Non-metallic Projectile And Method Of Manufacturing The Same

Abstract

The invention includes a non-metal, polymer projectile that can be launched from a launching device having a smooth or rifled bore, wherein the launch is facilitated using combustion, vacuum, air pressure, or hydraulic pressure.

Description

[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 14/939,194, filed on Nov. 12, 2015, in the name of Randy S. Teig and Adam H. Teig, and entitled MECHANICALLY ADAPTABLE PROJECTILE AND METHOD OF MANUFACTURING THE SAME.

BACKGROUND OF THE INVENTION

[0002] Projectiles, such as bullets and missiles, may be fired from a variety of delivery devices such as handguns, rifles, rocket launchers, and the like. Each projectile will have penetration, fracturing and other characteristics particular to that type and make of projectile. An end user may purchase a projectile based on the penetration, fracturing and other characteristics of the projectiles available for sale. However, the end user is not able to customize projectiles to achieve particular characteristics as may be desired. There is a need, therefore, for a projectile that may be mechanically adapted by an end user so as to achieve desired penetration, fracturing or other characteristics.

SUMMARY OF THE INVENTION

[0003] The Mechanically Adaptable Projectile of the present invention can be propelled from a cartridge, shell, or vessel by various means, to include but not limited to, explosion, air, spring, magnetic energy, vacuum, or gravity for the purpose of using the projectile for impacting objects in applications similar to, but not limited to, hunting, law enforcement use of force and tactics, target practice, self defense, firearms training and recreational shooting. The projectile will generally be created in the form and shape of a bullet, missile, or ballistic projectile of many different dimensions to be used in firearms and launching devices of a variety of styles to include, but not limited to, rifled and smooth bore firearms, rail guns, tubes, and devices used for launching or firing projectiles. Using a series of Core Projectile Modules the manufacturer can customize the projectiles by adding or omitting Interchangeable Components that will alter the size, mass, shape, internal ballistics, external ballistics, and mechanical characteristics of the projectile. In another embodiment, the projectile may be manufactured entirely of a non-metallic, polymer material that provides for enhanced environmental properties, and also allows for launching the projectile using less robust launching devices which may be damaged by the use of metallic projectiles.

BRIEF DESCRIPTION OF THE DRAWINGS

[0004] FIG. 1 shows an exterior schematic view of a Prior Art projectile.

[0005] FIG. 2 shows an exploded cross section of an embodiment of a mechanically adaptable projectile.

[0006] FIG. 3 shows a cross section of an embodiment of a mechanically adaptable projectile.

[0007] FIG. 4 shows an exploded cross section of an embodiment of a mechanically adaptable projectile.

[0008] FIG. 5 shows an exploded cross section of an embodiment of a mechanically adaptable projectile.

[0009] FIG. 6 shows an exploded cross section of an embodiment of a mechanically adaptable projectile.

[0010] FIG. 7 shows a cross section of an embodiment of a mechanically adaptable projectile.

[0011] FIG. 8 shows a cross section of an embodiment of a mechanically adaptable projectile.

[0012] FIG. 9 shows a cross section of an embodiment of a mechanically adaptable projectile.

[0013] FIG. 10 shows a cross section of an embodiment of a mechanically adaptable projectile.

[0014] FIG. 11 shows a side view of one example embodiment of a non-metallic projectile.

[0015] FIG. 12 shows a side cross sectional view of the projectile of FIG. 11.

[0016] FIG. 13 shows a side view of another example embodiment of a non-metallic projectile.

[0017] FIG. 14 shows a side cross sectional view of the projectile of FIG. 13.

[0018] FIG. 15 shows a side view of another example embodiment of a non-metallic projectile.

[0019] FIG. 16 shows a side cross sectional view of the projectile of FIG. 15

[0020] FIG. 17 shows a side view of another example embodiment of a non-metallic projectile.

[0021] FIG. 18 shows a side cross sectional view of the projectile of FIG. 17.

[0022] FIG. 19 shows a side view of another example embodiment of a non-metallic projectile.

[0023] FIG. 20 shows a side cross sectional view of the projectile of FIG. 19.

[0024] FIG. 21 shows a side view of another example embodiment of a non-metallic projectile.

[0025] FIG. 22 shows a side cross sectional view of the projectile of FIG. 21.

[0026] FIG. 23 shows a side view of another example embodiment of a non-metallic projectile.

[0027] FIG. 24 shows a side view of another example embodiment of a non-metallic projectile.

[0028] FIG. 25 shows a side view of another example embodiment of a non-metallic projectile.

[0029] FIG. 26 shows a side view of another example embodiment of a non-metallic projectile.

[0030] FIG. 27 shows a side cross sectional view of the projectile of FIG. 26.

[0031] FIG. 28 shows a side view of another example embodiment of a non-metallic projectile.

[0032] FIG. 29 shows a side cross sectional view of the projectile of FIG. 28.

[0033] FIG. 30 shows a side view of another example embodiment of a non-metallic projectile.

[0034] FIG. 31 shows a side cross sectional view of the projectile of FIG. 30.

[0035] FIG. 32 shows a schematic side view of one embodiment of a launching device for a non-metallic projectile.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0036] Definition as used in this description include: Mechanics (Mechanically, Mechanical)--deals with the action of forces on the bodies and with motion, comprised of kinetics, statics, and dynamics; Reactive Qualities--How the projectile reacts when striking a target medium; Mechanical Characteristics--The relationship of the reactive qualities and mechanics; and, Mechanical Design--Visible characteristics of the component.

