Ammunition round with frangible projectile

Abstract

A projectile has a particulate filler distributed in a toughened polymer resin and composite mixture in which the composite mixture is melted or mixed with a curative agent or foaming agent prior to injection or pouring into a mold, usually under pressure. The particulate filler has a density greater than a density of the resin and can include metals and additives to add weight and other mechanical properties to the composite mixture. The polymer resin can be about 3% to about 30% by weight of the total projectile composition having an average density less than the density of lead. The particulate filler can be about 70% to 97% by weight of the total projectile composition and can include copper, tungsten, lead, brass, iron, bismuth, and / or steel.

Description

AMMUNITION ROUND WITH FRANGIBLE PROJECTILE byRobert J. Folaron et al.TITLEAMMUNITION ROUND WITH FRANGIBLE PROJECTILECROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This Patent Cooperation Treaty (PCT) patent application claims benefit of United States Provisional Patent Application Serial Number 63 / 505,781 filed in the United States Patent and Trademark Office on June 2, 2023, which is incorporated herein by reference thereto in its entirety.BACKGROUND OF THE DISCLOSURE

[0002] Conventional small arms ammunition, i.e., ammunition designed for use in portable and semi-portable firearms such as pistols, rifles, and shotguns, typically comprises a cartridge with a casing loaded with a propellant powder and a projectile (e.g., a bullet). An impact-sensitive primer ignites the propellant powder when struck by a firing pin, causing the projectile to be propelled, i.e., fired, downrange.

[0003] Projectiles for conventional small arms ammunition are predominantly manufactured from lead or lead alloys, often jacketed in copper. Lead is often chosen for conventional small arms ammunition because it is sufficiently soft to engage rifling in a barrel without causing damage to the barrel. Additionally, its high density, when compared to other materials, helps maintain velocity thereby providing good range, muzzle energy, and effective target penetration.

[0004] Despite these advantages, lead possesses significant environmental and health concerns as a source of both indoor and outdoor pollution. Moreover, the rising cost of lead has made its continued use in conventional small arms ammunition less economically viable. Efforts to replace lead with alternative materials have encountered several challenges. For example, alternative materials such as tungsten, while effective, are prohibitively expensive. Other alternative materials such as polymers and polymer-metal composites, often lack necessary structural integrity and fail to achieve desired target penetration. Additionally, projectiles made from lead face limitations in their expansion characteristics and resultant wounding effects, particularly in pistol ammunition. Due to a relatively low muzzle energy that can be safely generated in pistol ammunition when compared to muzzle energy of, for example, rifles, restricts expansion and subsequent “stopping power” of conventional pistol ammunition, thus reducing its effectiveness.

[0005] Therefore, a need exists for a projectile with performance characteristics of lead, while being more cost-effective and environmentally friendly. A need exists for the projectile to exhibit superior downrange and / or on-target performance characteristics, including enhanced stopping power or wounding effect.BRIEF SUMMARY OF THE DISCLOSURE

[0006] The present disclosure is directed in general to frangible projectiles used in ammunition cartridges. The frangible projectiles may comprise toughened polymer resin compositions with nano-particle additives.

[0007] In one embodiment, a projectile and ammunition round may include a toughened polymer matrix, specifically a toughened polymer resin comprising an elastomer-modified epoxy functional adduct formed by a reaction of a bisphenol liquid epoxy resin and a carboxyl terminated butadiene-acrylonitrile elastomer, a particulate filler distributed in and through the toughened polymer resin, and a curative agent by which the toughened polymer resin with distributed particulate filler is cured. The cured toughened polymer resin with distributed particulate filler forms a projectile body in a desired projectile shape, e.g., the shape of a bullet. Once formed, the frangible projectile is incorporated into a shell casing to provide an ammunition round. Preferably, the elastomer content is about 30%-60% by weight with respect to the toughened polymer resin. Preferably, the filler has a density greater than a density of the resin, and preferably the projectile has an average density equal to or less than the density of lead.

[0008] In another embodiment, a projectile with a toughened polymer resin, a curative agent, and a particulate filler is provided. The curative agent cures the toughened polymer resin, and the particulate filler is distributed throughout the resin. In this embodiment, the particulate filler has a density greater than a density of the resin. In one aspect, the cured toughened polymer resin is about 3%-30% by weight of the total projectile composition.

[0009] In another aspect of the disclosure, the projectile has an average density that is less than the density of lead, for example, less than 65% of the density of lead. In a further embodiment, the particulate filler is about 70%-97% by weight of the total projectile composition. Further, the particulate filler may include copper. Advantageously, the projectile is substantially lead-free, and the particulate filler may include a material selected from the group consisting of copper, tungsten, lead, brass, bismuth, iron, and steel.

