Patent Description:
<CIT>describes a prior art cartridge for a remote electroshock weapon.

The present invention provides an electrode for a conducted electrical weapon, as set out in claim <NUM>, and a method for winding a filament for an electrode of a conducted electrical weapon, as set out in claim <NUM>. Optional features of the invention are set out in the dependent claims.

A conducted electrical weapon ("CEW") is a device that provides a stimulus signal to a human or animal target to impede locomotion of the target. A CEW may include a handle and one or more removable deployment units (e.g., cartridges). A removable deployment unit inserts into a bay of the handle. A deployment unit may include one or more wire-tethered electrodes (e.g., darts) that are launched by a propellant toward a target to provide the stimulus signal through the target. A stimulus signal impedes the locomotion of the target. Locomotion may be inhibited by interfering with voluntary use of skeletal muscles and/or causing pain in the target. A stimulus signal that interferes with skeletal muscles may cause the skeletal muscles to lockup (e.g., freeze, tighten, stiffen) so that the target may not voluntarily move.

A stimulus signal may include a plurality of pulses of current (e.g., current pulses). Each pulse of current delivers a current (e.g., amount of charge) at a voltage. A voltage of at least a portion of a pulse may be of sufficient magnitude (e.g., <NUM>,<NUM> volts) to ionize air in a gap to establish a circuit to deliver the current of the pulse to a target. A gap of air may exist between an electrode (e.g., dart) and tissue of the target. Ionization of air in the gap establishes an ionization path of low impedance for delivery of the current to the target.

The stimulus signal is generated by a signal generator. The signal generator is controlled by a processing circuit, which also controls a launch generator. The processing circuit receives input from a user interface, and possibly information from other sources. The user interface may be as simple as a safety position (e.g., on/off) and a pull of a trigger to fire the weapon. An example of information from other sources may be a signal that indicates that a deployment unit is loaded into a bay in the handle and ready for use.

The processing circuit may send commands to the launch generator to launch one or more electrodes and/or engage the signal generator based on input received from the user interface or other possible sources. Upon receiving a launch command from the processing circuit, the launch generator controls the propulsion system to provide a force to launch one or more electrodes.

A force for launching one or more electrodes from a deployment unit may include release of a rapidly expanding gas. The force from the gas propels the one or more electrodes toward the target. As an electrode flies toward the target, the electrode deploys (e.g., extends) a wire-tether (e.g., filament, wire). The filament may be wound in a winding (e.g., coils). The winding may be positioned (e.g., stored) in the electrode. The winding of the filament may unravel (e.g., uncoil) to deploy the filament.

An electrode may land on or near a target. The filament then extends from the deployment unit that is inserted into the handle to the electrode positioned on or near the target. One end of the filament remains coupled to the deployment unit and through the deployment unit to a signal generator in the handle to deliver the current. The other end of the filament remains coupled to the electrode, or at least to a portion thereof (e.g., front, spear), to deliver the current to the target via the filament.

An electrode may include a spear. A spear may couple to target clothing or embed in target tissue to retain the electrode coupled to the target.

A filament is stored in a body of the electrode prior to deployment. A filament deploys from the winding through an opening (e.g., nozzle) in the back of the electrode. The end of the filament that couples to the electrode remains coupled before, during, and after launch and impact with the target. The end of the filament that is coupled to the deployment unit remains coupled to the deployment unit and through the deployment unit to the handle of the CEW while the deployment unit is inserted into the handle.

A filament may be wound into a winding and positioned in a body of the electrode during manufacture (e.g., assembly) of the electrode. While forming the winding, a body of the electrode may be separated from a front of the electrode. A front portion of the electrode may include a spear. A first end portion of the filament may extend through the body and out an opening in the rear of the body. A mandrel (e.g., spindle) may be inserted through the opening in the rear of the body. Filament from a spool of filament may be wound around the mandrel to form the winding. Once the winding has been formed, the wire from the spool may be cut to form a second end portion of the filament. The second end of the filament may be coupled to a front portion of the electrode. The mandrel may be extracted from the winding and from the body via the rear of the electrode. The body may be coupled to the front of the electrode so as to position (e.g., trapped, held, retained) the winding in a cavity of the body of the electrode.

During assembly of a deployment unit, the first end of the filament that extends from the rear of the electrode is coupled to the deployment unit.

A propulsion system may provide a force for launching one or more electrodes from a deployment unit. A propulsion system provides the force to propel one or more electrodes toward a target. A propulsion system may release a rapidly expanding gas to propel one or more electrodes. A propulsion system may receive a signal for launching (e.g., releasing the rapidly expanding gas) responsive to operation of a control (e.g., switch, trigger) of a user interface of the CEW. A propulsion system may include a pyrotechnic that ignites (e.g., burns) to release a compressed gas from a canister to launch the electrodes. The compressed gas from the canister rapidly expands to provide a force to launch the electrodes.

A manifold may transport (e.g., delivery, carry, direct) the rapidly expanding gas from the compressed gas to one or more electrodes to launch the electrodes from the deployment unit. A manifold may include structures (e.g., channels, guides, passages) for transporting a rapidly expanding gas from a source (e.g., burning pyrotechnic, canister of compress gas) of the rapidly expanding gas to the electrodes. A manifold may transport a rapidly expanding gas from the source to one or more bores that hold the one or more electrodes respectively. A manifold may be formed of a pliable material (e.g., silicone) to decrease an amount of expanding gas not transported (e.g., lost) prior to arrival at the bores and to improve manufacturability and assembly.

