Projectile trap and shooting range

Abstract

A shooting range including a shooting station positioned at one end of a firing lane. A projectile trap is disposed at an opposite end of the firing lane for collecting projectiles fired from the shooting station. The projectile trap comprises a deceleration chamber defined by a first scroll wall and a second scroll wall for dissipating kinetic energy of the projectiles and a funneling portion for directing projectiles into the deceleration chamber. The first scroll wall is curved and has a concave surface. The first scroll wall is positioned so that the concave surface of the first scroll wall generally faces in a direction towards the shooting station. The first scroll wall comprises a steel body substrate and has an enhanced impact resistant portion. The enhanced impact resistant portion has an impact resistant layer comprising a plurality of ceramic particles and a binding material bound to a forward facing surface of the steel body substrate.

We claim: 
     
         1 . A shooting range, comprising:
 a shooting station positioned at one end of a firing lane;   a projectile trap disposed at an opposite end of the firing lane for collecting projectiles fired from the shooting station;   the projectile trap comprising a deceleration chamber defined by a first scroll wall and a second scroll wall for dissipating kinetic energy of the projectiles and a funneling portion for directing projectiles into the deceleration chamber;   the first scroll wall being curved and having a concave surface, the first scroll wall being positioned so that the concave surface of the first scroll wall generally faces in a direction towards the shooting station, the first scroll wall comprising a steel body substrate and having an enhanced impact resistant portion, the enhanced impact resistant portion having an impact resistant layer comprising a plurality of ceramic particles and a binding material bound to a forward facing surface of the steel body substrate;   the second scroll wall being curved and having a concave surface, the second scroll wall being positioned so that the concave surface of the second scroll wall generally faces in a direction away from the shooting station;   the concave surface of the first scroll wall and the concave surface of the second scroll wall cooperating to define the deceleration chamber;   the first scroll wall and the second scroll wall positioned with respect to each other to define an entrance slot to the deceleration chamber, the entrance slot being positioned to allow projectiles fired from the shooting station to enter the deceleration chamber;   the first scroll wall and the second scroll wall further positioned with respect to each other to define an exit slot from the deceleration chamber, the exit slot being positioned so that gravity causes material from de-energized projectiles to exit the deceleration chamber via the exit slot;   the funneling portion of the projectile trap comprising an upper steel plate and a lower steel plate disposed on opposite sides of a horizontal plane to define an entry channel;   the upper steel plate being oriented at a first acute angle relative to the horizontal plane and the lower steel plate being oriented at a second acute angle relative to the horizontal plane so that projectiles striking one or both of the steel plates are directed through the entrance slot of the deceleration chamber, wherein a Cross sectional area of the entry channel decreases in a direction of projectile travel;   wherein the enhanced impact resistant portion is positioned proximate the entrance slot of the deceleration chamber; and   wherein projectiles directed through the entrance slot of the deceleration chamber by the upper steel plate and the lower steel plate strike the enhanced impact resistant layer.   
     
     
         2 . The shooting range of  claim 1 , wherein the particles comprise a material selected from the group consisting of aluminum oxide, boron carbide, boron nitride, silicon carbide, silicon nitride, and zirconium oxide. 
     
     
         3 . The shooting range of  claim 1 , wherein the particles of the impact resistant layer are bound to the steel body substrate by the binding material. 
     
     
         4 . The shooting range of  claim 1 , wherein:
 the steel body substrate comprises a first metal alloy; and   the binding material comprises a second metal alloy different from the first metal alloy.   
     
     
         5 . The shooting range of  claim 4 , wherein the first metal alloy comprises AR500 steel. 
     
     
         6 . The shooting range of  claim 4 , wherein the first metal alloy and the second metal alloy both comprise chromium. 
     
     
         7 . The shooting range of  claim 4 , wherein the first metal alloy and the second metal alloy both comprise nickel. 
     
     
         8 . The shooting range of  claim 1 , wherein the thermal spraying process comprises a flame spraying process. 
     
     
         9 . The shooting range of  claim 8 , wherein the thermal spraying process comprises a high velocity oxy-fuel spraying process. 
     
     
         10 . The shooting range of  claim 8 , wherein the thermal spraying process comprises a plasma spraying process. 
     
