Patent Description:
In livestock production plants, it is important to stun and disable an animal for processing. Although numerous methods have been used to stun livestock, captive bolt mechanisms have proven to be the most efficient, inexpensive, and humane way to disable the animal. Particularly, pneumatic captive bolt devices have been used in this capacity.

<CIT> and <CIT> and <CIT>, disclose pneumatic animal stunners that, among other things, include a physical catch for the piston that drives the stunning rod.

<FIG> show a prior art catch arrangement for a stunner in which stunning rod <NUM> extending rightward (forward) from a piston <NUM> has a leftward (rearward) end with outwardly extending lips <NUM> that may be alternately held and released by inward extending lips at the end portion 4a of a catch <NUM>. At a central portion of the body of catch <NUM> is an inwardly extending flange 4b which is pivotable about an outwardly extending flange 6a of catch pivot post <NUM>. A catch piston <NUM> includes an inner bore 5a at a forward end, an inner bore 5c at a rearward end, and a relief portion 5b between the two. In the hold position of <FIG>, the catch piston <NUM> is slid longitudinally rearward so that forward inner bore 5a contacts and moves catch forward end 4a toward and into engagement with stunning rod lips <NUM>, at the same time that rearward inner bore 5c contacts the outer surface of catch rearward end 4c. In the release position of <FIG>, the catch piston <NUM> is slid longitudinally forward so that forward inner bore 5a moves forward of catch forward end 4a, and the relief portion 5b permits catch forward end 4a to move outward and out of engagement with stunning rod lips <NUM> as the flange 4b of catch <NUM> pivots about catch post pivot flange 6a. At the same time, catch piston rearward inner bore 5c slides forward and then moves out of contact with the outer surface of catch rearward end 4c. Upon release of the stunning rod lips, compressed air behind piston <NUM> moves stunning rod <NUM> forward to stun the animal.

The catch and other components of such prior designs function well, but in operation some of its components are subject to sliding engagement with other components, and therefore interference and/or wear, which causes drag and/or requires periodic replacement of such components. This gradual wear of such components is compounded by the overall weight and density of the stunning rod used with the stunner, which is typically composed of steel in the prior art. The stunning rod is also subject to rotation during usage.

Compressed air usage by prior art stunners is also an issue, since excess air volume needed for each stunner cycle increases costs of operation. Additionally, the operator is subject to fatigue when using the stunner repeatedly, due to the shock of the stunning rod projection and retraction in each operation cycle combined with the heavy weight/high density of the steel stunning rod.

Bearing in mind the problems and deficiencies of the prior art, it is therefore an object of the present invention to provide an animal stunner having a release system which reduces wear of the moving parts controlling the operation of the animal stunner.

It is another object of the present invention to provide an animal stunner having reduced drag on movement between the catch and catch piston during operation.

A further object of the invention is to provide an animal stunner having reduced wear on the catch and catch piston as a result of repeated operation and reduced premature failure.

It is yet another object of the present invention to provide an animal stunner having more reliable stunning due to a stronger and improved catch system.

Yet a further object of the present invention is to provide an animal stunner having improved operator safety as a result of a stronger catch system.

Another object of the present invention is to provide an animal stunner having lower compressed air usage between each stunner cycle.

A further object of the invention is to provide an animal stunner having improved operator comfort and reduction of possible injury.

Yet another object of the present invention is to provide an animal stunner in which the stunning rod slides easily and reliably without rotation.

Still another object of the present invention is to provide an animal stunner in which the stunning rod slides in a faster and more accurate manner while simultaneously reducing the overall wear of the inner components of the stunner and fatigue experienced by the operator over multiple, continuous cycles of use.

Still other objects and advantages of the invention will in part be obvious and will in part be apparent from the specification.

The above and other objects, which will be apparent to those skilled in the art, are achieved in the present invention which is directed in one aspect to a stunning rod adapted for use in a pneumatic animal stunner for stunning an animal according to claim <NUM>, wherein the rod is mountable with a piston and movable within an inner chamber in the stunner, and the inner chamber has a catch for alternately holding and releasing the stunning rod. The rod comprises an elongated body having a density, a forward end sized to receive a detachable tip, an opposite rearward end adapted to receive an outwardly extending lip for engagement with the catch. The rod stunning further comprises a detachable tip for striking an animal's head, the detachable tip being received in and secured to the forward of the end elongated body, the detachable tip having a density greater than the density of the elongated body. The stunning rod is capable of being driven forward along a longitudinal axis within the stunner inner chamber to stun an animal, and rearward along the longitudinal axis to retract and hold the stunning rod by the catch.

In a related aspect the present invention is directed to a method of making a stunning rod adapted for use in a pneumatic animal stunner for stunning an animal according to claim <NUM>, wherein the rod is mountable with a piston and movable within an inner chamber in the stunner, and the inner chamber has a catch for alternately holding and releasing the stunning rod. The method comprises providing an elongated body having a density, a forward end sized to receive a detachable tip, an opposite rearward end adapted to receive an outwardly extending lip for engagement with the catch. The method also comprises providing a detachable tip for striking an animal's head, the detachable tip having a density greater than the density of the elongated body. The method further comprises attaching the detachable hardened tip to the elongated body forward end to create a stunning rod. The stunning rod is capable of being driven forward along a longitudinal axis within the stunner inner chamber to stun an animal, and rearward along the longitudinal axis to retract and hold the stunning rod by the catch.

