Abstract:
A replaceable cartridge is provided for insertion into a diversionary device. The cartridge includes a housing with a first chamber containing an ignitable composition. A breakable seal covers a first end of the first chamber. The cartridge also includes a piston within the housing and having a first position at a second end of the first chamber. The piston is movable towards the second end of the first chamber whereby, when a trigger for the diversionary device is activated, the piston moves towards the first end of the first chamber to discharge the ignitable composition through the breakable seal for subsequent ignition outside of the diversionary device.

Description:
RELATED APPLICATION DATA 
       [0001]    The present application is related to commonly-assigned and co-pending U.S. application Ser. No. 12/268,574, entitled DIVERSIONARY DEVICE WITH VERTICALLY DEPLOYED PAYLOAD, Ser. No. 12/268,595, entitled SHOCK-STABILIZED FIRING MECHANISM FOR DIVERSIONARY DEVICE, Ser. No. 29/327,668, entitled DIVERSIONARY DEVICE, and Ser. No. 29/327,670, entitled DIVERSIONARY DEVICE, all filed on the filing date hereof, which applications are incorporated herein by reference in their entireties. 
     
    
     TECHNICAL FIELD 
       [0002]    The present invention relates generally to diversionary devices, also known as stun grenades and flash-bang grenades and, in particular, to [a diversionary device in which the payload is vertically deployed and ignited above the device] [a replaceable cartridge for a diversionary device containing an explosive powder] [a shock-stabilized firing mechanism for a diversionary device]. 
       BACKGROUND ART 
       [0003]    Diversionary devices are used in a variety of military and law enforcement situations. Specifically, the device is intended to disorientate an adversary without inflicting permanent damage or harm. The device accomplishes this by producing a disorientating flash of light and a confusingly loud noise. Devices of this sort are often referred to as “stun grenades” or “flash-bang grenades.” 
         [0004]    For example, a diversionary device might be used by a police SWAT team during a sniper situation. After forcing open the door to the room in which the sniper is located, one of the team members will toss or roll a diversionary device into the room close to the suspect. After a brief delay, the device goes off, producing a bright flash that temporarily blinds and a loud noise that temporarily deafens the suspect. The effects of the flash and noise last only a second or two which is enough for the SWAT team to rush into the room and subdue the suspect. 
         [0005]    While the concept is sound in theory, in practice conventional diversionary devices have a number of disadvantages. Conventional diversionary devices may be inherently unstable and subject to accidental or premature detonation, especially when thrown. The devices typically contains a metal powder that violently combines with an oxidizer. The resulting explosion occurs within the body of the device and creates a zone of extreme pressure. This overpressure may blow out windows and shred furniture. In addition, the explosion creates significant heat which can cause furniture and other items to burn and can even cause a major fire. Because conventional diversionary devices are typically cylindrical with dispersion ports at one or both ends, the explosive force and heat is substantially non-directional. Moreover, the explosion may also result in a recoil reaction by the device, causing it to shoot rapidly in an unpredictable direction. It will be appreciated, therefore, that the use of a diversionary device may result in serious injury to the user or to the suspect. In fact, numerous injuries have been documented to police and military personnel as well as to suspects, with the latter also resulting in costly litigation against jurisdictions. 