[0037] The present invention is novel in the ammunition and gun related industry by introducing manufacturer and end user adaptability and customization to a range of projectiles that may be used in modern rifles, pistols, guns and other projectile launching devices.

[0038] A first embodiment includes a Core Projectile Module of varied mechanical designs and calibers that utilizes materials with a specific gravity no less than that of water and no more than 270 percent greater than that of water; tensile strength properties no less than 10,000 pounds per square inch; compressive strength properties no less than 10,000 pounds per square inch; and a coefficient of friction of no more than 0.3. The Core Projectile Component is capable of being fitted with Interchangeable Components (See FIGS. 1-10, as will be discussed in detail below), or of being used as a projectile in many of its basic unaltered forms. The design of the Core Projectile Module may include varying mechanical designs to facilitate a range of mechanically adaptable options depending on the intended use of the projectile. In one embodiment, The Interchangeable Component may be added or omitted to alter the rate of fracturing. The Core Projectile Module has its own mechanical qualities that may be altered by the Interchangeable Component. Altering the rate of fracture will predictably alter the depth of penetration and propagation of pressure waves upon impact with a given medium, therein maximizing the intensity of ballistic pressure waves relative to a specified animal target; causing remote cerebral effects as well as remote effects on the spine and internal organs of an animal. This phenomenon is commonly referred to as "hydrostatic shock." The present invention is specifically designed to embody chosen qualities and characteristics to efficiently deliver a hydraulic reaction and explosive effects on tissue and organs. The Interchangeable Components enable the manufacturer or the end user to customize the round to perform differently according to varying distances, varying weights and varying hide thickness of different animals.

[0039] A second embodiment includes a Core Projectile Module of varied mechanical designs and calibers that utilizes materials with a specific gravity no less than that of water and no more than 270 percent greater than that of water, tensile strength properties no less than 10,000 pounds per square inch, compressive strength properties no less than 10,000 pounds per square inch, and a coefficient of friction of no more than 0.3. The Core Projectile Module is capable of being fitted with Interchangeable Components (See FIGS. 1-10), or of being used as a projectile in many of its basic unaltered forms. The design of the Core Projectile Module may include varying mechanical designs to facilitate a range of mechanically adaptable options depending on the intended use of the projectile. The Core Projectile Module is specifically designed to embody chosen qualities and characteristics to propagate energy efficiently enough to induce ballistic shock waves through the target medium, causing the target medium to react violently to the ballistic pressure waves with or without the use of the Interchangeable Components. The unique utilization of the described materials, varied manufacturing and assembly methods, varied velocities, varied sizes, and varied designs of Interchangeable Components enables the creation of a wide variety of projectile design combinations. This novel feature will allow the manufacturer or end user to create a projectile that efficiently and predictably penetrates and propagates energy into specified target mediums. The manufacturer can alter a Core Projectile Module by adding or omitting Interchangeable Components (see FIGS. 1-10) to achieve desired penetration and reactions between the projectile and the intended non-animal target. Among other desirable outcomes, the manufacturer can create a projectile that prevents over penetration of the projectile through an intended target whether animal, vegetable or other materials, thus preventing it from striking unintended animals or things that may be behind the intended target. The qualities of the Core Projectile Module and Interchangeable Components, in their array of configurations, enable the manufacturer or end user to create a projectile that will efficiently fracture when striking a known material, which fracturing causes rapid propagation of pressure waves into the target, causing the materials to react violently to the pressure wave. The projectile pulverizes building materials commonly used in constructing walls in buildings. This may cause significant damage and flying debris within the room beyond the wall. This is a desirable condition in instances of covering fire and suppression fire used by law enforcement and military. It is also desirable that the projectiles used in covering fire be of the type that reduces the incidents of over penetration. Current projectiles used in conventional firearms, in this kind of situation, present a significant risk of over penetrating and striking a subject or object beyond the wall structure.

[0040] A third embodiment includes a Core Projectile Module of varied mechanical designs and calibers that utilizes materials with a specific gravity no less than that of water and no more than 270 percent greater than that of water, tensile strength properties no less than 10,000 pounds per square inch, compressive strength properties no less than 10,000 pounds per square inch, and a coefficient of friction no more than 0.3. A Core Projectile Component manufactured from the specified materials will have a bearing surface with a low friction coefficient enabling it to pass down the barrel of a rifle or gun more easily, which lowers heat and pressure within the barrel, enabling higher muzzle velocities and faster external ballistic speed passing through the air, while simultaneously reducing recoil relative to the caliber and mass of the projectile and the powder charge. These material characteristics enable the projectile to achieve higher flight speeds than previous art made from materials with a higher friction coefficient and an equal ballistic coefficient.

[0041] A fourth embodiment includes an Interchangeable Component (See FIGS. 1-10) which may be made from numerous materials including but not limited to copper, brass, aluminum, ceramics and polymers. Interchangeable Components may be designed to interchange with a varying range of calibers and designs of Core Projectile Module of previously discussed embodiments. The Interchangeable Component may allow the manufacturer or the end user to alter the size, mass, shape, and style of the projectile for the purpose of customizing the internal and external ballistics of the Mechanically Adaptable Projectile according to the materials or specified medium the projectile will be striking. The Interchangeable Component may be added or omitted to facilitate a predictable rate of fracturing, penetration and propagation of pressure waves upon impact with a specified medium, therein maximizing the intensity of ballistic pressure waves. The optional Interchangeable Component may alter the mechanical characteristics of a projectile. Altering the rate of fracture may change the propagation of ballistic pressure waves and depth of penetration of the projectile into a specified medium. The ability to alter the reactive characteristics of the projectile may enable the user to customize the rounds for a desired effect on a specified target medium.

