Multifunctional composite projectiles and methods of manufacturing the same

Abstract

The present invention is directed to composite projectiles and the manufacture thereof for a wide range of purposes and applications through variation of the composite makeup of such composite projectiles. Embodiments of the invention include composite projectiles configured for manufacture using melt-flow manufacturing methods use-cases and composite projectiles having specialized performance for more effective use in specific use-cases.

Claims

1. A composite projectile, comprising: a leading end, and a trailing end; at least one drag-inducing element comprising a side-cut into an external surface of a composite projectile; the at least one drag-inducing element further comprising a trailing aspect, the at least one drag-inducing element being a plurality of drag-inducing elements radially distributed around the leading end of the projectile, the respective side-cuts of each drag-inducing element each comprising a cylindrical form, each cylindrical form being parallel to a path of travel of the composite projectile; the trailing aspect of the at least one drag-inducing element having a surface which is substantially orthogonal to the path of travel of the composite projectile; and wherein, the composite projectile comprises a mixture comprising (by weight): greater than 0% and less than 10% of a polymer; 85-95% metallic particles, the metallic particles having a maximum dimension of 250 microns; and greater than 0% and up to 5% of carbon particles having a maximum dimension of 50 microns, wherein the mixture is homogeneously incorporated and processed in a melt-flow manufacturing process.

2. A composite projectile, comprising: a leading end; a trailing end; and at least one drag-inducing element comprising a side-cut into an external surface of a composite projectile, the at least one drag-inducing element further comprising a trailing aspect, the trailing aspect of the at least one drag-inducing element having a surface which is substantially orthogonal to the path of travel of the composite projectile, the at least one drag-inducing element comprising a plurality of drag-inducing elements radially distributed around the leading end of the projectile, each surface of the trailing aspects of the drag-inducing elements being a concave form that extends toward the trailing end of the projectile further than an outer boundary of the trailing aspect of the drag-inducing element; wherein, the composite projectile comprises a mixture comprising (by weight): greater than 0% and less than 10% of a polymer; 85-95% metallic particles, the metallic particles having a maximum dimension of 250 microns; and greater than 0% and up to 5% of carbon particles having a maximum dimension of 50 microns, wherein the mixture is homogeneously incorporated and processed in a melt-flow manufacturing process.

3. A composite projectile, comprising: a leading end; a trailing end; and at least one drag-inducing element comprising a side-cut into an external surface of a composite projectile, the at least one drag-inducing element further comprising a trailing aspect, the trailing aspect of the at least one drag-inducing element having a surface which is substantially orthogonal to the path of travel of the composite projectile, the at least one drag-inducing element further comprising a plurality of drag-inducing elements radially distributed around the leading end of the projectile, each surface of the trailing aspect of the drag-inducing elements comprising between 10% and 80% of a frontal area of the composite projectile; wherein, the composite projectile comprises a mixture comprising (by weight): greater than 0% and less than 10% of a polymer; 85-95% metallic particles, the metallic particles having a maximum dimension of 250 microns; and greater than 0% and up to 5% of carbon particles having a maximum dimension of 50 microns, wherein the mixture is homogeneously incorporated and processed in a melt-flow manufacturing process.

4. A composite projectile, comprising: a leading end; a trailing end; and at least one drag-inducing element comprising a side-cut into an external surface of a composite projectile, the at least one drag-inducing element further comprising a trailing aspect, the trailing aspect of the at least one drag-inducing element having a surface which is substantially orthogonal to the path of travel of the composite projectile, the at least one drag-inducing element further comprising a plurality of drag-inducing elements radially distributed around the leading end of the projectile, each surface of the trailing aspect of the drag-inducing elements comprising between 12% and 67% of a frontal area of the composite projectile; wherein, the composite projectile comprises a mixture comprising (by weight): greater than 0% and less than 10% of a polymer; 85-95% metallic particles, the metallic particles having a maximum dimension of 250 microns; and greater than 0% and up to 5% of carbon particles having a maximum dimension of 50 microns, wherein the mixture is homogeneously incorporated and processed in a melt-flow manufacturing process.

