Projectile cartridge assembly and launcher system for firing the same

Abstract

A cartridge and launcher system for firing projectiles and method of firing the same. The launcher system has a chamber, barrel forward the chamber, and a bolt rearward of the chamber capable of activating a cartridge. The cartridge is a projectile assembly which includes a base insert subassembly having a base and a cartridge combustion insert, and a jacket subassembly having a jacket housing and a thrust post secured therein. The thrust post being couplably engaged with the jacket housing. A casing is couplable to the jacket housing assembly. The combustion insert holds a propellant charge in a combustion chamber, and the thrust post extends therewithin. Upon activation of the charge, gases force the thrust post away from the base, uncoupling the assembly from the base insert subassembly.

Description

BACKGROUND OF THE INVENTION1. Field of the Invention

[0001] 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.2. Description of the Related Art

[0002] 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.

[0003] 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.SUMMARY OF THE INVENTION

[0004] 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.

[0005] It is another object of the present invention to provide a simpler non-lethal projectile and cartridge assembly which decreases costs.

[0006] 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.

[0007] Still other objects and advantages of the invention will in part be obvious and will in part be apparent from the specification.

[0008] 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.

[0009] 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.

[0010] The cartridge combustion insert is formed integral with the base.

[0011] The combustion chamber includes a propellant charge.

[0012] The base may be constructed of rigid light-weight metals or alloys, such as: aluminum, aluminum alloys, steel, steel alloys, and / or leaded alloys.

[0013] The projectile cartridge assembly includes a primer flash hole providing a gas transport cavity, attaching the primer recess cavity with the combustion chamber.

[0014] 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.

[0015] The cartridge jacket housing may include diametrically opposed flats to facilitate insertion of the cartridge casing or cover over the jacket housing.

[0016] 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.

[0017] The thrust post disc may include diametrically opposed flats to facilitate insertion within the jacket housing.

[0018] The projectile may comprise a fluid carrying capsule retained by or attached to the cartridge casing or cover.

[0019] 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.

[0020] 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.

[0021] 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.

[0022] 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.

[0023] 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.

[0024] 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.BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The features of the invention believed to be novel and the elements characteristic of the invention are set forth with particularity in the appended claims. The figures are for illustration purposes only and are not drawn to scale. The invention itself, however, both as to organization and method of operation, may best be understood by reference to the detailed description which follows taken in conjunction with the accompanying drawings in which:

[0026] FIG. 1 depicts a side view of a projectile launcher assembly according to one embodiment of the present invention;

[0027] FIG. 2A depicts a side, cross-sectional view of a portion of the projectile launcher assembly of FIG. 1, along lines A-A, and including a chambered cartridge according to one embodiment of the present invention;

[0028] FIG. 2B depicts a side, cross-sectional view of a portion of the projectile launcher assembly of FIG. 1, along lines A-A, and upon ballistic ignition of the chambered cartridge;

[0029] FIG. 3 depicts a side view of a cartridge according to one embodiment of the present invention;

[0030] FIG. 4 depicts a side, cross-sectional view of the cartridge of FIG. 3, along lines A-A;

[0031] FIG. 5 depicts a side view of the cartridge casing or housing of FIG. 3;

[0032] FIG. 6 depicts a side, cross-sectional view of a portion of the cartridge casing or housing of FIG. 5, along lines F-F;

[0033] FIG. 7 depicts a side view of the cartridge jacket housing of FIG. 3;

[0034] FIG. 8 depicts a side, cross-sectional view of the cartridge jacket housing of FIG. 7, along lines B-B;

[0035] FIG. 9 depicts a side view of the cartridge base of FIG. 3;

[0036] FIG. 10 depicts a side, cross-sectional view of the cartridge base of FIG. 9, along lines C-C;

[0037] FIG. 11 depicts a side view of a portion of a cartridge combustion insert of FIG. 3;

[0038] FIG. 12 depicts a side, cross-sectional view of the cartridge combustion insert of FIG. 11, along lines D-D;

[0039] FIG. 13 depicts a side view of a thrust post for insertion within the cartridge combustion insert of FIG. 12;

[0040] FIG. 14 depicts a perspective view of a portion of an alternate combustion insert of a cartridge according to one embodiment of the present invention;

[0041] FIG. 15 depicts a perspective view of a portion of an alternate thrust post according to one embodiment of the present invention;

[0042] FIG. 16 depicts a side view of a cartridge according to one embodiment of the present invention;

[0043] FIG. 17 depicts a rearward facing, cross-sectional view of the cartridge of FIG. 16, along lines C-C;

[0044] FIG. 18 depicts a side, cross-sectional view of a cartridge according to one embodiment of the present invention, during ballistic operations;

[0045] FIG. 19 depicts a flow diagram of an example method for ballistic operation of a cartridge chambered within a projectile launcher assembly according to one embodiment of the present invention;

[0046] FIG. 20 depicts a front view of a thrust post of a cartridge according to one embodiment of the present invention, displaying thrust post alignment strut;

[0047] FIG. 20A depicts an enlarged front view of a portion of FIG. 20;

[0048] FIG. 21 depicts a side view of a portion of a cartridge according to one embodiment of the present invention, displaying thrust post alignment strut;

[0049] FIG. 22 depicts a side, cross-sectional view of a portion of a cartridge according to one embodiment of the present invention, displaying jacket housing alignment recess;

