EP1348103A1

EP1348103A1 - Method of manufacture of powder-based firearm ammunition projectile employing electrostatic charge

Info

Publication number: EP1348103A1
Application number: EP01990262A
Authority: EP
Inventors: Harold F. Beal
Original assignee: Individual
Current assignee: Individual
Priority date: 2001-01-03
Filing date: 2001-12-31
Publication date: 2003-10-01
Also published as: CA2433638A1; CA2433638C; WO2002054008A1

Abstract

A first metal powder having a density greater than the density of lead is mixed with a second metal powder having a density not greater than the density of lead and a matrix micronized polymeric powder which is itself a poor electrical conductor but susceptible to accumulation of an electrostatic charge thereon during handling and/or transportation thereof. The mixing of these metal powders and the micronized polymeric powder is performed under conditions which maintain, promote or enhance the electrostatic environment within a mixing vessel with the result that the metal and non-metal powders become substantially uniformly distributed throughout the mixture, and retain their uniform distribution after removal from the mixing vessel, and carry forward such uniform distribution into and throughout subsequent conversion of the mixture into ammunition projectiles without the heavy and light metal powder particulates separating, according to their respective densities, into semi-layers or strata.

Description

METHOD OF MANUFACTURE OF A POWDER-BASED

FIREARM AMMUNITION PROJECTILE

EMPLOYING ELECTROSTATIC CHARGE

RELATED APPLICATIONS

[0001] This application is a non-provisional application based on Provisional Application Serial No. 60/259,566, filed January 3, 2001, entitled: METHOD FOR THE MANUFACTURE OF A POWDER-BASED FIREARM AMMUNITION PROJECTILE EMPLOYING ELECTROSTATIC CHARGE, and is a continuation-in-part of copending application of Serial No. 09/198,823, filed November 24, 1998, entitled: METHOD FOR THE MANUFACTURE OF A FRANGIBLE NONSINTERED POWDER-BASED PROJECTILE FOR USE IN GUN AMMUNITION AND PRODUCT OBTAINED THEREBY ; which is a continuation in part of Serial No. 08/922,129, filed August 28, 1997, entitled: PROJECTILE FOR AMMUNITION CARTRIDGE (now U.S. Pat. No. 5,847,313) (which is a continuation in part of Serial No. 08/792,578, filed January 30, 1997, entitled: PROJECTILE FOR AMMUNITION CARTRIDGE); Serial No. 08/843,450, filed April 16, 1997, entitled: SMALL BORE FRANGIBLE AMMUNITION PROJECTILE (abandoned) ; Serial No. 08/842,635, filed April 16, 1997, entitled: AMMUNITION PROJECTILE AND METHOD FOR MAKING SAME (abandoned ) ; Serial No. 08/888,270, Filed July 3, 1997, entitled: PLATED PROJECTILE FOR USE IN SUBSONIC AMMUNITION FOR SMALL-BORE SEMI-AUTOMATIC OR AUTOMATIC WEAPONS AND METHOD FOR MAKING SAME (abandoned ) ( (which is a continuation in part of applications Serial No. 08/843,450, filed April 16, 1897, entitled: SMALL BORE FRANGIBLE AMMUNITION PROJECTILE (abandoned), and Serial No. 08,815,003, filed March 14, 1997, entitled: SUBSONIC AMMUNITION, now U.S. Pat. No. 5,822,904, issued October 20, 1998)) ; and Serial No. 08/887,774, filed July 3, 1997, entitled: JACKETED PROJECTILE FOR USE IN SUBSONIC AMMUNITION FOR SMALL-BORE SEMI-AUTOMATIC OR AUTOMATIC WEAPONS AND METHOD FOR MAKING SAME (abandoned) ( which is a continuation in part of Serial No. 08/843,450 and 08/815,003 which are referenced hereinabove) . Priority is claimed based upon the foregoing referenced applications, and each of the foregoing applications in its entirety is incorporated herein by reference. 3 O 3 Φ 3 ≤ α Hi rt tr O -r c < -^r TJ Tl so. O __, o OJ 3 TJ Hi TJ i TJ T r-"! TJ CΛ 3^" 0J ι-^ *1

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apparatus employed in the mixing of metal powders in accordance with one aspect of the method of the present invention;

Figure 3 is a schematic representation of one embodiment of apparatus employed for die-forming a core in accordance with one aspect of the present invention

Figure 4 is a further schematic representation of the apparatus depicted in Figure 3 and showing a cold-pressed core following its removal from a forming die; and

Figure 5 is a representation, partly in section, of one embodiment of a firearm ammunition projectile produced by the method of the present invention.

