Systems, methods and apparatus for use in distributing irritant powder

The present embodiments provide apparatuses for use in launching an inhibiting powder. These embodiments comprise a source of impulse pressure that induces a propellant pressure, a barrel cooperated with the source of impulse pressure to receive the propellant pressure, inhibiting powder positioned within an interior of the barrel, a burst diaphragm secured between the source of the impulse pressure and the inhibiting powder, and an actuator that activates the source of impulse pressure to deliver an expanding gas producing an increasing pressure that is applied to the burst diaphragm where the burst diaphragm bursts when the applied pressure exceeding a burst threshold, resulting in a release of the propellant pressure into the barrel to drive the inhibiting powder from the barrel in substantially an aerosol form generating a cloud of inhibiting powder.

FIELD OF THE INVENTION

The present invention relates generally to irritant powders, and more particularly to methods and systems of dispersing irritant powders.

BACKGROUND

For several decades, Law Enforcement agencies have used various non-lethal weapons to gain control of suspects, quell riots, save hostages, and the like. Many of these non-lethal weapons typically require a large launcher platform such as a shotgun, rifle or pistol to deploy projectiles. These generally large platforms can make the use of these launchers cumbersome in some circumstances.

To date, other than pepper spray, the general public typically has not had access to a simple, low cost, non-lethal projectile launcher. Further, there are generally no non-lethal projectile launchers that are easily carried and used for personal defense at home, in the car or when on foot.

SUMMARY OF THE EMBODIMENTS

The present invention advantageously addresses the needs above as well as other needs through the provision of the method, apparatus, and system for use in launching loose powder to generate a powdered cloud. Some embodiments provide apparatuses for use in launching an inhibiting powder. These embodiments comprise a source of impulse pressure that induces a propellant pressure; a barrel cooperated with the source of impulse pressure to receive the propellant pressure; inhibiting powder positioned within an interior of the barrel; a burst diaphragm secured between the source of the impulse pressure and the inhibiting powder; and an actuator that activates the source of impulse pressure to deliver an expanding gas producing an increasing pressure that is applied to the burst diaphragm where the burst diaphragm bursts when the applied increasing pressure exceeding a burst threshold of the burst diaphragm, where the bursting of the burst diaphragm results in a release of the propellant pressure into the barrel to drive the inhibiting powder from the barrel in substantially an aerosol form generating a cloud of inhibiting powder extending from an exit end of the barrel and out a distance from the exit end of the barrel.

Other embodiments provide launch systems. At least some of these launch systems comprise a frame; a source of impulse pressure cooperated with the frame; a barrel secured relative to the frame and cooperated with the source of impulse pressure to receive a propellant pressure from the source of impulse pressure; powder load positioned within an interior of the barrel, the powder load comprising a powdered inhibiting substance; a burst diaphragm secured between the source of the impulse pressure and the powder load, wherein the burst diaphragm retains the impulse pressure from the source of impulse pressure until a pressure of about equal to a burst threshold of the burst diaphragm such that the burst diaphragm bursts releasing a propellant pressure into the barrel to drive the powder load from the barrel in substantially an aerosol form generating a powder cloud of powder load extending from a exit end of the barrel.

Some embodiments provide methods of providing an individual with protection. These methods activate, in response to an actuation, a source of impulse pressure; launch loose powder from a launch system; and generate a powder cloud comprising the loose powder that has dimensions larger than a human torso.

A better understanding of the features and advantages of the present invention will be obtained by reference to the following detailed description of the invention and accompanying drawings which set forth an illustrative embodiment in which the principles of the invention are utilized.

DETAILED DESCRIPTION

The present embodiments provide a launching system or device that when activated expels a cloud of irritant powder towards a target, such as a threatening target, as a means of non-lethal defense and/or for subduing a target. This irritant cloud may have a distracting, incapacitating and/or repelling effect on the target, be it a human or animal. The irritant and distraction effects on the target may allow the user to retreat to a safer location, get away from an attacker, or if used by law enforcement or security personnel, subdue an individual for capture and/or arrest. The concept of a small handheld powder launch system can have many embodiments depending on the desired application. The basic operation, however, is typically similar. When threatened by an attacker or animal, for example, a user generally points or aims the launch system in the threat direction and activates the system, for example through a triggering mechanism, that results in the substantially instantaneous deployment of an irritant powder payload cloud and/or a non-lethal projectile towards the target.

There are many advantages to a device that deploys a simple blast of irritant cloud from the muzzle of a compact self defense launching system. In some embodiments, an irritant powder is launched towards the target(s) that generates a cloud comprised at least partially of the irritant powder with the intention that the cloud contacts the target(s) directly, drifting on air currents towards the target(s), or just placing a barrier irritant cloud between the user and the threat.

Therefore, the launching of a non-lethal powder, to generate a powder irritant cloud, launched from a compact system provides many advantages over conventional projectiles and/or other self defense devices. For example, a powder irritant cloud does not require a precise aim point on the target to affect the target such as with a projectile. Further, unlike most conventional projectiles, the powder irritant cloud can affect more than one threatening targets due to its relatively large volume and ability to float on the air currents. A powder irritant cloud can utilize a cross or back wind to further disperse its irritant towards distant target(s). Unlike solid projectiles, a powder irritant cloud can hang in the air and be an effective temporary barrier between the user and the threat, and unlike pepper spray the powder cloud typically is visible. Still further, devices that launch some projectiles, in some areas of the United States and the World, may be considered a weapon, e.g., launching a projectile carrying an inhibiting substances (such as some projectiles described in U.S. Pat. Nos. 7,194,960; 6,546,874; 6,393,992; and 5,965,839, and Patent Application Publication Nos. 2005/0188886 and 2006/0027223, all of which are incorporated herein by reference in their entirety) may be considered, in some areas of the United States or the World, a chemical weapon, while the launching of a loose powder that rapidly deploys into a cloud of inhibiting powder is not considered a weapon and can be carried and/or used by the general public and/or non-law enforcement individuals. Many other advantages are provided by a launch system that launches loose powder to generate a cloud of irritant powder as described below and will be apparent to those skilled in the art.

The powder launch systems of the present embodiments can utilize any number of different types of impulse energy sources to eject and/or otherwise launch the loose powder, including impulse sources employed within compact hand held devices. One or more of these different types of impulse energy sources are used in launch systems to propel the non-lethal powder loads of the present embodiments toward a target. For example, the impulse energy source can be from a launch system using the pressure impulse from a conventional firearm primer; an electrically fired primer; a burning gas generator common to automobile airbag technology; known gunpowder technology; by spark ignition of propane, butane or other hydrocarbons; sources of compressed gas such canisters, cylinders or cartridges of compressed gas (e.g., such as found in refillable paintball gas cylinders); replaceable compressed gas cartridges (e.g., cartridges such as used in air pistols and inflation devices); and other such sources of impulse pressure and/or combinations of sources of impulse pressure. For example, by utilizing disposable and/or replaceable compressed gas cartridges filled with air, nitrogen, carbon dioxide and/or other gases, some launch systems of the present embodiments may be fabricated as a disposable (e.g., one time use) launch system, and/or a portion of the launch system can be disposable and replaced in an easily reloadable launch system.

As described above, the launch systems according to some embodiments launch a loose powder that rapidly generates a cloud of powder extending from the launch system. Launch systems and/or method of some implementations can launch one load or multiple loads at a time or in succession. A launch system may be capable of one or multiple launchings through one or multiple barrels using various configurations. The launch systems of some embodiments provide a source of gas impulse in a barreled device. The choice of impulse gas energy can depend on many factors, such as but not limited to, desired design, launch system size and/or weight, desired powder cloud dispersion, size and/or weight of a launch load, and/or other application factors. As introduced above, the powder loads of the present embodiments can be utilized with many existing launchers, and/or launch systems utilizing impulse pressure mechanisms (e.g., impulse gas) designed specifically to launch irritant, non-lethal powder loads described herein.