[0050] FIG. 23 depicts a side, cross-sectional view of a portion of a cartridge according to one embodiment of the present invention, displaying thrust post alignment strut and jacket housing alignment recess;

[0051] FIG. 24 depicts a side view of a cartridge according to another embodiment of the present invention;

[0052] FIG. 25 depicts a side, cross-sectional view of the cartridge of FIG. 24, along lines A-A;

[0053] FIG. 26 depicts an exploded view of the cartridge of FIGS. 24 and 25;

[0054] FIG. 27 depicts a side, exploded, cross-sectional view of the cartridge of FIG. 26, along lines B-B;

[0055] FIG. 28A depicts a side view of a thrust post of a cartridge according to one embodiment of the present invention;

[0056] FIG. 28B depicts a front view of the thrust post of FIG. 28A;

[0057] FIG. 29A depicts a perspective view of a jacket housing of a cartridge according to one embodiment of the present invention;

[0058] FIG. 29B depicts a front view of the jacket housing of FIG. 29A;

[0059] FIG. 30 depicts an exploded view of a cartridge according to one embodiment of the present invention; and

[0060] FIG. 31 depicts a side, cross-sectional view of the cartridge of FIG. 30, along lines A-A.DETAILED DESCRIPTION OF THE INVENTION

[0061] 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.

[0062] 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.

[0063] 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.

[0064] 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.

[0065] In describing the embodiment of the present invention, reference will be made herein to FIGS. 1-31 of the drawings in which like numerals refer to like features of the invention.

[0066] 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.

[0067] The cartridge 10 generally comprises a forward projectile 50 and rearward cartridge casing 30. 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 projectile 50 is coupled to an exterior surface 62 of jacket housing 60. Cartridge casing 30 comprises an insert channel 38 for securing a combustion insert 20 containing some amount of propellant (not shown). A thrust post 70 is disposed within the combustion insert propellant chamber 25 and proximate the muzzle-side interior surface of jacket housing 60.

[0068] FIGS. 1, 2A and 2B depict side and cross-sectional views of a cartridge 10 according to one embodiment of the present invention chambered within a launcher assembly 100. Launcher assembly 100 comprises a cartridge-receiving chamber 116 between a forward barrel 120 and dorsal bolt 110. Bolt 110 includes a bolt face 112 and extractor 188 which contact and engage cartridge casing 30, ensuring proper registration and headspace of cartridge 10 within the launcher assembly 100. A firing pin 114 is disposed within an aperture central to the bolt face 112 for striking operations of primer 18 during ballistic operations. Upon ignition of the propellant charge within the combustion insert 20, gas pressure will increase within the insert and ultimately explode into the combustion chamber 25, forcing the cartridge thrust post 70 against the projectile jacket housing 60 and dislodging / severing the connection between the projectile assembly 200 (i.e., thrust post 70, jacket housing 60, and projectile 50) and the cartridge casing 30 (FIG. 2B). After separation, the propulsive force of thrust post 70 against the jacket housing 60 and projectile 50 will propel the projectile assembly 200 through the launcher barrel 120, engaging the barrel rifling 122 to provide spin before exiting the barrel muzzle (not shown) in ballistic flight.

[0069] 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.

[0070] FIGS. 3 and 4 depict side and cross-sectional views of a cartridge 10 according to one embodiment of the present invention. A cartridge 10 suitable for use in a projectile launcher is shown comprising a substantially cylindrical cartridge casing 30 with an extractor groove 31 (See FIGS. 3 and 9) and an insert channel 38 formed therein for ease of insertion of the combustion insert 20. The cartridge casing 30 includes a substantially cylindrical-shell coupling element 32 extending from a forward surface 36 that is opposite a rear surface 34.

[0071] The coupling element 32 of cartridge casing 30 fits about and engages a coupling end 51 formed on an open-ended projectile 50. A bearing surface 56 extends to the coupling end 51, which surrounds a substantially cylindrical open-ended projectile base 59. Coupling end 51 comprises 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.

[0072] The coupling end 51 fits about and engages coupling element 32 of the cartridge casing 30 by an interference. In some embodiments, When contacted, coupling end 51 taper may extend to a larger diameter at the open-ended projectile base 59, which interlocks with the coupling element 32 to form a physical interlock between cartridge casing 30 and projectile 50. Mechanical crimping of the coupling element 32 can also be applied to increase the projectile pull force. The projectile 50 may also be welding or bonding to cartridge casing 30 using solvent, adhesive, spin-welding, vibration-welding, ultrasonic-welding, or laser-welding techniques.

[0073] Combustion insert 20 has a substantially cylindrical open-ended sidewall 12 extending from forward end opening 16 rearward to opposite end 22, defining the interior of combustion chamber 25 (See FIG. 12). Combustion chamber 25 may 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 chamber 25 may be varied to provide the volume necessary for complete filling of the chamber 25 to a volumetric measurement appropriate to ensure ballistic performance of the projectile assembly.

[0074] Combustion insert 20 may be constructed of any sufficiently rigid light-weight metals or alloys such as aluminum, aluminum alloys, steel, steel alloys, and / or leaded alloys. The insert 20 may be manufactured with coupling flange 26 formed on end 22. Coupling flange 26 projects radially from opposite end 22 and the received primer 18. The combustion insert 20 fits within the insert channel 38 of the cartridge casing 30, creating an interference engagement between combustion insert 20 and the cartridge casing 30.

