Less-Lethal Wad System for Fragile Projectile Protection
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Solution Overview
Problem
Current less-lethal munitions, such as tasers and rubber projectiles, are inaccurate and prone to causing unnecessary harm due to manufacturing imperfections and fragility, making them ineffective for incapacitating individuals without causing harm, especially in riot and crowd-control scenarios where gunpowder-firing configurations are required.
Innovation Solution
A wad system comprising a disc-shaped base with extendable tabs that can be configured to securely hold elongate or spherical projectiles, providing a distributed load and shock absorption to protect the projectile during ignition, allowing for the use of fragile projectiles in gunpowder-burning weapons while ensuring accurate and safe incapacitation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional spherical or elongate less-lethal projectiles are used, then the projectiles can be fired from launchers, but they are too fragile to withstand gunpowder burning and cause manufacturing imperfections leading to inaccuracy
Solution Approach 1:
The projectile is divided into multiple segments: a resilient body portion that absorbs shock and maintains structural integrity, and a separate cap portion that can be removed or replaced. This segmentation allows each part to be optimized independently - the body for durability and the cap for precision manufacturing.
Solution Approach 2:
The projectile uses composite construction with a resilient body material (such as rubber or polymer) combined with a cap material. This composite structure provides both the fragility resistance needed for gunpowder firing and the manufacturing precision required for accuracy, as each material can be selected for its specific properties.
2Speed
If gunpowder-firing configurations are used to increase range and effectiveness, then the projectiles can reach greater distances, but the fragile projectiles cannot withstand the ignition force and are damaged
Solution Approach 1:
The resilient body portion is designed to absorb and cushion the shock of gunpowder ignition before the force can damage the projectile. This prior cushioning allows the projectile to withstand the high-stress environment of gunpowder firing while maintaining its structural integrity and reaching greater distances.
Solution Approach 2:
The wad acts as an intermediary between the gunpowder and the projectile, distributing the ignition force evenly across the projectile surface. This intermediary protection allows the fragile projectile to be fired from gunpowder-burning weapons without direct exposure to concentrated ignition forces.
3Object-affected harmful factors
If rubber projectiles are used in shotgun shells, then less-lethal force can be applied, but manufacturing imperfections cause inaccuracy and serious injury or death
Solution Approach 1:
The cap portion of the projectile can be manufactured with high precision and consistent dimensions, ensuring accurate flight characteristics. The resilient body provides the less-lethal force capability, while the precision-crafted cap ensures manufacturing consistency and accuracy, reducing the harmful effects of variability.
4Ease of manufacture
If spherical projectiles are used for less-lethal devices, then the projectiles are easier to manufacture, but they are notoriously inaccurate
Solution Approach 1:
By separating the projectile into a simple resilient body and a precision cap, the manufacturing complexity is distributed. The body can be easily manufactured using simple molding processes, while the cap can be precision-manufactured separately and attached, combining ease of manufacture with manufacturing precision.
Data Source
AI summary
This invention relates to less-lethal munitions. More particularly, the invention relates to a wad and a less-lethal round of ammunition adapted for use with a conventional firearm, which less-lethal shell enables the firearm to propel less-lethal projectiles therefrom. According to a first aspect of the invention there is provided a wad operatively received within an ammunition casing, the wad comprising a substantially disc-shaped base; and a plurality of tabs extending from the base defining a receiving zone therebetween, with at least some of the tabs provided with an inwardly projecting formation for urging against a projectile operatively received within the receiving zone.