FIG. 1depicts a simplified cross-sectional diagram of a launch system100according to some embodiments. The launching system includes a frame or body110and a barrel assembly112. Within the frame110is mounted a source of impulse pressure114. The barrel assembly112includes an entry orifice or opening116, a barrel or barrel bore118with an exit end120opposite from the entry opening116. In some implementations, the frame110is removably mounted with the barrel assembly112such that the entry opening116is cooperated with the source of impulse pressure114allowing the impulse pressure to enter the barrel118, upon activation of an actuator (not shown), providing a propellant pressure into the barrel118. The removable mounting can include threading122, spring loaded pins, pin and grooves and substantially any other such methods or combination of methods of securing that, at least temporarily, fixes the frame110with the barrel assembly112while the source of impulse pressure114generates and directs the impulse pressure into the barrel118.

A powder load124comprising powder that is unenclosed and is positioned within the barrel118. The powder load124is a loose powder load in that at least a majority of the powder124upon being ejected from the barrel118is loose and unenclosed to rapidly disperse into the powder cloud extending from substantially the exit end120of the barrel118as described above and further below. The powder load124is propelled, upon activation of the launch system100, along the barrel118by the propulsion pressure and launched or ejected from the exit end120of the barrel assembly112. In some implementations, a pusher or plunger126is positioned with the barrel118adjacent the powder load124, between the source of impulse pressure114and the powder load124such that the propulsion force is directed against the pusher126to drive the pusher along the barrel118, which in turn pushes the powder load124along and out of the barrel assembly112. Typically, the pusher126is configured to establish a seal with the interior surface of the barrel118so that substantially all, and preferably all of the propulsion pressure does not leak around the pusher126and is thus substantially maintained behind the pusher126. Further in some instances, the pusher126can be configured to provide equal distribution of the propulsion pressure and/or focus the propulsion pressure, for example, by including a rounded or tapered inlet, not shown, in the surface of the pushing that receives the propulsion pressure. In other embodiments, however, the pusher126is not included and the source of impulse pressure114directs the propulsion pressure directly on the powder load124.

The pusher126can be configured from substantially any relevant material that can receive the propulsion pressure and travel along the barrel118to drive the powder load124from the barrel assembly112at a desired velocity. Further, it is desirable that the pusher124be relatively light weight so that it is rapidly decelerates upon leaving the barrel assembly112to fall to the ground, typically before reaching a target. Additionally and/or alternatively, the pushing can be configured to have a relatively large wind drag to aid in decelerating the pusher upon exiting the barrel assembly112. The pusher126can be fabricated from any number of materials such as, but not limited to, urethane foam, polymer foam, Styrofoam, paper, cardboard, plastic, rubber, and/or other such similar materials or combinations of materials.

A seal or retaining member128can further be incorporated into the barrel118in some implementations to retain the powder load124within the barrel118and/or seal the powder load124within the barrel providing a barrier between the powder load and exterior environmental conditions. Typically, the seal128establishes a seal and/or is secured within the barrel118to establish a seal with the interior surface of the barrel118to protect the powder load124from the environment. The seal128is shown inFIG. 1being positioned within the barrel118; however, the seal can extend from the exterior of the barrel into the barrel. Additionally or alternatively, a cap or other structure (not shown) can be positioned on the exit end120of the barrel118and/or can extend into the barrel to provide, in part, an additional seal to keep foreign objects out of the barrel118and/or to provide an indication that the launch system100has not been activated and that the barrel assembly112contains a powder load124to be launched. Still other structures can be incorporated with the exit end120of the barrel112in those instances where a cap is not included to provide an indication of whether the barrel assembly112has been previously activated to launch the powder load.

The seal128(and/or cap when present) is also typically constructed to rapidly decelerate upon being driven from the barrel assembly112, and can be fabricated from any number of materials such as, but not limited to, paper, cardboard, urethane foam, polymer foam, Styrofoam, plastic, rubber, wax, paraffin and/or other such similar materials or combinations of materials. In some implementations the seal128is further secured, such as glued to the interior surface of the barrel118to enhance and/or ensure the seal and to retain the powder load124. The glue can be selected to readily break upon a sufficient pressure being applied by the propulsion pressure allowing the seal128to detach from the interior surface of the barrel118and be ejected from the barrel assembly112. The glue can be substantially any relevant glue, and in some instances is waterproof or water resistant glue, such as but not limited to TiteBond III™ or other relevant waterproof and/or water resistant glues. Similarly, a retaining member, such as an O-ring, may be employed to maintain the positioning of the seal128(and/or pusher126) within the barrel118. Additionally or alternatively, the seal128can be constructed of a material, or be assembled with weakening features that allow the seal to at least partially break apart when the propulsion pressure drives the powder load124against the seal releasing the powdered load to be driven along and out of the barrel assembly112.

The powder load124comprises a powder that is propelled along the barrel and ejected from the exit end120of the barrel assembly112in substantially an aerosol to generate a powdered cloud extending from the exit end120of the barrel toward a target, and in some instances about a target when the target is within range. The powder load124, in some embodiments as depicted inFIG. 1, is free and loose and retained by the pusher126, the seal128and the interior surface of the barrel118such that the powder load124is in contact with the interior surface of the barrel118prior to and while being driven along the barrel assembly112to be ejected from the exit end120of the barrel118. Typically, when the barrel118is loaded with the pusher126, and loose powder124, the loose powder is in an uncompressed state, and in some instances is not packed or compressed when added to the barrel118. In other embodiments, however, the loose powder may be partially tapped or compressed, may be inserted as a tablet, may be retained in a membrane or film prior to activation of the launch system100, and/or other such configurations that are ejected from the barrel assembly112as loose powder in substantially a loose, free and in some instances an aerosol state.

The powder load124, as described above, typically includes one or more powdered irritant and/or inhibiting substances. The irritating and/or inhibiting powder can comprise one or more irritants such as, but not limited to: one or more capsaicinoids; capsaicin; nonivamide; PAVA; oleoresin capsaicinoid (OC); a pepper derived irritant; powdered tear gas (CS or CN); and/or maloderants. The powder irritants may be naturally occurring or synthetically produced. In some implementations, the powder load124may be pure irritant powder or may be mixed with one or more types of inert powders to achieve a desired concentration of irritant effect on a target. Inert powders such as barium sulfate, baby powder, cornstarch, talc, trisodium phosphate, silicon dioxide, flour, baking powder, chalk, gypsum and/or similar non-toxic inert powders may be used to achieve the desired irritant concentration and give more visibility to the cloud. Relatively “heavy mass powders” such as barium sulfate or other similar non-toxic heavy powders may be added to the powder mixture to achieve a further launching or throw distance for the powder cloud in some implementations. Visually colored, ultraviolet (UV) fluorescent and/or other such marking powders may additionally or alternatively be also be used or added to the mixture to achieve a marking function if desired. Inert powder or inert powder mixture loads can also be used without adding the irritant powder for the purpose of a training or demonstration load that simulates the cloud performance of the irritant powder loads. The powder load124can comprise powder, in some implementations, as described in related U.S. Pat. Nos. 7,194,960; 6,546,874; 6,393,992; and 5,965,839, and Patent Application Publication Nos. 2005/0188886; and 2006/0027223, all of which are incorporated herein by reference in their entirety.

As described above, the powder load124is ejected from the exit end120of the barrel assembly112to generate the cloud of inhibiting powder. To achieve the desired cloud in some instances the powdered load124is expelled from the barrel assembly112as an aerosol that rapidly expands as it travels away from the barrel assembly112and launch system100. The powder load configuration and/or particle sizes of the powder load can affect the aerosolizing effect. In some embodiments, an average particle size of at least the inhibiting powder portion of the powder load124is less than about 200 microns, and typically is less than about 100 microns, for example, the particle sizes can be between 5-100 microns, where smaller irritant powder particles typically aids in the hang time or time of suspension of the irritant powder particles and thus the cloud. Other components of the powder load may have larger particle sizes. For example, weighting particles may have larger sizes, where the weighting particles aid in dispersing the launched inhibiting powder.