[0075] The jacket housing 60 fits within the open-ended projectile base 59 in an interference engagement of the projectile 50 with the substantially cylindrical open-ended middle body component 62 and jacket cap 65. The middle body component 62 extends from jacket cap 65 to insertion element 61. Insertion element 61 surrounds the jacket housing end opposite jacket cap 65, preferably for use with an insertion tool (not shown) during assembly to aid with insertion of the jacket housing 60 within the open-ended projectile base 59. Insertion element 61 extends within casing counterbore, ensuring coaxial alignment of the projectile assembly 200 within the casing 30.

[0076] Thrust post 70 comprises a spindle post 72 extending from breech end 71 towards topside end 75, and is directly coupled at topside end 75 to a disc element / whorl 74. During assembly, disc element / whorl 74 is sized to cover and encapsulate the combustion insert forward opening 16, while spindle post 72 extends within the combustion chamber 25. Spindle post 72 may be sized to form a transition or clearance engagement with the combustion chamber 25.

[0077] Thrust post disc or head 74 fits within the jacket housing 60, creating an interference engagement of the jacket housing interior 63 with the disc or head 74. After assembly, the thrust post topside end 75 will contact the muzzle-side interior surface 66 of jacket housing 60 and circumferentially engage the jacket housing internal sidewall 64.

[0078] FIGS. 5 and 6 depict a flat base projectile 50 with a rounded nose 55. The ogive 54 of projectile 50 extends from a rounded nose 55 to a shoulder band 52 surrounding the projectile's outer circumferential surface. The longitudinal distance from the rounded nose 55 to the shoulder band 52 is the head or ogive distance 57, and the distance from the shoulder band 52 to the coupling end 51 defines the length of the bearing surface 56. Shoulder band 52 is manufactured from a soft metal such as gilding metal, copper, lead, and the like. The bearing surface 56 extends to the coupling end 51, which surrounds a substantially cylindrical open-ended projectile base 59. Coupling end 51 is 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 end 51 fits 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 projectile 50 may also be welding or bonding to cartridge casing using solvent, adhesive, spin-welding, vibration-welding, ultrasonic-welding or laser-welding techniques. Projectile 50 may be constructed of a resilient material such as rubber, nylon, plastics and the like.

[0079] FIGS. 7 and 8 depict side and cross-sectional views of a cartridge jacket housing 60 according to one embodiment of the present invention. The jacket housing 60 fits within the open-ended projectile base (not shown), creating an interference engagement of the projectile interior with the substantially cylindrical open-ended middle body component 62 and jacket cap 65. The middle body component 62 extends from jacket cap 65 to insertion element 61. Insertion element 61 surrounds the jacket interior 63 opposite jacket cap 65 for use with an insertion tool (not shown) during assembly to aid with insertion of the jacket housing 60 within the open-ended projectile base. Insertion element 61 extends within casing counterbore 46, ensuring coaxial alignment of the complete projectile assembly within the cartridge casing. Jacket housing interior 63 is 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 surface 66 of jacket housing 60, with circumferential engagement with the internal sidewall 64.

[0080] FIGS. 9 and 10 depict side and cross-sectional views of cartridge casing 30 according to one embodiment of the present invention. Substantially cylindrical cartridge casing 30 may 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 casing 30 includes an extractor groove 31 and an insert channel 38 formed therein for ease of insertion of the combustion insert (not shown). The cartridge casing 30 includes a substantially cylindrical-shell coupling element 32 extending from a forward surface 36 that is opposite a rear surface 34. The combustion insert fits within the insert channel 38 of the cartridge casing 30, creating an interference (or friction) engagement of the aperture wall 39 with the combustion insert.

[0081] The coupling element 32 of cartridge casing 30 fits about and engages the projectile coupling end (not shown), creating an interference engagement between cartridge casing 30 and the projectile. Further mechanical crimping of the coupling element 32 can also be applied to increase the projectile pull force. A casing counterbore 46 may be formed within the casing cavity 48 and extends towards aperture wall 39. Counterbore 46 receives the jacket housing insertion element (not shown), ensuring coaxial alignment of the projectile assembly within the cartridge casing 30.

[0082] FIGS. 11 and 12 depict side and cross-sectional views of a cartridge combustion insert according to one embodiment of the present invention. Combustion insert 20 has a substantially cylindrical open-ended sidewall 12 extending from forward end opening 16 rearward to opposite end 22, defining the interior of combustion chamber 25. 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 chamber 25 may be varied to provide the volume necessary for complete filling of the chamber 25 to a volumetric measurement appropriate to ensure ballistic performance of the projectile assembly.

[0083] Combustion insert 20 may 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 insert 20 may be manufactured with coupling flange 26 formed on opposite end 22. Coupling flange 26 projects radially from the opposite end 22 and a primer recess 28 is formed therein for receiving the primer (not shown). Primer recess 28 extends from opposite end 22 toward the forward end 23, and is encapsulated by an engagement element 42. A primer flash hole 21 is located in the primer recess 28, extending to the opposite end 22 into the combustion chamber 25.

[0084] The combustion insert 20 fits within the insert channel of the cartridge casing (not shown), creating an interference engagement of the aperture wall 39 with the engagement element 42 and coupling flange 26. Primer flash hole 21 is located in the primer recess 28, extending to the opposite end 22 into the combustion chamber 25.