A canister (e.g., capsule) holds (e.g., retains) a compressed gas (e.g., air, nitrogen, inert). Release of the gas from the canister provides the force for propelling the one or more electrodes. A canister may be filled with a gas at a high pressure then sealed to retain the gas in the canister at the high pressure. Filling a canister may include placing a canister in a pressurized environment that contains the gas at the high pressure. The canister may include one or more openings that permit the passage of the gas from the environment into a cavity of the canister. The openings may be sealed to seal the gas in the canister. In an implementation, the canister includes a cavity having an opening. A lid is positioned in the opening. The lid is welded to the canister to seal the gas in the canister. The lid may include one or more notches to form openings between the lid and a body of the canister to permit the flow of gas from the environment into the cavity. The lid may be welded to the body. Welding the lid to the body seals the openings formed by the notches thereby retaining the gas in the canister.

A CEW performs the functions of a CEW and includes the structures as discussed above. The CEW includes a deployment unit and a handle. The deployment unit performs the function of a deployment unit and the handle performs the function of a handle as discussed above.

The deployment unit includes a propulsion system, a manifold, an electrode, and an electrode. The propulsion system performs the functions of a propulsion system as discussed above. The manifold performs the functions of a manifold as discussed above. The electrodes perform the functions of an electrode as discussed above.

The handle includes a launch generator, a processing circuit, a signal generator, and a user interface. The launch generator and processing circuit perform the functions of a launch generator and a processing circuit as discussed above. The signal generator and user interface perform the functions of a signal generator and a user interface as discussed above.

Although only deployment unit is mentioned above, the CEW may cooperate with one or more deployment units at the same time. One or more deployment units may couple (e.g., insert into) the handle at the same time. The handle may include one or more bays for respectively receiving one deployment unit.

The handle may provide signals from the signal generator and/or launch generator to the deployment unit. A launch signal from the launch generator may cooperate with (e.g., instruct, initiate, control, operate) the propulsion system to launch the electrodes from the deployment unit. A stimulus signal from the signal generator may be delivered (e.g., transported, carried) by the electrodes and their respective filaments to a human or animal target to interfere with locomotion of the target.

The handle may have a form-factor for ergonomic use by a human user. A user may hold (e.g., grasp) the handle. A user may manually operate the user interface to operate (e.g., control, initiate operation of) the CEW. A user may aim (e.g., point) the CEW to direct the deployment of the electrodes toward a specific target.

A processing circuit includes any circuitry and/or electrical/electronic subsystem for performing a function. A processing circuit may include circuitry that performs (e.g., executes) a stored program. A processing circuit may include a digital signal processor, a microcontroller, a microprocessor, an application specific integrated circuit, a programmable logic device, logic circuitry, state machines, MEMS devices, signal conditioning circuitry, communication circuitry, a conventional computer, a conventional radio, a network appliance, data busses, address busses, and/or a combination thereof in any quantity suitable for performing a function and/or executing one or more stored programs.

A processing circuit may further include conventional passive electronic devices (e.g., resistors, capacitors, inductors) and/or active electronic devices (e.g., op amps, comparators, analog-to-digital converters, digital-to-analog converters, programmable logic). A processing circuit may include conventional data buses, output ports, input ports, timers, memory, and arithmetic units.

A processing circuit may provide and/or receive electrical signals whether digital and/or analog in form. A processing circuit may provide and/or receive digital information via a conventional bus using any conventional protocol. A processing circuit may receive information, manipulate the received information, and provide the manipulated information. A processing circuit may store information and retrieve stored information. Information received, stored, and/or manipulated by the processing circuit may be used to perform a function and/or to perform a stored program.

A processing circuit may control the operation and/or function of other circuits and/or components of a system. A processing circuit may receive data from other circuits and/or components of a system. A processing circuit may receive status information and/or information regarding the operation of other components of a system. A processing circuit may perform one or more operations, perform one or more calculations, provide commands (e.g., instructions, signals) to one or more other components responsive to data and/or status information. A command provided to a component may instruct the component to start operation, continue operation, alter operation, suspend operation, and/or cease operation. Commands and/or status may be communicated between a processing circuit and other circuits and/or components via any type of buss including any type of conventional data/address bus.

A processing circuit may include memory for storing data and/or programs for execution.

A launch generator provides a signal (e.g., launch signal) to a deployment unit. A launch generator may provide a launch signal to one or more propulsion systems of one or more deployment unit respectively. A launch signal may initiate (e.g., start, begin) operation of a propulsion system to launch one or more electrodes. A launch signal may ignite a pyrotechnic. A handle may include a connector for coupling one or more conductors from a launch generator to one or more deployment units while the deployment units are coupled to (e.g., inserted into) the handle. A launch generator may be controlled by and/or cooperate with a processing circuit to perform the functions of a launch generator. A launch generator may receive power for a power supply (e.g., battery) to perform the functions of a launch generator. A launch signal may include an electrical signal provided at a voltage. A launch generator may include circuits for transforming power from a power supply into a launch signal. A launch generator may include one or more transformers to transform a voltage from a power supply into a signal provided at a higher voltage.