[0010] In another embodiment, a cartridge may comprise a casing with a projectile projecting from an end of the casing in which the cartridge may also comprise a propellant that is adapted to propel the projectile from the casing. In an aspect of the present disclosure, the casing may be formed from a material such as brass, bi-metallic, aluminum alloy, polymer, and polymer-metallic.

[0011] In yet another embodiment, a projectile may include a toughened polymer resin, a curative agent, and a particulate filler distributed throughout the resin. In an aspect of the present disclosure, the filler has a density greater than a density of the resin. Further, the particulate filler may be 70%-90% by weight of the total projectile composition.

[0012] In another embodiment, a projectile may include a polymer resin, a curative agent configured to cure the polymer resin, a particulate filler distributed through the polymer resin, and a payload for target penetration. Further, the particulate filler may have a density greater than a density of the polymer resin. The cured polymer resin may be about 3%-30% by weight of the total projectile composition. Also in this embodiment, the payload may comprise metal balls that are mixed in the particulate filler. Additionally or alternatively, a cavity may be formed in the resin, wherein the metal balls are inserted in the cavity.

[0013] In various embodiments, a toughened polymer resin system does not require a separate curative agent to achieve a final “cured” state, such as a thermoplastic resin system.

[0014] Additional objects and advantages of the present subject matter are set forth in, or will be apparent to, those of ordinary skill in the art from the description herein. Also, it should be further appreciated that modifications and variations to the specifically illustrated, referenced, and discussed features, processes, and elements hereof may be practiced in various embodiments, and uses of the disclosure may be present without departing from the spirit and scope of the subject matter. Variations may include, but are not limited to, substitutions of equivalent means, features, or steps for those illustrated, referenced, or discussed, and the functional, operational, or positional reversal of various parts, features, steps, or the like. Those of ordinary skill in the art will better appreciate the features and aspects of the various embodiments, and others, upon review of the remainder of the specification.BRIEF DESCRIPTION OF THE DRAWINGS

[0015] A full and enabling disclosure of the present subject matter, including the best mode thereof directed to one of ordinary skill in the art, is set forth in the specification, which refers to the appended figures.

[0016] FIGURE 1 is a perspective view of an exemplary ammunition cartridge with a molded, fragmenting projectile according to an aspect of the disclosure.

[0017] FIGURE 2 is a top perspective view of molded, fragmenting projectiles as used in FIGURE 1

[0018] FIGURE 3 shows exemplary materials that may be used in constructing the molded, fragmenting projectiles as in FIGURE 1.

[0019] FIGURE 4 is a sectional, elevational view of another embodiment of a molded, fragmenting projectile.

[0020] FIGURE 5 is a partial, sectional view of molded, fragmenting projectiles according to another aspect of the disclosure.

[0021] FIGURE 6 is a sectional, elevational view of a molded, fragmenting projectile in an ammunition cartridge according to another aspect of the disclosure. FIGURE 6 also shows a conventional projectile by way of comparison.

[0022] FIGURE 7 are partial, sectional, elevational, and perspective views of fragmenting projectiles according to further aspects of the disclosure.

[0023] FIGURE 8 shows examples of payloads that can be carried by molded, fragmenting projectiles according to another aspect of the disclosure.

[0024] FIGURE 9 shows another exemplary payload that can be carried by molded, fragmenting projectiles according to an aspect of the disclosure.

[0025] FIGURE 10 shows impact examples of molded, fragmenting projectiles upon targets according to further aspects of the disclosure.DETAILED DESCRIPTION OF THE DISCLOSURE

[0026] As required, detailed embodiments are disclosed herein; however, the disclosed embodiments are merely examples and may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merelyas a basis for the claims and as a representative basis forteaching one skilled in the art to variously employ the exemplary embodiments of the present disclosure, as well as their equivalents.

[0027] Unless defined otherwise, all technical, engineering, and scientific terms used herein have the same meaning as is commonly understood by one of ordinary skill in the art to which this disclosure belongs. In the event that there are a plurality of definitions for a term, phrase, or acronym herein, those in this section prevail unless stated otherwise.

[0028] Wherever the phrase “for example,” “such as,” “including,” and the like are used herein, the phrase “and without limitation” is understood to follow unless explicitly stated otherwise. Similarly, “an example,” “exemplary,” and the like are understood to be non-limiting.

[0029] The term “substantially” allows for deviations from the descriptor that do not negatively impact the intended purpose. Descriptive terms are understood to be modified by the term “substantially” even if the word “substantially” is not explicitly recited.

