Sound Reducing Systems for Use with Projectile Launchers

This is a continuation of U.S. patent application Ser. No. 18/184,593, filed Mar. 15, 2023, which claimed priority of and to U.S. Provisional Patent Application Ser. No. 63/320,505, filed Mar. 16, 2022, each of which is hereby incorporated herein by reference in its entirety.

The present invention relates generally to propulsion systems for use with entangling projectile launching systems.

It has been recognized for some time that police and military personnel can benefit from the use of devices other than firearms to deal with some hostile situations. To address this need, the present applicant developed a commercially successful product known as the BolaWrap®. This device, and others developed by the present applicant, have allowed law enforcement personnel to address potentially dangerous situations without resorting to the use of a firearm, and without engaging in hand-to-hand combat.

This type of launching system generally utilizes a projectile that includes a tether and a pair of anchors or pellets carried at ends of the tether. The projectile is expelled from a launcher at very high speeds by utilizing a pressure source, such as a cartridge containing a propellant. For more background on the general concept of entangling projectiles, the reader is directed U.S. Pat. No. 10,107,599, which is hereby incorporated herein by reference to the extent it is consistent with the teachings herein.

While the BolaWrap® systems have enjoyed widespread success, the present applicant has continued to develop technology to even further improve the operation and acceptance of such devices.

In accordance with one aspect of the technology, a cassette for deploying one or more anchors is provided. The cassette can include at least one socket in fluid communication with a pressure source, at least one anchor being positionable within the at least one socket and at least one slidable piston positionable in the at least one socket between the anchor and the pressure source such that the slidable piston is propelled along the socket in response to a pressure wave generated by the pressure source to thereby expel the anchor from the socket. The slidable piston can include a first, substantially rigid component and a second, substantially pliable component, the pliable component partially circumscribing the rigid portion. A portion of the rigid component of the piston can be seated against a portion of the anchor when the anchor and piston are positioned within the socket.

In accordance with another embodiment, a cassette for deploying one or more anchors can be provided. The cassette can include at least one socket in fluid communication with a pressure source, at least one anchor being positionable within the at least one socket, and at least one slidable piston positionable in the at least one socket between the anchor and the pressure source such that the slidable piston is propelled along the socket in response to a pressure wave generated by the pressure source to thereby expel the anchor from the socket. The slidable piston can include a first, substantially rigid component and a second, substantially pliable component, the pliable component partially circumscribing the rigid portion. The slidable piston and the anchor can each carry an alignment feature, the respective alignment features being engageable with one another when the anchor and piston are positioned within the socket to ensure proper alignment of the anchor within the socket.

In accordance with another aspect, a cassette for deploying one or more anchors is provided, the cassette including at least one socket in fluid communication with a pressure source, at least one anchor being positionable within the at least one socket, and at least one slidable piston positionable in the at least one socket between the anchor and the pressure source such that the slidable piston is propelled along the socket in response to a pressure wave generated by the pressure source to thereby expel the anchor from the socket. The slidable piston can include a first, substantially rigid component and a second, substantially pliable component, the pliable component partially circumscribing the rigid portion. A portion of the pliable component of the piston can be seated against the pressure source so as to create a standoff space between the rigid component of the slidable piston and the pressure source when the anchor and piston are positioned within the socket.

Additional features and advantages of the invention will be apparent from the detailed description which follows, taken in conjunction with the accompanying drawings, which together illustrate, by way of example, features of the invention.

Reference will now be made to the exemplary embodiments illustrated in the drawings, and specific language will be used herein to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Alterations and further modifications of the inventive features illustrated herein, and additional applications of the principles of the inventions as illustrated herein, which would occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention.

As used herein, the singular forms “a” and “the” can include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a socket” can include one or more of such sockets, if the context dictates.