5. A composite projectile, comprising: a leading end; a trailing end; and at least one drag-inducing element comprising a side-cut into an external surface of a composite projectile, the at least one drag-inducing element further comprising a trailing aspect, the trailing aspect of the at least one drag-inducing element having a surface which is substantially orthogonal to the path of travel of the composite projectile, the at least one drag-inducing element further comprising a plurality of drag-inducing elements radially distributed around the leading end of the projectile, each surface of the trailing aspect of the drag-inducing elements comprising between 15% and 60% of a frontal area of the composite projectile; wherein, the composite projectile comprises a mixture comprising (by weight): greater than 0% and less than 10% of a polymer; 85-95% metallic particles, the metallic particles having a maximum dimension of 250 microns; and greater than 0% and up to 5% of carbon particles having a maximum dimension of 50 microns, wherein the mixture is homogeneously incorporated and processed in a melt-flow manufacturing process.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1—A side view of a composite projectile of certain embodiments

(2) FIG. 2—A side view of a composite projectile of certain embodiments

(3) FIG. 3—A side view of a composite projectile of certain embodiments

(4) FIG. 4—A side view of a composite projectile of certain embodiments

(5) FIG. 5—A side view of a composite projectile of certain embodiments

(6) FIG. 6—A side view of a composite projectile of certain embodiments

(7) FIG. 7—A side view of a composite projectile of certain embodiments

(8) FIG. 8—A perspective view of a composite projectile of certain embodiments

(9) FIG. 9A—A perspective view of a composite projectile of certain embodiments

(10) FIG. 9B—A side view of a composite projectile of certain embodiments

(11) FIG. 9C—A front view of a composite projectile of certain embodiments

(12) FIG. 10—A side view of a composite projectile of certain embodiments

(13) FIG. 11A—A side view of a composite projectiles of certain embodiments comprising a cap at a trailing end

(14) FIG. 11B—A cross-sectional view of a composite projectiles of certain embodiments comprising a cap at a trailing end

(15) FIG. 11C—A side view of a composite projectiles of certain embodiments comprising a cap at a trailing end

(16) FIG. 11D—A cross-sectional view of a composite projectiles of certain embodiments comprising a cap at a trailing end

(17) FIG. 11E—A side view of a composite projectiles of certain embodiments comprising a cap at a trailing end

(18) FIG. 11F—A cross-sectional view of a composite projectiles of certain embodiments comprising a cap at a trailing end

(19) FIG. 11G—A side view of a composite projectiles of certain embodiments comprising a cap at a trailing end

(20) FIG. 11H—A cross-sectional view of a composite projectiles of certain embodiments comprising a cap at a trailing end

(21) FIG. 12A—A side view of a composite penetrator of certain embodiments

(22) FIG. 12B A side view of a composite penetrator of certain embodiments

(23) FIG. 12C—A side view of a composite penetrator of certain embodiments

(24) FIG. 12D—A side view of a composite penetrator of certain embodiments

(25) FIG. 12E—A side view of a composite penetrator of certain embodiments

(26) FIG. 13A—A side view of a composite penetrator of certain embodiments

(27) FIG. 13B—A side view of a composite penetrator of certain embodiments

(28) FIG. 13C—A side view of a composite penetrator of certain embodiments

(29) FIG. 13D—A side view of a composite penetrator of certain embodiments

(30) FIG. 13E—A side view of a composite penetrator of certain embodiments

(31) FIG. 13F—A side view of a composite penetrator of certain embodiments

(32) FIG. 13G—A side view of a composite penetrator of certain embodiments

(33) FIG. 14A—A front view of an alignment element of certain embodiments

(34) FIG. 14B—A perspective view of an alignment element of certain embodiments

(35) FIG. 15—A cross-sectional view of a composite projectile of certain embodiments