[0030] The term “about” when used in connection with a numerical value refers to the actual given value, and to the approximation to such given value that would reasonably be inferred by one of ordinary skill in the art, including approximations due to the experimental and or measurement conditions for such given value.

[0031] The term “effective amount” means a value of plus or minus 10% of any stated value unless a different, specific value or range is provided.

[0032] The term “lead-free” refers to a projectile that does not use lead intentionally in its composition but may include a trace amount of lead as an unavoidable impurity in other components of a projectile composition.

[0033] The term “toughness” means an ability to absorb energy and plastically deform before fracturing as opposed to being “brittle.” A “toughened resin” refers to a polymer containing an elastomeric component that imparts toughness and comprises the cured state of the resin. A chemical component providing the quality of toughness may be provided by any constituent component used to produce the resin or may result from a curing reaction.

[0034] The term “hardener” refers to any type of curative agent for a resin.

[0035] The term “ranges” includes all combinations of sub-ranges. For instance, a range from 100-200 includes ranges from, e.g., 110 to 150, 170 to 190, and 153 to 162. Similarly, “limits” means all sub-limit combinations, e.g., a limit of up to 7 also includes a limit of up to 5, up to 3, and up to 4.5.

[0036] The term “frangible” refers to a composition that is designed to exit a barrel of a weapon, that is a rifle, pistol, shotgun, or other suitable weapon, in a substantially monolithic form and fragment into multiple pieces either during flight, upon impact with an object, or upon initiation of a fragmentation event initiated by a timer, a pressure change or sensor, el cetera.

[0037] The term “frangible jacket” refers to a characteristic of an external surface and / or physical construction of the projectile being made from a “frangible” material, wherein a primary shape of the projectile and its physical strength are derived from the frangible material. This may also include frangible materials with a thin layer of solid metal around a bearing surface of the projectile. The term “frangible jacket” is not to be confused with projectiles referred to as “jacketed frangible,” wherein the projectile is monolithically manufactured of frangible material, with a thin layer of metal designed to “contain” the projectile made of frangible material.

[0038] The term “cargo” or “payload” refers to something that is not required to achieve an overall physical shape / size or basic physical / mechanical characteristic of the projectile required for loading into a cartridge, or to achieve an appropriate or desired launch / flight of the projectile. Cargo is utilized to deliver new projectile effects, or to enhance projectile effects. In addition, or alternatively, cargo may deliver effects additive to the base kinetic energy delivered through a combination of mass and velocity.

[0039] The term “target penetration” refers to comprehensive ballistic capabilities of an ammunition round, such as the projectiles disclosed herein, encompassing its performance in and on a target. This includes an ability of the projectile to penetrate a surface of the target, a creation and characteristics of a wound channel, and overall wounding effect in and on the target. Target penetration, also referred to as “effect on target,” involves assessment of the round’s entry, trajectory, and exit within the target, as well as resultant damage inflicted. This definition encompasses parameters such as depth of penetration, expansion, fragmentation, energy transfer, and tissue disruption, providing a holistic view of the projectile’s efficacy in achieving its intended ballistic and terminal effects.

[0040] The terms “comprising,” “including,” “having,” “involving” (and similarly “comprises,” “includes,” “has,” and “involves”), and the like are used interchangeably and have the same meaning. Specifically, each of the terms is defined consistent with the common United States Patent Law definition of “comprising” and is therefore interpreted to be an open term meaning “at least the following,” and is also interpreted not to exclude additional features, limitations, aspects,et cetera. Thus, for example, “a device having components a, b, and c” means that the device includes at least components a, b, and c. Similarly, a phrase such as: “a method involving a, b, and c” means that the method includes at least steps a, b, and c.

[0041] Where a list of alternative component terms is used, e.g., “a structure such as ‘a,’ ‘b,’ ‘c,’ ‘d’ or the like,” or “a or b,” such lists and alternative terms provide meaning and context for the sake of illustration, unless indicated otherwise. Also, relative terms such as “first,” “second,” “third,” “front,” and “rear” are intended to identify or distinguish one component or feature from another similar component or feature, unless indicated otherwise herein.

[0042] Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise,” “comprising,” and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense, that is, in the sense of “including, but not limited to.”

[0043] The various embodiments of the disclosure and / or equivalents falling within the scope of the present disclosure overcome or ameliorate at least one of the disadvantages of the prior art or provide a useful alternative to the prior art.

