Projectile Cartridge Assembly and Launcher System for Firing the Same

The present invention relates in general to the field of ammunition, specifically to a projectile cartridge assembly, which may also be used for non-lethal applications, and a launcher system for firing the cartridge.

The use of non-lethal projectiles in weapon systems include the use of frangible projectiles, which are designed to disintegrate upon target impact thereby minimizing penetration of the target. The use of these non-lethal projectiles can often require specialized equipment, meaning that a non-lethal weapon system cannot be used for lethal applications. Weapon launcher systems that are used for lethal applications may employ non-lethal ballistics such as beanbags or rubber projections, but are inaccurate, posing potential dangers even when used properly.

Launcher systems of the prior art, including those employing non-lethal piston/rocket projectiles, utilize a barrel adapted to receive a projectile with a charge of propellant and a magazine adapted to hold additional projectiles. These projectiles include a piston mounted for shiftable movement relative to a main body. When propellant in the projectile is ignited, either mechanically or electrically, the propellant forces the piston forward from a retracted position during a period of initial thrust. After the piston moves to a fully extended position, the propellant exits through vent holes to provide an additional thrust for the projectile, while safely discharging pressure from within the projectile. While sufficiently accurate, shifting of the cartridge within the barrel bore prior to ballistic ignition can reduce the impact energy produced by the firing pin assembly, resulting in a failure to fire.

Bearing in mind the problems and deficiencies of the prior art, it is therefore an object of the present invention to provide a projectile cartridge assembly that may be fired within a launching system with improved accuracy.

It is another object of the present invention to provide a simpler non-lethal projectile and cartridge assembly which decreases costs.

Another object of the present invention is to provide a cartridge which ensures proper loading, seating, and firing operations within a launcher system, where the cartridge may also be used for non-lethal applications.

Still other objects and advantages of the invention will in part be obvious and will in part be apparent from the specification.

The above and other objects, which will be apparent to those skilled in the art, are achieved in the present invention which is directed to a projectile cartridge assembly comprising: a projectile; a base-insert subassembly including: a base having a forward end and a rear end, the base forward end including a substantially cylindrical coupling element or skirt for receiving a cartridge casing or cover, the base rear end including a primer recess cavity; and a cartridge combustion insert extending from the base in the forward direction, having a substantially cylindrical open-ended sidewall terminating at a forward open end, and a combustion chamber therein; a jacket subassembly comprising: substantially cylindrical cartridge jacket housing having a closed forward end, and an open base end, the open base end having first diameter sized for clearance of a forward end of a thrust post; the thrust post including a spindle post having a post base end and the thrust post forward end including a disc or head, wherein upon assembly of the jacket subassembly, the thrust post topside end will contact a muzzle-side interior surface of the jacket housing and circumferentially engage an internal sidewall of the jacket housing; and the cartridge casing or cover having a casing base end including a substantially cylindrical shell forming a flange.

The base coupling element or skirt may include an outer diameter increasing as the base coupling element extends in a forward direction for attachment to the cartridge casing or cover.

The cartridge combustion insert is formed integral with the base.

The combustion chamber includes a propellant charge.

The base may be constructed of rigid light-weight metals or alloys, such as: aluminum, aluminum alloys, steel, steel alloys, and/or leaded alloys.

The projectile cartridge assembly includes a primer flash hole providing a gas transport cavity, attaching the primer recess cavity with the combustion chamber.

The jacket housing includes a second diameter closer to the forward end than the first diameter, the jacket housing second diameter sized to receive the disc or head in a tighter fit than the jacket housing first diameter.

The cartridge jacket housing may include diametrically opposed flats to facilitate insertion of the cartridge casing or cover over the jacket housing.

The cartridge jacket housing top side is a substantially flat surface, having a beveled edge as the top side descends to an outer surface of the cartridge jacket housing.

The thrust post disc may include diametrically opposed flats to facilitate insertion within the jacket housing.

The projectile may comprise a fluid carrying capsule retained by or attached to the cartridge casing or cover.