[0085] The primer recess 28 is sized so as to receive the primer (not shown) in an interference fit during assembly. Primer flash hole 21 communicates through the opposite end 22 of substantially cylindrical insert 20 into the combustion chamber 25 so that upon detonation of the primer (not shown) the propellant charge in combustion chamber 25 will 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.

[0086] FIG. 13 depicts a side view of a cartridge thrust post according to one embodiment of the present invention. Thrust post 70 may be constructed of a metal or alloy such as low carbon steel, leaded alloys, and the like. The thrust post comprises a spindle post 72 extending from breech end 71 to topside end 75, and is directly coupled at topside end 75 to a disc element / whorl 74. During assembly, and with further reference to FIG. 4, disc element / whorl 74 is sized to cover and encapsulate the combustion insert forward opening (not shown). Spindle post 72 extends within and is sized to form a transition or clearance engagement with the combustion chamber 25. Disc element / whorl 74 may include knurling 74′, which will engage the jacket housing interior (not shown), assuring thrust post remains in place and is co-axial to the jacket housing. Knurling 74′ may comprise a straight knurl, having about 25 per inch pitch.

[0087] With additional reference to FIG. 4, thrust post disc or head 74 fits within the jacket housing interior, creating an interference engagement of the disc or head 74 with the jacket housing internal sidewall. After assembly, the thrust post topside end 75 will contact the muzzle-side interior surface 66 of jacket housing 60 and circumferentially engage the jacket housing internal sidewall 64.

[0088] FIG. 14 depicts a perspective view of an alternate combustion insert of a cartridge according to one embodiment of the present invention. The combustion insert 20 substantially cylindrical open-ended sidewall 12 may include one or more channels 45 disposed on the sidewall outer surface. The number of channels will depend on the specific application and ballistic performance but may include 1, 2, 3, 4, 5, or more channels. One embodiment includes four channels 45 spaced equidistant to expel, collectively, combustion gases from the exploding propellant to the cartridge exterior to improve ballistic performance of the projectile assembly 200 (See FIGS. 2A, 2B, and 18).

[0089] Advantageously, combustion insert channel(s) 45 (as well as the thrust post vent port(s) 47 of FIG. 15) will relieve gas pressure within the combustion chamber 25, preventing excessive gas pressure which may otherwise not be relieved in situations where the projectile assembly mass is too high. During ballistic operation of the cartridge, forces resulting from the exploding propellant (or high energy primer) are applied across a subcaliber cross-sectional area of the projectile assembly. As a result, internal gas pressures produced by exploding propellant or high energy primer will increase proportionally with the projectile assembly's mass. One manner of compensation is to utilize slower burning propellants, though such propellants would require a propellant charge large enough to generate gas pressure rates fast enough to create high, but not excessive, chamber pressures needed for proper ballistic operations.

[0090] By way of example, a 0.50-caliber projectile assembly would utilize an approximately 0.21-caliber combustion insert forward opening 16. In effect, an essentially 0.21-caliber bore must fire a projectile assembly mass equivalent to that of a 9-mm round. Increasing the projectile assembly mass may produce an imbalance with the propellant charge mass and burn rate, resulting in improper ballistic operations. Channel(s) 45, as well as vent ports 47, allow propellant gases to egress the combustion chamber 25 of the combustion insert, into the larger volume of the jacket housing interior (via vent port(s) 47), and the cartridge exterior (via channel(s) 45), thereby regulating and / or relieving internal gas pressures to ensure proper ballistic operations.

[0091] FIG. 15 depicts a perspective view of an alternate thrust post of a cartridge according to one embodiment of the present invention. Spindle 72 may include one or more vent ports 47 extending from breech end 71 toward the topside end 75. The number of vent ports will depend on the specific application and ballistic performance but may include 1, 2, 3, 4, 5, or more vent ports. One embodiment includes two vent ports 47 to direct rocket energy from the exploding propellant within the combustion chamber towards the insert exterior surface 12 and the jacket housing interior 64 (See FIG. 17). The exposure of the equidistant vent ports 47 around the periphery of spindle post 72 as the thrust post 70 is forced away from the combustion insert during propulsion act as valves to aid the cartridge ballistic process. Upon communication of the thrust post vent port(s) 47 with the combustion insert outer channel(s) 45, combustion products will be directed to the cartridge exterior, ensuring proper ballistic operations.

[0092] FIGS. 16-18 depict side and cross-sectional views of a cartridge comprising the thrust post and combustion insert of FIGS. 14 and 15, according to one embodiment of the present invention. The cartridge 10 comprises cartridge casing 30 rearwardly secured to a projectile 50. The projectile interior surface 41 engages the exterior surface 62 of jacket housing 60, encapsulating the combustion insert 20. Channel(s) 45 are disposed on a portion of the insert sidewall 12, resulting in a clearance fit between channel(s) 45 of combustion insert 20 and the internal sidewall 64 of jacket housing 60. The thrust post 70 is disposed within the combustion insert propellant chamber 25 and central the cartridge 10, resulting in a clearance fit between vent port(s) 47 of thrust post 70 and the combustion chamber 25. Channels 45 within the combustion insert 20 and vent ports 47 within the thrust post 70 may redirect combustion products during ballistic operations, expelling rocket energy from the exploding propellant which will improve ballistic performance. The exposure of the vent port(s) 47 around the periphery of spindle post 72 as the thrust post 70 is forced away from the combustion insert 20 during propulsion act as valves to aid ballistic processes of cartridge 10. Upon ignition of the propellant, gas pressure within combustion chamber 25 will force thrust post 70 towards forward end 23 of the combustion insert 20, exposing vent port(s) 47 to the combustion insert outer channel(s) 45. Upon communication of the vent port(s) 47 with the channel(s) 45, combustion products will be directed between the exterior of combustion insert sidewall 12 and the jacket housing interior 64, exerting a rocket energy charge over a larger cartridge volume to improve separation of the cartridge assembly 200 from the base 30.