[0042] In a fifth embodiment, the mechanical characteristics of the projectile are affected by the techniques used in manufacturing, such as utilizing specified materials, pressures and heat to enable different manufacturing techniques. Each unique manufacturing method will be used to predictably alter the mechanical characteristics of the various components comprising a Mechanically Adaptable Projectile, thereby altering the characteristics of the pressure wave that is introduced into the specified target upon impact of the projectile. The methods include, but are not limited to, injection molding, blow molding, rotational molding, extrusion molding, lathe/mill machining, and stamping. The chosen method of manufacturing alters the performance of the projectile in a predictable and marketable manner. This enables a manufacturer to use the same material and change the marketable characteristics of the end product by altering the method of manufacturing and not changing the physical design or type of material. For example, a projectile of identical style, shape and size can have two distinct mechanically functional qualities if one is made through a machine lathe process and another is made by an injection molding process. This manufacturer design flexibility allows adjustment of the number of mechanical characteristics for a projectile of identical size, style and shape.

[0043] A sixth embodiment a Core Projectile Module includes varied mechanical designs and calibers that utilizes materials with a specific gravity no less than water and no more than 270 percent greater than that of water, tensile strength properties no less than 10,000 pounds per square inch, compressive strength properties no less than 10,000 pounds per square inch, and a coefficient of friction of no more than 0.3. The unique utilization of the specified range and combination of materials, varied velocities, varied sizes, varied mass and varied mechanical designs of a Core Projectile Module enables the manufacturer to create a projectile that efficiently and predictably propagates ballistic pressure waves into specified targets. The rapid fracturing causes the energy from the projectile to rapidly propagate into the animal being impacted by the projectile. This reduces the depth of wound channels. There is a direct connection to the depth of the wound channel and the amount of traumatic vascular tearing. In other words, the present invention allows the end user to choose components of a projectile so as to provide a desired depth of projectile channel upon impact. Previous art relies on vascular injuries and blood loss to increase their incapacitative capabilities. More vascular tearing requires more significant medical intervention to prevent blood loss. This present invention allows the manufacturer to create a projectile that relies on ballistic pressure waves and remote cerebral effects from ballistic pressure waves that shock the system into incapacitation, rather than vascular injuries and blood loss. By design this projectile will penetrate less and therefore create less vascular tearing associated with a wound channel, thus decreasing the surgical complexity of repairing vascular injuries related to a wound channel. This present invention, therefore, departs from the prior art by changing the mechanism of incapacitation from vascular tearing and trauma, which causes massive bleeding, to relying primarily on ballistic shock waves that cause remote cerebral effects as well as remote effects on the spine and internal organs of an animal. This phenomenon is commonly known as "hydrostatic shock." Each of the mechanisms of incapacitation has their lethal concerns, but incapacitation by hydrostatic shock may provide more immediate incapacitation while allowing for more minutes for medical intervention, thereby increasing combat effectiveness while pushing back the margin of lethality.

[0044] In a seventh embodiment, the Interchangeable Component (see FIGS. 1-10) can be fitted inside of the Core Projectile Module, or on the outside of the Core Projectile Module. This enables the Mechanically Adaptable Projectile to be customized to withstand extreme barrel pressures, rifling friction, and extreme velocities as well as preloading stress on the Core Projectile Module. The projectile may also be customized by altering the internal structures to change the rate of fracturing upon impact.

[0045] In an eighth embodiment, the interchangeable Component can be added or omitted to the core projectile component to reduce the friction coefficient and mass. This will enable the manufacturing of low recoil cartridges and safe rounds for indoor ranges and other target applications. It will also optimize the projectile's ability to fly through the air for longer distance shooting (see FIGS. 1-10). The ability to alter the external and internal ballistics of the Core Projectile Module enables the manufacturer or the end user to customize the projectile to accommodate different shooters or different launching mechanisms requiring similar calibers but utilizing varied pressures.

[0046] In a ninth embodiment, the Interchangeable Component can be added to the Core Projectile Module to change the length, shape, mass, ballistic characteristics, rifling twist requirements and specific density of the projectile.

[0047] In a tenth embodiment, the Interchangeable Component can be added to the Core Projectile Module to optimize the projectile to match the barrel twist of a firearm.

[0048] In an eleventh embodiment the adaptable qualities of a given Mechanically Adaptable Projectile can be changed after the cartridge is fully completed without removing the projectile from the casing.

[0049] The Core Projectile Module will now be described. Prior art projectiles may include a clad projectile which may have an exterior shape similar to the inventive projectile 10 (FIG. 1). One may note that the inventive projectile may include many similarities in outward appearance to a prior art projectile. Referring to FIG. 2, in the embodiment shown, projectile 10 includes a tip 12, bearing surface 14, head or ogive 16, meplat 34, heel 20, base 22, boat or tail 24, cannelure 26 and shoulder 28. This example is one of many amongst the many mechanical designs of projectile or missles 10 which may be manufactured. Even though the external shape of the inventive projectile may look similar to the shape of the prior art projectile, in the Mechanically Adaptable Projectile components can be adapted by the manufacturer or the end user to facilitate the adaptation of the internal and external ballistics of the projectile. In particular, the end user may opt not to alter the Core Projectile Module as manufactured if it already meets the requirements of the end user or the manufacturer. However, the end user or manufacturer may insert an Interchangeable Component into the tip (hollow point) to alter the depth, mass, shape of Core Projectile Module, or apply an Interchangeable Component to the exterior to alter the size(caliber), friction coefficient of the bearing surface, the length or shape of the projectile. These abilities also enable the end user to adapt the projectile to the optimal rifling twist and other stabilization features relative to the distance it will need to travel and the medium it will be striking. This enables the projectile's mechanical qualities to be adapted to the needs or intent of the manufacturer or user, whether the projectile is being used by military or law enforcement to provide covering fire, breaching a door, shooting an animal, target shooting (indoor or outdoor), or by others who may be teaching a new shooter by using reduced recoil rounds in a specific gun until the new shooter learns how the gun functions, or other non military or law enforcement applications.

