PROJECTABLE RESIN TARGET AND METHOD

Abstract

A breakable shooting target, formed from a composition including a binder component, selected from one or more natural fatty acids, and a binder modifier component, selected from one or more metal oxides, the binder and binder modifier together comprising between about 14% and about 24% of the composition; a viscosity modifier component, selected from one or more plant-based resins comprising between about 0.1% and about 15% of the composition; and a filler component comprising between about 70% and 86% of the composition. The composition is molded into a disk shape and cast in a state of sufficient strength and brittleness, that the target can be launched from a target launching trap, fly through the air in a reproduceable path, and when hit with multiple shot shell pellets fired from a shotgun, the target will shatter into multiple pieces.

Claims

1. A breakable shooting target, formed from a composition comprising: a binder component, selected from one or more natural fatty acids, and a binder modifier component, selected from one or more metal oxides, the binder and binder modifier together comprising between about 14% and about 24% of the composition; a viscosity modifier component, selected from one or more plant-based resins comprising between about 0.1% and about 15% of the composition; and a filler component comprising between about 70% and 86% of the composition; the composition molded into a disk shape and cast in a state of sufficient strength and brittleness, that the target can be launched from a target launching trap, fly through the air in a reproduceable path, and when hit with multiple shot shell pellets fired from a shotgun, the target will shatter into multiple pieces.

2. The breakable shooting target according to claim 1 wherein the binder component has been heated with a non-stochiometric amount of the binder modifier component to at least partially convert at least some of the fatty acid of the binder into salts of the conjugate fatty acid to produce a blend of fatty acids and conjugate bases, with a melting point higher than the melting point of the fatty acid.

3. The breakable shooting target of claim 2, wherein the viscosity modifier component comprises at least one of rosin ester, resin ester, and a glycerol ester of rosin.

4. The breakable shooting target of claim 3, wherein the rosin ester, resin ester, or glycerol ester of rosin comprise about 3-10% of the composition.

5. The breakable shooting target of claim 2, wherein the viscosity modifier component comprises pine resin.

6. The breakable shooting target of claim 5, wherein pine resin comprises about 4-9% of the composition.

7. The breakable shooting target of claim 2, wherein the binder component comprises stearic acid.

8. The breakable shooting target of claim 7, wherein stearic acid comprises about 8-14% of the composition.

9. The target of claim 8, comprising stearic acid at about 9-11% of the composition.

10. The breakable shooting target of claim 8, wherein the binder modifier component comprises calcium oxide.

11. The target of claim 10 wherein calcium oxide comprises between about 0.7 and about 1.2% of the composition.

12. The target of claim 11, comprising calcium oxide from about 0.75 to about 0.916% of the composition.

13. The target of claim 2, wherein the filler is selected from the group consisting of calcium carbonate, talc, gypsum, clay, silicate, aluminate, and sulphate.

14. The target of claim 12, wherein the filler comprises calcium carbonate.

15. The target of claim 12, wherein the filler comprises calcium carbonate in an amount of about 70-85%.

16. The target of claim 2, wherein the composition has an LD50 of about 15,000 mg/kg or greater.

17. The target of claim 2, wherein the composition is substantially free of pitch.

18. The target of claim 2, cast in a state of sufficient strength and brittleness, that when shot at with a 12 gauge shotgun by shooters standing at least 25 yards behind the launching trap, at least 90% of hit targets will break, counting an unbroken target hit by less than 3 pellets as a miss.

19. The target of claim 2, cast in a state of sufficient resistance to heat, that the target will maintain its shape and dimensions, without deformation, after being exposed to 140 F. for at least 5 hours.

20. A target suitable for shooting sports, comprising pine resin, stearic acid, calcium oxide, and filler, cast into a disk of sufficient brittleness, that when launched from a trap into the air and shot at with shot shell pellets from a 12 gauge shotgun fired at least 25 yards behind the trap, no less than 90% of hit targets will break, counting targets hit by 0, 1, or 2 pellets as a miss.

