Abstract:
A non-lethal payload delivery assembly for use with a launching device having a non-lethal payload releasably contained in a carrier assembly. The carrier assembly being openable upon application of a deploying force to deploy the non-lethal payload after the carrier assembly and the non-lethal payload are launched as a unit from the launching device. An openable sabot assembly releasably contains the carrier assembly during before and during launch. The sabot assembly configured to absorb launch forces that exceed the strength of the carrier assembly alone independent of the sabot assembly. A payload deployment system connected to the carrier assembly is activatable after separation of the carrier unit from the sabot assembly following launch. The payload deployment system opens the carrier assembly for deployment of the non-lethal payload away from the carrier assembly and before reaching the target.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This non-provisional application claims priority to Provisional U.S. Patent Application No. 60/333,578, entitled SABOT-LAUNCHED DELIVERY APPARATUS FOR NON-LETHAL PAYLOAD, filed Nov. 27, 2001, hereby incorporated in its entirety by reference thereto. 
    
    
     BACKGROUND 
     Law enforcement and military personnel often use non-lethal weapons to help dissuade persons from engaging in unlawful or undesirable behavior. The non-lethal weapons used for this application, such as airborne irritant agents and shot-filled bags, typically deliver induced or inflicted discomfort. The non-lethal payload is contained in a carrier projectile, given flight impetus by some source of stored energy, accelerated in the barrel of the launching device, and then sent on an aerodynamic trajectory to the target. 
     While the actual non-lethal payload depends on its carrier projectile&#39;s kinetic energy to perform its mission, the projectile itself is not configured or intended to deliver blunt trauma. It is desirable for the carrier projectile to rapidly shed its kinetic energy upon release of the non-lethal payload. A projectile constructed from lightweight material will quickly shed kinetic energy, but it will not be able to withstand the forces of launch while in the barrel of the launching device. 
     SUMMARY OF THE INVENTION 
     Under one aspect of the present invention, a non-lethal payload delivery assembly is provided having a carrier assembly releasably contained in a sabot assembly. Under another aspect, a method for launching the non-lethal payload delivery assembly from the launching device while protecting the carrier assembly from the forces of launch is provided. In one embodiment, the non-lethal payload delivery assembly includes a carrier assembly that releasably contains a non-lethal payload. The carrier assembly is openable upon application of a deploying force to deploy the non-lethal payload after the carrier assembly and the non-lethal payload are launched as a unit. 
     The carrier assembly is releasably contained in a sabot assembly having a plurality of sections movable from a closed position substantially surrounding the carrier assembly to an open position exposing the carrier assembly upon launch from the launching device. The sabot assembly is configured to absorb launch forces that exceed the deploying force during launch and allowing the carrier assembly and the non-lethal payload to survive the launch as a unit. A payload deployment system is connected to the carrier assembly and is activatable after launch for delivery of the deploying force that opens the carrier assembly for deployment of the non-lethal payload away from the carrier assembly. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a schematic view of a non-lethal payload delivery system in accordance with one embodiment of the invention. 
     FIG. 2 is a side elevation of a non-lethal payload delivery assembly used with the system of FIG.  1 . 
     FIG. 3 is an enlarged isometric view of a partially unassembled portion of the non-lethal payload delivery assembly of FIG.  2 . 
     FIG. 4 is an enlarged isometric view of a carrier assembly of the non-lethal payload delivery assembly of FIG.  2 . 
     FIG. 5 is an enlarged cross-sectional view taken substantially along lines  5 — 5  of FIG. 2 showing the non-lethal payload delivery assembly. 
     FIG. 6 is a cross-sectional view of a non-lethal payload delivery assembly in accordance with an alternate embodiment of the invention. 
    
    
     DETAILED DESCRIPTION 
     The present disclosure describes apparatus and methods for launching a non-lethal payload and delivering the payload to a target area. In the following description, many specific details are set forth in order to provide a thorough understanding of various embodiments of the invention. One skilled in the art, however, will understand that the invention may be practiced without these details. In other instances, well-known structures associated with sabot-delivery systems have not been shown or described in detail to avoid unnecessarily obscuring the description of the embodiments of the invention. FIGS. 1-6 illustrate a system and components of the non-lethal payload delivery system in accordance with the embodiments of the present invention. Several of the components described below with reference to FIGS. 1-6 can also be used for performing methods in accordance with aspects of the present invention. Therefore, like references refer to like components and features throughout the various figures. 