[0050] Prior art projectiles may include toxic materials as its base component, whereas the new Mechanically Adaptable Projectile utilizes a non toxic polymer that reduces complications of soil contamination and risk to pregnant shooters. The low friction coefficient of the Core Projectile Module (FIG. 2) will reduce barrel wear and enables higher velocities compared to old art with a similar ballistic coefficient. The Core Projectile Module example shown in FIG. 2 is one of many potential mechanical designs. This example was lathe turned, but may be manufactured by other means to include, but not limited to, injection molding, blow molding, rotational molding, extrusion molding, hydro forming, and stamping. The method of manufacturing depends on the mechanical characteristics desired.

[0051] A Core Projectile Module Impact analysis will now be described. When the Core Projectile Module strikes a medium with lower specific gravity than water, the depth of penetration is deeper than in mediums with a specific gravity of water or greater. This is a predictable quality due to the specifications of the material, manner it is manufactured, combination of mechanical qualities and internal and external ballistics. The adaptability of the inventive projectile enables the changing or adding of Interchangeable Components to the Core Projectile Module by the end user or manufacturer for the purpose of adapting the mechanical qualities, thus altering the propagation of ballistic pressure waves, such as by altering the Core Projectile Module by adding Interchangeable Components with varying specific gravities, friction coefficients and shapes.

[0052] For example, when viewing a hole in a material, such as a piece of wood, through which a projectile has traveled, the shape of the hole may indicate that there is a slight projectile instability with the rifle used. The inventive projectile could be used with such a rifle and fitted with an Interchangeable Component that alters the overall specific gravity of the projectile thereby causing stabilized rotation of the projectile fired from that particular rifle. In this manner, the user of the particular rifle could adapt the projectiles fired from his rifle to provide a more stable projectile travel path from the rifle.

[0053] In another example of use, a material, such as a piece of wood, may show splitting on the backside of the board around the projectile path of the inventive projectile. The board may be split in a conical pattern outward from the centerline of the projectile path. At the center of the pressure pattern there may be more crushing of the wood material as the pressure wave propagates through the wood. The depth of the damage along the centerline of the projectile's path may be deeper and grows shallower as the pressure wave propagates outward from the centerline. This demonstrates how the building material violently reacted to the ballistic pressure wave which results in crushing and fragmenting of the material from the inventive projectile. A typical projectile path of the inventive projectile through a medium will show a widening damage path as the ballistic pressure wave propagates through the wood.

[0054] The Specific Gravity, Projectile Fracturing, and Ballistic Pressure Wave Propagation properties will now be described.

[0055] When a ballistic pressure wave impacts an object with a specific gravity nearly equal to that of water, the crushed particles from the medium will ride on the pressure wave as it blows back toward the direction from which the projectile originated. In one test conducted on the inventive projectile, the remaining particles from a Core Projectile Component that was fired into a wood medium were examined. The original Core Projectile Component weighed 151 grains (0.345 ounces). The recovered fragments from the Core Projectile Component weighed 11 grains (0.025 ounces). Such an efficient fracturing and crushing of the Core Projectile Component enables efficient propagation of ballistic pressure waves through the medium.

[0056] In one embodiment including a Core Projectile Module with the addition of an Interchangeable Component, the Interchangeable Component is designed to delay the fragmentation of the Core Projectile Module, allowing the projectile to enter the medium more deeply before fragmenting and propagating the ballistic pressure wave into the medium. The Interchangeable Component is altering the mass, tip, meplat, ogive, ballistic coefficient and overall length of the projectile. All of these changes combine to alter the mechanical characteristics, external ballistics and internal ballistics of the projectile when it impacts varying mediums. The end user or the manufacture is able to adapt the projectile to optimize specific qualities depending on the use of the projectile.

[0057] Additionally, in this particular embodiment, the components in this particular projectile are lathe turned from Delrin.RTM. 150E and 6061 T6 aluminum. This provides for known ductility of the material components, thereby creating a predictable, marketable quality. Annealing one or both of the components will alter the ductility of the components. This can be done before assembling or as an assembled projectile. Changing the ductility of one or both of the components provides a change in fracturing characteristics, which in turn provides a predictable performance change in the Mechanically Adaptable Projectile. Also, the predictable performance of this exact configuration can be altered by changing the method of manufacture, thereby increasing the applications of a single mechanical design by the number of alternate manufacturing methods.

[0058] FIG. 2 shows that insertion of an Interchangeable Component 30 into the Core Projectile Component 32 reduces the size of the hollow point 34 and, depending on material changes mass and depending on fit tolerance, can be used to preload stress on the projectile 10 to alter reactive qualities upon impact. It will also increase the size of the meplat 18 without altering the length of the projectile. Inserting an interchangeable component 30 into the tip of the Core Projectile Component 32 changes the tip 12, ogive 16 and meplat 18.

[0059] FIG. 3 shows a core projectile component 32 having an interior cavity 36 for receiving an interchangeable component 30 (FIG. 2), such as a hollow point 34 (FIG. 2), whereas cavity 36 has a smaller diameter 40 than a cavity 36 of component 32 of FIG. 2.

