Method of making a polymeric subsonic ammunition cartridge

Abstract

The present invention provides a method of making a subsonic ammunition cartridge having a polymeric casing body having a generally cylindrical hollow polymer body having a body base at a first end thereof and a mouth at a second end to define a propellant chamber; a propellant insert positioned in the propellant chamber to reduce the internal volume of the propellant chamber, wherein the propellant chamber has an internal volume that is at least 10% less than the open internal volume of a standard casing of equivalent caliber; and a primer insert positioned in the body base and in communication with the propellant chamber.

What is claimed is: 
     
         1 . A method of preparing a polymeric subsonic ammunition comprising the steps of:
 providing a substantially cylindrical primer insert comprising a base having a top surface opposite a bottom surface, a substantially cylindrical coupling flange that extends from the top surface forming a substantially cylindrical inner surface, a substantially cylindrical primer wall that extends from the bottom surface wherein a substantially cylindrical primer recess is formed by the inner surface of the substantially cylindrical primer wall and a groove formed on the circumference of an outer surface of the substantially cylindrical primer wall, wherein the substantially cylindrical inner surface is opposite the substantially cylindrical primer recess, and a primer aperture formed through the base to connect the substantially cylindrical inner surface to the substantially cylindrical primer recess;   forming a substantially cylindrical polymeric middle body having the substantially cylindrical primer insert at a first end and a substantially cylindrical polymeric coupling region at a second end by contacting a polymeric material with the substantially cylindrical primer insert, wherein the polymeric material covers the substantially cylindrical coupling flange and extends over the substantially cylindrical inner surface to form a primer flash hole and extends over the outer surface of the substantially cylindrical primer wall to the groove; wherein a propellant chamber extends from the substantially cylindrical polymeric coupling region to the primer flash hole;   coupling a substantially cylindrical polymeric bullet-end component to the substantially cylindrical polymeric middle body, wherein the substantially cylindrical polymeric bullet-end component comprises a substantially cylindrical polymeric coupling end opposite a bullet aperture, wherein the substantially cylindrical polymeric coupling end mates to the substantially cylindrical polymeric coupling region and extends the propellant chamber from the bullet aperture to the primer flash hole; and   positioning a propellant insert in the propellant chamber to reduce the internal volume of the propellant chamber, wherein the propellant chamber has an internal volume that is at least 10% less than the open internal volume of a standard casing of equivalent caliber.   
     
     
         2 . The method of  claim 1 , wherein the substantially cylindrical polymeric bullet-end component comprises a shoulder positioned between the substantially cylindrical polymeric coupling end and the bullet aperture. 
     
     
         3 . The subsonic ammunition cartridge of  claim 1 , wherein the internal volume that is about 10.1, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, or 25% less than the open internal volume of a standard casing of equivalent caliber. 
     
     
         4 . The subsonic ammunition cartridge of  claim 1 , wherein the primer insert is overmolded into the substantially cylindrical polymeric middle body. 
     
     
         5 . The method of  claim 1 , wherein the substantially cylindrical primer insert further comprises a flash hole groove formed about the primer aperture on the bottom surface and the polymer extends over the substantially cylindrical inner surface to the flash hole groove to form a primer flash hole. 
     
     
         6 . The method of  claim 1 , wherein the propellant chamber contains a propellant volume such that a projectile does not exceed a velocity of 1200 feet per second at sea level under standard atmospheric conditions when fired. 
     
     
         7 . The method of  claim 1 , wherein the propellant chamber contains a propellant volume such that a projectile does not exceed the velocity of 1086 feet per second at standard atmospheric conditions when fired. 
     
     
         8 . The method of  claim 1 , further comprising the step of securing a projectile to the bullet aperture by a mechanical interference, adhesive, ultrasonic welding, the combination of molding in place and adhesive, or hot crimping after molding. 
     
     
         9 . The method of  claim 1 , wherein the substantially cylindrical polymeric middle body comprises a polymers selected from the group consisting of polyurethane prepolymer, cellulose, fluoro-polymer, ethylene inter-polymer alloy elastomer, ethylene vinyl acetate, nylon, polyether imide, polyester elastomer, polyester sulfone, polyphenyl amide, polypropylene, polyvinylidene fluoride or thermoset polyurea elastomer, acrylics, homopolymers, acetates, copolymers, acrylonitrile-butadinen-styrene, thermoplastic fluoro polymers, inomers, polyamides, polyamide-imides, polyacrylates, polyatherketones, polyaryl-sulfones, polybenzimidazoles, polycarbonates, polybutylene, terephthalates, polyether imides, polyether sulfones, thermoplastic polyimides, thermoplastic polyurethanes, polyphenylene sulfides, polyethylene, polypropylene, polysulfones, polyvinylchlorides, styrene acrylonitriles, polystyrenes, polyphenylene, ether blends, styrene maleic anhydrides, polycarbonates, allyls, aminos, cyanates, epoxies, phenolics, unsaturated polyesters, bismaleimides, polyurethanes, silicones, vinylesters, urethane hybrids, polyphenylsulfones, copolymers of polyphenylsulfones with polyethersulfones or polysulfones, copolymers of poly-phenylsulfones with siloxanes, blends of polyphenylsulfones with polysiloxanes, poly(etherimide-siloxane) copolymers, blends of polyetherimides and polysiloxanes, and blends of polyetherimides and poly(etherimide-siloxane) copolymers. 
     