     FIG. 1 is a schematic view of a non-lethal payload delivery system  10 , illustrating the various components of the system. The delivery system  10  includes a launching device  12  that launches a non-lethal payload delivery assembly  14  along a selected trajectory  16  toward a designated target  18 . The delivery assembly  14  includes a sabot assembly  20  adapted to be loaded into and launched from a barrel  21  of the launching device  12 . The sabot assembly  20  releasably contains and protects a carrier assembly  22  during the launch process. 
     The carrier assembly  22  carries a non-lethal payload  24  from the launching device  12  along the trajectory  16  to a selected location away from the target  18 . The carrier assembly  22  then ejects the non-lethal payload  24  for delivery to the target. The non-lethal payload  24  can be any one of several non-lethal devices, such as airborne irritant agents, shot-filled bags, foams, flash/bang grenades, rubber pellets, anti-traction agents, or the like. 
     FIG. 2 is an enlarged elevation view of the non-lethal payload delivery assembly  14  with the carrier assembly  22  shown in a nested position in the sabot assembly  20  and in a pre-firing configuration. In this pre-firing configuration, the sabot assembly  20  is adapted to protect the carrier assembly  22  and the non-lethal payload  24  (not visible), particularly during the launch. In the illustrated embodiment, the sabot assembly  20  includes an integral propulsion system  26  that drives the sabot assembly and the carrier assembly  22  out of the launching device  12  (FIG. 1) as a unit. 
     As best seen in FIGS. 2 and 3, the propulsion system  26  is received in and on a hollow, perforated shaft  28  of a tail boom  30  that forms a reward end portion  32  of the sabot assembly  20 . The tail boom  30  also includes a plurality of alignment fins  42  connected to the aft end of the shaft  28 . The alignment fins  42  help provide alignment of the sabot assembly  20  within the barrel  21  of the launching device. 
     The propulsion system  26  includes a conventional ignition cartridge  34  inserted into the perforated shaft  28 , and a horseshoe-shaped propellant increment  36  mounted onto a middle portion of the perforated shaft. The ignition cartridge  34  of the illustrated embodiment is similar to an M299 ignition cartridge used in various military applications. The propellant increment  36  is similar to an M205 horseshoe propellant increment, which is also used in military applications. The propulsion system  26 , when activated creates high-pressure propelling gasses within the barrel  21  of the launching device  12  (FIG. 1) to fire the non-lethal payload delivery assembly  14  out of the launching device as a unit. 
     The shaft  28  of the tail boom  30  is connected at its forward end to a cylindrical sealing feature  38  of the sabot assembly  20 . The sealing feature  38  is positioned forwardly adjacent to the propulsion system  26  and provides an aft driving surface  40  against which high-pressure propelling gasses from the propulsion system push during launch. The high-pressure propelling gases cause the sealing feature  38  to flare radially and substantially seal against the barrel  21  of the launching device  12  (FIG.  1 ). Accordingly, the sealing feature  38  prevents blow-by of the propelling gasses during launch from the launching device  12  (FIG.  1 ). 
     The sealing feature  38  of the sabot assembly  20  is pivotally connected to a plurality of parallel longitudinal sections, also referred to as sabot petals  44 . When the sabot assembly  20  is in the pre-fired configuration, the sabot petals  44  define an elongated cylindrical area that releasably contains the carrier assembly  22 . Accordingly, the sabot petals  44  surround and isolate the carrier assembly  22  from the launch environment within the barrel  21  of the launching device  12  (FIG. 1) when the propulsion system  26  is activated. The sabot petals  44  may be constructed of metal, plastic, or other material suitable to protect the carrier assembly  22  from launching forces created in the launching device  12  (FIG.  1 ). 
     As best seen in FIGS. 2 and 5, the aft ends  46  of the sabot petals  44  are pivotally connected to the sealing feature  38 , but the forward ends  48  are free and not integrally connected to each other. In the illustrated embodiment, the sabot petals  44  are banded together near the forward ends by a plurality of bands  50 . The bands  50  hold the sabot petals  44  in a closed, launching position, thereby enclosing the carrier assembly  22  within the sabot assembly  20  in an alternate embodiment, the sabot petals  44  can have integral breakable tabs interconnecting adjacent petals and holding the sabot petals in the closed position until the delivery assembly  14  is launched. The breakable tabs are configured to break and release the sabot petals after the delivery assembly  14  is fired from the launching device. 