(36) FIG. 16A—A perspective view of a composite projectile of certain embodiments

(37) FIG. 16B—A cross-sectional view of a composite projectile of certain embodiments

(38) FIG. 17A—A perspective view of a composite projectile of certain embodiments

(39) FIG. 17B—A side view of a composite projectile of certain embodiments

(40) FIG. 17C—A front view of a composite projectile of certain embodiments

DETAILED DESCRIPTION

(41) Certain embodiments of the present invention comprise a composite projectile for use in applications such as door breaching and/or neutralization of organic and inorganic targets. Such embodiments comprise less than 10% polyamide, 85-95% of dense metal particles, such as tungsten, and up to 5% carbon particles having a maximum dimension of 50 microns. In certain embodiments, the carbon particles have a maximum dimension of 20 microns. It will be appreciated that in the context of the present application, percentages for the mixture of embodiments are provided by mass or weight. In certain embodiments, the dense metal particles have a maximum dimension of 250 microns, while in other embodiments it may be desired to use dense metal particles having a maximum dimension of 150 microns. When these particles are homogeneously mixed and formed through a melt-flow process, the characteristics imparted upon the resulting composite projectile provide rapid dissipation of energy when the composite projectile impacts a target. Such embodiments are designed to provide shrapnel-free and ricochet-free characteristics. It is a further aspect of such embodiments to prevent the destructive energy or particles from the composite projectile from traveling beyond the intended target area. The dense metal particles are typically of a metallic element or compound to provide a specified weight for a given caliber. Examples of a composite projectile 1000 for use in door breaching and/or neutralization of organic and inorganic targets are shown in FIG. 1-FIG. 3. Certain embodiments comprise a flat face 1010 at a leading end 1001 of the composite projectile to form what is commonly referred to as a “wadcutter” or “semi-wadcutter” tip, and a taper 1020 at a trailing end 1002 of the composite projectile to form what is commonly referred to as a “boat-tail.” Certain embodiments comprise radial recesses 1030 at a medial portion of the composite projectile to form what are commonly referred to as “driving bands.” Flat faces 1010 are commonly associated with projectiles having a lower muzzle velocity and are used to provide increased projectile expansion and deformation upon impact. A taper 1020 at a trailing end 1002 of a composite projectile serves to provide additional accuracy by reducing drag and making the composite projectile less susceptible to cross winds. Radial recesses 1030 are used to engage with the rifling of a barrel while limiting the drag on the composite projectile and wear on the barrel. The result is a faster muzzle velocity and less friction and degradation of the interior of the barrel. It may be desired for certain embodiments to comprise a composite projectile with lower levels of kinetic energy delivered to the target than embodiments comprising dense metal particles. Certain embodiments comprise iron or steel metal particles. Such embodiments deliver lower levels of kinetic energy for training purposes such as within a shoot-house.

(42) It will be appreciated that the percentages as provided herein surround measurement of composition by weight, however it will be appreciated that such percentages can be applied in volumetric measurement while in keeping with the spirit and scope of the present invention.

(43) Certain embodiments comprise a composite projectile for use in shrapnel-free and ricochet-free shooting practice as well as for the neutralization of organic and inorganic targets. Such embodiments comprise less than 10% of a polyamide, 85-95% of inexpensive metal particles such as aluminum or steel or iron, and up to 5% carbon particles having a maximum dimension of 50 microns. In certain embodiments, carbon particles have a maximum dimension of 20 microns. In certain embodiments, the metallic particles comprise a maximum dimension of 150 microns, while other embodiments comprise metallic particles having a maximum dimension of 250 microns. Homogeneous mixing and forming through a melt-flow process results in an inexpensive composite projectile which will not carry destructive outside the target area after striking a desired target. An example of a composite projectile 1000 for use in shrapnel-free and ricochet-free shooting practice as well as for the neutralization of organic and inorganic targets is shown in FIG. 4. Certain embodiments comprise a convex conical form 1050 with a flat face 1010.

