Advanced Modular Ammunition and Cartridges and Systems

Abstract

Modular cartridges are disclosed that can be initially assembled, disassembled, and reprocessed by hand. The cartridge case is suitable for use with a variety of projectile designs and weights and for use with a range of propellant amounts and primer types. The variety of projectiles and range of propelling forces permits the present invention to provide cartridges for all types of uses, including indoor and outdoor target shooting, training, non-lethal self-protection, and lethal uses. The cartridges include a case, a projectile, a primer, and a selectable amount of propellant (if any), and primer housing insert” and which is configured to be releasably attached to the striking end of the case and to contain the primer and the desired amount of propellant.

Claims

1. A subassembly for an ammunition cartridge, the subassembly comprising: a) a reusable case having a forward end and an aft end, the forward end being adapted to releasably attach to a bullet having a forward end and an aft end and a pressure chamber extending from its aft end and the case having an external wall extending from the case's aft end to the case's forward end, the case being adapted for use in at least one of a revolver and a rifle; b) a primer cap; and c) a reusable primer housing insert having a forward end and an aft end, the primer housing insert being adapted to releasably attach proximal to its aft end to an inside of the case's external wall proximal to the aft end of the case and having a first recess proximal to the primer housing insert's aft end adapted to releasably contain the primer cap and a channel communicating from the first recess to or through the primer housing insert's forward end; wherein when the subassembly is combined with the bullet to form an ammunition cartridge, the forward end of the primer housing insert extends into the bullet's pressure chamber without connecting to the bullet and the primer housing insert is configured to expel a gas pressure pulse axially through its forward end into the bullet's pressure chamber.

2. A component of an ammunition cartridge for at least one of a revolver and a rifle, the ammunition cartridge comprising, in addition to the component, a case having an exterior wall and a bullet, the component comprising a reusable primer housing insert having a forward end and an aft end, the primer housing insert being adapted to releasably attach proximal to its aft end to an inside of the exterior wall of the case proximal to an aft end of the case and having a first recess proximal to its aft end adapted to releasably contain a primer cap and a channel communicating from the first recess to or through the primer housing insert's forward end wherein when the component is combined with the bullet and the case to form the ammunition cartridge, the forward end of the primer housing insert extends into a pressure chamber of the bullet which is proximal to the aft end of the bullet without the primer housing insert connecting to the bullet and the primer housing insert is configured to expel a gas pressure pulse axially through its forward end into the bullet's pressure chamber.

3. A system comprising a plurality of modules adapted to be manually combined to form at least one ammunition cartridge for at least one of a revolver and a rifle, the modules including a case having an exterior wall, a bullet, and a reusable primer housing insert, wherein the primer housing insert has a forward end and an aft end and is adapted to releasably attach proximal to its aft end to an inside of the exterior wall of the case proximal to an aft end of the case and has a first recess proximal to its aft end and adapted to releasably contain a primer cap and a channel communicating from the first recess to or through the primer housing insert's forward end wherein when the primer housing insert is combined with the bullet and the case to form the ammunition cartridge, the forward end of the primer housing insert extends into a pressure chamber of the bullet which is proximal to the aft end of the bullet without the primer housing insert connecting to the bullet and the primer housing insert is configured to expel a gas pressure pulse axially through its forward end into the bullet's pressure chamber.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The criticality of the features and merits of the present invention will be better understood by reference to the attached drawings. It is to be understood, however, that the drawings are designed for the purpose of illustration only and not as a definition of the limits of the present invention. Unless otherwise specified, the drawings are not to scale.

[0020] FIG. 1 is a centerline longitudinal cross-sectional view of a typical prior art cartridge.

[0021] FIGS. 2A-F show a first pistol cartridge according to an embodiment of the present invention.

[0022] FIG. 2A is a side elevational view of the first pistol cartridge of FIG. 2A.

[0023] FIG. 2B is a bottom view of the first pistol cartridge of FIG. 2A.

[0024] FIG. 2C is an exploded perspective view of the first pistol cartridge of FIG. 2A.

[0025] FIG. 2D is a centerline longitudinal view of the first pistol cartridge of FIG. 2A.