21. The target of claim 20, comprising calcium oxide and stearic acid, having an LD50 of about 15,000 mg/kg or greater, and being substantially free of pitch.

22. The target of claim 20, cast in a state of sufficient resistance to heat, that the target will maintain its shape and dimensions after being exposed to 130 F. for at least 7 days, without observable deformation.

23. The target of claim 22, cast in a state of sufficient resistance to heat, that the target will maintain its shape and dimensions after being exposed to 150 F. for at least 30 days, without observable deformation.

24. The target of claim 20, wherein the stearic acid has a polymorphic structure.

25. A breakable shooting target, formed from a composition comprising: a binder component, selected from one or more natural fatty acids, and a binder modifier component, selected from one or more metal oxides, the binder and binder modifier together comprising between about 14% and about 24% of the composition; a viscosity modifier component, selected from one or more plant-based resins comprising between about 0.1% and about 15% of the composition; and a filler component comprising between about 70% and 86% of the composition; the composition molded into a disk shape and cast in a state of sufficient strength and brittleness, that the target can be launched from a target launching trap, fly through the air in a reproduceable path, and when hit with multiple shot shell pellets fired from a shotgun, the target will shatter into multiple pieces.

26. The breakable shooting target according to claim 18 wherein the binder comprises stearic acid and comprises 10% and 14% of the composition, and wherein the binder modifier is calcium oxide and is 0.7% to 1.5% of the composition.

27. The breakable shooting target according to claim 19 wherein the binder component has been heated with the binder modifier component to at least partially convert at least some of the fatty acid to produce a blend of fatty acids and conjugate bases, with a melting point higher than the melting point of the fatty acid.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] For a fuller understanding of this disclosure, reference is made to the following description in connection with the accompanying drawings, in which:

[0019] FIG. 1 is a perspective view of a shooter engaged in a shooting activity in which shot shell pellets are fired at a flying target;

[0020] FIG. 2 is a side view of the target of FIG. 1; and

[0021] FIG. 3 is a plan view of the target of FIG. 1.

[0022] The drawings are presented for purposes of illustration only. They are not necessarily to scale, and are not to be interpreted as limiting.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] This disclosure relates to a shooting activity, such as trap shooting, skeet shooting, sporting clays, and the like, having a reduced environmental impact. Targets in accordance with this disclosure can be substantially pitch free, can be formed of essentially non-toxic components, and can be stored for extended periods of time under adverse environmental conditions without significant deformation and/or breakage. The targets can still be launched and broken properly, even when hit by a minimal number of shot shell pellets. Targets in accordance with preferred embodiments of this disclosure can lack pitch or other environmentally undesirable ingredients.

[0024] In preferred embodiments of this disclosure, a shooting target can be formed with a non-toxic and/or non-environmentally adverse binder. Preferred binders are readily mixed with suitable aggregate fillers. Molding is a preferred target forming method. Accordingly, preferred binders should be readily meltable. Upon mixing the aggregate filler and binder, the mixture should exhibit excellent forming and flowability characteristics for proper manufacturability.

[0025] In preferred methods, the binder is heated to form the molten material and solidifies during cooling after being injected into the mold. Once cured, the newly formed targets should exhibit properties which promote removal from the mold. The produced target should exhibit sufficient strength to survive being launched yet, paradoxically, provide excellent shatter results when contacted in flight or otherwise by as few as three shot shell pellets. Further, the material composition of the target should not warp or otherwise deform at normal storage temperatures to provide consistent flight characteristics. Targets in accordance with this disclosure should maintain geometric integrity at temperatures in the range of 150-180 F. (66-82 C.) for 1-4 weeks or longer.

[0026] The LD50 of targets in accordance with this disclosure should be over 10,000 mg/kg, preferably over 15,000 mg/kg, with a relatively harmless determination on the Hodge and Stener scale. Other toxicity studies that resulted in an essentially or practically Non-Toxic determination include a fresh water algae study, a seedling emergence study on ryegrass, and an acute toxicity screening on earthworms.

