moreover, when the payload delivery
system includes two layers--a payload cup and a cup-shaped
stabilizer--a temporary lamination effect results that provides
strength to the complete payload delivery system. This lamination
strength allows for relatively thin payload cups and stabilizers to
be used, even for steel shot, much like the thinner shot cups
traditionally suitable only for lead shot. As a result, this
present system provides the necessary barrel protection function,
allows a clean separation from the shot column to provide good
patterns, and avoids complicated molded features that increase
costs.
[0141] According to one aspect, the payload delivery system is
sufficiently versatile for use in loading large or small bird shot,
buck shot, slugs, or other type projectiles. Shotshell cartridges
loaded with the disclosed payload delivery system can otherwise
employ standard shotshell components and loading methods for their
construction. By way of example, the shotshell cases or hulls,
primers, propellant or powder, shot or other projectiles such as
slugs, gas seals when the selected gas seal is not integral to the
payload delivery system and is not a wadless obturating medium, and
the like, have all been described in abundant detail. Treatises and
handbooks that can be referenced for describing suitable other
components include Thomas J. Griffin, editor, Shotshell Reloading
Handbook, 5.sup.th ed., Lyman Publications, Lyman Products
Corporation, Middletown, Conn., c. 2007 and Don Zutz, Hodgdon
Powder Company Shotshell Data Manual, 1.sup.st ed., Hodgden Power
Company, Shawnee Mission, Kans., c. 1996.
[0142] Any variety of projectile types, shapes, and number can be
loaded into a cartridge such as a shotshell using the disclosed
payload delivery system. For example, all sizes of lead,
lead-containing, lead-free, frangible, penetrating, and other
projectiles can be employed, including all sizes of birdshot,
buckshot, and slug projectiles. Any combination or mixture of shot
sizes can be advantageously loaded using payload delivery system as
provided herein. This technology is further applicable to
ammunition loaded with shot comprising or consisting of steel,
bismuth, tungsten, tin, iron, copper, zinc, aluminum, nickel,
chromium, molybdenum, cobalt, manganese, antimony, alloys thereof,
composites thereof, and any combinations thereof. These shot
loadings can be standard loadings, buffered loadings, duplex
loadings, loadings using any conventional configuration, whether
simple or complex. For example, shot loadings can comprise at least
one additional wad used with the payload delivery system according
to this disclosure.
[0143] By way of example, some embodiments of the cartridge payload
delivery system of this disclosure that include the forward folding
stabilizer can be used to launch single solid projectiles. In these
configurations, and not as a limiting feature, the solid projectile
can use an optional spacer or plug, which can be in contact with
and, if desired, can be attached to the aft portion of the solid
projectile in its pre-launched configuration. While the spacer can
be used to fill any void space for properly matching the cartridge
contents to the available cartridge space, the stabilizer can
function as a sabot for the solid projectile. When a forward
folding stabilizer is used with a sub-bore diameter single
projectile, regardless of whether a spacer is used or not, the
sabot effect of the forward folding stabilizer centers the
projectile within the bore, imparts cushioning properties, and
boosts accuracy. This aspect of using the stabilizer itself as a
solid payload cup or sabot allows tailoring the stabilizer such
that it can fill all available space between the single projectile
and the actual bore diameter of the launching device, such as a
firearm, a concept that is carried over to using the stabilizer
with a separate payload cup.
[0144] As illustrated in FIGS. 6 and 7 that show the unfolding and
inversion of the cup-shaped forward folding stabilizer, after
firing the solid projectile-stabilizer combination, in which the
stabilizer is attached to the solid projectile with or without a
spacer, the cup-shaped stabilizer unfolds and inverts to slow the
payload delivery system in a controlled manner. Alternatively, when
the cup-shaped stabilizer is not attached to the solid projectile,
the cup-shaped stabilizer opens and slows to cleanly release the
solid projectile payload. If desired, a payload cup element also
can be used in combination with a solid projectile and cup-shaped
stabilizer component, if so desired. Further, the projectile can
include a rounded fore end while the aft end of the can be closed
about the rear of the projectile, which optionally can be partially
hollow, or the aft end of the projectile can be open. Any
additional structures or features that are conventionally used in
loading solid projectiles such as slugs, can be used with the
forward folding stabilizing payload delivery system of this
disclosure, as long as the additional structures or features do not
interfere with the loading or function of the payload delivery
system and stabilizer as described herein.
