WARHEADS AND WEAPONS AND METHODS INCLUDING SAME

FIELD

The present invention relates to warheads and, more particularly, to warheads for damaging an inflight target.

BACKGROUND

Missiles and artillery launched projectiles are used to intercept and damage or destroy inflight targets such as missiles and re-entry vehicles. Known weapons for this purpose may employ a hit-to-kill vehicle or projectile, a fragmentation warhead, or a non-hit to kill, kinetic energy projectile warhead.

SUMMARY

According to some embodiments, a warhead for damaging an inflight target includes a frame system, a projectile ejection force generator, and a plurality of long rod penetrators (LRPs). The frame system has a frame lengthwise axis. The projectile ejection force generator is operative to generate an ejection force. The LRPs are mounted on the frame system. Each of the LRPs has an LRP lengthwise axis extending substantially parallel to the frame lengthwise axis. The warhead is configured such that the LRPs structurally support the frame system against axial loads on the frame system. The warhead is configured to dispense the LRPs radially outwardly using the ejection force to thereby form a matrix of the LRPs to intersect the target.

In some embodiments, the projectile ejection force generator is an explosive charge.

In some embodiments, the ratio of the total mass of the explosive charge to the total combined mass of the LRPs is less than 5 percent.

In some embodiments, the ratio of the total mass of the explosive charge to the total mass of the warhead is in the range of from about 0.1 percent to 5 percent.

In some embodiments, the frame system includes an axially extending central beam, a central cavity is defined in and extends axially through the central beam, the projectile ejection force generator is disposed in the central cavity, and the LRPs are located around the central beam.

In some embodiments, the frame system includes a plurality of partition walls each extending radially and axially. The partition walls are circumferentially spaced apart about the frame lengthwise axis to define a plurality of circumferentially distributed bays between the partition walls. Each of the bays contains a respective bundle of the LRPs.

In some embodiments, each of the LRPs has opposed front and rear ends, and the front and rear ends of each LRP each engage a respective one of the level divider walls.

In some embodiments, the plurality of levels includes a first level containing a first set of the LRPs having a first combined mass, the plurality of levels includes a second level containing a second set of the LRPs having a second combined mass, and the second combined mass is greater than the first combined mass.

In some embodiments, the plurality of levels includes a first level containing a first set of the LRPs each having a first LRP length, the plurality of levels includes a second level containing a second set of the LRPs each having a second LRP length, and the second LRP length is greater than the first LRP length.

In some embodiments, the plurality of levels includes a first level containing a first set of the LRPs formed of a first LRP material, the plurality of levels includes a second level containing a second set of the LRPs formed of a second LRP material, and the first LRP material is different than the second LRP material.

According to some embodiments, the warhead includes a shell surrounding the LRPs. The LRPs are disposed radially between the frame system and the shell. The warhead further includes a plurality of rigid support inserts disposed radially between the LRPs and the shell and configured to resist buckling of the LRPs under load.

In some embodiments, the support inserts are formed of metal.

According to some embodiments, the projectile ejection force generator is an explosive charge, and the frame system includes an axially extending central beam. A central cavity is defined in and extends axially through the central beam. The explosive charge is disposed in the central cavity. The LRPs are located around the central beam. The warhead includes a shell surrounding the LRPs. The frame system includes a plurality of radially extending level divider walls. The level divider walls are axially spaced apart along the frame lengthwise axis to define a plurality of axially distributed levels. Each of the levels contains a respective set of the LRPs. The frame system includes a plurality of partition walls each extending radially and axially. The partition walls are circumferentially spaced apart about the frame lengthwise axis to define a plurality of circumferentially distributed bays between the partition walls. Each of the bays contains a respective bundle of the LRPs.

In some embodiments, the central beam, the level divider walls, and the partition walls form a unitary structure.

In some embodiments, the LRPs are disposed radially between the central beam and the shell, and the warhead further includes a plurality of rigid support inserts disposed radially between the LRPs and the shell and configured to resist buckling of the LRPs under load.

According to some embodiments, the frame system includes a plurality of radially extending level divider walls. The level divider walls are axially spaced apart along the frame lengthwise axis to define a plurality of axially distributed levels. Each of the levels contains a respective set of the LRPs. The frame system includes a plurality of partition walls each extending radially and axially. The partition walls are circumferentially spaced apart about the frame lengthwise axis to define a plurality of circumferentially distributed bays between the partition walls on each of the levels. Each of the bays contains a respective bundle of the LRPs. The bays defined in at least one of the levels are rotationally offset from the bays defined in another of the levels.

According to some embodiments, the LRPs are regular hexagonally-shaped in cross-section, and the LRPs are packed in sidewall-to-sidewall contact.

In some embodiments, the projectile ejection force generator includes a pressurized gas generator. In some embodiments, the projectile ejection force generator further includes an inflatable airbag configured to be inflated by pressurized gas from the pressurized gas generator.

In some embodiments, the projectile ejection force generator includes a spring.

According to some method embodiments, a method for damaging an inflight target includes providing a projectile weapon including a warhead. The warhead includes a frame system, a projectile ejection force generator, and a plurality of long rod penetrators (LRPs). The frame system has a frame lengthwise axis. The projectile ejection force generator is operative to generate an ejection force. The LRPs are mounted on the frame system. Each of the LRPs has an LRP lengthwise axis extending substantially parallel to the frame lengthwise axis. The warhead is configured such that the LRPs structurally support the frame system against axial loads on the frame system. The warhead is configured to dispense the LRPs radially outwardly using the ejection force to thereby form a matrix of the LRPs to intersect the target. The method further includes launching the weapon using artillery.

