Modular case ammunition and methods of assembly

Abstract

A hybrid ammunition cartridge for a firearm is includes a substantially cylindrical casing defining a body portion having a neck at a forward end and a base at a rearward end, the base including a rim. A projectile is mounted in the neck. Brass is used in the casing at the neck to hold the projectile at the proper crimp. Brass is also used in the rim to house the primer and to provide a surface at which a hook or any suitable mechanism can be used to extract the cartridge from the firearm. The remaining body portion is then manufactured from a composite material having suitable mechanical properties.

1 . A method of manufacturing a hybrid ammunition body, said method comprising:
 providing a casing formed from a first material, said casing defining an interior area;   providing a charge vessel formed from a second material;   providing a propellant in an interior area defined by said charge vessel; and   inserting said charge vessel into said casing;   wherein said casing defines a first distal end portion adapted to receive a projectile; and   wherein said charge vessel is removably retained in said casing.   
     
     
         2 . The method of  claim 1 , wherein said first material is metal and said step of providing said casing includes forming said casing, at least in part, by drawing and extruding said metal. 
     
     
         3 . The method of  claim 1 , wherein said casing defines a second distal end portion opposite said first distal end portion, said second distal end portion defining a pocket adapted to receive a primer, said casing further defining a channel extending into said interior area. 
     
     
         4 . The method of  claim 3 , further comprising hermetically sealing said channel. 
     
     
         5 . The method of  claim 3 , further comprising inserting a primer in said pocket. 
     
     
         6 . The method of  claim 3 , wherein said first material is metal, wherein said step of providing said casing further includes forming said casing, at least in part, by drawing and extruding said metal, and wherein said pocket is formed by folding a portion of said second distal end into said interior area. 
     
     
         7 . The method of  claim 1 , wherein said first material is brass and said second material is a polymer. 
     
     
         8 . The method of  claim 3 , wherein said first distal end portion and said second distal end portion are joined by at least two strips extending therebetween. 
     
     
         9 . The method of  claim 8 , wherein said at least two strips define at least two openings therebetween. 
     
     
         10 . The method of  claim 1 , wherein said step of inserting said charge vessel into said casing includes:
 holding said casing using a fixture,   presenting said charge vessel to an opening defined by said casing,   urging said charge vessel into said opening, and   compressing said charge vessel into said casing to seat said charge vessel in said casing.   
     
     
         11 . The method of  claim 10 , further comprising inserting a projectile into said casing. 
     
     
         12 . A method of assembling live ammunition, said method comprising the steps of:
 retrieving a casing from a casing inventory;   retrieving a charge vessel from a charge vessel inventory;   inserting said charge vessel directly into said casing to provide an assembled casing and charge vessel;   inserting a primer into said assembled casing and charge vessel; and   applying at least one of a thermal barrier and a waterproof coating to said assembled casing and charge vessel.   
     
     
         13 . The method of  claim 12 , further comprising puncturing said charge vessel to cause said primer to be in communication with a propellant in said charge vessel. 
     
     
         14 . The method of  claim 13 , wherein said step of puncturing said charge vessel comprises puncturing a blister gate. 
     
     
         15 . The method of  claim 12 , further comprising inserting a projectile into said assembled casing and charge vessel. 
     
     
         16 . The method of  claim 12 , further comprising sizing said assembled casing and charge vessel to cause an outer surface of said charge vessel to be flush with an outer surface of said casing. 
     
     
         17 . A hybrid ammunition cartridge, comprising:
 a casing formed from a first material and having a base portion defining a pocket therein;   a charge vessel formed from a second material inserted directly into said casing,   a propellant located in said charge vessel; and   a projectile mounted in said casing;   wherein said hybrid ammunition cartridge can be rendered live upon an insertion of a primer in communication with said propellant.   
     
     
         18 . The hybrid ammunition cartridge of  claim 17 , wherein at least a portion of said charge vessel is exposed through at least a portion of said casing. 
     
     
         19 . The hybrid ammunition cartridge of  claim 18 , wherein said casing comprises said base portion, at least two strips extending from said base portion, and a neck attached to said at least two strips. 
     
     
         20 . The hybrid ammunition cartridge of  claim 19 , wherein said casing includes a hardness gradient along a length thereof. 
     
     
         21 . The hybrid ammunition cartridge of  claim 20 , wherein a material of said base portion of said casing is defined in part by a particular hardness value. 
     
     
         22 . The hybrid ammunition cartridge of  claim 20 , wherein a material of said casing intermediate said base portion and said neck is defined in part by a particular hardness value. 
     
     
         23 . The hybrid ammunition cartridge of  claim 20 , wherein a material of said neck is defined in part by a particular hardness value. 
     
     
         24 . The hybrid ammunition cartridge of  claim 17 , wherein said base portion includes a rim extending peripherally around said base portion. 
     
     
         25 . The hybrid ammunition cartridge of  claim 17 , wherein said first material of said casing is a metal. 
     
     
         26 . The hybrid ammunition cartridge of  claim 17 , wherein said second material of said charge vessel comprises a polymer material. 
     
     
         27 . The hybrid ammunition cartridge of  claim 26 , wherein said polymer material is selected from the group consisting of polyphenylsulfone, polystyrene, polypropylene, acrylonitrile butadiene styrene, polyvinyl chloride, polyethylene, polyester terephthalate, polymethylmethacrylate, polyamide, styrene-acrylonitrile, and combinations of the foregoing materials. 
     
     
         28 . A method of manufacturing a hybrid ammunition body, said method comprising:
 providing a casing formed from a first material, said casing defining an interior area;   molding a charge vessel into said interior area defined by said casing, said charge vessel being formed from a second material; and   providing a propellant in an interior area defined by said charge vessel;   wherein said casing defines a first distal end portion adapted to receive a projectile.   
     