[0145] Other cartridge systems can advantageously use the
cup-shaped stabilizer of this disclosure, including but not limited
to, an ammunition cartridge, a flare cartridge; a grenade launcher
cartridge, a smoke flare cartridge, a signaling device cartridge, a
chemical munitions cartridge, a distraction device cartridge, or a
pyrotechnic launching device cartridge. Thus, specialty cartridges
using the disclosed payload delivery system also can be
advantageously loaded with, for example, frangible projectiles,
rubber projectiles (for example, rubber shot and rubber baton
projectiles), bean bag projectiles, tear gas- or oleoresin capsicum
(OC)-containing projectiles, liquid-filled marking projectiles,
tracer projectiles, penetrator projectiles (for example, steel
penetrator or armor-piercing projectiles), flechette projectiles,
incendiary projectiles (for example, titanium sponge-containing
projectiles and zirconium sponge-containing projectiles), flare
projectiles, and the like, or any suitable combination thereof.
[0146] FIG. 10 illustrates one embodiment of a shotshell that
incorporates the payload delivery system with forward folding
stabilizer according to this disclosure. This figure is intended to
be non-limiting and demonstrates a simplified schematic of one way
the payload delivery system of the present disclosure can be loaded
and used. Full details of shotshell components such as shotshell
hulls, primers, propellants, shot and the like can be found in
various handbooks, such as Thomas J. Griffin, editor, Shotshell
Reloading Handbook, 5.sup.th ed., Lyman Publications, Lyman
Products Corporation, Middletown, Conn., c. 2007 and Don Zutz,
Hodgdon Powder Company Shotshell Data Manual, 1.sup.st ed., Hodgden
Power Company, Shawnee Mission, Kans., c. 1996.
[0147] In the illustration of FIG. 10, the arrangement of the
shotshell components is demonstrated which employs the payload
delivery system as illustrated in FIGS. 5A or 9D in a shotshell
construction. Thus, FIG. 10 illustrates, for example, the shotshell
case 155 and its rim 160, the brass or head 165, the primer 170,
base wad 175, and propellant 180 adjacent to the gas seal 110 with
its gas-sealing skirt 130. The gas seal of FIG. 10 is a pre-formed
gas seal 110 which is shown linked by connector 60 to the forward
folding stabilizer 35 and the payload cup 10, and adjacent the
rearward end of the stabilizer. The payload cup 10 houses the shot
185, and the shell can be crimped at the forward end with a star-
or fold-crimp 190 of some type, such as a 6- or 8-point star crimp.
This figure is not intended to be limiting, as any shotshell can be
loaded with the payload delivery system of this disclosure, using
standard procedures known to one of ordinary skill, and as
described in the various treatises and handbooks such as those
referenced.
[0148] In another aspect, additional cartridge components can be
used with the present payload delivery system in shotshell or other
cartridge loadings, as long as loading and firing that component in
the cartridge does not adversely affect the utility of the
disclosed payload delivery system. For example, upon firing a
shotshell the column of shot pellets contained in the shot cup
portion of the payload delivery system initially resists the
acceleration and "set back" forces are applied by the shot in a
rearward direction to the base of the wad structure. Therefore, if
desired, the payload cup can include a metal or stiff paper liner
to resist the deformation, or the payload cup bottom can be a
thicker plastic material as compared to the sidewalls.
[0149] There are countless variations and combinations of the
structures of the disclosed shotshell components, and this
disclosure anticipates that any combination or feature of one
component can be selected for use with any other particular feature
in another component.
[0150] While not limiting, the payload delivery system of this
disclosure is especially advantageous for loading shotshells with
steel shot. Conventional steel plastic wads are typically much
thicker and harder plastic that lead shot wads, a feature that
requires larger propellant charges or longer burning propellant to
make up for their poor gas sealing qualities. Such loads are
inefficient in their burning of propellants and may result in
greater felt recoil. More recent steel wads have relied on complex
slits, petals, cut outs, flaps, and airbrakes of various shapes for
stability in flight, which greatly increases the required tooling
and overall manufacturing costs. Such complex and hard structures
may encounter problems with certain shotgun chokes and do not
always result in stable flight.
