Frangible non-lethal projectile

Abstract

A method of manufacturing a non-lethal impact projectile having a nose composed of a frangible, rigid, polymer foam material such that the nose crushes upon impact with a target to disperse energy, thereby reducing the kinetic energy transferred to the target. The projectile is provided with a cavity to retain a payload, such as marker agents, lacrimators, irritants, inflammatory agents, odorants or inert powders, such that the payload is laterally dispersed upon impact to further dissipate energy transferred to the target.

1 . A method of manufacturing a non-lethal projectile comprising the steps of:
 providing a projectile nose composed of a frangible, rigid, polymer foam material and comprising a cavity;   loading a payload into said cavity;   sealing said cavity by attaching a plug wall;   providing a non-frangible projectile base; and   joining said projectile base to said projectile nose.   
   
   
       2 . The method of  claim 1 , wherein said projectile nose has a rounded forward end and a cylindrical wall, said cylindrical wall being thinner than said forward end, such that said thinner cylindrical wall breaks prior to said forward end upon impact to absorb and dissipate impact energy and such that said payload is dispersed laterally through said cylindrical wall in multiple directions upon impact, and wherein said plug wall is joined to said cylindrical wall prior to joining said projectile base to said projectile nose. 
   
   
       3 . The method of  claim 1 , wherein said projectile base comprises a forward wall joined to a base cylindrical wall, and wherein said step of joining said projectile base to said projectile nose comprises joining said projectile nose to said projectile forward wall. 
   
   
       4 . The method of  claim 2 , wherein said projectile base comprises a forward wall joined to a base cylindrical wall, and wherein said plug wall of said projectile nose is joined to said projectile forward wall. 
   
   
       5 . The method of  claim 1 , further comprising the step of choosing said payload from the group of payloads consisting of marker agents, lacrimators, irritants, inflammatory agents, odorants and inert powders. 
   
   
       6 . The method of  claim 1 , further comprising the step of choosing said plug wall from the group of plug walls consisting of plug walls having resilient, impact-absorbing compositions. 
   
   
       7 . The method of  claim 2 , further comprising the step of choosing said plug wall from the group of plug walls consisting of plug walls having resilient, impact-absorbing compositions. 
   
   
       8 . A method of manufacturing a non-lethal projectile comprising the steps of:
 providing a projectile nose composed of a frangible, rigid, polymer foam material and comprising a rounded forward end and a cylindrical wall which together define a cavity, said cylindrical wall being thinner than said forward end, such that said thinner cylindrical wall breaks prior to said forward end upon impact to absorb and dissipate impact energy and such that a payload is dispersed laterally through said cylindrical wall in multiple directions upon impact;   loading a payload into said cavity;   sealing said cavity by attaching a plug wall to said cylindrical wall, whereby the combination of said forward end, said cylindrical wall and said rear plug wall completely encase said payload during subsequent manufacturing steps;   providing a non-frangible projectile base; and   joining said projectile base to said projectile nose.   
   
   
       9 . The method of  claim 8 , wherein said projectile base comprises a forward wall joined to a base cylindrical wall, and wherein said step of joining said projectile base to said projectile nose comprises joining said projectile nose to said projectile forward wall. 
   
   
       10 . The method of  claim 9 , wherein said step of joining said projectile base to said projectile nose comprises joining said projectile forward wall to said rear plug wall. 
   
   
       11 . The method of  claim 8 , further comprising the step of choosing said payload from the group of payloads consisting of marker agents, lacrimators, irritants, inflammatory agents, odorants and inert powders. 
   
   
       12 . The method of  claim 8 , further comprising the step of choosing said plug wall from the group of plug walls consisting of plug walls having resilient, impact-absorbing compositions. 
   
   
       13 . The method of  claim 9 , further comprising the step of choosing said plug wall from the group of plug walls consisting of plug walls having resilient, impact-absorbing compositions. 
   
   
       14 . The method of  claim 10 , further comprising the step of choosing said plug wall from the group of plug walls consisting of plug walls having resilient, impact-absorbing compositions.