POLYMER PROJECTILE HAVING AN INTEGRATED DRIVING BAND

Abstract

A lightweight projectile having an integrated metal band positioned around the exterior of the polymer base of the projectile. The metal band may be a driving band that protrudes from the polymer base to minimize the contact between the polymer base and the rifling to reduce friction between the barrel and the projectile as the projectile is fired. The lightweight projectile may be propelled with less propellant force than conventional projectiles of the same caliber while still retaining the ballistic advantages of a spin stabilized projectile.

Claims

1. A lightweight projectile for firing from a 5.56 millimeter rifled barrel and in combination with a telescoping casing, the projectile adapted to be fired through a rifled barrel, comprising: a projectile defining a bullet shape and including: a polymer projectile body defining a sealed interior space and including a frangible polymer cap; a metal band that extends circumferentially around the polymer projectile body, the metal band including an embedded portion that extends inwardly into the polymer projectile body; and a marking media contained within the sealed interior space, wherein: the frangible polymer cap is configured to release the marking media on impact; and the weight of the projectile is less than 10 grains.

2. The lightweight projectile and casing of claim 1, wherein the metal band is a driving band.

3. The lightweight projectile and casing of claim 1, wherein the metal band provides 10 to 20% of the total weight of the projectile.

4. The lightweight projectile and casing of claim 1, wherein the metal band includes an exposed portion that extends radially outward from the embedded portion.

5. The lightweight projectile and casing of claim 4, wherein the exposed portion projects radially outward beyond the polymer projectile body to define a maximum radial dimension of the projectile, the exposed portion being a driving band configured to engage the rifling of the barrel to impart spin stabilization to the projectile.

6. The lightweight projectile and casing of claim 4 wherein the embedded portion has an axial thickness that is greater than an axial thickness of the exposed portion.

7. The lightweight projectile and casing of claim 4, wherein the exposed portion and the embedded portion are configured to define one of a T-shape and an L-shape when viewed in cross-section.

8. The lightweight projectile and casing of claim 4, wherein the exposed portion comprises a flexible material such that a portion of the exposed portion folds over upon engagement by the rifling of the barrel.

9. The lightweight projectile and casing of claim 1, wherein: the polymer projectile body includes a base that cooperates with the frangible polymer cap to define the interior space; and the metal band is positioned at a juncture between the frangible polymer cap and the base.

10. The lightweight projectile and casing of claim 1, wherein the metal band comprises one of aluminum, copper, and brass.

11. The lightweight projectile and casing of claim 1, wherein the metal band is adjacent to an outwardly protruding polymer rib extending from the polymer projectile body.

12. A cartridge for firing a lightweight projectile from a conventional firearm having a rifled barrel, comprising: a projectile comprising: a polymer projectile body including a cap and a base and defining an interior space; at least one metal band positioned on the polymer projectile body that extends circumferentially around the polymer projectile body, the at least one metal band including a projecting portion that extends in an axial direction along the polymer projectile body; and a marking media contained within the interior space, wherein: the polymer cap is configured to release the marking media on impact; and the weight of the projectile is less than 10 grains.

13. The cartridge of claim 12, wherein the at least one metal band is positioned on the base.

14. The cartridge of claim 13, wherein the at least one metal band includes a thin metallic layer.

15. The cartridge of claim 12, wherein: the cap and the base define and are concentric about a longitudinal axis, the projectile body adapted to rotate about the longitudinal axis; and the projecting portion extends in a direction radially outward from the longitudinal axis.

16. The cartridge of claim 15, wherein the projecting portion is configured to engage the rifling of a rifled barrel to impart spin stabilization to the projectile.

17. The cartridge of claim 12, comprising: a cartridge casing including an elongated hollow base that defines a first opening, a second opening, and a reduced diameter portion between the first opening and second opening; a polymer insert insertable into the first opening and defining a seating portion configured to receive the projectile; and a primer for generation of a gas when ignited, the primer being disposed proximate the second opening of the cartridge casing, the reduced diameter portion configured to direct the gas into a gas jet to propel the projectile out of the seating portion of the polymer insert.

18. A method of fabricating a lightweight projectile having an exterior surface and comprising a polymer and a rifled barrel of a firearm, comprising: forming at least one metal band, the metal band comprising one of brass and copper; positioning the at least one metal band in a mold for a first component of the projectile; and injecting polymer into the mold so that the metal band is at least partially embedded into the first component of the projectile.

