Plastisol Less-Lethal Projectile Composite Design
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Solution Overview
Problem
Current non-lethal ammunition can cause severe injury or death due to penetration or ricochet, failing to ensure safety for intended targets and bystanders.
Innovation Solution
Development of less-lethal ammunition using synthetic materials like plastisol with dispersed weighting substances (bismuth or tungsten) to create projectiles with controlled trajectory and energy distribution, reducing variance in performance and cost, and incorporating a buffer and gas seal for reliable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rubber-coated bullets are used as non-lethal ammunition, then the intent is to reduce lethality, but the projectiles can penetrate skin and bone causing severe injury or death
Solution Approach 1:
The patent uses composite materials consisting of a flexible polymer matrix (such as polyurethane, silicone rubber, or thermoplastic elastomer) combined with embedded weighting particles (such as tungsten, bismuth, or steel shot). This composite structure provides sufficient weight for ballistic performance while maintaining surface flexibility to prevent penetration, resolving the contradiction between achieving lethal trajectory and avoiding harmful penetration.
Solution Approach 2:
The patent modifies the physical parameters of the projectile by controlling the durometer (hardness) of the polymer material to be between 20-80 Shore A, optimizing the balance between structural integrity and flexibility. Additionally, the weighting particle concentration is adjusted (typically 10-50% by weight) to achieve desired trajectory characteristics without compromising the non-lethal flexible surface property.
2Ease of operation
If springy or flexible coating is disposed to steel or hard materials, then the projectile can be formed with flexibility, but it can bounce and ricochet causing harm
Solution Approach 1:
The patent creates a homogeneous composite material where weighting particles are uniformly distributed throughout the flexible polymer matrix. This integration eliminates the interface between hard and soft materials that could cause stress concentration and ricochet, while the distributed weighting provides consistent trajectory control. The resulting monolithic structure maintains flexibility without the rebound issues of coated hard projectiles.
Solution Approach 2:
The patent applies local quality by concentrating the weighting particles throughout the projectile volume rather than as a surface coating, with the flexible polymer providing uniform matrix support. This distribution ensures that every region of the projectile contributes to both weight and flexibility, preventing localized hard spots that could cause unpredictable ricochet behavior while maintaining overall projectile flexibility for safe deformation upon impact.
3Ease of manufacture
If traditional non-lethal ammunition is manufactured, then production can proceed with conventional methods, but the performance variance and cost are high
Solution Approach 1:
The patent employs self-service manufacturing techniques where the flexible polymer matrix itself serves as the binding medium that naturally distributes and embeds the weighting particles during mixing and molding. This eliminates the need for separate coating operations, adhesive applications, or complex assembly steps, achieving both manufacturing simplicity and consistent particle distribution for uniform performance across all projectiles.
Solution Approach 2:
The patent utilizes composite material processing where weighting particles (tungsten, bismuth, or steel shot) are mixed into the flexible polymer matrix in a controlled ratio (10-50% by weight). This composite approach allows for consistent material properties and predictable ballistic performance while using readily available materials and standard polymer processing equipment, achieving both manufacturing ease and performance precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a more reliable and cost-effective non-lethal ammunition with reduced risk of penetration or ricochet, ensuring consistent performance and effective energy delivery over a range of 0-50 yards without penetrating ballistic gel at point-blank range.
Implementation Method 1
The projectile can be formed from a material including a bearing material and a weighting substance dispersed within the bearing material
Data Source
AI summary
A less-lethal projectile is disclosed herein. The less-lethal projectile can include a case having an interior; a powder charge located in the interior; and a projectile located in the interior, adjacent to the buffer, wherein the projectile is formed from a material that includes plastisol.