Non-lethal munitions having densified materials

Abstract

A non-lethal projectile having a nose component, a driving band adjacent the nose component and a body component wherein one or more of the projectile components comprises densified materials such as elastomers and foam that incorporate a dense filler material. The dense filler material is a heavy metal powder. The body component of the projectile includes a stabilizing component such as fins, drag stabilizing tails or streamers, or rifling bands for spin stabilization.

1 . A non-lethal projectile comprising:
 a nose component; and   a body component,   wherein at least one of the nose component or the body component comprises a densified material comprising an elastomer or foam having a densified powder filler.   
     
     
         2 . The projectile of  claim 1  wherein the non-lethal projectile further comprises a driving band positioned on the body component. 
     
     
         3 . The projectile of  claim 1  further comprising means for providing aerodynamic stability of the projectile during flight. 
     
     
         4 . The projectile of  claim 3  wherein the means for providing aerodynamic stability includes at least one of a fin, tail or ribbon attached to the body component for drag stabilization. 
     
     
         5 . The projectile of  claim 1  wherein the elastomer of the nose or the body portion is at least one of a polyurethane, polyolefin, silicon rubber, polyvinyl chloride or polystyrene and the densified powder filler is a heavy metal being at least one of tungsten, lead or iron. 
     
     
         6 . The projectile of  claim 1  wherein the nose component is in elastomeric foam densified by the mixture of a heavy metal powder. 
     
     
         7 . The projectile of  claim 1  further comprising a shell casing for receipt of the base component. 
     
     
         8 . The projectile of  claim 1  wherein the projectile is to be fired from a 12 gauge launching system. 
     
     
         9 . The projectile of  claim 1  wherein the projectile is to be launched from a 37 or 40 mm gas gun. 
     
     
         10 . The projectile of  claim 1  wherein the body component is molded or machined polycarbonate. 
     
     
         11 . The projectile of  claim 5  wherein the filler has a mean particle size of about 20 to about 150 microns. 
     
     
         12 . A less-than lethal munition comprising a projectile having a nose section and a body section wherein at least one of the nose section and the body section comprises a polymer that is densified by a powder filler to maximize kinetic energy delivered by the munition. 
     
     
         13 . The munition of  claim 12  further comprising a driving band positioned on the body section. 
     
     
         14 . The munition of  claim 12  further comprising a means for providing aerodynamic stability comprising at least one of a fin, tail, or ribbon attached to the body section of the munition for drag stabilization. 
     
     
         15 . The munition of  claim 12  wherein the polymer is selected from the group including polyurethane, polyolefin, silicon rubber, polyvinyl chloride or polystyrene. 
     
     
         16 . The munition of  claim 12  wherein the nose section is a foam polymer. 
     
     
         17 . A method of manufacturing a non-lethal projectile comprising the steps of:
 selecting a desired elastomer material for the projectile;   calculating a required amount of filler material for a desired density of the projectile;   compounding the selected elastomer material and the calculated filler material; and   molding the compounded elastomer and filler materials into the projectile.   
     
     
         18 . The method of  claim 17  further comprising molding a nose component and a body component of the projectile. 
     
     
         19 . The method of  claim 18  further comprising the step of joining the nose component and the body component by an adhesive or by over molding. 
     
     
         20 . The method of  claim 18  wherein the step for molding the nose component is by foaming.