SUMMARY OF INVENTION

[0008] In accordance with one embodiment of the method of the present invention, a first metal powder having a density greater than the density of lead is mixed with a second metal powder having a density not greater than the density of lead to provide a mixture of these powders. In accordance with one aspect of the present invention, there is simultaneously mixed with these metal powders a matrix micronized polymeric powder which is itself a poor electrical conductor but very susceptible to accumulation of an electrostatic charge during handling and/or transportation thereof. The mixing of these metal powders and the micronized polymeric powder is performed under conditions which maintain, promote or enhance the electrostatic environment within a blender, for example, with the result that the mixed metal and non-metal powders become substantially uniformly distributed throughout the mixture, and retain their uniform distribution after removal from the blender. In accordance with a further aspect of the present invention, this uniformity of distribution of the powder particles within the mixture carries forward into and throughout subsequent conversion of the mixture into ammunition projectiles without the heavy and light metal powder particulates separating, according to their respective densities, into semi-layers or strata, even when vibrated in the course of transfer of the mixed powders from the blender to a storage container, during the storage of the mixture, and/or during subsequent manufacturing steps involving the mixture. OJ o tr rt o 3 H- - TJ TJ QJ 3" (0. OJ 3 σ TJ σ rt T rt hi o Φ £ TJ 3 μ- rt 3 o rt TJ TJ

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distributed radially about the longitudinal axis of the completed projectile, and (h) recovery of the finished projectile.

[0011] Figures 3 and 4 schematically depict one embodiment of a die 12 for cold-pressing an aliquot 14 of the powder mixture into a self-supporting core 16 (see Figure 4). The depicted die 12 includes a die body 18 defining a die cavity 20 adapted to receive therein an aliquot of the powder mixture. The bottom end 22 of the die cavity is closed by a first punch 24. A second punch 26 is provided for insertion into the die cavity to compact the aliquot of powder into a core. After formation of the core, the second punch is withdrawn (see Figure 4) and the second punch is activated to push the pressed core out of the die.

[0012] Figure 2 depicts one suitable blender for use in the mixing the powders in accordance with the present invention. Preferably, the blender 40 employed in the present invention comprises a "V" shaped blender having a shell 42 of a polymeric, e.g. acrylic resin, material for a time sufficient to uniformly mix the metal powders and the polymeric powder into a mixture of substantially uniformly distributed metal and non-metal powder particles. The depicted blender comprises a frame 44 which rotatably supports the "V" shaped shell 42 therein. Rotation of the shell is effected by a motor (not shown) contained within a housing 48 also supported by the frame, as is well known in the art. Notably, the frame is electrically isolated as by insulative feet 50 (typical), such as rubber cushions.

[0013] Whereas the mechanism or mechanisms by which the uniformity of distribution of the two or more metal powders having different densities is initially developed and subsequently maintained during manufacturing operations is unknown with certainty, it has been found that in the absence of an electrostatic charge within the blender, when the mixture of removed from the blender, the heavy and light metal powders will deleteriously separate, by gravity according to their respective densities, into at least semi-layers strata of heavy metal powder and light metal powder. The magnitude of the electrostatic charge is known to be relatively small in that no physical "electrical shock or sparking" can be detected upon grounding of a quantity of the mixed powders. On the other hand, the powder mixture of the present invention exhibits clear indications of electrostatic interaction and/or a combination of electrostatic interaction and mechanical interaction 3 so CΛ OJ c OJ rt 3 tr £ XI rt O ■-• 3 TJ XI rt rt ft⁾ rt ■-. O o 3 3 hi o t φ ^* rt 3 tr Φ rt 3 Φ β μ- hi ι- O O SD (D hi £ - 3 tr o Hi 3 μ- 3 rt Φ 3 tr hh X φ SO o 3 ^' O < O 3 to o OJ 3 o rt H SD O Φ Φ o X X O Λ t < r rt o I-¹ hi Φ β TJ hi φ ^* μ- Φ 3 Φ rt < rt Φ O rt hi TJ CΛ rt β hi o hi rt Φ Φ 3 3 O U1 H μ- μ- 3 o 3" (O hi o (D rt μ- 3^* l-i μ- *• O hi SO rt 3 SO. TJ rt φ tr Φ rt μ- X! 3" O Φ φ σ 3 O μ- rt Φ o > rt CΛ TJ μ- 0J Φ rt Φ ft) Φ OJ Φ TJ O O (O M H¹ Φ Q⁾ Φ ^* o 3 rt 3 o so CΛ rt hi hi 3 ft⁾ rt CΛ hi £ XI Φ < 3 r

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core disposed therein, may be initially die-formed to define an ogive and thereafter the open end of the jacket may ne partly or fully closed to capture the core within the jacket. Commonly the jacket is formed of copper metal which also serves a lubricative function between the rifle barrel and the projectile.

[0024] Cores for projectiles of various caliber firearms may be made employing the method of the present invention, particularly 50 caliber and smaller firearms. The cores may be formed from various combinations of metal powders and various weight percentages of each of the metal powders. For example, in the method of the present invention, tungsten powder may be employed in weight percentages of between about 10% to about 99%. Other heavy metal powders such as uranium, tantalum, or combinations of such metal powders or their carbides may be employed. Similarly, tin, zinc, bismuth, aluminum, copper and/or combinations of these lighter metal powders, in amounts from 90% to about 3%, by wt . , may be employed. In all instances, between about 0.01% and about 1.5%, by wt . of a micronized polyethylene non-metal powder, such as Acumist 12 available from Allied Signal Advanced Materials of Morristown, NJ, or like non-metal micronized polymeric powder, need be included in the mixture.