[0044] Detailed reference will now be made to the drawings in which examples embodying the present subject matter are shown. The detailed description uses numerical and letter designations to refer to features of the drawings. The drawings and detailed description provide a full and written description of the present subject matter, and of the manner and process of making and using various exemplary embodiments, so as to enable one skilled in the pertinent art to make and use them, as well as the best mode of carrying out the exemplary embodiments. The drawings are not necessarily to scale, and some features may be exaggerated to show details of particular components. Thus, the examples set forth in the drawings and detailed descriptions are provided by way of explanation only and are not meant as limitations of the disclosure. The present subject matter thus includes any modifications and variations of the following examples as may fall within the scope of the appended claims and their equivalents.

[0045] Turning now to FIGURE 1, a cartridge or “round” is broadly designated by element number 10 and includes a molded, frangible projectile 12 and a generally cylindrical shell or casing 14 having a base, also referred to as a first or proximal end, 16 and a mouth or opening formed at a second or distal end 18 from which the molded, frangible projectile 12 extends. Any caliber of cartridge 10 may be utilized such as 20mm, 11.4mm (.45 in.) caliber Automatic Colt® Pistol cartridge (“.45 ACP”), and the like.

[0046] The base 16 in FIGURE 1 includes a primer pocket (not shown) with a flash hole in communication with an interior of the casing 14. A primer (not shown) is disposed in the primer pocket, and a powder charge of propellant, such as smokeless gunpowder, is loaded in the interior of the casing 14 in communication with the flash hole. The casing 14 may be drawn from brass or aluminum alloys or molded from plastic. Any commercially available casing 14 is suitable for this purpose. Further, “caseless” ammunition rounds may be utilized. In this instance, a propellant charge is loaded into a projectile having an extended base forming a powder enclosure, or wherein propellant is mixed with a suitable binder and molded into a shape of a cartridge case. In this type of ammunition, the projectile, such as projective 12, is fixed in position relative to the propellant. In addition to breech-loading firearms, the principles of the present disclosure are applicable to such caseless ammunition, as well as to muzzle-loading firearms using either separate powder-and-ball or combustible (e.g., paper) cases.

[0047] FIGURE 2 shows that various payloads may be inserted into the molded, frangible projectile 12. As explained in greater detail below, the moldable projectile 12 may have a solid core or a hollow core, also referred to as a cavity, 20 and a boat-tail end or base 22. Internal payloads within the cavity 20 may include chemical or metallic powders, crystalline incendiary materials, solid cores, target marking compounds, and preformed fragments, and the projectile 12 may further include aerodynamic tips, penetrative tips, tracing compound inserts, brass drive band base cups, impact fired shaped charges, and the like, as explained below.

[0048] With reference now to both FIGURES 1 and 2, the projectile 12 is retained in the mouth 18 of the casing 14. As briefly introduced above, the projectile 12 may include a non-metallic matrix with a particulate filler distributed therethrough. The projectile 12 preferably is lead-free. Nonetheless, the filler may comprise lead in alternative embodiments. More specifically, the matrix is a toughened polymer resin. A preferred toughened epoxy resin is an elastomer-modified epoxy functional adduct formed by the reaction of a bisphenol, a liquid epoxy resin, and a carboxyl terminated butadiene-acrylonitrile elastomer. The elastomer content is approximately 30%-60% by weight. This material is commercially available from the Dow Chemical Company under the trademark FORTEGRA™ 201.

[0049] The filler may be any powder or particulate. Non-limiting examples include lead, depleted uranium, copper, tungsten, bismuth, ceramic, bronze, iron and steel, clay, mica, silica, calcium carbide, and micro-encapsulated materials. A selected material is encapsulated in aparticulate-sized shell. In any case, the filler preferably is of higher density than the cured, toughened polymer resin system.

[0050] FIGURE 3 shows exemplary materials or powders 24 that may be used to form the molded, frangible projectiles 12. The materials or powders 24, and combinations thereof, may include copper or brass nano-particles 26, tungsten nano-particles 28, and / or iron or steel nano-particles 30. The materials 24 may be blended to achieve desired cost, weight, and performance for the projectiles 12. For instance, polymerized, nano-particle-constructed projectiles 12 made from these materials 24 have significantly improved on-target and in-target performance when compared to homogenous metallic projectiles, such as solid lead projectiles, even though the disclosed projectiles 12 may have less mass than the metallic projectiles. Depending on material selection, the projectiles 12 are also less toxic than lead.

[0051] Turning to FIGURE 4, an exemplary projectile 112 having a hollow core 120 and a base 130 can be filled or loaded with a penetrating device or penetrator 132, an energetic compound 134, and a penetrating rod 136, which may be sharpened aluminum to achieve initial penetration of a target. Upon impacting the target, the projectile 112 disintegrates and the penetrator 132 pierces the target.

