Polymer Composite Ammunition Casings with Embedded Metal Bushing
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Solution Overview
Problem
Current non-metal ammunition casings tend to split during firing, failing to withstand the internal forces, which limits their use in weapons due to manufacturing, aesthetic, economic, and structural shortcomings.
Innovation Solution
Development of polymer-based composite casings with a single continuous polymer wrap embedding a metal bushing, where the polymer wrap extends to cover the metal bushing except for an extraction rim, providing structural integrity and aesthetic appeal while being economical to manufacture and use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If non-metal ammunition casings are used, then weight is reduced and manufacturing cost is decreased, but the casing splits during firing and fails to withstand internal forces
Solution Approach 1:
The patent applies composite materials by combining polymer material with metal reinforcement elements (metal bushing, metal mesh, or metal fibers) within the polymer casing structure. This creates a composite casing that maintains the lightweight advantage of polymers while gaining the strength and force-withstanding capability of metal components, directly resolving the contradiction between weight reduction and strength maintenance.
2Ease of manufacture
If polymer material is used for casings, then manufacturing cost is reduced and ease of manufacture is improved, but the casing lacks structural integrity to withstand firing forces
Solution Approach 1:
The patent integrates metal reinforcement elements (bushing, mesh, or fibers) into the polymer casing structure through manufacturing processes such as injection molding or overmolding. This composite approach maintains the ease of polymer manufacturing while incorporating metal components that provide the necessary structural integrity and reliability to withstand firing forces.
Solution Approach 2:
The patent applies metal reinforcement selectively at specific locations within the casing structure where strength is most needed (such as the base, shoulder, or rim areas). This local quality approach maintains overall manufacturing simplicity while providing targeted strength enhancement to improve reliability during firing.
3Strength
If traditional metal casings are used, then structural integrity is maintained, but weight is increased and manufacturing cost is increased
Solution Approach 1:
The patent uses composite materials where a polymer matrix provides the basic casing structure (maintaining low weight) while embedded metal elements (bushing, mesh, or fibers) provide localized strength enhancement. This composite structure achieves the required strength-to-weight ratio by combining materials strategically rather than using solid metal throughout.
Solution Approach 2:
The patent concentrates metal reinforcement only in specific high-stress areas of the casing (such as the base, shoulder, or rim) rather than using metal throughout the entire casing. This local quality approach reduces overall weight compared to traditional metal casings while maintaining necessary strength where it is most critical.
4Shape
If polymer casings are used, then aesthetic appeal is improved and cost is reduced, but the casing lacks the structural framework to prevent splitting during firing
Solution Approach 1:
The patent creates a composite casing structure where the polymer provides the outer aesthetic shell while embedded metal elements (bushing, mesh, or fibers) create an internal structural framework. This framework prevents splitting during firing while the polymer exterior maintains aesthetic appeal and smooth appearance.
Solution Approach 2:
The patent nests metal reinforcement elements within the polymer casing structure (metal bushing embedded in polymer, or metal mesh/fibers embedded in polymer matrix). This nested structure allows the metal framework to provide structural stability against splitting while the outer polymer layer maintains aesthetic appearance, effectively combining both requirements.
Data Source
AI summary
Polymer-based composite casings and ammunition containing the same are disclosed. Methods of making and using polymer-based composite casings and ammunition containing the same are also disclosed.