       SUMMARY OF THE INVENTION 
       [0006]    The present invention provides a replaceable cartridge for insertion into a diversionary device. The cartridge includes a housing with a first chamber containing an ignitable composition. A breakable seal covers a first end of the first chamber. The cartridge also includes a piston within the housing and having a first position at a second end of the first chamber. The piston is movable towards the second end of the first chamber whereby, when a trigger for the diversionary device is activated, the piston moves towards the first end of the first chamber to discharge the ignitable composition through the breakable seal for subsequent ignition outside of the diversionary device. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]      FIG. 1A  is one perspective view of one embodiment of the diversionary device of the present invention; 
           [0008]      FIG. 1B  is another perspective view of the diversionary device; 
           [0009]      FIG. 1C  is an end view of the diversionary device; 
           [0010]      FIG. 1D  is a side view of the diversionary device; 
           [0011]      FIG. 1E  illustrates the diversionary device with the sections pulled apart while being cocked; 
           [0012]      FIG. 2  is an exploded view of components within the housing of the diversionary device; 
           [0013]      FIGS. 3A and 3B  are perspective views of a trigger assembly of the present invention; 
           [0014]      FIGS. 3C and 3D  are exploded views of the trigger assembly; 
           [0015]      FIG. 4A  is a perspective view of a cartridge of the present invention; 
           [0016]      FIG. 4B  is an exploded view of components of the cartridge; 
           [0017]      FIG. 4C  is a cut-away view of the cartridge housing; 
           [0018]      FIG. 4D  is illustrates a primer mount used in the cartridge; 
           [0019]      FIG. 5A  is a perspective view of the dispersion end of diversionary device; 
           [0020]      FIG. 5B  is an exploded view of the rear section of the diversionary device; 
           [0021]      FIG. 5C  illustrates the diversionary device in an unlatched position with a cartridge to be loaded; and 
           [0022]      FIG. 6  illustrates the device on a floor with the cloud igniting above it. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0023]    The described features, structures or characteristics of the invention may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention can be practiced without one or more of the specific details, or with other methods, components and so forth. In other instances, well-known structures, materials or operations are not shown or described in detail to avoid obscuring aspects of the invention. Furthermore, for clarity a component may be described as being “secured” or “attached” or “connected” to another component. However, it will be understood that other, intermediate, components may be used and that the described connections may be functional connections rather than necessarily being direct physical connections. 
       Housing 
       [0024]      FIGS. 1A and 1B  are perspective views of one embodiment of the housing  100  of the diversionary device of the present invention while  FIGS. 1C and 1D  are end and side views, respectively, of the housing. For purposes of convenience in describing the device  100 , one of the two largest or primary surfaces of the housing  102  will be considered the “top” surface or side and the opposite surface  104  will be considered to be the “bottom” surface or side, with the length L of the device being parallel to a first axis x-x. Similarly, one of the two smallest surfaces  106 , in planes orthogonal to the first and second primary sides will be considered to be the “front” end and the opposite surface  108  will be considered to be the “rear” end, with the width and height of the device being parallel to second and third axes y-y and z-z, respectively. And, of the two intermediate-sized surfaces of the housing  100 , orthogonal to the first and second primary sides  102 ,  104  and to the front and rear ends  106 ,  108 , one such surface  110  will be considered to be the “right” side and the opposite surface  112  will be considered to be the “left” side. It will be appreciated, however, that functionally, the designations “top,” “bottom,” “front,” “rear,” “left” and “right” are arbitrary and used herein only for description purposes. 
         [0025]    A rear section  500  of the housing  100  includes a circular dispersion port  502 A in the top surface  102  and another circular dispersion port  502 B in the bottom surface  104 , aligned with each other and centered on an axis parallel to the z-z axis. The length L of the device  100  is greater than the height H and the width W. The dimensions L, H and W are selected such that, when the device is thrown or rolled into a room or other area, it will come to rest on either the top  102  or bottom  104  side with one or the other of the dispersion ports  502 ,  504  facing upwards. Additionally, a slim profile enables the device to be more easily stored and carried. By way of example only, in one embodiment L=8 inches, H=1.5 inches and W=2.75 inches. It will be appreciated that the scope of the claims is not limited to these dimensions but that other dimensions will provide the benefit of the device coming to rest on the top or bottom surfaces when thrown or rolled. 
         [0026]    An opening in the left side  112  of the housing  100  permits a trigger bar  114  to slide parallel to the x-x axis from a locked position (towards the front  106 ), in which the diversionary device is prevented from activating, to a ready position (towards the rear  108 ), which releases a hammer block and permits a trigger mechanism to operate, as will be explained in detail below. An opening in the right side  110  of the housing  100  permits a slide switch  116  to activate a timer, as will also be explained below. 