[0052] FIGURE 5 shows “Signature on Target” (“SOT”) variations of the exemplary projectile 112 in FIGURE 4. From left to right, SOT with Tip, SOT Different Energetic Primer and “Firing Pin”, SOT with Tip and Tracer, and SOT Primer and Tracer.

[0053] FIGURE 6 shows a cartridge 210 having a frangible projectile 212 inserted in a casing 214. In this example, the projectile 212 includes a hollow core 220 with body material 222 blended for desired weight and a tip 236 inserted or molded into the hollow core 220. Drive bands and base cup 238 seal the projectile 212 above powder or propellant 240, which in turn is above a primer 242

[0054] FIGURE 7 shows exemplary projectiles 312 with molded-in features for aerodynamics and on-target effects. For instance, ballistic and penetrative tips, tracer cups, gas checks, and semi-jackets may be used in a variety of projectiles 312.

[0055] FIGURE 8 shows a variety of payloads, penetrators, and energetic compounds 412, such as radiological materials, radar reflective materials, and luminescent payloads. Such payloads may be used in molded cavities of projectiles according to the present disclosure for training, target marking, and special purpose applications.

[0056] FIGURE 9 shows a cartridge 510 having a frangible projectile 512 in a casing 514. In this example, the projectile 512 includes a cavity 520 with a payload of cylindrical or spherical fragments 522 carried therein. On the right side of FIGURE 9, results are shown of the frangible projectile 512 engaging with targets. More particularly, the fragments 522 may be tungsten ball fragments measuring one-sixteenth of an inch in diameter (1 / 16 in.) or greater, and the balls 522 may be blended in the matrix or inserted in the cavity 520.

[0057] FIGURE 10 shows target penetrating results from another cartridge 610 using a frangible projectile 612, which, in this example, was a 7.62x51mm SOT. Specifically, from left to right, the fragmenting frangible projectile 612 caused holes in a steel plate with a 1 / 2 inch thickness that were twenty percent (20%) larger than holes caused by a heavier, conventional 147 grain full metal jacket 7.62x51mm bullet.

[0058] Examples of various frangible projectile compositions and test results are provided below.

[0059] Example 1 : Projectiles having nominal dimensions conforming to the .45 ACP standard were produced using varying amounts of the toughened epoxy resin described above as the matrix, and more specifically, a toughened polymer resin comprising an elastomer-modified epoxy functional adduct formed by the reaction of a bisphenol, a liquid epoxy resin, a carboxyl terminated butadiene-acrylonitrile elastomer, and iron powder (US Standard Mesh size 108) as the filler, using the following process.

[0060] First, the epoxy resin was heated to a temperature of approximately 49°C (120°F) to reduce its viscosity and permit mixing and distribution of the filler. The proper temperature depends on particle size. The finer the powder, the lower the viscosity needed for proper mixing. Next, the filler was mixed into the resin. After mixing, a hardener, an amine, was added to the resin and filler mixture at a ratio of 10 parts resin to 1 part hardener. The mixture was then poured into a prepared projectile mold. The resin, filler, and hardener mixture was cured to produce an epoxy polymer, and the projectile was removed from the mold. The finished projectiles were found to have the filler distributed throughout the resin. The mass of the projectiles varied depending on the type and amount of filler used, as well as the total length of the projectile. The mass of the projectile can be varied from a baseline by changing either its density or its volume. This is limited by a need to maintain a minimum length to ensure that the projectile does not jam in a barrel and will not tumble during flight. Projectiles were produced with a range of masses from less than 2.6g (40 grains) to over 5.8g (90 grains). By comparison, a conventional lead projectile with the sameexterior dimensions would typically have a mass of about 14.9g (230 grains). Accordingly, the average density of the projectiles was less than 45% of the density of a lead projectile of equal exterior dimensions.

[0061] For the example caliber tested, and for the specific combination of resin, hardener, and filler used with the example caliber, a range of approximately 3% to 30% by weight of resin was preferred. The preferred proportion of resin varies based on a plurality of factors including, but not limited to, the type of resin and hardener, the type and size of filler, and so forth. In one tested example, the composition of the projectile was about 6% by weight resin and about 94% by weight filler. The composition and manufacturing method described above results in the epoxy bonding to the iron particle filler, thus creating a homogeneous and cohesive matrix which allows it to withstand the forces created during firing of the projectile. The properties of this projectile are such that, in response to an impact of enough force to fracture the projectile, the projectile will break into large fragments having significant mass that are substantially larger than powder particles, instead of breaking up into powder or dust, which is generally common with known prior art projectiles of composite construction. As an example, the fragments may have a minimum size on the order of about 2.5mm (0.10 in.), or about 20 times the size of powder particles.