According to some embodiments, a warhead for damaging an inflight target includes a frame system, a projectile ejection force generator, and a plurality of long rod penetrators (LRPs). The frame system has a frame lengthwise axis. The projectile ejection force generator is operative to generate an ejection force. The LRPs are mounted on the frame system. Each of the LRPs has an LRP lengthwise axis extending substantially parallel to the frame lengthwise axis. The warhead is configured to dispense the LRPs radially outwardly using the ejection force to thereby form a matrix of the LRPs to intersect the target. The frame system includes a plurality of partition walls each extending radially and axially. The partition walls are circumferentially spaced apart about the frame lengthwise axis to define a plurality of circumferentially distributed bays between the partition walls. Each of the bays contains a respective bundle of the LRPs.

In some embodiments, the projectile ejection force generator is an explosive charge. The frame system includes an axially extending central beam. A central cavity is defined in and extends axially through the central beam. The explosive charge is disposed in the central cavity. The LRPs are located around the central beam. The warhead includes a shell surrounding the LRPs. The frame system includes a plurality of radially extending level divider walls. The level divider walls are axially spaced apart along the frame lengthwise axis to define a plurality of axially distributed levels. Each of the levels contains a respective set of the LRPs.

In some embodiments, the central beam, the level divider walls, and the partition walls form a unitary structure.

In some embodiments, the LRPs are disposed radially between the central beam and the shell. The warhead further includes a plurality of rigid support inserts disposed radially between the LRPs and the shell and configured to resist buckling of the LRPs under load.

According to some embodiments, a warhead for damaging an inflight target includes a frame system, a projectile ejection force generator, and a plurality of long rod penetrators (LRPs). The frame system has a frame lengthwise axis. The projectile ejection force generator is operative to generate an ejection force. The LRPs are mounted on the frame system. Each of the LRPs has an LRP lengthwise axis extending substantially parallel to the frame lengthwise axis. The warhead is configured to dispense the LRPs radially outwardly using the ejection force to thereby form a matrix of the LRPs to intersect the target. The warhead includes a shell surrounding the LRPs. The LRPs are disposed radially between the frame system and the shell. The warhead further includes a plurality of rigid support inserts disposed radially between the LRPs and the shell and configured to resist buckling of the LRPs under load.

According to some embodiments, a warhead for damaging an inflight target includes a frame system, a projectile ejection force generator, and a plurality of long rod penetrators (LRPs). The frame system has a frame lengthwise axis. The projectile ejection force generator is operative to generate an ejection force. The LRPs are mounted on the frame system. Each of the LRPs has an LRP lengthwise axis extending substantially parallel to the frame lengthwise axis. The warhead is configured to dispense the LRPs radially outwardly using the ejection force to thereby form a matrix of the LRPs to intersect the target. The LRPs are regular hexagonally-shaped in cross-section. The LRPs are packed in sidewall to sidewall contact.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying figures are included to provide a further understanding of the present invention, and are incorporated in and constitute a part of this specification. The drawings illustrate some embodiments of the present invention and, together with the description, serve to explain principles of the present invention.

FIG. 1 is a schematic view of a weapon system including a projectile weapon according to embodiments of the invention, wherein the projectile weapon has been exploded to damage an inflight target.

FIG. 2A is a schematic, side view of the exploded projectile weapon of FIG. 1.

FIG. 2B is a schematic, end view of the exploded projectile weapon of FIG. 1.

FIG. 3 is a front perspective view of the weapon of FIG. 1.

FIG. 4 is a cross-sectional view of the projectile weapon of FIG. 1 taken along the line 4-4 of FIG. 3.

FIG. 5A is a cross-sectional view of the projectile weapon of FIG. 1 taken along the line A-A of FIG. 4.

FIG. 5B is a cross-sectional view of the projectile weapon of FIG. 1 taken along the line B-B of FIG. 4.

FIG. 5C is a cross-sectional view of the projectile weapon of FIG. 1 taken along the line C-C of FIG. 4.

FIG. 5D is a cross-sectional view of the projectile weapon of FIG. 1 taken along the line D-D of FIG. 4.

FIG. 5E is a cross-sectional view of the projectile weapon of FIG. 1 taken along the line E-E of FIG. 4.

FIG. 6 is a fragmentary, front perspective view of a warhead forming a part of the projectile weapon of FIG. 1.

FIG. 7 is an exploded, front perspective view of the warhead of FIG. 6.

FIG. 8 is a front perspective view of a long rod projectile forming a part of the warhead of FIG. 6.

FIG. 9 is an end view of the long rod projectile of FIG. 8.

FIG. 10 is an end view of a support insert forming a part of the warhead of FIG. 6.

FIG. 11 is a perspective view of the support insert of FIG. 10.

FIG. 12 is a fragmentary, front perspective view of a warhead according to further embodiments.

FIG. 13 is a front perspective view of a frame system forming a part of the warhead of FIG. 12.

DESCRIPTION

The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which illustrative embodiments of the invention are shown. In the drawings, the relative sizes of regions or features may be exaggerated for clarity. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

It will be understood that when an element is referred to as being “coupled” or “connected” to another element, it can be directly coupled or connected to the other element or intervening elements may also be present. In contrast, when an element is referred to as being “directly coupled” or “directly connected” to another element, there are no intervening elements present. Like numbers refer to like elements throughout.

In addition, spatially relative terms, such as “under”, “below”, “lower”, “over”, “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “under” or “beneath” other elements or features would then be oriented “over” the other elements or features. Thus, the exemplary term “under” can encompass both an orientation of over and under. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

Well-known functions or constructions may not be described in detail for brevity and/or clarity.