The stunning rod elongated body between the rearward end and forward end may have a density less than that of steel, and less than the density of the detachable tip. The stunning rod elongated body density may be less than <NUM>/cm<NUM> and the detachable tip density may be greater than <NUM>/cm<NUM>. The stunning rod elongated body may be made of aluminum, and the detachable tip may be made of hardened steel.

The stunning rod forward end of the elongated body may have a beveled opening and the detachable tip may have a beveled lower end received in the forward end, the forward end beveled opening and the tip lower end being beveled at supplementary angles.

The stunning rod elongated body may include a piston movable within an inner chamber in the stunner, wherein the piston is adjacent the elongated body rearward end and integral and of one piece with the body. The elongated body rearward end may be threaded to receive a complementarily threaded outwardly extending lip for engagement with the catch. The stunning rod elongated body and detachable tip according to the invention have non-circular cross sections.

In yet another aspect the present invention is directed to a pneumatic animal stunner, wherein the stunner has an inner chamber, and including a stunning rod as described above mountable with a piston and movable within the inner chamber, and wherein the inner chamber has a catch for alternately holding and releasing the stunning rod for stunning an animal.

The features of the invention believed to be novel and the elements characteristic of the invention are set forth with particularity in the appended claims. The figures are for illustration purposes only and are not drawn to scale. The invention itself, however, both as to organization and method of operation, may best be understood by reference to the detailed description which follows taken in conjunction with the accompanying drawings in which:.

In describing the embodiment(s) of the present invention, reference will be made herein to <FIG> of the drawings in which like numerals refer to like features of the invention.

Structure and operation of the exemplary animal stunner <NUM> is shown in general in <FIG>. The stunner <NUM> includes an outer elongated hollow housing <NUM>, an outer housing nose or front end <NUM>, a tail end <NUM>, a stunning rod <NUM> and a catch <NUM> for holding and releasing the stunning rod <NUM>. The portion of the animal stunner <NUM> having a catch is shown in detail in <FIG> and <FIG>. The forward and rearward directions described herein are with respect to the stunner front end <NUM>, and inward and outward directions described herein are with respect to the longitudinal axis <NUM>. A piston <NUM> surrounded by an O-ring seal <NUM> slides within an inner cylindrical chamber <NUM> forward and rearward along axis <NUM>, and carries stunning rod <NUM>. The rearward end of stunning rod <NUM> ends in an outward extending lip <NUM> that is alternately held and released by catch <NUM>, and the forward end of the stunning rod extends through head contact <NUM> to be driven toward the animal's head when the catch releases the stunning rod lip <NUM>.

Stunner <NUM> may be operated by pressurized fluid, such as (but not limited to) compressed air for the example shown. Outward of and shown as surrounding inner chamber <NUM> adjacent its central portion and rearward end is annular cylindrical first pressure or fire chamber <NUM>. Compressed air can move freely and quickly between fire chamber <NUM> to the region of inner chamber <NUM> behind piston <NUM> upon operation of main valve <NUM>. As shown in <FIG>, annular cylindrical second pressure or return chamber <NUM> is also adjacent to, and shown as surrounding inner chamber <NUM> adjacent its central portion and forward end in the example of <FIG>. A catch piston chamber <NUM> is located adjacent and around catch piston <NUM>, which itself holds and releases catch <NUM>. Chambers <NUM>, <NUM>, <NUM> and <NUM> may be pressurized to operate the stunner shown, as will be described in more detail below.

A first or main trigger <NUM> in main handle <NUM> is used to control a main handle valve <NUM> to the pressurized fluid, compressed air as used herein, to initiate the sequence that fires the stunning rod. For purposes of safety, to operate the exemplary stunner shown there are two additional conditions that must be met before the catch mechanism for the stunning rod is released. The head contact activator <NUM> located at the front of the tool must be in contact with the animal to receive the stroke and a second or auxiliary trigger <NUM> in auxiliary handle <NUM> must be manually operated. Although it is possible to construct and operate the stunner with only one of these three, at least two, and preferably all three, should be employed for safety.

An embodiment of the present invention employing main trigger <NUM>, controlling main handle valve <NUM>, and head contact activator <NUM> is shown in <FIG>. In this embodiment, a second or auxiliary trigger is not provided, and instead a grip handle <NUM> is positioned at the tail end <NUM> of housing <NUM>. Grip handle <NUM> as shown in <FIG> comprises a mounting bracket <NUM> and an inner handle bar <NUM> secured by a pair of connecting rods <NUM> extending inwardly from a pair of mounting bracket arms 212a, 212b. A flexible mount <NUM> of rubber or other polymer surrounds inner bar <NUM> to provide cushioning to outer handle tube <NUM> disposed thereover. In this embodiment the operator may hold grip handle <NUM> in one hand while holding main handle <NUM> in the other. While depressing and holding trigger <NUM> in main handle <NUM>, the operator may then displace head contact activator <NUM> against the head of the animal to fire the stunning rod.