As used herein, the term “substantially” refers to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result. As an arbitrary example, an object that is “substantially” enclosed is an article that is either completely enclosed or nearly completely enclosed. The exact allowable degree of deviation from absolute completeness may in some cases depend upon the specific context. However, generally speaking the nearness of completion will be so as to have the same overall result as if absolute and total completion were obtained. The use of “substantially” is equally applicable when used in a negative connotation to refer to the complete or near complete lack of an action, characteristic, property, state, structure, item, or result. As another arbitrary example, a composition that is “substantially free of” an ingredient or element may still actually contain such item so long as there is no measurable effect as a result thereof.

As used herein, the term “about” is used to provide flexibility to a numerical range endpoint by providing that a given value may be “a little above” or “a little below” the endpoint.

Relative directional terms can sometimes be used herein to describe and claim various components of the present invention. Such terms include, without limitation, “upward,” “downward,” “horizontal,” “vertical,” etc. These terms are generally not intended to be limiting, but are used to most clearly describe and claim the various features of the invention. Where such terms must carry some limitation, they are intended to be limited to usage commonly known and understood by those of ordinary skill in the art in the context of this disclosure.

As used herein, a plurality of items, structural elements, compositional elements, and/or materials may be presented in a common list for convenience. However, these lists should be construed as though each member of the list is individually identified as a separate and unique member. Thus, no individual member of such list should be construed as a de facto equivalent of any other member of the same list solely based on their presentation in a common group without indications to the contrary.

Numerical data may be expressed or presented herein in a range format. It is to be understood that such a range format is used merely for convenience and brevity and thus should be interpreted flexibly to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. As an illustration, a numerical range of “about 1 to about 5” should be interpreted to include not only the explicitly recited values of about 1 to about 5, but also include individual values and sub-ranges within the indicated range. Thus, included in this numerical range are individual values such as 2, 3, and 4 and sub-ranges such as from 1-3, from 2-4, and from 3-5, etc., as well as 1, 2, 3, 4, and 5, individually.

This same principle applies to ranges reciting only one numerical value as a minimum or a maximum. Furthermore, such an interpretation should apply regardless of the breadth of the range or the characteristics being described.

The present technology relates broadly to components used in non-lethal engagement systems. The present launchers are sometimes referred to as ensnarement or entanglement systems. They can be effectively used as an aid in impeding the movement of or detaining aggressive or fleeing subjects. Devices in accordance with the present technology can be advantageously used to temporarily impede a subject's ability to walk, run, or use his or her arms in cases where law enforcement, security personnel or military personnel wish to detain a subject, but do not wish to use lethal or harmful force or to engage in close proximity hand-to-hand combat. The technology provides a manner by which the arms or legs of a subject can be temporarily tethered or bound, to the extent that the subject finds it difficult to continue moving in a normal fashion. The present applicant has developed a number of such systems, available commercially under the brand name BolaWrap®.

The present application is directed to such systems that include sound reducing or dampening capability. As shown generally in, a launcher of the present technology can generally utilize a cassettethat includes pressure source(s)that, when activated, generate(s) a high pressure wave. This wave in turn expels a pair of anchors or pellets,, from a pair of sockets or cylinders,formed in or carried by the cassette. A tethercan connect the anchors, although it is not shown connected in this view to aid in clarity. A shield or covercan be installed over the entire assembly to protect the assembly from dust, moisture, etc.

The system can include a sliding piston,that is positioned in a respective socket,upstream of the anchor or pellet,. When a pressure sourceis activated, the resulting pressure wave contacts the piston and propels the piston along the length of the socket. As the piston is propelled forward it, in turn, propels the anchors or pellets forcefully from the sockets. While the anchors are propelled from the sockets, the sliding piston is prevented from exiting the sockets. In this manner, the sliding piston creates an expansion chamber within the socket that receives the pressurized gas resulting from activation of the pressure source. This in turn greatly reduces the soundwave generated as a result of firing the launcher. In one non-limiting example, the intensity of the soundwave is reduced from about 155 dB to below about 140 dB. In some cases, reduction to about 115-135 dB has been achieved.