[0026] FIG. 2E is a centerline longitudinal cross-sectional view of the first pistol cartridge of FIG. 2A.

[0027] FIG. 2F is a partially cut-away perspective view of the first pistol cartridge of FIG. 2A.

[0028] FIG. 3 is a partially cross-sectional perspective view of a second pistol cartridge according to an embodiment of the present invention.

[0029] FIG. 4 is an exploded longitudinal cross-sectional view of a first revolver cartridge according to an embodiment of the present invention.

[0030] FIG. 5 is an exploded longitudinal cross-sectional view of a second revolver cartridge according to an embodiment of the present invention.

[0031] FIG. 6 is an exploded bottom perspective view of a rifle cartridge according to an embodiment of the present invention.

[0032] FIGS. 7A-7F are longitudinal centerline cross-sectional views of examples of some of the many types projectile designs that may be used as part of the modular cartridges of the present invention.

[0033] FIGS. 8A-8F are as longitudinal centerline cross-sectional views of some of the configurations that the primer housing inserts of the present invention can have.

[0034] FIG. 9 is a longitudinal centerline cross-sectional view of another pistol cartridge embodiment of the present invention showing an o-ring connection between the case and the primer housing insert.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0035] In this section, some preferred embodiments of the present invention are described in detail sufficient for one skilled in the art to practice the present invention. It is to be understood, however, that the fact that a limited number of preferred embodiments are described herein does not in any way limit the scope of the present invention as set forth in the appended claims. It is also to be understood that whenever a range of values is presented, the range is to be construed as disclosing its endpoints and every point therebetween as if each point was expressly described.

[0036] The present invention provides modular, hand-assembly cartridges for pistols, revolvers, and rifles. Several preferred embodiments are described in this section, with examples being given of pistol cartridges, revolver cartridges, and rifle cartridges. Additionally, for each particular type of pistol, revolver, and rifle, the present invention provides for a variety of different modular components which can be assembled to produce a cartridge that is tailored to the particular type of use the shooter desires, including indoor and outdoor target shooting, training, and self-protection uses.

[0037] FIGS. 2A-F show a first pistol cartridge 200 according to an embodiment of the present invention. The cartridge 200 is configured for use in indoor or outdoor target shooting and small game hunting.

[0038] FIGS. 2A and 2B are, respectively, a side elevational view and a bottom (striking end) view of the assembled cartridge 200. In FIG. 2A the projectile 202 and the case 204 of the cartridge 200 are visible. In FIG. 2B, portions of the case 204, the primer housing insert 206, and the primer 208 are visible. FIG. 2C is an exploded perspective view of the cartridge 200 which shows the three primary components of the cartridge 200, i.e., the primer housing insert 206, the case 204, and the projectile 202, prior to the components being hand-assembled by the user to construct the cartridge 200. To make the assembly, the user simply manually nests and rotationally seats the primer housing insert 206 into the striking end 210 of the case 204 and manually seats the projectile 202 into the discharge end 212 of the case 204. The exterior geometries of the case 204 and the projectile 202 are adapted to conform to the one or more breech chambers in which the cartridge the cartridge 200 is intended to be used.

[0039] For an understanding of the interior configuration of the cartridge 200, refer now to FIG. 2D, which is a centerline longitudinal view of case 204 and to FIGS. 2E and 2F, which are, respectively, a centerline longitudinal cross-sectional view and a partially cut-away perspective view of the cartridge 200. The following discussion of the interior configuration of the cartridge 200 will start with a description of the case 204 and then progressively proceed to descriptions of the projectile 202 and the primer housing insert 206.

[0040] The case 204 has at its discharge end 212 a first cavity 214 (also called an “upper retaining pocket”) and a second cavity 216 (also called a “base pocket”) which are adapted to nestingly receive the intermediate and base (or neck) portions 218, 220 of the projectile 202. Preferably, the shoulder 222 that is formed between the first and second cavities 214, 216 is beveled inward to help guide the projectile base 220 as it passes from the first to second cavities 214, 216 when the projectile 202 is being inserted into the case 204. The walls 224, 226, respectively, of the first and second cavities 214, 216 are preferably straight (as shown), but either or both of them may be partly or wholly tapered inward if desired to accommodate a similarly tapered projectile. A seating shoulder 228 is at the end of the second cavity 216 to accommodate the endface 230 of the projectile base 220.

