MULTIFUNCTIONAL COMPOSITE PROJECTILES AND METHODS OF MANUFACTURING THE SAME

Abstract

Composite projectiles include various material compositions, diameters, and cavities within the projectiles having a variety of cavity diameters, sidewalls, and bottoms selected and formed to induce different levels of penetration and disintegration of the composite projectiles upon impact with targets.

Claims

1. A molded frangible composite projectile, comprising: a leading end; a trailing end; a projectile diameter; and a pressure-inducing cavity formed within the composite projectile, the pressure-inducing cavity defining a cavity depth, a cavity diameter, a cavity sidewall, and a cavity bottom and being configured to induce disintegration of the composite projectile upon impact with a target, the projectile diameter and the cavity diameter defining a ratio dictating a depth of penetration of the target.

2. The molded frangible composite projectile as in claim 1, wherein the composite projectile has kinetic energy upon discharge from a weapon, the leading end and the cavity being configured to use a majority of the kinetic energy to form a wound cavity in the target and to cause the trailing end to form a retained mass configured to deliver remaining kinetic energy into the wound cavity.

3. The molded frangible composite projectile as in claim 1, wherein the composite projectile is formed from a mixture that excludes carbon particles.

4. The molded frangible composite projectile as in claim 1, wherein a ratio between the projectile diameter to the cavity diameter further dictates the depth of penetration of the target.

5. The molded frangible composite projectile as in claim 4, wherein the ratio between the projectile diameter to the cavity diameter is greater than 2.5:1.

6. The molded frangible composite projectile as in claim 4, wherein the ratio between the projectile diameter to the cavity diameter is less than 2.5:1.

7. The molded frangible composite projectile as in claim 1, wherein the cavity depth to the cavity diameter defines an aspect ratio that dictates the depth of penetration of the target.

8. The molded frangible composite projectile as in claim 7, wherein the aspect ratio is 6.5:1 to 3.5:1.

9. The molded frangible composite projectile as in claim 7, wherein the aspect ratio is 3.4:1 to 2:1.

10. The molded frangible composite projectile as in claim 7, wherein the aspect ratio is 1.9:1 to 0.1:1.

11. The molded frangible composite projectile as in claim 1, wherein the cavity bottom is V-shaped in cross-section.

12. The molded frangible composite projectile as in claim 1, wherein the cavity bottom is U-shaped in cross-section.

13. The molded frangible composite projectile as in claim 1, wherein the cavity bottom is flat in cross-section.

14. The molded frangible composite projectile as in claim 1, wherein the cavity bottom is round in cross-section.

15. The molded frangible composite projectile as in claim 1, wherein the cavity sidewall is stepped in cross-section.

16. The molded frangible composite projectile as in claim 1, wherein the target is hardened, the composite projectile being configured to deliver a retained mass into the hardened target upon impact.

17. The molded frangible composite projectile as in claim 1, wherein the target is a soft target, the composite projectile being configured to disintegrate upon impact with the soft target.

18. A molded frangible composite projectile, comprising: a leading end; a trailing end, the leading and trailing ends being monolithically molded from a mixture including 85-95% metallic particles and less than 10% of a polymer; a projectile diameter; and a cavity formed within the composite projectile, the cavity defining a cavity opening, a cavity depth, a cavity diameter, a cavity sidewall, and a cavity bottom and being configured to induce pressure within the cavity and disintegration of the composite projectile upon impact with a target, the cavity opening being at least concentric with the cavity sidewall.

19. The molded frangible composite projectile as in claim 18, wherein the projectile diameter and the cavity diameter define a ratio to induce pressure and dictate a depth of penetration of the target.

20. The molded frangible composite projectile as in claim 18, wherein the cavity depth and cavity diameter define an aspect ratio dictating a depth of penetration of the target.

21. The molded frangible composite projectile as in claim 18, wherein the cavity sidewall is formed at an angle in a direction away from the cavity opening and towards the cavity bottom such that the cavity opening is larger than the cavity bottom, the angle contributing to the pressure within the cavity to dictate a rate of expansion.