A signal generator provides a signal. A signal that accomplishes electrical coupling and/or interference with locomotion of a target may be referred to as a stimulus signal. A stimulus signal may include a current provided at a voltage. A stimulus signal through target tissue may interfere with (e.g., impede) locomotion of the target. A stimulus signal may impede locomotion of a target through inducing fear, pain, and/or an inability to voluntary control skeletal muscles as discussed above.

A stimulus signal may include a one or more (e.g., series) of pulses of current. Pulses of a stimulus signal may be delivered at a pulse rate (e.g., <NUM> pps) for a period of time (e.g., <NUM> second). A signal generator may provide a pulse having a voltage in the range of <NUM> to <NUM>,<NUM> volts. A pulse of current may be provided at one or more magnitudes of voltage. A pulse may include a high voltage portion for ionizing gaps of air to electrically couple a signal generator to a target. A pulse provided at about <NUM>,<NUM> volts may ionize air in one or more gaps of up to one inch in series between a signal generator and a target. Ionizing of air in the one or more gap between a signal generator and a target establishes low impedance ionization paths for delivering a current from a signal generator to a target. After ionization, the ionization path will persist (e.g., remain in existence) as long as a current is provided via the ionization path. When the current provided by the ionization path ceases or is reduced below a threshold, the ionization path collapses (e.g., ceases to exist) and the electrode is no longer electrically coupled to target tissue. Ionization of air in one or more gaps establishes electrical connectivity (e.g., electrically couple) of a signal generator to a target to provide the stimulus signal to the target. A signal generator remains electrically coupled to a target as long as the ionization paths exist (e.g., persist).

A pulse may include a lower voltage portion (e.g., <NUM> to <NUM>,<NUM> volts) for providing current through target tissue to impede locomotion of the target. A portion of a current used to ionize gaps of air to establish electrical connectivity may also contribute to the current provided through target tissue to impede locomotion of the target.

A pulse of a stimulus signal may include a high voltage portion for ionizing gaps of air to establish electrical coupling and a lower voltage portion for providing current through target tissue to impede locomotion of the target. Each pulse of a stimulus signal may be capable of establishing electrical connectivity of a signal generator with a target and providing a current to interfere with locomotion of the target.

A signal generator includes circuits for receiving electrical energy (e.g., power supply, battery) and for providing the stimulus signal. Electrical/electronic components in the circuits of a signal generator may include capacitors, resistors, inductors, spark gaps, transformers, silicon controlled rectifiers, and analog-to-digital converters. A processing circuit may cooperate with and/or control the circuits of a signal generator to produce a stimulus signal.

A user interface provides an interface between a user and a CEW. A user may control, at least in part, a CEW via the user interface. A user may provide information and/or commands to a CEW via a user interface. A user may receive information and/or responses from a CEW via the user interface. A user interface may include one or more controls (e.g., buttons, switches) that permit a user to interact and/or communicate with a device to control (e.g., influence) the operation (e.g., functions) of the device. A user interface of a CEW may include a trigger. A trigger may initiation an operation (e.g., firing, providing a current) of a CEW.

A propulsion system provides a force. A force may launch one or more electrodes from a deployment unit. A rapidly expanding gas may provide a force for launching one or more electrodes. A burning pyrotechnic may provide a rapidly expanding gas. Release of a pressurized gas from a canister may provide a rapidly expanding gas. In one implementation, the propulsion system contains a canister of highly pressurized gas. A rapidly expanding gas from a pyrotechnic operates to release the pressurized gas from the canister to launch the one or more electrodes. A propulsion system may provide the force needed to launch one or more electrodes.

A manifold (e.g., channel, passage) may direct (e.g., transfer, transport) a force of the rapidly expanding gas from the source of the rapidly expanding gas to the one or more electrodes to launch the electrodes.

A launch generator may cooperate with a propulsion system to launch one or more electrodes. A launch generator may provide a signal to a propulsion system. A signal may initiate (e.g., begin, start) an operation of the propulsion system to launch one or more electrodes. A signal from a launch generator may be referred to as a launch signal. A launch signal may ignite a pyrotechnic.

A force of rapidly expanding gas from the pyrotechnic may rupture (e.g., open) a canister filled with a compressed gas. The ruptured canister quickly releases a rapidly expanding gas. A manifold transports the rapidly expanding gas from the canister to the rear of one or more electrodes. The force delivered to the rear of the one or more electrodes accelerates the electrodes away from the deployment unit toward a target.

An electrode is propelled (e.g., launched) from a deployment unit toward a target. An electrode couples to a filament. A signal generator may provide a stimulus signal to a target via a filament that is electrically coupled to a filament. An electrode may include any aerodynamic structure to improve accuracy of flight toward the target. An electrode may include structures (e.g., spear, barbs) for mechanically coupling the electrode to a target. Movement of an electrode out of a deployment unit toward a target deploys (e.g., pulls) the filament coupled to the electrode. The filament extends from the cartridge in the handle to the electrode at the target. An electrode may be formed in whole or part of a conductive material for delivery of the current into target tissue. The filament is formed of a conductive material. A filament may be insulated or uninsulated.