[0062] Example 2: The projectiles described above can be incorporated into cartridges having greater powder loads. In combination with a lower-weight projectile, a necessary muzzle velocity and energy to exhibit lethality (i.e., temporary, and permanent wounding characteristics), similar to a lead projectile when used as offensive or defensive ammunition, was achieved.

[0063] For example, projectiles described above in 7.62x51mm caliber, having a weight of about 5.8g (90 grains), were loaded into cartridges with a powder load sufficient to generate a muzzle velocity of about 914 m / s (3000 ft / s) to 975 m / s (3200 ft / s) when fired from a 40.6cm (16 in.) long barrel.

[0064] The cartridges were found to exhibit unexpected performance characteristics. The projectiles had excellent structural integrity and did not fail or break up in flight even at the extremely high muzzle velocities as a result of a synergistic interaction between the polymer resin and the particulate filler.

[0065] Similar projectiles were fired into water-soaked paper telephone books at a range of about 13.7m (15 yds). The projectiles exhibited excellent target penetration, approximately 15.2cm (6 in.) depth. The projectiles also showed a “shotgun blast” effect. A projectile of nominal .45ACP diameter, approximately 11 46mm (0.451 in ), was found to produce an entry hole in a target of about 5.1cm (2 in.) diameter, and an exit hole much greater than 5.1cm (2 in.) diameter. In thin, tough targets such as steel drumheads, the same projectile was found to produce a through-hole of about 5.1cm (2 in.) diameter. This is a larger hole than would be expected even with either a conventional hollow-point or a soft lead “dum-dum” projectile. Observation after firing suggests that the projectile remained intact in flight to the target. The projectiles may expand to a larger diameter upon initial contact when compared to its unfired state, creating the large-diameter holes mentioned above. Recovered projectiles were found to be in fragments of a size significantly larger than powder. The proj ectiles may have broken up into fragments upon initial contact with the target or may have broken up after substantial intact expansion. The “shotgun blast” effect and large hole size was observed regardless of exactly when or how the projectile expanded and / or fragmented.

[0066] The principles of the present disclosure are applicable to composite projectiles having other compositions that also display the penetration and expansion / fragmentation properties described above. For example, other polymer resins, not necessarily classified as “toughened,” may be found that interact with a filler to produce the projectile properties described herein. This type of expansion and / or fragmentation stands in stark contrast to prior art composite projectiles, which are typically configured to disintegrate into powder-sized particles. This superior performance was observed when the muzzle energy was about 1.22kJ (900 ft-lb) or greater. The mass of the projectile and the powder charge may be varied to achieve this energy level. The amount of the propellant and the mass of the projectile preferably are selected to produce a muzzle energy of at least 400 foot-pounds when fired from a 5-inch-long barrel, and more preferably are selected to produce a muzzle energy of at least 900 foot-pounds when fired from a 5-inch-long barrel. Moreover, the perceived recoil of these cartridges was no greater than reference cartridges of the same caliber loaded with conventional jacketed lead projectiles to standard velocities. Furthermore, the cartridges did not exhibit signs of over-pressurization, such as case cracking or raised primers, and are therefore suitable for use in known firearms.

[0067] These projectiles and ammunition rounds are especially lethal and suitable for hunting, military, law enforcement, or self-defense purposes while maintaining recoil at levels equal to or less than conventional lead projectile rounds. For example, the performance of these projectiles and ammunition rounds allow a handgun to provide lethality that is typically associated with rifle ammunition. Furthermore, the performance of these projectiles and ammunition rounds allowrifles, such as those chambered in 5.56mm, to perform “up a caliber,” meaning that 5.56mm ammunition in accordance with the subject matter disclosed herein exhibits the same or similar ballistic performance when compared to that of a conventional, lead 30-caliber round.

[0068] The loads may be varied to suit a particular end use. For example, if the projectile mass is reduced to about 2.6g (40 grains), minimal to no penetration of a target is observed. At about 3.9g (60 grains), some penetration is observed. At 5.2g to 5.8g (80 grains to 90 grains), excellent penetration is observed, as described above. Projectiles of lower masses may be desirable as target rounds or non-lethal rounds. Projectiles without filler also may be used as target rounds or non- lethal rounds.

[0069] Additional aspects of the present disclosure may include one or more of the following objectives or outcomes.