[0151] In contrast, the present payload delivery system can be used
with steel shot without the need for the complex slits, cut outs,
or airbrakes, because the stability and flight characteristics are
influenced by the simple, inexpensive cup-shaped forward folding
stabilizers disclosed here. The ease of manufacturing and lower
cost make these useful for many cartridge delivery systems, not
merely for shotshells. Moreover, superior patterns can result for
longer range delivery of a projectiles, because the rapid and
consistent opening of the forward folding stabilizer provides high
drag in a symmetric fashion, which releases the payload or
projectiles cleanly for excellent ballistic performance.
Vanes Formed from the Projectile Cup Itself
[0152] FIGS. 11A-D illustrate perspective views of another
embodiment of the payload delivery system according to this
disclosure, illustrating the formation of an integrated or
monolithic payload cup and stabilizer, while FIG. 11E provides a
sectional view of a gas seal that is useful with the FIGS. 11A-D
embodiments. This integrated or "unibody" payload cup-stabilizer
200 includes a payload cup portion 205 and a stabilizer portion 210
that are formed from the same piece. This integrated structure may
be referred to as a "stabilized payload cup" 200, to emphasize its
single piece construction and to distinguish it from the two or
more piece constructions also disclosed herein. Because the payload
cup portion 205 and the stabilizer portion 210 of the stabilized
payload cup 200 are made from the same piece they have the same
composition. For example, the stabilized payload cup 200 can be
made from a tube 215 that is cut to length and provided with a
series of slits such as the longitudinal slits 220 shown in FIG.
11A.
[0153] The tube 215 from which the stabilized payload cup is formed
is open at each end, and an example of such a structure is an
extruded plastic tube that can be produced very inexpensively. The
slits 220 in the tube can extend from the aft end of the tube 225
for a portion or fraction of the length of the cut tube. In the
embodiment shown in FIG. 11A, the longitudinal slits extend about
half the distance from the aft end 225 to the forward end 230 of
the tube. Accordingly, FIG. 11A shows the stabilized payload cup
200 after the tube has been cut to length and slit, but before the
vanes 235 or ribbons that are formed from the longitudinal slits
have been folded forward. FIG. 11B illustrates the slit tube of
FIG. 11A as the vanes are being folded forward, and in FIG. 11C,
the forward folding of the vanes is complete. Once folding is
complete, the vanes are now aligned alongside the payload cup
portion 205 of the stabilized payload cup 200. FIG. 11 illustrates
the stabilized payload cup as having identical vanes, but any of
the vane structures disclosed herein are suitable, because any of
slits can be used.
[0154] In one aspect, once forward folding is complete, the
original tube from which the stabilized payload cup 200 is made no
longer has the same aft end at the original tube. Therefore, once
the vanes being forward folded along the cylindrical side wall of
the tube, a derivative aft end 240 and a derivative aft edge are
defined. In those embodiments in which the length of the vanes is
substantially the same as the length of the payload cup portion
205, the forward end of the stabilized payload cup 200 includes a
contiguous payload cup portion 205 and stabilizer portions 210, and
therefore can be considered to constitute or define a derivative
fore end 245 and a derivative fore edge.
[0155] Also shown in FIG. 11C is a separate pre-formed gas seal,
for example, a standard double-ended "H-wad" type gas seal 250,
which can be used along with the stabilized payload cup 200 to both
form the bottom or base of the payload cup on which the payload
will sit and to provide its obturating function. Thus, the gas seal
250 has both separating and obturating functions. FIG. 11C further
illustrates that the gas seal can be loaded into the cartridge
adjacent the propellant, and the stabilized payload cup 200 can be
loaded into the cartridge adjacent or on top of (forward) the
pre-formed gas seal, followed by the payload and any subsequent
components. In some embodiments, the gas seal is selected so that
it can just fit inside the folded stabilized payload cup as shown
in FIG. 11D. A small portion of the gas seal that does not extend
completely into the folded stabilized payload cup can be seen in
the embodiment of FIG. 11D, but any extent of insertion in the
interior of the cup is possible. In other embodiments, it is
possible that the folded stabilized payload cup 200 can be sized
such that it sits atop the gas seal and the gas seal does not
extend within the interior cavity of the payload cup portion
205.