[0027] This disclosure relates to the selection and processing of a suitable binder and modifiers that create a target that is able to be manufactured, stored for prolonged periods in elevated temperatures at or up to 150 F. (66 C.), and preferably at least 165 F. (74 C.), launched from a trap device, exhibit sufficient breakability even when impacted with a low number of projectiles, exhibit low/non-toxicity with an LD50>10,000 preferably >15,000 mg/kg.

[0028] Suitable binders and modifier combinations are included in the range of about 14-24% by weight. Preferred compositions include about 14-18% by weight of the mix of binder and modifier.

[0029] Fillers are utilized to create the desired final product. Calcium carbonate, e.g., limestone in a powdered form (>90% passing the U.S. Mesh size 100) is a preferred filler. Other suitable fillers include gypsum, clays, silicates, aluminates, sulfates, and other predominately inorganic powders. The fillers can be included at approximately, 70-86% by weight.

[0030] The base binder is preferably produced from a fatty acid, such as palmitic acid, stearic acid, myristic acid, or a blend of multiple fatty acids. Stearic acid is preferred. The fatty acid can be derived from tallow, vegetable oils, palm oils, or other bio-based materials. The fatty acid typically should possess a titre in the range of 86-162 F. (30-72 C.), and preferably in the 122-158 F. (50-70 C.) range. Titre is the point at which a fatty acid will crystalize. The heat of crystallization causes a temperature rise.

[0031] Fatty acids, such as stearic acid, have been studied and identified as polymorphs. It is believed that the specific chemistry and processing conditions determine the final crystalline form of the fatty acid. This crystalline form typically influences the properties of the final clay target product.

[0032] Pitch is amorphous and a pseudo solid or a liquid that does not flow. Unlike pitch, the fatty acid component of the base binder is preferably in a crystalline form. The benefit of a crystalline base material is that when modified, it provides improved heat resistance until melt point. Amorphous materials such as pitch exhibit plastic properties and will begin to deform during heating long before reaching the identified softening point of the material. In contrast, crystalline materials will hold their shape for longer periods, even as the melt point is being approached.

[0033] The base binder in accordance with this disclosure is advantageously modified through a chemical reaction with a metal oxide. Preferred metal oxides include iron oxide, copper oxide, zinc oxide, magnesium oxide, and calcium oxide. It is preferred that calcium oxide is utilized. The ratio of calcium oxide to fatty acid is one way to control the chemical modification. The calcium oxide should be added at a 3-10% ratio by weight of fatty acid. It is preferred that the calcium oxide is added at 7-9.5% by weight of the fatty acid. All percentages used herein are by weight, unless indicated otherwise.

[0034] In a preferred manufacturing method, this mixture of fatty acid and metal oxide is stirred continuously and then heated to a temperature of about 275-300 F. (135-150 C.), and preferably about 290-300 F. (143-150 C.). A visible chemical reaction occurs which is believed to convert the fatty acid into the salt(s) of the conjugate fatty acid. Due to the typical blend of fatty acids used and the relatively low ratio of metal oxide (less than stoichiometric requirements of complete conversion) it is believed that a blend of fatty acids and conjugate bases form. This blend of fatty acids and conjugate bases (such as octadecanoate) following the chemical reaction possess a higher melting point than the original fatty acids. The melt point is typically in the range of 175-225 F. (79-107 C.). A melt point of 190-210 F. (88-99 C.) is preferred. This higher melting point base binder is preferred to provide a material that has enhanced application performance (e.g., breakability/brittleness/frangibility during shooting) and thermal durability properties necessary for shipping, storage, and warm climate exposure.

[0035] Viscosity modification is advantageous for manufacturability and application performance. Examples of viscosity modification include sugar alcohols (glycerol, isomalt, xylitol), natural waxes (soy wax, carnauba wax, etc.), paraffin waxes, petroleum derived waxes, surfactants, and natural resins (pine resin, gum rosin, glycerol esters, rosin, Greek pitch, rosin ester, and esters of wood). Typically, viscosity modifiers are added at between 0.1-15%, depending on the type of modifier utilized. The timing of viscosity modification addition with respect to the chemical reaction of the fatty acid and metal oxide may result in chemical changes to the viscosity modifier.