The aerosolizing effect is also, at least in part, dependent on the amount of propulsion force applied and/or the speed at which the loose powder is propelled from the barrel assembly112. In some implementations the propulsion force applied to the powder load124is greater than 200 psi, and typically greater than 400 psi. The amount of propulsion force is further dependent on the size and/or weight of the powder load124(and pusher126and seal128when relevant). For example, with a powder load124having a weight of about 5 grams, a propulsion force of over 700 psi can effectively launch the powder load, in some implementations, to generate an expanding cloud that is greater than about 8 feet deep extending from a position of the exit end120at the time of launch, and with a width (generally perpendicular to the depth at about 8 feet) of at least about 3 feet. Various cloud sizes, shapes and depths can be obtained by changing the elements and parameters of the launch system and/or load.

The powder load124, typically, is a fine particle powdered substance such that the particle sizes or grain are less than 1000 microns in diameter, and preferably less than 500 microns, more preferably less than 250 microns, and in many instances less than 100 microns. It has been found that the generally the smaller the particle diameter in a powdered load124, the more effective the dispersal, and typically the larger the volume of the dispersal, of the powder into a cloud upon being launched from the launch system100. In some instances, the nature of the cloud produced is similar to, for example, a cloud that is formed when clapping erasers together, only generally much larger in volume. As will be seen, it is advantageous that the powder load124produce a fine cloud of the powder such that the cloud will be dispersed on and about the target, such that the target inhales the substance, and/or creates a relatively large suspended powder cloud barrier (e.g., larger than an adult human head, adult human torso or adult human body).

As described above, the powder load124can include an inhibiting substance, and in some instances comprises a powdered oleoresin capsicum powder or capsaicin powder that has a particle size of less than 500 microns, preferably less than 100 microns, and more preferably less than 20 microns, e.g. 5 to 10 microns in diameter. Thus, when such powder is rapidly launch from a launch system100a cloud of finely powdered substance124is produced that has a depth of at least about 6 feet, and a width of at least 2 feet and preferably at least 3 feet in diameter. This cloud advantageously “wafts” in the air for several seconds, for example, more than 5 seconds and with some powder loads124more than 10 seconds before settling, allowing sufficient time for a target to inhale the powdered substance, and maintain a suspended powder barrier allowing a user to escape. Further, the amount of inhibiting substance and/or portion of inhibiting powder within the powder load124can vary depending on many factors. For example, the powder load124can contain about 5% PAVA (Capsaicin TI, nonivamide) capsacinoids by weight, with about 95% by weight of inert substances, such as barium sulfate and/or weighting substance(s).

Still referring toFIG. 1, the frame110and/or barrel assembly112can be constructed of substantially any material or combinations of materials that withstand the impulse and propulsion pressures induced by the activation of the launch system100. For example, the frame110and/or barrel assembly112can be fabricated from any number of materials such as, but not limited to, plastic, metal, metal alloys and/or other such similar materials or combinations of materials. In some implementations, one or more components of the frame110and/or barrel assembly112are formed from molded metal and/or plastic, such as injection molded plastic and/or reinforced plastic (e.g., reinforced with metal, fiberglass or other reinforcement materials). Additionally in some embodiments, the barrel118may be opaque or partially opaque so that a user can verify that the powder load124has not been launched.

Further, as introduced above, the frame110and barrel assembly112can be constructed to be detachable. This allows, in some embodiments, the barrel assembly112to be pre-loaded with the pusher126, powder load124and seal128. Similarly, the launch system110can be constructed such that the barrel is a replaceable and/or disposable portion that is readily removed from the frame110allowing subsequent and/or alternative barrels112loaded with powder loads124to be easily, and typically, rapidly attached replacing a barrel from which the powder load124had been launched, to replace a barrel that may have a defect, to replace a barrel having a first type of powder load with a barrel having a different type of powder load, and other such applications. The barrel118can be substantially any size that is capable of providing the rapid expulsion of the loose powder load124while maintaining sufficient pressure within the barrel to provide the desired propulsion force to launch the loose powder load at sufficient velocity to induce the powder cloud. For example, in some instances, the barrel has a length that is less than 3 inches, and in some embodiments less than 2 inches greater than a length of the pusher126, powder load124and seal128(e.g., in some embodiments, the length of the barrel118is less than 3 inches); and with a diameter that is between about 0.25 inches to 2.0 inches, for example about 0.7 inches.

As described above, powder loads of the present embodiments, such as powder load124, can be launched using any number of different types of impulse energy sources. Again, the impulse energy source can be, for example, from a launch system using the pressure impulse from a conventional firearm primer; an electrically fired primer; a burning gas generator common to automobile airbag technology; known gunpowder technology; by spark ignition of propane, butane or other hydrocarbons; sources of compressed gas such canisters or cartridges of compressed gas (e.g., such as found in refillable paintball gas cylinders); replaceable compressed gas cartridges (e.g., cartridges such as used in air pistols and inflation devices); and other such sources of impulse pressure and/or combinations of sources of impulse pressure.

In actuating the launch system100, an actuator, such as a trigger button, lever, trigger or other such actuator, activated to release a spring mechanism, move a drive mechanism, actuate a valve, move a levered wedge mechanism or other such method to release the impulse pressure. In some embodiments that utilize compressed gas as at least a portion of the impulse pressure, the actuator causes a compressed gas cartridge to be forces into contact with a puncture pin; a valve to be opened; or uses other release to affect a release of the compressed gas to be directed into the barrel118and propel the powder load124from the barrel118(or shell cartridge containing the powder loads in some alternative embodiments). The expanding gases released into the barrel118launch the powder load124(or one or more various powder loads described below) towards the intended target. Alternatively or additionally, in those embodiments that utilize a primer, gunpowder and/or chemical gas generator as the source of impulse pressure114, then the actuator causes an ignition of the primer, gunpowder, chemical gas generator, etc., which produces hot gases that cause an impulse of expanding gas to propel the powder load124from the barrel118(or cartridge shell).

FIG. 2shows a simplified cross-sectional view of a launch system200, similar to that ofFIG. 1, with a membrane powder load210comprising powder212retained within a membrane214. As introduced above, in some implementations the powder load212is retained within a membrane or film prior to activation of the launch system100. The membrane214is typically relatively thin and easily ruptured, and can be constructed of substantially any relevant material or combinations of materials such as, but not limited to, plastic, plastic wrap, paper, wax paper, foam, wax and/or other such similar materials or combinations of materials. Typically, the force applied by the pusher126, in response to the impulse pressure, against the membrane powder load210(as well as the force of the membrane powder load210against the seal128) readily breaks the membrane214and the loose powder212is released from the membrane such that the loose powder212is in contact with the interior surface of the barrel118for a least a portion of the length of the barrel118as the loose powder212travels along the barrel118toward the exit end120of the barrel assembly112to be ejected from the barrel assembly112in a loose, and in some instances an aerosol state. The broken membrane is relatively light and typically has very poor aerodynamics (particularly after being ruptured within the barrel118), and as such rapidly falls to the ground and typically does not strike the intended target.

Some embodiments include one or more tabs224, knife edges, pins or the like positioned within the barrel118or at the exit end120of the barrel assembly112. The one or more tabs224cut, snag or otherwise rupture the membrane as the membrane powder load210is propelled along the barrel118. In some instance multiple tabs provide multiple cuts and/or effectively shred or partially shred the membrane214. Additionally or alternatively, a bar or cross-bar structure (not shown) can be fixed within the barrel118or at the exit end120of the barrel to rupture the membrane214. Still further, in some instances the membrane may be glued to the interior of the barrel, the interrior or a portion of the interior of the barrel may rough or other such mechanisms can be used to rupture the membrane.

The barrel118of the launch system200depicted inFIG. 2is shown with a length that is longer than the barrel of the launch system100ofFIG. 1. It is noted that the length of the barrel assembly112and/or bore118can vary depending on payload weight, desired dispersion effect, amount of propulsion forces, launch distance and other such factors. The length of the barrel does not significantly alter the dispersion of the powder load124in generating a powder cloud, for at least short or relatively short distances of less than about 15 feet. The longer barrel, however, may simplify assembly of varying powder launch loads and/or embodiments of the launch system as described below.