         [0027]    The housing  100  may be constructed of any appropriate material although it is preferred that the material be lightweight. The housings of conventional diversionary devices are typically constructed of steel. While relatively strong, repeated use weakens the metal to such an extent that the number of reloads that is allowed is limited to prevent dangerous cracking or breaking. In contrast, in one embodiment of the diversionary device of the present invention, the housing  100  is constructed from aluminum. As illustrated in  FIG. 1E , the device is cocked by pulling two spring-loaded sections A and B away from each other, then releasing it, moving internal components from a safe position into a cocked position. The double-headed arrow and bracket  10  in  FIG. 1E  indicate the approximate amount by which the two sections A and B are separated. Consequently, it is preferable that the housing include a gripping area  118  at least partially around the housing  100  near the front end  106  to aid cocking the device. Channels (such as those shown in  FIGS. 1A and 1B ), ridges or the like may also be formed in, on or around the outside of the housing for easier handling. 
         [0028]    One feature of the diversionary device of the present invention is the ability to accept a removable cartridge into the housing (such as illustrated in  FIG. 4A ). The cartridge contains ignitable powder, primer and, in some embodiments, an oxidizer to enhance the flash and batteries to power the device. The ignitable powder may comprise powdered aluminum and the oxidizer comprise potassium perchlorate. It will be appreciated that other powders and oxidizers that affect the brightness and loudness may be used. To accommodate the cartridges, the rear section  500  opens, such as with a hinge  516 , as illustrated in  FIG. 5C  and may be closed and secured to the rest of the housing  100  with a pull knob  518  capable of being screwed down, or otherwise secured, to the housing  100 . 
         [0029]      FIG. 2  is an exploded view of the components of the diversionary device within the housing  100 . Shown are the rear section  500 , the firing mechanism  300 , the trigger bar  114  and a timing circuit board  202  to which the slide switch  116  is attached. 
       Firing Mechanism 
       [0030]      FIGS. 3A and 3B  are perspective views of the firing mechanism  300  of the diversionary device of the present invention and  FIGS. 3C and 3D  exploded views. The firing mechanism includes a base or carrier  302  to which other components are directly or indirectly attached. A rotary solenoid  304  secured to a platform on the carrier  302  has a shaft (not shown) which rotates in an axis which is parallel to the x-x axis of the housing  100 . Secured to the underside of the carrier  302  is a second printed circuit board  306  on which are mounted the trigger switch  308  and cutoff switch  310 . The second printed circuit board  306  includes a first set of terminals which contact a power source in a removable cartridge and a second set of terminals which are electrically connected to corresponding terminals on the solenoid  304  to provide power thereto. The second printed circuit board  306  also includes a third set of terminals which are electrically connected to corresponding terminals on the first printed circuit board  202  to provide power thereto. When the device is not cocked, the cutoff switch  310  is in an open state (safe position), preventing the flow of current from the power source to the timing circuit board  222 . When the device is cocked, the cutoff switch  310  is in a closed state. After the trigger switch  308  is released, current is allowed to flow to the timing circuit board  222 , activating the rotary solenoid at the end of the predetermined timing delay. 
         [0031]    Secured to the shaft of the rotary solenoid  304  is a cam  312 . Instead of being secured directly to the shaft, the cam  312  may be secured to a turntable or other intermediate component(s) which is (are) secured to the shaft. 