[0093] FIG. 18 depicts a side, cross-sectional view of a cartridge according to one embodiment of the present invention, during ballistic operations. Impact of the primer 18 by a firing pin assembly (not shown) causes the primer to react chemically, generating heat which ignites the propellant charge within the combustion insert 20. Another embodiment may use a high energy primer in lieu of a propellant charge, or used with less propellant charge.

[0094] Gas pressure will increase within the combustion insert 20 and ultimately explode into the combustion chamber 25, forcing the spindle post 72 of thrust post 70 against the projectile jacket housing 60 in direction 92. As the spindle post 72 begins to extend within the combustion chamber, combustion products 90 will begin to vent within combustion chamber 25, and egress thrust post disc or head 74 and combustion inert forward end 23, providing further propulsive forces in direction 96. Upon communication of the vent port(s) 47 with the channel(s) 45, combustion products 90 will be directed between the exterior of combustion insert and the jacket housing interior. The exerted rocket energy charge within the cartridge will dislodge / sever the connection between the projectile assembly 200 and the cartridge casing 30. After separation, the projectile assembly 200 will be propelled through the launcher barrel, engaging the barrel rifling to provide spin before exiting the barrel muzzle in ballistic flight.

[0095] FIG. 19 depicts a flow diagram of an example method for ballistic operation of a cartridge chambered within a projectile launcher assembly according to one embodiment of the present invention. The method 700 includes securing a cartridge according to an embodiment of the present invention within a chamber of a launcher assembly (block 702). An impact force produced by a trigger assembly is received by the firing pin, which is configured to transfers the received force to impact a primer disposed within the primer recess of the cartridge (block 704). The firing pin may contact the surface of the primer, causing a chemical reaction of the primer to generate heat, which if sufficient in energy may propel the thrust post and jacket housing, or if used in conjunction with a propellant charge, ignites the propellant charge in the combustion chamber (block 706). 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 post against the projectile jacket housing and uncoupling the connection between the projectile assembly and the cartridge casing (block 708). After separation, the propulsive force of thrust post against the jacket housing and projectile will propel the projectile assembly (i.e., thrust post, jacket housing, and projectile) from the launcher barrel in ballistic flight (block 710).

[0096] In some embodiments, combustion products of the ignition may be expelled through channels and vent ports within the combustion insert and the thrust post during propulsion, expelling rocket energy from the exploding propellant. The exposure of the vents around the periphery of spindle post as the thrust post is forced away from the combustion insert during propulsion act as valves to aid the cartridge ballistic process. Upon communication of the thrust post vents with the combustion insert channel(s), gas pressure will be vented over a larger cartridge volume, ensuring proper ballistic operations.

[0097] FIGS. 20, 20A, and 21 depicts a top and side views of a cartridge thrust post according to one embodiment of the present invention, displaying an alignment strut. Thrust post 70 may be constructed of a metal or alloy such as low carbon steel, leaded alloys, and the like. Thrust post comprises a spindle post 72 extending from breech end 71 to topside end 75, and is directly coupled at topside end 75 to a disc element / whorl 74. The outer circumference of disc element / whorl 74 may include a plurality of engagement teeth 78, which will engage the jacket housing interior (not shown) in an interference fit, assuring thrust post remains in place and is co-axial to the jacket housing. Engagement teeth may comprise opposing sloping surfaces 78b, 78c, terminating in a substantially flat surface 78a to increase frictional engagement between thrust post 70 and the jacket housing interior to further ensure co-axial alignment during ballistic operations. An alignment strut 79 may be formed and extend from the topside end 75 opposite breech end 71. Alignment strut 79 is sized to fit within and engage a jacket housing alignment recess (not shown) in an interference fit, ensuring coaxial alignment of the thrust post 70 within the jacket housing interior (not shown) at all stages of ballistic operation (i.e., interior ballistic, external ballistic, and terminal ballistic operational stages).

[0098] FIGS. 22 depict side and cross-sectional views of a cartridge jacket housing according to one embodiment of the present invention, displaying an alignment recess. The jacket housing 60 fits within the open-ended projectile base (not shown), creating an interference engagement of the projectile interior with the substantially cylindrical open-ended middle body component 62 and jacket cap 65. The middle body component 62 extends from jacket cap 65 to insertion element 61. Insertion element 61 surrounds the jacket interior 63 opposite jacket cap 65 for use with an insertion tool (not shown) during assembly to aid with insertion of the jacket housing 60 within the open-ended projectile base. An alignment recess 69 is formed within the jacket housing interior 63 for insertion of a thrust post alignment strut (not shown) in an interference fit during assembly. The alignment recess 69 ensures coaxial alignment of the thrust post (not shown) within the jacket housing interior 63 at all stages of ballistic operation (i.e., interior ballistic, external ballistic, and terminal ballistic operational stages). After assembly, the thrust post topside end will contact the muzzle-side interior surface 66 of jacket housing 60, with circumferential engagement with the internal sidewall 64. The jacket housing interior 63 may include a chamfered section 40 surrounding the internal sidewall 64 opposite the jacket end including insertion element 61 to direct propulsion forces and improve ballistic flight of the projectile assembly.