     When the sabot petals  44  are in the closed, launching position, the forward ends  48  form an open, cup-shaped area  52  at the leading end of the sabot assembly  20 . When the propulsion system  26  is activated and the sabot assembly  20  and the carrier assembly  22  are fired from the barrel  21  (FIG. 1) of the launching device  12  (FIG.  1 ), the cup-shaped area  52  of the sabot assembly  20  acts to catch air therein. The air becomes substantially trapped in the cup-shaped area  52 , resulting in a significant pressure build up within the cup-shaped area. This pressure build up results in a radially outward force being exerted against the sabot petals  44 . 
     While the sabot assembly  20  is still in the barrel  21  of the launching device  12  (FIG.  1 ), the barrel holds the sabot petals in the closed, launching position around the carrier assembly  22 . Upon exit from the barrel  21  (FIG.  1 ), however, the sabot petals  44  are no longer confined by the barrel  21  to the closed, launching position. The bands  50  around the sabot petals  44  are elastomeric bands specifically designed to break when subjected to the radially outward forces encountered immediately after the sabot assembly  20  exits the barrel  21  (FIG.  1 ). The radial forces break the bands  50 , and the sabot petals  44  are then free to pivot in a flowering motion from the closed, launching position to an open, deploying position. In the illustrated embodiment, the sabot petals  44  each have a thin hinge portion  54  that connects the respective sabot petal to the sealing feature  38 . Accordingly, these hinge portions  54  provide the pivot points for the sabot petals  44  as they flare toward the open, deployed position, thereby facilitating the flowering action to deploy the carrier assembly  22  along its trajectory  16  (FIG. 1) toward the target  18 . 
     When the sabot petals  44  are in the open, deploying position, the carrier assembly  22  is fully exposed. The sabot assembly  20  has a much larger cross-sectional area in a plane substantially normal to the trajectory  16  (FIG.  1 ), and this larger cross-sectional area greatly increases the aerodynamic drag on the sabot assembly  20 , thereby rapidly decelerating the sabot assembly  20  immediately after launch. While the carrier assembly  22  exits the barrel  21  (FIG. 1) with substantially the same velocity as the sabot assembly  20 , the carrier assembly is not fixed to the sabot assembly and is not subjected to the same deceleration. Accordingly, the rapid deceleration of the open sabot assembly  20  allows for clean axial separation of the carrier assembly  22  from the sabot assembly. After separation, the open sabot assembly  20  drops harmlessly to the ground a short distance in front of the launching device  12  (FIG. 1) while the carrier assembly  22  continues on its trajectory  16  toward the target  18  for delivery of the non-lethal payload  24 . 
     FIG. 4 is an enlarged isometric view of the carrier assembly  22  shown separated from the sabot assembly  20  (FIG.  1 ). The carrier assembly  22  has a generally cylindrical body  56  that fully contains the non-lethal payload  24  in the illustrated pre-fired condition. The body  56  has a tapered nose section  58 , a tapered aft section  60 , and a plurality of molded aerodynamic stabilizing fins  62  integrally attached to the tapered aft section. The fins  62  provide stability to the launched carrier assembly  22  after the carrier assembly separates from the sabot assembly  20  (FIG.  1 ). In one embodiment, the fins  62  can have features such as a leading edge bevel that will induce slow rolling or spining of the carrier assembly  22  about its longitudinal axis during flight to increased the carrier assembly&#39;s in-flight stability. 
     The body  56  and stabilizing fins  62  of the carrier assembly  22  of the illustrated embodiment are fabricated of a molded fiber material configured for stable, accurate aerodynamic flight. The molded fiber material, however, is not strong enough by itself to withstand the forces of launch within the launching device  12  (FIG.  1 ). Accordingly, the sabot assembly  20  described above isolates the carrier assembly  22  from the launch environment. The molded fiber material used for the carrier assembly  22  for the illustrated embodiment is manufactured by Armtec Defense Products, of Coachella, Calif. In this embodiment, the body  56  and stabilizing fins  62  of the carrier assembly  22  have a one-piece molded configuration molded around the non-lethal payload  24 , although alternate embodiments can have a multi-piece configuration. 