[0070] Cargo-Carrying / Payload-Carrying: Presuming that the jacket is frangible, when the projectile impacts a target (hard or soft), the frangible jacket disintegrates, and the cargo is delivered. The cargo can be a visual bloom, incendiary reaction, explosive reaction, explosion amplification, armor / barrier penetrator, balls / spheres, marking / tracking compound, shrapnel, et cetera. Additionally, multiple types of cargos may be mixed in the same projectile load. a) A significant advantage to this approach is that the projectile jacket “gets out of the way” quickly without directly affecting the cargo being carried. i) For Signature-On-Target (SOT), this means the visual bloom naturally seeks to expand radially (providing a larger bloom) versus the projectile preferring to push into and through the target. ii) For armor-piercing, as described below, this means the penetrator is released into the target with more energy / velocity, because it does not need to “strip” out of the copper jacket for release. b) Another significant advantage to this approach is that the cargo / payload can be integrated into the frangible jacket, such as in the case of an explosive reaction, explosion amplification, incendiary, visual bloom, or marking. c) Cargo may be added to the frangible projectile at any point during manufacturing of the projectile. This may include: i) Cargo that is placed directly into the frangible material;ii) Cargo that is pre-assembled and then integrated into the projectile during formation of the projectile; and iii) Cargo that is assembled and / or integrated into the projectile after formation of the projectile.

[0071] Manufacturing: a) The projectile may be molded around the cargo / payload. b) The cargo / payload may be inserted / assembled into the projectile after the projectile is molded. i) The cargo / payload may further be inserted from the front or the rear. ii) The cargo / payload may also be assembled and then sealed-off with adhesive, a tip, a cap, et cetera. Sealing may be done at either the front or the rear. c) The cargo / payload can be molded into the frangible jacket. i) Preferably, the payload is added to the polymer resin system prior to molding. ii) Alternatively, the payload can be integrated into the frangible jacket as a separate molding step. d) The Cargo may comprise: i) Discrete element(s) that are manufactured separately and then assembled as outlined above. ii) Integral elements within the frangible projectile / jacket material and molded directly.

[0072] SOT: The projectiles disclosed herein may act as a replacement for tracer rounds or may comprise a “traditional” tracer + SOT round. Further, the projectiles described herein may comprise a “new” tracer + SOT. a) The projectiles disclosed herein may comprise energetics-based projectiles of the following compositions: i) Nano-metals; ii) Nano-additives; and iii) Additional additives b) The projectiles disclosed herein may exhibit a plurality of visual blooms including:i) Visual booms; ii) Thermal booms; and iii) Colored booms within a visual wavelength spectrum.

[0073] Tracer: a) Tracer functionality of the projectiles described herein may include traditional tracer compounds. b) Further, the tracer functionality of the projectiles described herein may include a new type of tracer compound / system. c) For example, the projectiles described herein may comprise a luminescent tracing or incendiary element which may be comprised of powders, slurries, pellets, optical lenses, or combustible or luminescent discs or cups.

[0074] Marking / Tracking: a) The projectiles described herein may comprise compounds or elements that may be left behind post-impact that may be tracked visually, thermally, or via other frequencies. Further, the compounds or elements may be tracked by human visuals, drones, satellites, et cetera.

[0075] Armor-Piercing: a) The projectiles described herein may comprise a plurality of penetrators. Such penetrators may vary in size, profile, shape, configuration, and make-up. b) The projectiles described herein may comprise a jacket-type penetrator similar to that of a lead-based, jacket road. The projectiles described herein remain frangible and may be constructed from materials including, but not limited to, copper and tungsten. c) Further, the projectiles described herein may comprise of uniformly or non- uniformly distributed parties, i.e., cargo, designed to fragment and amplify effectiveness of the projectile.

[0076] Open-Tip / Hollow-Point: In an alternate embodiment of the projectiles described herein, an open or hollow-point configuration may be employed. In this instance, the projectile may expand into multiple pieces. In an alternate embodiment, the projectile may comprise a single piece with wing, as is traditional for monolithic copper type projectiles.

[0077] Flutes / External Features: In an alternate embodiment of the projectiles described herein, flutes and other external features may be employed. The flutes and other external features are designed to impart energy radially in soft targets, increasing the so-called wound channel or wound cavity within the target.