In a second aspect, the present invention is directed to a projectile assembly comprising: a projectile; a base having a forward end and a rear end, the base forward end including a substantially cylindrical coupling element and an insert channel formed internally therein to facilitate insertion of a cartridge casing cover, the base rear end including an aperture for receiving the cartridge combustion insert, the base sidewall having an outer extractor groove; the cartridge combustion insert extending from the base rear end in the forward direction, having a substantially cylindrical open-ended sidewall terminating at a forward end, and a combustion chamber therein; a jacket housing having a closed forward end, and an open base end, the jacket housing open base end having first diameter sized for clearance of the cartridge combustion insert; a thrust post including a spindle post having a spindle post base end and a thrust post forward end including a disc or head, wherein upon assembly the thrust post forward end contacts a muzzle-side interior surface of the jacket housing forward end and circumferentially engages an internal sidewall of the jacket housing; and the cartridge casing or cover having a casing base end including a substantially cylindrical shell forming a flange, wherein upon assembly the cartridge casing flange inserts within the base insert channel.

In a third aspect, the present invention is directed to a projectile assembly for marking a target, comprising: a fluid carrying capsule retained by or attached to a cylindrical shell cartridge casing or cover, the capsule having a base end and a forward end, and including an aft-extending skirt having a smaller diameter than a largest diameter of the capsule, the skirt extended from the capsule base end; a base-insert subassembly including: a base having a forward end and a rear end, the base forward end including a substantially cylindrical coupling element or skirt for receiving a cartridge casing or cover, the base rear end including a primer recess cavity; and a cartridge combustion insert extending from the base in the forward direction, having a substantially cylindrical open-ended sidewall terminating at a forward open end, and a combustion chamber therein; a jacket subassembly comprising: substantially cylindrical cartridge jacket housing having a closed forward end, and an open base end, the open base end having first diameter sized for clearance of a forward end of a thrust post; the thrust post including a spindle post having a base end and the thrust post forward end including a disc or head, wherein upon assembly of the jacket subassembly, the thrust post topside end will contact a muzzle-side interior surface of the jacket housing and circumferentially engage an internal sidewall of the jacket housing; and the cartridge casing or cover having a casing base end including a substantially cylindrical shell forming a flange, and an open forward end; and wherein the capsule skirt is received by the open forward end of the cartridge casing.

The cartridge casing open forward end may include knurled grooves exposed at the top surface for receiving the capsule skirt, facilitating a press or friction fit for the capsule.

In a fourth aspect, the present invention is directed to: a method of firing a projectile from a launcher, comprising: securing a cartridge into the launcher, the cartridge having: a base-insert subassembly including: a base having a forward end and a rear end, the base forward end including a substantially cylindrical coupling element or skirt for receiving a cartridge casing or cover, the base rear end including a primer recess cavity; and a cartridge combustion insert extending from the base in the forward direction, having a substantially cylindrical open-ended sidewall terminating at a forward open end, and a combustion chamber therein; a jacket subassembly comprising: a substantially cylindrical cartridge jacket housing having a closed forward end, and an open base end, the open base end having first diameter sized for clearance of a forward end of a thrust post; the thrust post including a spindle post having a base end and the thrust post forward end including a disc or head, wherein upon assembly of the jacket subassembly, the thrust post topside end will contact a muzzle-side interior surface of the jacket housing and circumferentially engage an internal sidewall of the jacket housing; and the cartridge casing or cover having a casing base end including a substantially cylindrical shell forming a flange; initiating a propellant charge provided in the cartridge combustion insert; forcing the thrust post against the jacket housing and away from the cartridge base; uncoupling the projectile from the base-insert assembly; and propelling the projectile in ballistic flight.

The method further includes the steps of: venting, via at least one vent port formed on a portion of the thrust post and/or at least one channel formed on an exterior surface of the cartridge combustion insert, internal gas pressures produced through initiation of the propellant charge; and regulating and/or relieving internal gas pressures produced by the initiated propellant charge to ensure proper ballistic operation.