In the exemplary figures included herein, only a cassette,, etc., with its accompanying components is shown. It will be readily understood by one of ordinary skill in the art that such cassettes are but one component of an overall launching system that may appear, for example, similar to other hand-held devices, such as the commercially available BolaWrap® device sold by the Applicant. The overall launching system will likely include one or more power sources, power switch, control circuitry, aiming components, charge indicators, etc. In the interest of clarity, however, the present figures are limited to the components carried on or in the cassette.illustrate additional embodiments of the technology. In these examples, an electronically initiated pressure source(see, for example,, etc.) can be utilized. Such pressure sources can be initiated by providing them with a controlled electrical charge, as will be readily understandable by one of ordinary skill in the art having possession of this disclosure. In some examples, the pressure source includes a microgas generator, which is a commonly available pyrotechnic charge.

show the cassettewith varying components omitted from each successive view to provide details of previously hidden components. In, an outer casingis shown that can be formed in a variety of configurations and from a variety of known materials. In, the outer casing is omitted, revealing a protective shield or cover. A tetheris shown in the configuration in which it can be stowed within the cassette. A pair of sockets,are also shown, further details of which are discussed in more detail below.

In, the sockets are omitted to reveal beneath a pair of anchors,. As will be appreciated, each socket is in fluid communication with a respective pressure source. In addition to the anchors, each socket,can carry a slidable piston,. The slidable pistons are positionable in a respective socket between an entangling projectile and the pressure source. In this manner, each slidable piston is propelled along a respective socket in response to a pressure wave generated by the pressure source to thereby expel the anchor from the socket.

As shown in more detail in, in one aspect of the technology, the slidable pistoncan include a first, substantially rigid componentthat can be formed from a material such as aluminum, steel, hardened composites, etc. The piston can also include a second, substantially pliable component. The pliable component can at least partially circumscribe the rigid component. In the views of, the pliable component is shown removed from the rigid component. Depending on the manner of applying the pliable component about the rigid component, however, physically separating the two as shown may not be practicable. While the pliable component can be formed in a manner that allows it to be slipped over or around the rigid component, in one example the pliable component can be formed about the rigid component during manufacture. In this case, physically separating the two and maintaining the pliable component intact may not be possible.

The pliable component can be formed from a variety of suitable materials, including without limitation, neoprene, Santoprene™, etc. These materials provide a relatively soft but tough article that remains pliable enough to allow the componentto create a seal with an inner diameter of the socket. This seal can be sufficient to maintain pressure zones behind and ahead of the piston, and will generally result in a fit that at least partially retards movement of the piston within the socket. In other words, the seal slightly resists movement of the piston within the socket such that the piston will generally remain in position within the socket until acted upon by the pressure wave generated by the pressure source. While the piston will move freely once acted upon by the pressure wave, normal handling of a launcher, or the force of gravity, is typically insufficient to overcome the force applied by the seal.

illustrate much the same features ofA throughC, except that in this embodiment the slidable piston′ is configured slightly differently than piston. In this example, piston′ includes pliable component′ and rigid component′. The various features described herein in relation to pistonalso apply to piston′, for example, various alignment features, standoff features, etc., as discussed in further detail throughout this specification.

Returning now to, this view includes the components of, except that the pliable componentof the slidable pistonis omitted to provide a clearer view of the rigid component.illustrates the cassette of, except that the slidable piston is omitted from view.

As shown in, the socketcan include a piston stopformed on or near an end thereof. The piston stop serves to prevent the pistonfrom exiting the socket during launch of the anchor(not shown in this view). The piston stop can take a variety of forms, but in the example shown includes a lip extending radially inwardly into an end of the socket. The lip can be sized to allow the anchor to freely exit the socket, but serves to block the piston from exiting the anchor. In one embodiment, once fired, the assembly cannot be reused again, as either or both the piston and the piston stop are damaged by the impact of the piston and the stop during launch.