(44) Certain embodiments comprise a composite projectile which exhibits explosive characteristics upon impact with a target. Such embodiments comprise less than 10% of a polyamide or other polymer capable of being processed in a melt-flow or casting process. The composite projectile further comprises 25-90% of weight inducing particles such as metallic particles, 5-65% of energetic or explosive particles such as aluminum nanoparticles, and up to 5% of carbon particles having a maximum dimension of 50 microns. In certain embodiments, the carbon particles have a maximum dimension of 20 microns. In certain embodiments, the weight inducing particles have a maximum dimension of 250 microns, while other embodiments comprise metallic particles with maximum dimension of 150 microns. The homogeneous mixing and forming through a melt-flow process results in a composite projectile which will react explosively when it impacts a target. An example of a composite projectile 1000, shown in FIG. 5, exhibits explosive characteristics upon impact comprises a flat face 1010. The flat face 1010, as shown provides a more substantial area in relation to the composite projectile 1000, thus resulting in a higher than normal pressure event when the composite projectile 1000 strikes a given target. The higher than normal pressure event provides necessary pressure levels to initiate the explosive reaction of the composite projectile 1000.

(45) Certain embodiments of the present invention comprise a composite projectile having uniquely identifiable characteristics to allow the composite projectile to be identified prior to and after the composite projectile has been fired from a weapon. Such embodiments comprise less than 10% of a polyamide or other polymer capable of being processed in a melt-flow or casting process and 85-95% of metal particles such as copper. In certain embodiments, the metal particles comprise a maximum dimension of 250 microns while other embodiments comprise a maximum dimension of 150 microns. The composite projectile further comprises up to 5% carbon particles having a maximum dimension of 50 microns or less, and less than 3% of unique identifying elements or molecules. In certain embodiments, the carbon particles have a maximum dimension of 20 microns. Homogeneous mixing and forming through a melt-flow process results in a composite projectile which is uniquely identifiable prior to and after use. It will be appreciated that synthetic molecules specifically made for the identification of composite projectiles may be used in the manufacture of such embodiments for increased identifiability. An example of a composite projectile 1000, shown in FIG. 6, having uniquely identifiable characteristics may be configured to be fired from any standard firearm. Certain embodiments, as shown, comprise a standard bulleted-nose 1040.

(46) Certain embodiments of the present invention comprise a composite projectile having less than 10% polyamide, 85-95% of metal particles, such as copper, and up to 5% carbon particles. In certain embodiments, the metal particles have a maximum dimension of 250 microns, while other embodiments comprise metal particles having a maximum dimension of 150 microns. In certain embodiments, the maximum dimension of the carbon particles comprises a maximum dimension of 20 microns, while other embodiments comprise a maximum dimension of 50 microns. It will be appreciated that composite projectiles may be designed to have a certain mass or density which may be tailored to a specific purpose through the variation of percentages. It will be further appreciated that composite projectiles of varying densities or masses may be produced using the same mold while varying the material composition of the composite projectile material mixture. An example of such an embodiment, as shown in FIG. 7, comprises a bulleted nose shape 1050 and a flat face 1010. It will be appreciated that such embodiments of varying densities can be configured to be fired from any standard firearm while remaining in spirit and scope of the present invention.

(47) It will be appreciated that composite projectiles may undergo post-processing or secondary manufacturing processes to modify the composite projectile. It may be desired in certain embodiments to add coatings, apertures, and/or plugs to a composite projectile for purposes of modifying ballistic trajectory, reloading action or on-target characteristics.

(48) Certain embodiments of the present invention surround ammunition casing for the firing of composite projectiles. Certain embodiments comprise a polymer-based casing. Certain embodiments comprise a steel casing. Certain embodiments comprise a casing having a combination of metal and polymer construction. Certain embodiments comprise a single-piece casing while others comprise multiple pieces assembled into a contiguous case. Such embodiments as disclosed are used to provide weight-reduction, increased reloadability, cost reductions, and or the ability to withstand higher pressures when a composite projectile is fired.

