Biodegradable and compostable shotgun shell for sustainable shooting

Abstract

A one-piece biodegradable shotgun shell hull comprising an integrated casing and base made from a hemp-based composite material. The hull has a first end with an aperture for receiving a primer and a second end with a crimping portion. A wad, also made of the hemp-based composite material, is positioned within the hull and secured by the crimping portion at the second end. The hemp-based composite material comprises over 80% hemp fibers, providing a sustainable and environmentally-friendly construction. This one-piece design simplifies manufacturing while offering a fully biodegradable shotgun shell solution.

Description

BIODEGRADABLE AND COMPOSTABLE SHOTGUN SHELL FOR SUSTAINABLESHOOTINGRELATED APPLICATIONSThis application claims the benefit of priority to U.S. Provisional Application serial number 63 / 469,790 entitled, “BIODEGRADABLE AND COMPOSTABLE SHOTGUN SHELL FOR SUSTAINABLE SHOOTING”, filed on May 30, 2023, which application is hereby incorporated by reference herein in its entirety.FIELD

[0001] The present inventive subject matter related to the field of material composition and design. More specifically, the present inventive subject matter related to shotgun shell material composition and design.BACKGROUND

[0002] Traditional shotgun shells have been a staple of hunting and shooting sports for generations, but they come with significant environmental drawbacks. These shells are typically made from non-biodegradable materials, including plastics which can take hundreds of years to break down in the environment. This results in pollution and negative impacts on wildlife and ecosystems. Partially biodegradable options have been introduced, but even then the materials still take years to break down and require specific disposal methods. Additionally, there are concerns about their durability and compatibility with all shotgun models. The need for a more fully biodegradable shotgun shell that does not compromise on performance has become increasingly important in today's world, where environmental sustainability is a growing concern.BRIEF DESCRIPTION OF THE DRAWINGS

[0003] Embodiments of the inventive subject matter may be best understood by referring to the following description and accompanying drawings, which illustrate such embodiments. In the drawings:

[0004] FIG. 1 is an exploded view of the biodegradable shotgun shell components according to various embodiments.

[0005] FIG. 2 is a perspective view of a one-piece hull according to various embodiments.

[0006] FIG. 3 is a cross-sectional view of the biodegradable shotgun shell components according to various embodiments.

[0007] FIG. 4 is a flow diagram of the steps for manufacturing biodegradable shotgun shells according to various embodiments.DESCRIPTION

[0008] In the following description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific embodiments which may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the present subject matter, and it is to be understood that other embodiments may be utilized and that structural, logical and material changes may be made without departing from the scope of the present subject matter. The following description of example embodiments is, therefore, not to be taken in a limited sense, and the scope of the present invention is defined by the appended claims.

[0009] A biodegradable shotgun shell is a unique and innovative product designed to replace traditional shotgun shells. According to various embodiments, the device comprises biodegradable materials that can be natural, natural-derived, or other organic types. The materials used include hemp, HDPE, PLA, organic enzymes, and other eco-friendly and sustainable components. According to some embodiments, natural polyamide fibers like silk or wool may be incorporated. The device comprises different biodegradable parts, such as a base, casing, and wad, all made from these natural or organic materials. This approach ensures the shotgun shell is environmentally conscious and biodegradable, reducing its environmental impact. Overall, the biodegradable shotgun shell represents a significant advancement in shotgun shell technology by offering a sustainable and environmentally-friendly alternative to traditional shells. Its use can help reduce the amount of non- biodegradable waste produced by hunting and shooting sports, while still providing a reliable and effective ammunition option for hunters and shooters alike.

[0010] As an innovation in the ammunition industry, the biodegradable shotgun shell described herein is composed of various layers, including a biodegradable casing and wad. In some embodiments the casing may be made of HEMP, HDPE, or PLA, while the wad may be made of organic enzyme or other biodegradable materials. The shot may be made of materials that are already in the industry. This composition may make the shell eco-friendly and may decompose naturally over time, which could reduce environmental pollution caused by traditional shotgun shells that are made of non-biodegradable materials.

[0011] The biodegradable shotgun shell may be compatible with all types of shotguns and may have comparable accuracy and range to traditional shells. It may be manufactured at a cost on par with or even lower than traditional shells, making it accessible to a wider market. The invention provides an effective solution to the environmental problems caused by traditional shells and may offer a more sustainable and eco-friendly alternative. The biodegradable shotgun shell not only benefit the environment but may also improve the user's experience by providing a reliable and effective option for hunting and shooting activities.