         [0032]    The firing mechanism  300  also includes a firing pin  314  positioned adjacent to the solenoid/cam assembly  304 / 312  and parallel to the x-x axis of the housing  100 . The firing pin  314  is hingably connected to a spring-loaded prop or link arm  316  which, in turn, is hingably connected to a trip lever  318 . The side of a top portion of the cam  312  facing the firing pin  314  and trip lever  318  has a diagonal cutout  313  into which a cam follower  320 , secured to the trip lever  318 , fits. Thus, when the rotary solenoid  304  is activated, the end of the trip lever  318  to which the cam follower  320  is attached is forced downward relative to the cam  312  while the opposite end of the trip lever  318  maintains a pivot point. This motion causes the spring-loaded prop  316  to release downward, in turn forcing the firing pin  314  downward also in a direction which is substantially orthogonal to the x-x axis from a cocked position to a fired position. The weight of a hammer  322  adds to the force with which the firing pin  314  moves. In one embodiment, the firing pin  314  directly or indirectly strikes a firing pin which, in turn, strikes one or more primers which accelerate pistons within the removable cartridge to begin the process of forcing an ignitable powder out of the cartridge. In the embodiment illustrated in  FIG. 3 , a splitter  324  is connected to or struck by the firing pin  314  which strikes primers to accelerate two parallel pistons in the cartridge, one piston to force the ignitable powder out of the cartridge and the other to force an oxidizer out of the cartridge to enhance the effects of the diversionary device. In another embodiment, the firing pin pierces a gas cylinder which releases gas to accelerate the pistons. 
         [0033]    Because the motion of the rotary solenoid  304  is orthogonal to the motion of the firing pin  314 , the firing mechanism  30  is unlikely to be accidentally activated. To further enhance the safety of the device, the firing mechanism  300  also includes a hammer block  326  which prevents accidental motion of the firing pin  314 . One end of the hammer block  326  fits into a vertical slot  328  in the firing pin  314  and is biased away from the firing pin  314 . The end of the hammer block  326  is maintained within the slot  328  in a safe position as long as the trigger bar  114  is in its forward locked or safe position. Sliding the trigger bar  114  away from the locked position towards the rear  108  of the housing, releases the hammer block  326  which disengages from the firing pin  314 , allowing the firing pin  314  to move downward when the rotary solenoid  304  is activated. 
       Removable Cartridge 
       [0034]      FIG. 4A  is a perspective view of a removable cartridge body  400  which is inserted into the housing  100  when the end section  500  is opened,  FIG. 4B  is an exploded view of the components within the cartridge body  400 ,  FIG. 4C  is a cut-away view of the cartridge body  400  and  FIG. 4D  illustrates a primer mount  420  used in the cartridge body  400 . The cartridge body  400  includes two sets of cylindrical chambers  402 A,  402 B and  404 A,  404 B formed therein. The chambers  402 A,  402 B in the first set are parallel to each other and formed partway through the front portion of the cartridge body  400  (the front and rear of the cartridge corresponding to the front  106  and rear  108  of the device housing  100 ) while the chambers  404 A,  404 B of the second set are parallel to each other and formed partway through the rear portion of the cartridge body  400 . One or more batteries  406 A,  406 B may be installed in the first chambers  402 A,  402 B and used to power the diversionary device when the cartridge  400  is inserted into the housing  100 . It will be appreciated that the scope of the present invention does not depend upon the number of batteries used or their electrical capacity. 
         [0035]    The chambers  404 A,  404 B of the second set serve to hold the ignitable powder and the oxidizer, respectively. A piston  408 A,  408 B is positioned at the front of each chamber  404 A,  404 B. A cover plate  410  is secured to the rear end of the cartridge body  400 . In one side of the cover plate  410 , in line with one chamber  404 A and the first piston  408 A, is a circular opening  412 . In the other side of the cover plate  410 , in line with the other chamber  404 B and the second piston  408 B, is another, smaller circular opening  414  surrounded by further small circular openings  416 . A breakable material  418 , such as foil, provides a seal between the cover plate  410  and the cartridge body  400  to retain the powder and oxidizer within their respective chambers. Secured to the inside of the cover plate  410  is a primer mount  420  having a small, circular opening  422  formed therethrough in line with the central small opening  414  in the cover plate  410 . This central opening  422  is surrounded by further small openings  424  (not all of which are labeled in  FIG. 4D ) in line with the surrounding openings  416  through the cover plate  410 . Primers  426  are fitted inside each of the surrounding openings  422  against the breakable seal  418  and small firing pins  428  are then fitted into the openings  422 , protruding out of the openings  422  (not all of the primers and firing pins are labeled in  FIG. 4D ). 
