US20200141706A1

US20200141706A1 - Small-arms ammunition with non-brass casing and non-lead projectile

Info

Publication number: US20200141706A1
Application number: US16/716,571
Authority: US
Inventors: Roy Stephen FOX
Original assignee: Timberghost Tactical LLC
Current assignee: Timberghost Tactical LLC
Priority date: 2017-07-27
Filing date: 2019-12-17
Publication date: 2020-05-07

Abstract

A small arms ammunition round comprises a non-brass casing comprising stainless steel and a non-lead projectile housed within the casing, the non-lead projectile comprising a matrix of at least one epoxy, at least one non-epoxy polymer, and copper. The casing includes a stainless steel shell housing and an aluminum (or stainless steel) primer housing which are press-fit together. The projectile has a tapered nose with spiral flutes.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. Non-Provisional patent application Ser. No. 16/046,307 filed Jul. 26, 2018; which claims priority benefit of U.S. Provisional Patent Application Ser. No. 62/537,632 filed Jul. 27, 2017, the entirety of which is hereby incorporated herein by reference.

BACKGROUND

Typical ammunition for rifles and handguns consists of a generally tubular brass shell casing bearing a lead bullet, with the tubular casing housing a percussion-responsive cap (primer) and a propellant charge disposed within the casing between the primer and the bullet. The desire for simplicity in manufacture, long shelf life, dimensional stability, and other factors, has led to widespread adoption of brass as the casing material and lead as the projectile.
Published EP patent application WO1983000213A1 of Palcher describes the use of polymeric materials in making the casing. The application even describes the possibility that the bullet (the projectile) itself can be partially formed of a polymeric material. The Palcher application describes that the conventional brass shell is rigid and hard, its side wall is very thin, and the whole is relatively inelastic. The Palcher application describes that the disclosed shell casings are fabricated with polymeric materials that exhibit high degrees of elongation, relatively high degrees of flexibility, and have different shapes.
The Palcher application describes that the preferred casing material is a polymer, being a thermoplastic rather than a thermosetting polymer, which has a high strength and is heat and flame resistant. In particular, the Palcher application describes that preferred casing materials are polysulfone, polyimide-amide and polyethylene sulfone.
U.S. Pat. No. 9,939,236 of Drobockyi et al discloses an alternative casing for use in a cartridge for a firearm, in which the casing comprises a sleeve and an attached base made of stainless steel. The sleeve is formed with a mouth for holding a bullet and an opposing bulkhead from which extends a nipple. The end of the nipple is flared radially outwardly within a passageway of the base, to form a special configuration lip and first seal. The nipple is shaped to make a second seal when press fitted into the passageway. A bulkhead is formed with a circumferential wave or ridge. The '236 Patent describes that the sleeve preferably is made from austenitic stainless steel that is worked to have differential hardness and magnetic properties along the sleeve length, with the nipple being of lesser hardness.
The Palcher application and the '236 Patent of Drobockyi et al address different problems in the field of firearms and each has their own technical hurdles to overcome in addressing those different problems. Indeed, as noted in Palcher, this is not a mere substitution of physical materials. The brass shell is rigid and hard. Its side wall is very thin, and the whole is relatively inelastic. Shell casings, according to the Palcher's disclosure, are fabricated with polymeric materials that exhibit high degrees of elongation without failure, relatively high degrees of flexibility, and different shapes as compared to the traditional brass casing. Similarly, various changes in the design of the shell are needed to make the stainless steel shell (casing) of the '236 Patent of Drobockyi workable.