In one embodiment, the stop, e.g., lip, can extend only partially about a circumference of the socket, so as to define a tether notch openingtherein. The openingcan serve several functions: in the examples shown (see, for example), the anchorcan include an anchor orientation protrusionthat can be alignable with the tether notch openingin the lip while the anchor is installed in the socket. In this manner, the anchor can be installed through the lipin only one orientation: this can ensure that the anchor is properly installed each time. In addition, as discussed in further detail below, the anchor orientation protrusion can also serve as a tether attachment that can receive and secure the tether therein.

As shown in, a retaining clipcan be engageable with the anchor, and also with the socket. The retaining clip aids in retaining the anchor in the socket prior to generation of the pressure wave. The retaining clip can also ensure that both the anchor and the pistonare precisely positioned, and remain so, within the socket. In one example, when the retaining clip is installed, a slight pre-load is applied to the anchor and through the slidable piston atop the pressure source. The pliable componentof the piston can aid in maintaining this pre-load, as the pliable component creates a slight resistant to movement within the socket and compresses slightly when displaced by the clip.

The retaining clip can ensure that the anchor is maintained in intimate contact with the piston during assembly, storage, haulage, etc. This intimate contact is maintained throughout operation of the launcher, up to the point where the anchor exits the socket while, as discussed below, the piston remains within the socket.

In the example of, the piston stoppositioned at the end of the socketcan be used to retain the retaining clipin position within the socket. In this example, the retaining clip includes two pliable arms,, that can be biased inward during installation to allow the clip to be installed, then spring outward when released to engage the inner surface of the retaining lip. The retaining clip can be formed from a sacrificial material, such as plastic, so that the retaining clip does not interfere with proper launch of the anchor. Once the pressure wave is applied to the anchor, the retaining clip can be destroyed as the anchor exits the socket. The retaining clip can be formed from a variety of materials, including polycarbonate, ABS, POM/Delrin, and the like, and blends thereof.

Generally speaking, the present technology advantageously provides various manners of orienting and aligning the anchor, slidable piston, retaining clip and pressure source within the socket. In one example, the piston and anchor can be configured such that a portion of the rigid component of the piston is seated against a portion of the anchor when the anchor and piston are positioned within the socket. As shown for example in, respectively, rigid piston component′ andeach include a contact surfacethat makes direct contact with a contact surfaceof anchor(see, for example). In this manner, the slidable piston can immediately begin transferring force to the anchor when the piston is subject to the pressure wave. The retaining clip, discussed above, can aid in maintaining the components in this position prior to launch.

The rigid component′,, respectively, of the slidable piston′,, can include an alignment feature′,, as can the anchor(see featurein). These respective alignment features can be engageable with one another when the anchor and piston are positioned within the socket to ensure proper alignment of the anchor within the socket. While the alignment features can take a variety of forms, in one embodiment, the alignment feature′,of the piston′,, respectively, can include a pin and the alignment feature() of the anchorcan include a pocket. The pin can be fittable within the pocket to ensure that the anchor is properly aligned relative to the slidable piston. The slidable piston can be maintained in alignment by the outer seal portion of the pliable component′,of the slidable piston. In these examples, these alignment features can ensure that both the piston and the anchor are concentrically centered within the socket when the pin is fitted within the pocket.

While the anchor and the rigid component of the piston are held in direct contact prior to initiation of the launcher, the rigid component of the piston and the pressure source can be maintained slightly spaced from one another. In one example, a portion of the pliable component of the piston can be seated against the pressure source so as to create a standoff space between the rigid component of the piston and the pressure source when the anchor and piston are positioned within the socket. This can be seen, for example, in, where a standoff space′ is maintained between pressure sourceand the rigid component of the′ of the piston. This space is maintained by the pliable component′ of the piston. Similarly, in, it can be seen that a standoff spaceis maintained between pressure sourceand the rigid component of the piston. While this distance can vary, in one example the standoff space is about 1 mm. In another example, the standoff space is about 2 mm. In another example, the standoff space can be from about 0.5 mm to about 3 mm.