FIG. 3depicts a simplified cross-sectional view of the launch system300, similar to the launch systems100,200ofFIGS. 1-2, with a powder load310, according to some embodiments, comprising the membrane powder load210, comprising powder212retained within a membrane214, and a projectile320. In the embodiment shown inFIG. 3, the powder load310is retained between a pusher126and a seal128. In some embodiments, the seal128is not included and instead the projectile320provides a seal or at least a sufficient seal to launch the payloads. Additionally or alternatively, an O-ring (not shown) or other similar structure can be incorporated into the barrel118to retain the projectile320within the barrel assembly112and/or to establish at least a sufficient environmental seal between the O-ring and the projectile320.

The projectile320includes a frangible shell322and a payload324. The payload324can include a powdered payload that can be that same as, similar to or different from the powder load124and/or powder212. In other embodiments, the payload324is a liquid payload and/or a combination of liquid and powder. The projectile320and/or payload324can be the same or similar to one or more of the projectiles and/or payloads described in U.S. Pat. Nos. 7,194,960; 6,546,874; 6,393,992; and 5,965,839, and Patent Application Publication Nos. 2005/0188886; and 2006/0027223, all of which are incorporated herein by reference in their entirety.

Upon activation of the actuator of the launch system300, the source of impulse pressure114delivers the propulsion force through the entry opening116and into the barrel118to drive the loose powder212and projectile320from the launch system300. Again, the membrane214ruptures during launch, typically as a result of the propulsion pressure and/or the force exerted on either side of the membrane powder load210by the pusher126and projectile320. As described above with reference toFIG. 2, one or more tabs224or other such structures can be incorporated into the barrel118or at the exit end120to ensure that the membrane214breaks prior to leaving the barrel118.

The amount and/or weight of the powder load310can be substantially the same as those described above. For example, the projectile320can have a weight of about 3 grams while the membrane powder load210can have a weight of about 2-3 grams, while employing a source of impulse pressure114that is substantially the same as those for the embodiments depicted inFIGS. 1-2and described above. It is noted, however, that the amount of propulsion force can vary depending on the size and/or weight of the powder load310, and in some instances the length of the barrel118between the projectile320and the exit end120. In some embodiments, the barrel112has a longer length when a projectile320is launched from the launch system300. The longer barrel length allows the projectile320to gain sufficient velocity when launched to have a desired launch distance and/or provide a desired kinetic impact at the target (e.g., that results in pain to the target). Further in some implementations, barrel118may include rifling that can induce rotation to the projectile320, which in some implementations enhances stability and/or increases a launch distance.

FIG. 4depicts a simplified cross-sectional view of the launch system400, similar to the launch systems100,200,300ofFIGS. 1-3, with a powder load410, according to some embodiments, comprising an unenclosed and free powder412and a projectile320positioned within the barrel118. The powder load410is retained between a pusher126and a seal128. In some embodiments, the seal128is not included and instead the projectile320or projectile and sealing structure (e.g., O-ring), provides a seal or at least a sufficient seal to protect the loose powder412from the environment. The powder412is a loose powder load in that at least a majority of the powder412when ejected from the barrel118is loose and unenclosed to rapidly disperse into the powder cloud extending from substantially the exit end120of the barrel118as described above and further below. In some instances the powder412can be tapped or lightly compressed while still being launched as loose powder. Upon activation the powder load410is propelled from the barrel118such that the projectile is launched while the powder412is ejected as a loose powder establishing a powder cloud.

The amount and/or weight of the powder load410can be substantially the same as those described above. For example, the projectile320can have a weight of about 3 grams while the powder load412can have a weight of about 2-3 grams, while employing a source of impulse pressure114that is substantially the same as those for the embodiments depicted inFIGS. 1-2and described above. It is noted, however, that the amount of propulsion force can vary depending on the size and/or weight of the powder load410, and in some instances the length of the barrel118between the projectile320and the exit end120. In some embodiments, the barrel112has a longer length when a projectile320is launched from the launch system400. The longer barrel length allows the projectile to gain sufficient velocity when launched to have a desired launch distance and/or provide a desired kinetic impact at the target (e.g., that results in pain to the target). Further in some implementations, barrel118may include rifling that can induce rotation to the projectile320, which in some implementations enhances stability and/or increases a launch distance.

FIG. 5depicts a simplified cross-sectional view of the launch system500, similar to the launch systems100,200ofFIGS. 1-2, with a powder load510, according to some embodiments, comprising powder512and a projectile320with a divider or separator514positioned between the powder512and the projectile320. The powder512is unbound and unencased other than by the interior of the barrel118, the pusher126and separator514, and in some instances can be similar to the powders124,412ofFIGS. 1 and 4. The powder512is a loose powder load in that at least a majority of the powder512when ejected from the barrel118is loose and unbounded to rapidly disperse into the powder cloud extending from substantially the exit end120of the barrel118as described above and further below. The divider514retains the powder512and substantially prevents the powder512from contacting the projectile320, which may in some instances avoid the powder512from being lodged between the shell322of the projectile320and the interior surface of the barrel118. In some instances, the lodging of powder512between the shell322of the projectile and the interior surface of the barrel118may jam the projectile within the barrel118and/or result in requiring an increased propulsion pressure to launch the powder load510. The divider514can be constructed of substantially any number of materials such as, but not limited to, urethane foam, polymer foam, Styrofoam, paper, cardboard, plastic, rubber, wax, paraffin and/or other such similar materials or combinations of materials. In some implementations, the divider514is similar to the pusher126and/or seal128. Further, the divider can create a seal with the interior of the barrel118and/or can be glued or otherwise secured with the interior of the barrel.

The powder512can be substantially similar to the powder124ofFIG. 1. The amount and/or weight of the powder512can, in some embodiments, be between about 2-3 grams when the projectile320has a weight of about 3 grams. The weight of the powder512and/or project can vary depending on an amount of propulsion force that can be generated from the source of impulse pressure114, and/or a desired launch distance of the projectile320. As described with regard to at leastFIG. 3, the length of the barrel assembly112can also be increased in some implementations to achieve a desired velocity of the projectile320at the exit end120of the barrel. Additionally or alternatively, the dimensions of the pusher126, divider514and/or seal128can also be adjusted.

FIG. 6depicts a simplified cross-sectional view of a launch system600according to some embodiments. The launch system600includes a frame610and a barrel assembly612. The frame610includes an actuator or trigger mechanism616and a driver618. The barrel assembly612comprises a source of impulse pressure620and a barrel622. Further, the source of impulse pressure620includes a compressed gas cartridge, cylinder or the like624, a puncture pin626, an expansion chamber628and a burst diaphragm or disc630. The barrel622includes an entry opening632and a barrel bore634. A load is incorporated into the barrel bore634and the load can include, in some implementations, a pusher640, powder payload642and a seal644.

In some implementations the barrel assembly612is detachable from the frame610, and further in some embodiments the barrel assembly612is replaceable such that upon activation of the launch system600and the launching of the powder payload642, the spent barrel assembly can be detached and a new barrel assembly612can be secured with the frame610. Substantially any mechanism can be employed to secure the barrel assembly612with the frame610. Some of these mechanisms can include, but are not limited to, screw threading, pin and groove, one or more spring loaded pins, latch(es) and other such methods.

FIG. 7depicts a simplified cross-sectional view of the frame610of the launch system600ofFIG. 6. The frame610as introduced above includes the trigger mechanism616and the driver618. Additionally, the frame610includes a barrel assembly receiving port710that receives and secures a barrel assembly612. In some implementations, the trigger mechanism further includes a trigger or actuator lever712that is pivotably secured with the frame610at a pivot714, with a rivet, screw, pin or other such mechanism. Further, the lever712is in contact with and/or secured with the driver618. A driver stop716is also included in some implementations as described fully below.