As used herein the expression “and/or” includes any and all combinations of one or more of the associated listed items.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

As used herein, “monolithic” means an object that is a single, unitary piece formed or composed of a material without joints or seams.

The term “automatically” means that the operation is substantially, and may be entirely, carried out without human or manual input, and can be programmatically directed or carried out.

The term “programmatically” refers to operations directed and/or primarily carried out electronically by computer program modules, code and/or instructions.

The term “electronically” includes both wireless and wired connections between components.

Some embodiments of the invention are directed to anti-missile weapons. In particular, weapons as disclosed herein may be used in accordance with methods of the invention to defend against, damage and destroy ballistic missiles, cruise missiles, and re-entry vehicles such as ballistic missile re-entry vehicles (BMRV). Weapons as disclosed herein may be used in accordance with methods of the invention to defend against, damage and destroy drones and other aircraft.

Weapons and warheads according to some embodiments are adapted for and used as artillery launched projectiles. In some embodiments, the artillery launched projectile is a hypervelocity projectile (HVP).

In other embodiments, the warhead is mounted on an airborne vehicle. In some embodiments, the warhead is mounted on a navigable vehicle. In some embodiments, the warhead is mounted on a missile or rocket.

Warheads according to some embodiments, and projectiles including said warheads, are particularly contemplated for use as non-hit to kill warheads that attack an inflight target (e.g., missile) using a standoff engagement between the warhead and the target. In some embodiments, the warhead is not a blast fragmentation or hit to kill warhead. In other embodiments, the warhead or weapon may also incorporate a blast fragmentation or hit to kill component or system, in which case the mechanisms disclosed herein are in addition to or supplemental to the blast fragmentation or hit to kill component.

In general, a warhead according to embodiments of the invention is a kinetic energy projectile warhead that uses kinetic energy projectiles (in some embodiments, long rod penetrators (LRPs)) to inflict damage on a high velocity target in flight. When the warhead is proximate to the predicted path of the target, the warhead detonates an explosive of the warhead. The detonation of the explosive forcibly disperses the projectiles into a collection, set, distribution, “wall” or matrix of the projectiles in space. The matrix may have a generally prescribed pattern. The target then flies through the projectile matrix so that the target strikes at least one of the projectiles. The kinetic energy of the high velocity target causes high energy impacts between the target and the projectiles of the matrix, thereby damaging the target. In some cases, these high energy impacts will cause the projectiles to penetrate the target.

In some embodiments, a relatively small amount of explosive is employed in the warhead so that the projectiles are essentially pushed out from stored or ready positions in the warhead into the matrix. In this case, the warhead does not rely predominantly on the kinetic energy of the dispersed projectiles to damage the target (e.g., as in the case of a blast fragmentation warhead). Rather, the warhead predominantly uses the kinetic energy of the target to damage the target.

In some embodiments, the warhead as described uses a non-hit to kill, standoff engagement with the target. In this case, the trajectory or path of the undetonated warhead does not or may not intersect the trajectory or path of the target. Instead, the explosive dispensation and dispersal of the projectiles spreads the projectiles into the path of the target.

Warheads according embodiments of the invention can provide a number of advantages. By presenting a spatially wide field of projectiles, the warhead increases the likelihood that it will intercept and disable the target. The warhead requires less explosive in the warhead, which provides improved safety, weight savings, and compactness of the warhead. In particular, the reduced explosive can provide a lower mass of explosive to overall mass of warhead ratio.

With reference to FIGS. 1-11, a weapon system 10 (FIG. 1) according to some embodiments is shown therein. The weapon system 10 includes an artillery 20 and a projectile weapon 50. The weapon 50 includes a warhead 100 according to embodiments of the invention.

The weapon system 10, the weapon 50, and the warhead 100 may be used as follows in accordance with some embodiments. The artillery 20 is used to launch the weapon 50 such that the weapon 50 flies along a weapon path FW in a forward flight direction F and comes into close proximity to an in-flight target M progressing along a target path FT. As discussed herein, the warhead 100 explodes and thereby disperses a wall or matrix W of projectiles 150 prior to encountering the target M. According to some embodiments and as illustrated in the figures, the projectiles are long rod projectiles (LRPs) 150. As the target M passes the exploded warhead 100, the target M flies through the matrix W and collides with one or more of the dispersed LRPs 150. The kinetic energy of the target M is applied to the intercepting LRPs 150 so that the LRPs 150 inflict damage on the target M. The target M may be a missile, a re-entry vehicle (e.g., ballistic missile re-entry vehicle), or other inflight vehicle, for example. The vehicle may be a manned aircraft or an unmanned aircraft (drone or aerial unmanned autonomous vehicle (UAV)).

The artillery 20 may be any suitable apparatus for launching the weapon 50 as described herein. As used herein, “artillery” means a projectile firing weapon including a propulsion mechanism and configured to shoot a projectile along an unpowered trajectory using a propulsion force generated by the propulsion mechanism of the artillery. In some embodiments, the artillery 20 is a tube-launched projectile firing weapon. In some embodiments, the artillery 20 is a cannon. In some embodiments, the artillery 20 is a large gun or cannon that propels the weapon 50 by exploding a propellant charge in the artillery 20. In some embodiments, the artillery 20 is a railgun that uses electromagnetic force in the artillery 20 to propel and launch the weapon 50 (e.g., by accelerating an armature forming a part of the weapon or a separate armature configured to displace the weapon 50).