[0041] Between the second cavity 216 and the striking end 210 of the case 204, the interior of the case 204 has a passageway 232 (also called a “lower retaining pocket”) the sides of which are configured to accommodate the outer geometry of the primer housing insert 206. These accommodations include threads 234 to engage the corresponding threads 236 of the primer housing insert 206 and a seating shoulder 238 against which a complimentary shoulder 240 of the primer housing insert 206 seats.

[0042] The projectile 202 has a pressure chamber 242 extending along its longitudinal centerline from its base end. The pressure chamber 242 is dimensioned to nestingly receive the post 244 of the primer housing insert 206 so that the post 244 extends into the thick-walled intermediate portion 218 of the projectile 202. The pressure chamber 242 is thus positioned to receive and dimensioned to accommodate the hot gas pressure pulse that is provided by the primer housing insert 206 during firing. The dimensions of pressure chamber 242 also are chosen to promote the balanced and stable flight of the projectile 204. The endwall 246 of the pressure chamber 242 may be of any configuration, e. g. flat, conical, etc., but is preferably domed so as to evenly distribute the pressure pulse to the projectile 202. The corner 248 of the pressure chamber 242 where the pressure chamber 242 terminates at the endface 230 of the base 220 may be squared, but is preferably rounded or beveled so as to help guide the primer housing insert post 244 as it is introduced into the pressure chamber 242.

[0043] The projectile 202 is releasably held seated within the first and second chambers 214, 216 of the case 204 by the elastic force exerted by one or more slightly raised circumferential bands (which are referred to herein as “pressure bands”, e.g. pressure band 250) against at least one of the interior walls 224, 226 of the first and second chambers 214, 216, respectively.

[0044] The primer housing insert 206 has a primer 252 releasably retained within a primer-receiving cavity 254. A passageway 256 extends axially from the primer-receiving cavity 254 to the discharge end 258 of the primer housing insert 206. The walls 260 of the passageway 256 may be straight or may be tapered inwardly along all or a portion of the length of the passageway 256. Optionally, the geometry of the walls 260 of the passageway 256 may take on other configurations so long as the walls 260 are designed to safely contain the hot gas pressure pulse that the passageway 256 is exposed to during the firing of the cartridge 200.

[0045] With the exception of the primer 208, all of the components of the cartridge 200 may be constructed of a synthetic material, e.g., injectable plastic. Alternatively, the case, the projectile, and/or the primer housing insert may be constructed in whole or in part of a metal, e.g., brass, aluminum, or copper, to name a few.

[0046] A second pistol cartridge 300 according to an embodiment of the present invention that is suitable for use self protection is shown in a partially cross-sectional perspective view in FIG. 3. Like the first pistol cartridge 200, the second pistol cartridge 300 comprises three main components, namely a projectile 302, a casing 304, and a primer housing insert 306. Also like the first pistol cartridge 200, all of the components of the second pistol cartridge 300 are resusable—except of course for the spent primer and propellant (if any). However, the second cartridge 300 differs from the first cartridge 200 in three main respects.

[0047] First, whereas the projectile 202 is a single piece component, the projectile 302 comprises a metal core 308 and a synthetic outer sleeve 310. The metal core 308 provides for additional weight, impact force, and penetration.

[0048] Second, in place of the pressure band 250 of projectile 202, the projectile 302 has an o-ring 312 seated in an o-ring groove 314 on the outer surface of its inner core 308 for holding and sealing the projectile 302 in place in the case 304.