     The carrier assembly  22  of the illustrated embodiment is adapted to open and deploy the non-lethal payload  24  when the carrier assembly is at a selected position along the trajectory  16  (FIG. 1) so that only the non-lethal payload reaches the target  18 . As best seen in FIGS. 4 and 5, the carrier assembly  22  includes a payload deployment system  64  contained within the molded body  56 . The payload deployment system  64  includes a nose-section radar  66  contained in the tapered nose section  58  and coupled to a microelectronic control system  68  contained near the tapered aft section  60 . The microelectronic control system  68  is also coupled to a fusing system  70  adapted to activate a plurality of linear-shaped charges  72  mounted along the inside surface of the molded body  56 . The fusing system  70  of the illustrated embodiment is an airburst fusing system substantially identical to the M734 multifunction fuse used in various military applications, although other fusing devices can be used in alternate embodiments. 
     The fusing system  70  is a “safe and arm” fusing system that does not activate the nose-section radar  66  until certain input criteria are met. For example, the fusing system  70  can include input sensors that monitor such things as acceleration forces, sabot discard, spin of the carrier assembly  22 , and/or elapsed time from launch. Once the input criteria are satisfied, the nose-section radar  66  is activated and sends selected data to the microelectronic control system  68 . The microelectronic control system  68  interprets the data from the nose-section radar  66 , and when predetermined conditions are satisfied, the control system activates a fuse that ignites the linear-shaped charges  72 . In the illustrated embodiment, the fusing system  70  includes a proximity fuse activated when the nose-section radar  66  senses that the carrier assembly  22  is at a selected height above the ground, although other activating criteria could be used. 
     The linear-shaped charges  72  are a series of small explosive charges that, when ignited, perforate and open the body  56  of the carrier assembly  22  to expose and deploy the non-lethal payload  24 . The air pressure and increased aerodynamic drag on the open perforated sections cause at least the body  56  of the molded fiber carrier assembly  22  to be shredded virtually instantly into a plurality of irregularly-shaped, light-weight remnant pieces. These remnant pieces will have a high aerodynamic drag, thereby resulting in very rapid deceleration and loss of kinetic energy. Accordingly, the remnant pieces will fall harmlessly to the ground away from the target  18  (FIG. 1) while the non-lethal payload  24  continues along the trajectory  16  to the target. 
     FIG. 6 is a cross-sectional view of the non-lethal payload delivery assembly  14  in accordance with an alternate embodiment of the invention. In this alternate embodiment, the reward end portion  32  of the sabot assembly  20  includes the tail boom  30  with the hollow shaft  28  that receives the ignition cartridge  34  and the propellant increment  36 . The tail boom  30 , however, does not include stabilizing fins as in the embodiment described above. The sabot assembly  20  maintains sufficient alignment within the barrel  21  of the launching device (FIG. 1) via the sealing feature  38  that flares into sealable engagement with the barrel during launch. In addition, the bands  50  around the sabot petals  44  are shaped and sized to slidably engage the inside surface of the barrel  21  when the sabot assembly  20  is inserted for launch. Accordingly, the bands  50  also help maintain axial alignment with the barrel  21  until the sabot assembly  20  exits the barrel, flowers and separates from a molded fiber carrier assembly  100  protectively contained therein. 
     The carrier assembly  100  in this alternate embodiment also has a slightly different configuration from the carrier assembly in the embodiment described above. The carrier assembly  100  has a generally bullet-shaped body portion  102  with a substantially flat aft end  104 . A plurality of stabilizing fins  106  are connected to the body&#39;s flat aft end  104  to provide aerodynamic stability to the carrier assembly  100  in flight along the trajectory  16  (FIG.  1 ). A layer of energy absorbent material  108  is positioned between ends of the stabilizing fins  106  and the sealing feature  38  of the sabot assembly  20 . The layer of energy absorbent material  108  helps isolate the carrier assembly  100 , particularly at the stabilizing fins  106  and the body&#39;s flat aft end  104 , from acceleration loads, known in the industry as “set back,” upon launch from the launching device  12  (FIG.  1 ). 
     From the foregoing, it will be appreciated that specific embodiments of the invention have been described herein for purposes of illustration, but that various modifications may be made without deviating from the spirit and scope of the invention. Accordingly, the invention is not limited except as by the appended claims.