22. The molded frangible composite projectile as in claim 18, wherein the cavity bottom defines a shape configured to dictate degrees of disintegration of the composite projectile.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0053] FIG. 1 is a side view of a composite projectile of certain embodiments;

[0054] FIG. 2 is a side view of a composite projectile of certain embodiments;

[0055] FIG. 3 is a side view of a composite projectile of certain embodiments;

[0056] FIG. 4 is a side view of a composite projectile of certain embodiments;

[0057] FIG. 5A side view of a composite projectile of certain embodiments;

[0058] FIG. 6 is a side view of a composite projectile of certain embodiments;

[0059] FIG. 7 is a side view of a composite projectile of certain embodiments;

[0060] FIG. 8 is a perspective view of a composite projectile of certain embodiments;

[0061] FIG. 9A is a perspective view of a composite projectile of certain embodiments;

[0062] FIG. 9B is a side view of a composite projectile of certain embodiments;

[0063] FIG. 9C is a front view of a composite projectile of certain embodiments;

[0064] FIG. 10 is a side view of a composite projectile of certain embodiments;

[0065] FIG. 11A is a side view of a composite projectiles of certain embodiments comprising a cap at a trailing end;

[0066] FIG. 11B is a cross-sectional view of a composite projectiles of certain embodiments comprising a cap at a trailing end;

[0067] FIG. 11C is a side view of a composite projectiles of certain embodiments comprising a cap at a trailing end;

[0068] FIG. 11D is a cross-sectional view of a composite projectiles of certain embodiments comprising a cap at a trailing end;

[0069] FIG. 11E is a side view of a composite projectiles of certain embodiments comprising a cap at a trailing end;

[0070] FIG. 11F is a cross-sectional view of a composite projectiles of certain embodiments comprising a cap at a trailing end;

[0071] FIG. 11G is a side view of a composite projectiles of certain embodiments comprising a cap at a trailing end;

[0072] FIG. 11H is a cross-sectional view of a composite projectiles of certain embodiments comprising a cap at a trailing end;

[0073] FIG. 12A is a side view of a composite penetrator of certain embodiments;

[0074] FIG. 12B is a side view of a composite penetrator of certain embodiments;

[0075] FIG. 12C is a side view of a composite penetrator of certain embodiments;

[0076] FIG. 12D is a side view of a composite penetrator of certain embodiments;

[0077] FIG. 12E is a side view of a composite penetrator of certain embodiments;

[0078] FIG. 13A is a side view of a composite penetrator of certain embodiments;

[0079] FIG. 13B is a side view of a composite penetrator of certain embodiments;

[0080] FIG. 13C is a side view of a composite penetrator of certain embodiments;

[0081] FIG. 13D is a side view of a composite penetrator of certain embodiments;

[0082] FIG. 13E is a side view of a composite penetrator of certain embodiments;

[0083] FIG. 13F is a side view of a composite penetrator of certain embodiments;

[0084] FIG. 13G is a side view of a composite penetrator of certain embodiments;

[0085] FIG. 14A is a front view of an alignment element of certain embodiments;

[0086] FIG. 14B is a perspective view of an alignment element of certain embodiments;

[0087] FIG. 15 is a cross-sectional view of a composite projectile of certain embodiments;

[0088] FIG. 16A is a perspective view of a composite projectile of certain embodiments;

[0089] FIG. 16B is a cross-sectional view of a composite projectile of certain embodiments;

[0090] FIG. 17A is a perspective view of a composite projectile of certain embodiments;

[0091] FIG. 17B is a side view of a composite projectile of certain embodiments;

[0092] FIG. 17C is a front view of a composite projectile of certain embodiments;

[0093] FIG. 18A is a cross-sectional side view of a composite projectile of certain embodiments;

[0094] FIG. 18B is a cross-sectional side view of a composite projectile of certain embodiments;