illustrate further exemplary embodiments of the technology. In these examples, the anchorcan include a head segment, a tail segment, and a shank segmentintermediate the head and tail segment. One or more hook segments,, etc., can be carried adjacent the head segment. The one or more hook segments can be operable to engage the person of a subject about which the entangling projectile has been deployed. An attachment baycan be formed in the shank segment. A tether,′ can be coupled to the anchor within and can extend from the attachment bay. The tether can be coupled within the attachment bay in a variety of manners, including by application of adhesive, forming a knot or other obstruction in the tether, permanent deformation of the attachment bay or portions of the anchor body (crimping), etc.

In the example of, the anchorcan include a tether attachmentcarried by the anchor distally from the attachment bay. The tether attachment can be operable to engage the tetherand maintain the tether in a taught condition between the tether attachment and an end (e.g., near tail segment) of the anchor. The tether attachment feature can ensure proper management of the tether as the tether is attached to the anchor, as the anchor is installed within the socket, and as the anchor is deployed from the socket during launch.

As best seen in, the tether attachmentcan include a pair of arms,that define an internal receiving space,. A distance between ends of the pair of arms can be smaller than an internal diameter of the internal receiving space. In this manner, the tether can be forced between the arms,until it clears this space and enters the internal receiving space. Once thus positioned, the arms resist movement of the tether out of this space. In one embodiment, the internal diameter of the internal receiving space substantially corresponds to, or is smaller than, an external diameter of the tether. In this manner, the tether can be securely cinched within the receiving space.

As seen in, this embodiment can also include a tether portthat can be in communication with the attachment bayto allow the tether to extend from the attachment bay to the tether port and extend from the tether port toward the tether attachment. Thus, the tether can be coupled to the anchor within the attachment bay, and can extend through the tether port and upward along the side of the anchor. In this manner, the tether can be securely attached coaxially or concentrically to the anchor, but can extend laterally adjacent the anchor as it extends out of the socket. This attachment scheme advantageously allows this tether management without interfering with the contact fit between the anchor and the rigid portion of the slidable piston.

For example, while the tether is omitted from view from 8, it will be appreciated that the path traversed by the tether from the attachment bay, through the tether portallows the tether to be fed away from the attachment bay without interfering with the fit between the pinof the piston and the pocket() of the anchor. In this manner, a centric opening can be formed in an end of the tail segment of anchor, and the tether can extend from the attachment bay and out of the tether port without traveling through the centric opening. While not so required, in the examples shown in the drawings, the attachment bay can be open only one side of the shank segment of the anchor. This can aid in securing the tether within the bay without adhesive or portions of the tether extending through the other side.

As shown in, the tether attachmentprovides a manner by which the tethercan be maintained in a substantially taught configuration adjacent the anchorwhile being installed within the socket, and while stored in the socket prior to launch.illustrates another embodiment by which this can be achieved. In this example, a stiffening agent (shown schematically at) can be applied to, or carried by, the tether′ in a location adjacent the anchor. The stiffening agent can aid in maintaining the tether is a substantially taught configuration as it extends along the shank segment of the anchor. The stiffening agent can be applied in addition to, or instead of, using the tether attachment.

The stiffening agent can be carried by the tether only in an area between opposing ends of the anchor: in other words, the portion of the tether that extends from the attachment bayand turns while exiting the tether portcan be left untreated, so as to remain flexible. Similarly, the portion of the tether that extends away from the anchor toward an opposing anchor can remain flexible as well.