     
         10 . The method of  claim 1 , wherein the substantially cylindrical polymeric bullet-end component comprises a polymers selected from the group consisting of polyurethane prepolymer, cellulose, fluoro-polymer, ethylene inter-polymer alloy elastomer, ethylene vinyl acetate, nylon, polyether imide, polyester elastomer, polyester sulfone, polyphenyl amide, polypropylene, polyvinylidene fluoride or thermoset polyurea elastomer, acrylics, homopolymers, acetates, copolymers, acrylonitrile-butadinen-styrene, thermoplastic fluoro polymers, inomers, polyamides, polyamide-imides, polyacrylates, polyatherketones, polyaryl-sulfones, polybenzimidazoles, polycarbonates, polybutylene, terephthalates, polyether imides, polyether sulfones, thermoplastic polyimides, thermoplastic polyurethanes, polyphenylene sulfides, polyethylene, polypropylene, polysulfones, polyvinylchlorides, styrene acrylonitriles, polystyrenes, polyphenylene, ether blends, styrene maleic anhydrides, polycarbonates, allyls, aminos, cyanates, epoxies, phenolics, unsaturated polyesters, bismaleimides, polyurethanes, silicones, vinylesters, urethane hybrids, polyphenylsulfones, copolymers of polyphenylsulfones with polyethersulfones or polysulfones, copolymers of poly-phenylsulfones with siloxanes, blends of polyphenylsulfones with polysiloxanes, poly(etherimide-siloxane) copolymers, blends of polyetherimides and polysiloxanes, and blends of polyetherimides and poly(etherimide-siloxane) copolymers. 
     
     
         11 . The method of  claim 1 , wherein the propellant insert comprises a polymers selected from the group consisting of polyurethane prepolymer, cellulose, fluoro-polymer, ethylene inter-polymer alloy elastomer, ethylene vinyl acetate, nylon, polyether imide, polyester elastomer, polyester sulfone, polyphenyl amide, polypropylene, polyvinylidene fluoride or thermoset polyurea elastomer, acrylics, homopolymers, acetates, copolymers, acrylonitrile-butadinen-styrene, thermoplastic fluoro polymers, inomers, polyamides, polyamide-imides, polyacrylates, polyatherketones, polyaryl-sulfones, polybenzimidazoles, polycarbonates, polybutylene, terephthalates, polyether imides, polyether sulfones, thermoplastic polyimides, thermoplastic polyurethanes, polyphenylene sulfides, polyethylene, polypropylene, polysulfones, polyvinylchlorides, styrene acrylonitriles, polystyrenes, polyphenylene, ether blends, styrene maleic anhydrides, polycarbonates, allyls, aminos, cyanates, epoxies, phenolics, unsaturated polyesters, bismaleimides, polyurethanes, silicones, vinylesters, urethane hybrids, polyphenylsulfones, copolymers of polyphenylsulfones with polyethersulfones or polysulfones, copolymers of poly-phenylsulfones with siloxanes, blends of polyphenylsulfones with polysiloxanes, poly(etherimide-siloxane) copolymers, blends of polyetherimides and polysiloxanes, and blends of polyetherimides and poly(etherimide-siloxane) copolymers. 
     
     
         12 . The method of  claim 1 , wherein the substantially cylindrical polymeric middle body, the substantially cylindrical polymeric bullet-end component and the propellant insert independently comprise a material selected from the group consisting of polyphenylsulfone, polycarbonate, and polyamide. 
     
     
         13 . The method of  claim 1 , wherein the substantially cylindrical polymeric middle body, the substantially cylindrical polymeric bullet-end component and the propellant insert independently comprise at least one additive selected from the group consisting of plasticizers, lubricants, molding agents, fillers, thermo-oxidative stabilizers, flame-retardants, coloring agents, compatibilizers, impact modifiers, release agents, reinforcing fibers and reinforcing agents. 
     
     
         14 . The method of  claim 1 , wherein the propellant insert has a substantially cylindrical shape. 
     
     
         15 . The method of  claim 1 , wherein the propellant insert has a free formed shape. 
     
     
         16 . The method of  claim 1 , wherein the propellant insert has a one or more ribs extending into the propellant chamber. 
     
     
         17 . The method of  claim 1 , wherein the propellant insert has a radial cross-section selected from the group consisting of circular, ovoid, octagonal, hexagonal, triangular, star, ribbed, square and a combination thereof. 
     
     
         18 . The method of  claim 1 , wherein the radial cross-section of the propellant chamber is irregular in shape or tapers along its longitudinal length. 
     
     
         19 . The method of  claim 1 , wherein the substantially cylindrical polymeric middle body, the substantially cylindrical polymeric bullet-end component and the propellant insert independently comprise the same polymeric material or different polymeric materials. 
     
     
         20 . The subsonic ammunition of  claim 1 , wherein the propellant chamber is formed of a separate propellant insert disposed within the internal cavity of the generally cylindrical hollow polymer body.