Patent Abstract:
A less than lethal cartridge for a projectile which when fired has a velocity which will not kill an individual struck by the projectile. The less than lethal cartridge has a rim which is deeper or thicker than a rim on a conventional lethal cartridge. The caliber of the cartridge is also selected so that regular lethal ammunition is not available in this caliber. The preferred caliber of the less than lethal cartridge is .490. The less than lethal cartridge contains a polymeric projectile or alternatively, a sealed filled polymeric pouch containing shot therein.

Full Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of U.S. patent application Ser. No. 13/299,906, filed on Nov. 18, 2011 now U.S. Pat. No. 8,511,231, and entitled LESS THAN LETHAL PROJECTILE AND METHOD FOR PRODUCING THE SAME, which is a division of Ser. No. 12/359,659, filed Jan. 26, 2009, now U.S. Pat. No. 8,061,274, issued Nov. 22, 2011 and entitled LESS THAN LETHAL PROJECTILE AND METHOD FOR PRODUCING THE SAME. The present application is also related to U.S. application Ser. No. 13/102,618, filed on May 6, 2011 and entitled REDUCED LETHALITY GUN. The contents of all of the aforementioned patents and applications are herein incorporated by reference. 
    
    
     FIELD OF THE INVENTION 
     This invention relates generally to less than lethal weapons, projectiles, and cartridges. In particular, the present invention is a cartridge containing a less than lethal projectile which is not intended to kill an individual and is also intended to minimize causalities. The less than lethal cartridge of the present invention is designed to be usable only in a less than lethal weapon, in that the rim of the less than lethal cartridge is deeper that the rim of a normal lethal cartridge. 
     BACKGROUND OF THE INVENTION 
     Law enforcement has long operated with what is called a “continuum of force”. It provides guidance to officers for selecting the type of weaponry to use in a variety of situations. The continuum normally begins with verbal commands. Should the subject or subjects not respond, the continuum may advise the next level of force until lethal force is absolutely necessary. In situations such as riots, prisons disturbances, hostages rescues, and the like the continuum of force is utilized. However, officers have long recognized that a wide and dangerous gap exists in the range of tools available to them. In the past, officers had very few options for riot control after verbal commands. Common tactics included advancing walls of officers with batons, or a charge by officers using flats of sabers. However, these tactics still resulted in serious bodily injury due to trampling or excessive police force as they march through crowds; furthermore, innocent civilians were at times injured by inadvertent striking or trampling. It was often that the tactics used were either too weak or too strong a response to some situations. As a result the use of high-pressure fire hoses, electroshock weapons, and non-lethal chemical agents (such as tear gas and offensive odor canisters) were employed to disperse a crowd. Unfortunately, the discretion of officers in utilizing these weapons and tactics led to either misuse by officers or insufficient force applied by officers to maintain peace. In certain situations, like the use of electroshock, the distance between the officer and the subject or subjects is too great for the weapon to be effective. Many of the electroshock weapons rely on an electrical cord or tether to deliver the electrical shock. What is needed in these situations is a less that lethal weapon which can stop the subject without killing them or creating serious bodily injury. 
     While law enforcement has long recognized the gap in the force of continuum, the concept is relatively new to the military. More and more, military forces are being deployed to situations involving peacekeeping and noncombat operations. A solider must be equipped and trained for peacekeeping and humanitarian assistance operations. In certain situations, law enforcement officers and military soldiers are required to use force to control crowds or individuals, as such less than lethal means are recommended by the force continuum. Less than lethal weapons and tactics are intended to be unlikely to kill or cause great bodily injury, thus minimizing civilian casualties and providing soldiers or officers with an alternative to lethal force. 
     A less than lethal projectile, provided in a less than lethal weapon, assures that the requisite less than lethal consequence exists and minimizes the soldiers or officers subjectivity in determining the amount of force to use when necessary. Thus heightening the margin of safety for civilians in a riot without minimizing the primary objective: to temporarily incapacitate, confuse, delay, or restrain. One type of projectile commonly used is a beanbag. Another type of impact device launched from a cartridge shell is a less than lethal projectile. 
     PRIOR ART 
     U.S. Pat. No. 6,655,294 discloses a beanbag suitable for installation in a cartridge or shell of a projectile found in a conventional handgun and the process for making the same. The beanbags are fabric bags that contain lead shot or pellets. The round is intended to flatten on impact, hitting face on, thereby spreading its energy over a larger area. When the bag leaves the gun it unrolls and rotates into the flat orientation to strike the target. Unfortunately, if the bag hits before it is completely unfurled or an edge-on orientation, the full force of the impact is distributed over a smaller area, causing more damage. Furthermore, because of their shape (square, rectangular, or circular) the bags are regarded as widely inaccurate and have been known to veer off course. 