A deployment unit of a CEW may include one or more electrodes. A deployment unit may include a manifold and/or a propulsion system. A propulsion system may include a canister and a pyrotechnic. A canister may hold a pressurized gas. A propulsion system, a manifold, a canister, a pyrotechnic may perform the functions of a propulsion system, a manifold, a canister, a pyrotechnic respectively discussed above.

A deployment unit may couple to (e.g., attach to, plug into, insert into) a handle. A deployment unit may be decoupled (e.g., detached) and separated (e.g., removed) from the handle. A deployment unit may be decoupled from a handle after a use (e.g., launch electrodes, deliver current) of the deployment unit. A used deployment unit may be replaced with an unused deployment unit and coupled to the handle. Coupling a deployment unit to a handle mechanically and electrically couples the deployment unit to the handle. Electrically coupling a deployment unit to a handle enables the deployment unit to communicate with the handle. Communication includes providing and/or receiving control signals (e.g., launch signal), stimulus signals, and/or information.

Another example of a CEW includes a handle, a first deployment unit, and a second deployment unit. The first deployment unit and the second deployment unit are inserted into the handle. The handle includes a trigger.

The handle performs the functions of a handle discussed above. The deployment units perform the functions of a deployment unit discussed above. The trigger performs the functions of a trigger discussed above.

In another example, the deployment unit is decoupled from the handle. The deployment unit includes a housing, a first electrode, a second electrode, a manifold , and a propulsion system. The electrodes perform the functions of an electrode discussed above. The manifold and propulsion system perform the functions of a manifold and a propulsion system respectively discussed above.

The housing includes a first bore and a second bore. The first electrode includes a body, a filament , a front wall, a rear wall, and a spear. The second electrode includes a body, a filament, a front wall, a rear wall, and a spear. The manifold includes a first outlet, a second outlet, an inlet, a channel, a first wall, and a second wall. The propulsion system includes a housing, an anvil, a canister, a lid, a pyrotechnic, a conductor, and an outlet. The anvil, canister, lid, pyrotechnic, and conductor are positioned in the housing.

The deployment unit cooperates with the handle to launch the electrodes toward a target to provide a stimulus signal to the target. A launch generator of the handle provides a launch signal to the conductor of the propulsion unit to launch the electrodes. The launch generator electrically couples to the conductor of the deployment unit. Electrical coupling may be accomplished by ionization of air in a gap between the launch generator and the conductor. The conductor transmits (e.g., carries, delivers) the launch signal to the pyrotechnic via the conductor.

The launch signal ignites the pyrotechnic. A rapidly expanding gas produced by the burning (e.g., ignition) of the pyrotechnic applies a force to the canister. The force moves the canister toward the anvil. The force presses the canister against the anvil thereby piercing (e.g., rupturing, opening) the canister. Piercing the canister releases a compressed gas held in the canister. The compressed gas exits the canister and enters into a passage of the anvil. The passage of the anvil carries (e.g., directs, guides) the now rapidly expanding compressed gas from the canister to the outlet of the propulsion system.

The rapidly expanding gas enters the inlet of the manifold. The rapidly expanding gas from outlet travels along the channel to the first outlet and the second outlet. The rapidly expanding gas exits the first outlet, enters the first bore, and applies a force on the first electrode which propels (e.g., launches) the first electrode from the first bore toward a target. The rapidly expanding gas exits the second outlet, enters the second bore, and applies a force on the second electrode which propels (e.g., launches) the second electrode from the second bore toward the target.

The rapidly expanding gas entering from the first manifold outlet launches the first electrode forward out of the first bore. The first electrode exits the first bore flying toward a target. As the first electrode travels toward the target, the filament stored within the body deploys through an opening in the rear wall. One end portion of the filament is mechanically coupled to the front of the deployment unit.

When the first electrode reaches the target, the spear couples to (e.g., enmeshes in, entangles in, attaches to) the target's clothing (e.g., garments, apparel, outerwear) or pierces and embeds into target tissue to mechanically couple to the target. The signal generator may electrically couple to the target through the first electrode via the deployed filament.

As with the first electrode, the rapidly expanding gas exits the second manifold outlet into the second bore to launch the second electrode out of the second bore. The second electrode exits the second bore and flies toward the target. As the second electrode travels toward the target, the filament stored within the body deploys through an opening in the rear wall. One end portion of the filament is mechanically coupled to the front of the deployment unit. The spear may mechanically couple the second electrode to target clothing or embed into target tissue. The signal generator may electrically couple to the target via the second electrode and the deployed filament.

The signal generator may provide a stimulus signal through target tissue via the filament, the first electrode, target tissue, the second electrode, and the filament. A high voltage stimulus signal ionizes air in any gaps to the electrically coupled signal generator to the target. The stimulus signal may provide a stimulus signal through the electrical circuit established with the target to impede locomotion of the target.

An implementation of electrode is now described. The electrode includes a body, a front wall, a rear wall, an opening, a filament, a spear, a groove, a band, and a recess. The electrode performs the function of an electrode discussed above.