<FIG> shows the animal stunner <NUM> with the catch <NUM> hold position, with valves in the neutral position, and with the air supply pressurized and prior to firing. An air hose (not shown) is attached to the supply port <NUM> on the main chamber valve body <NUM>, and main valve body <NUM> is pressurized by the compressed air. Main valve <NUM> within valve body <NUM> is positioned to the right by spring (not shown) pressure and pressure force conveyed from air passages <NUM> (connected to supply port <NUM>) through the main handle valve <NUM> and then through passageway <NUM>. The main valve spool <NUM> in this position will simultaneously pressurize, via passageways <NUM>, <NUM> and <NUM>, the fire chamber <NUM> and also the smaller return chamber <NUM>, both at a slower fill rate. The stunning rod piston <NUM> is fully pressurized by air flow from fire chamber <NUM> behind the piston, and retained from movement by the closed catch <NUM> assembly holding stunning rod lip <NUM>, as will be explained further below. The main handle valve <NUM> is in the neutral position and not yet activated by main trigger <NUM>, and valve <NUM> is extended by spring (not shown) pressure downward, so that the air passage via passageway <NUM> to the head contact <NUM> is vented through the main handle valve <NUM>. The head contact <NUM> is extended by spring (not shown) pressure forward (rightward). Any air pressure on the extend side of the catch piston <NUM> in chamber <NUM> is vented via passageways <NUM> through the auxiliary handle vent <NUM>, and any air pressure in passageway <NUM> is vented via passageway <NUM> through the head contact vent <NUM>. The area under and behind the stunning rod piston <NUM> is vented through the main valve body <NUM> into the exhaust port <NUM>. The stunner will not fire in this position, wherein main trigger <NUM>, auxiliary trigger <NUM> and head contact <NUM> are not depressed.

<FIG> shows the animal stunner with the catch <NUM> release position, with valves <NUM>, <NUM>, <NUM> and <NUM> in the firing position. To commence the firing sequence, the main handle valve <NUM> is activated by the operator depressing main trigger <NUM> with one hand, head contact <NUM> is activated by the operator pressing against the animal's head to move the contact rearward (leftward), and auxiliary handle valve <NUM> is activated by the operator depressing auxiliary trigger <NUM> with the other hand. As the main handle valve moves into the upward position, air passage from the main handle valve <NUM> to main valve spool (spring end) is exhausted via passageway and air passage from the main handle valve <NUM> to head contact <NUM> is pressurized via passageway <NUM>. Compressed air also flows via air passage <NUM> to the catch piston cylinder chamber <NUM> after flow through the head contact valve <NUM>, passageway <NUM> and passageway <NUM> through the auxiliary handle valve <NUM>. As a result of head contact <NUM> being depressed and auxiliary handle valve <NUM> being pressurized, catch piston <NUM> is moved by the compressed air in chamber <NUM> and extends forward (rightward) to its limit and opens the catches <NUM>. As a result, stunning rod <NUM> is released and moves forward (rightward) at a high rate of speed, while the air in chamber <NUM> under and forward of the stunning rod piston <NUM> is exhausted through passageway <NUM> and the main valve body <NUM> exhaust port <NUM>.

<FIG> shows the animal stunner <NUM> with the stunning rod <NUM> in the full forward, end-of-stroke position. The stunning rod stroke is stopped by the annular cushions <NUM> next to and inside of the nose housing <NUM>. In this position the stunning rod piston seal <NUM> extends forward and beyond the small holes <NUM> in the liner <NUM> of chamber <NUM> allowing air flow into the main valve reverse passage <NUM> to the bottom (rightward) end of the main valve spool <NUM>. As main valve <NUM> is pressurized, the spool commences moving upward (leftward) against the pressure of the spring to reverse the flow of air to the stunning rod piston <NUM>.

<FIG> shows the animal stunner near the end of the firing sequence with the air in main valve <NUM> moved into the reverse position to retract the stunning rod, as a result of compressed air flow from reverse passage <NUM> (<FIG>). Both main handle valve <NUM> and auxiliary handle valve <NUM> are still depressed and activated, but head contact <NUM> is released from the animal's head so that contact valve <NUM> returns to the forward (rightward) position. Main valve <NUM> reverse passage <NUM> is pressurized forcing the main valve spool to move upward (leftward) against the pressure of the spring, so that the main valve body air flow is reversed. As this occurs, fire air chamber <NUM> is exhausted through the main valve body <NUM> into the exhaust port <NUM>, and air flow is reversed via passage <NUM> from the catch piston <NUM> chamber <NUM> through open auxiliary handle valve <NUM>, passageways <NUM> and <NUM> and out through the head contact <NUM> vents <NUM> when the head contact <NUM> is released. The compressed air pressure immediately available from the return chamber <NUM> causes pressurized air to move freely and quickly to flow via passageways <NUM> (<FIG> and <FIG>), main valve <NUM> and passageway <NUM> into the forward (rightward) end of chamber <NUM> (<FIG>). Although return chamber <NUM> is volumetrically smaller and contains less pressurized fluid than fire chamber <NUM>, it is sized to provide sufficient air to drive piston <NUM> and stunning rod <NUM> rearward. This use of compressed air from adjacent return chamber <NUM> reduces the volume of air needed as compared to prior art methods where the air to return the piston is supplied via internal passageways from the supply port. Instead of relying on a short, higher pressure blast of compressed air through the supply port at the same time the piston return cycle is initiated, the present invention pre-supplies the compressed piston return air at the same time the fire chamber is pressurized, during the longer time available between operation cycles. This permits restriction orifices of desired sizes to be used at the supply port <NUM>, thereby saving on total air volume usage by the stunner.