[0099] FIG. 23 depicts a side, cross-sectional view of a cartridge projectile assembly according to one embodiment of the present invention, displaying thrust post alignment strut and jacket housing alignment recess. The projectile assembly 200 comprises a jacket housing 60 fit within the open-ended projectile base 59 of the projectile in an interference engagement with the substantially cylindrical open-ended middle body component 62 and jacket cap 65. Thrust post 70 is co-axial to the housing interior 63 such that disc element / whorl 74 engages jacket housing internal sidewall 64 in an interference fit. An alignment strut 79 of thrust post 70 fits within and engages a jacket housing alignment recess 69 in an interference fit, further ensuring coaxial alignment of the thrust post 70 within the jacket housing interior 63 at all stages of ballistic operation.

[0100] FIGS. 24-31 depict another embodiment of the present invention. As a way to mitigate misalignment, the current embodiment considers forming a single unit of the cartridge base with the cartridge combustion insert. This single sub-assembly helps deter the primer from moving out of its recess pocket due to the relative thinness of the primer outer diameter and the combustion chamber wall.

[0101] FIGS. 24 and 25 depict side and cross-sectional views of a cartridge 300, respectively. Cartridge 300 suitable for use in a projectile launcher is shown comprising an outer projectile 355 supported on a substantially cylindrical cartridge casing or cover 350, and encompassing two subassemblies. (It is possible for the outer projectile to include a fluid carrying capsule retained by or attached to the cartridge casing or cover.)

[0102] In this embodiment, as a first subassembly 320, a base 330 is combined with the cartridge combustion insert 312, and may be integral therewith. The forward end of cartridge base 330 is formed with a substantially cylindrical coupling element 332 facing opposite the cartridge base rear surface 334. The outer diameter of coupling element 332 increases slightly as it extends forward from base 330, thereby forming a skirt for attachment to a flange end 351 of cartridge casing 350. This slight increase in diameter, increasing with the extension forward, provides for a slideable interference or snap-fit attachment to the inner diameter of flange 351 of casing 350.

[0103] Cartridge combustion insert 312 extends from base 330, and has a substantially cylindrical open-ended sidewall extending to forward end opening 316, the opposite end defining the interior of combustion chamber 325. If a high energy primer is not utilized, combustion chamber 325 may contain a propellant charge (not shown), which may comprise a nitrocellulose propellant, nitroglycerin propellant, and the like. The propellant charge is activated by ignition primer 18. The interior volume of combustion chamber 325 may be varied to provide the volume necessary for complete filling of the chamber 325 to a volumetric measurement appropriate to ensure ballistic performance of the projectile assembly.

[0104] Cartridge combustion insert 312 may be constructed of any sufficiently rigid light-weight metals or alloys such as aluminum, aluminum alloys, steel, steel alloys, and / or leaded alloys, and other metal alloys. The cartridge combustion insert may also be the same material as the base 330, and may be formed integrally with the base. Primer recess cavity 328 is formed within the cartridge base rear surface 334, encapsulating the primer within the cartridge base. A primer flash hole 321 is located in the primer recess 328, extending into the combustion chamber 325.

[0105] The combination of the base 330 with the cartridge combustion insert 312 (base-insert subassembly 320) ensures concentricity, such that the combined base-insert assembly 320 provides for a more precise coaxial alignment than a multiple piece design.

[0106] The primer recess 328 is sized so as to receive the primer 18 (see FIG. 27) in an interference or friction fit during assembly. Primer flash hole 321 communicates through the substantially cylindrical insert 312 into the combustion chamber 325 so that upon detonation of the primer, the propellant charge in combustion chamber 325 is ignited.

[0107] FIGS. 26 and 27 depict exploded and cross-sectional views of cartridge 300, respectively. Ignition primer 18 is loaded into primer recess 328 of base 330. The base-insert assembly 320 with ignition primer may be assembled as a separate first sub-assembly. A second sub-assembly (jacket subassembly) comprising a cartridge jacket housing 360 and thrust post 370 is shown. The jacket housing 360 has a diameter at its base open end 359 sized to allow for clearance of the head of thrust post 370. Thrust post 370 may be constructed of a metal or alloy such as low carbon steel, leaded alloys, and the like. Thrust post 370 comprises a spindle post 372 extending from a breech or base end 371 to a forward or topside end 375. Spindle post 372 extends within and is sized to form a transition or clearance engagement with the combustion chamber 325. A disc head 374 is located at the forward end of spindle post 372, and which will engage the jacket housing interior (not shown), assuring thrust post remains in place and is co-axial to the jacket housing. The internal diameter of cartridge jacket housing 360 is larger at the open end 359, providing clearance for insertion of the thrust post and thrust disc head 374. Additionally, the internal diameter of cartridge jacket housing 360 at the forward end receives the disc element / whorl 374 in a interference fit. Line 376 depicts the approximate demarcation of this diameter change. The insertion of the thrust post into the cartridge jacket housing forms the second sub-assembly.

[0108] After assembly, the thrust post topside end 375 will contact the muzzle-side interior surface 366 of jacket housing 360 and substantially circumferentially engages the jacket housing internal sidewall 364.