FIG. 8depicts a simplified cross-sectional view of the barrel assembly612, according to some embodiments, that can be utilized in the launch system600ofFIG. 6.FIG. 9depicts an enlarged view of a portion of the barrel assembly612ofFIG. 8showing the compressed gas cartridge624, the puncture pin626, the expansion chamber628, burst diaphragm630and entry opening632. Referring to FIGS.6and8-9, in some embodiments the barrel assembly612is assembled from a cartridge holder or housing812and the barrel622that are secured together with the burst diaphragm630positioned proximate an interface between the cartridge holder812and the barrel622. The cartridge holder812, in some implementations, is secured with the barrel622through threading, gluing, tongue and groove, welding and other relevant methods, or combinations of methods. For example, the cartridge holder812can include threading814to be screwed together with the barrel622, and a further adhesive or glue can be included, that in implementations may at least partially melt the material of the cartridge holder and/or barrel to further secure, bond and/or partially weld the components together. Securing the cartridge holder812and barrel622maintains the relationship between the cartridge holder812and the barrel during launching and can withstand the pressures generated in launching the loose powder load642and/or a projectile. In some implementations, for example, the cartridge holder812and the barrel622can be secured by applying glue (e.g., Instant Krazy Glue™) that can be brushed onto threads814of one or both the cartridge holder812and the barrel622. In some instances the burst diaphragm630is retained in position by clamping the burst diaphragm or a frame or ring positioned with and/or secured with the burst diaphragm between the cartridge holder812and the barrel622. Alternatively, or additionally, the burst diaphragm630is also glued or otherwise sealed in place. For example, a glue, such as LOCTITE Superflex Clear RTV™) can be applied on one or both sides of the burst diaphragm (e.g., on both sides of a perimeter of the burst diaphragm630to help in preventing leaks). Additionally in some implementations, the barrel assembly612is has a cylindrical structure to take advantage of the inherent structural strength to aid in withstanding the launch pressures.

The compressed gas cartridge624is slidably positioned within a cartridge port or chamber912of the barrel assembly612that allows the compressed gas cartridge624to slide, when driven by the driver618, from a first position separated from the puncture pin626to a second position in contact with and punctured by the puncture pin626. In some implementations a cartridge seal914is positioned within the cartridge port912proximate the puncture pin626. The compressed gas cartridge624transitions from a first position when driven by the driver618to a second position to be punctured by the puncture pin626. Typically, the compressed gas cartridge624is further in contact with the cartridge seal914that establishes a seal relative to the compressed gas cartridge and the puncture pin such that substantially all of the released gas is directed into the expansion chamber628, either through and/or around the puncture pin626. The cartridge seal914can be configured from substantially any relevant mechanism, such as an O-ring, washer or other such mechanism, and similarly can be constructed of substantially any relevant material to establish the desired seal. In some implementations, the cartridge seal914is part of a puncture pin assembly that further contains the puncture pin626and allows the puncture pin to be secured within the barrel assembly612relative to the cartridge seal912. It is noted that the launch system600is shown such that the driver618drives the compressed gas cartridge624onto the puncture pin626. In other embodiments, however, the puncture pin626can be driven into the compressed gas cartridge624to puncture the cartridge and release the gas, or both can be driven toward the other.

A passage, conduit or other such tube916can be included in some implementations that extends between the puncture pin626and the expansion chamber628to carry the gas released from the compressed gas cartridge624into the expansion chamber628. The released gas from the compressed gas cartridge can flow through and/or around the puncture pin626and into the expansion chamber.

The burst diaphragm630seals the expansion chamber628from the entry opening632and the barrel bore634. As compressed gas continues to be released from the compressed gas cartridge624, pressure builds within the expansion chamber628and against the burst diaphragm630. When the pressure within the expansion chamber628exceeds a burst threshold of the burst diaphragm, the burst diaphragm bursts or ruptures rapidly releasing the gas from the expansion chamber628, through the entry opening632and into the barrel bore634. The cross-sectional areas of the burst diagraph630and entry opening632are relatively large compared with the size of the puncture hole in the cartridge resulting from being punctured by the puncture pin. Further, the burst opening that results within the burst diaphragm as a result of bursting is also relatively large compared to the puncture hole, and in some instances is about the size of the entry opening116(e.g., in those instances where the burst diaphragm ruptures into the entry opening116). In some implementations, the area of the burst opening and/or entry opening116is 5, 10 or more times the size of the puncture hole. Because of the relatively large size of the burst opening through which the compressed gas is released into the barrel bore634, a relatively large amount of compressed gas is rapidly released into the barrel bore634to provide a greater propulsion pressure onto the pusher640and powder load642than otherwise would be provided from the puncture hole alone. The rapidly explosive rupturing of the burst diaphragm provides the relatively large opening to effect the rapid release of the propulsion force. The launch system can be configured such that a size of a resulting burst opening is established or tuned depending desired cloud dimensions, a load weight, burst diaphragm material and/or thickness, an amount of propulsion pressure, an expected amount of impulse pressure and/or other such factors. Additionally, in some implementations the rupture of the burst diaphragm results in an audible noise, report, retort and typically a relatively loud pop or bang (typically that can be heard by a human at more than 15 feet away, generally at more than 20 feet away and in some instances more than 30 feet away), that can startle a target, may notify others individuals in the area of the threat, and in some instance induces a reaction by the target, such as taking an involuntary breath that can cause the target to breath in some of the inhibiting powder of the powder cloud1210.

The size and/or volume of the expansion chamber628typically depends on the compressed gas stored within the compressed gas cartridge624, the volume of the compressed gas cartridge624, a burst threshold of the burst diaphragm or a combination of one or more of these. For example, when the compressed gas cartridge624stores liquid carbon dioxide (CO2), the volume of the expansion chamber628is typically configured to be equal to or larger than the volume of the compressed gas cartridge624. This is due, at least, to the fact that as the carbon dioxide bottled in liquid form is released there is a phase transition as the liquid transitions and expands into a gaseous state. In some implementations, the volume of the expansion chamber628is greater that twice the volume of the compressed gas cartridge624. For example in some embodiments, the volume of the compressed gas cartridge is about 0.1 cubic inches, while the volume of expansion chamber628is about 0.5 cubic inches, providing about a 5-to-1 amplification of the volume with the use of the expansion chamber628in cooperation with the burst diaphragm630. As another example, the volume of the expansion chamber628can be about 0.09 cubic inches, which can comprise two connected cylinders, one that is about 0.382 inch in diameter and about 0.417 inches long, and the other that is about 0.627 inch in diameter and about 0.133 inches long. Other sources of compressed gas and/or types of gas can be utilized as introduced above, such as air, nitrogen, other relevant gases or combinations of gases. The expansion chamber628and/or burst diaphragm630can be configured, selected and/or otherwise tuned to one or more desired performance characteristics, such as but not limited to desired cloud dimensions, a powder load weight, an amount of propulsion pressure, an expected amount of impulse pressure, burst diaphragm material and/or thickness, and/or other such factors.

The burst diaphragm630can be constructed of substantially any relevant material capable of withstanding the desired pressures and rupturing at about a desired pressure threshold. Further, the burst diaphragm630, in some embodiments, is a replaceable, disposable rupture disk membrane secured between the barrel bore634and the expansion chamber628. When the gas pressure in the expansion chamber volume reaches the stress limits of the membrane material of the burst diaphragm, the burst diaphragm ruptures and the expanded gas is released to accelerate the powder load642(and/or one or more projectiles) out of barrel bore634. The burst diaphragm630can be constructed of Mylar™, polyethylene terephthalate (PET) Polyester film, paper, plastics, metal, and substantially any other relevant material that maintains the expanding gas within the expansion chamber allowing gas pressure to build until a predefined and/or desired pressure is attained at which point the burst disk ruptures. For example, in some implementations the burst diaphragm630can be made of Mylar™ with a thickness of more than 1.5 mm, for example, 3 mm, or other such thickness to provide a burst threshold at a desired level, and/or include structural weakening features.