[0012] To use the biodegradable shotgun shell, the shooter would load it into their shotgun in the same way they would load a traditional shell. Once fired, the biodegradable components of the shell will degrade naturally over time without causing harm to the environment.

[0013] Referring to FIG. 1 , a biodegradable shotgun shell 100 comprises a casing 102 having a generally cylindrical shape. The casing 102 is made of a biodegradable material, such as hemp, HDPE, PLA, or a combination thereof. The casing 102 has a first end and a second end. The first end 110 is open to allow for the insertion of a primer 114 and other internal components. The second end 112 includes a crimping portion 116 for securing a wad 108 within the casing 102.

[0014] The biodegradable shotgun shell 100 further comprises a base 104 attached to the casing 102 at the second end. The base 104 provides stability and support for the shell 100 during firing. The base 104 may be made of a biodegradable material, such as a biodegradable plastic or metal. The casing 102 is open at one end toallow for the insertion of ammunition and has a sealing mechanism at the other end to prevent the ammunition from falling out during use. The sealing mechanism may include a flexible cap that is attached to the end of the casing using a sonic weld. The end of the casing 102 may be scored to enable a roll crimp to secure the flexible cap in place.

[0015] For the closure mechanism, the casing 102 can incorporate added crease lines or points to facilitate the crimping process; a roll crimp or star crimp may be used. If a roll crimp is employed, the shot card would be made from the biodegradable material discussed herein, providing a further natural and biodegradable component.

[0016] The crease lines or points can be molded or embossed into the casing 102 for example during the injection molding process. These creases act as predetermined folding points, allowing for a controlled and consistent crimp to be formed when the casing end is folded over the wad 108 or shot card. This crimping action securely seals the shotgun shell while maintaining the biodegradable nature of the product.

[0017] Additionally, the specific crimp pattern, whether a roll crimp or star crimp, can be optimized for the chosen casing 102 and wad 108 materials. This tailoring ensures a tight seal while minimizing potential damage to the biodegradable components during the crimping process.

[0018] The base 104 includes sufficient structure such that it is secure enough that the ejector can pull on it without breaking apart. The base 104 includes an aperture 106 for receiving the primer. The primer may be a standard primer used in shotgun shells and is designed to ignite propellant charge upon firing. According to various embodiments, the base 104 includes thicker or reinforced wall structure beginning from the proximal end (where the aperture 106 is present) and extending toward the distal end where the base 104 attaches to the casing 102. This reinforced structure will extend to substantially the height of the primer in order to offer additional strength to the base 102 and stability for the primer.

[0019] According to additional embodiments, there is a reinforced structure in the casing 102 above the base 104 and below the wad 108. This reinforced area serves two potential purposes: firstly, it reinforces the walls surrounding the propellant charge, providing enhanced strength and integrity where the propellant will be ignited. Secondly, it can be designed to create a secure seating area for the wad 108, ensuring proper positioning and alignment during the firing process.

[0020] The wad 108 is a component made of a biodegradable material, such as hemp, recycled paper, cotton, spider silk, or other biodegradable material / composite. The wad 108 is positioned within the casing 102 and is secured in place by a crimping at the second end of the casing 102. The wad 108 serves to separate the propellant charge from the shot and provides a gas seal during firing. The wad 108 may be compressed against the shot to prevent movement during firing and to ensure consistent shot patterns. Polyamide fibers can be incorporated into the casing 102, base 104 and / or wad 108 compounds to impart enhanced strength and flexibility to the final product. These natural or synthetic fibers, such as silk or wool act as reinforcements within the polymer matrix. When dispersed throughout the compound, the polyamide fibers create a fiber-reinforced composite material. The high tensile strength and modulus of polyamide fibers contribute significantly to improving the overall mechanical properties of an injection molded part. The incorporation of these fibers or hemp material increases the material's resistance to impact, flexural, and tensile forces, making the product more durable and less prone to fracture or deformation under load. Additionally, the flexibility inherent to incorporated fibers helps maintain the ductility of the composite, preventing it from becoming overly brittle.

[0021] This combination of strength and flexibility offered by polyamide fiber reinforcement is particularly advantageous for shotgun shells. In some embodiments, the fibers can be oriented during the injection molding process to further optimize the mechanical properties in the desired directions, tailoring the product's characteristics to meet specific design requirements.

