I saw it happen, once. The fellow used t-shirt material (just mic'd my tee shirt at .010") for patching in a .45, with a .440 ball - CVA percussion longrifle 1974-maybe? He said it was easy to load, but he had to wipe his bore every 2 or 3 shots or so.
Some feel it is obvious that his too-thin patch left something smoldering in the breech and when he was pushing the next one down, the powder ignited and sent the ball and rod pieces through his right hand - he was wiping every 2 or 3 shots. Perhaps the thin patch wasn't the real reason for the discharge, after-all. Perhaps wiping was?
Maybe we've been lucky but maybe it's due to the combinations & methods we use when shooting? Between just the two of us, not including our friends who load similarly, Taylor and I have shot ten's of thousands of rounds since we discovered thick patches and larger balls with no wiping and have never had anything like those ignitions happen to us or to those we shoot with - who use similar combinations. Totally, many tens of thousands of shots. One of our local friends (shoots 100 times or more every week of the year, without fail) has well over 10,000 rounds fired from each gun Taylor has built him + his others - no wiping between shots & no accidental discharges.
He uses thinner patches than we do, but still, no accidental discharges- and no wiping. We all use combinations that do not require wiping over a day's shooting. Is THAT an important factor? When we clean our rifles, the water does not turn jet black as it does for so many other people - is the amount of fouling left in our bores, a factor?
I totally understand what Dan is talking about concerning patent breeches and the possibility of burning hot fouling building in the breech area - or even against the breech plug of a flinter - perhaps especially with a coned vent liner.
This buildup of breech fouling must be especially prevalent in very hot dry conditions - yet these accidents mostly seems to happen back in the hot, but humid and MOIST Eastern USA where many people seem to use thin patching & wipe a lot because they HAVE to. Is that a factor?
I had one Eastern gentleman tell me he uses a very loose patch on an undersized brush for wiping between shots, so that it the cleaning patch doesn't push fouling down to the breech, but when he pulls it out, it bunches and pulls out all that built up fouling from the rifling - every shot - strange - we don't get built up fouling in the rifling - is that a factor?
Is WIPING between shots a major causal factor in accidental discharges because it pushes fouling down to the breech, fouling that ends up being compacted there, shot after shot, then could perhaps become a hard mass of especially hot fouling in the breech? Is wiping in that manner the ACTUAL cause of the buildup of fouling and of these ignitions? Is wiping itself a factor?
Wiping does sound like a good, solid idea from the safety standpoint- but is this actual or misconceived? Obviously these ignitions do and have happened - but WHY are they happening so often to people who are wiping so much? I really do believe THAT has to be addressed and not excluded from discussion or subsequent thought.
For some people and their load combinations, perhaps wiping between shots should be mandatory - if failure to wipe is a condition of these strange ignitions. But- so many of these ignitions happen to people who do wipe - why?
Perhaps the method of wiping should be addressed, rather than wiping or not?