(49) It will be appreciated that embodiments such as composite projectiles and polymer-based casings result in composite projectiles and casings having a higher level of lubricity than found in the prior art. The increased lubricity of such embodiments allows for the mechanically driven reloading of a firearm with an unfired cartridge with less friction or resistance. Thus, resulting in increased reloadability with increased reliability, decreased frequency of mechanical failure events, and reduced wear on the reloading mechanisms of the firearm. An example of a composite projectile having increased lubricity is shown in FIG. 8, wherein a composite projectile 1000 further comprises an outer surface 1060 having a polymeric coating.

(50) Certain embodiments comprise a composite projectile having a colorant added and homogeneously incorporated prior to the production of the composite projectile. This results in a composite projectile having a particular color or tint which is identifiable by the user of the composite projectile. It may be desired to color-code composite projectiles according to their intended purpose, allowing a user to identify composite projectiles for particular purposes by color, without a need for a secondary or post-processing step of coating or coloring.

(51) Certain embodiments, as shown in FIG. 9A-FIG. 9C, comprise a composite projectile having a drag-inducing element 1100. In certain embodiments, a drag-inducing element 1100 comprises a side-cut into the external surface 1110 of a composite projectile. In certain embodiments a drag-inducing element 1100 further comprises a plurality of fillets or chamfers into the external surface 1110 of a composite projectile. Although it is typically preferred that such drag-inducing elements 1100 are symmetrically configured around the external surface 1110 of the composite projectile, it will be appreciated that in certain use-cases drag-inducing elements 1100 are asymmetrically spaced around the external surface 1110 of the composite projectile are in keeping with the spirit and scope of the present invention. It will be further appreciated that the number of drag-inducing elements 1100 is not limited to a total of six as shown in FIG. 9A-FIG. 9C.

(52) Referring once again to FIG. 9A-FIG. 9C and FIG. 17A-FIG. 17C, in certain embodiments the drag-inducing element 1100 of a projectile comprises a cylindrical cut 2000 in a forward aspect 2010, or the ogive of the projectile. Such drag-inducing elements 1100 can be oriented parallel to the path of travel 2100 of the projectile, as demonstrated in FIG. 17A while it is in keeping with the spirit and scope of the present invention for such cylindrical cuts to be askew from parallel from the path of travel 2100 of the projectile.

(53) Referencing FIG. 9A-FIG. 9C and FIG. 17A-FIG. 17C, certain embodiments of the present invention comprise a drag-inducing element 1100 having a trailing aspect 2200 which is substantially orthogonal to the path of travel 2100 of the projectile. As used herein regarding the trailing aspect 2200 of a drag-inducing element, “substantially orthogonal” comprises a surface which is orthogonal to the path of travel 2100, a surface within 15-degrees of orthogonal to the path of travel 2100, or concave surface oriented toward the path of travel 2100 of the projectile. It will be appreciated that a concave surface directed toward the path of travel 2100 in the instant application comprises a surface 2210 of the trailing aspect of the drag-inducing element which extends toward the trailing end 1002 of the projectile further than the outer boundary 2220 of the trailing aspect of the drag-inducing element. It will be appreciated that the trailing aspects 2200 of a drag-inducing element are intended to induce turbulent flow, which disrupt the aerodynamics of a projectile in flight whereby the projectile tumbles and results in a rapid decrease in the effectiveness of projectile as it travels beyond the intended range of use.

(54) It will be appreciated by those skilled in the art that the frontal area 2400 of a projectile is defined by the area of the projectile which is projected along the velocity vector or path of travel 2100. In certain embodiments of the present invention, the surface 2210 of trailing aspect 2200 of the drag-inducing elements comprise between 10%-80% of the frontal area 2400 of the projectile. In certain embodiments of the present invention, the surface 2210 of trailing aspect 2200 of the drag-inducing elements comprise between 12%-67% of the frontal area 2400 of the projectile. In certain embodiments of the present invention, the surface 2210 of trailing aspect 2200 of the drag-inducing elements comprise between 15%-60% of the frontal area 2400 of the projectile.