         [0036]    The cartridge body  400  also includes a third set of parallel chambers  430 A,  430 B in which two primer tubes  432 A,  432 B are fitted. Shotgun primers  434 A,  434 B, or comparable devices, are fitted into the front ends of the primer tubes  422 A,  432 B and are ignited when the firing pin  314  (or splitter  324 ) strikes them. The resulting detonations force the pistons  408 A,  408 B rearward towards the cover plate  410 . The first piston  408 A forces the ignitable powder through the larger opening  412  of the cover plate  410  and through the breakable seal  418 , into the rear section of the housing  100  and out one of the dispersion ports  502 A,  502 B, depending on the surface upon which the housing  100  is resting. 
         [0037]    The second piston  408 B forces the oxidizer through the small, central opening  422  in the cover plate  410  and through the breakable seal  418 , into the rear section of the housing  100  and out one of the dispersion ports  502 A,  502 B. The second piston  408 B also strikes the firing pins  428  which ignite the primers  426  whose ignition breaks the breakable seal  418  through the surrounding openings  416 . 
         [0038]    Preferably, the second piston  408 B is heavier than the first piston  408 A so that it moves more slowly. Thus, there is a slight delay, such as about 10 milliseconds for example, after the ignitable powder and oxidizer have been discharged out of the cartridge  400  and before the primers ignite. The delay allows the ignitable powder and oxidizer to mix and form a cloud outside and above the diversionary device before being ignited. 
       Dispersion Ports 
       [0039]      FIG. 5A  is a perspective view and  FIG. 5B  is an exploded view of the rear section  500  of the diversionary device. The rear section  500  includes an end cap or bumper  504 , which preferably is a rubberized or other protective material, and a nozzle body  506 . The nozzle body  506  has a circular opening  502  formed therethrough parallel with the z-z axis of the housing  100 . The two ends of the opening  502  comprise the dispersion ports  502 A,  502 B. The inner end of the nozzle body  500  also has a cutout  508  which intersects the opening  502 . To accommodate a removable cartridge with chambers for both an ignitable powder and an oxidizer, the cutout  508  may be oblong in the direction of the y-y axis. A strike plate  510  is secured to the inner end of the nozzle body  506 . The strike plate  510  has two circular openings formed therethrough which align with the ends of the powder and oxidizer chambers  404 A,  404 B, thus allowing the contents of the chambers  404 A,  404 B to be discharged into the nozzle body and out of one of the two dispersion ports  502 A,  502 B. Preferably, the opening which aligns with the oxidizer chamber  404 B is offset from the dispersion ports. As the oxidizer is discharged from the oxidizer, it is forced 90 degrees to the dispersion port. The rapid turn slows the oxidizer and creates turbulence, promoting high-speed mixing with the powder. 
         [0040]    As previously noted, the diversionary device of the present invention will come to rest on one of the two primary surfaces of the housing  100 , either the top surface  102  or the bottom surface  104 . The rear section  500  also includes a ball  512  within the opening  502 . The ball  512  is kept within the opening  502  by retaining plates or grills  514 A,  514 B secured to the nozzle body  506  at the dispersion ports  502 A,  502 B, respectively. When the diversionary device is at rest on one of the two primary surfaces  102 ,  104 , gravity causes the ball  512  to fall into what is then the lower part of the opening  502 ; that is, the part closest to the ground. The ball  512  then acts as a seal to prevent the ignitable powder and oxidizer from discharging out of what is the lower dispersion port. The powder and oxidizer, therefore, are forced out of what is then the upper dispersion port to form a cloud above the diversionary device and be ignited ( FIG. 76 ). While other methods of sealing the lower dispersion port may be used, the ball  512  has the advantage of being relatively inexpensive to manufacture and is capable of withstanding the high temperatures and pressures which occur when the device is used. 
         [0041]    To replace a cartridge, the rear section  500  may be completely removable from the main housing body  100  or may be opened on a hinge  516 , as illustrated in  FIG. 5C , and then secured with a pull-knob and screw  518  after the cartridge has been inserted. 
         [0042]    The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiment was chosen and described in order to best explain the principles of the invention, the practical application and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.