The filament is wound into a winding. The winding of the filament is stored (e.g., stowed) within the body. A first end portion of the filament mechanically couples to the electrode. The first end portion is held (e.g., pressed, retained, compressed, squeezed, pinched) between the front wall and the body. The first end portion of the filament extends forward of the front wall. The first end portion and the filament do not electrically couple to the body or the spear. When the spear is proximate to or imbedded into target tissue, a high voltage stimulus signal ionizes the air in a gap between the first end portion of the filament and the spear, the front wall, or the body to provide a current to the target. The spear, front wall, and body may be formed of a metal to conduct the stimulus signal.

A second end portion of the filament extends through the opening in the rear wall and mechanically couples to the deployment unit. The second end portion remains coupled to the deployment unit before, during and after launching the electrode. The filament deploys from the winding in the body though the opening as the electrode travels away from the deployment unit toward a target.

The front wall includes a groove. The groove may encircle all or a part of the circumference of the front wall. The band is positioned in the groove. The band encircles at least a portion of the front wall. The band couples to the front wall in the groove. The spear mechanically couples to the front wall. The body may be formed of a metal. In an implementation the body is formed of aluminum. The body is positioned around the front wall and around the band. The front wall may be formed of a metal. In an implementation the front wall is formed of zinc. The body couples to the band which couples the front wall to the body. The band may be formed of a metal. In an implementation, the body is welded to the band to couple the body to the front wall.

The body remains coupled to the band and the band to the front wall before, during, and after launch of the electrode. The body remains coupled to the band and the band to the front wall before, during, and after impact of the electrode with a target.

The rear wall mechanically couples to the body. In an implementation, the rear wall is positioned in the rear open end of the cylindrical body. The rear wall may be coupled to the body using any conventional coupling (e.g., glue, interference).

A second implementation of an electrode is now described. The electrode includes a body, a front wall, a rear wall, and a filament. The front wall includes a channel, a retainer, a spear, a groove, and a recess. The rear wall includes an opening (e.g., nozzle). The body is deformed to form a crimp. Crimping the body provides a force to mechanically couple (e.g., bind) the body to the front wall. The electrode performs the function of an electrode discussed above.

The filament is wound into a winding. The winding of the filament is stored (e.g., stowed) within the body. A first end portion of the filament passes through the channel and extends forward of the front wall. A first end portion of the filament mechanically couples to the retainer. The retainer is positioned in the channel and mechanically couples to the front wall. The first end portion is held (e.g., pressed, retained, compressed, squeezed, pinched) in the retainer.

The structure and function of a retainer may be performed by one or more walls of the channel. A filament may be placed in the channel. The channel includes one or more walls. The filament is positioned between the one or more walls to extend forward of the front wall. One or more walls of the channel may be deformed (e.g., bend, crimped, squished) so that the one or more walls come into contact with the filament to retain the filament in the channel. For example, the channel may have a "U" shape such that the filament lies in the lower portion of the "U" shape and the upper portion of the "U" shape are pushed together to close the exit from the channel.

The first end portion of the filament is not electrically coupled to the body or the spear. When the spear is proximate to or imbedded into target tissue, a high voltage stimulus signal ionizes air in a gap between the first end portion of the filament and the spear, the front wall, and/or the body to provide a current to the target. The spear, the front wall, and the body may be formed of a metal to conduct the stimulus signal.

A second end portion of the filament extends through the opening in the rear wall and mechanically couples to the deployment unit. The second end remains coupled to the deployment unit before, during and after launching the electrode. The filament deploys from the winding in the body though the opening as the electrode travels away from the deployment unit toward a target.

The spear mechanically couples to the front wall. When the electrode reaches a target, the spear couples to target clothing or pierces and embeds into target tissue to mechanically couple the spear to the target. In some instances, the impact of the electrode with a target causes the body of electrode to pivot around the location where the spear is mechanically coupled to or embedded into the target. A force of the angular momentum caused by the pivoting of the electrode and/or a recoil force may decouple the body from the front wall. Decoupling the body from the front wall leaves the spear coupled to the target while the force of the angular momentum overcomes the binding force of the crimp from the groove, and the body and the remaining winding are thrown (e.g., moved) away from the front wall and the target. The retainer retains the filament coupled to the front wall before, during, and after impact of the electrode with the target and separation of the body from the front wall.

Impact of the electrode pushes the spear into target clothing and/or tissue. The separation of the body and the winding from the front wall reduces a likelihood that the angular momentum or a force of impact may decouple the spear from the target.

The rear wall mechanically couples to the body. In an implementation, the rear wall is positioned in the rear open end of the cylindrical body. The rear wall may be coupled to the body using any conventional coupling.

A winding of a filament may be formed for insertion into and storage in the body of an electrode. Winding a filament may position a first end portion of a filament proximate to a front wall of an electrode for coupling to the front wall or between the front wall and the body as discussed above. Winding a filament may position a second end portion of a filament so that the second end potion extends through an opening in a rear wall of an electrode for coupling to a deployment unit.

During winding, a front wall of the electrode is positioned a distance forward of the body of the electrode. The rear wall of the electrode is coupled to the body. A mandrel of the winding machine may extend through the opening in the rear wall and extend forward until an end portion of the mandrel is inserted into a recess in the front wall. The filament may be wound around the mandrel in the space between the front wall and the body to form the winding. Once the winding is formed, the winding may be moved by the mandrel into the cavity of the body. As the mandrel moves the winding into the body, the front wall moves toward the body. As the winding is positioned in the body, the front wall is positioned with respect to the body for coupling the body to the front wall.