In a fifth aspect, the present invention is directed to a launcher system for firing projectiles comprising: a launcher assembly comprising a chamber adapted to receive a cartridge; a barrel forward the chamber, and a bolt rearward of the chamber, the bolt including a firing mechanism for activating the cartridge; and a cartridge comprising: a projectile assembly comprising: an outer projectile; a jacket housing coupled within an interior portion of the outer projectile; and a thrust post coupled within an interior portion of the jacket housing; a cartridge casing coupled to an end of the projectile assembly and including a combustion insert extending between and interior to the cartridge casing and the projectile assembly; the thrust post extending within a portion of the combustion insert; the thrust post comprising a disc element and spindle post extending therefrom; a propellant charge provided in the combustion insert such that when the firing mechanism activates the cartridge and the charge is initiated, gases are created which force the thrust post away from the cartridge casing, uncouple the projectile assembly from the cartridge casing, and engage projectile assembly with the launcher to provide ballistic flight of the projectile assembly.

Embodiments of the present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.

It will be understood that, although the terms first, second, etc., may be used herein to describe various components, these components should not be limited by these terms. These terms are only used to distinguish one component from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of the present invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. Also, as used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. It will be further understood that the terms “include” and/or “including” when used herein, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof.

Relative terms such as “below,” “above,” “upper,” “lower,” “horizontal,” “vertical,” “top,” “bottom,” “rear,” “front,” “side,” or the like may be used herein to describe a relationship of one element or component to another element or component as illustrated in the figures. It will be understood that these terms are intended to encompass different orientations of the device in addition to the orientation depicted in the figures.

Additionally, in the subject description, the words “exemplary,” “illustrative,” or the like are used to mean serving as an example, instance or illustration. Any aspect or design described herein as “exemplary” or “illustrative” is not necessarily intended to be construed as preferred or advantageous over other aspects or design. Rather, use of the words “exemplary” or “illustrative” is merely intended to present concepts in a concrete fashion.

In describing the embodiment of the present invention, reference will be made herein toof the drawings in which like numerals refer to like features of the invention.

The present invention provides ammunition used within a launcher system. The ammunition may be employed and/or adapted for non-lethal applications. As a general rule, non-lethal applications utilize an impact energy in the range of 28 to 33 joules.

The cartridgegenerally comprises a forward projectileand rearward cartridge casing. For non-lethal, marking applications, the projectile may comprise a fluid carrying capsule retained by or attached to the cartridge casing or cover. The interior of projectileis coupled to an exterior surfaceof jacket housing. Cartridge casingcomprises an insert channelfor securing a combustion insertcontaining some amount of propellant (not shown). A thrust postis disposed within the combustion insert propellant chamberand proximate the muzzle-side interior surface of jacket housing.

depict side and cross-sectional views of a cartridgeaccording to one embodiment of the present invention chambered within a launcher assembly. Launcher assemblycomprises a cartridge-receiving chamberbetween a forward barreland dorsal bolt. Boltincludes a bolt faceand extractorwhich contact and engage cartridge casing, ensuring proper registration and headspace of cartridgewithin the launcher assembly. A firing pinis disposed within an aperture central to the bolt facefor striking operations of primerduring ballistic operations. Upon ignition of the propellant charge within the combustion insert, gas pressure will increase within the insert and ultimately explode into the combustion chamber, forcing the cartridge thrust postagainst the projectile jacket housingand dislodging/severing the connection between the projectile assembly(i.e., thrust post, jacket housing, and projectile) and the cartridge casing(). After separation, the propulsive force of thrust postagainst the jacket housingand projectilewill propel the projectile assemblythrough the launcher barrel, engaging the barrel riflingto provide spin before exiting the barrel muzzle (not shown) in ballistic flight.

It is possible for a high energy primer to be used in lieu of a propellant charge, provided the high energy primer is capable of providing the desired explosive forces for propulsion. This would eliminate the propellant charge in the firing process.

depict side and cross-sectional views of a cartridgeaccording to one embodiment of the present invention. A cartridgesuitable for use in a projectile launcher is shown comprising a substantially cylindrical cartridge casingwith an extractor groove(See) and an insert channelformed therein for ease of insertion of the combustion insert. The cartridge casingincludes a substantially cylindrical-shell coupling elementextending from a forward surfacethat is opposite a rear surface.