The artillery 20 may be mounted in any suitable manner for fixed operation or mobile operation. The artillery 20 may be configured for and used on land, on water (e.g., at sea), or in air. In some embodiments, the artillery 20 is mounted on or conveyed by a land-based vehicle. In some embodiments, the land-based vehicle is a tank. In some embodiments, the artillery 20 is mounted on a watercraft (e.g., a warship).

The exemplary artillery 20 shown in FIG. 1 includes a cannon including a barrel 22 and a propulsion mechanism 24. The barrel 22 has a terminal opening 22A through which the weapon 50 is ejected. The propulsion mechanism 24 may include, for example, artillery propellant.

The weapon 50 includes a front end 52A and an opposing rear end 52B and defines a lengthwise axis J-J. The weapon 50 has a tail section 54 on the rear end 52B, and a nose 56 on the front end 52A. The warhead 100 is mounted between the tail section 54 and the nose 56. The weapon 50 may also include an onboard control system 60. The control system 60 may be operative to selectively control the detonation of the warhead 100 as described herein. In some embodiments, the on-board system 60 is operative to automatically, programmatically and electronically detonate the warhead 100. The control system 60 may also be operative to communicate with a remote terminal or controller and or to control guidance of the weapon 50.

The warhead 100 defines a lengthwise war head central axis A-A. The warhead 100 has a front end 102A and an opposing rear end 102B. The warhead 100 includes a support system 110, a plurality of LRPs (referred to herein collectively as the LRPs 150), and a projectile ejection force generator in the form of an expelling charge and, more particularly, in the form of an explosive charge 140.

The support system 110 includes a tubular shell 112 defining an internal chamber 112A. The support system 110 further includes a frame system or truss 120 and a plurality of support members or inserts 114.

The frame system 120 has a lengthwise axis E-E. The frame system 120 includes a central beam 122 extending from a front end 122A to a rear end 122B. The frame system 120 further includes a front wall 128, a rear wall 129, multiple level divider walls 130, and multiple circumferential partition walls 132.

The central beam 122 extends continuously from the rear wall 129 to the front end 120A. The central beam 122 is tubular and defines a central cavity 124 extending the length of the central beam 122. In some embodiments and as shown, the central cavity 124 is cylindrical. In some embodiments and as shown, the outer surface of the central beam 122 is faceted and has substantially planar outer surfaces 125.

The rear wall 129 and the level divider walls 130 are substantially planar. The rear wall 129 and the level divider walls 130 each extend substantially orthogonal to the axis E-E and project radially outwardly from the central beam 122.

The partition walls 132 are substantially planar. The partition walls 132 each extend axially substantially parallel to the axis E-E and project radially outwardly from the central beam 122. The partition walls 132 collectively form three beams (extending axially, and circumferentially spaced apart about the frame axis E-E) of the triple beam or tribeam axial load support structure 120.

In some embodiments, each wall 128, 129, 130 extends fully from the central beam 122 to the shell 112. In some embodiments, each partition wall 132 extends fully from the central beam 122 to the shell 112, and also extends fully from the adjacent rearward divider wall 129 or 130 to the adjacent forward divider wall 128 or 130.

The rear wall 129 and the level divider walls 130 each define a respective tier or level T1-T5 between the wall 129 or level divider wall 130 and the next wall 128 or level divider wall 130. Each level T1-T5 includes three partition walls 132 that divide the level T1-T5 into three circumferentially distributed bays B. Thus, the tiers T1-T5 are serially axially distributed along the frame axis E-E, and the bays B are serially circumferentially distributed about the frame axis E-E. As shown and discussed below, each bay B contains a plurality of the LRPs 150 and one or more of the support inserts 114.

The shell 112 surrounds the bays B so that the shell 112 and the frame system 120 together form five canisters C1-C5. Each canister C1-C5 includes a respective one of the levels T1-T5 and the LRPs 150 and support inserts 114 contained therein.

Additionally, each canister C1-C5 is subdivided into three bay subcanisters, housings or enclosures DC (FIG. 5E) by the three partition walls 132 in the respective canister C1-C5. Each of these bay enclosures DC surrounds and defines a respective one of the bays B and is defined by a section of the shell 112, opposed end or divider walls 128, 130, 129, and opposed partition walls 132. As discussed below, each bay enclosure DC contains a bundle of the LRPs 150, and a support insert 114.

Each support insert 114 includes opposed end faces 115, an axially and circumferentially extending outer surface 116, and an axially and circumferentially extending inner surface 118. The outer surface 116 is contoured to substantially conform to the shape of the inner surface of the shell 112. The outer surface 116 may be directly attached to the shell 112. The inner surface 118 is contoured to substantially conform to the shapes of the LRPs 150 immediately adjacent the inner surface 118.

The support inserts 114 may be formed of any suitable rigid material. In some embodiments, each support insert 114 is formed of metal. In some embodiments, the support inserts 114 are formed of titanium. In some embodiments, the support inserts 114 are 3D printed.

The shell 112 may be formed of any suitable rigid material. In some embodiments, the shell 112 is formed of a metal. In some embodiments, the shell 112 is formed of titanium.

The frame system 120 may be formed of any suitable rigid material. In some embodiments, the frame system 120 is formed of a metal. In some embodiments, the frame system 120 is formed of titanium.

In some embodiments, the central beam 122, the front wall 128, the rear wall 129, the level divider walls 130, and the circumferential partition walls 132 are constructed as a rigid, unitary member. In some embodiments, the central beam 122, the front wall 128, the rear wall 129, the level divider walls 130, and the partition walls 132 are a monolithic component.