The pressurized air in chamber <NUM> forward end retracts the stunning rod <NUM> rearward (leftward) as shown in <FIG> until piston <NUM> contacts the forward end <NUM> of catch piston <NUM>. As a result of the piston striking it, the catch piston <NUM> is retracted rearward (leftward) into the catch cylinder <NUM>, which closes the catches <NUM> by forcing them inward to capture stunning rod lip <NUM>, so that the stunning rod <NUM> is retained by the catches, as shown in <FIG>.

When the main handle valve <NUM> is returned to neutral as a result of main trigger <NUM> being released and in the undepressed position (<FIG>), air passage to main valve spool (spring end) is again pressurized, and shifts valve <NUM> to its original position. Both fire chamber <NUM> and return chamber <NUM> are again pressurized, air passage to the nose is exhausted via vent <NUM>, auxiliary handle valve <NUM> is returned to neutral as a result of auxiliary trigger <NUM> being released, any pressure is vented through vent <NUM> of the auxiliary handle valve <NUM> so that air passage to the catch piston <NUM> is vented two ways for safety, and will not fire again until the firing sequence is again started. The order of firing sequence has no impact on the stunner performance, and both triggers <NUM>, <NUM> and the head contact <NUM> must be activated in any order before firing will occur in this embodiment.

Main handle <NUM> is shown in <FIG> as being secured directly to main valve body <NUM>. To provide cushioning to mitigate any shock due to the firing of the stunning rod, and therefore reduce operator injury and increase operator comfort, there may be provided a cushion mount for main handle <NUM>. Such a mount <NUM> is shown in <FIG> for insertion between main handle <NUM> and main valve body <NUM>. Cushion mount <NUM> includes a first or upper portion <NUM>, which is connected or otherwise secured to the lower side of housing <NUM>, and a second or lower portion <NUM>, which is connected or otherwise secured to the upper end of main handle <NUM>. Upper portion <NUM> includes passageways 156a, 158a, 160a which mate at upper surface 222a with passageways <NUM>, <NUM>, <NUM>, respectively, (<FIG>) opening from the lower end of main valve body <NUM>. Passageways 156a, 158a, 160a connect through upper portion <NUM> at side surface 222b with fittings 224a, 224b, 224c, respectively. In lower portion <NUM> passageways 156b, 158b, 160b mate at lower surface 226a with passageways <NUM>, <NUM>, <NUM>, respectively, (<FIG>) opening from the upper end of main handle <NUM>. Passageways 156b, 158b, 160b connect through lower portion <NUM> at side surface 226b with fittings 228a, 228b, 228c, respectively. Hoses or tubes 234a, 234b, 234c connect fittings 224a, 224b, 224c with fittings 228a, 228b, 228c, respectively.

Between mount upper portion <NUM> and a lower portion <NUM> there are provided a pair of anti-shock members 230a, 230b, which may be made of rubber cushions or other flexible polymer. Anti-shock members 230a, 230b may be in the configuration of elongated blocks (i.e., parallelepipeds) or other shapes disposed on either side between a central flange 222c extending downwardly from upper portion <NUM>, and a pair of side flanges 226c, 226d extending upwardly from lower portion <NUM>. One or more fasteners <NUM>, here shown as three bolts, may extend in the same direction as or normal to longitudinal axis <NUM> into and through corresponding aligned openings in side flange 226c, anti-shock member 230a, central flange 222c, anti-shock member 230b and side flange 226d. The major surfaces of members 230a, 230b and axes of the fasteners <NUM> are contained in planes parallel to the longitudinal axis <NUM> of the housing <NUM>. Except for the fasteners, anti-shock members 230a, 230b completely isolate mount upper portion <NUM> from mount lower portion <NUM>, and absorb vibration and shock transmitted from the body of stunner <NUM> to main handle <NUM>.

With or without the anti-shock members, mount <NUM> may be provided in different patterns of passageways 156a, 158a, 160a and/or passageways 156b, 158b, 160b, to connect to the main handle <NUM> and/or main valve body <NUM> at different orientations than the conventional one shown in the drawings, where the trigger <NUM> movement is aligned with the longitudinal axis <NUM> of the stunner housing <NUM>. As shown in <FIG>, this would permit handle <NUM> and trigger <NUM> movement to be mounted to main valve body <NUM> or housing <NUM> in a different fixed position and aligned to an orientation other than that of stunner longitudinal axis <NUM>, for example, with handle <NUM>' and trigger <NUM>' movement in a direction <NUM>° to axis <NUM>. The different main handle orientations may accommodate different layouts in the plant operations or operator comfort, for example, due to pneumatic activation instead of mechanical activation of the valve with the trigger.