[0156] In some embodiments, when the gas seal extends partially or
substantially within the cavity formed by the sidewall cup of the
payload cup portion 205 of the stabilized payload cup 200, it is
possible to attach the gas seal 250 and the stabilized payload cup
200. For example, referring to the FIG. 11D illustration, the
integral stabilized payload cup and the gas seal can be attached by
a melting process, by a punching method, by a sonic weld process,
by staking the stabilized payload cup 200 and the gas seal 250, and
the like. In various embodiments, at least one stake can be used to
attach the stabilized payload cup and the gas seal, for example,
extending through the side of the stabilized payload cup, such that
the stake extends into the side wall of the gas seal and unites
these two components. Such embodiments provide a stable,
inexpensive method to form the base of the payload cup and to
provide its obturating function. Any type of connector can be used,
for example, a stake, a weld, a rivet, a screw, a staple, a pin, a
bolt, a brad, an anchor, an adhesive, a tack, or a nail, or in
certain embodiments, multiple connectors, or any combination of
these connectors can be used. When attachment means such as a stake
or staple are used, the attachment means are employed so as not to
also attach a forward folded vane to the side or edge of the gas
seal. For example, such elements are generally used to attach the
gas seal and the stabilized payload cup either before the forward
folding of the vanes, or with the stake, staple, and the like being
inserted between the vanes such that only the side of the
stabilized payload cup and not a vane are attached to the edge of
the gas seal. Some of these attachment methods, for example melting
or a sonic weld process, may work best when the integral stabilized
payload cup and the gas seal are made of appropriate materials.
[0157] Accordingly, this disclosure also provides for a payload
delivery system comprising, in its pre-launched configuration:
[0158] a stabilized payload cup comprising a tube with an open fore
end, an open aft end, and a cylindrical side wall defining a cavity
that terminates at a fore edge and an aft edge; [0159] the open aft
end comprising a plurality of longitudinal slits defining a
plurality of vanes extending from the aft edge along a portion of
the length of the cylindrical side wall, the vanes being forward
folded along the cylindrical side wall, thereby defining a
derivative aft end and a derivative aft edge. This payload delivery
system can further comprising a gas seal, for example, it can
further comprise a pre-formed gas seal coaxially aligned with the
stabilized payload cup and adjacent the derivative aft end. Some
embodiments can comprise an obturating medium adjacent the
derivative aft end of the stabilizing component as the gas seal,
but the preferred method and structure is to use a pre-formed gas
seal with the stabilized payload cup.
[0160] One useful type of gas seal 250 which can be used in various
embodiments of the stabilized payload cup 200 can be shaped to
include a recessed forward portion 255, which has a smaller
diameter that the gas sealing skirt 260 situated at the aft portion
of the gas seal. One embodiment of such a gas seal is illustrated
in the sectional view in FIG. 11E, in which this particular
embodiment shows an optional concave portion at the fore end. This
type of gas seal embodiment is advantageous because the recessed
forward portion 255 can fit securely into the inside of the
stabilized payload cup 200, while the slightly larger diameter gas
sealing skirt 260 on the exterior aft end of the stabilized payload
cup can perform its obturating function.
[0161] In some embodiments, the plurality of longitudinal slits can
extend about 50% the length of the cylindrical side wall from the
aft end to the fore end. The aft end of the stabilized payload cup
also can comprise at least 3 vanes, if desired. Alternatively, the
aft end of the stabilized payload cup can comprise at least 4
vanes, or alternatively, the aft end of the stabilized payload cup
can comprise at least 6 vanes. Thus, these vanes invert from
forward folded to rearward folded during flight. In other
embodiments, a portion of the vanes can be removed from the aft
edge of the stabilized payload cup. For example, the open aft end
can comprise an even number of longitudinal slits defining an even
number of vanes, and wherein alternating vanes are removed from the
aft edge of the stabilized payload cup. Although not limited to a
particular material, common materials used for the stabilized
payload cup can be, can consist essentially of, or can comprise
polyethylene, polypropylene, or poly(vinyl chloride).