19. The method of claim 18 comprising assembling the first component with a second component after putting marking material into the first component or the second component.

20. The method of claim 19, wherein the first component in the step of assembling is one of a base of the projectile and a cap of the projectile, and wherein the second component in the step of assembling is an other of the cap of the projectile and the base of the projectile.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The invention can be completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:

[0026] FIG. 1 is a side view of a non-lethal projectile having a driving band according to an embodiment of the present invention.

[0027] FIG. 2 is a cross-sectional side view of the non-lethal projectile depicted in FIG. 1.

[0028] FIG. 3 is a perspective view of the non-lethal projectile depicted in FIG. 1.

[0029] FIG. 4 is an exploded view of the non-lethal projectile depicted in FIG. 1.

[0030] FIG. 5 is a side view of a non-lethal projectile having a driving band according to an embodiment of the present invention.

[0031] FIG. 6 is a cross-sectional side view of the non-lethal projectile depicted in FIG. 5.

[0032] FIG. 7 is a perspective view of the non-lethal projectile depicted in FIG. 5.

[0033] FIG. 8 is a cross-sectional perspective view of the non-lethal projectile depicted in FIG. 5.

[0034] FIG. 9 is an exploded perspective view of the non-lethal projectile depicted in FIG. 5.

[0035] FIG. 10 is an exploded perspective view of a non-lethal projectile having a driving band according to an embodiment of the present invention.

[0036] FIG. 11 is an exploded, cross-sectional perspective view of the non-lethal projectile depicted in FIG. 10.

[0037] FIG. 12 is a partial cross-sectional side view of the non-lethal projectile depicted in FIG. 10.

[0038] FIG. 13 is a cross-sectional side view of the non-lethal projectile depicted in FIG. 10.

[0039] FIG. 14 is a partial cross-sectional perspective view of the non-lethal projectile depicted in FIG. 10.

[0040] FIG. 15 is an exploded perspective view of a non-lethal projectile having a driving band according to an embodiment of the present invention.

[0041] FIG. 16 is an exploded, cross-sectional perspective view of the non-lethal projectile depicted in FIG. 15.

[0042] FIG. 17 is a partial cross-sectional side view of the non-lethal projectile depicted in FIG. 15.

[0043] FIG. 18 is a cross-sectional side view of the non-lethal projectile depicted in FIG. 15.

[0044] FIG. 19 is a partial cross-sectional perspective view of the non-lethal projectile depicted in FIG. 15.

[0045] FIG. 20 is a partial cross-sectional side view of a non-lethal cartridge for firing a non-lethal projectile having a driving band according to an embodiment of the present invention.

[0046] FIG. 21 is a side view of the non-lethal cartridge depicted in FIG. 20.

[0047] FIG. 22 is a perspective view of the non-lethal cartridge depicted in FIG. 20.

[0048] FIG. 23 is a partial cross-sectional perspective view of the non-lethal cartridge depicted in FIG. 20 prior to deployment of a telescoping portion of the cartridge.

[0049] FIG. 24 is a partial cross-sectional perspective view of the non-lethal cartridge depicted in FIG. 20 after deployment of a telescoping portion of the cartridge.

[0050] FIG. 25 is a partial cross-sectional side view of a projectile base according to an embodiment of the present invention.

[0051] FIG. 26 is a cross-sectional side view of the projectile base depicted in FIG. 25.

[0052] FIG. 27 is a cross-sectional partial view of the projectile base depicted in FIG. 26 showing a driving band according to an embodiment of the present invention.

[0053] FIG. 28 is a partial cross-sectional side view of a projectile base according to an embodiment of the present invention.

[0054] FIG. 29 is a cross-sectional side view of the projectile base depicted in FIG. 28.

[0055] FIG. 30 is a cross-sectional partial view of the projectile base depicted in FIG. 29 showing a driving band according to an embodiment of the present invention.

[0056] FIG. 31 is a partial cross-sectional side view of a projectile according to an embodiment of the present invention.

[0057] FIG. 32 is a cross-sectional side view of a projectile according to an embodiment of the present invention.

[0058] FIG. 33 is a cross-sectional partial view of a projectile according to an embodiment of the present invention with a metal base and a polymer cap.

[0059] FIG. 34 is a partial cross-sectional side view of a projectile base according to an embodiment of the present invention.

