Polymer Ammunition Cartridge with Fiber-Reinforced Composite Insert

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Solution Overview

Problem

Conventional ammunition cartridge casings made from brass are heavy, expensive, and hazardous, and existing plastic alternatives fail to provide reliable, safe, and consistent ballistic performance, often resulting in jamming or safety issues due to insufficient bullet seating and casing strength.

Innovation Solution

A polymeric ammunition cartridge design featuring a ductile polymer or fiber-reinforced composite middle body and bullet-end, with a cylindrical insert and primer recess, utilizing welding or bonding techniques to ensure consistent pressure and joint strength, allowing for interchangeability with brass casings and improved handling characteristics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If plastic cartridge casings are used to reduce weight and cost, then weight and manufacturing cost are improved, but reliability and ballistic performance deteriorate due to insufficient casing strength and bullet seating consistency

Engineering Contradiction:

Improvecartridge casing weightVSAvoidballistic performance consistency

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The patent employs fiber-reinforced polymeric composite materials for the cartridge casing, combining organic polymer matrix with inorganic fiber reinforcement (such as glass, carbon, or aramid fibers). This composite structure provides both the weight reduction benefits of polymers and the strength/casing integrity requirements, achieving uniform bullet seating and consistent ballistic performance while maintaining lighter weight compared to traditional brass casings.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If plastic cartridge casings are used to reduce cost, then manufacturing cost is improved, but safety and handling characteristics worsen due to insufficient casing strength and potential breakage

Engineering Contradiction:

Improvemanufacturing costVSAvoidsafety and handling risks

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The fiber-reinforced polymeric composite material provides both cost advantages over brass and enhanced safety characteristics. The composite structure delivers sufficient casing strength to prevent breakage during handling and firing, while the polymer matrix allows for cost-effective manufacturing processes such as injection molding, achieving economical production without compromising safety or handling characteristics.

Inventive Principle:

Principle #40Composite materials

3Weight of moving object

If conventional plastic materials are used for cartridge casings, then weight is reduced, but bullet seating uniformity and chamber pressure consistency deteriorate

Engineering Contradiction:

Improvecartridge casing weightVSAvoidbullet seating uniformity

Core Design Contradiction:

Weight of moving objectVSManufacturing precision

Solution Approach 1:

The fiber-reinforced polymeric composite material provides the structural rigidity and dimensional stability required for precise bullet seating. The fiber reinforcement network within the polymer matrix maintains uniform casing dimensions and bullet cavity geometry, ensuring consistent bullet seating depth and uniform chamber pressure generation across all cartridges, while retaining the weight benefits of polymer-based construction.

Inventive Principle:

Principle #40Composite materials

4Adaptability or versatility

If lightweight polymer materials are used for cartridge casings, then operational capabilities are improved, but casing strength and resistance to high pressure deteriorate

Engineering Contradiction:

Improveoperational capabilitiesVSAvoidcasing strength

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The fiber-reinforced polymeric composite material achieves an optimal balance between lightweight construction and high casing strength. The fiber reinforcement (glass, carbon, or aramid) embedded in the polymer matrix provides exceptional strength-to-weight ratio, enabling the casing to withstand high chamber pressures and extreme operational conditions while maintaining lightweight characteristics that enhance operational capabilities and mission performance.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS11543218B2Polymer ammunition having an alignment aid, cartridge and method of making the same

Publication Date: 2023.01.03 TRUE VELOCITY IP HOLDINGS LLC

AI summary

One embodiment of the present invention provides a polymeric ammunition cartridge and methods of making and using the same. The cartridge includes a substantially cylindrical insert connected to a substantially cylindrical polymeric middle body. The substantially cylindrical insert includes a top surface opposite a bottom surface and a substantially cylindrical coupling element that extends from the bottom surface, a primer recess in the top surface that extends toward the bottom surface, a primer flash hole positioned in the primer recess to extend through the bottom surface, and a flange that extends circumferentially about an outer edge of the top surface. The substantially cylindrical polymeric middle body includes a substantially cylindrical polymeric bullet-end and a substantially cylindrical polymeric coupling end connected by a powder chamber, wherein the substantially cylindrical polymeric coupling end extends over the substantially cylindrical coupling element and covers a circumferential surface of the primer flash hole.