Definitions
[0162] To define more clearly the terms used herein, the following
definitions are provided, which are applicable to this disclosure
unless otherwise indicated by the disclosure or the context. To the
extent that any definition or usage provided by any document
incorporated herein by reference conflicts with the definition or
usage provided herein, the definition or usage provided herein
controls.
[0163] The terms "payload delivery system", "projectile delivery
system", "cartridge payload delivery system" and the like are used
interchangeably in this disclosure. Unless stated otherwise or
unless the context requires otherwise, the use of any of these
terms does not specify any particular type of projectile or payload
intended to be launched from the cartridge that includes the
components. Moreover, any combination of components that includes a
disclosed stabilizer component can be considered to constitute a
payload delivery system according to this disclosure, as the
context allows or requires.
[0164] As used herein, a wad or cartridge wad according to this
disclosure refers to the payload delivery system that combines a
disclosed stabilizer with any type of cup, container, receptacle or
holder for at least one projectile, whether shot, a slug
projectile, or any type of payload to be launched by the cartridge.
The term wad is often used in describing shotshell components, but
by no means is the use of this term or this entire disclosure so
limited. To the contrary, it is understood that this disclosure and
the appended claims are not limited to shotshells, because the
disclosed structures, components, and methods have a wide utility
and are adaptable to any number of payload delivery systems, for
example, those applicable to launching chemical, pyrotechnic,
signaling, non-lethal, and other complex payloads in their
respective cartridges.
[0165] As the context allows, the term "cartridge" can refer to the
finished manufactured article, such as a completed ammunition
cartridge. However, in some contexts, the term "cartridge" may
refer to the empty cartridge "case", "hull", or "casing", having an
inner wall defining a cavity that is charged according to this
disclosure to provide the finished article, as apparent from its
particular use.
[0166] Reference to the forward end or fore end of a particular
component or cartridge means the end that is further downrange when
the component or cartridge is in its intended orientation for
firing or launching. The fore end may also be termed the leading
end or leading edge, the top, the downrange end, the distal end, or
the crimp end, and these terms are used interchangeably.
[0167] Reference to the rearward or rear end of a particular
component or cartridge means the end that is further uprange when
the component or cartridge is in its intended orientation for
firing or launching. The rear end may also be termed trailing end
or trailing edge, the aft portion or aft end, the bottom, the
uprange end, the proximal end, the primer end, or the brass end,
and these terms are used interchangeably.
[0168] A cup-shaped stabilizer, forward folding stabilizer, forward
folded stabilizer, stabilizer cup, stabilizer with cut side wall,
or simply, "stabilizer" and similar terms are used in this
disclosure to refer to the element of the payload delivery system
that contains a disclosed structure with vanes. Such terms
generally are used interchangeably regardless of whether that
component is used with or without a payload cup, and regardless of
whether that component is attached to any projectile or any other
component.
[0169] Reference to an obturating component or obturating member
can include any component, whether pre-formed or not, that can
provide a seal against expanding propellant gases, and can
comprise, can consist of, or can be a pre-formed gas seal or an
obturating medium. Unless the context requires otherwise or unless
otherwise provided, the term gas seal also can refer to either a
pre-formed gas seal or an obturating medium. Moreover, when
describing a gas seal as a pre-formed gas seal, such a reference
includes a separate component and a component integrated into a
more complex payload delivery system or combined with another
component, as the context requires.
[0170] Throughout this specification, various publications may be
referenced. The disclosures of these publications are hereby
incorporated by reference in pertinent part, in order to more fully
describe the state of the art to which the disclosed subject matter
pertains. The references disclosed are also individually and
specifically incorporated by reference herein for the material
contained in them that is discussed in the sentence in which the
reference is relied upon. To the extent that any definition or
usage provided by any document incorporated herein by reference
conflicts with the definition or usage provided herein, the
definition or usage provided herein controls.