The burst diaphragm630may rupture by exceeding the stress limit of the material, alternatively by coming in contact with a sharp device within the barrel assembly612that causes the burst diaphragm to puncture releasing the built-up gas, and/or by breaking a seal or other means of rupturing the burst diaphragm. The burst diaphragm630, in some implementations, is scored to control or change the pressure at which the burst diaphragm bursts. The scoring can be in substantially any configuration to establish weakening points that allow, in some implementations, more precise and consistent bursting at desired pressure thresholds. Additionally and/or alternatively, the burst diaphragm630under pressure may be designed to burst using other methods such as: mechanical cutting or piercing of the burst diaphragm; using heated coils or electrical arcs to create or melt a weak section or an initial pin or small hole in the burst diaphragm; or other methods of aiding rupturing the diaphragm material. Typically, the burst diaphragms have consistent burst thresholds providing consistent operation of the launch system600between launches (e.g., by replacing a spent barrel assembly612with a new, loaded barrel assembly). Other embodiments of the launch system600may employ one or more of a mechanical valve that opens; a fixed diaphragm that opens by moving, folding and the like without rupture (e.g., using magnets that release at defined pressures); a friction held or other types of gas plug; and/or other relevant types of gas retainer design methods that can be made to move or open to allow gas flow. The burst diaphragm630, valve and/or gas plug at least in part allows sufficient gas pressure and volume to buildup, and once the burst diaphragm ruptures (or is otherwise released) the gas enters the barrel bore634providing a propulsion force on the pusher640to propel the powder load642from the barrel bore634creating the desired powder cloud.

Referring back toFIGS. 6-7, the driver618can be substantially any mechanism that responds to the actuation lever712to drive the compressed gas cartridge624onto the puncture pin626, or that drives the puncture pin into the compressed gas cartridge. In some implementations, the driver618transfers the motion of the actuation lever712to the compressed gas cartridge624or puncture pin626. For example, as the lever712is actuated by an external force (represented by the arrow labeled720) the lever pivots at the pivot714and activates the driver618to move the compressed gas cartridge624to be punctured by the puncture pin626. In some embodiments, the frame610further includes a driver stop716. The driver stop is cooperated with the driver618to maintain a positioning of the driver618, at least prior to activation.

FIGS. 10-11show a simplified front view and a side view, respectively, of a driver1010that can be employed for the driver618of the launch system600ofFIGS. 6-7. The driver1010includes a fixed fulcrum arm pair1012and a lever fulcrum arm1014. As shown inFIG. 11, the fixed fulcrum arm pair1012can include two fulcrum arms1020-1021that are positioned on either side of the lever fulcrum arm1014. It will be apparent to those skilled in the art that other configurations can be utilized. For example, the fixed fulcrum arm pair1012or lever fulcrum arm1014can be replaced by a single, generally Y-shaped fulcrum arm. The fixed fulcrum arm pair1012is secured with the frame610at a first pivot1024, and pivots relative to the frame610at the pivot1024. Further, the fixed fulcrum arm pair1012is secured with the lever fulcrum arm1014at a second pivot1026. Similarly, the lever fulcrum arm1014is pivotably secured with the actuator lever712at a third pivot1028.

Upon activation of the actuation lever712, the lever fulcrum arm1014is moved toward the fixed fulcrum arm pair1012. As the lever fulcrum arm1014is moved toward the fixed fulcrum arm pair1012both the lever fulcrum arm1014and the fixed fulcrum arm pair1012move, at the second pivot1026, generally laterally and/or perpendicular to the force applied by the lever fulcrum arm at pivot1028. This lateral movement of the lever fulcrum arm1014and the fixed fulcrum arm pair1012results in a relatively large lateral movement for a relatively small vertical motion.

As introduced above, some embodiments include a driver stop716. The driver stop716can maintain a positioning of the lever fulcrum arm1014relative to the fixed fulcrum arm pair1012. Particularly, the driver stop716prevents the lever fulcrum arm1014from being aligned with the fixed fulcrum arm pair1012, and maintains an angle1030between the lever fulcrum arm1014and the fixed fulcrum arm pair1012. This angle1030ensures that the driver618will bend at the second pivot1026and induce the lateral motion to drive the compressed gas cartridge624onto the puncture pin626(or the puncture pin into the compressed gas cartridge). In some implementations, the actuation lever712in cooperation with the driver618can induce 40 lbs or more of pressure that can be exerted on the compressed gas cartridge624to puncture the cartridge.

As described above, the launch systems100,600rapidly launch loose powder, e.g., loose powder124(and in some instances a projectile, e.g., projectile320) generating a powder cloud.FIG. 12depicts a simplified block diagram representation of a powder cloud1210generated following the activation, by a user1214, of a launch system1212(which can be similar, for example, to the launch systems100,600ofFIGS. 1-9) directed at a target1216. The use of the expansion chamber628and the burst diaphragm630allows the launch system1212to rapidly apply the propulsion pressure to the pusher126,640. As described above, the burst diaphragm630fails at a burst threshold providing a relatively large hole through which the compress gas rapidly, and in some instances substantially instantaneously exits. The built up pressure within the expansion chamber628can be substantially any relevant pressure to achieve the desired propulsion pressure. In some implementations, burst threshold can be 600 psi or more. For example, when using compressed gas cartridge624holding compressed carbon dioxide at about 800 psi, the burst diaphragm630can be selected to have a rupture threshold of less than 800 psi, and the expansion chamber can be configured with a volume that allows the compressed carbon dioxide to be released from the compressed gas cartridge624, phase transition to the gaseous state, and generate a sufficient pressure within the expansion chamber628and against the burst diaphragm630to rupture the burst diaphragm providing a rapid release of the gas to drive the pusher640to propel substantially all, and preferably, the entire power load642from the barrel622. As a result, the loose powder642is launched from the barrel622in less than one second, typically less than one half a second, and more typically in less than hundreds of milliseconds from the time the compressed gas cartridge624is punctured.

Further, the propulsion pressure when released from the expansion chamber628is sufficient to launch the loose powder load642at a sufficient velocity to generate the cloud1210of powder (which in some embodiments as described above, include inhibiting powder) establishing a barrier between the user1214and the target1216. Further, the rapid launch of the loose powder load642results in the rapid dispersion of the powder cloud1210that has a depth1218, measured from a exit end of the barrel at the time of launch and an advancing front end1220of the cloud, within less than a second, typically less than one half a second, and some implementations within less than tens of milliseconds from the time the compressed gas cartridge624is punctured. For example, some embodiments establish an propulsion pressure of between about 600 and 800 psi resulting in a rupture of the burst diaphragm630and propel the loose powder642from the launcher610at a velocity of greater than 100 feet per second, typically greater than 200 feet per second, and in some instance at about 300 feet per second or more, to produce a powder cloud1210that has a depth1218(measured generally parallel with the length of the barrel622at the time of launch) of more than 5 feet, and typically more than 8 feet, and in some instances as much as 14 feet or more, in less than one half a second from the time the compressed gas cartridge624is punctured; additionally, the loose powder642exits the exit end120of the barrel622at an angle1222relative to an axis of the barrel length that is generally greater than about 10 degrees, and in some instances greater than 20 degrees such that a width of the powder cloud1210is greater than about 2 feet, and typically greater than about 3 feet when measured at a depth1220of at least 8 feet. The launch system can be configured and/or tuned to achieve a desired exit velocity depending on one or combinations of the many variables, such as but not limited to, source gas pressure and volume, expansion chamber and volume, burst disk material and thickness, entry opening and/or burst diaphragm retaining ring hole, barrel length, payload weight and other such factors and/or combinations of factors.

As the powder cloud1210advances it envelops the target1216in those instances where the target1216is within at least the depth range of the powder cloud and/or should the target try to advance toward the user1214. The inhibiting powder within the powder cloud1210rapidly contacts and affects the target1216inhibiting and in some instances effectively disabling the target1216. Further, because the launch systems100,600launch the loose powder load124,642that generates the large powder cloud1210, that is typically about as large as or larger than an average adult human, the user1214is not required to have good aim or directly hit the target1216with a projectile and still achieve effective deterrent results. Instead, the powder cloud1210establishes a barrier between the user and the target1216and in some instances surrounds and/or envelopes the target1216. This powder cloud1210further “wafts” in the air for several seconds, for example, for more than 6 seconds and in some instances as much as 10 seconds or more before settling, allowing sufficient time for the target1216to inhale the powdered substance and/or get irritant powder in the target's eyes, as well as allow the user1214sufficient time to flee with the barrier of the powder cloud1210protecting the user's retreat.