(55) Certain embodiments, as shown in FIG. 10, comprise a composite projectile having what is commonly referred to as a “rebated” base. A rebated base 1130 of a composite projectile, is commonly associated with a tapered base 1020 such as a boat-tail. A boat-tail surrounds the tapered base 1020 at the trailing end 1002 of a composite projectile. In certain embodiments a rebated base 1130 provides a 90-degree shoulder in conjunction with the boat-tail at the trailing end 1002 of the composite projectile.

(56) Certain embodiments, as seen in FIG. 11A-FIG. 11H, comprise a cap 1140 configured to shield the trailing end 1002 of a composite projectile from the heat and pressure associated with a propelling charge. A cap 1140 of certain embodiments comprises a copper or cupronickel material, however it will be appreciated that use other materials known to those in the art are in keeping with the spirit and scope of the present invention. In certain embodiments, as seen in FIG. 11A-FIG. 11B, a cap 1140 comprises a form which covers the trailing end 1002 of the composite projectile. In certain embodiments, as shown in FIG. 11C-FIG. 11D, a cap 1140 comprises a form which covers the trailing end 1002 of a composite projectile, and further comprises an alignment element 1150. The alignment element 1150 of certain embodiments, as shown in FIG. 11C-FIG. 11D is characterized by a central recess which is configured to receive the trailing end 1320 of a hardened penetrator. An alignment element in such embodiments serves to align a hardened penetrator 1145 with the cap 1140 and thereby the composite projectile 1000 in preparation for the molding process. In certain embodiments, as shown in FIG. 11E-FIG. 11F, comprises a cap 1140 which covers the trailing end 1002 of the composite projectile 1000, and further comprises fingers 1160 which extend toward the leading end 1001 of the composite projectile. The fingers 1160 of such embodiments serve to provide increased attachment of the cap 1160 to the composite projectile as well as to engage with the rifling of the barrel of a firearm. In certain embodiments, as shown in FIG. 11G-FIG. 11H, it may be desired for the cap 1140 to further comprise a collar 1170 which extends toward the leading end 1001 of a composite projectile. The collar 1170 of such embodiments serves to provide increased attachment of the cap 1140 to the composite projectile 1145 as well as to engage with the rifling of the barrel of a firearm. It will be appreciated that a cap as disclosed herein surrounds the shielding of the leading end of a composite projectile. However, it will be further appreciated that a cap of certain embodiments is disposed at the leading end of a composite projectile and configured to shield the leading end of the composite projectile while in keeping with the spirit and the scope of the present invention.

(57) It is an aspect of certain embodiments of the present invention to prevent the shifting of a hardened penetrator within projectile such as caused by the heat from initiation of a propelling charge. In certain embodiments, a cap is affixed to the trailing end 1002 of a composite projectile to shield the base of the composite projectile from the heat of the initiation of the propelling charge.

(58) In certain embodiments, as shown in FIG. 12A-FIG. 12E, a hardened penetrator 1145 of the present invention can comprise a number of profiles. In certain embodiments, as shown in FIG. 12A, a hardened penetrator comprises a 60-degree included angle 1300 and a consistent profile. In certain embodiments, as shown in FIG. 12B, a hardened penetrator 1145 comprises a profile which tapers down from the leading end 1310 toward the trailing end 1320 of the hardened penetrator. In certain embodiments, as shown in FIG. 12C, a hardened penetrator 1145 comprises a 30-degree included angle 1300 which serves to provide more piercing ability for the hardened penetrator 1145. As seen in FIG. 12D, certain embodiments comprise a hardened penetrator having a frustum 1330 at the leading end 1001. The flat portion of the frustum provides more blunt force impact by the hardened penetrator against a hard target for purposes of fracturing the target versus piercing the target. In certain embodiments, as shown in FIG. 12E, a hardened penetrator 1145 comprises a conical tip 1340 with a rebated body 1350, thus once the leading end 1001 of the hardened penetrator traverses through the target, the rebated body 1350 of the hardened penetrator 1145 follows without impedance.

