# US 7,607,394 B2 · Lead-free projectiles > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 7,607,394 B2 - Document ID: US7607394B2 - Status: Granted - Kind: B2 - Application number: 10/474,512 - Filed: 2002-04-24 - Published: 2004-07-08 - Granted: 2009-10-27 - Earliest claimed: 2001-04-24 - Inventors: Anthony Joseph Cesaroni - Web page: https://patentgrep.com/patent/US7607394B2 ## CPC - F42B 12/745: {the core being made of plastics; Compounds or blends of plastics and other materials, e.g. fillers} - F42B: EXPLOSIVE CHARGES, e.g. FOR BLASTING, FIREWORKS, AMMUNITION (explosive compositions C06B; fuzes F42C; blasting F42D) ## Abstract A lead-free projectile having a metal jacket (10) with a tip in the form of a truncated parabellum. The metal jacket (10) is partially filled with cold-pressed metal powder (18), the remainder of the metal jacket being filled with metal-filled polymer (26). The metal-filled polymer (26) extends through the truncated parabellum and forms a tip on the projectile. A projectile (bullet) having a higher grain is obtained. Methods of manufacture are also disclosed. ## Claims ### Claim 1 A lead-free projectile having a metal jacket with a tip in the form of a truncated parabellum, said metal jacket being partially filled with cold-pressed metal powder and being filled with metal-filled polymer, said metal-filled polymer extending through the truncated parabellum and forming a tip on said projectile. ### Claim 2 (depends on 1) The lead-free projectile of claim 1 in which the projectile is a bullet. ### Claim 3 (depends on 1) The lead-free projectile of claim 1 in which the jacket is a copper jacket. ### Claim 4 (depends on 1) The lead-free projectile of claim 1 in which the metal powder is copper or tungsten. ### Claim 5 (depends on 1) The lead-free projectile of claim 1 in which the metal-filled polymer comprises a polymer filled with particles of at least one of copper, tungsten, bismuth, tin and stainless steel. ### Claim 6 (depends on 5) The lead-free projectile of claim 5 in which the polymer is selected from the group consisting of ethylene/methacrylic acid copolymer ionomer, polyetherester elastomers and polyamide. ### Claim 7 (depends on 6) The lead-free projectile of claim 6 in which the polymer comprises an ethylene/methacrylic acid copolymer ionomer. ### Claim 8 (depends on 7) The lead-free projectile of claim 7 in which the ethylene/methacrylic acid copolymer ionomer has a melt index of at least 5. ### Claim 9 (depends on 6) The lead-free projectile of claim 6 in which the polymer is a polyamide. ### Claim 10 (depends on 9) The lead-free projectile of claim 9 in which the polyamide is nylon. ### Claim 11 (depends on 1) The lead-free projectile of claim 1 in which an amount of metal powder is 20 to 90% of the volume of the jacket. ### Claim 12 (depends on 1) The lead-free projectile of claim 1 in which an amount of metal powder is 40 to 80% of the volume of the jacket. ### Claim 13 (depends on 1) The lead-free projectile of claim 1 in which the tip of the parabellum is one of parabolic, rounded and hollow point. ### Claim 14 (depends on 1) The lead-free projectile of claim 1, wherein the metal-filled polymer comprises an ionomer. ### Claim 15 (depends on 1) The lead-free projectile of claim 1, wherein the metal-filled polymer comprises an amorphous polymer. ### Claim 16 A method of forming a lead-free projectile, comprising: (a) placing a pre-formed open ended metal jacket in a mould, said jacket being formable under pressure; (b) adding a pre-determined amount of metal powder into said jacket; (c) compacting said powder by cold pressing the powder in the jacket; (d) forming the open end of the jacket into a truncated parabellum; and (e) filling the jacket by injecting a metal-loaded polymer therein and forming a tip of said metal-loaded polymer on the projectile exterior to the truncated parabellum. ### Claim 17 (depends on 16) The method of claim 16 in which the projectile is a bullet. ### Claim 18 (depends on 16) The method of claim 16 in which the jacket is a copper jacket. ### Claim 19 (depends on 16) The method of claim 16 in which the metal powder is copper or tungsten. ### Claim 20 (depends on 16) The method of claim 16 in which the metal-filled polymer comprises a polymer filled with particles of at least one of copper, tungsten, bismuth, tin and stainless steel. ### Claim 21 (depends on 16) The method of claim 16 in which the polymer is selected from the group consisting of ethylene/methacrylic acid copolymer ionomer, polyetherester elastomer and polyamides. ### Claim 22 (depends on 21) The method of claim 21 in which the polymer is the ethylene/methacrylic acid copolymer ionomer. ### Claim 23 (depends on 22) The method, of claim 22 in which the ethylene/methacrylic acid copolymer ionomer has a melt index of at least 5. ### Claim 24 (depends on 21) The method of claim 21 in which the polymer is a polyamide. ### Claim 25 (depends on 24) The method of claim 24 in which the polyamide is nylon. ### Claim 26 (depends on 16) The method of claim 16 in which the amount of metal powder is 20 to 90% of the volume of the jacket. ### Claim 27 (depends on 16) The method of claim 16 in which the amount of metal powder is 40 to 80% of the volume of the jacket. ### Claim 28 (depends on 16) The method of claim 16 in which the tip is one of parabolic, rounded and hollow point. ### Claim 29 (depends on 16) The lead-free projectile of claim 16, wherein the metal-filled polymer comprises an ionomer. ### Claim 30 (depends on 16) The lead-free projectile of claim 16, wherein the metal-filled polymer comprises an amorphous polymer.