An alternate embodiment of a stunning rod useful in the stunner of the present invention is shown in <FIG>. This alternate embodiment of stunning rod <NUM>' depicted herein may be used in place of stunning rod <NUM> described previously, and comparable portions of the rod are numbered similarly, but with a prime ( ' )mark.

The stunning rod embodiment shown <NUM>' has an elongated body <NUM>' extending along a longitudinal axis <NUM>' (<FIG>), with the elongated body <NUM>' having a forward end <NUM> and an opposite rearward end <NUM>. Body <NUM>' may be solid for all or a portion of its length (<FIG>), or may be hollow for all or a portion of its length (<FIG>). The forward end <NUM> has a lip <NUM> extending out from the elongated body <NUM>' parallel to the longitudinal axis <NUM>'. The forward end <NUM> is sized with the same diameter(s) as the stunning rod body for striking (e.g. penetrating) an animal's head. Alternatively, the rod forward end <NUM> may be sized or may have an attachment (not shown) that has a sufficiently larger diameter to prevent penetration of the animal to be stunned. A hardened tip <NUM>, as shown in <FIG>, may further be attached to the forward end <NUM> of the stunning rod <NUM>' in the manner as shown in <FIG> by employing a threaded or other fastener <NUM>. A stepped down central projection <NUM> with a diameter less than that of the opposite tip end is fitted into a comparably sized opening <NUM> in the end of the elongated body <NUM>, so that the tip shoulder <NUM>' of tip <NUM>' contacts the stunning rod body end <NUM>. The opposite rearward end <NUM> has formed in (or received as a separate piece as shown in <FIG>, and <FIG>) an outwardly extending lip <NUM>' for engagement with a catch <NUM>, as described elsewhere herein. If the catch lip <NUM>' is a separate piece, it may be secured by a fastener <NUM> into the end <NUM> (<FIG>) or complementarily threaded with end <NUM> and screwed on.

As shown in <FIG>, the stunning rod <NUM>' also has a mounting portion <NUM> adjacent to the elongated body <NUM>' and located between the forward end <NUM> and rearward end <NUM>. The mounting portion <NUM> may have a circular profile for receiving a piston <NUM>'. The mounting portion <NUM> has a radially outwardly extending flange <NUM> which is perpendicular to the elongated body <NUM>', as shown in <FIG>. Referring to <FIG>, the piston <NUM>' has a cylindrical body with the front and rear surfaces both being flat. The piston <NUM>' has a circular inner bore <NUM>' for slideably receiving the stunning rod <NUM>'. In particular, the size of the inner bore <NUM>' conforms to the radial measurements of the mounting portion <NUM>, which is also circular in shape. The piston <NUM>' is axially received and rests on mounting portion <NUM> in a tight sliding fit against flange <NUM>.

Alternatively, piston <NUM>' may be integrally formed with rod <NUM>' of one piece, as shown in <FIG>. The elongated body <NUM>' has a circular profile adjacent to the piston <NUM>' portion of the stunning rod <NUM>'. On the forward end <NUM> facing side of the piston <NUM>', the elongated body <NUM>' flanges out in a semicircular manner where the forward-facing surface of the piston <NUM>' and elongated body <NUM>' integrally meet. The rearward end <NUM> adjacent piston <NUM>' may receive or have integrally formed therein of one piece a lip <NUM>' (<FIG>) for engaging the catch.

Referring to <FIG>, all or a portion of the length of body <NUM>' of stunning rod <NUM>' between the piston <NUM>' and forward end <NUM> is configured to have a first pair of opposite sides <NUM> each having a first radius R1 and a first diameter D1, and width W1 between them in the Y-direction, and a second pair of opposite sides <NUM> each having a second radius R2 and a second diameter D2, and width W2 between them in the X-direction. The first radius R1 of the first pair of opposite sides <NUM> may be different from and larger than the second radius R2 of the second pair of opposite sides <NUM>. The first width W1 between the first pair of sides <NUM> may be different from and smaller than the second width W2 of the second pair of sides <NUM>. The rod <NUM>' slides in the stunner in a comparably shaped opening in the nose and nose guide of the stunner, discussed further below. The first radius R1 may be any suitable dimension, such as from about <NUM> -. <NUM> inches (<NUM> - <NUM>), e.g., <NUM> in. (<NUM>) and the second radius R2 may be any suitable dimension, such as from about <NUM> - <NUM> inches (<NUM> - <NUM>), e.g. <NUM> in. The first width W1 may thus be any suitable dimension, such as from about <NUM> - <NUM> inches (<NUM> - <NUM>), and the second width W2 may be any suitable dimension, such as from about. <NUM> inches (<NUM> - <NUM>), e.g., <NUM> in. Other sizes and dimensions may be employed. Stunning rod tip <NUM> as shown in <FIG> may be likewise configured to have the same first radius and first diameter, second radius and second diameter, and widths in the Y- and X-directions, respectively, as stunning rod body <NUM>'.