[0095] FIG. 18C is a cross-sectional side view of a composite projectile of certain embodiments;

[0096] FIG. 18D is a cross-sectional side view of a composite projectile of certain embodiments;

[0097] FIG. 18E is a cross-sectional side view of a composite projectile of certain embodiments;

[0098] FIG. 18F is a cross-sectional side view of a composite projectile of certain embodiments;

[0099] FIG. 19 is a cross-sectional side view of a composite projectile of certain embodiments;

[0100] FIG. 20 is a cross-sectional side view of a composite projectile of certain embodiments;

[0101] FIG. 21 is a side view of results of a certain composite projectile being fired into a transparent gel block;

[0102] FIG. 22 is a side view of results of a certain composite projectile being fired into a transparent gel block;

[0103] FIG. 23 is a side view of results of a certain composite projectile being fired into a transparent gel block;

[0104] FIG. 24 is a side view of results of a certain composite projectile being fired into a transparent gel block;

[0105] FIG. 25 is a side view of results of a certain composite projectile being fired into a transparent gel block;

[0106] FIG. 26 is a side view of results of a certain composite projectile being fired into a transparent gel block;

[0107] FIG. 27 is a side view of results of a certain composite projectile being fired into a transparent gel block; and

[0108] FIG. 28 is a side view of results of a certain composite projectile being fired into a transparent gel block.

DETAILED DESCRIPTION

[0109] Certain embodiments of the present disclosure 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% 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. Percentages herein 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.

[0110] 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.

[0111] Exemplary percentages provided herein surround measurement of composition by weight, however, such percentages can be applied in volumetric measurement while in keeping with the spirit and scope of the present disclosure.

[0112] 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, 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 other embodiments, carbon particles are not utilized. 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.

[0113] 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.

[0114] Certain embodiments of the present disclosure 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. 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.

[0115] Certain embodiments of the present disclosure 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. 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. Such embodiments of varying densities can be configured to be fired from any standard firearm while remaining in spirit and scope of the present disclosure.

[0116] Composite projectiles according to the disclosure 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.

[0117] Certain embodiments of the present disclosure surround ammunition casing for the firing of composite projectiles. Certain embodiments comprise a polymer-based casing.

[0118] 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.

[0119] Some embodiments, such as composite projectiles and polymer-based casings, have composite projectiles and casings with 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.

[0120] 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.

[0121] Certain embodiments, as shown in FIG. 9AFIG. 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, in certain use-cases drag-inducing elements 1100 may be asymmetrically spaced around the external surface 1110 of the composite projectile are in keeping with the spirit and scope of the present disclosure. 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.

[0122] Referring again to FIG. 9AFIG. 9C and FIG. 17AFIG. 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 disclosure for such cylindrical cuts to be askew from parallel from the path of travel 2100 of the projectile.

[0123] With continued reference to FIG. 9AFIG. 9C and FIG. 17AFIG. 17C, certain embodiments of the present disclosure 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 IS-degrees of orthogonal to the path of travel 2100, or concave surface oriented toward the path of travel 2100 of the projectile. Here, a concave surface directed toward the path of travel 2100 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. 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.

[0124] Those skilled in the art will appreciate 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 disclosure, 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 disclosure, 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 disclosure, the surface 2210 of trailing aspect 2200 of the drag-inducing elements comprise between 15%-60% of the frontal area 2400 of the projectile.

[0125] 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.

[0126] Certain embodiments, as seen in FIG. 11AFIG. 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, other materials known to those in the art may be used within the spirit and scope of the present disclosure. In certain embodiments, as seen in FIG. 11AFIG. 11B, a cap 1140 comprises a form which covers the trailing end 1002 of the composite projectile. In certain embodiments, as shown in FIG. 11CFIG. 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. 11CFIG. 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. A cap as disclosed herein surrounds the shielding of the leading end of a composite projectile. However, a cap of certain embodiments may be 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 disclosure.