[0060] FIG. 4 shows insertion of an Interchangeable Component 30 into the base 22 of the Core Projectile Component 32. Changing the base 22, shoulder 28, length 42 (FIG. 3) and mass of projectile 10.

[0061] FIG. 5 shows insertion of an Interchangeable Component 30 to alter the tip 12 so that it is pointed, thereby altering the size of the meplat 18 and the ogive 16 of projectile 10. This Interchangeable Component 30 can be made of a material that alters the mass of the projectile.

[0062] FIG. 6 shows that insertion of an Interchangeable Component 30 into the Core Projectile Component 32 reduces the size of the hollow point 36 and increases the size of the meplat 18 without altering the length of the projectile.

[0063] FIG. 7 shows that insertion of an Interchangeable Component 30 into the Core Projectile Component 32 may decrease the size of the hollow point 34 and increases the size of the meplat 18 while also may increase the overall length of the projectile 10.

[0064] FIG. 8 shows that insertion of an Interchangeable Component 30 into the Core Projectile Component 32 may increase the size of the tip 12 while reducing or eliminating the hollow point and, increases the size of the meplat 18 while also may increase the length of the projectile.

[0065] FIG. 9 shows an Interchangeable Component 30 being fitted to the outside of the Core Projectile Component 32. The Interchangeable Component 30 may be sized to have an external diameter 44 greater than, equal to, or less than the external diameter 46 of the Core Projectile Component 32.

[0066] FIG. 10 shows an exploded view of an Interchangeable Component 30 being fitted to the outside of the Core Projectile Component 32. The Interchangeable Component 30 may be fitted to the Core Projectile Component 32 by any means, such as press fit, adhesive, or welding, for example. Use of the component may allow changing: the length of the projectile; the diameter of the projectile; and the material that interacts with the launcher.

[0067] In another example embodiment, the invention may include a projectile made completely from a polymer with no metallic cladding, jacket or core. The inventive non-metallic projectile made entirely from polymer material provides many benefits. First, the specified polymer may be obtained in multiple colors such as red, yellow, green, blue and white, for example. Manufacturing the projectiles in such a variety of colors allows for branding, color coding, and purpose-built ammunition. Second, the polymer may be purchased as a food grade material which does not include dangerous toxins, such as the toxins found in metallic ammunition. Use of a food grade polymer material provides an added benefit for those who use the projectiles for hunting or varmint control on agricultural facilities because projectiles will not contaminate the ground on which they fall, will not contaminate an animal that eats a projectile off the ground, and will not contaminate the meat of an animal that is hunted with the projectile. Third, the specified polymer projectile enables efficient energy propagation when impacting mediums with a specific gravity of 1.0. All of these advantages are provided by the inventive polymer projectile and not by prior art metallic projectiles.

[0068] The inventive polymer projectiles may be manufactured with a blind bore at the forward end or at the rearward end of the projectile. The projectile may also be made with a through and through bore. Projectiles having a bore may also be threaded or manufactured having a hollow base with a diameter less than that of the bearing surface which is made to match the diameter of a launching device such as a firearm. The internal diameter of bored projectiles may have one or more grooves included therein that may enable hydraulic pressure to fracture the projectile depending on where the groove is located and the dimension of the groove. The groove may also enable snap fitting a component into the bore. In one embodiment the groove may be circumferentially formed into the inner wall of the bore. A more economical method would be to use a helical thread on the inner surface of the bore during the machining process. Such features serve to alter the mechanical characteristics of the projectile upon impact. These interior structures, low sectional density and specific gravity combine to provide a low ballistic coefficient which is desirable in our projectile applications and is usually undesirable in technology using metal materials.

[0069] The low dynamic coefficient of friction and low sectional density make the polymer projectiles suitable for use in remote, unmanned, weapon platforms for law enforcement and military missions. The low sectional density also enables launching of the inventive projectile with use of compressed air or a vacuum. The polymer projectiles enable the use of carbon fiber barrels for launching whereas metallic projectiles, due to their high sectional density and comparatively high dynamic friction coefficient, will destroy a carbon fiber barrel during launch. The load of a polymer projectile also reduces ammunition weight so substantially, compared to metallic projectiles, so that platforms used to launch polymer projectiles may allow for the carrying of double the firepower compared to metallic projectiles. Preferred embodiments of polymer projectiles will now be described.

[0070] FIG. 11 shows a side view of one example embodiment of a non-metallic one-piece polymer projectile 50 having a base 52, a bearing surface 54, and a forward end 56 forming a tapered nose 58 shape and a meplate 60. An unsealed blind bore 62 extends along an axis 64 from the forward end 56 of the projectile 50.

[0071] FIG. 12 shows a side cross sectional view of the projectile 50 of FIG. 11.

[0072] FIG. 13 shows a side view of another example embodiment of a non-metallic polymer projectile 50. One-piece projectile 50 has a base 52, a bearing surface 54, and a forward end 56 forming a tapered nose 58 shape and a meplate 60. An unsealed blind bore 62 extends along an axis 64 from the forward end 56 of the projectile 50. Blind bore 62 includes an interior diameter 66 threaded with a helical structure 68 used to convert between rotational and linear movement or force of a component attached within the blind bore.

[0073] FIG. 14 shows a side cross sectional view of the projectile 50 of FIG. 13.