(59) As seen in FIG. 13A-FIG. 13G, certain embodiments comprise hardened penetrators 1145 having external features. As seen in FIG. 13A, a hardened penetrator 1145 of certain embodiments comprises an annular recess 1400 substantially perpendicular to the longitudinal axis 1410 of the hardened penetrator. Certain embodiments comprise a plurality of annular recesses 1400. In certain use cases, such annular recesses 1400 serve to reduce friction when passing through soft armor and allowing a composite projectile to traverse further within soft armor due to increased surface area for binding with the polymer of a composite projectile. As seen in FIG. 13B, certain embodiments comprise longitudinal channels 1420 along the length of a hardened penetrator 1145 for reduced surface area for interaction with a target as well as increased surface area for binding with a polymer of a composite projectile. In certain embodiments, as shown in FIG. 13C-FIG. 13D, a hardened penetrator 1145 comprises longitudinal fins 1430. In certain embodiments, as seen in FIG. 13E, a hardened penetrator 1145 comprises a boat-tail 1440 at the trailing end 1402 of the hardened penetrator. In certain embodiments, as seen in FIG. 13F-FIG. 13G, a hardened penetrator 1145 comprises a helical element 1450, such as a helical groove 1451 or helical protuberance 1452, on the external surface 1460 of the hardened penetrator. In certain use cases, such helical elements 1450 induce axial spinning and allow the hardened penetrator 1145 to pass more easily through a soft armor such as those using aramid fiber based textiles.

(60) In certain embodiments, as shown in FIG. 14A-FIG. 14B, an alignment element 1500 provides alignment for a hardened penetrator 1145 within a composite projectile. In certain embodiments the alignment element 1500 comprises a recess 1510 configured to receive the hardened penetrator 1145, and offset elements 1520 configured to maintain a consistent radial offset 1530 from external aspects of a resulting projectile. In certain embodiments, the alignment element 1500 comprises a material makeup substantially consistent with the polymeric make-up of the composite projectile. As such, when the composite projectile is molded, the alignment element becomes integrated with the composite projectile. In certain embodiments, the alignment element 1500 comprises a metallic composition. In certain embodiments the alignment element 1500 comprises an open-celled matrix or foam structure such as a polymer, metal, or ceramic—configured to allow the permeation of a molten polymer into and around the structure of the alignment element 1500.

(61) In certain embodiments, shown in FIG. 15, a composite projectile 1000 is configured for fragmentation such that an expansion inducing element 1600 at the leading end 1001 of the composite projectile creates outward fragmentation upon impact with a target. In certain embodiments, the expansion inducing element 1600 comprises a conical form having a base 1610 at the leading end 1001 of the composite projectile and tapers inward toward the trailing end 1002 of the composite projectile. It will be appreciated that certain embodiments comprise a double-conical form (not shown) wherein a first conical element has a base affixed to a base of a second conical element. Thus, resulting in a tip of the first conical element at the leading end 1001 of the composite projectile, and the tip of the second conical element offset toward the trailing end 1002 of the composite projectile.

(62) In certain embodiments, shown in FIG. 16, an expansion inducing element 1650 comprises a segmented element characterized by solid aspects 1660 and perforations 1670. Such an expansion inducing element serves to control the fragmentation patterning and expansion of the composite projectile 1000 upon impact.