[0025] Whereas the present invention has been described in considerable detail for purposes of teaching one skilled in the art how to carry out the invention, it will be recognized by such person skilled in the art that the concepts of the present invention may be carried out employing not significantly different apparatus and/or operational parameters. Optionally, the method may include additional steps, depending upon the desired characteristics of the resultant projectile, such as the incorporation of additional components, such as a cap at the leading end, and internally of, the jacket. Further, multiple cores may be included within a single jacket. Other modifications and alternatives will be recognized by one skilled in the art.

Claims

WHAT IS CLAIMED:

Claim 1. A method of producing a mixture of at least two metal powders comprising the steps of

introducing into a mixing vessel a first metal powder having a density greater than the density of lead,

introducing into said mixing vessel a second metal powder having a density not greater than the density of lead;

introducing into said mixing vessel a micronized polymeric powder;

mixing said powders within said mixing vessel in an electrostatic environment for a time sufficient to produce a mixture within which at least said first and second metal powders are substantially uniformly mixed throughout said mixture and stabilized against separation of said first and second metal powders, by gravity, as a function of their respective densities.

Claim 2. The method of Claim 1 wherein at least said first and second metal powders of said mixture do not separate into semi- layers or strata subsequent to the removal of said mixture from said mixing vessel and during subsequent manufacturing operations directed to the die pressing of aliquots of said mixture into self- supporting compacts.

Claim 3. The method of Claim 1 wherein said micronized polymeric powder carries an electrostatic charge.

Claim 4. The method of Claim 1 wherein said micronized polymeric powder comprises a polyolefin powder.

Claim 5. The method of Claim 4 wherein said micronized polyolefin powder comprises micronized polyethylene powder.

Claim 6. The method of Claim 1 wherein said micronized polymeric powder is present in said mixture at a quantity of between about 0.01% and about 1.5%, by weight, based upon the total weight of said first and second metal powders.

Claim 7. The method of Claim 6 wherein said micronized polymeric powder is present in said mixture at a quantity of not greater than 1.5% and not less than 0.01%, by weight, based upon the total weight of said first and second powders.

Claim 8. The method of Claim 1 wherein said powders are mixed in a "V" blender.

Claim 9. The method of Claim 1 wherein said micronized polymeric powder comprises micronized oxidized polyethylene powder having an average particle size of between about 6 and about 18 microns .

Claim 10. The method of Claim 9 wherein said micronized polymeric powder is of an average particle size of about 12 microns.

Claim 11. The method of Claim 9 wherein said micronized polymeric powder has a density of about 0.99 g/cc.

Claim 12. The method of Claim 9 wherein said micronized polymeric powder carries an electrostatic charge at least while in said mixing vessel.

Claim 13. The method of Claim 2 wherein said micronized polymeric powder remains within said mixture throughout the conversion of aliquots of said mixture into one or more die-pressed self-supporting compacts.

Claim 14. A method of producing a powder-based core for a gun ammunition projectile comprising the steps of introducing into a mixing vessel a first metal powder having a density greater than the density of lead,

introducing into said mixing vessel a micronized polymeric powder;

mixing said powders within said mixing vessel in an electrostatic environment for a time sufficient to produce a mixture within which at least said first and second metal powders are substantially uniformly mixed throughout said mixture and stabilized against separation of said first and second metal powders, by gravity, as a function of their respective densities, dividing said mixture into individual aliquots and die-pressed each of said aliquots, at room temperature and without removal of said micronized polymeric powder from said mixture, into individual self-supporting compacts.

Claim 15. The method of Claim 14 wherein said first metal powder is chosen from a group comprising tungsten, uranium, tantalum, or carbides thereof, and/or combinations thereof, and said second metal powder is chosen from a group comprising tin, zinc, magnesium, iron, copper, bismuth or combinations or alloys thereof.

Claim 16. The method of Claim 14 wherein said micronized polymeric powder comprises polyethylene powder having a density of about 0.99 g/cc and an average particle size of about 12 microns.

Claim 17. The method of Claim 14 wherein said micronized polymeric powder is present in said mixture at between 0.01% and 1.5%, by weight, based upon the total weight of said first and second metal powders present in said mixture.

Claim 18. A powder mixture suitable for conversion by die- pressing at room temperature into a self=supporting core for a projectile for gun ammunition comprising

a first metal powder having a density greater than the density of lead,

a second metal powder having a density not greater than the density of lead, and

a micronized polymeric powder carrying an electrostatic charge,

at least said metal powders being substantially uniformly distributed throughout said mixture and stabilized against separation thereof, by gravity and as a function their respective densities, during conversion of said mixture into individual die- pressed cores at room temperature.

Claim 19. The mixture of Claim 18 wherein said first metal powder is tungsten, said second metal powder is tin or zinc, and said micronized polymeric powder is polyethylene powder having a density of about 0.99 g/cc and an average particle size of about 12 microns .

Claim 20. The mixture of Claim 19 wherein said polyethylene powder is present in said mixture at a quantity of between 0.01% and 1.5%, by weight, based on the total weight said first and second metal powders within said mixture.