[0074] FIG. 15 shows a side view of another example embodiment of a non-metallic projectile 50 manufactured entirely of polymer. One-piece projectile 50 has a base 52, a bearing surface 54, and a forward end 56 forming a tapered nose 58 shape and a meplate 60. An unsealed blind bore 62 extends along an axis 64 from the forward end 56 of the projectile 50. The projectile body 50 includes an interior diameter 66 having a groove 70 formed circumferentially on the inner diameter 66 of the bore 62.

[0075] FIG. 16 shows a side cross sectional view of the projectile 50 of FIG. 15.

[0076] FIG. 17 shows a side view of another example embodiment of a non-metallic projectile 50. One-piece projectile 50 has a rearward end 72, a forward end 56, and a bearing surface 54. The forward end 56 forms a tapered nose 58 and a meplate 60. The rearward end 72 includes an unsealed blind bore 62 extending along an axis 64 from the rearward end 72 toward the forward end 56.

[0077] FIG. 18 shows a side cross sectional view of the projectile 50 of FIG. 17.

[0078] FIG. 19 shows a side view of another example embodiment of a non-metallic projectile 50. One-piece projectile 50 has a base 52, a bearing surface 54, and a forward end 56 forming a tapered nose 58 shape and a meplate 60. An unsealed blind bore 62 extends along an axis 64 from the rearward end 72 of the projectile 50. The bore 62 includes an interior diameter 66 threaded with a helical structure 68 that is used to convert between rotational and linear movement or force of a component attached within the blind bore.

[0079] The helical structure has three purposes: to enable an insert to be threadibly attached such that rotating an insert will move the insert forward and aft within the bore of the projectile; to enhance hydraulic pressure inside the blind bore thereby facilitating fracturing when there is not a component threaded therein; and to change the way the core projectile module fractures and releases energy into a target. Also, when utilizing the projectiles with a through and through bore and a helical structure the helical structure will facilitate rotation of the projectile when fired utilizing a rail gun structure where the projectile slides on the external diameter of a launcher and where the external diameter of the launcher presses against the inner diameter of the projectile instead of the outer surface of the projectile pressing against the inner wall of the bore. In this application the helical structure will convert the linear force of the projectile into rotational movement similar that of rifling in a barrel.

[0080] FIG. 20 shows a side cross sectional view of the projectile 50 of FIG. 19.

[0081] FIG. 21 shows a side view of another example embodiment of a non-metallic projectile 50. One-piece projectile 50 has a base 52, a bearing surface 54, and a forward end 56 forming a tapered nose 58 shape and a meplate 60. An unsealed blind bore 62 extends along an axis 64 from the rearward end 72 of the projectile 50. The projectile body 50 includes an interior diameter 66 having a groove 70 formed circumferentially on the inner diameter wall 66 of the bore 62.

[0082] FIG. 22 shows a side cross sectional view of the projectile 50 of FIG. 21.

[0083] FIG. 23 shows a side view of another example embodiment of a non-metallic projectile 50. One-piece projectile 50 has a rearward end 72, a bearing surface 54, and a forward end 56. The forward end 56 and rearward end 72 have the same short truncated cone shape, wherein both ends are absent a blind bore. In other words, projectile 50 of FIG. 23 is solid throughout its body and does not include a core of a different material. Additionally, projectile 50 does not include cladding on the projectile or crimping of projectile body 50.

[0084] FIG. 24 shows a side view of another example embodiment of a non-metallic projectile 50. One-piece projectile 50 has a rearward end 72, a bearing surface 54, and a forward end 56. The forward end 56 and rearward end 72 have the same pointed cone shape, wherein both ends are absent a blind bore. In other words, projectile 50 of FIG. 24 is solid throughout its body.

[0085] FIG. 25 shows a side view of another example embodiment of a non-metallic projectile 50. One-piece projectile 50 has a rearward end 72, a bearing surface 54, and a forward end 56. The forward end 56 and rearward end 72 have the same tall truncated cone shape, wherein both ends are absent a blind bore. In other words, projectile 50 of FIG. 25 is solid throughout its body.

[0086] FIG. 26 shows a side view of another example embodiment of a non-metallic projectile 50. One-piece projectile 50 has a base 52, a bearing surface 54, and a forward end 56. An unsealed bore 62 extends along an axis 64 from the forward end 56 through the rearward end 72 of the projectile body 50. In this embodiment, bore 62 includes no threads or groove.

[0087] FIG. 27 shows a side cross sectional view of the projectile 50 of FIG. 26.

[0088] FIG. 28 shows a side view of another example embodiment of a non-metallic projectile 50. One-piece projectile 50 has a base 52, a bearing surface 54, and a forward end 56. An unsealed bore 62 extends along an axis 64 from the forward end 56 through the rearward end 72 of the projectile body 50. Bore 62 includes an interior diameter 66 threaded with a helical structure 68 used to convert between rotational and linear movement or force.

[0089] FIG. 29 shows a side cross sectional view of the projectile 50 of FIG. 28.

[0090] FIG. 30 shows a side view of another example embodiment of a non-metallic projectile 50. One-piece projectile 50 has a base 52, a bearing surface 54, and a forward end 56. An unsealed bore 62 extends along an axis 64 from the forward end 56 through the rearward end 72 of the projectile body 50. The projectile body 50 includes an interior diameter 66 having a groove 70 formed circumferentially on the inner diameter wall 66 of the bore 62. The use of grooves 70 and/or helical structure 68 on projectile 50 is utilized to alter the mechanical characteristics of the projectile.

[0091] FIG. 31 shows a side cross sectional view of the projectile 50 of FIG. 30.