The coupling elementof cartridge casingfits about and engages a coupling endformed on an open-ended projectile. A bearing surfaceextends to the coupling end, which surrounds a substantially cylindrical open-ended projectile base. Coupling endcomprises a conical tapered joint or notched element, but may also be configured as a male or female connecting element in alternate embodiments of the invention.

The coupling endfits about and engages coupling elementof the cartridge casingby an interference. In some embodiments, When contacted, coupling endtaper may extend to a larger diameter at the open-ended projectile base, which interlocks with the coupling elementto form a physical interlock between cartridge casingand projectile. Mechanical crimping of the coupling elementcan also be applied to increase the projectile pull force. The projectilemay also be welding or bonding to cartridge casingusing solvent, adhesive, spin-welding, vibration-welding, ultrasonic-welding, or laser-welding techniques.

Combustion inserthas a substantially cylindrical open-ended sidewallextending from forward end openingrearward to opposite end, defining the interior of combustion chamber(See). Combustion chambermay contain a propellant charge (not shown) if the cartridge is not utilizing a high energy primer. The propellant charge may comprise a nitrocellulose propellant, nitroglycerin propellant, and the like. The interior volume of combustion chambermay be varied to provide the volume necessary for complete filling of the chamberto a volumetric measurement appropriate to ensure ballistic performance of the projectile assembly.

Combustion insertmay be constructed of any sufficiently rigid light-weight metals or alloys such as aluminum, aluminum alloys, steel, steel alloys, and/or leaded alloys. The insertmay be manufactured with coupling flangeformed on end. Coupling flangeprojects radially from opposite endand the received primer. The combustion insertfits within the insert channelof the cartridge casing, creating an interference engagement between combustion insertand the cartridge casing.

The jacket housingfits within the open-ended projectile basein an interference engagement of the projectilewith the substantially cylindrical open-ended middle body componentand jacket cap. The middle body componentextends from jacket capto insertion element. Insertion elementsurrounds the jacket housing end opposite jacket cap, preferably for use with an insertion tool (not shown) during assembly to aid with insertion of the jacket housingwithin the open-ended projectile base. Insertion elementextends within casing counterbore, ensuring coaxial alignment of the projectile assemblywithin the casing.

Thrust postcomprises a spindle postextending from breech endtowards topside end, and is directly coupled at topside endto a disc element/whorl. During assembly, disc element/whorlis sized to cover and encapsulate the combustion insert forward opening, while spindle postextends within the combustion chamber. Spindle postmay be sized to form a transition or clearance engagement with the combustion chamber.

Thrust post disc or headfits within the jacket housing, creating an interference engagement of the jacket housing interiorwith the disc or head. After assembly, the thrust post topside endwill contact the muzzle-side interior surfaceof jacket housingand circumferentially engage the jacket housing internal sidewall.

depict a flat base projectilewith a rounded nose. The ogiveof projectileextends from a rounded noseto a shoulder bandsurrounding the projectile's outer circumferential surface. The longitudinal distance from the rounded noseto the shoulder bandis the head or ogive distance, and the distance from the shoulder bandto the coupling enddefines the length of the bearing surface. Shoulder bandis manufactured from a soft metal such as gilding metal, copper, lead, and the like. The bearing surfaceextends to the coupling end, which surrounds a substantially cylindrical open-ended projectile base. Coupling endis shown comprising a conical tapered joint or notched element, but may also be configured as a male or female connecting element in alternate embodiments of the invention. Coupling endfits about and engages coupling element of the cartridge casing (not shown) by an interference fit. Mechanical crimping of the coupling element can also be applied to increase the projectile pull force. The projectilemay also be welding or bonding to cartridge casing using solvent, adhesive, spin-welding, vibration-welding, ultrasonic-welding or laser-welding techniques. Projectilemay be constructed of a resilient material such as rubber, nylon, plastics and the like.