[0049] Third, the configuration of primer housing insert 306 is more complex than that of the primer housing insert 206. The primer housing insert 306 includes an outer shell that is similar exteriorly to the primer housing insert 206 as it has threads 316 and a post 318 and is preferably made of a synthetic material. However, the inner configuration of the primer housing insert 306 is different in that it contains a metal liner 320. The metal liner 320 has an outer flange 322 that forms the striking end endface of the primer housing insert 306. The metal liner 320 also has a primer 324, which is removably retained within a primer-receiving cavity 326, and a passageway 328 extending from the primer-receiving cavity 326 to the discharge end of the primer housing insert 306. Although the passageway 328 is adapted to optionally contain loose or pelletized propellant, e.g., such as propellant pellet 330 (which for clarity sake is shown in FIG. 3 as floating in the passageway 328), in some embodiments the passageway 328 contains no propellant. In embodiments in which the passageway 328 does contain a propellant, it is necessary to provide a closure to the discharge end of the passageway 328 which will be dislodged or which will open upon firing so that the hot gas pressure pulse emanating from the primer and/or the propellant can exit the discharge end of the passageway 328. The closure may be made by way of a plug or other dislodgable or burstable (e.g., a membrane of film) obstruction or, as shown in FIG. 3, by crimped closure 332 of the end of the metal liner 320.

[0050] Referring now to FIG. 4, there is shown an exploded longitudinal cross-sectional view of a first revolver cartridge 400 which has a single-piece synthetic projectile 402, a case 404, and a primer housing insert 406. These components are similar to those shown with regard to first pistol cartridge 200. The projectile 402 has a pressure band 408 that aids in sealingly retaining the base 410 of the projectile 402 in the base pocket 412 of the case 404. The case 404 is similar to the base 204 with its features being adapted to the contours and dimensions of the different breech chamber for which it is designed to be used. The synthetic primer housing insert 406 removeably retains a primer 414 in a primer-receiving pocket 416 and has threads 418, a post 420, and a tapered-to-straight passageway 422 which are similar to the corresponding features of primer housing insert 206. However, while the primer housing insert 202 contained only the primer 252, the primer housing insert 406 contains, in addition to the primer 414, a propellant pellet 424 (which for clarity sake are shown in FIG. 4 as floating in the passageway 422), and a retaining plug 426.

[0051] In FIG. 5, a second revolver cartridge 500 according to an embodiment of the present invention is shown as an exploded longitudinal cross-sectional view. The cartridge 500 comprises a two-piece projectile 502, a case 504, and a primer housing insert 506. The projectile 502 has a metal core 508 and a synthetic sleeve 510. An elongated o-ring 512 is seated in a groove on the base 514 of the projectile 502 for sealingly retaining the projectile 502 within the case 504. A small vent hole is provided in the base 514 to help relieve internal air pressure during the assembly of cartridge 500. The case 504 is identical to the case 404. The primer housing insert 506 is metal and has a crimped discharge end 516 to retain loose or pelletized propellant, e.g. propellant pellets 518 (which for clarity sake are shown in FIG. 5 as floating in the passageway 520), and a primer 522 releasably retained within a primer-receiving cavity 524.

[0052] A rifle cartridge 600 according to an embodiment of the present invention is shown in FIG. 6, which is an exploded bottom perspective view showing all of the individual components and subcomponents of the cartridge 600. The main components of the cartridge 600 are a projectile 602, a case 604, and a primer housing insert 606. The subcomponents of the projectile 602 are a sleeve 608, a metal core 610, and an extended o-ring 612. An o-ring groove 614 is provided in the metal core 610 for receiving the o-ring 612. A small vent hole 616 is also provided in the metal core 610. The metal primer housing insert 606 has threads 618 which are adapted to screw into complementary threads 620 of the case 604. The discharge end 622 of the primer housing insert 606 is crimped closed. The primer housing insert 606 has as its subcomponents a propellant 624 and a primer 626. Note that the flange 628 on the striking end of the primer house insert 606 has two recesses 630a, 630b that allow for a rod, screwdriver tip, or a spanner tool to be used to help seat and unseat the primer housing insert 606 within case 604. Note that the post 632 of the primer housing insert 606 has optional marking bands 634. The color and number of marking bands 634 are used to readily indicate to the user the amount of propellant (if any) and/or the type of primer 626 that primer housing insert 606 contains.