     U.S. Pat. No. 7,089,864 discloses a projectile launched from a weapon shell required at impact to have a low lethality consequence, in which the projectile is fitted in the shell in a shape characterized by a blunt or flat end in the direction of flight. Unfortunately, this low lethality projectile is susceptible to being unstable during its path of flight due to its relatively low weight and slower rate of speed. Furthermore, the projectile is only capable of being fired from a 37 mm or 40 mm weapon shell thus limiting the selection of munitions available to the officer or soldier. In addition, the disadvantages associated with the low lethality projectile also include the method of producing the same. 
     U.S. Pat. No. 6,374,742 discloses a method of shaping a projectile comprising the steps of filling an unbounded rear end of an unfilled tubular sock having a closed front end, forming folds in the tubular sock immediately forward of the rear opening, and manually inserting the tubular sock into a projectile compartment of a 37 mm or 40 mm weapon shell. In so far as the method of sealing the projectile is disclosed as a fold, it is possible that upon impact the projectile may bust, spilling the rubber pellets. Therefore a more reliable seal is desired. Additionally, the method disclosed is not conducive for mass production of the device because it cannot be manufactured on an automated production line. In point of fact, many of the steps of production in the &#39;742 patent involve manual labor. 
     U.S. Pat. No. 3,745,924 discloses a plastic ballistic cartridge whose ballistics are equivalent to the metallic cartridges at that time and can be fired in existing firearms. The non-expanding metal head is securely attached to the breech end of the plastic casing by compressively squeezing the rear end of the plastic casing between a metal head and a second metallic member, either an annular support member plus a primer or by the primer itself. 
     U.S. Pat. No. 7,441,504 discloses a base for a cartridge body for ammunition. The base has an ignition device and an attachment device at one end. The attachment device can attach the base to a cartridge casing body. The base is made from plastic, ceramic, or a composite material. This ammunition is a lethal type of ammunition. 
     U.S. Pat. No. 7,204,191 discloses a lead-free, composite polymer based bullet and cartridge case wherein the composite polymer material includes a tungsten metal powder, nylon 6/6, nylon 6, short glass fibers, as well as additives and stabilizers. The cartridge case includes a lip lock configures to matingly engage a cannelure formed along an outer circumferential surface of the bullet. The cartridge case also includes resilient walls wherein the cast may be formed in a single step process by injection molding or a two-step process including injection molding and a welding process. 
     While these prior art devices may be suitable for the particular purpose for which they are designed, they would be unsuitable for the purposes of the present invention as heretofore described. 
     SUMMARY OF THE INVENTION 
     A less than lethal cartridge for firing a low pressure less that lethal projectile. The less than lethal cartridge has a rim which is deeper or thicker than a rim on a conventional lethal cartridge. The caliber of the less than lethal cartridge is also selected so that regular, lethal ammunition is not available in this caliber. The preferred caliber is .490. The less that lethal cartridge contains a polymeric projectile or alternatively, a sealed filled polymeric pouch which contains shot within. The sealed filled polymeric pouch is formed in a form, fill, and seal machine. An automatic loading ammunition machine containing empty shell casings automatically loads the empty shell casings with a pre-determined quantity of wad, primer, and gun powder, and subsequently moves the projectile or polymeric pouch into a projectile compartment of the empty shell casing thereby producing a fully-loaded shell casing adapted to be loaded into a barrel of a gun. 
     Accordingly, it is an objective of the present invention to provide a less than lethal cartridge with a lethal projectile which can only be used in a weapon designed for less than lethal cartridges. 
     It is another objective of the present invention to provide a less than lethal cartridge with a projectile which has a rim that is deeper than the rim of a conventional cartridge with a lethal projectile. 
     It is still another objective of the present invention to provide a less than lethal cartridge with a projectile that will only fire in a weapon that is specifically designed to fire the less than lethal cartridge and will not fire a conventional cartridge that contains a lethal projectile. 
     It is a further objective of the present invention to provide a less than lethal cartridge with a projectile which has a caliper that conventional lethal ammunition is not available in. 
     It is a further objective of the present invention to provide a less than lethal projectile that does not kill but stuns and incapacitates. 
     Another objective of the present invention is to provide a less than lethal projectile comprising a sealed filled pouch constructed of polymeric material which does not burst upon impact. 