In other embodiments, one or more of the components 122, 130, 132 may be movably mounted on the others. For example, in some alternative embodiments, the circumferential partition walls 132 may be mounted such that they can float relative to the beam 122. In some alternative embodiments, one or more of the level divider walls 130 may be mounted such that they can float relative to the beam 122.

In some embodiments, the thickness N1 (FIG. 4) of the shell 112 is in the range of from about 0.15 cm to 0.5 cm.

In some embodiments, the thickness N2 (FIG. 4) of the sidewall of the central beam 122 is in the range of from about 0.1 cm to 0.5 cm.

In some embodiments, the inner diameter D2 (FIG. 7) of the central cavity 124 is in the range of from about 0.5 cm to 2.5 cm.

In some embodiments, the thickness N3 (FIG. 4) of the each level divider wall 130 is in the range of from about 0.1 cm to 0.5 cm.

In some embodiments, the thickness N4 (FIG. 5D) of the each partition wall 132 is in the range of from about 0.1 cm to 0.5 cm.

In some embodiments, each level T1-T5 has a height 116 (FIG. 4; i.e., the axial distance between the inner surfaces of the walls 128, 129, 130 defining the respective level T1-T5) in the range of from about 4.5 cm to 9 cm. The heights 116 of the levels T1-T5 may be different from one another.

The LRPs 150 include a first set of LRPs 151 contained in the bays B of the first level T1, a second set of LRPs 152 contained in the bays B of the second level T2, a third set of LRPs 153 contained in the bays B of the third level T3, a fourth set of LRPs 154 contained in the bays B of the fourth level T4, and a fifth set of LRPs 155 contained in the bays B of the fifth level T5.

The LRPs 151-155 are assembled as subsets or bundles G of LRPs 150 in each bay B.

More particularly, each set of LRPs 151-155 is subdivided into three circumferentially distributed subsets or bundles G of LRPs 150, and each of these bundles G is contained in a respective one of the bays B. For example, as shown in FIG. 5E, the level T5 includes three circumferentially distributed bundles GA, GB, GC of the LRPs 155, and each of these bundles GA, GB, GC is disposed in a respective one of the bay enclosures DC.

According to some embodiments and as shown, the LRPs 150 are each individually preformed. One of the LRPs 155 will be described in more detail hereinbelow. It will be appreciated that this description likewise applies to the other LRPs 151-155. However, it will also be appreciated that the LRPs 151-155 of each level T1-T5 may differ from the LRPs 151-155 of another level T1-T5 in one or more respects. For example, LRPs in each level T1-T5 may differ from one another in shape, length, weight, and/or material.

The LRP 155 is a long rod penetrator (LRP) and has a lengthwise axis I-I and extends axially from a front end 160A to a rear end 160B. The LRP 155 has side faces 164 distributed circumferentially about the axis I-I, and end faces 166 on either end 160A, 160B.

In some embodiments, the side faces 164 are substantially planar. In some embodiments and as shown, the LRP 155 has a regular hexagonal cross-sectional shape. In some embodiments, each of the end faces 166 is substantially planar. In some embodiments, the side face of the LRP 155 is cylindrical.

In some embodiments, each LRP 150 has a length L1 (FIG. 8) in the range of from about 1.5 cm to 6 cm.

In some embodiments, each LRP 150 has a diameter D1 (FIG. 9) in the range of from about 0.25 cm to 1.5 cm.

In some embodiments, the ratio of the length L1 (FIG. 8) of each LRP 150 to its diameter D1 (FIG. 9) is at least 3:1 and, in some embodiments, is in the range of from about 3:1 to 24:1.

In some embodiments, each LRP 150 has a weight of at least 1 gram and, in some embodiments, in the range of from about 15 grams to 165 grams.

The LRPs 150 may be formed of any suitable rigid material. In some embodiments, each LRP 150 is formed from a material having a high sectional density to increase penetration performance. In some embodiments, some or all of the LRPs 150 are formed of metal. In some embodiments, some or all of the LRPs 150 are formed of tungsten.

The LRPs 151-155 may have different dimensions (length and diameter), shapes, and materials from one another.

As illustrated in FIGS. 4-6, the LRPs 151-155 are packed in each bay B about the central beam 122. The LRPs 151-155 are oriented such that their lengthwise axes I-I are parallel with the warhead lengthwise axis A-A and the frame system lengthwise axis E-E. The support inserts 114 are in turn packed around the LRPs 151-155. The shell 112 is in turn installed about the inserts 114. The inner surfaces 118 of the support inserts 114 are shaped to conform to the irregular shape of the LRP bundle G in each bay B. FIGS. 5A-5E are cross-sectional views of the warhead 100 taken along the lines 5A-5A, 5B-5B, 5C-5C, 5D-5D and 5E-5E, respectively.

One or more of the bays B may contain LRPs that are axially stacked (end 166 to end 166) on one another in the bay. Such an arrangement is shown for the LRPs 151 in the bays B of the first level T1. Each of the stacks includes three LRPs 151.

In some embodiments, in the foregoing manner, substantially all of the free space in each canister C1-C5 or bay enclosure DC is occupied by rigid components (i.e., the LRPs 151-155 and the support inserts 114). The LRPs 151-155 are firmly secured in face 164 to face 164 contact with one another and with the partition walls 132 and the central beam outer faces 125.

In some embodiments, each support insert 114 is firmly secured with its outer surface 116 in contact with the shell 112, its inner surface 118 in contact with the LRPs 150, and its end faces 115 in contact with the adjacent walls 128, 129, 130.