[0053] Referring to FIGS. 7A-7F, there are shown longitudinal centerline cross-sectional views of examples of some of the many projectile designs that may be used as part of the modular cartridges of the present invention. FIG. 7A shows a synthetic practice service projectile 700. FIG. 7B shows a training projectile 702 which has a rubber cap 704, a synthetic body sleeve 706, and a metal core 708 which has two groove-seated o-rings 710a, 710b. FIG. 7C shows a training projectile 712 which has a synthetic body sleeve 714 and a metal core 716 which has a single o-ring 718. FIG. 7D shows a self-defense projectile 720 which has a synthetic body sleeve 722 and an exposed round-tipped metal core 724 having a single groove-seated o-ring 726. FIG. 7E shows another self-defense projectile 728, this one having a synthetic body sleeve 730, an exposed flat sinter tip metal core 732, and a single groove-seated o-ring 734. Finally, FIG. 7F shows still another self-defense projectile 736 which has a synthetic sleeve 738, an exposed pointed stinger metal core 740, and a single groove-seated o-ring 742.

[0054] Some of the configurations that the primer housing inserts of the present invention can have are illustrated in FIGS. 8A-8F as longitudinal centerline cross-sectional views. Note that in these figures when propellant is shown, for clarity it is depicted in the form of a floating stylized pellet. Propellant can be in the form of loose powder or as one or more pellets or as a combination of loose powder and pellets. FIG. 8A shows a synthetic body primer housing insert 800 having the configuration already described above for the primer housing insert 206. It includes threads 802, a post 804, a primer 806, and a tapered-to-straight passageway 808. FIG. 8B shows a metal body primer housing insert 810 which has a propellant pellet 812 in its passageway 814 and a plug 816 closing the discharge end of the passageway 814. FIG. 8C shows a two-piece primer housing insert 818 which has a synthetic outer body 820 and a metal liner 822. The primer housing insert 818 is the same as the two-piece primer housing insert 306, except that instead of having a crimped end to its passageway 824, the passageway 824 is sealed with a plug 826. FIG. 8D shows a two-piece primer housing insert 828 which is the same as the two-piece primer housing insert 306. FIG. 8E shows another a two-piece primer housing insert 830 which differs from the two-piece primer housing inserts 818, 828 in three principal respects. First, the post 832 of its outer body 834 has a thinner wall than those of the other two primer housing inserts 818, 828. Second, its passageway 836 is wider than those of the other two primer housing inserts 818, 828 allowing it to contain more propellant 838. Third, instead of using crimping or a plug to close the discharge end of its passageway 836, the primer housing insert 830 uses a thin film 840 for that purpose. FIG. 8F shows another two-piece primer housing insert 842. Primer housing insert 842 is the same as the primer housing insert 830, except that the discharge end of its passageway 844 has a crimped closure 846.

[0055] It is to be understood that although some features are described above as part of the description of one or another embodiment of the present invention, the present invention includes adapting the features shown on one embodiment for use on other embodiments. For example, some embodiments described using one or more o-rings to interconnect a projectile to a case while others described using one or more pressure bands for that purpose. The present invention contemplates embodiments which use one or the other or both of those means for interconnecting the projectile and case.

[0056] It is also to be understood that it is preferred that all of the components of the modular cartridges of the present invention be made of materials which are environmentally friendly. Nonetheless, the inventor understands that environmentally friendly materials may not be available or affordable under some circumstances and so includes within the scope of the present invention the use of any and all types of materials which are fit on an engineering basis for use in the modular cartridges having the components described herein.

[0057] It is also to be understood that any size and kind of primer and propellant that is otherwise suitable for use in a particular small arm may be used in the construction and use of the modular cartridges of the present invention. Also, although only center-fire cartridges are described above, rim-fire cartridges are also within the scope of the present invention and may be constructed by adapting the primer-receiving cavity and the passageway to be sufficiently off-center, at least at the striking end of the cartridge, for the firing pin of the small arm to fire the rimfire primer. Of course, if a particular small arm is adapted for use with both centerfire and rimfire cartridges, then either a centered location or an off-centered location for the rimfire primer may be used.