[0109] Casing 350 forms the outer body shell of the cartridge. Flange 351 is inserted over skirt 332, and held firmly to base 330 by interference fit due to the slight increase in diameter of the base skirt, increasing as it extends forward. Cavity 341 receives the second sub-assembly.

[0110] FIGS. 28A and 28B depict the thrust post design 370 of the current embodiment. FIG. 28A depicts a side view of the thrust post. FIG. 28B depicts a top view of the thrust post head or disc 374. Thrust post 372 terminates with thrust post disc or head 374 at the forward end (the thrust post “head”). Two diametrically opposed flats 374′ are depicted in the thrust post disc or head 374. One flat may be utilized; however, multiple flats (two or more) providing symmetry may be more efficient under certain firing conditions. The flats 374′ permit evacuation of air as the thrust post head is inserted within cartridge jacket housing 360 and pressed home. The flats remove any unwarranted pneumatic effect that could adversely affect seating of the thrust post. Although two flats are depicted, a plurality of flats may be employed in various sizes to achieve the air evacuation desired. Although symmetry of the flats is preferred, it is not necessitated.

[0111] FIG. 29A depicts a perspective view of the cartridge jacket housing 360 having diametrically opposed flats 367. The top side 365 of cartridge jacket housing 360 is preferably a flat surface, and may include a beveled edge 368 as it descends to the outer surface 362. FIG. 29B depicts a top side view of cartridge jacket housing 360, illustrating the diametrically opposed flats 367.

[0112] FIGS. 30 and 31 depict yet another embodiment of the present invention. In this instance, the purpose of the round has been altered from applying an impact force to a target to mark the target with a fluid. This embodiment depicts how the projectile (marker round) may be altered to suit this purpose. FIG. 30 is an exploded view of the marker round cartridge 390. A fluid carrying capsule 391, e.g., a gelatin capsule, may be retained by or attached to a cylindrical shell cartridge casing or cover 350′ using an adhesive, or potentially may be retained with a force / press / friction fit. The fluid carrying capsule 391 may also be in the geometric form of a sphere. For the latter, an aft-facing skirt 392, having a smaller diameter than the largest diameter of capsule 391 is extended from the base 393 of capsule 391. In this embodiment, skirt 392 is received by the open end 357′ of casing 350′. The capsule may be as shown in the illustrations, or it may be spherical, in which case, a spherical depression located in the front of the projectile would receive and locate the sphere. Under such circumstances, an adhesive may be employed for attachment.

[0113] The internal diameter of cartridge casing or cover 350′ is sized to receive skirt 392. The opposite end 359′ of cartridge casing or cover 350′ is sized to provide clearance for insertion of base-insert assembly 320.

[0114] FIG. 31 is an exploded, cross-sectional view of cartridge 390 of FIG. 30. When utilizing an adhesive or polymeric bond to attach capsule 391, the topside forward end of casing 350′ may have internally knurled grooves 358, forming an innermost surface that presents an interference fit with the capsule skirt 392, and an outermost surface that forms an airspace with the capsule skirt 392 for adhesive movement, allowing for egress of adhesive during assembly, if too much adhesive has been applied. If adhesive is not used, the topside forward end of casing 350′ may be sized for receiving skirt 392 in a manner that facilitates an interference fit, press fit, or friction fit, for capsule skirt 392.

[0115] Thus, the present invention provides one or more of the following advantages: a sealed combustion chamber provides positive gas management for a plurality of controlled ballistic velocities; allows for reduced firing pin spring force which decreases forces on the launcher assembly during cocking cycle; provides a non-lethal projectile which is easy to manufacture, reducing cost; and simplifies non-lethal cartridge assembly.

[0116] The present invention provides for a method of firing a projectile from a launcher, where the method comprises securing a cartridge having a projectile assembly and cartridge casing within a chamber of a launcher assembly, the projectile assembly having 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; thus producing, by a trigger assembly, an impact force to impact a primer disposed within the cartridge casing; initiating a propellant charge provided in a combustion insert of the cartridge casing; forcing the thrust post against the jacket housing and away from the cartridge casing; uncoupling the projectile assembly from the cartridge casing; and propelling the projectile assembly out of the barrel in ballistic flight.

[0117] The method further including 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 combustion insert internal gas pressures produced by the initiated propellant charge into a larger volume area of the cartridge and / or an exterior portion of the cartridge; and regulating and / or relieving internal gas pressures produced by the initiated propellant charge to ensure proper ballistic operation.

[0118] Thus, having described the invention, what is claimed is:

Claims

1. A projectile cartridge assembly comprising:a projectile;a base-insert subassembly including:a base having a forward end and a rear end, said base forward end including a substantially cylindrical coupling element or skirt for receiving a cartridge casing or cover, said base rear end including a primer recess cavity; anda cartridge combustion insert extending from said 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, said open base end having first diameter sized for clearance of a forward end of a thrust post;said thrust post including a spindle or thrust post having a thrust post base end and said thrust post forward end including a disc or head, wherein upon assembly of said jacket subassembly, the thrust post topside end will contact a muzzle-side interior surface of said jacket housing and circumferentially engage an internal sidewall of said jacket housing; andsaid cartridge casing or cover having a casing base end including a substantially cylindrical shell forming a flange.

2. The projectile cartridge assembly of claim 1 wherein said base coupling element or skirt includes an outer diameter increasing as said base coupling element extends in a forward direction for attachment to said cartridge casing or cover.