SUMMARY OF THE INVENTION

In a first preferred example form, the present invention comprises a small arms ammunition round having a non-brass casing and a non-lead projectile housed within the casing. Preferably, the non-brass casing includes stainless steel and the non-lead projectile includes a matrix of at least one epoxy, at least one non-epoxy polymer, and copper.
Preferably, the casing comprises a stainless steel shell housing and an aluminum primer housing which are press-fit together.
Also optionally, the projectile has a tapered nose with spiral flutes.
In a second preferred example form, the present invention comprises a small arms ammunition round having a non-brass casing and a non-lead projectile housed within the casing.
Preferably, the non-brass casing comprises a stainless steel casing. Preferably, the non-brass casing also comprises an aluminum casing. Most preferably, the stainless steel casing is for housing the projectile and the aluminum casing is for housing a primer, with the stainless steel casing and the aluminum casing being press-fit together.
Also optionally, the projectile has a tapered nose with spiral flutes.
Optionally, the primer base could also be made of stainless steel, such as a 416 stainless steel alloy, for example.
Also optionally, the projectile can be constructed with hBN (hexagonal Boron Nitride) powder to achieve a poly/molded projectile. This ultra-fine hBN powder acts as a friction-reduction agent when applied, through an optional steel/ceramic shot vibration/shot peening process, into the pores of the projectile. The use of hBN powder can provide multiple advantages in this application, including: reduced friction between the projectile and the barrel rifling, thus decreasing pressure, reducing barrel wear, increasing velocity, improving accuracy and minimizing the extreme velocity spread between many rounds.
With these constructions, a novel small arms round is provided, including an all stainless steel/aluminum cased, polycarbonate/copper tipped, high-performance cartridge. The resulting round is lightweight and exhibits high performance. For example, the novel small arms rounds/cartridges reduce weight compared to heavy traditional ammo by as much as 30-60%. Moreover, the projectiles exhibit a velocity increase of about 15-30% over conventional rounds, and reduce recoil by 10-25%. Advantageously, the novel rounds eliminate lead and copper fouling in the gun barrels.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

FIG. 1 is a schematic plan view of a small arms round including a non-brass shell casing and a non-lead projectile according to an example form of the present invention.

FIG. 2 is a schematic plan view of a non-lead projectile portion of the small arms round of FIG. 1.

FIG. 3 is a schematic end view of a non-lead projectile portion of the small arms round of FIG. 1.

FIG. 4 is a schematic perspective view of a small arms round including a non-lead projectile portion in an alternate example form of the present invention.