The mandrel may be extracted from the winding via the opening in the rear wall, thereby leaving the winding positioned in the body of the electrode. The first end portion of the filament may be coupled to a retainer for coupling the filament to the electrode or the first end portion of the filament may be held between the front wall and the body.

The body may be coupled to the front wall to complete assembly of the filament.

A machine winds a filament into a winding of the electrode. The machine includes an apparatus to hold and rotate the electrode and an apparatus that supplies the filament for the winding process. The apparatus that rotates the electrode includes the mandrel, the belt, and the motor. The apparatus that supplies the filament includes the spool, the arm, the worm gear, and the controller. The electrode includes the front wall, the spear, the filament, the winding, the body, the rear wall, and the rear wall opening. During the winding process, the body is separated from the front wall. The mandrel is extended through the opening of the rear wall and extended forward until an end portion of the mandrel is positioned in the recess of the front wall.

A process for winding a filament into an electrode includes:.

In an implementation, the filament is an insulated wire having an outer diameter of about <NUM>/<NUM> inches. In an implementation, the conductor of the filament is a copper-clad steel that is insulated with a Teflon insulator. In an implementation, the insulator on the filament includes a clear coat proximate to the conductor that is covered with a coat having a green color to provide greater visibility to the filament when used in the field.

The propulsion system includes a housing, pyrotechnic, conductor, canister, and anvil. The canister is positioned and the anvil is partially positioned inside the housing. The canister includes a cavity, which holds a pressurized gas sealed within the canister by a lid. The anvil includes a channel and an outlet. The propulsion system performs the function of a propulsion system discussed above.

The manifold includes an inlet, a channel, a first wall, a second wall, and first and second outlets. The manifold performs the function of a manifold discussed above.

The deployment unit cooperates with the handle to launch the first and second electrodes , propelled by the force of a rapidly expanding gas released by the propulsion system. The propulsion system is activated when the launch generator of the handle provides a launch signal via the conductor to ignite the pyrotechnic.

A rapidly expanding gas produced by the burning (e.g., ignition) of the pyrotechnic applies a force to the canister. The force moves the canister toward the anvil. The force presses the canister against the anvil so that a portion of the anvil pierces (e.g., ruptures, opens) the canister. Piercing the canister releases a compressed gas held within the cavity. The compressed gas exits the canister into the channel of the anvil. The channel guides (e.g., directs) the rapidly expanding compressed gas from the canister to the outlet of the anvil. The manifold transports (e.g., delivers, directs) a rapidly expanding gas from the pierced canister through the inlet, the channel, and the first and second outlets to launch the first and second electrodes positioned in first and second bores , respectively.

The force provided by the rapidly expanding gas from the canister determines the speed at which the first and second electrodes are launched toward a target. Preferably, the force provided by the rapidly expanding gas from the canister is consistent between deployment units so that the speed of launch of electrodes from different deployment units will be consistent. A consistent speed of launch of the first and second electrodes contributes to consistent accuracy in flight and aiming of the first and second electrodes with respect to a target. Variations in the force provided by the compressed gas stored in the cavity of the canister reduces the accuracy of launch of the first and second electrodes.

Two sources of variation in the force provided by the compressed gas in the canister include variations in the filling of the cavity of the canister and loss of gas from the manifold.

A first implementation of the manifold was divided into several sections which are formed using injection molding. The parts were rigid to provide strength and were welded together to form the manifold. The small parts provide shapes that are easily molded using injection molding; however, difficulties in assembly and joining the parts resulted in gaps between the parts and thereby gas leaks from the manifold. The gas leaks reduced the force of the expanding gas delivered to launch the first and second electrodes , the accuracy of electrodes in flight, and force of impact of the electrodes with the target.

The leaking of gas from a manifold formed from smaller parts may be overcome by forming the manifold as a single piece of material. However, forming the manifold in a single piece precludes the use of injection molding because the one-piece manifold could not be removed from the mold.

Forming the manifold from a flexible (e.g., pliable) material (e.g., silicone, rubber) permits molding of the manifold as a single piece which can be removed from a mold. However, a concern regarding a manifold formed of a flexible material was that the flexile material could not withstand the force applied by the expanding gas and would therefore structurally fail (e.g., blow out, compress, rupture, deform, separate). Prototypes of the manifold formed from silicone have shown that adding first and second support walls in the housing to provide support to a flexible manifold enable the flexible manifold to deliver the rapidly expanding gas from the canister to the first and second bores without structural failure and without suffering losses (e.g., leaks) of the gas from the flexible manifold. Further, a flexible material enables the manifold to better seal to the outlet of the anvil and to the inlets of the first and second bores thereby further reducing gas leaks. Accordingly, a manifold formed of flexible materials is manufacturable using conventional injection molding techniques while still delivering the rapidly expanding gas with little or no loss.

The canister includes the body, the cavity, the lid , and notches. The canister performs the function of a canister discussed above.