     
         29 . The method of  claim 28 , wherein said first material is metal and said step of providing said casing includes forming said casing, at least in part, by drawing and extruding said metal. 
     
     
         30 . The method of  claim 28 , wherein said casing defines a second distal end portion opposite said first distal end portion, said second distal end portion defining a pocket adapted to receive a primer, said casing further defining a channel extending from said pocket into said interior area. 
     
     
         31 . The method of  claim 30 , further comprising hermetically sealing said channel. 
     
     
         32 . The method of  claim 30 , further comprising inserting a primer in said pocket. 
     
     
         33 . The method of  claim 30 , wherein said first material is metal, wherein said step of providing said casing further includes forming said casing, at least in part, by drawing and extruding said metal, and wherein said pocket is formed by folding a portion of said second distal end into said interior area. 
     
     
         34 . The method of  claim 28 , wherein said first material is brass and said second material is a polymer. 
     
     
         35 . The method of  claim 30 , wherein said first distal end portion and said second distal end portion are joined by at least two strips extending therebetween. 
     
     
         36 . The method of  claim 35 , wherein said at least two strips define at least two openings therebetween. 
     
     
         37 . The method of  claim 28 , wherein said step of molding said charge vessel includes:
 providing a mold defining a mold cavity therein,   positioning said casing in said mold cavity, said casing defining an open neck portion, said core being inserted through said open neck portion, said core and an inner surface of said mold cavity cooperating to define a void therebetween,   disposing a polymer in said void,   upon said polymer being cured, removing said core, and   removing said ammunition body from said mold.   
     
     
         38 . The method of  claim 37 , wherein said step of disposing said polymer in said void comprises vacuum forming softened polymer around said core. 
     
     
         39 . The method of  claim 37 , wherein said step of disposing said polymer in said void comprises injection molding said polymer around said core. 
     
     
         40 . The method of  claim 28 , wherein said step of molding said charge vessel comprises blow molding said charge vessel. 
     
     
         41 . The method of  claim 28 , wherein said step of molding said charge vessel comprises compression molding said charge vessel. 
     
     
         42 . The method of  claim 28 , wherein said step of molding said charge vessel comprises vacuum forming said charge vessel. 
     
     
         43 . An ammunition body, comprising:
 a casing formed from a first material, said casing defining an interior area;   a charge vessel formed from a second material, said charge vessel being positioned in said interior area defined by said casing;   a propellant located in an interior area defined by said charge vessel; and wherein   said casing includes a first distal end portion defining a pocket therein adapted to receive a primer.   
     
     
         44 . The ammunition body of  claim 43 , wherein said casing defines a channel extending from said pocket into said interior area. 
     
     
         45 . The ammunition body of  claim 43 , wherein said charge vessel includes a blister gate in communication with said channel. 
     
     
         46 . The ammunition body of  claim 43 , further comprising a primer located in said pocket. 
     
     
         47 . The ammunition body of  claim 46 , further comprising a hermetic seal on said primer. 
     
     
         48 . The ammunition body of  claim 43 , wherein said casing includes a second distal end portion generally opposite said first distal end portion, and wherein said casing includes at least two strips extending between said first and second distal ends, at least two openings in said casing being located between said first and second strips. 
     
     
         49 . The ammunition body of  claim 43 , further comprising a rim machined into said base portion of said casing. 
     
     
         50 . The ammunition body of  claim 43 , wherein outer surfaces of said casing and said charge vessel are flush with each other. 
     
     
         51 . The ammunition body of  claim 43 , wherein said first material is metal and said second material is polymeric. 
     
     
         52 . A hybrid ammunition cartridge, comprising:
 a casing formed from a first material and having a base portion defining a pocket therein;   a charge vessel formed from a second material molded directly into said casing,   a propellant located in said charge vessel; and   a projectile mounted in said casing;   wherein said hybrid ammunition cartridge can be rendered live upon an insertion of a primer in communication with said propellant.   
     
     
         53 . The hybrid ammunition cartridge of  claim 52 , wherein at least a portion of said charge vessel is exposed through at least a portion of said casing. 
     
     
         54 . The hybrid ammunition cartridge of  claim 53 , wherein said casing comprises said base portion, at least two strips extending from said base portion, and a neck attached to said at least two strips. 
     
     
         55 . The hybrid ammunition cartridge of  claim 54 , wherein said casing includes a hardness gradient along a length thereof. 
     
     
         56 . The hybrid ammunition cartridge of  claim 55 , wherein a material of said base portion of said casing is defined in part by a particular hardness value. 
     
     
         57 . The hybrid ammunition cartridge of  claim 55 , wherein a material of said casing intermediate said base portion and said neck is defined in part by a particular hardness value. 
     
     
         58 . The hybrid ammunition cartridge of  claim 55 , wherein a material of said neck is defined in part by a particular hardness value. 
     
     
         59 . The hybrid ammunition cartridge of  claim 52 , wherein said base portion includes a rim extending peripherally around said base portion. 
     
     
         60 . The hybrid ammunition cartridge of  claim 52 , wherein said first material of said casing is metal. 
     
     
         61 . The hybrid ammunition cartridge of  claim 52 , wherein said second material of said charge vessel comprises polymer. 
     
     
         62 . The hybrid ammunition cartridge of  claim 61 , wherein said polymer material is selected from the group consisting of polyphenylsulfone, polystyrene, polypropylene, acrylonitrile butadiene styrene, polyvinyl chloride, polyethylene, polyester terephthalate, polymethylmethacrylate, polyamide, styrene-acrylonitrile, and combinations of the foregoing materials.