<FIG> depict yet another embodiment of the stunning rod <NUM>" which may be used in place of stunning rod <NUM> and <NUM>' described previously, and comparable portions of the rod are numbered similarly, but with double prime (") markings. This embodiment of the stunning rod <NUM>" is composed of an elongated solid aluminum body <NUM>" having a forward end <NUM>" and rearward end <NUM>". Stunning rod piston <NUM>" may be integrally formed and of one piece with rod body <NUM>" (as shown in <FIG>), or rod body <NUM>" may be configured to receive piston <NUM>" as a separate piece (as shown in Figs. _44 and <NUM>). The opposite rearward end <NUM>" may have formed in, or received as a separate piece, an outwardly extending lip for engagement with a catch, as shown in <FIG>, and <FIG> and as described elsewhere herein with previous stunning rod embodiments <NUM> and <NUM>'. The elongated body <NUM>" may have a constant radius extending substantially the entire length of rod <NUM>" (<FIG>), or may have first and second differing radii as shown in previous embodiments (<FIG>). The elongated body <NUM>" may be made of any suitably strong metal, alloy or composite material that is both lighter in weight than steel and having a lower density. More than one material may be used to construct the elongated body of the rod.

This light weight and density results in an increase in striking speed when the stunning rod <NUM>" is released from the catch, as compared to a stunning rod conventionally made entirely of steel. The use of such aluminum or other lighter weight and density body <NUM>" additionally creates less recoil for end-users of the stunner <NUM>, and also results in a smoother impact with the animal. The lightweight elongated body may also decrease manufacturing costs, because it enables lower cost solid bodies to be employed, and eliminates any need to employ higher cost hollow bodies. Instead of or in addition to aluminum (having a density of approximately <NUM>/cm<NUM>), other materials may be used to form the stunning rod body, such as, but not limited to, carbon fiber (density of approx. <NUM>/cm<NUM>), silicon (density of approx. <NUM>/cm<NUM>), silicon nitride (density of approx. <NUM>/cm<NUM>), titanium density of (approx. <NUM>/cm<NUM>), and the like, with densities lower than <NUM>/ cm<NUM>, less than that of steel (density of approx. <NUM>/cm<NUM>).

An alternate embodiment of the detachable hardened tip or striking end <NUM> previously described is shown as tip <NUM>" secured to the forward end <NUM>" of the aluminum stunning rod <NUM>" (<FIG>). The embodiment of tip <NUM>" as shown in <FIG> has a circular cross section with stepped down central projection <NUM>" with a diameter less than that of the opposite tip end that may be fitted into a comparably sized opening <NUM>" in the end of the elongated body <NUM>" (<FIG>). When installed, the shoulder <NUM>" of tip <NUM>" contacts the end <NUM>" of stunning rod body <NUM>". A fastener (such as fastener <NUM> shown in <FIG>) may be fitted through central opening <NUM>" to secure tip <NUM>" to the forward end <NUM>" of body <NUM>". If elongated body <NUM>" has a non-circular cross section with first and second differing radii as shown in previous embodiments (<FIG>), then tip <NUM>" will likewise have a non-circular cross section with comparable first and second differing radii (<FIG>).

Another tip embodiment is further shown in <FIG>, wherein a central shaft <NUM>'' extending longitudinally from detachable hardened tip <NUM>" has a diameter less than that of the tip end and is threaded to be fastened within a comparably threaded bore <NUM>" in the center of the forward end <NUM>" of the aluminum stunning rod body <NUM>". Conversely, a threaded shaft may instead protrude from the forward end <NUM>" to be threadingly received by a threaded bore in the detachable hardened tip <NUM>" (not shown). Lower, outer edges <NUM>" of tip <NUM>" facing (and adjacent upon connection to) the stunning rod forward end <NUM>" are beveled inwardly from the outer tip diameter to the threaded shaft at an acute angle α of about <NUM>° with respect to the longitudinal axis <NUM>, as shown in the embodiment. Outer edges <NUM>" of forward end <NUM>' of the rod body <NUM>" are beveled at an angle β of about <NUM>° with respect to the longitudinal axis <NUM>. Angle α may be any other angle less than <NUM>°, for example an angle in the range of <NUM>° to <NUM>°, to which angle β may be supplementary, with such combination being meant to further increase the contact and holding strength of hardened tip <NUM>" within the rod body <NUM>". Thus upon attachment, the combined angles α, β of the hardened tip edges <NUM>" and forward end edges <NUM>" form a substantially <NUM>° angle. This combination of the beveled ends <NUM>", <NUM>" and threaded connectors <NUM>", <NUM>" greatly decreases the likelihood of detachment of the hardened tip <NUM>" during operational use of the stunner <NUM>. The detachable hardened tip <NUM>" may be made of steel, so that elongated body portion of the stunning rod has a density less than that of the tip. If the elongated body <NUM>" is made of more than one material, the elongated body in this embodiment has an average density less than the density of the detachable hardened tip.