The canister holds (e.g., retains) a compressed gas (e.g., air, nitrogen, inert). Rapid release of the gas from the canister provides a force for propelling first and second electrodes from the deployment unit. The canister is filled with compressed gas by positioning the canister in a pressurized environment that contains a gas at a high pressure. While the canister is in the pressurized environment, the cavity is filled with the gas at the high pressure. The canister is then sealed while still positioned in the high-pressure environment so that the canister retains the compressed gas in the cavity.

A portion of the lid is welded to the body prior to inserting the canister into the high-pressure environment to reduce the difficulty and cost of welding the lid to the body to seal the high-pressure gas in the cavity. Partial welding of the lid to the body closes some of the notches, but leaves multiple notches open thereby allowing the compressed gas to flow freely into the cavity. When the cavity is at the same pressure as the environment, the remainder of the lid is welded to the body thereby trapping the high-pressure gas in the cavity of the canister.

The size of the notches provide passages for the high-pressure gas to enter and completely fill the cavity, so that the pressure and volume of gas held in the cavity is consistent across multiple canisters in different manufacturing lots. The consistent filling of canisters with gas at the same pressure provides high-pressure canisters with little variation in pressure over many lots. Manufacturing canisters that are filled to a consistent high-pressure and volume of gas increases the distance, predictability and accuracy of launching electrodes from a deployment unit.

Further related aspects of the disclosure are described below.

A method for forming a winding of a filament for an electrode for a conducted electrical weapon, the method comprising: pushing an end portion of a mandrel through an opening in a rear wall of the electrode toward a front wall of the electrode until the end portion of the mandrel enters a recess in the front wall, whereby the mandrel remains positioned in the opening; pushing a first end portion of the filament through the opening alongside the mandrel thereby positioning the first end portion of the filament rearward of the rear wall, the first end portion of the filament remains positioned through the opening and rearward of the rear wall before, during, and after forming the winding; rotating the mandrel to wind the filament around the mandrel to form a winding; and after forming the winding: positioning a second end portion of the filament forward of the front wall; and coupling a body of the electrode to the front wall whereby the body encloses the winding; and removing the mandrel so that the winding remains in the body positioned between the front wall and the rear wall.

The above method wherein rotating further comprises moving an arm with respect to the mandrel to form successive layers of the filament around the mandrel to form the winding.

The above method wherein: pushing the end portion of the mandrel comprises pushing the mandrel in a first direction; and pushing the first end portion of the filament comprises pushing the first end portion of the filament in a second direction opposite the first direction.

The above method wherein coupling comprises coupling the body to a band positioned in a groove of the front wall whereby the second end portion of the filament is trapped between the body and the front wall to retain the second end portion of the filament.

The above method wherein positioning the second end portion comprises: positioning the second end portion in a channel of the front wall; and crimping one or more walls of the channel to retain the filament in the channel.

The above method wherein positioning the second end portion comprises: positioning the second end portion in a retainer of a channel of the front wall; and crimping the retainer to retain the filament in the channel.

The above method wherein coupling the body to the front wall comprises crimping a portion of the body into a groove of the front wall.

The above method wherein coupling comprises: moving the body toward the front wall to bring a portion of the body in contact with the front wall thereby enclosing the winding; and crimping the portion of the body into a groove of the front wall.

An electrode for a conducted electrical weapon ("CEW"), the electrode configured to cooperate with a provided winding machine to form a winding, the electrode comprising: a front wall, the front wall includes a recess; a rear wall, the rear wall includes an opening; a spear coupled to the front wall; a body having a cavity therein, the cavity for enclosing the winding, a forward portion of the body is configured to couple to the front wall, a rearward portion of the body coupled to the rear wall; wherein: before the forward portion of the body is coupled to the front wall: a mandrel of the winding machine is inserted into the opening of the rear wall until an end portion of the mandrel rests in the recess of the front wall; the mandrel rotates as a filament is provided to form the winding; and the mandrel is removed from the recess and the opening in the rear wall whereby the winding remains inside the cavity of the body.

The above electrode wherein a shape of the opening in the rear wall comprises a triangle whereby the mandrel and an end portion of the filament fit through the opening at the same time.

The above electrode wherein an arm of the winding machine moves with respect to the mandrel as the mandrel rotates to wind successive layers of the filament around the mandrel to form the winding.

The above electrode wherein the front wall further comprises a band wherein: the forward portion of the body couples to the band to couple the body to the front wall; a first end portion of the filament is trapped between the body and the front wall to retain the first end portion of the filament.

The above electrode wherein the front wall further comprises a channel wherein: a first end portion of the filament is positioned in the channel; the first end portion of the filament extends forward of the front wall; at least one wall of the channel is deformed to retain the first end portion of the filament in the channel.

The above electrode wherein the front wall further comprises a channel and a retainer wherein: a first end portion of the filament is positioned in the channel and in the retainer; the retainer is deformed to retain the first end portion of the filament coupled to the front wall.