(63) For purposes of further disclosure, the following references generally related to projectiles and manufacturing methods are hereby incorporated by reference in their entireties: U.S. Pat. No. 9,383,178 to Powers, issued on Jul. 5, 2016, which discloses a Hollow point bullet and method of manufacturing same; U.S. Pat. No. 9,188,416 to Hash et al., issued on Nov. 17, 2015, which discloses lead-free, corrosion-resistant projectiles and methods of manufacture; U.S. Pat. No. 9,057,591 to Hash et al., issued on Jun. 16, 2015, which discloses lead-free, corrosion-resistant projectiles and methods of manufacture; U.S. Pat. No. 8,833,262 to Leasure, issued on Sep. 16, 2014, which discloses a lead-free reduced ricochet limited penetration projectile; U.S. Pat. No. 7,992,500 to Williams, issued on Aug. 9, 2011, which discloses a method and apparatus for self-destruct frangible projectiles; U.S. Pat. No. 5,616,642 to West et al., issued on Apr. 1, 1997, which discloses a lead-free frangible ammunition; U.S. Pat. No. 5,237,930 to Belanger et al., issued on Aug. 24, 1993, which discloses a frangible practice ammunition; U.S. Pat. No. 9,388,090 to Joshi et al., issued on Jul. 12, 2016, which discloses a fast ignition and sustained combustion of ionic liquids; U.S. Pat. No. 9,372,054 to Padgett, issued on Jun. 21, 2016, which discloses a narrowing high strength polymer-based cartridge casing for blank and subsonic ammunition; U.S. Pat. No. 9,227,353 to Williams, issued on Jan. 5, 2016, which discloses a molding apparatus and method for operating same; U.S. Pat. No. 9,194,680 to Padgett et al., issued on Nov. 24, 2015, which discloses polymer-based machine gun belt links and cartridge casings and manufacturing method; U.S. Pat. No. 9,046,333 to Masinelli, issued on Jun. 2, 2015, which discloses a bullet; U.S. Pat. No. 8,997,653 to Calvert, issued on Apr. 7, 2015, which discloses a stroke inducing bullet; U.S. Pat. No. 8,893,621 to Escobar, issued on Nov. 25, 2014, which discloses a projectile; U.S. Pat. No. 8,881,654 to Seecamp, issued on Nov. 11, 2014, which discloses bullets with lateral damage stopping power; U.S. Pat. No. 8,393,273 to Weeks, issued on Mar. 12, 2013, which discloses bullets, including lead-free bullets, and associated methods; U.S. Pat. No. 8,365,672 to Martinez, issued on Feb. 5, 2013, which discloses a frangible bullet and its manufacturing method; U.S. Pat. No. 8,312,815 to Joys et al., issued on Nov. 20, 2012, which discloses lead free frangible bullets; U.S. Pat. No. 8,225,718 to Joys et al., issued on Jul. 24, 2012, which discloses lead free frangible bullets; U.S. Pat. No. 8,308,986 to Stuart, issued on Nov. 13, 2012, which discloses a bismuth compounds composite; U.S. Pat. No. 5,035,183 to Luxton, issued on Jul. 30, 1991, which discloses a frangible nonlethal projectile; U.S. Pat. No. 6,149,705 to Richard A. Lowden et al, issued on Nov. 21, 2000, which discloses environmentally safe projectiles made of two different metals, one that is significantly more malleable and acts as a binder to the higher density material and forms the shape of the bullet under compression; U.S. Pat. No. 10,126,105 to Paul Lemke, et al., issued on Nov. 13, 2018 which discloses projectiles having notches configured to improve the aerodynamics of the projectile; and U.S. patent application Ser. No. 15/495,367, to Folaron et al., filed on Apr. 24, 2017, which discloses an injection molding apparatus and method of use.

(64) While various embodiments of the present invention have been described in detail, it is apparent that modifications and alterations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and alterations are within the scope and spirit of the present invention. Further, the inventions described herein are capable of other embodiments and of being practiced or of being carried out in various ways. In addition, it is to be understood that the phraseology and terminology used herein is for the purposes of description and should not be regarded as limiting. The use of “including,” “comprising,” or “adding” and variations thereof herein are meant to encompass the items listed thereafter and equivalents thereof, as well as, additional items.