Referring to <FIG>, an outer housing nose <NUM>' surrounds the stunning rod <NUM>' and includes a nose guide <NUM>' with an opening through which the stunning rod passes. The bore in the outer housing nose guide <NUM>' is slightly larger than and conforms to the radii R1, R2 and widths W1, W2 (as shown in <FIG>) of the stunning rod <NUM>' so as to permit sliding movement in the longitudinal direction. Unlike the circular cross section of the body <NUM> of stunning rod <NUM> described previously, the non-circular cross section configuration of the rod body <NUM>' with different widths in the X- and Y-directions prevents rotational movement of the rod about the longitudinal axis <NUM>' within the nose guide and housing upon firing of the stunner.

The structure and operation of catch <NUM> with respect to the stunning rod is shown in more detail in <FIG>. <FIG> show the stunning rod <NUM> comprising an elongated body <NUM> having a longitudinal axis <NUM>. A stunning rod lip <NUM> is disposed on one end of the stunning rod <NUM>. <FIG> show a catch piston <NUM> having a smooth inner bore <NUM> and a catch piston flange <NUM>. The stunning rod <NUM> is axially disposed on piston <NUM> within the housing <NUM> and is capable of being driven forward along the longitudinal axis <NUM> towards the front end of the housing <NUM> when pressurized air or other pneumatic fluid enters the chamber, as described above. The stunning rod <NUM> shown with the forward end sized for striking (e.g. penetrating) the animal's head, but other stunning rod designs and styles may be employed, including those with sufficiently large diameter of the forward end to prevent penetration of the animal being stunned. The alternate embodiment of stunning rod <NUM>' may be employed in place of the embodiment <NUM> shown in <FIG>.

<FIG> show catch <NUM> having a catch body <NUM>, at the forward end a catch end portion <NUM> with inward extending lips and near the rearward end an outward extending catch flange <NUM>. Catch <NUM> is mounted within the housing <NUM> outside of the stunning rod longitudinal axis <NUM> for alternately holding and releasing the stunning rod <NUM>. The catches <NUM> shown in <FIG> are two of four arcuate catches that may be arrayed around axis <NUM> as shown in their hold position (<FIG>) and employed in the example depicted in the drawings. Fewer or more than four catches may be employed. Catch body <NUM> rotates with respect to a catch pivot or post, shown herein in the form of a catch pivot ring <NUM> extending around the outer sides of the catch bodies (<FIG> and <FIG>). The catch flange <NUM> extends outwardly away from axis <NUM> and is engageable with a catch pivot ring inner lip <NUM> extending inwardly from the end of the cylindrical body <NUM> of catch pivot ring <NUM> shown in <FIG>.

As shown in <FIG> and <FIG>, catch body portion <NUM> is pivotally mounted on inner lip <NUM>, between stationary catch pivot ring <NUM>, disposed on a side away from axis <NUM>, and stationary catch support <NUM> (see also <FIG>), disposed on a side toward axis <NUM>. The catch support <NUM> has a cylindrical body portion <NUM> and includes a circular support head <NUM> disposed adjacent the back portion of the housing <NUM> and a circular catch support distal end <NUM> which is disposed within the four arcuate catches <NUM>. An external groove <NUM> is disposed in and around the outside of body <NUM> adjacent end <NUM> to receive an optional O-ring (discussed further below). The catch body portion <NUM> is disposed on an outward side of catch support <NUM> away from the stunning rod longitudinal axis <NUM>. The catch <NUM> includes the end portion <NUM> extending from the body portion <NUM> toward the housing front end <NUM> and distal from the catch support <NUM>. Since the example employs a plurality of catches (four) arrayed about longitudinal axis <NUM>, each catch <NUM> is constructed and held between catch pivot ring <NUM> and catch support <NUM> so that their ends <NUM> are normally extended away from each other and axis <NUM>. The catch end portion <NUM> is movable by catch piston <NUM> to a hold position toward the longitudinal axis <NUM>, where it engages stunning rod lip <NUM> preventing the stunning rod <NUM> from being driven forward. In the hold position catch body <NUM> is in contact with both the stationary catch pivot ring <NUM> and the stationary catch support distal end <NUM>.

When catch piston <NUM> is longitudinally moved forward (<FIG>), as will be described further below, the constraint placed on catch end portion <NUM> is removed, and the end portion <NUM> moves outward to a release position away from stunning rod lip <NUM> and the stunning rod longitudinal axis <NUM> permitting the stunning rod <NUM> to be driven forward. Outward movement of catch end portion <NUM> is caused by sliding movement of the angle or taper between the forward portion of stunning rod lip <NUM> and the rearward portion of the inward facing lip of catch end portion <NUM>, as stunning rod <NUM> moves longitudinally forward. Catch end portion <NUM> may optionally be assisted in being urged to spring outward by an optional catch tension O-ring or elastic member <NUM> wrapped around the body <NUM> of the catch support <NUM>, in groove <NUM>. When in the hold position (<FIG>), O-ring or elastic member <NUM> is compressed by catch body <NUM>, so that when catch piston <NUM> moves forward, member <NUM> expands, thereby urging the catch body <NUM> and end <NUM> away from axis <NUM>, which assists in reducing wear on the outer forward tapered surface of stunning rod lip <NUM>. In this catch end portion release position away from axis <NUM>, catch body <NUM> is in contact with the stationary catch pivot ring <NUM> and out of contact with the stationary catch support distal end <NUM>. The catch flange <NUM> is engaged with the catch pivot ring inner lip <NUM>, allowing the catch flange <NUM> to be held pivotally between the catch pivot ring inner lip <NUM> and the catch support cylindrical body portion <NUM> (<FIG>), allowing the catch <NUM> to pivot about the catch flange as shown in <FIG>.