[0092] FIG. 32 shows a polymer projectile 50 being launched along an axis 76 from a launching device 78, such as a carbon fiber barrel 80 attached to a compressed air or a vacuum device 82. The non-metallic projectile 50 produces less heat then prior art metallic projectiles and, therefore, may be launched using a carbon fiber barrel 80 or other types of non-metallic barrels. Moreover, compressed air may be used to launch projectile 50 without the use of gun powder, primer, and the like. For these reasons, the non-metallic projectile, which may be manufactured as one single unit of non-metallic material, i.e., manufactured from a single piece of plastic, generally will not be susceptible to damage by moisture.

[0093] The present inventive polymer projectile 50 has many advantages over and differences from the prior art. In particular, polymer projectile 50 does not include an insert. Instead, projectile 50 is manufactured as a single, integral piece. Projectile 50 does not require gun power, primer or a casing to be functional, as is required by prior art projectiles. In contrast projectile 50 may be launched using a vacuum cannon. The low sectional density of projectile 50 may enable many launching systems that can be adapted to unmanned remote controlled launching platforms. In contrast, the sectional density of prior art projectiles would make the use of a vacuum cannon improbable.

[0094] Projectile 50 does not deliver a payload. Additionally, projectile 50 may include a bore that extends entirely through the projectile 50, from front end 56 and through rearward end 72 of the projectile. In contrast, prior art projectiles may include a hermetically sealed ampule (insert) to prevent moisture infiltration. Moisture infiltration in the present invention is not a concern because the projectile 50 is manufactured of polymer which does not oxidize or otherwise corrode. Additionally, projectile 50 does not utilize gun powder or primer for launching and so the infiltration of water would not degrade its launching ability.

[0095] Projectile 50 is a one-piece, projectile manufactured completely of a single man-made material, such as a polymer, that provides material specifications outside the material specifications of metallic projectiles. In particular, in one example embodiment projectile 50 may be manufactured of Quadrant EPP Acetron.RTM. POM-H Homopolymer Acetal. The Acetron.RTM. may have a specific gravity of 1.41 g/cc, a water absorption of 0.20%, a tensile strength of 75.8 MPa, and a dynamic coefficient of friction of 0.25. Such properties result in a projectile 50 that may be launched by less powerful launching devices than prior art metallic projectiles, and may reach in-flight velocities that are much higher than the in-flight velocities of metallic projectiles, such that the inventive non-metallic projectile of the present invention may reach in-flight velocities in excess of 4100 Feet Per Second, as was recorded in one example embodiment of a projectile using 12 gauge projectiles with a broad impact surface. Such in-flight speeds are unheard of for metallic projectiles.

[0096] In another embodiment projectile 50 may be manufactured of Global EPP POM C Acetal Copolymer.RTM.. The Global Acetal Copolymer.RTM. may have a specific gravity of 1.41 g/cc, a water absorption of 0.20%, a tensile strength of 70.0 MPa, and a dynamic coefficient of friction of 0.25. Such properties result in a projectile 50 that may be launched by less powerful launching devices than prior art metallic projectiles, and may reach in-flight velocities that much higher than the in-flight velocities of metallic projectiles, such as in-flight velocities of in excess of 4100 Feet Per Second using 12 gauge projectiles with a broad impact surface. Such in-flight speeds are unheard of for metallic projectiles.

[0097] In another embodiment projectile 50 may be manufactured of Torlon.RTM. 7130 Polyamide-imide (PAI), 30% Caron Fiber. The Torlon Copolymer.RTM. may have a specific gravity of 1.48 g/cc, a water absorption of 0.26%, and a tensile strength of 221 MPa. Such properties result in a projectile 50 that may be launched by less powerful launching devices than prior art metallic projectiles, and may reach in-flight velocities that much higher than the in-flight velocities of metallic projectiles, such as in-flight velocities of in excess of 4100 Feet Per Second using 12 gauge projectiles with a broad impact surface. Such in-flight speeds are unheard of for metallic projectiles.

[0098] Non-metallic polymer projectile 50 utilizes materials with a specific gravity no less than that of water and no more than 270 percent greater than that of water; tensile strength properties no less than 10,000 pounds per square inch; compressive strength properties no less than 10,000 pounds per square inch; and a coefficient of friction of no more than 0.3. These properties result in a projectile 50 that can be launched with a launching device 78 that utilizes a force of 12000 PSI or less, yet the projectile 50 may reach in-flight speeds of in excess of 4100 Feet Per Second using 12 gauge projectiles with a broad, or slightly flat face format, and may travel distances of 100 yards or more.

[0099] In a preferred embodiment projectile 50 is a one-piece, finless projectile, entirely constructed of polymer weighing more than 7 grains, and having a bearing surface, a rearward end, and a forward end. The polymer may have a specific gravity equal to or greater than 1 and equal to or less than 2.16, and a tensile strength specification of 6000 pounds per square inch or greater, a compressive strength specification of 6000 pounds per square inch or greater, and a dynamic coefficient of friction against a steel surface of 0.5 or less. The projectile may have a ballistic coefficient in the range of 0.02 to 0.1 that facilitates rapid energy propagation from the projectile into a target upon impact.