[0127] Certain embodiments of the present disclosure 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.

[0128] In certain embodiments, as shown in FIG. 12AFIG. 12E, a hardened penetrator 1145 of the present disclosure 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.

[0129] As seen in FIG. 13AFIG. 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. 13CFIG. 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. 13FFIG. 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.

[0130] In certain embodiments, as shown in FIG. 14AFIG. 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 [0131] such as a polymer, metal, or ceramicconfigured to allow the permeation of a molten polymer into and around the structure of the alignment element 1500.

[0132] 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. Some embodiments may include 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.

[0133] 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.

[0134] Turning to FIGS. 18A-20, exemplary molded, frangible, open-tip or hollow point projectiles 2000 are shown with a variety of cavity shapes and sizes. These projectiles 2000 may have formulations that utilize metal fillers and polymers and may or may not contain carbon particles. As explained in detail below, sidewalls of the projectile 2000 cavities may be straight (cylindrical) or angled (conical), but preferably an angle will not be a reverse angle (smaller at the opening of a cavity than at a base of the cavity, i.e., the opening and the sidewalls will at least be concentric or tubular in shape). Leading edges of the cavities may be larger or smaller relative to a major (largest) diameter of the projectiles 2000, and depths of the cavities may be shallow or deep relative to the overall length of the projectiles.

[0135] The bases of the cavities may have a variety of geometries to promote certain events upon impact. For example, a geometry at a base can promote a shearing action above the mass-retained base or the geometry may be used to create a forward-ejection (similar to a shape charge at the bottom of the cavity).

[0136] The cavity dimensions of the following projectiles 2000 will promote deeper or shallower penetration into a soft target, depending on user requirements. For instance, a larger diameter cavity will not penetrate as deeply as a smaller diameter cavity. A hydraulic action of the soft target material entering the cavity promotes pressure extending outward thus breaking the projectile apart. Thus, depth-of-penetration may be dictated by a combination of forward speed of a particular projectile 2000, a size of its cavity, and a configuration of the cavity.

[0137] More particularly, in the following configurations, the projectiles 2000 may include molded materials designed to disintegrate upon impact with a hard object. Various blends of molding materials may be used to generate variations of disintegration and mass retention upon impact. The density of a particular molding material can be adjusted to meet weight and center-of-gravity requirements to create, for instance, a maximum wound channel by the disintegrating projectile 2000. But while the projectiles 2000 can be used to deliver lethality as a duty round, they can be safely used as training rounds with no fragment splash-back or ricochet.

[0138] As detailed below, numerous cavity configurations may be used in the projectiles 2000 to generate variations of disintegration and mass retention upon impact with various targets (e.g., soft such as flesh or paper, or hard/hardened such as armor or steel-reinforced concrete). Weight and center-of-gravity can be adjusted by a combination of material properties and cavity size and shape and configurations. For instance, conical shapes at a bottom of a base of a projectile 2000 will promote a shape charge.

[0139] Cavity design parameters in the following exemplary projectiles 2000 may include: [0140] a. Sidewall angles: zero-degrees (straight-wall) to 89-degrees (shallow), where zero-degrees promotes less expansion and greater than 1-degree promotes increasingly faster rate of expansion. Thus, the angle of the cavity sidewall contributes to pressure within the cavity to dictate a rate of expansion. [0141] b. Projectile Diameter to Cavity Diameter Ratios: higher ratios of >2.5:1 generally promote deeper penetration while lower ratios <2.5:1 generally promote shallower penetration. [0142] c. Cavity Depth to Cavity Diameter or Aspect Ratios: High-Aspect Ratios of approximately 6.5:1 to 3.5:1; Medium-Aspect Ratios of approximately 3.4:1 to 2:1; and Low-Aspect Ratios of approximately 1.9:1 to 0.1:1. [0143] d. Cavity-Base Geometries: depth of cavity determines mass retained in a base when impacting a soft target. A forward-facing U or V shape promotes a forward ejection of hot gas/plasma/ejecta while an inverted V or U promotes quicker shear from the mass-retained base. Thus, the shape of the cavity bottom dictates levels or degrees of disintegration of the composite projectile.