[0060] FIG. 35 is a cross-sectional side view of the projectile base depicted in FIG. 34.

[0061] FIG. 36 is a cross-sectional partial view of the projectile base depicted in FIG. 35 showing a driving band according to an embodiment of the present invention.

[0062] FIG. 37 is a partial cross-sectional side view of a projectile base according to an embodiment of the present invention.

[0063] FIG. 38a is a cross-sectional detail of the driving band on the projectile base depicted in FIG. 37.

[0064] FIG. 38b is a cross-sectional detail a portion of the driving band on the projectile base depicted in FIG. 37 that has engaged a land of barrel rifling.

[0065] FIG. 38c is a cross-sectional detail a portion of the driving band on the projectile base depicted in FIG. 38b that has engaged a groove of barrel rifling.

[0066] FIG. 39 is a partial cross-sectional side view of a projectile base according to an embodiment of the present invention.

[0067] FIG. 40 is a cross-sectional side view of the projectile base depicted in FIG. 39.

[0068] FIG. 41 is a cross-sectional partial view of the projectile base depicted in FIG. 40 showing a two driving band configuration according to an embodiment of the present invention.

[0069] FIG. 42 is a front view of a projectile according to an embodiment of the present invention traveling through a barrel in which the lands of the rifling etch grooves in the driving band.

[0070] FIG. 43 is a front view of a projectile according to an embodiment of the present invention traveling through a barrel in which the lands of the rifling fold over the driving band.

[0071] FIG. 44 is a side view of a projectile according to an embodiment of the present invention.

[0072] FIG. 45 is a cross-sectional side view of the projectile depicted in FIG. 44.

[0073] FIG. 46 is a top view of a metal driving band in isolation.

[0074] FIG. 47 is a side view of the metal driving band of FIG. 46.

[0075] While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION OF THE DRAWINGS

[0076] As shown in FIGS. 1 to 4, a non-lethal projectile 2, according to an embodiment of the present invention, presents an primarily polymer body 3 configured as a sealed enclosure and comprising a forward portion configured as a frangible cap 4, a rearward portion or projectile base 6 and at least one driving band 8, the components meeting at a juncture 7. The projectile is suitably bullet shaped and sealingly encloses marking media 15 therein. The frangible cap 4 can further comprise an engagement portion 10 for affixing the cap 4 to the projectile base 6. The projectile base 6 has a cooperating engagement portion 11 can further comprise a cup portion 12 and a base portion 14. The engagement portion 10 is receivable within the cup portion 12 to affix the cap 4 to the projectile base 6 and to define a cavity 13 for receiving a payload. In one aspect, in addition to marking media 7 that is deposited on the target upon impact to identify the location of the impact, other payloads may be utilized a solid material that provides additional mass to the projectile for accurate flight without marking the target. In the configuration illustrated, the frangible cap 4 can comprise a transparent material allowing for visual identification of the color of the marking media. According to an embodiment of the present invention, the projectile 2 can also comprise a solid bullet shaped base comprising a single polymer material and being light weight, such as less than 5 grains for a 5.56 mm diameter projectile, and having one or more metal driving bands extending therefrom. The projectile has an axis A. The marking media may be a liquid, paste, gel, powder or other material.

[0077] The driving band 8 extends radially around the exterior of the projectile base 6. In one embodiment, the driving band 8 is positioned around the base portion 14 of the projectile base 6. A projecting portion 9 of the driving band 8 protrudes from outward from the projectile base 6 to engage the rifling of a barrel when the projectile 2 is fired. An embedded portion 11 of the driving band 6 is inset into the projectile base 6. In one aspect of the present invention, the driving band 6 comprises a cantilevered ring shape in which the driving band 6 is perpendicular to the axis of the projectile base 6 and the projecting portion 9 cantilevers radially outward from the projectile base 6 as shown in FIGS. 46-47. In one aspect, the embedded portion 11 can have the same thickness as the projecting portion 9 as shown in FIGS. 1-2 and 34-36. In another aspect, the embedded portion 11 can have a greater thickness than the projecting portion 9 as shown in FIGS. 5-6 and 28-32. In this configuration, the embedded portion 11 and projecting portion 9 are arranged in a T-shaped configuration wherein the projecting portion 9 extends from approximately the center of the embedded portion 11 as shown in FIGS. 28-30. Alternatively, the embedded portion 11 and projecting portion 9 is arranged in an L-shaped configuration as shown in FIGS. 5-6 and 25-27. The projectile base 6 can further comprise a groove 16 for receiving the embedded portion 11 of the driving band 8.