[0036] Biopolymers are an advantageous additive for the promotion of desired mechanical properties and for enhancing the environmentally impacting properties of the target. Biopolymers such as starches are advantageously added to enhance the breakability (e.g., the performance of the clay target during shooting). Starches are comprised of amylose and amylopectin, and the ratio of amylose and amylopectin varies based on the source of starch. For example, waxy corn or waxy maize starch contains very high levels of amylopectin, as do waxy potato starches. Beyond the natural form of starch, the biopolymer can be modified, which affords changes in performance during manufacturing and end-product properties. Natural starches such as corn starch and potato starch may increase desirable performance characteristics of the clay target. Modified starches, such as pre-gelled corn starch and acid modified starches offer property changes during manufacturability. However, high amylopectin starches are preferred for the mechanical properties imparted in the clay target. Biopolymer content, such as starches, can be added in the range of 0-25% by weight of the base binder.

EXAMPLES

[0037] The following Examples are for illustration and are not to be interpreted as limiting:

Ingredients for Use During Target Manufacture

a) Fillers

[0038] Limestone [0039] Magnesium Carbonate [0040] Sand [0041] Carbon Black

b) Viscosity Reducers and Brittleness Additives

[0042] Rosin [0043] Gum Rosin [0044] Colophony [0045] Greek Pitch [0046] Glycerol ester of wood [0047] Wood ester [0048] Rosin Ester [0049] Resin Ester [0050] Pine Resin [0051] Glycerol Ester of Rosin [0052] Glycerol Ester of Resin [0053] Starch [0054] Corn flour [0055] Corn starch [0056] Wheat flour [0057] Modified starch [0058] Glycerin or Glycerol [0059] Carnauba Wax [0060] Vegetable oil [0061] Coconut oil [0062] Corn syrup

c) Base Binder

[0063] Stearic Acid (e.g., Soy, Palm Oil, Tallow)

d) Reaction Materials

[0064] Black Iron Oxide [0065] Calcium Oxide [0066] Lithium Hydroxide [0067] Magnesium Oxide [0068] Potassium Hydroxide [0069] Sodium Hydroxide [0070] Zinc Oxide

Preferred Ingredients for Targets in Accordance with this Disclosure

Example 1

[0071] 1. Stearic acid, about 8-14%, preferably about 9-11%, most preferably 9.5-10.5%. [0072] 2. Calcium Oxide, about 0.791-0.875%, preferably about 0.750-0.916%, most preferably, about 0.78%. [0073] 3. Pine Resin about 3-10%, preferably about 4-9%, most preferably 5-7%. [0074] 4. Carbon black, optional, about 0-1.5%, preferably about 0.1-1%, most preferably 0.25-0.7% [0075] 5. Calcium Carbonate: about 70-85%, preferably about 74.5-84%, most preferably 79-83%

Example 2

[0076] 1. Stearic Acid about 8-14%, preferably about 9-11%, most preferably 9.5-10.5%. [0077] 2. Calcium Oxide about 0.750-0.916%, preferably 0.791-0.875%, most preferably 0.78%. [0078] 3. Pine Resin about 3-10%, preferably about 4-9%, most preferably 5-7%. [0079] 4. Carbon Black, optional, preferably about 0-1.5%. [0080] 5. Calcium Carbonate, about 70-85%, preferably about 74.5-84%, most preferably 79-83%

[0081] Stearic Acid is an acceptable example of a fatty acid, which is essentially a long hydrocarbon chain containing a carboxyl group at one end and a methyl group at the other.

[0082] Calcium Oxide is a white caustic alkaline solid, commonly produced in the form of quicklime.