     A further objective of the present invention is to provide a less than lethal cartridge containing a polymeric sealed pouch containing non-toxic shot within. In the rare instance where the polymeric pouch is ruptured on impact or otherwise punctured, the shot therein will not harm the environment or the suspect. 
     A still further objective of the present invention is to provide a method of producing a less than lethal cart using a form, fill, and seal machine in combination with a loading ammunition machine. The combination will allow for a cost effective mass production assembly of the less than lethal projectile. 
     An additional objective of the present invention is to provide a less than lethal cartridge that may be fired from a weapon. The pressure in the cartridge being a low pressure, such as below 1000 psi. The speed of the projectile will have a range between 260 and 600 feet per second. 
     An additional objective of the present invention is to provide a less than lethal cartridge including a polymeric pouch which has a tail on its trailing end to provide stability during flight and accuracy of the projectile. 
     It is still another objective of the present invention to provide a less that lethal cartridge that can be used in a handgun. 
     Other objectives and advantages of this invention will become apparent from the following description taken in conjunction with any accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. Any drawings contained herein constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1  is a cross sectional view of a polymeric pouch of the present invention; 
         FIG. 2  is a cross sectional view of an alternative polymeric pouch of the present invention; 
         FIG. 3  is a cross sectional view of an exemplary cartridge casing for use with the present invention; 
         FIG. 4  is a cross sectional view of a cartridge containing the polymeric pouch of the present invention; 
         FIG. 5  is a pictorial view of an exemplary vertical form, fill, and seal machine; 
         FIG. 6  is a pictorial representation of an exemplary ammunition loading machine; 
         FIG. 7  is a front perspective view of a cartridge of the present invention containing an alternative less than lethal projectile; 
         FIG. 8  is a side view of a cartridge of the present invention containing the alternative less that lethal projectile of  FIG. 7 ; 
         FIG. 9  is a cross sectional view of the cartridge in  FIG. 8 ; and 
         FIG. 10  is a cross sectional view taken along line A-A in  FIG. 9 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Detailed embodiments of the instant invention are disclosed herein, however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific functional and structural details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representation basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. 
       FIGS. 1-10 , which are now referenced, illustrate the present invention and the manner in which it is assembled. Like components are numbered consistently throughout. The less than lethal projectile  1  is constructed from a filled sealed pouch  10  and an empty shell casing  30 . As shown in  FIG. 1  a pouch  10  is constructed from polymeric material, more specifically, a bi-axially oriented polyethylene terephthalate polyester film (boPET). The boPET film sheet is of sufficient strength to not burst upon impact. The boPET is typically available in a variety of thicknesses, which are measured in ‘mils’. The mil is not a metric unit of measure, one mil equals 0.001 inches. It is preferred that the boPET used is at least 4 mils. The boPET film sheet has a high tensile strength and is transparent. Although boPET is the preferred polyester film it is contemplated that other polymeric film sheets may be used in construction of the pouch  10 . The pouch  10  includes an outer surface  12  and an inner surface  14  with defines a compartment  16 . The compartment is filled with shot  18  of a predetermined amount of tungsten granules, a non-toxic metal. The shot  18  has a weight within the range of 260 to 437.5 grains. In the art, grain is a unit measure of weight. The shot  18  is non-toxic so that in the rare instance that the pouch  10  should burst on impact due to punctures, the shot  18  within will not harm the suspect or the environment. The alternative embodiment of the pouch  10  comprises a leading end  20  and a trailing end  22  as illustrated in  FIG. 2 . 
     The pouch  10  includes a tail  24  on the trailing end  22 . The leading end  20  is sealed on all edges after the pouch is filled with the shot  18 . The leading end  20  and the trailing end  22  are not in communication with each other and include a seam  26  thereinbetween as a means of separation. The tail  24  includes a triangular notch  28 . This assists the tail  24  in providing stability to the projectile while the projectile is in flight. 
     As illustrated in  FIG. 3 , a less than lethal cartridge  30  is provided. The less than lethal cartridge  30  includes an empty cylindrical shell case  40 , a closed end  32 , and open end  34 . The less than lethal cartridge  30  has a rim portion  36  adjacent the closed end  32 , a head portion  38 , and a shell case  40  nearest the open end  34 . The rim portion  36  includes a primer  42 . The primer  42  is in alignment with a firing pin of a weapon (not shown). Adjacent the head portion  38  is the gun powder charge  44  and a wad  46 . When the firing pin (not shown) strikes the primer  42 , the primer  42  fires and ignites the gun powder  44 . The head portion  38  may be constructed of brass, plastic, or any other suitable material. The shell case  40  includes a projectile compartment  48  for receiving and holding the pouch  10  within the cylindrical walls of the shell case  40 . When the gun powder  44  is ignited pressure is built up behind the wad  46  and subsequently the wad  46  and pouch  10  are propelled down the barrel of a weapon by the expanding gases from the gun powder. 