[0058] Cases for use with modular cartridges of the present invention are preferably made from a synthetic material or a metal that is suitable for the pressures and handling that the cartridges are expected to encounter as well as providing a suitable atmospheric seal for avoiding any undesirable degradation of any propellant that the cartridge is to contain.

[0059] At the time of the writing of this document, there are well over 500 different kinds of small firearm cartridges, most adapted to fit only the breech chamber of one particular small firearm. The present invention includes modular cartridges adapted for use in all existing small firearms as well as those small firearms that may be later developed. The modular cartridge system allows any particular firearm, the mixing and matching of primer housing inserts and projectiles with the cases adapted for use of that particular firearm, thus greatly simplifying stocking of ammunition. Accordingly, it is to be understood that the present invention includes within its scope systems and methods of operating the systems which include the provision and/or assembly and/or the disassembly of the components of the modular cartridges described herein.

[0060] A preferred method of using the modular cartridge system of the present invention is to provide a shooter with the case, the projectile or projectiles of his choice, and the primer housing inserts having the loading and design of his choice, and permitting the shooter to assemble the cartridge himself or herself. It is also within the scope of the present invention that the modular cartridges be provided already assembled to the shooter. In either circumstance, after firing the cartridge, the shooter may recover the projectile for reuse (except in embodiments wherein a single-use projectile was used or a reusuable projectile becomes lost) and remove the primer housing insert from the case and replace it with a fresh primer housing insert and insert into the case along with the original or a different projectile.

[0061] A primer housing insert may be reused by dislodging the spent primer from the primer-receiving cavity of the primer housing insert and replacing it with a fresh primer. If the primer housing insert was designed to hold propellant, the propellant may be replaced with the desired amount of fresh propellant which is safe for use in the particular primer housing insert and a suitable closure be made for the discharge end of the primer housing insert passageway. For safety reasons, it is preferred that the fired primer housing inserts be returned to a manufacturer for reconditioning, particularly those which include a propellant and even more particularly, those which used a crimped closure to contain the propellant.

[0062] It should be understood that although the modular cartridges of the present invention described above used a threaded connection for connecting the primer housing insert and the case, other means connections may be used. For example, a bayonet-type connector may be used, e.g., with the primer housing insert having one or more radially-extending projections which fit into complementary grooves of the case so that the primer housing may be seated by a combined rotating-thrust motion. Another connection means is the use of one or more releasable tab and slot combinations. A tab and slot combination optionally may also include the use of grooves for guiding the advance or withdrawal of the tab or tabs into or from the slot or slots. It is also to be understood that where threads are used as the connection means or as part of the connection means, the threads may be of the single-lead or of the multiple-lead type. An example of still another means of connection is shown in FIG. 9 which is a longitudinal centerline cross section of a third pistol cartridge 900 according to an embodiment of the present invention. The cartridge 900 comprises a projectile 902, a case 904, and a primer housing insert 906. The case 902 and the primer housing insert 906 are connected by way of o-rings 908a, 908b which are seated in complentary o-ring grooves in the case 904 and the primer housing insert 906.

[0063] It is also be understood although the primer housing inserts described above contain a discrete primer, it is within the present invention to seat within the primer housing inserts cartridge blanks which contain a primer. In such embodiments, the primer-receiving cavity and the passageway may be combined in whole or in part to accommodate the blank. Such blanks may also include a desired amount propellant.

[0064] It is to be understood that although the present invention is preferred for use with small arms, it is within the scope of the present invention that its modular cartridges described above be dimensionally configured for use with cartridges for larger weapons as well. Such cartridges would comprise a casing, a projectile, and a primer housing insert.

[0065] It is also to be understood that since the present invention is primarily concerned with providing reusable components, the projectiles are preferably designed for non-lethal uses. However, it is within the scope of the present invention for the modular cartridges to include single-use projectiles that are designed for lethal uses, e.g., those that are designed to expand upon impact. To be sure, it is to be understood that the present invention encompasses the adaptation of all types of projectiles—both recoverable and non-recoverable (including those of lethal design)—for use with the modular cartridges described above.

[0066] All patent applications and patents, both foreign and domestic, and all other publications referenced herein are incorporated herein in their entireties to the full extent permitted by law.