[0022] According to some embodiments, to further enhance the performance and reduce friction during the firing process, a natural or naturally-derived friction-reducing component or coating can be incorporated onto the wad 108 or the inner surface of the casing 102. This friction-reducing element, such as plant (or animal / insect)-based waxes, oils, or lubricants, helps minimize the friction between the wad and the casing as the wad travels through the barrel. By reducing this friction, the shotgun shell can achieve improved ballistic performance and consistency, while maintaining its biodegradable and eco-friendly properties.

[0023] Referring now to FIG. 2, an alternative embodiment of a biodegradable shotgun shell 200 is illustrated in a perspective view. In this embodiment, the shell 200 comprises a one-piece hull 202 that incorporates both the casing and the base into a single, integrated component. The one-piece hull 202 may be manufactured using injection molding, additive printing (e.g., 3D printing), or other suitable manufacturing processes, utilizing biodegradable materials such as hemp, HDPE, PLA, or a combination thereof.

[0024] The one-piece hull 202 includes an aperture 204 at one end for receiving a primer. The aperture 204 is designed to securely hold the primer in place during firing. By combining the casing and base into a single component, this alternative embodiment simplifies the assembly process and reduces the number of individual parts required for the biodegradable shotgun shell. The one-piece hull 202 may also provide enhanced structural integrity and improved resistance to environmental factors, such as moisture and temperature fluctuations.

[0025] According to various embodiments, the one-piece hull 202 includes a thick wall, infilled or reinforced structure beginning from the proximal end (where the aperture 102 is present) and extending toward the distal end where the wad would be inserted. This reinforced structure will extend to substantially the height of the primer in order to offer additional strength to the one-piece hull 202 and stability for the primer.

[0026] Additionally, according to other embodiments, the one-piece hull 202 incorporates reinforced structure above the area containing the aperture 204 and extending upwards towards the portion where the wad will be seated. This reinforced area can serve two purposes: firstly, it reinforces the walls surrounding the propellantcharge, providing enhanced strength and integrity where the propellant will be ignited. Secondly, it creates a secure seating area for the wad, ensuring proper positioning and alignment during the firing process.

[0027] Similar to as discussed with reference to Fig. 1, a closure mechanism for the one-piece hull 202 can incorporate added crease lines or points to facilitate the crimping process; a roll crimp or star crimp may be used. If a roll crimp is employed, the shot card would be made from the biodegradable material discussed herein, providing a further natural and biodegradable component.

[0028] The crease lines or points can be molded or embossed into the one-piece hull 202 for example during the injection molding process. These creases act as predetermined folding points, allowing for a controlled and consistent crimp to be formed when the casing end is folded over the wad or shot card. This crimping action securely seals the shotgun shell while maintaining the biodegradable nature of the product.

[0029] Additionally, the specific crimp pattern, whether a roll crimp or star crimp, can be optimized for the chosen one-piece hull 202 and wad materials. This tailoring ensures a tight seal while minimizing potential damage to the biodegradable components during the crimping process.

[0030] FIG. 3 illustrates a cross-sectional view of a biodegradable shotgun shell 300, depicting the various components and their arrangement within the shell. The shell 300 comprises a casing 302, a base 304 with an aperture 306 for receiving a primer, and a wad 308.

[0031] The wad 308 is positioned within the casing 302 and serves to separate the propellant charge from the shot. The wad 308 creates a space 310 within the casing 302 for housing the propellant charge. Additionally, the wad 308 includes a cup-like structure 312 designed to hold the shot in place during firing. In some embodiments, the casing 302 and the base 304 may be integrated into a single, one-piece hull (similar to the embodiment shown in FIG. 2).

[0032] The casing 302, base 304, and wad 308 are all constructed from biodegradable materials, such as hemp, HDPE, PLA, recycled paper, or a combination thereof. The use of these biodegradable materials ensures that the shotgun shell 300 is environmentally friendly and will degrade naturally over time, reducing the environmental impact compared to traditional, non-biodegradable shotgun shells. The casing 302 and wad 308 may be secured using sonic welds, crimping, or other suitable means.

[0033] FIG. 4 is a flow diagram of the steps for manufacturing biodegradable shotgun shells 400 according to various embodiments. The manufacturing process for the biodegradable shotgun shell begins with material preparation (402). This step involves gathering and processing the necessary biodegradable materials, such as hemp, HDPE, PLA, and organic enzymes. Material should be stored and maintained at appropriate moisture levels and temperature to facilitate manufacturing in such a manner to obtain the characteristics desired from the material. The hull (casing and base) production (404) follows, where the biodegradable materials are molded, extruded or printed into the desired shape for the casing and base components. Simultaneously, the wad production (406) takes place, utilizing biodegradable materials like recycled paper, hemp, or cotton to create the wad component.