[0171] As used in the specification and the appended claims, the
singular forms "a," "an," and "the" include plural referents,
unless the context clearly dictates otherwise. Thus, for example,
reference to "a projectile" includes a single projectile such as a
slug, as well as any combination of more than one projectile, such
as multiple pellets of shot of any size or combination of sizes.
Also for example, reference to "a projectile" includes multiple
particles of a chemical composition or mixture of compositions that
constitutes a projectile, and the like.
[0172] Throughout the specification and claims, the word "comprise"
and variations of the word, such as "comprising" and "comprises,"
means "including but not limited to," and is not intended to
exclude, for example, other additives, components, elements, or
steps. While compositions and methods are described in terms of
"comprising" various components or steps, the compositions and
methods can also "consist essentially of" or "consist of" the
various components or steps.
[0173] "Optional" or "optionally" means that the subsequently
described element, component, step, or circumstance can or cannot
occur, and that the description includes instances where the
element, component, step, or circumstance occurs and instances
where it does not.
[0174] Therefore, this disclosure both literally includes and
literally excludes such components as desired or required.
[0175] Unless indicated otherwise, when a range of any type is
disclosed or claimed, for example a range of the particle sizes,
percentages, temperatures, and the like, it is intended to disclose
or claim individually each possible number that such a range could
reasonably encompass, including any sub-ranges or combinations of
sub-ranges encompassed therein. When describing a range of
measurements such as sizes or weight percentages, every possible
number that such a range could reasonably encompass can, for
example, refer to values within the range with one significant
figure more than is present in the end points of a range, or refer
to values within the range with the same number of significant
figures as the end point with the most significant figures, as the
context indicates or permits. For example, when describing a range
of percentages such as from 85% to 95%, it is understood that this
disclosure is intended to encompass each of 85%, 86%, 87%, 88%,
89%, 90%, 91%, 92%, 93%, 94%, and 95%, as well as any ranges,
sub-ranges, and combinations of sub-ranges encompassed therein.
Applicants' intent is that these two methods of describing the
range are interchangeable. Accordingly, Applicants reserve the
right to proviso out or exclude any individual members of any such
group, including any sub-ranges or combinations of sub-ranges
within the group, if for any reason Applicants choose to claim less
than the full measure of the disclosure, for example, to account
for a reference that Applicants are unaware of at the time of the
filing of the application.
[0176] Values or ranges may be expressed herein as "about", from
"about" one particular value, and/or to "about" another particular
value. When such values or ranges are expressed, other embodiments
disclosed include the specific value recited, from the one
particular value, and/or to the other particular value. Similarly,
when values are expressed as approximations, by use of the
antecedent "about," it will be understood that the particular value
forms another embodiment. It will be further understood that there
are a number of values disclosed herein, and that each value is
also herein disclosed as "about" that particular value in addition
to the value itself.
[0177] In any application before the United States Patent and
Trademark Office, the Abstract of this application is provided for
the purpose of satisfying the requirements of 37 C.F.R. .sctn.1.72
and the purpose stated in 37 C.F.R. .sctn.1.72(b) "to enable the
United States Patent and Trademark Office and the public generally
to determine quickly from a cursory inspection the nature and gist
of the technical disclosure." Therefore, the Abstract of this
application is not intended to be used to construe the scope of the
claims or to limit the scope of the subject matter that is
disclosed herein. Moreover, any headings that are employed herein
are also not intended to be used to construe the scope of the
claims or to limit the scope of the subject matter that is
disclosed herein. Any use of the past tense to describe an example
otherwise indicated as constructive or prophetic is not intended to
reflect that the constructive or prophetic example has actually
been carried out.
[0178] Those skilled in the art will readily appreciate that
modifications are possible in the exemplary embodiments disclosed
herein without materially departing from the novel teachings and
advantages according to this disclosure. Accordingly, all such
modifications and equivalents are intended to be included within
the scope of this disclosure as defined in the following claims.
Therefore, it is to be understood that resort can be had to various
other aspects, embodiments, modifications, and equivalents thereof
which, after reading the description herein, may suggest themselves
to one of ordinary skill in the art without departing from the
spirit of the present disclosure or the scope of the appended
claims.
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