3. The projectile cartridge assembly of claim 1 wherein said cartridge combustion insert is formed integral with said base.

4. The projectile cartridge assembly of claim 1 wherein said combustion chamber includes a propellant charge.

5. The projectile cartridge assembly of claim 4 wherein said propellant charge includes nitrocellulose propellant or nitroglycerin propellant.

6. The projectile cartridge assembly of claim 1 wherein said base is constructed of rigid light-weight metals or alloys.

7. The projectile cartridge assembly of claim 6 wherein said base is constructed of aluminum, aluminum alloys, steel, steel alloys, and / or leaded alloys.

8. The projectile cartridge assembly of claim 1 including a primer flash hole providing a gas transport cavity, attaching said primer recess cavity with said combustion chamber.

9. The projectile cartridge assembly of claim 1 including an ignition primer sized for insertion within said primer recess cavity.

10. The projectile cartridge assembly of claim 1 wherein said jacket housing includes a second diameter closer to said forward end than said first diameter, said jacket housing second diameter sized to receive said disc or head in a tighter fit than said jacket housing first diameter.

11. The projectile cartridge assembly of claim 1 wherein said cartridge jacket housing includes at last one flat or diametrically opposed flats to facilitate insertion of said cartridge casing or cover over said jacket housing.

12. The projectile cartridge assembly of claim 11 wherein said cartridge jacket housing top side is a substantially flat surface, having a beveled edge as said top side descends to an outer surface of said cartridge jacket housing.

13. The projectile cartridge of claim 1 wherein said thrust post disc or head includes at least one flat or diametrically opposed flats to facilitate insertion within said jacket housing.

14. The projectile cartridge of claim 1 wherein said projectile comprises a fluid carrying capsule retained by or attached to said cartridge casing or cover.

15. A projectile assembly comprising:a projectile;a base having a forward end and a rear end, said base forward end including a substantially cylindrical coupling element and an insert channel formed internally therein to facilitate insertion of a cartridge casing cover, said base rear end including an aperture for receiving said cartridge combustion insert, said base sidewall having an outer extractor groove;said cartridge combustion insert extending from said 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, said jacket housing open base end having first diameter sized for clearance of said cartridge combustion insert;a thrust post including a spindle post having a thrust post base end and a thrust post forward end including a disc or head, wherein upon assembly said thrust post forward end contacts a muzzle-side interior surface of said jacket housing forward end and circumferentially engages an internal sidewall of said jacket housing; andsaid cartridge casing or cover having a casing base end including a substantially cylindrical shell forming a flange, wherein upon assembly said cartridge casing flange inserts within said base insert channel.

16. The projectile assembly of claim 15 wherein said cartridge casing flange forms an interference fit with said base channel insert.

17. The projectile assembly of claim 15 wherein said thrust post includes a disc element and spindle post extending therefrom.

18. The projectile assembly of claim 17 wherein said thrust post extends within a portion of the combustion insert.

19. The projectile assembly of claim 15 including a propellant charge provided in the combustion insert such that when a firing mechanism activates the cartridge, said propellant charge is initiated, gases are created which force the thrust post away from the cartridge base.

20. The projectile assembly of claim 15, wherein the thrust post includes at least one vent port formed on a portion of the thrust or spindle post, and optionally, the combustion insert includes at least one channel formed on an exterior surface of the combustion insert.

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

22. The projectile assembly of claim 21 wherein said cartridge casing open forward end include knurled grooves exposed at the top surface for receiving said capsule skirt, facilitating a press or friction fit for said capsule.

23. A method of firing a projectile from a launcher, comprising:securing a cartridge into said launcher, said cartridge having:a base-insert subassembly including: a base having a forward end and a rear end, said base forward end including a substantially cylindrical coupling element or skirt for receiving a cartridge casing or cover, said base rear end including a primer recess cavity; and a cartridge combustion insert extending from said 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, said open base end having first diameter sized for clearance of a forward end of a thrust post;said thrust post including a spindle post having a post base end and said thrust post forward end including a disc or head, wherein upon assembly of said jacket subassembly, the thrust post topside end will contact a muzzle-side interior surface of said jacket housing and circumferentially engage an internal sidewall of said jacket housing; andsaid cartridge casing or cover having a casing base end including a substantially cylindrical shell forming a flange;initiating a propellant charge provided in said cartridge combustion insert, when a high energy primer is not employed;forcing the thrust post against the jacket housing and away from the cartridge base;uncoupling the projectile from the base-insert assembly; andpropelling the projectile in ballistic flight.

24. The method of claim 23 further including 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 said high energy primer or said propellant charge; andregulating and / or relieving internal gas pressures produced by the initiated propellant charge to ensure proper ballistic operation.

25. 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; anda cartridge comprising: a projectile assembly comprising:an outer projectile;a jacket housing coupled within an interior portion of the outer projectile; anda 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; anda 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.

26. The launcher assembly of claim 25, wherein the thrust post includes at least one vent port formed on a portion of the spindle post, and optionally, the combustion insert includes at least one channel formed on an exterior surface of the combustion insert.

27. The launcher assembly of claim 26, wherein the at least one vent port and / or at least one channel allow propellant gases to egress the combustion insert into a larger volume area of the cartridge and / or an exterior portion of the cartridge to regulating and / or relieving internal gas pressures produced by the propellant gases.

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