An electrode for a conducted electrical weapon ("CEW"), the electrode comprising: a front wall; a spear, the spear coupled to the front wall, the spear for coupling the electrode to a human or animal target to deliver a current to the target to impede locomotion of the target; a metal band, the metal band positioned at least partially around the front wall, the metal band coupled to the front wall; a winding of a filament, the filament for providing the current to at least one of the spear and the target; a rear wall, the rear wall includes an opening; a body having a cavity therein, the winding positioned in the cavity, a forward portion of the body coupled to the band, a rearward portion of the body coupled to the rear wall; wherein: a first end portion the filament extends rearward of the rear wall through the opening, the first end portion for coupling to a provided signal generator of the CEW, the signal generator for providing the current; a second end portion of the filament extends forward of the front wall to provide the current via a circuit formed by at least one of contact and ionization; and the second end portion of the filament is coupled to the electrode and remains coupled before, during, and after impact of the electrode with the target.

The above electrode wherein the second end portion of the filament is positioned in a channel in the front wall.

The above electrode wherein the body applies a force on the second end portion of the winding in the channel to couple the second end portion of the filament to the electrode.

The above electrode wherein the body is coupled to the band by welding.

A deployment unit for launching a wire-tethered electrode toward a human or animal target to deliver a current through the target to impede locomotion of the target, the deployment unit comprises: an anvil having an inlet and an outlet; a canister, the canister contains a pressurized gas; a bore having an inlet and an outlet; a manifold having an inlet, an outlet and a passage between, the manifold formed of a flexible material, the manifold constructed as a single piece; the wire-tethered electrode, the wire-tethered electrode positioned in the bore; a first wall and a second wall, the first wall positioned proximate to an exterior of the manifold on a first side of the manifold, the second wall positioned proximate to an exterior of the manifold on a second side of the manifold; the anvil pierces the canister to release the pressurized gas; the pressurized gas enters the inlet of the anvil; the pressurized gas exits the outlet of the anvil into the inlet of the manifold; a force of the expanding gas in the passage presses the exterior of the manifold on the first side and second side against the first wall and second wall respectively; the pressure on the first side and on the second side applies a force on the manifold to seal the flexible material of the inlet of the manifold to the outlet of the anvil and flexible material of the outlet of the manifold to the inlet of the bore to reduce leakage of the pressurized gas around the from the inlet and the outlet of the manifold; the single piece construction of the manifold transfers the rapidly expanding gas from the canister to the bore via the passage with little or no leakage of the pressurized gas from the manifold; the rapidly expanding gas exits the outlet of the manifold into the inlet of the bore; the force of the rapidly expanding gas pushes the electrode out the outlet of the bore to launch the electrode toward the target.

The above deployment unit wherein the first side of the manifold is opposite the second side of the manifold.

The above manifold wherein the manifold is manufacturable using conventional injection molding techniques.

A canister for providing a rapidly expanding gas to launch a wire-tethered electrode toward a human or animal target to provide a current through the target to impede locomotion of the target, the canister comprising: a body, the body having a cavity for holding a pressurized gas; an opening, the opening providing fluid communication between the cavity and an atmosphere surrounding the body; a lid having a plurality of notches around a circumference of the lid, the lid for sealing the opening to retain the pressurized gas in the cavity, wherein: prior to placing the canister into an atmosphere of the pressurized gas: the lid is positioned over the opening and welded to the body around a first portion of the circumference of the lid; welding the lid along the first portion of the circumference seals the notches around the first portion of the circumference whereas the notches around the second portion of the lid remain open thereby providing fluid communication with the cavity; after placing the canister into the atmosphere of the pressurized gas: the pressurized gas enters the cavity via the notches around the second portion of the circumference; and welding the lid along the second portion of the circumference seals the notches of the second portion thereby sealing the pressurized gas in the cavity.

The foregoing description discusses embodiments, which may be changed or modified without departing from the scope of the invention as defined in the claims. Examples listed in parentheses may be used in the alternative or in any practical combination. As used in the specification and claims, the words 'comprising', 'comprises', 'including', 'includes', 'having', and 'has' introduce an open-ended statement of component structures and/or functions. In the specification and claims, the words 'a' and 'an' are used as indefinite articles meaning 'one or more'. While for the sake of clarity of description, several specific embodiments of the invention have been described, the scope of the invention is intended to be measured by the claims as set forth below. In the claims, the term "provided" is used to definitively identify an object that not a claimed element of the invention but an object that performs the function of a workpiece that cooperates with the claimed invention. For example, in the claim "an apparatus for aiming a provided barrel, the apparatus comprising: a housing, the barrel positioned in the housing", the barrel is not a claimed element of the apparatus, but an object that cooperates with the "housing" of the "apparatus" by being positioned in the "housing". The invention includes any practical combination of the structures and methods disclosed. While for the sake of clarity of description several specifics embodiments of the invention have been described, the scope of the invention is intended to be measured by the claims as set forth below.

Claim 1:
An electrode for a conducted electrical weapon "CEW" the electrode comprising:
a front wall;
a spear coupled to the front wall, the spear for coupling the electrode to a target to deliver a current through the target;
a rear wall including an opening;
a body defining a cavity, wherein a forward portion of the body is detachably coupled to the front wall and a rearward portion of the body is coupled to the rear wall; and
a filament winding stored within the cavity, wherein the filament winding comprises a plurality of successive layers including a first filament layer and a last filament layer, wherein the first filament layer comprises a first end portion and the last filament layer comprises a second end portion, and wherein the first end portion extends rearward the body through the opening and the second end portion is coupled to a front portion of the electrode.