This is in contrast to many non-lethal deterrent systems in that many non-lethal deterrent systems require the user to be directly hit with a projectile or stream of liquid. Further, some deterrent systems, such as canisters of pepper spay, additionally require relatively long periods of time of, in some instances, 10 seconds or more to empty the canister of the inhibiting substance. Still further, many deterrent systems not only require a direct hit of the target but further require the inhibiting substance to be a directed stream into the targets eyes, which can be particularly difficult in stressful situations where an assailant is rapidly approaching and trying to prevent the inhibiting substance from hitting his/her eyes.

The rapidly dispersed powder cloud1210does not require a direct hit of a projectile or require that the powder be specifically directed into the target's eyes. Instead, the powder envelops the target1216and enters the target's eyes (even passing around glasses), mouth and nasal cavity to inhibit the target1216. Further, the powder cloud can pass around and/or through barriers to content a target, including passing around obsticles that a target might be hiding behind, passing around glasses and other obsticles, obstructions and/or barriers.

Some embodiments, as described above can additionally include a projectile320. These embodiments additionally allow the user to launch that projectile320, which will typically travel a further distance that the powder cloud1210. Additionally, the impact of the projectile320provides a kinetic impact on the target that can result in pain to the target.

The powder loads124,624and/or payload324of a projectile320, as described above, can comprise any of the following substances: an inhibiting substance such as oleoresin capsicum (also referred to as “OC”), capsaicin, nonivamide (i.e., one or more of the hottest active ingredients or capsaicinoids within oleoresin capsicum), tear gas (e.g., CS or CN), PAVA and other such natural and synthetic inhibiting substances; a marking or tagging substance, such as a colored dye, UV dye, IR dye or other such marking substance; a malodorant; and/or an inert substance, such as barium sulfate, baby powder, corn starch, talcum or other such inert substances; weighting substances; and/or any combination thereof. For example, the powder124,624and/or payload324in accordance with some embodiments can include a combination of oleoresin capsicum and barium sulfate (or alternatively, a combination of PAVA (nonivamide) and barium sulfate and/or other such inert powders and/or weighting particles), at a desired ratio(s). Alternatively, a combination of PAVA and/or oleoresin capsicum, and/or other inhibiting substance, and a colored dye, malodorant and/or other marking substance, may be employed to simultaneously incapacitate the target and mark the target for later identification. In some embodiments a marking substance, a chemical marker or chemical fingerprinted paint, such as produced by Yellow Jacket, Inc. of California, can be used which effectively leaves a chemical ID or chemical fingerprint on the target, which can be used by the police to verify a person was struck by a non-lethal projectile. As such, the chemical marker can include a chemical ID, identifying the batch of the marker, that is formulated into the marker during manufacture. For example, a fleck of the chemical marker found on a suspect two weeks after being impacted with the chemical marker, can be chemically identified and traced to launch system100; thus, the suspect may be linked to a crime scene by the chemical marker. In yet other alternatives, it may be desirable to employ only a marking substance or only an inert substance, such as barium sulfate or talcum, as the powder load124, such as when the launch system100,600is being used for training purposes. Similarly, any projectile320can be filled with an inhibiting powder or liquid, inert powder or liquid, and/or could be empty.

In some embodiments, the projectile320includes the shell322, for example, a spherical capsule (although other shapes of projectile bodies may be used) separable into two about equal halves (e.g. a first part and a second part), wherein the halves contain a powdered impairing substance sufficient in amount so that the shell322is about or greater than 50% full and preferably between about 60% and 99% full, for example, from between 75% and 95%, for example, about 90% filled with a powdered substance324and wherein, to facilitate manufacture of the projectile320, the powdered substance324within each half is compressed into a ball, tablet, mount and placed in one half and sealed with the other half. Alternatively, the powder(s)324could be compressed into each separate half and retained therein by a thin membrane, for example a paper foil, which contacts the inhibiting substance during assembly of the projectile320. In this embodiment, the thin membrane is sufficiently strong to retain the desired substance324within the shell322as it is manufactured or assembled, yet frangible enough to readily rupture subsequent to sealing of the shell322and prior to, or at least simultaneously with, impact with the target.

The powder load124and/or payload324of the projectile320may, for example, contain at least 0.5% inhibiting substances (such as PAVA, nonivamide (from natural or pharmaceutically and/or synthetically produced sources) or oleoresin capsicum), e.g., between 1% and 30%, e.g., between 5% and 20%, with a remainder of the powder load124(or payload324) being either an inert substance or a marking substance or a different inhibiting substance, such as tear gas powder or a powder malodorant. Alternatively, the powder load124and/or payload324may, for example, comprise at least 0.1% capsaicin (which is an active ingredient within oleoresin capsicum in either natural form or pharmaceutical produced form), and preferably at least 0.5% capsaicin with the remainder of the powder load124and/or payload324as either a marking substance, an inert substance, and/or a malodorant. Similarly, more than one inhibiting substance may be combined to provide a total of at least 0.1% to about 30% or more of inhibiting substances (e.g., depending on the target to be impacted, such as a higher percentage may be employed for impacting large animals).

In some variations, the powder load124and/or payload324may include fragments of solid material to enhance dispersion of the loose powder load124and/or payload324. For example, crushed walnut shells, rice, wood shavings, metal particles, such as metal powder or metal particles, or the like may be added to the powder to help carry the powder away from the launch system100and/or a point of rupture of the projectile320against a target. The solid material, having a greater density and mass than the powder load124(e.g., of inhibiting substance, inert substance and/or marking substance) tends to project further from the launch system100, thereby facilitating dispersion of the loose powder load124as it is carried by the solid material.

In further variations, a visible marking agent, a covert UV or IR visible dye, malodorant, or other taggant can be added to the powder load124and/or payload324of the projectile320in order to provide a mechanism for identifying the target at a later time. This feature of this variation may be particularly useful in law enforcement or military applications, where evidence gathering may be enhanced if the target can be marked. By combining a marking agent with an inhibiting substance a significant synergism is achieved. In another aspect, marking can be effected by bruising of the target due to the kinetic impact of the projectile320against the target.

In some embodiments of a marking substance, the projectile shell322, e.g., capsule, may contain a chemical compound that has a particularly offensive odor, also referred to as a malodorant. In use, the projectile320can be launched at a suspect, such that the suspect will have an unwelcome odor on his or her person. Such odor will effectively “mark” the person. Additionally, a projectile320containing a malodorant as at least part of the payload324may be used to repel or keep persons away from a particular area. An area impacted by one or more projectiles320will typically smell so offensive that it will keep others from coming near the smell. The malodorant has applications in crowd dispersal and crowd control, as well. On example of a malodorant that has a particularly offensive odor is called “Dragons Breath” which is an organic sulfur compound produced by DeNovo Industries, of The Woodlands, Tex. In variations of this embodiment, a projectile320can include as the payload320, or at least part of the payload, a glass capsule contained within the projectile shell322. The glass capsule seals within itself certain malodorants, such as Dragons Breath and/or other sulfur compounds, that have solvent properties that can eat through a plastic variety projectile shell. The glass capsule within the projectile body is ruptured upon impact of the projectile body, releasing the malodorant. In further variations, the glass capsule is guided centrally within the projectile with protrusions formed within the projectile. These protrusions center the glass capsule within the projectile capsule and additionally may provide pressure points to assist in the fracturing of the glass capsule upon impact.

In yet a further variation, the payload324within the projectile320can include a powdered inhibiting substance combined with a liquid or gas irritant, or other agent to be delivered. The liquid or gas, and the powdered irritant can be carried in separate chambers, in for example, separate halves of the projectile320using membranes described herein to contain the powdered inhibiting substance and the other agent, keeping them separated, if needed. If a liquid or gas is contained by one or both of the membranes, such membranes can be made, for example out of plastic, vinyl, rubber or the like. The projectile320can be similar to those described at least in U.S. Pat. Nos. 7,194,960; 6,546,874; 6,393,992; and 5,965,839, and Patent Application Publication Nos. 2005/0188886, and 2006/0027223, all of which are incorporated herein by reference in their entirety.