[0078] While the present subject matter has been described in detail with respect to specific embodiments thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing may readily produce alterations to, variations of, and equivalents to such embodiments. Accordingly, the scope of the present disclosure is by way of example rather than by way of limitation, and the subject disclosure does not preclude inclusion of such modifications, variations, and / or additions to the present subject matter as would be readily apparent to one of ordinary skill in the art.EXEMPLARY EMBODIMENTS

[0079] By way of example and not of limitation, exemplary embodiments as disclosed herein may include, but are not limited to:

[0080] Embodiment 1 : A projectile comprising a toughened polymer resin, a curative agent by which the toughened polymer resin is cured, and a particulate filler distributed through the toughened polymer resin, the particulate filler having a density greater than a density of the toughened polymer resin, and wherein the cured toughened polymer resin is about 3% to 30% by weight of the total projectile composition.

[0081] Embodiment 2: The projectile as in Embodiment 1, wherein an average density of the projectile is less than the density of lead.

[0082] Embodiment 3: The projectile as in Embodiments 1 or 2, the projectile has an average density that is less than about 65 % of the density of lead.

[0083] Embodiment 4: The projectile as in any of the foregoing Embodiments, wherein the particulate filler is about 70% to 97% by weight of the total projectile composition.

[0084] Embodiment 5: The projectile as in any of the foregoing Embodiments, wherein the particulate filler includes copper.

[0085] Embodiment 6: The projectile as in any of the foregoing embodiments, wherein the projectile is substantially lead-free.

[0086] Embodiment 7: The projectile as in any of the foregoing embodiments, wherein the particulate fdler includes a material selected from the group consisting of copper, tungsten, lead, brass, bismuth iron, and steel.

[0087] Embodiment 8: A projectile comprising a polymer resin, a curative agent configured to cure the polymer resin, a particulate filler distributed through the polymer resin, the particulate filler having a density greater than a density of the polymer resin, and a payload for target penetration.

[0088] Embodiment 9: The projectile as in Embodiment 8, wherein the cured polymer resin is about 3% to 30 % by weight of the total projectile composition.

[0089] Embodiment 10: The proj ectile as in Embodiments 8 or 9, wherein the payload is a plurality of metal balls mixed in the particulate filler, or further including a cavity formed in the resin, the metal balls being carried in the cavity.

[0090] Embodiment 11: The projectile as in any of the foregoing Embodiments, wherein the polymer resin does not require a separate curative agent to achieve a cured or solidified state.

[0091] While the present subject matter has been described in detail with respect to specific embodiments thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing may readily produce alterations to, variations of, and equivalents to such embodiments. Accordingly, the scope of the present disclosure is by way of example rather than by way of limitation, and the subject disclosure does not preclude inclusion of such modifications, variations, and / or additions to the present subject matter as would be readily apparent to one of ordinary skill in the art.

Claims

CLAIMSI claim:

1. A projectile comprising: a toughened polymer resin; a curative agent by which the toughened polymer resin is cured; and a particulate filler distributed through the toughened polymer resin, the particulate filler having a density greater than a density of the toughened polymer resin, and wherein the cured toughened polymer resin is 3% to 30 % by weight of the total projectile composition.

2. The projectile as in Claim 1, wherein an average density of the projectile is less than the density of lead.

3. The projectile as in Claim 1, wherein the projectile has an average density that is less than 65% of the density of lead.

4. The projectile as in Claim 1, wherein the particulate filler is 70% to 97% by weight of the total projectile composition.

5. The projectile as in Claim 1, wherein the particulate filler includes copper.

6. The projectile as in Claim 1, wherein the projectile is substantially lead-free.

7. The projectile as in Claim 1, wherein the particulate filler includes a material selected from the group consisting of copper, tungsten, lead, brass, bismuth iron, and steel.

8. A projectile comprising: a polymer resin; a curative agent configured to cure the polymer resin; a particulate filler distributed through the polymer resin, the particulate filler having a density greater than a density of the polymer resin; and a payload configured for effect on target.

9. The projectile as in Claim 8, wherein the cured polymer resin is 3% to 30% by weight of the total projectile composition.

10. The projectile as in Claim 8, wherein the payload is a plurality of metal balls mixed in the particulate filler.

11. The proj ectile as in Claim 8, wherein tire resin further comprises a cavity formed therein, and wherein the payload is the plurality of metal balls being carried in the cavity.

12. The projectile as in Claim 8, wherein the payload comprises a plurality of uniformly distributed particles.

13. The projectile as in Claim 8, wherein the payload comprises a plurality of non-uniformly distributed particles.

14. The projectile as in Claim 8, wherein the payload comprises a luminescent element capable of igniting, detonating, ejecting, or actuating the payload contained within the projectile.

15. The projectile as in Claim 14, wherein the luminescent element includes a material selected from the group consisting of a powder, slurry, pellet, optical lenses, and combustible discs or cups.

16. The projectile as in Claim 8, wherein the polymer resin does not require a separate curative agent to achieve a cured state.

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