[0144] In FIG. 18A a projectile 2000 according to the foregoing is shown with a high-aspect-ratio (depth:diameter ratio as defined above), pressure-inducing element or cavity 2010 having low-angle sidewalls 2012 and a flat bottom 2014. The exemplary projectile 2000 includes a leading end 2001 near a cavity opening 2010 and a trailing end 2002 near a base 2016, the majority of which is retained upon target impact.

[0145] The exemplary projectile 2000 in FIG. 18B is also shown with its leading end 2001, its trailing end 2002, the high-aspect-ratio cavity 2010 but includes an inverted-V bottom 2018 to promote quicker shear from the mass-retained base 2016.

[0146] FIG. 18C shows yet another exemplary projectile 2000 with a high-aspect-ratio cavity 2010. In this example, however, a deep-V bottom 2020 is utilized to promote a forward ejection of gas and ejecta while much of the base 2016 is retained upon target impact.

[0147] FIG. 18D shows a projectile 2000 with a high-aspect-ratio cavity 2010 and a rounded bottom 2022 located forward of the base 2016.

[0148] FIG. 18E shows a projectile 2000 with a high-aspect-ratio cavity 2010 and a shallow-V bottom 2024 located forward of the base 2016.

[0149] FIG. 18F shows a projectile 2000 with a high-aspect-ratio cavity 2010 and a flat bottom 2014 located forward of the base 2016. Similar to FIG. 18A, this exemplary projectile 2000 also includes low-angle sidewalls 2012, but these include a stepped portion 2026.

[0150] With reference now to FIG. 19, a projectile 2000 is shown with a medium-aspect-ratio cavity 2010, a flat bottom 2014 located forward of its base 2016, and medium-angle sidewalls 2028.

[0151] FIG. 20 shows a projectile 2000 with a low-aspect-ratio cavity 2010, a flat bottom 2014 located forward of its base 2016, and high-angle sidewalls 2030.

[0152] Turning now to FIGS. 21-28, test results are shown in which various projectiles 2000 as described above produce different wound channels and fragmentation patterns 3000 upon penetration of ballistic gel blocks 1 at entry holes or points 3.

[0153] FIGS. 21 and 22 show entry holes 3 from a right side of the gel block 1 in which a front cavity section of a projectile 2000, such as those described above, opens up and breaks apart in a primary wound channel 3000 with a retained mass of the base 2016 penetrating deeper to a left side of the gel block 1.

[0154] FIG. 23 shows an entry hole 3 from a right side of the gel block 1 in which a front cavity section of a projectile 2000, such as those described above, opens up and breaks apart in a primary wound channel 3000 with much of the base 2016 fragmenting but penetrating deeper to a left side of the gel block 1.

[0155] FIG. 24 shows an entry hole 3 from a right side of the gel block 1 in which a front cavity section of a projectile 2000, such as those described above, opens up and breaks apart in a primary wound channel 3000 with much of the base 2016 fragmenting but penetrating deeper to a left side of the gel block 1.

[0156] FIG. 25 shows an entry hole 3 from a right side of the gel block 1 in which a front cavity section of a projectile 2000, such as those described above, opens up and breaks apart in a primary wound channel 3000 with much of the base 2016 fragmenting but penetrating deeper to a left side of the gel block 1.

[0157] FIGS. 26, 27, and 28 show a projectile 2000, such as those described above, impacting and forming an entry hole 3 from a left side of the gel block 1 in which a front cavity section of a projectile 2000, such as those described above, opens up and breaks apart in a primary wound channel 3000 with nearly complete fragmentation but achieving deep penetration to a right side of the gel block 1.

[0158] While various embodiments of the present disclosure 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 disclosure. 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.