The type of stiffening agent used can vary, but in one embodiment can be a chemical agent, such as a curable and/or hardenable adhesive, applied to the tether which thereby increases a stiffness of the tether. The stiffening agent can also include a mechanical agent applied to the tether to increase a stiffness of the tether. This can include, for example, strands of a stiffer material, such as wire strands, or a sheath of stiffer material, such as a woven wire shield.

illustrate various additional embodiments of the technology in which the piston is formed in different configurations and/or from differing materials than the embodiments discussed previously. Generally, as used herein, the terms “pliable” and “rigid” are relative terms. In the examples provided above, the pliable component of the piston can be a material that can be easily compressed, such as, for example, neoprene, Santoprene™, etc. However, in some embodiments, the relatively pliable material can be selected from materials such as more rigid thermoplastics, material sold under the tradename Delrin (Polyoxymethylene, or POM), and the like. These materials, while relatively soft compared to metals such as steel, are not easily compressed at room temperature. Thus, while such materials are referenced herein as “relatively pliable,” such reference is made relative to another material, often a much more rigid material, such as steel.

In the example shown in, the pistonis monolithic (e.g., formed from a single material). It can be formed from a relatively pliable material, such as Delrin, a thermoplastic, or the like. In this example, the piston includes an outer diameter Dthat is larger than an inner diameter Dof the socket. In this manner, engagement between the outer diameter of the piston and the inner diameter of the socket partially retards movement of the piston within the socket. That is, once installed in position within the socket, the piston will not easily move during manufacture, storage, haulage, etc. However, once the pressure sourceis activated, the piston will be propelled freely down the socket.

The degree of difference between the outside diameter Dof the pistonand the inside diameter Dof the socketcan vary. In one embodiment, however there is an interference of about 1.83% between the two. This interference fit can range, in other embodiments, from about 0.5% to about 4.0%. In one example, the nominal inner diameter Dis about 8.2 mm and the nominal outside piston diameter Dis about 8.35 mm, resulting in the 1.83% interference fit. In one example, the socketcan be formed from stainless steel, such as 304L, with a wall thickness of around 0.56 mm. Suitable ranges of wall thickness can vary from about 0.25 mm to about 2.0 mm. This fit can advantageously allow the piston to be precisely positioned where desired during assembly. In some embodiments, the socket, as that term is used herein, can include a laser welded assembly that includes a MicroGas Generator Assembly (“MGGA”): e.g., the socket assembly as a whole can include a launch tube and a MGG (MicroGas Generator) pressure source.

In some embodiments of the technology discussed above, a portion of the piston is placed in intimate contact with the pressure source during assembly. This can allow the creation of a standoff distance or space between a portion of the piston and an end of the pressure source (see, e.g.,in). In some embodiments, however, for example some of those shown in, the piston can include a pressure receiving cupthat can include a floor surface(e.g., a surface at the floor of the cup, if viewed in an upright position). The floor surface of the pressure receiving cup can be spaced from an end of the pressure sourceto create a standoff space (, for example, in) between the floor surface of the pressure receiving cup and the pressure source when the anchor and piston are positioned within the socket. In some embodiments, this standoff space is between about 1 mm and about 2 mm.

The floor surface of the pressure receiving cup of the piston can be shaped in a variety of configurations, including a generally bowl-shaped or rounded depression. It can also include a generally planar surface, as shown in, for example. The sidewalls forming the cup can extend substantially completely around the bowl, or can include openings or gaps therein (similar to the embodiment shown in).

The interference fit between the outside diameter of the piston and the inside diameter of the socket can advantageously allow the standoff space to be precisely configured, without requiring that a portion of the piston be installed in intimate contact with a portion of the pressure source. While the drawings provided herewith are not necessarily drawn to scale, and do not necessarily show components precisely spaced relative to one another,illustrate exemplary spacings of pistons,,, etc., relative to the pressure source

In the example of, pistonincludes a first, relatively pliable componentand a second, relatively rigid component. In the example of, pistonincludes a first and second relatively pliable componentsand a third, relatively rigid component. In the example of, pistonincludes first and second relatively pliable componentsand a third, relatively rigid component. In the example of, pistonis formed from a single material, typically a metallic material such as steel. In the example of, pistonincludes a first, relatively pliable componentand a second, relatively rigid component