In some embodiments, the fit between the ends 166 of the LRPs 150 and the level divider walls 130 is snug or tight with well controlled tolerance across all of the LRPs 150 to avoid creating uneven stress distributions. In some embodiments, the height 116 of each level T2-T5 is no more than (i.e., the permitted tolerance) 2 mm greater than the length L1 of the LRPs 152-155 disposed in that level T2-T5. In the case of the level T1, the height 116 of the level T1 is no more than 2 mm greater than the total length L8 (FIG. 7) of each axial stack of the LRPs 151 (i.e., the axial, end-to-end stack of three LRPs 151). In some embodiments, both end faces 166 of each LRP 152-155 are held in firm or mating contact with the adjacent walls 129, 130 defining the level containing the LRP. Similarly, in some embodiments, the endmost faces 166 of the LRPs 151 in an LRP stack are held in firm or mating contact with the adjacent walls 128, 130 defining the level T1.

The explosive charge 140 is disposed in and fills the length of the central beam cavity 124 from a front end 140A to a rear end 140B. In some embodiments and as shown, the explosive charge 140 extends from the rear wall 129 to a front-end wall 127. In some embodiments and as shown, the explosive charge 140 extends only through part of the height of the first level T1 so that a portion 124A of the cavity 124 does not contain explosive. In some embodiments, the explosive charge 140 has a substantially uniform cross-sectional area from end 140A to end 140B.

Any suitable explosive may be used for the explosive charge 140. In some embodiments, the explosive charge 140 is a high energy (HE) explosive. Suitable explosives may include plastic bonded military grade types, including, PBXN-109, PBXN-110, CL-20, AFX-757, Composition B, or C4.

In some embodiments, the explosive charge 140 is a low explosive (LE) charge. A low explosive is a chemical mixture that deflagrates. That is, the low explosive material explodes in the form of subsonic combustion propagating through heat transfer, with hot burning low explosive material heating the next layer of the cold low explosive material and igniting it. The exploding low explosive changes into gas by rapidly burning or combusting without generating a high pressure wave as generated by detonation of a high explosive. The rate of combustion of a low explosive is less than 632 meters/second.

As discussed above, in use in accordance with some embodiments, the weapon 50 is launched from the artillery 20 such that the weapon 50 flies into proximity with the target M. The propulsion mechanism 24 of the artillery 20 applies a large launch force to the weapon 50 that forces the weapon 50 through the barrel 22 and the terminal opening 22A in the forward direction F. The weapon 50 is thereby propelled by the artillery 20 to travel the weapon flight path FW. In some embodiments, the weapon 50 travels the flight path without the aid of onboard propulsion. Prior to coming into close proximity to the target M, the control system 60 detonates the explosive charge 140. For example, the control system 60 may detonate the explosive charge 140 a prescribed period of time prior to the closest proximity between the flight paths FW and FT. In some embodiments, the detonation of the explosive charge 140 is initiated at the rear end 140B and propagates progressively from the rear end 140B the front end 140A.

Upon detonation, the HE explosive charge 140 generates gas pressure and shock waves that eject, drive or project the LRPs 151-155 radially outward in radial directions R (i.e., circumferentially distributed azimuthal directions relative to the axis A-A). The LRPs 151, 152, 153, 154 and 155 of each canister C1-C5 or level T1-T5 are projected in radial projection patterns P1, P2, P3, P4 and P5, respectively (FIG. 2A) circumferentially about axis A-A. The combination of the radial projection patterns P1-P5 forms a combined projection pattern PC (FIGS. 2 and 3) (extending 360 degrees circumferentially about the axis A-A). The shell 112 may be blown off or disintegrated, but typically will not significantly affect the paths or energies of the LRPs 151-155.

FIG. 2A is a side view of the exploded weapon 50 at a first time after the detonation of the explosive charge 140, and FIG. 2B is a front-end view of the weapon 50 at this first time.

The dispensed LRPs 151-155 will thus form a wall or matrix W of the LRPs 151-155 that extends circumferentially outwardly from the axis A-A. The detonation of the explosive charge 140 is timed such that the target M will fly through this matrix W. It will be appreciated that the matrix W will spatially expand as a function of time, and the detonation of the explosive charge 140 may be timed to achieve a prescribed or preferred pattern PC at the time of intersection between the target M and the matrix W.

The warhead 100 is configured such that the long rod penetrators 151-155 continue to be oriented with their lengthwise axes I-I substantially or generally parallel to the axis A-A. In some embodiments, the axis A-A is substantially parallel with the direction of travel of the weapon 50 at the time of detonation of the explosive charge 140. In this way, the LRPs 151-155 will tend to initially impact the target M with their front ends 160A and end faces 166. This may help to more efficiently inflict damage on the target M, including by penetrating the target M.

In some embodiments, the dispensed the LRPs 150 are ejected from the bays B at a velocity of less than 1000 m/s and, in some embodiments, at a velocity in the range of from about 100 m/s to 1000 m/s.

Various aspects of the warhead 100 may be selected to determine the shapes of the patterns P1-P5, PC.

The weapon 50 and the warhead 100 may be particularly well-suited for launching using artillery (e.g., cannon) or a gun.

Because the warhead 100 is used as a non-hit to kill warhead, it can be constructed using a relatively small amount of explosive. In some embodiments, the explosive charge 140 is an HE explosive and the ratio the mass of the explosive charge 140 to the combined masses of the LRPs 151-155 is less than 5%. In some embodiments, the explosive charge 140 is an HE explosive and the ratio the mass of the warhead 100 as a whole (including all of the LRPs 150, the support system 110 and the support inserts 114) to the mass of the explosive charge 140 is in the range of from about 0.1% to 5%.