[0078] As shown in FIGS. 39-41, the projectile 2 can further comprise a second driving band 56 cooperating with the first driving band 8 to minimize yaw effects and polymer portions of the projectile from engaging the rifling of the barrel. In one aspect, the driving band 6 can extend in a helical arrangement around the projectile base 6. In this configuration, the helically arranged driving bands 6 can engage the air after firing to further spin stabilize the projectile 2.

[0079] According to an embodiment, the projectile 2 can be sized to replicate the dimensions of the bullet for 5.5645 mm NATO (5.56 NATO) or .223 REMINGTON ammunition. The conventional bullets of 5.56 NATO cartridges and .223 REMINGTON have a diameter of 0.224 in (5.70 mm). According to an embodiment, the driving band 8 can have an outer diameter of 0.223 in (5.66 mm) and a thickness of 0.005 (0.127 mm) in such that the projecting portion 9 of the driving band 8 protrudes from the projectile base 6 for engaging the rifling of barrels sized for 5.56 NATO or .223 REMINGTON ammunition. In one aspect, the projectile base 6 can be dimensioned such that such that the outer diameter of the projectile base 6 is such that the projectile base 6 can travel through the barrel without engaging the rifling. According to an embodiment, the inner diameter of the driving band 8 can comprise 0.154 in (3.912 mm) such that the embedded portion 11 of the driving band 8 is seated within the projectile base 6.

[0080] Although the projectile 2 is sized to approximate the conventional equivalent, the weight of the projectile 2 is less than the conventional equivalent. A conventional bullet weight for a 5.56 NATO bullet can be about 4 grams. In one embodiment, the total weight of the projectile 2 for simulating 5.56 NATO bullet and containing a payload media can weight about 0.24 grams wherein the driving band 8 comprises about 15% of the total weight of the projectile 2; in other embodiments, from 10 to 20%. In aspect, the total weight of the projectile 2 with a payload media can be about 5 to 10% of the weight of the equivalent projectile. In another aspect, the total empty weight of the projectile 2 without a payload media can be about 1 to 5% of the weight of an equivalent conventional projectile 2. In embodiments the total weight of the projectile is less than 5 grains. In embodiments the total weight of the projectile is less than 6 grains. In embodiments the total weight of the projectile is less than 7 grains. In embodiments the total weight of the projectile is less than 10 grains. The inventors have discovered that projectiles of less than 4.25 grains may be fired from telescoping 5.56 mm practice cartridges as illustrated in FIGS. 20-24, using only the propellant in the primer, at velocities up to about 520 fps using metal driving bands. With such velocities accuracy is extremely good and the kinetic energy is under 62 ft-lb/inch. This arrangement provides better accuracy and less energy than conventional 5.56 mm practice ammunition with marking projectiles. With less energy, the ammunition is safer.

[0081] The projectile base 6 can comprise principally a thermoplastic polymer. Other embodiments can comprise ceramic material, compressed fibrous pulp, lightweight metal or other lightweight material that can be formed to define a projectile base 6. The driving band 8 can comprise a gilding metal, a more rigid polymer than that used to form the projectile base 6, a metal impregnated polymer or other composite material. According to an embodiment, the driving band can comprise 110 Copper (99.9% copper, 0.04% oxygen). Other materials include brass. The material of the driving band 8 provides more advantageous engagement characteristics than the base material of the projectile base 6. For example, better coefficient of friction with respect to firearm barrels, less sloughing of material, easier deformation to conform to the rifling of the barrel. The frangible cap 4 can comprise a frangible material, such as polystyrene, adapted to fracture upon impact with the target to release the payload within the cavity and/or reduce force with which the projectile 2 impacts the target.

[0082] In an embodiment of the present invention, the driving band 8 can serve to weight the exterior of the projectile base 6 to further facilitate spin stabilization of the projectile 2. The protruding portion 9 and/or the embedded portion 11 of the driving band 8 can be varied in size to increase or decrease the weight of the driving band 8 relative to the rest of the projectile 2 as shown in FIGS. 5-14. In one aspect, the weight of the driving band 8 can be about 10 to 20% of the total weight of the projectile 2.

