Solid Metallic Thread Extrusion for Conductive Energy Delivery
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Solution Overview
Problem
Existing non-lethal conducted energy devices (CEDS) or conductive energy weapons (CEWS) have limitations such as limited shot capacity, accuracy issues due to wire tugging, restricted range, potential for permanent injury, and high costs associated with electricity delivery systems.
Innovation Solution
A device that extrudes multiple metallic threads at temperatures below their melting point, using a pressurization system to achieve velocities of up to 160 feet per second, and delivers non-lethal electrical energy through these threads to incapacitate targets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional CEDS use darts with insulated wires propelled by gunpowder or spring drives, then the device can deliver electrical current to a target, but the random tugging of wires causes darts to miss the target and the effective range is limited to 15-30 feet
Solution Approach 1:
The patent replaces the mechanical spring drive system with a pneumatic or hydraulic pressurization system that forces conductive material through an orifice. This substitution eliminates the random tugging and mechanical complexity of dart propulsion, providing more reliable and accurate delivery of conductive material to the target while extending effective range beyond 15-30 feet.
Solution Approach 2:
The patent extracts and eliminates the dart component entirely, using only the conductive material delivery mechanism. By removing the dart and its associated propulsion system, the invention eliminates the source of random tugging and accuracy problems while maintaining the core function of delivering electrical current to the target.
2Reliability
If CEDS use liquid or molten conductive beams, then the device can deliver current to a target, but ionic conductors have too much resistivity to carry the required peak currents
Solution Approach 1:
The patent changes the physical state parameter of the conductive material from liquid or molten (ionic) form to solid metallic form. This parameter change dramatically reduces resistivity, enabling the material to carry the high peak currents required for effective CED operation while maintaining reliability.
Solution Approach 2:
The patent uses solid metallic conductive material that combines low resistivity with the ability to be pressurized and extruded through an orifice. This material selection optimizes both current carrying capacity and deliverability, overcoming the limitations of ionic conductors.
3Productivity
If alloy reservoirs are maintained at elevated temperature in standby mode, then the device can quickly extrude conductive material, but a significant amount of energy is required to compensate for heat loss
Solution Approach 1:
The patent performs preliminary action by pre-forming solid metallic conductive material into an extrudable state at ambient temperature. This eliminates the need for continuous heating during standby, significantly reducing energy consumption while maintaining the ability to quickly extrude material when needed through pressurization alone.
Solution Approach 2:
The patent uses solid metallic material that can be stored indefinitely at ambient temperature without degradation or energy input. This disposable-style approach to material storage eliminates ongoing energy costs associated with maintaining molten or elevated temperature reservoirs.
4Temperature
If hand-held device volume is increased for insulation, then thermal energy can be maintained, but portability is compromised
Solution Approach 1:
The patent changes the operating temperature parameter from elevated/molten to ambient/solid state. This parameter change eliminates the need for significant insulation volume, keeping the hand-held device compact and portable while still enabling effective conductive material delivery through pressurization.
5Ease of operation
If molten metal threads are extruded, then the material can flow easily, but the threads break up by Rayleigh instability
Solution Approach 1:
The patent changes the material state from molten to solid, and adjusts the extrusion parameters (pressure, temperature, orifice size) to enable solid metallic material to be extruded as stable threads. This parameter optimization prevents Rayleigh instability while maintaining adequate flow and extrusion capability.
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 efficient, cost-effective, and versatile means of delivering non-lethal electrical energy with increased range and accuracy, reducing the risk of permanent injury and allowing for the incapacitation of multiple targets with a single thread.
Implementation Method 1
pressurizing a reservoir of metallic conductor initially at a temperature below its melting point. The method includes flowing the metallic conductor through an orifice to form a continuous thread with axial velocity
Implementation Method 2
The pressure and shear force through the extrusion tip sufficiently heat the material into a malleable state and transforms the larger solid metal material into a thread
Implementation Method 3
deliver electrical energy to an object through the plurality of metallic wires. The method further includes applying a potential differential along the thread so that current flows between the reservoir and the remote target
Data Source
AI summary
A method of delivering charge to a remote target includes pressurizing a reservoir of metallic conductor initially at a temperature below its melting point. The method includes flowing the metallic conductor through an orifice to form a continuous thread with axial velocity, so that a user might direct the axial velocity of the thread to intercept the remote target. The method further includes applying a potential differential along the thread so that electrical current flows between the reservoir and the remote target.