     
         11 . A method for maintaining or repairing an existing firing range having a shooting station positioned at one end of a firing lane and a projectile trap disposed at an opposite end of the firing lane for collecting projectiles fired from the shooting station, the projecting trap comprising a scroll wall at least partially defining a deceleration chamber, the method comprising depositing a plurality of ceramic particles and a binding material onto a concave surface of the scroll wall to form an impact resistant layer. 
     
     
         12 . The method of  claim 11 , wherein impact resistant layer is applied to the concave surface of the scroll wall while the scroll wall is attached to the bullet trap. 
     
     
         13 . The method of  claim 11 , wherein depositing the plurality of ceramic particles and the binding material onto the concave surface of the scroll wall to form the impact resistant layer, comprises:
 providing a plurality of ceramic particles and a binding material;   creating a plasma plume by passing a flow of gas through an electric arc;   directing the plasma plume toward the concave surface of the scroll wall;   injecting the ceramic particles and the binding material into the flow of gas so that the ceramic particles and the binding material pass through the plasma plume, wherein heat from the plasma plume causes the binding material to become molten binding material; and   depositing the ceramic particles and the molten binding material onto the concave surface of the scroll wall to form an impact resistant layer.   
     
     
         14 . The method of  claim 11 , depositing the plurality of ceramic particles and the binding material onto the concave surface of the scroll wall to form the impact resistant layer, comprises:
 providing a plurality of ceramic particles and a binding material;   providing a flow of gases including a fuel gas and oxygen;   igniting the flow of gases create a flame;   directing the flow of gases toward the concave surface of the scroll wall;   injecting the ceramic particles and the binding material into the flow of gases so that the ceramic particles and the binding material pass through the flame, wherein heat from the flame causes the binding material to become molten binding material; and   depositing the ceramic particles and the molten binding material onto the concave surface of the scroll wall to form an impact resistant layer.   
     
     
         15 . The method of  claim 11 , wherein the ceramic particles comprise a material selected from the group consisting of aluminum oxide, boron carbide, boron nitride, silicon carbide, silicon nitride, and zirconium oxide. 
     
     
         16 . The method of  claim 11 , wherein the ceramic particles become bound to the substrate layer by the binding material. 
     
     
         17 . A method of fabricating a scroll wall for a bullet trap, the method comprising:
 providing a sheet of material;   cutting a flat steel plate from the sheet of material;   bending the flat steel plate to create a scroll wall having a desired curvature;   attaching a strongback to the scroll wall; and   depositing a plurality of ceramic particles and a binding material onto a concave surface of the scroll wall to form an impact resistant layer.   
     
     
         18 . The method of  claim 17 , wherein depositing the plurality of ceramic particles and the binding material onto the concave surface of the scroll wall to form the impact resistant layer, comprises:.
 providing a plurality of ceramic particles and a binding material;   creating a plasma plume by passing a flow of gas through an electric arc;   directing the plasma plume toward the concave surface of the scroll wall;   injecting the ceramic particles and the binding material into the flow of gas so that the ceramic particles and the binding material pass through the plasma plume, wherein heat from the plasma plume causes the binding material to become molten binding material; and   depositing the ceramic particles and the molten binding material onto the concave surface of the scroll wall to form an impact resistant layer.   
     
     
         19 . The method of  claim 17 , depositing the plurality of ceramic particles and the binding material onto the concave surface of the scroll wall to form the impact resistant layer, comprises:
 providing a plurality of ceramic particles and a binding material;   providing a flow of gases including a fuel gas and oxygen;   igniting the flow of gases create a flame;   directing the flow of gases toward the concave surface of the scroll wall;   injecting the ceramic particles and the binding material into the flow of gases so that the ceramic particles and the binding material pass through the flame, wherein heat from the flame causes the binding material to become molten binding material; and   depositing the ceramic particles and the molten binding material onto the concave surface of the scroll wall to form an impact resistant layer.   
     
     
         20 . The method of  claim 18 , wherein the ceramic particles comprise a material selected from the group consisting of aluminum oxide, boron carbide, boron nitride, silicon carbide, silicon nitride, and zirconium oxide.