The warhead 100 must survive the high acceleration of launching from an artillery cannon. Because the weapon 50 must be rapidly accelerated in order to complete the flight path FW, the weapon 50 (including the frame system 120) is subjected to large launch loading along the weapon lengthwise axis J-J, the warhead central axis A-A, and the frame lengthwise axis E-E. The launch loading requirement on the warhead 100 when launching the weapon 50 from artillery is drastically higher than experienced by a warhead deployed on a missile, for example (approximately 30,000 Gs for artillery launch versus approximately 20 Gs for a missile system).

In some embodiments, the weapon 50 is launched as described herein as a hypervelocity projectile (HVP) to a travel velocity of at least mach 1.

Absent adequate provision, these large launch loading forces would tend to axially compress or otherwise deform the warhead 100, which may damage the warhead and prevent the weapon 50 or the warhead 100 from operating as intended. While the launch load may be countered using a stronger shell 112 or frame system 122, doing so may add undesirable added weight or impede deployment of the LRPs. Several aspects of the warhead 100 may contribute to enabling the warhead 100 to withstand these artillery launch loads.

The warhead 100 addresses this problem by using the LRPs 150 as axial load bearing members or structural supports that reinforce or structurally support the frame system 120 against axial loads (i.e., along axis E-E) on the frame system 120. That is, the LRPs 150 receive the launch load transferred from the frame system 120 and thereby limit or prevent the frame system 120 from being axially compressed or collapsed by the launch load. Because the LRPs 150 and the frame system 120 support the launch load, the warhead 100 can be constructed such that little or none of the axial launch load is born by the shell 112, and the shell 112 can therefore be made relatively thin.

The performance of the LRPs 150 as launch load bearing members is enabled or enhanced by several aspects of the warhead construction.

Because the LRPs 150 are long slender long rods stacked on top of each other, they would ordinarily tend to experience failure due to buckling very easily during launch loading. The shapes of the LRPs 150 and the arrangements of the LRPs 150, the frame system 120, and the support inserts 114 serve to prevent or inhibit buckling of the LRPs 150 under axial load so that the LRPs 150 can reliability serve as loaded bearing elements.

The warhead 100 uses regular hexagonal-shaped rods 150 because they can pack in a way where each side 164 is touching (and is constrained by) another LRP 150. This vastly limits each LRP's 150 ability to sway side to side and cause buckling.

Also, the “buckling supports” or support inserts 114 provide more support against buckling. The support inserts 114 accomplish this both by providing face-to-face engagement support between the side faces 164 of the outer LRPs 150 and the conforming inner surface 118 of the support inserts 114, and by taking up extra space in the bay B. The support inserts 114 may be 3D printed metal structures that attach to the outer casing 112.

The partitions walls 132 and bays B that subdivide each level T1-T5 enable closer packing between the LRPs 150, and can limit or reduce relative lateral displacement between the LRPs 150.

The frame system 120 distributes the axial launch loading between the frame system 120 and the LRPs 150 themselves. This is accomplished or enhanced by rigidly affixing or connecting all or some of the divider walls 128, 129, 130 to the central beam 122 and relatively sizing the lengths L1 of the LRPs 150 and the heights 116 of the levels T1-T5 such that the ends 166 of the LRPs 150 fit snugly against the adjacent walls 128, 129, 130 or with only very small axial gaps (e.g., no more than 1 mm) between the ends 166 of the LRPs 150 and their adjacent walls 128, 129, 130.

The reinforcement of the frame system 120 and the warhead 100 by the LRPs 150 may be particularly effective in the case of embodiments (e.g., as illustrated in FIGS. 4-7) wherein the frame system 120 is a multibeam (e.g., tribeam, as shown), unitary member, structure or truss. In these embodiments, the level divider walls 128, 129, 130 are all rigidly connected to the central beam 122 and the partition walls 132 so that the launch load can be directly transferred from the truss 120 to the LRPs 151-155 on each level via the walls 128, 129, 130. The unitary truss 120 may also be 3D printed.

Warheads according to embodiments of the invention (e.g., the warhead 100) may include or provide the following aspects, alternatives and advantages:

- Artillery cannon or gun launched non-hit to kill BMD warhead.
- Dispenses long rod penetrators (LRPs) into space and uses energy of the target against itself.
- Uses very low ratio of explosive charge to dispensed mass (less than 5%).
- Multiple bays to vary the LRP distribution (each bay dispenses at a different velocity since it is mass dependent).
- Each bay has a different mass of LRPs—Controlled by varying LRP material and packing pattern
- Unlike some other artillery warhead designs that use a very thick aeroshell for structural support, a warhead of the present invention can use a thin aeroshell because the structure loading is handled by the tribeam frame system and the LRPs themselves. The support system of the frame system 120 and the support inserts 114 helps support and distribute loading amongst the rods 150 and away from the thin aeroshell 112.
- In some embodiments, the “tribeam” frame system 120 (including the beam 122, the level divider walls 130 and the partition walls 132) is 3D printed as a unitary member.
- In some embodiments, the rods 150 are hexagonal-shaped to improve packing efficiency and improve structural rigidity by limiting space between the LRPs to reduce buckling. In some embodiments, the rods 150 are regular hexagonal-shaped.
- Metal buckle supports 114 are added to confine the LRPs 150 against the aeroshell 112 to prevent buckling outward. The supports 114 may be 3D printed.
- Rod length may be varied (e.g., in the bays of level T1 versus the other levels T2-T5) to selectively modify the dispense pattern.
- Warheads according to embodiments of the invention can use a relatively small amount of HE explosive charge 140 to simply push the rods 150 out into space, and then have the target M fly through the “wall” W of LRPs 150 to do damage, effectively using the kinetic energy of the target M against itself. The warhead can thereby be constructed to have a relatively low C/M ratio (mass of HE explosive/overall mass of warhead ratio) (i.e., a “Low C/M kinetic energy rod warhead”). A low C/M ratio may be very important. Similarly, in some embodiments as described herein wherein the projectile ejection force generator is a an expelling charge or mechanism other than an HE explosive charge, the expelling charge or mechanism can be relatively small in volume and mass, so that the ratio of the mass of the expelling charge or mechanism to the mass of the warhead is relatively low.
- The dispense pattern of the LRPs 151-155 can be selectively tuned, set, or adjusted using one or more techniques that are conveniently implemented in the inventive design. One such technique is to use different rod material (e.g., a special type of metal in the bays of level T4 as discussed in the attached) and adjusting the size or amount of HE explosive in level T1 (i.e., within the bays of level T1) to modify the dispersal pattern to optimize lethality against a given target.