     As shown in  FIG. 4 , the polymeric bag  10  is interposed within the cylindrical walls  49  of the shell case  40  producing a cartridge  30 , herein known as a less than lethal cartridge. As defined, a cartridge  30  is ammunition consisting of a cylindrical casing containing an explosive charge and a projectile, which can be fired from a gun. The leading end  20  of the polymeric pouch  10  being nearest the open end  34  of the less than lethal cartridge  30  at the shell case  40  and the trailing end  22  of the polymeric pouch  10  being adjacent to the wad  46  or gun powder  44  depending on the weapon used. 
     To construct the loaded less than lethal cartridge  30  a vertical form, fill, and seal machine  60  is used in combination with an ammunition loading machine  90 . By way of example, U.S. Publication No. 2005/0193689 is an example of a vertical form, fill, and seal machine for forming pouches with contents therein. As illustrated in  FIG. 5 , a vertical form, fill, and seal machine  60  having a hopper  61  is loaded with shot having a predetermined amount of tungsten granules  64 . A polymeric film sheet  100  is continuously drawn about a pouch former and filler  74  on the form, fill, and seal machine  60 . More specifically, the polymeric film roll  100  has a support shaft  66  which is coupled to a drive motor  68  which rotates the polymeric film roll  100  to dispense film  100  at a predetermined rate. Rollers  70  are placed intermittently. Furthermore, the polymeric film sheet  100  is disposed about a stationary guide roll which feeds the polymeric film sheet  100  thru a tension means  72  to maintain the polymeric film sheet  100  taut as it is fed and guided about the pouch former and filler  74 . The polymeric film sheet  100  is wrapped about the pouch former and filler  74  to form an overlapped polymeric film having overlapping free edges  102 . While wrapped about the pouch former and filler  74 , the overlapping free edges  102  are heat sealed together with a vertical sealing bar  76  forming a vertical seal  104  and producing a hollow sleeve  106  having a top portion  108  defining an opening  109  and a bottom portion  110  defining an opening between the overlapped polymeric film  100 . The vertical sealing bar  76  is actuated by a piston or other suitable actuation means  78  to position the vertical sealing bar against the overlapping free edges  102  and to retract it therefrom. Then the bottom portion  110  of the hollow sleeve  106  is heat sealed by a traverse sealing bar  80  to form a traverse seam  112 , the hollow sleeve  106  is then filled from the top portion opening  109  with shot  18  from the pouch former and filler  74 . Concurrently therewith the top portion  108  of the filled hollow sleeve  106  is heat sealed by a traverse sealing bar  80  and detached from the bottom portion  110  of another pouch (which is concurrently about to be filled) with a sealing jaw  84  producing a filled sealed polymeric pouch  10 . The traverse sealing bar  80  is actuated by a piston or other suitable actuation means  82  to position the traverse sealing bar  80  against the top portion  108  and bottom portion  110  of the hollow sleeve  106  and to retract it therefrom. The sealing jaw  84  is also actuated by a piston or other suitable actuation means  86 . Once detached the filled sealed pouch  10  is fed onto a conveyor  88 . The heating means forming seams on the polymeric film sheet  100  is a resistive heating element having a temperature control. The vertical form, fill, and seal machine  60  allows for change in the size of the pouch  10  and a different grain weight for shot  18 . The conveyor  88  feeds the filled sealed pouch  10  through a collator station  89  that properly positions the pouch in the correct orientation to be loaded onto an ammunition loading machine  90 . The collator station  89  is a device for placing the pouch  10  in an orientation suitable for entering the ammunition loading machine  90 . It is contemplated that the collator station  89  positions the pouch  10  with the tail end  24  leading to enter the ammunition loading machine  90  for tail first loading within the empty casing  40 . 