[0083] Calcium stearate can be produced through dehydration synthesis, by heating and mixing stearic acid and calcium oxide:

##STR00001##

Description of Reaction

Steps

[0084] 1. Heat stearic acid to 275-300 F. ( ) n reaction pot with agitation. [0085] 2. Introduce calcium oxide (7-10% of weight of stearic acid) with agitation. [0086] 3. Reaction which produces calcium stearate begins immediately, peaking at 4-6 minutes.
This process is exothermic and the temperature of the mix typically rises.

[0087] It is believed that forming the calcium stearate in this manner leads to improved crystallinity, which leads to improved target characteristics, including both heat resistance and breakability.

Formulation of Blend Following the Reaction

Steps

[0088] 1. Add carbon black for desired color and viscosity reducer to the reaction material. [0089] 2. Agitate the material until the blend is homogenous and the temperature is stable. Preferred temperatures are 325 F. to 350 F. [0090] 3. Add calcium carbonate gradually, allowing the material to maintain temperature and become homogenous.

[0091] One of the most important characteristics of a target is how well it launches, flies, and then breaks, even when hit by a small number of shot shell pellets. The following shooting tests were performed with targets made in accordance with this disclosure. Shooters were standing over 25 yards (about 27 yards) from the launching trap. Often, shooters will stand closer to the trap, such as 16 yards or less, which makes it easier to break the targets. At some competitions, including the examples herein, the shooters stand 27 yards behind the trap. These targets were considered environmentally friendly and essentially nontoxic. Unbroken targets were caught in a tarp, examined for shot shell pellet marks and the number of shot shell pellets that had hit, but not broken the target, was recorded.

Example 3

[0092] Shooting for Example 3 was conducted on an outdoor American trap field from the 27 yard line with full choke 12 gauge shotguns. Shot shells had a 2 inch shell length, 7 shot size shell load, and a muzzle velocity of 1250 feet per second. In evaluating the breakage performance of targets in accordance with this disclosure, it cannot be reasonably expected that targets hit by 0, 1 or 2 shot shell pellets will break. Therefore, as used herein, a missed target is an unbroken target hit by 0, 1 or 2 shot shell pellets. A hit target is a target that was (1) broken by at least one pellet; or (2) hit by 3 or more pellets and remained unbroken.

TABLE-US-00001 #/100 #/100 #/100 #/100 #/100 #/100 Unbroken Unbroken Unbroken Unbroken Unbroken Unbroken Targets Targets Targets Targets Targets Targets # With 0 With 1 with 2 With 3 with 4 with 5 Target Targets Hits Hit Hits Hits Hits Hits Sample Weight Thrown (Miss) (Miss) (Miss) (Hit) (Hit) (Hit) A 96 g 100 3 3 3 3 0 1 B 96 g 100 8 3 2 2 0 0 C 96 g 100 11 5 3 0 0 0 D 96 g 100 11 4 2 0 0 0

[0093] As can be seen, the targets of Example 3 performed as well as or better than conventional pitch targets. Of 400 targets launched, 58 were considered misses, i.e., hit by 0, 1 or 2 shot shell pellets, based on visually examining unbroken targets for pellet strike marks. That left 342 hit targets. Of those 342 hit targets, only 6 (1.75%) did not break. Thus, 336 of 342 hit targets (>98%) were broken. This small percentage of hit (by 3 or more shot shell pellets without breaking) but unbroken targets is characteristic of a high performing target. Acceptable targets in accordance with this disclosure are constructed with sufficient strength and brittleness, such that when launched from a trap and shot at with shot shell pellets, at least 90% of hit targets will break. It is preferable to construct the targets such that at least 95% of hit targets will be broken. In general, the shooting performance of targets in accordance with this disclosure was indistinguishable or better than pitch targets.

[0094] Certain changes may be made in carrying out the above method and in the devices and compositions set forth without departing from the spirit and scope of this disclosure, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

[0095] It is also to be understood that the following claims are intended to cover all of the generic and specific features of this disclosure herein described and all statements of the scope of this disclosure which, as a matter of language, might be said to fall therebetween.