As shown, the frame system 120 includes four level divider walls 130 and fifteen partition walls 132. However, the warhead 120 may include more or fewer level divider walls, partition walls, levels, bays, canisters, and/or projectiles (e.g., LRPs).

With reference to FIGS. 12 and 13, an alternative construction of the warhead 100 is shown therein as a warhead 200. The warhead 200 is only shown in fragmentary views showing a frame system 220 and LRPs 251-255. The frame system 220 replaces the frame system 120 in the warhead 100, and the LRPs 251-255 replace the LRPs 151-155, respectively, of the warhead 100. The remainder of the warhead 200 may be constructed, used, and operated in the same manner as the warhead 100.

The frame system 220 includes a central beam 222, a front end wall 228, a rear wall 229, level divider walls 230, circumferential partition walls 132, and bays B corresponding to components 122, 128, 129, 130, 132, and B, respectively. The frame system 220 differs from the frame system 120 in that the bays B of each level T1-T5 of the warhead 200 are angularly offset, rotated, or non-aligned about the central axis E-E with respect to the bays B of one or more of the other levels T1-T5. For example, in the depicted frame system 220, the bays B of levels T1, T3 and T5 are angularly offset from the bays B of the levels T2 and T4 by about 60 degrees.

The rotationally offset configuration of the bays B may provide certain benefits. This arrangement can better distribute launch loads across the LRPs 251-255. The rotationally offset configuration may increase the structural resistance of the frame system 220 itself due to the mid-span support provided by the tribeam connection of the aft side of each bay divider 232.

The rotationally offset configuration also changes the dispersion pattern of the LRPs 251-255. This can be used to selectively adjust the dispersion pattern to combat different threats (e.g., targets M).

As described above, in some embodiments an explosive charge 140 is used as the projectile ejection force generator to generate the ejection force to dispense the LRPs radially outwardly to thereby form a matrix of the LRPs to intersect the target. In some embodiments, the explosive charge 140 is an HE explosive material and the ejection force includes shock waves and gas pressure generated from the detonated HE explosive and directly applied to the projectiles 150 to eject the projectiles.

In some embodiments, the explosive charge 140 is a low explosive and the ejection force includes gas pressure generated from the ignited LE explosive (e.g., by deflagration) and directly applied to the projectiles 150 to eject the projectiles. In this case, in some embodiments, the projectiles are not ejected by shock waves generated by the explosive charge 140.

According to further embodiments, other projectile ejection force generators or deployment mechanisms may be used in place of or in addition to the explosive charge 140.

In some embodiments, the explosive charge 140 is omitted and the projectile ejection force generator is a gas generator that rapidly generates a pressurized gas that pushes the projectiles 150 out. In some embodiments, this pressurized gas acts directly on the projectiles. In some embodiments, the gas generator is a non-explosive gas generator. In some embodiments, the gas generator is installed in the central cavity 124.

In some embodiments, the explosive charge 140 is omitted and the projectile ejection force generator includes an expelling system including a gas generator in combination with one or more airbags. In this case, the gas generator may be installed in the central cavity 124 and used to inflate the one or more airbags in the bays B. The inflating airbag(s) will push the LRPs 150 radially outward into space. In some embodiments, the LRPs 150 are attached to (e.g., sewn into) the airbag itself to maintain proper alignment of the LRPs 150 during dispersion.

In some embodiments, the explosive charge 140 is omitted and the projectile ejection force generator is a spring-force system. The spring-force system may include a loaded spring (e.g., a compressed spring) and a release mechanism. When the spring is released, the spring force pushes the LRPs 150 radially outward into space.

As discussed above, it is contemplated that weapons including a warhead as disclosed herein can also be deployed using mechanisms other than artillery.

Many alterations and modifications may be made by those having ordinary skill in the art, given the benefit of present disclosure, without departing from the spirit and scope of the invention. Therefore, it must be understood that the illustrated embodiments have been set forth only for the purposes of example, and that it should not be taken as limiting the invention as defined by the following claims. The following claims, therefore, are to be read to include not only the combination of elements which are literally set forth but all equivalent elements for performing substantially the same function in substantially the same way to obtain substantially the same result. The claims are thus to be understood to include what is specifically illustrated and described above, what is conceptually equivalent, and also what incorporates the essential idea of the invention.

WARHEADS AND WEAPONS AND METHODS INCLUDING SAME

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