[0034] According to some embodiments, materials such as hemp, HDPE, PLA, and organic enzyme are used to prepare the biodegradable casing by extruding the HDPE and PLA into thin sheets, then heating and shaping the sheets into the desired shape using specialized molds. The wad may additionally be made from organic materials or recycled plastics that have been ground up and molded into the desired shape.

[0035] According to other embodiments, injection molding is used to manufacture the components (hull, base (as applicable), wad). The composition of the raw material may consist of 80-90% hemp and 15-20% binding agent, such as a biodegradable polymer like PLA or PBAT. Additionally, the material composition can be infused with natural polyamide fibers, such as silk, wool, or other plant-based fibers, to enhance strength and flexibility.

[0036] The incorporation of hemp provides a sustainable and biodegradable base material, while the binding agent helps to hold the composition together and impart desired mechanical properties. The natural polyamide fibers act as reinforcements within the polymer matrix, creating a fiber-reinforced composite material. These fibers contribute significantly to improving the overall mechanical properties, increasing resistance to impact, flexural, and tensile forces, while maintaining ductility and preventing brittleness.

[0037] By carefully controlling the ratios and types of materials used, the injection molding process can produce components with tailored characteristics, optimized for their specific roles within the biodegradable shotgun shell. This approach allows for the creation of a high-performance, eco-friendly product that meets the necessary durability and functional requirements while minimizing environmental impact.

[0038] Once the individual components are produced, they undergo quality control (408) to ensure they meet the required specifications and standards. The assembly process (410) then commences, where the casing, base, wad, primer, propellant charge, shot, and any additional buffer or components are carefully assembled together. This step may involve techniques such as crimping, sonic welding, or other suitable methods to securely join the components. Sealing the end of the shell may include a flexible cap, with sonic welding used to attach the cap. A roll crimp may also be used. The end of the shell may be scored for it to be crimped over in this manner.

[0039] After assembly, the biodegradable shotgun shells undergo final testing (412) to verify their performance, reliability, and adherence to safety standards. This may include drop tests, water resistance tests, and ballistic evaluations. Once the shells have passed the necessary tests, they proceed to the packaging stage (414), where they are appropriately packaged for distribution and sale. The packaged biodegradable shotgun shells are then ready for distribution to retailers, sporting goods stores, or directly to consumers.

[0040] According to various embodiments, the biodegradable shotgun shell is designed to be used in temperatures ranging from -20 to 90 degrees Fahrenheit, andis able to withstand impact without cracking, denting, breaking, or disfiguring. The end of the shell is sealed with a flexible cap using sonic welding, and a roll crimp may be used to attach the scored end of the shell to the cap. The shell is designed to avoid water absorption and swelling, making it suitable for use in wet conditions.

[0041] According to various embodiments, The biodegradable and compostable shotgun shell is designed to be used in a standard shotgun and is compatible with existing manufacturing processes. The shell comprises a biodegradable casing that can be made of hemp, coffee, cotton, wood, flax, coconut, or bamboo. The casing is designed to hold the shot and wad in place and to seal the gunpowder charge. The wad may be made of a biodegradable material, such as Hemp and / or a combination of Hemp and polypropylene, which disintegrates rapidly upon impact with the shot. The wad serves to protect the barrel of the shotgun and to provide a cushion for the shot, reducing the chance of damage to the gun.

[0042] After the shot has been fired, the user would be able to leave the spent shell in nature without worrying about specific disposal requirements. The shell is made from biodegradable materials that will decompose naturally, eliminating the need for the user to pick up and dispose of the shell. The decomposition process can take several months to a few years, depending on environmental factors, but ultimately the shell will break down and return to the earth. Overall, using the biodegradable shotgun shell is a simple and convenient way for users to enjoy their sport without leaving a negative impact on the environment.

[0043] The biodegradable shotgun shell has a primary purpose of providing a more environmentally friendly option for hunters and shooting enthusiasts. However, the invention may also have alternative uses beyond its intended purpose. For example, the biodegradable shell may be utilized in the military for training purposes, providing a safe and eco-friendly option for firearm training exercises. Additionally, the technology behind the biodegradable shell may be adapted for use in other industries where there is a need for eco-friendly ammunition, such as in law enforcement or pest control.

