Cast Polymer Composite Projectile with Embedded Penetrators
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional metallic ballistic projectiles are costly, environmentally problematic due to lead content, and limited in supply, with manufacturing complexities that hinder embedding of features like penetrators and electronics.
Innovation Solution
Cast polymer composite projectiles made from a thermoset resin and powdered metal, allowing for the incorporation of penetrators, fragmentation structures, and micro-electronics, using simple and cost-effective manufacturing methods that eliminate the need for copper and lead, and enable precise replication of shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional metallic projectiles are used, then penetration capability is achieved, but cost and environmental harm increase due to copper and lead content
Solution Approach 1:
The patent uses a composite material consisting of thermoset resin and powdered metal (such as iron, steel, or tungsten) to create a projectile body that eliminates the need for toxic lead and copper while maintaining structural integrity and penetration capability. The composite structure allows the powdered metal particles to provide density and strength, while the thermoset resin matrix binds them together and provides structural continuity.
2Ease of manufacture
If metallic components are used in projectiles, then traditional manufacturing is simplified, but embedding features like penetrators and electronics becomes difficult
Solution Approach 1:
The patent incorporates penetrators, fragmentation structures, and electronic components into the projectile during the molding process itself, before the final product is completed. The mold cavity is designed to hold these embedded features in their correct positions, and the thermoset resin composite is then molded around them, securing them in place. This preliminary embedding eliminates the need for separate assembly steps and ensures proper positioning.
Solution Approach 2:
The use of thermoset resin as a binding matrix provides a versatile medium that can easily accommodate and secure various embedded features such as metal penetrators, electronic components, and fragmentation structures. The resin's ability to flow into mold cavities and then固化 into a rigid structure allows for complex internal geometries and embedded features that would be difficult to achieve with traditional metallic construction methods.
3Strength
If semi-precious metals like copper are used, then projectile performance is improved, but manufacturing cost increases considerably
Solution Approach 1:
The patent changes the material composition parameters by replacing expensive semi-precious metals like copper with more cost-effective powdered metals such as iron, steel, or tungsten. The thermoset resin matrix compensates for any potential performance differences, allowing the use of cheaper metal powders while maintaining overall projectile performance through the composite structure.
Solution Approach 2:
The composite structure allows the use of inexpensive powdered metals that would not perform adequately as pure metals. The thermoset resin matrix provides structural support and binds the powdered metal particles together, creating a composite material that achieves the required mechanical properties and performance at a lower cost than traditional copper-based projectiles.
4Strength
If lead is used as the main component, then projectile density and performance are maintained, but supply limitations and environmental issues arise
Solution Approach 1:
The patent changes the chemical composition by replacing lead with alternative materials - specifically powdered metals (iron, steel, tungsten) combined with thermoset resin. This substitution maintains the required density and performance characteristics through the composite structure while eliminating dependence on lead supply chains and avoiding environmental contamination from lead.
Solution Approach 2:
The composite material combines powdered metal particles with thermoset resin to create a projectile that achieves the necessary density and mechanical properties without using lead. The powdered metal provides density and strength, while the resin matrix provides structural continuity and binding, creating a lead-free alternative that performs equivalently to traditional lead-based projectiles.
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 projectiles with enhanced penetration and fragmentation capabilities, reduced collateral damage, and the ability to embed features like penetrators and electronics, while being lighter and more cost-effective, addressing supply limitations and environmental concerns.
Implementation Method 1
curing the polymer composite at a predetermined temperature and a predetermined pressure for a predetermined duration
Data Source
AI summary
Embodiments of a projectile are provided herein. In some embodiments, a projectile includes a body made of a cast polymer composite material comprising a thermoset resin and a powdered steel. In some embodiments, a projectile includes: a body made of a cast polymer composite material comprising a thermoset resin and a powdered metal; a metal core embedded in the body having a front portion that tapers radially inward to define a front end of the projectile; and a casing assembly coupled to the body.