The present invention provides a primer insert for use in a polymeric ammunition cartridge includes a top surface opposite a bottom surface and a extraction flange that extends circumferentially about an outer edge of the top surface; a coupling element that extends from the bottom surface, wherein the substantially cylindrical coupling element is adapted to receive a polymer overmolding; a primer recess in the top surface that extends toward the bottom surface, wherein the primer recess comprises a recess bottom and a circular recess side wall; a primer flash aperture through the recess bottom that extends through the bottom surface, wherein the primer flash aperture is adapted to receive a polymer overmolding to form a flash hole; and a groove in the primer recess positioned around the primer flash aperture adapted to receive a polymer overmolding, wherein the groove extends at least partially over the bottom surface and the groove is adapted to receive polymer at least partially over the bottom surface.

The present invention provides a method of making a substantially cylindrical insert by metal injection molding by providing a primer insert injection mold to form a substantially cylindrical metal primer insert, injection molding the metal injection molding feedstock into the primer insert injection mold to form a first substantially cylindrical metal primer insert having a first size; debinding the first substantially cylindrical metal primer insert to remove the first binding agent; and sintering the first substantially cylindrical metal primer insert to remove the second binding agent and form the substantially cylindrical metal primer insert having a second size.

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.

The present invention provides a method of coding polymer ammunition cartridges by providing a first colored polymer forming a polymeric bullet-end upper portion comprising a bullet-end coupling element extending to a bullet-end aperture to engage a bullet; providing a second colored polymer forming a polymeric middle body comprising a first coupling end connected to the bullet-end coupling element and a second coupling end connected to a primer insert to form a propellant chamber that connects the bullet-end aperture to the primer insert; and coding the first colored polymer, the second colored polymer or both to identify a projectile type, an ammunition type, a propellant charge, or a combination thereof.

The present invention provides a polymer ammunition cartridge having a primer insert having: a top surface; a bottom surface opposite the top surface; a coupling element that extends from the bottom surface, wherein the coupling element comprises an interior surface and an exterior surface, wherein the interior surface comprises: a transition region that transitions from the bottom surface to a second segment wherein the transition region has a radius of from 0.1 to 0.2; a first segment extending from the second segment and terminates at a tip, wherein the first segment has a first segment distance from 0.06 to 0.14 inches and the second segment has a second segment distance from 0.05 to 0.15 inches, wherein the second segment has a second segment angle from +3 to −3 degrees relative to the first segment angle and the first segment has a first segment angle from +6 to −6 degrees from perpendicular to the top surface; a primer recess in the top surface that extends toward the bottom surface; a primer flash aperture positioned in the primer recess through the bottom surface; and a flash aperture groove in the primer recess and positioned around the primer flash aperture and adapted to receive a polymer overmolding through the primer flash aperture.

The present invention provides a polymer ammunition cartridge having a primer insert having: a top surface; a bottom surface opposite the top surface; a coupling element that extends from the bottom surface, wherein the coupling element comprises an interior surface and an exterior surface, wherein the interior surface comprises: a transition region that transitions from the bottom surface to a second segment wherein the transition region has a radius of from 0.1 to 0.2; a first segment extending from the second segment and terminates at a tip, wherein the first segment has a first segment distance from 0.06 to 0.14 inches and the second segment has a second segment distance from 0.05 to 0.15 inches, wherein the second segment has a second segment angle from +3 to −3 degrees relative to the first segment angle and the first segment has a first segment angle from +6 to −6 degrees from perpendicular to the top surface; a primer recess in the top surface that extends toward the bottom surface; a primer flash aperture positioned in the primer recess through the bottom surface; and a flash aperture groove in the primer recess and positioned around the primer flash aperture and adapted to receive a polymer overmolding through the primer flash aperture.

One embodiment of the present invention provides a method of making a polymeric ammunition cartridge having wicking texturing about the projectile aperture.

One embodiment of the present invention provides a method of making a polymeric ammunition cartridge having wicking texturing about the projectile aperture.

The present invention provides a diffuser ring adapted to fit a primer recess in an ammunition cartridge comprising: a diffuser ring sized to fit in a primer recess for an ammunition cartridge comprising a diffuser top surface opposite a diffuser bottom surface, a diffuser aperture positioned through the diffuser top surface and the diffuser bottom surface such that the diffuser aperture can align with a flash hole, and a diffuser neck positioned about the diffuser aperture to extend away from the diffuser top surface, wherein the diffuser neck is sized to fit at least partially through the flash hole.

The present invention provides a diffuser cup adapted to fit a primer recess in an ammunition cartridge comprising: a diffuser ring sized to fit in a primer recess for an ammunition cartridge comprising a diffuser top surface opposite a diffuser bottom surface, a diffuser aperture positioned through the diffuser top surface and the diffuser bottom surface such that the diffuser aperture can align with a flash hole, and a diffuser neck positioned about the diffuser aperture to extend away from the diffuser top surface, wherein the diffuser neck is sized to fit at least partially through the flash hole; and a cup wall attached to the diffuser ring to extend away from the diffuser bottom surface, wherein the cup wall is configured to frictionally fit a primer and frictionally fit a primer recess.