[0044] Embodiments of the invention described in the above paragraphs and examples may be applied for bicyclists, pedestrians, motorcyclists, automobiles and other modes of transportation which may be at risk of collision from approaching automobiles.

[0045] Thus, example embodiments of the inventive subject matter are disclosed. One skilled in the art will appreciate that the present teachings can be practiced with embodiments other than those disclosed. The disclosed embodiments are presented for purposes of illustration and not limitation, and the present teachings are limited only by the claims that follow.

[0046] The Abstract is provided to comply with 37 C.F.R. §1 .72(b) to allow the reader to quickly ascertain the nature and gist of the technical disclosure. The Abstract is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.

Claims

What is claimed is:1 . A biodegradable shotgun shell comprising: a casing made of a hemp-based composite material, the casing having a first open end and a second end with a crimping portion; a base attached to the second end of the casing, the base made of the hemp-based composite material and comprising an aperture for receiving a primer; a wad made of the hemp-based composite material and positioned within the casing, the wad secured within the casing by the crimping portion.

2. The biodegradable shotgun shell of claim 1 , wherein the hemp-based composite material comprises over 80% hemp fibers.

3. The biodegradable shotgun shell of claim 1 , wherein the hemp-based composite material comprises 10-20% biodegradable binding agent.

4. The biodegradable shotgun shell of claim 1 , wherein the hemp-based composite material comprises is infused with natural polyamide fibers to enhance strength and flexibility.

5. The biodegradable shotgun shell of claim 1 , further comprising a reinforced portion in the base, the reinforced portion surrounding the aperture for receiving the primer, the reinforced portion extending from a proximal end of the base adjacent to the aperture towards a distal end of the base attached to the casing, the reinforced portion providing increased strength and stability to the base around the primer.

6. The biodegradable shotgun shell of claim 1 , further comprising a reinforced portion within the casing surrounding an area for housing a propellant charge, the reinforced portion providing increased strength and structural integrity to the casing walls in the area where the propellant charge will be ignited during firing.

7. A one-piece biodegradable shotgun shell hull comprising:an integrated casing and base made of a hemp-based composite material, the hull having a first end and a second end with a crimping portion; an aperture at the first end of the hull for receiving a primer; a wad made of the hemp-based composite material and positioned within the hull, the wad secured within the hull by the crimping portion at the second end.

8. The one-piece biodegradable shotgun shell hull of claim 7, wherein the hempbased composite material comprises over 80% hemp fibers.

9. The one-piece biodegradable shotgun shell hull of claim 7, wherein the hempbased composite material comprises 10-20% biodegradable binding agent.

10. The one-piece biodegradable shotgun shell hull of claim 7, wherein the hempbased composite material is infused with natural polyamide fibers to enhance strength and flexibility of the hull.11 .The one-piece biodegradable shotgun shell hull of claim 7, further comprising a reinforced portion surrounding the aperture for receiving the primer, the reinforced portion extending from a proximal end adjacent to the aperture towards the second end, the reinforced portion providing increased strength and stability to the hull around the primer.

12. The one-piece biodegradable shotgun shell hull of claim 7, further comprising a reinforced portion within the hull surrounding an area for housing a propellant charge, the reinforced portion providing increased strength and structural integrity to the hull walls in the area where the propellant charge will be ignited during firing.

13. A method of manufacturing a biodegradable shotgun shell, comprising: preparing a biodegradable material composition comprising hemp fibers and a biodegradable binding agent; molding the biodegradable material composition to form a hull having a first integrated base end including an aperture for receiving a primer, and a second end with a crimping portion;molding a wad from the biodegradable material composition; assembling the hull wad, primer, propellant charge, and shot to create the biodegradable shotgun shell; and crimping the crimping portion of the casing over the wad to secure the wad within the casing.

14. The method of claim 13, wherein the biodegradable material composition comprises 80-90% hemp fibers.

15. The method of claim 13, wherein the biodegradable material composition comprises 10-20% of the biodegradable binding agent.

16. The method of claim 13, wherein preparing a biodegradable material composition includes incorporating a natural polyamide fiber to enhance strength and flexibility.

17. The method of claim 13, further comprising forming a reinforced portion in the base end surrounding the aperture for receiving the primer.

18. The method of claim 13, further comprising forming a reinforced portion within the hull surrounding an area for housing the propellant charge.

19. The method of claim 13, wherein the molding steps comprise injection molding the biodegradable material composition.

20. The method of claim 13, wherein the molding step comprises: extruding the biodegradable material composition into sheets; and heating and shaping the sheets to form the hull using specialized molds.

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