[0083] As shown in FIGS. 5 to 9, according to an embodiment, each driving band 8 can further comprise a cylindrical portion 18 that is flush with the exterior of the projectile base 6. The flattened portion 18 provides additional weight around the exterior of the projectile base 6 to facilitate the spin of the projectile 2 during flight and improve the ballistic characteristics of the projectile 2. In this configuration, the groove 16 can shaped to increase or decrease the amount of material in the flattened portion 18 to change of center of mass of the projectile 2.

[0084] As shown in FIGS. 10 to 14, according to an embodiment, each driving band 8 can further comprise a weighting portion 20 positioned within a cavity 20 defined within the base portion 14. In this configuration, the material used for the driving band 8 can be denser than the material used for the projectile base 6 such that the weighting portion 20 moves the center of mass of the projectile 2 toward the rear of the projectile base 6 for improved ballistic characteristics.

[0085] As shown in FIGS. 15 to 19, according to an embodiment, the driving band 8 can be integral to the projectile base 6. In this configuration, the projectile base 6 can comprise a lightweight metal capable of engaging the rifling with minimal friction without increasing the weight of the projectile 2 such that the momentum of the projectile 2 can cause injury or death upon impact. The lightweight metal can include, but is not limited to aluminum, copper, steel and various alloys thereof.

[0086] As shown in FIGS. 46 to 47, according to an embodiment of the present invention, a projectile 60 comprises a cup portion 62, a connector portion 64 and a base portion 66. The connector portion 64 defines a first socket 68 for receiving the cup portion 62 and a second socket opposite the first socket 70 for receiving base portion 66. The connector portion 64 further comprises a protruding portion 72 for engaging the rifling of the barrel. In this configuration, the connector portion 64 can comprise a lightweight gilding metal such as the driving band 8 while the cup and base portions 62, 66 comprise lightweight polymers.

[0087] As shown in FIGS. 1 to 19, the frangible cap 2 can define at least one notch 22 for engaging the projectile base 6. In this configuration, the cup portion 12 can further comprise a protrusion 24 corresponding to each notch 22 to retain the engagement portion 10 of the cap 2 within the cup portion 12.

[0088] As shown in FIGS. 25-27, the projectile can further comprise a second driving band 58 at the frangible cap 2 also adapted to engage rifling of the barrel. The second driving band 58 cooperates with the driving band 8 positioned on the projectile base 6 to facilitate travel of the projectile 2 through the barrel minimal or no portions of the projectile base 6 or frangible cap 2 being directly engaged by the rifling of the barrel. As shown in FIGS. 26 and 27, the driving band may be placed at the juncture 73 of the cap 2 and base 6. In one aspect, the second driving band 58 can be embedded into the frangible cap similar to the first driving band.

[0089] As shown in FIGS. 20 to 24, in an embodiment of the present invention, the non-lethal projectile 2 can be fired from a reduced energy cartridge 30 adapted to propel the projectile 2 with gases generated only by a primer 32 from a conventional firearm. The cartridge 30 further comprises a cartridge casing 34, a neck portion 36 and a telescoping insert 38 adapted to telescope upon firing to trigger the cycling mechanism of the firearm. The cartridge casing 34 defines an internal cavity having a first opening 40 and a second opening 42. The neck portion 36 can comprise an insert portion 44 receivable within the first opening 40 affix the neck portion 36 to the cartridge casing 34. The neck portion 36 can also comprise a seating portion 45 for receiving the projectile 2. According to an embodiment, the neck portion 36 can be shaped to fit within the chamber of a firearm sized for 5.56 NATO cartridges. According to an embodiment, the neck portion 36 can comprise a glass filed nylon that is resistant to the temperatures associated with the hot gases.

[0090] The telescoping insert 38 comprises a telescoping portion 46 and a rim 48. The telescoping portion 46 is receivable within the second opening 42 such that the rim 48 is positioned against the second opening 42. The telescoping insert 38 defines a channel 50 for receiving the primer 32 and adapted to channel gases generated by igniting the primer 32 toward the projectile 2. According to an embodiment, the telescoping portion 46 can further comprise a gasket 52 engagable to the casing 34 to prevent gases from escaping between the telescoping portion 46 and the casing 34.

[0091] According to an embodiment, the cartridge casing 34 can define a flash hole 54 between the telescoping portion 46 and the projectile 2. During firing, the flash hole 54 compresses the gases generated by the ignited primer 32 into a gas jet, which propels the projectile 2 down the barrel of the firearm and to the target. Correspondingly, the projectile base 6 can define an indent 56 for capturing the gas jet to more efficiently fire the projectile 2 down the barrel.