[0100] The projectile 50 may have a body with an open ended or unsealed bore extending axially from the forward end of the projectile body, or axially from the rearward end of the projectile body. The projectile may also have a body with an open ended or unsealed bore extending axially from the forward end of the projectile body including an interior diameter having a groove formed circumferentially on the inner diameter wall of the bore. The projectile may have a body with an open ended or unsealed bore extending axially from the rearward end of the projectile body including an interior diameter having a groove formed circumferentially on the inner diameter wall of the bore. The projectile may have a body with an open ended or unsealed bore extending axially from the forward end of the projectile body including an interior diameter threaded with a helical structure used to convert between rotational and linear movement or force. The projectile may have a body with an open ended or unsealed bore extending axially from the rearward end of the projectile body including an interior diameter threaded with a helical structure used to convert between rotational and linear movement or force. The projectile may have a bearing surface to engage and obturate the inner surface of the barrel of a launching device, such as a firearm bore, causing pressure to build, thereby facilitating launch of the projectile. The projectile may have a bearing surface to engage the inner surface of a launching device, such as a rifled firearm bore, causing bearing surface etching as the projectile passes through a rifled bore to facilitate spin stabilization. The projectile may have an open ended or unsealed bore extending axially from the forward end of the projectile through the entire length of the projectile and out the rearward end, including an interior diameter threaded with a helical structure used to convert between rotational and linear movement or force. The projectile may have a body with an open ended or unsealed bore extending axially from the forward end of the body through the entire length on through the rearward end of the body, including an interior diameter having a groove formed circumferentially on the inner diameter wall of the bore.

[0101] In summary, in one embodiment, the present invention includes a non-metallic projectile, such as a projectile manufactured entirely of polymer, that may include an insert secured to a forward end, an insert secured to a rearward end, an insert inserted into the projectile, or an embodiment where no insert is utilized and only the polymer projectile itself is launched. Because the projectile is manufactured entirely of non-metallic material it exhibits unexpected and advantageous properties, such as in-flight speeds of over 4100 feet per second, the ability to be launched from a non-metallic vacuum cannon, the ability to be manufactured as a single, integral piece; launching ability without the use of gun power, primer or a casing; and the ability of the projectile to be launched using launching systems that can be adapted to unmanned remote controlled launching platforms. Additionally, the use of a non-metallic polymer projectile allows for non-toxic materials to be used and color coding of the projectile. These and other advantages are provided by the non-metallic projectile of the present invention.

[0102] In the above description numerous details have been set forth in order to provide a more thorough understanding of the present invention. It will be obvious, however, to one skilled in the art that the present invention may be practiced using other equivalent designs.

Claims

1. A non-metallic projectile, comprising a projectile body manufactured as a single, integral piece of polymer, said body including a tip, a bearing surface, an ogive, a meplat and a tail.

2. The projectile of claim 1 wherein said body has a specific gravity at least equal to a specific gravity of water and less than 270% greater than a specific gravity of water.

3. The projectile of claim 1 wherein said body has a tensile strength of at least 10,000 pounds per square inch.

4. The projectile of claim 1 wherein said body has a compressive strength of at least 10,000 pounds per square inch.

5. The projectile of claim 1 wherein said body has a coefficient of friction of no more than 0.3.

6. The projectile of claim 1 wherein said projectile component includes a hollow interior region.

7. The projectile of claim 6 wherein said hollow interior region is chosen from a region that extends from said tip to said tail such that said hollow interior region extends completely through said projectile, a region that extends from said tip into said body, and a region that extends from said tail into said body.

8. The projectile of claim 1 wherein said projectile is chosen to have a specific gravity that matches a specific gravity of a medium into which the projectile will be fired.

9. The projectile of claim 1 wherein said projectile is chosen to have a specific gravity that will maximize a ballistic pressure wave created by said projectile upon impact with a medium into which the projectile will be fired.

10. The projectile of claim 6 wherein said hollow interior region includes at least one of a helical structure and a groove.

11. A non-metallic projectile, comprising: one-piece body having an absence of fins, being manufactured entirely of polymer, weighing more than 7 grains, and having a bearing surface, a rearward end, and a forward end.

12. The projectile of claim 11 wherein said polymer has a specific gravity of at least 1.0 and at most 2.16 g/cc.

13. The projectile of claim 11 wherein said polymer has a tensile strength of at least 6000 pounds per square inch, and a compressive strength of at least 6000 pounds per square inch.

14. The projectile of claim 11 wherein said polymer has a dynamic coefficient of friction against a steel surface of at most 0.5.

15. The projectile of claim 11 wherein said body includes a bore chosen from a bore extending axially through said rearward end of said body and into a central region of said body, a bore extending axially through said forward end of said body and into said central region of said body, and a bore extending axially through said forward end, through said central region and through said rearward end of said body, said bore including a hollow interior surface having a surface feature chosen from a groove formed circumferentially on said hollow interior surface of said bore, a helical structure formed on said hollow interior surface of said bore, said helical structure used to convert between rotational and linear movement or force, and a smooth interior surface on said hollow interior surface of said bore.

16. A launching system, comprising: a launching device including a carbon fiber barrel that includes an interior barrel surface that defines a launching aperture; and a one-piece projectile manufactured entirely of polymer, said projectile including a bearing surface that engages said interior surface and obturates said launching aperture of said barrel so as to facilitate a pressure increase within said launching device prior to launch of said projectile.

17. The launching system of claim 16 wherein said interior surface of said barrel contacts and etches said projectile bearing surface as said projectile passes through said barrel so as to facilitate spin stabilization of said projectile during launch.

18. The launching system of claim 17 wherein said projectile includes a body having an open ended bore, said bore including an interior bore surface threaded with a helical structure that converts an axially linear force on said body into rotational movement of said body.

19. The launching system of claim 17 wherein said projectile includes a body having an open ended bore, said bore including an interior bore surface having a groove formed circumferentially there around.

20. The launching system of claim 16 wherein said projectile includes a ballistic coefficient in a range of 0.02 to 0.1 and an in flight velocity of at least 4100 feet per second.