     U.S. Pat. No. 4,116,109 is an example of an ammunition loading machine. As shown in  FIG. 6 , the ammunition loading machine  90  is fed empty shell casings  40 , herein known as hulls. A drive chassis  92  which operates a dial  94  about an axis, transport the less than lethal cartridges  30  successively to a series of circumferentially-spaced loading stations, such as the casing loading station  95 , wad and powder filler  96 , the shot charger  97 , shot feeder  98 , and the crimping fixture  99 . The empty shell casings  40  are automatically loaded with a pre-determined quantity of wad and gun powder. The pre-determined amount of wad, primer, and gun powder is dependent on the intended use of the less than lethal projectile. As a less than lethal projectile firing from a weapon with low pressure may contain more wad or gun powder than a less than lethal projectile firing from a weapon with high pressure. Then the filled sealed pouch  10  is automatically moved into the projectile compartment  48  of the empty shell casing  40 . The filled sealed pouch  10  is loaded with the tail end  24  adjacent to the wad  46 , for tail first loading. Lastly, the projectile compartment  48  is crimped to producing a fully-loaded cartridge  30 , herein known as a less than lethal cartridge, adapted to be loaded into a barrel of a firearm. The automatic loading ammunition machine can be loaded with various caliber shell casings and various lengths for shell casing. Furthermore, the automatic loading ammunition machine allows for varying the amount of gun powder and wad in a shell casing. 
     The less than lethal cartridge  30  is capable of being fired from a weapon of low pressure, specifically a weapon having a chamber pressure as low as 600-700 psi. Because of the ability of the less than lethal cartridge  30  to be fired at an extremely low pressure the less than lethal cartridge  30  can be adapted to be fired from any handgun of any size or caliber. Preferably, the firearm used to discharge the less than lethal cartridge  30  comprises of a stationary barrel with a plurality of bores with a revolving firing pin. By way of example U.S. Pat. No. 1,348,035 disclosed such a device. However, it should be noted that the less than lethal projectile is not limited to this type of firearm. It is also contemplated that a rail may be positioned on the firearm. The rail is equipped with a light source of up to 120 lumens, this amount of light may temporarily blind the suspect and provide increase safety to the user. The rail can is also equipped with a laser. The laser capability provides a beam of light towards the intended target. The laser capability allows the user better accurate in firing the firearm. The rail further including a video and audio camera for documentation of the foregoing events. 
     An alternative embodiment of the present invention is illustrated in  FIGS. 7-10 . A less than lethal cartridge  120  is illustrated in  FIG. 7 . The less than lethal cartridge  120  includes a casing  122 , a solid projectile or bullet  124 , propellant or gun powder  126 , a wad  128  and a rim portion  130 . The rim portion  130  is secured to one end of the casing  122  and seals off that end of the casing. The casing  122  includes a cylindrical wall portion  132  and an open end  136 . The rim portion includes a primer  138 . The primer is preferably a mixture of an explosive lead styphnate blended with non-corrosive fuels and oxidizers which burns through a flash hole  140  and ignites the propellant or gun powder  126 . The diameter of the primer is preferably 0.207 inches, but can be any other comparable dimension. The flash hole or passageway  140  from the primer to the gun powder  126  is illustrated as having a diameter of 0.080 inches, but can be any other comparable dimension. 
     The inner diameter of casing  122  varies from 0.435 inches at point  142  to 0.430 inches at point  144 . This difference in inner diameter of the casing assists in retaining the projectile  124  within the casing  122  until the less than lethal cartridge is fired. While these dimensions are preferable, any other comparable dimensions can be employed. The less than lethal projectile  124  is a single piece made from a polymer. It can be made from a mixture of nylon 6/6, nylon 6 and glass fibers. The percentages of each of the materials of the mixture will vary depending upon the desired physical characteristics of the projectile  124 . It can also be made from a mixture of materials having properties similar to those recited hereinabove. 
     The outer diameter of the casing  122  and the outer diameter of the projectile  124  are the same. In a preferred embodiment the outer diameters are both 0.490 inches. While this is a preferred embodiment, these diameters can be other dimensions. The only requirement is that both outer diameters are the same. The thickness  148  of the shell casing  122  is preferably 0.030 inches. While this is a preferred embodiment, these diameters can be other dimensions. The thickness  150  of the rim  130  is preferably 0.100 inches. The diameter  152  of the rim  130  is preferably 0.566 inches. The length  154  of the casing  122  is preferably 1.250 inches. The caliper or outer diameter  156  of the cartridge, the casing  122  and the projectile  124  are preferably 0.490 inches. The overall length  158  of the less than lethal cartridge  120  is preferably 2.030 inches. The diameter  160  of the primer  138  is preferably 0.207 inches. The diameter  162  of the flash hole  140  is preferably 0.80 inches. While these dimensions are preferred they can be any other comparable dimensions. 
     All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference. 
     It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and any drawings/figures included herein. 
     One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.

Technology Classification (CPC): 5