The catch <NUM> may be an arcuate section of a cylinder having an inner catch end portion <NUM> and an outer flange <NUM>. The catch <NUM> shown in <FIG> has an arc of less than <NUM>° as shown in <FIG> so that four catches <NUM> may be arranged cylindrically about the longitudinal axis <NUM> and within the catch pivot ring <NUM> with sufficient space between the catches <NUM> for the catches <NUM> to pivot on the catch pivot ring inner lip <NUM> without interfering with one another. The four catches <NUM> are supported from collapsing on one another by the catch support <NUM>.

The catch piston <NUM> is disposed adjacent the catch end portion <NUM> on a catch side away from the longitudinal axis. The catch piston <NUM> is in sliding contact with the catch <NUM> adjacent the catch end portion <NUM> and out of contact with the catch body portion <NUM>. The catch piston <NUM> is adapted to slide in the directions of the longitudinal axis <NUM> between a first, rearward position, shown in <FIG>, urging the catch end portion <NUM> toward the stunning rod lip <NUM> longitudinal axis <NUM> in the hold position, thereby holding and preventing the stunning rod <NUM> from being driven forward, and a second, forward position, shown in <FIG>, permitting the catch end portion <NUM> to move to the release position away from the stunning rod lip <NUM> longitudinal axis <NUM>, releasing and permitting the stunning rod <NUM> to be driven forward.

As described above in connection with <FIG>, at the end of the firing sequence piston <NUM> reverses direction in chamber <NUM>, and moves rearward to strike the forward end <NUM> of catch piston <NUM>, to move it rearward and force catches <NUM> inward, as shown in <FIG>. In the closed or locked position, the catch end portion <NUM> is fully engaged with the stunning rod lip <NUM>, holding the stunning rod <NUM> from moving forward. The catch <NUM> is held in the fully engaged position by the catch piston inner bore <NUM>. In operation, as the firing sequence commences, the pneumatic pressure in chamber <NUM> moves the catch piston <NUM> forward (rightward) toward the housing front end <NUM>. Once the inner bore <NUM> moves forward past the catch end portion <NUM>, as shown in <FIG>, the catch <NUM> pivots about the catch pivot ring inner lip <NUM> wherein each catch end portion <NUM> moves outward from the cylindrical orientation, disengaging the catch end portion <NUM> and the stunning rod lip <NUM>. In the disengaged position, the catch body portion <NUM> is not in contact with the catch piston <NUM> or the stationary catch support distal end <NUM>. The force of pressurized air drives piston <NUM> forward and stunning rod <NUM> (or <NUM>'/<NUM>") moves along the stunning rod longitudinal axis <NUM> toward the housing front end <NUM> from the force of the pressurized air or other pneumatic fluid.

The present invention therefore provides an improved animal stunner in which the stunning rod exhibits an increase in striking speed when the stunning rod is released from the catch, creates less recoil for users of the stunner, and also results in a smoother impact with the animal. The stunning rod elongated body enables lower cost solid bodies to be employed, with a gain in animal stunning effectiveness.

While the present invention has been particularly described, in conjunction with a specific preferred embodiment, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. It is therefore contemplated that the appended claims will embrace any such alternatives, modifications and variations falling within the scope of the present invention.

Claim 1:
A stunning rod (<NUM>', <NUM>") adapted for use in a pneumatic animal stunner (<NUM>) for stunning an animal, the rod (<NUM>', <NUM>") being mountable with a piston (<NUM>', <NUM>") and movable within an inner chamber (<NUM>) in the stunner, the stunning rod characterized in that the rod <NUM>', <NUM>" comprises:
an elongated body (<NUM>', <NUM>") having a density and a forward end (<NUM>, <NUM>") sized to receive a detachable tip (<NUM>, <NUM>"), an opposite rearward end (<NUM>, <NUM>") adapted to receive an outwardly extending lip (<NUM>, <NUM>') for engagement with a catch within the pneumatic animal stunner (<NUM>); and
a detachable tip (<NUM>, <NUM>") for striking an animal's head, the detachable tip (<NUM>, <NUM>") being received in and secured to the forward end (<NUM>, <NUM>") of the elongated body (<NUM>', <NUM>"), the detachable tip (<NUM>, <NUM>") having a density greater than the density of the elongated body (<NUM>', <NUM>");
wherein the stunning rod (<NUM>', <NUM>") is capable of being driven forward along a longitudinal axis (<NUM>) within the stunner inner chamber (<NUM>) to stun an animal, and rearward along the longitudinal axis (<NUM>) to retract and hold the stunning rod (<NUM>',<NUM>") by the catch (<NUM>); and
wherein the elongated body and the detachable tip have a non-circular cross section.