depict side and cross-sectional views of a cartridge jacket housingaccording to one embodiment of the present invention. The jacket housingfits within the open-ended projectile base (not shown), creating an interference engagement of the projectile interior with the substantially cylindrical open-ended middle body componentand jacket cap. The middle body componentextends from jacket capto insertion element. Insertion elementsurrounds the jacket interioropposite jacket capfor use with an insertion tool (not shown) during assembly to aid with insertion of the jacket housingwithin the open-ended projectile base. Insertion elementextends within casing counterbore, ensuring coaxial alignment of the complete projectile assembly within the cartridge casing. Jacket housing interioris sized so as to receive the thrust post topside end (not shown) in an interference fit during assembly. After assembly, the thrust post topside end will contact the muzzle-side interior surfaceof jacket housing, with circumferential engagement with the internal sidewall.

depict side and cross-sectional views of cartridge casingaccording to one embodiment of the present invention. Substantially cylindrical cartridge casingmay be constructed of any sufficiently rigid light-weight metals or alloys such as aluminum, aluminum alloys, steel, steel alloys, and/or leaded alloys, and the like. Cartridge casingincludes an extractor grooveand an insert channelformed therein for ease of insertion of the combustion insert (not shown). The cartridge casingincludes a substantially cylindrical-shell coupling elementextending from a forward surfacethat is opposite a rear surface. The combustion insert fits within the insert channelof the cartridge casing, creating an interference (or friction) engagement of the aperture wallwith the combustion insert.

The coupling elementof cartridge casingfits about and engages the projectile coupling end (not shown), creating an interference engagement between cartridge casingand the projectile. Further mechanical crimping of the coupling elementcan also be applied to increase the projectile pull force. A casing counterboremay be formed within the casing cavityand extends towards aperture wall. Counterborereceives the jacket housing insertion element (not shown), ensuring coaxial alignment of the projectile assembly within the cartridge casing.

depict side and cross-sectional views of a cartridge combustion insert according to one embodiment of the present invention. Combustion inserthas a substantially cylindrical open-ended sidewallextending from forward end openingrearward to opposite end, defining the interior of combustion chamber. Combustion chamber may contain a propellant charge (not shown), if a high energy primer is not utilized. The propellant charge may comprise a nitrocellulose propellant, nitroglycerin propellant, and the like. The interior volume of combustion chambermay be varied to provide the volume necessary for complete filling of the chamberto a volumetric measurement appropriate to ensure ballistic performance of the projectile assembly.

Combustion insertmay be constructed of any sufficiently rigid light-weight metals or alloys such as aluminum, aluminum alloys, steel, steel alloys, and/or leaded alloys, and the like. The insertmay be manufactured with coupling flangeformed on opposite end. Coupling flangeprojects radially from the opposite endand a primer recessis formed therein for receiving the primer (not shown). Primer recessextends from opposite endtoward the forward end, and is encapsulated by an engagement element. A primer flash holeis located in the primer recess, extending to the opposite endinto the combustion chamber.

The combustion insertfits within the insert channel of the cartridge casing (not shown), creating an interference engagement of the aperture wallwith the engagement elementand coupling flange. Primer flash holeis located in the primer recess, extending to the opposite endinto the combustion chamber.

The primer recessis sized so as to receive the primer (not shown) in an interference fit during assembly. Primer flash holecommunicates through the opposite endof substantially cylindrical insertinto the combustion chamberso that upon detonation of the primer (not shown) the propellant charge in combustion chamberwill be ignited. In at least one embodiment, a high energy primer may be used, which would eliminate the need for a propellant charge, or greatly reduce the amount of propellant charge.

depicts a side view of a cartridge thrust post according to one embodiment of the present invention. Thrust postmay be constructed of a metal or alloy such as low carbon steel, leaded alloys, and the like. The thrust post comprises a spindle postextending from breech endto topside end, and is directly coupled at topside endto a disc element/whorl. During assembly, and with further reference to, disc element/whorlis sized to cover and encapsulate the combustion insert forward opening (not shown). Spindle postextends within and is sized to form a transition or clearance engagement with the combustion chamber. Disc element/whorlmay include knurling′, which will engage the jacket housing interior (not shown), assuring thrust post remains in place and is co-axial to the jacket housing. Knurling′ may comprise a straight knurl, having about 25 per inch pitch.