[0092] During firing, the projectile 2 travels through the rifled barrel of the firearm such that the driving band 8 is engraved by the rifling of the barrel. The rifling imparts a spin to the projectile 2 such that the projectile 2 is spin stabilized once the projectile 2 leaves the barrel. In one aspect, the driving band 8 comprises a material of sufficient hardness such that projection portion 9 of the driving band 8 to be etched in the same way as a conventional bullet as shown in FIG. 42. After the initial etching, the projectile 2 travels through the barrel with minimal friction. In another aspect, the driving band 8 can comprise a more flexible material allowing the projecting portion 9 to flex when engaged by the rifling such that the projecting portion 9 folds over when engaged by the rifling as shown in FIG. 43. According to an embodiment, the driving band 8 can unfurl and separate from the projectile 2 after the projectile 2 exits the muzzle of the barrel or travel with the projectile 2 to the target.

[0093] FIG. 28 illustrates a driving band having an outwardly an forward exposed surface 61 configured as a conical surface, that is angled or tapered toward the front of the bullet. Also the driving band has a support portion 63 configured as a unitary circular rib on the base.

[0094] Referring to FIGS. 29-33, additional embodiments with T-shaped (in the cross section) driving bands are illustrated. FIGS. 29 and 30 illustrate a configuration where the base may be overmolded on the band, that is with the band placed in the mold first and the polymer injected second. FIG. 31 illustrates a driving band 8 assembled by sliding the band on the base 6 over a reduced diameter portion 82. Features such as bumps or wedge shaped portions 83 extending from the surface of the reduced diameter portion may be utilized to secure the band in place. The band will typically be applied to the base, the marker material 84 added to the cap 4 or base, and then the cap and base will be assembled together. The projectiles then may be placed in the casings. Alternatively the base may already be in the casing prior to assembly of the cap and addition of marking material. The band in this embodiment has a T-shaped cross section and may be formed of aluminum or copper or brass or other metals. In FIG. 32, a T-shaped driving band is embedded in the base such as by overmolding the base polymer thereon. A leading driving band 87 may be a conventional polymer formed of the material of the cap, such as polystyrene, or may be metal or metalized as described herein. FIG. 33 illustrates a projectile configured as a bullet shaped sealed enclosure 3 with an aluminum base 6 and a polymer cap 4. The driving band 8 is aluminum and is unitary and integral with the base. The cap may have a second driving band 87 that is a polymer or metal or metalized as disclosed herein. The aluminum base 6 may have a recess 90 in an inwardly facing wall surface 93 to cooperate with an outwardly extending ring 94 in the skirt of the cap.

[0095] FIGS. 37-38c illustrate embodiments of the invention where the driving band 8 or a portion 96 of the driving band is comprised of a polymer, generally the polymer forming the base 6, and further by a metal portion 97 or metalized portion. Portions of the driving band that engage lands of the rifling may be deformed, primarily by the polymer portion 96 deforming while still retaining the exterior layer of metal or metalized material. Such metal may be a foil adhered to the polymer by adhesives or by partially melting the polymer. Such metallization may be by depositing metal on the band.

[0096] FIGS. 44 and 45 illustrate a projectile 60 in an embodiment with an axial section 64 formed of metal with a polymer base 66 therebelow and a cap portion 62 with a closed cavity 63 therein, with marking material 65 therein. The band has surface extensions 64 providing capture regions for the base and cap both of which can be overmolded on the band. The band can be metal or metalized polymer or other materials that has a coefficient of friction less than the polymer or polymers of the base and cap. The cap may have a further driving band 68 which also may be metalized or metal or may be the material of the cap.

[0097] A method of making a non-lethal projectile with at least one driving band, according to an embodiment of the present invention, can comprise separately stamping or forming the driving band and the polymer base. The driving band can then be fitted over the polymer base to affix the driving band to the polymer base. Alternatively, the driving band can be placed in a mold and the projectile base or the base portion of the projectile base can be molded over the driving band. According to another embodiment, a polymer driving band can be over-molded onto a pre-molded polymer base. Powdered metal can be sintered onto a driving band on a polymer base.

[0098] All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

[0099] While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and described in detail. It is understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.