FIGS. 13 and 14depict a side view and a cross-sectional view, respectively, of a launch system1300according to some embodiments. The launch system1300includes a frame1310and a barrel assembly1312.FIG. 15depicts a side view of the frame1310of the launch system1300ofFIGS. 13-14. Referring toFIGS. 13-15, the launch system1300further includes a safety1314, an actuator or trigger lever1316, a driver1418, a driver stop1414, and an actuator lever biasing member1416fixed with the frame1310. The barrel assembly comprises a source of impulse pressure1420and a barrel1422. Further, the source of impulse pressure1420comprises a compressed gas cartridge1424, a puncture pin1426, an expansion chamber1428and a burst diaphragm1430. The barrel622includes an entry opening1432and a barrel bore1434. A load is incorporated into the barrel bore1434and the load can include, in some implementations, a pusher1440, powder payload1442and a seal1444.

The safety1314is slidably secured with the actuator lever1316and extends, when in an active state to prevent activation of the launch system1300, through a hole1326of the frame1310. In operation, a user would slide the safety1314in a direction away from the exit end1436of the barrel1434, for example, by press the extended portion of the safety1314that extends through the hole1326of the frame1310. The actuator lever1316is further cooperated with the lever biasing member1416that biases the actuator lever1316away from the frame1310. Upon depression of the actuator lever1316, the lever biasing member1416compresses, the actuator lever1316drives the driver1418into the compressed gas cartridge1426to force the compressed gas cartridge onto the puncture pin1426. The punctured compressed gas cartridge1424releases compressed gas through and/or around the puncture pin1426to enter the expansion chamber1428. In some implementations the expansion chamber1428comprises two cooperated sub-chambers (which in some instances are connecting cylinders)1450,1452. For example, the volume of the expansion chamber628can be about 0.1 cubic inches, where the first cylindrical sub-chamber1450can have a diameter that is about 0.4 inch and about 0.42 inches deep, and the second cylindrical sub-chamber1452can have a diameter of about 0.63 inch and a depth of about 0.14 inches.

Once the pressure within the expansion chamber exceeds a burst threshold of the burst diaphragm1430, the propulsion pressure rapidly enters the barrel bore1434to drive the pusher1440that in turn drives the powder1442from the barrel1422. Some embodiments may further include a site1330and/or laser site (not shown, but may be activated, for example upon disengaging the safety1314) to aid the user in aiming the launch system1300. Additionally, some embodiments may include a key ring1332, clip or other fastener on which keys or other devices can be secured and/or that can provide for easy of carrying.

FIG. 16depicts a simplified flow diagram of a process1600of assembling a launch system, such as the launch system600or1300ofFIGS. 6-9and13-15, respectively. In step1610the driver1418is positioned and secured within a first half of the frame1310. In step1612, a safety1314and spring1416are secured with the actuator lever1316. In step1614, the actuator lever1316is positioned and pivotably secured with the frame and the driver1418, such that the spring1416cooperates with the frame1310. In step1616, a second half of the frame is secured with the first half of the frame to maintain a positioning of the actuator lever1316and driver1418. In step1618, a driver stop1414is positioned within the frame1310to prevent the fixed fulcrum arm pair1012and a lever fulcrum arm1014from being aligned and maintaining an angle between the fixed fulcrum arm pair1012and a lever fulcrum arm1014.

In step1620a puncture pin assembly, comprising the puncture pin1426, a cartridge seal914and gas passage or tube916are cooperated. In step1622the puncture pin assembly is secured within the cartridge holder or housing812. In step1624a burst diaphragm or disc1430is positioned relative to the expansion chamber1428formed in the cartridge holder812. In some embodiments the burst diaphragm1428is glued or otherwise secured and/or sealed with the cartridge holder812. In step1626a barrel1422is secured with the cartridge holder812, for example screwed to the cartridge holder812, with the entry opening1432being positioned adjacent the burst diaphragm1428. Again, in some embodiments, the burst diaphragm1428is glued or otherwise secured and/or sealed with the barrel1422. Similarly in some implementations, the barrel is a further glued with the cartridge holder812.

In step1630, a pusher1440is positioned within the barrel bore1434adjacent the entry opening1432. In step1632, the powder load1442is positioned within the barrel bore1434adjacent the pusher1440. In step1634, a seal1444is secured within the barrel bore1434adjacent the powder load1442sandwiching the unenclosed powder load between the pusher1440and the seal1444. Typically, the seal1444is inserted into the barrel bore1434to a depth that will keep the powder load sealed in the barrel. Additionally, the seal can further be glued or otherwise sealed with the interior of the barrel bore in some embodiments. In step1636a compressed gas cartridge1424is inserted into the cartridge holder812adjacent the cartridge seal914and the puncture pin1426. In some implementations, the assembled frame1310and the barrel assembly1312can be distributed separately. In other embodiments, an additional step1638can be implemented where the frame1310and the barrel assembly1312are detachably secured to each other prior to distribution.

FIG. 17depicts a simplified flow diagram of a process1700of activating a launch system, such as one of launch systems600and1300ofFIGS. 6-9and13-15, respectively. In step1710, the safety1314, when present, is disengaged. In step1712the launch system1300is generally aimed at a target. In step1714the actuator lever1316is compressed, depressed, squeezed or otherwise activated launching the load and producing a large volume, visible cloud that can potentially inhibit a target and/or provide a temporary inhibiting barrier. In some embodiments, the process1700further includes step1716, where the spent barrel assembly is removed from the frame1310and a new barrel assembly1312is secured with the frame1310. The process can terminate following one of steps1714or1716, or can return to step1712to again generally aim the launch system for the deployment of a subsequent powder cloud1210to produce an additional powder cloud, effectively enlarging an inhibiting barrier and/or adding to the previous cloud. As a result, the process in some implementations activates, in response to an actuation, a source of impulse pressure, launches loose powder from a launch system, and generates a powder cloud comprising the loose powder that has dimensions larger than a human torso. Typically, the loose powder launched comprises inhibiting powder such that the powder cloud comprises an inhibiting powder cloud.

For several decades, law enforcement agencies have used various non-lethal weapons to gain control of suspects, quell riots, save hostages, etc. Most of these non-lethal deployments utilize a rather large launcher platform such as a shotgun, rifle or pistol to deploy the projectiles. Further, to date, other than pepper spray, the general public has not had access to a simple, low cost, non-lethal launcher that could be easily carried and used for personal defense at home, in the car or when on foot. The present embodiments provide low cost, compact non-lethal personal defense launch systems that can be quickly deployed and are effective on human and animal targets.

Many conventional launch systems utilize a projectile to affect the target. For example, U.S. Pat. Nos. 7,194,960, 6,546,874, 6,393,992, and 5,965,839, incorporated herein by reference in their entirety, describe many embodiments of frangible irritant powder filled projectiles, and systems to launch such projectiles, that can affect targets utilizing irritant powder clouds. These projectiles can be employed, as described above, in some present embodiments.

Further, the present embodiments series of non-lethal powder loads that can be launched by many different types of propulsion force or pressure, and from many types of launchers, to be used against a target, such as a threatening human or animal. Some of the launch systems are that can be used to launch the loose powder loads are described here. However, other launchers may be used, in some implementations. One or more such compact launch device that could be utilized to launch the loose or projectile-less irritant powder loads described herein include one or more of the launching devices described in co-pending U.S. patent application Ser. No. 11/129,230, filed May 12, 2005, to Vasel et al., and entitled COMPACT PROJECTILE LAUNCHER.

At least some embodiments of the launch systems described herein easily fit in a person's hand, a purse, pocket, glove box, and the like, and are capable of launching the loose powder loads of powder irritants, inert substances and/or marking substances. Further, these launch systems expel a cloud of irritant powder towards a target, for example, as a non-lethal defense. This irritant powder cloud typically has a distracting, incapacitating and/or repelling effect on the target, be it a human or animal, and in some instances is visible to a target further inhibiting the target. The irritant and distraction effects on the target may allow the user to retreat to a safer location, get away from an attacker, or if used by law enforcement or security personnel, subdue an individual for arrest. The propulsion force or pressure used to launch the loose powder can include, but are not limited to, compressed gas, firearm primers, gunpowder, burning hydrocarbons, chemical gas generators or other means to accelerate these non-lethal irritant powder loads towards the intended target(s). The innovative chemical loads described herein can be directly loaded in barrels attached to these many launch devices or loaded into cartridge shells that can be utilized in these or other types of launchers.