DETAILED DESCRIPTION OF THE EXAMPLE EMBODIMENTS

FIG. 1 shows an example embodiment of a small arms round according to one form of the present invention. The example small arms ammunition round 100 shown in FIG. 1 includes a non-brass casing 110 and a non-lead projectile 150 housed within the casing. Preferably, the non-brass casing 110 includes stainless steel and the non-lead projectile 150 includes a matrix of at least one epoxy, at least one non-epoxy polymer, and copper. Optionally, the non-epoxy polymer can include nylon (either entirely or as a component thereof). Preferably, the casing 110 comprises a stainless steel shell housing 111 and an aluminum primer housing 112 which are press-fit together adjacent joint 115.
Also preferably, the projectile has a tapered nose with spiral flutes. As generally described in published US Patent Application Number 20160231093 of Lemke, the projectile 150 has an outer geometry comprising several notches 152-154 extending in a longitudinal direction (i.e., axial direction). Notches 152-154 are present in a number equal to or greater than two and preferably are disposed in such a manner as to avoid an imbalance of the rotation of projectile 150 about its dissecting axis, which could cause a deviation of a flight path 159. In some embodiments, the number of notches is three. However, the number of notches can be four or another quantity.
As further shown in FIG. 1, exemplary projectile 150 has a notch configuration that increases an outer surface area of the end portion 155 of projectile 150. Each notch 152-154 can comprise a first notch surface portion in combination with a second notch surface portion (which can be a spherical surface). The spherical surface portion makes the notched projectile structurally stronger so that when projectile 150 hits a soft element, it avoids the formation and propagation of cracks which would tend to cause it to decompose into small fragments.
In some embodiments, projectile 150 can be manufactured by injection molding a polymeric material (e.g., a polyamide) filled with metal particles. In some embodiments, projectile 150 can be manufactured by sintering and/or machining with or without electrochemical coating. Preferably, in some embodiments, projectile 150 is manufactured with a base material that will not deform easily upon impact and decompose into fragments upon impact, such as a violent impact against a hard surface, to ensure that it remains a frangible projectile 150 by definition.
As shown in FIG. 2, in some embodiments of the present invention, projectile 150 travels after a shot, making a trajectory 159 with a rotational movement 160 along axis of projectile 150 so as to ensure stability during flight. On impact, energy of projectile 150 makes projectile 150 decompose into fragments, which are thrown in various directions, such as directions 161, 162, 163, producing only a small damaged area on a hard surface. The production of such fragments prevents projectile 150 from ricocheting uncontrollably and reaching an unintended target.
The novel projectile has a degree of “engineered frangibility” which by design means that it will penetrate most “hard surfaces” such as a thin metal car door, an automotive windshield, wood, a tree trunk of modest size, building walls of drywall and wood studs, even mild steel plate (although the windshield and mild steel plate will cause deformation of the nose of the projectile to some degree). When the projectile encounters these types of somewhat “hard surfaces”, it tends to retain its rotation and its shape (except as noted) and tends to penetrate in a manner similar to a normal projectile. These are “hard surfaces”, but can be penetrated by small arms fire to some degree.
There are other “hard surfaces” which are more impenetrable to small arms fire. Examples of such include hardened steel competition targets, concrete walls, sidewalks, stone, heavy cast iron, thick steel plating, thick bullet-proof glass, and similar materials, which are generally impenetrable to small arms fire. When the projectile encounters these truly “hardened surfaces”, typically it then loses its rotational momentum and all penetration quickly halts, as the projectile fragments into many tiny particles.
In some embodiments of the present invention, as projectile 150 travels along path 159 and, at the same time, it undergoes a rotational movement 160 around axis of projectile 150 to ensure stability during flight. Upon impact on a relatively soft target, penetration occurs due to the projectile velocity and dampening of the rotational movement. Dampening is due to the effect of the soft element resistance cut by notches 152, 153, 154 of projectile 150 more or less acting as if it were a drill. Dampening tends to cause an increase in resistance of projectile 150 and an increase in the amount of damaged tissue, increasing the amount of transmitted energy (i.e., kinetic and rotational) and the size of the damaged area in the form of a temporary cavity.
In some embodiments, the rear or bottom of projectile 150, opposite the tip 158 in the longitudinal direction, can have a slightly conical geometry, also called a “boat tail”, to increase the aerodynamics of projectile 150.
In a second preferred example form, the present invention comprises a small arms ammunition round having a non-brass casing and a non-lead projectile housed within the casing.
Preferably, the non-brass casing comprises at least a stainless steel casing portion. Preferably, the non-brass casing also comprises an aluminum casing portion. Most preferably, the stainless steel casing is provided for housing the projectile and the aluminum casing is provided for housing a primer, with the stainless steel casing portion and the aluminum casing portion being press-fit together. Also preferably, the projectile has a tapered nose with spiral flutes.
FIG. 4 shows an alternative form of the present invention. The example small arms ammunition round 400 shown in FIG. 4 includes a non-brass casing 410 including a stainless steel projectile housing portion 411 and an aluminum primer housing portion 412 which are press-fit together adjacent joint 415. A non-lead projectile 450 is housed within the casing (within projectile housing portion 411). Preferably, the non-brass casing portion 410 includes a stainless steel portion and the non-lead projectile 450 includes a matrix of at least one epoxy, at least one non-epoxy polymer, and copper. Optionally, the non-epoxy polymer can include nylon (either entirely or as a component thereof). Optionally, the nose portion 452 of the projectile 450 is smoothly tapered and does not bear the spiral flutes of the previous example.
With these constructions, a novel small arms round is provided, including an all stainless steel/aluminum cased, polycarbonate/copper tipped, high-performance cartridge. The resulting round is lightweight and exhibits high performance. For example, the novel small arms rounds/cartridges reduce weight compared to heavy traditional ammo by as much as 30-60%. Moreover, the projectiles exhibit a velocity increase of about 15-30% over conventional rounds, and reduce recoil by 10-25%. This increase in velocity is believed to be due to the lighter weight (lower mass) being accelerated by comparably similar forces developed by the similar amounts of gunpowder contained in the casings. Advantageously, the novel rounds eliminate lead and copper fouling in the gun barrels.
Advantageously, the present invention provides a substantial weight savings per round, which can be extremely beneficial in military applications. For example, a soldier that carries 200 rounds of 5.56 mm ammunition into battle at a weight of about 5.2 lbs can obviously carry a limited supply of ammunition. The present invention allows the soldier to carry the same number of rounds at half the weight or carry the same weight but twice the amount of ammunition (twice the number of rounds). Carrying twice the number of rounds can mean the difference between life and death in that the additional rounds can significantly extend the soldier's ability to fight.
Moreover, police often must carry a certain volume of ammo on their person. The average 45 ACP with 230 grain bullet weighs 325 grains, 20.9 grams, or 0.7 ounces. If required to carry 9 cartridges in the gun and two extra clips, the total weight is 1 lb, 3 oz of bullet weight. However, if the same policeman was carrying the novel ammunition according to the present invention, with its sleek, lightweight stainless steel and aluminum casing and the projectile, total cartridge weight would be 8.4 oz., a weight savings of 55%.
Also, military armory engineers have been trying to develop a load for both .223 and .308 calibers that will shoot with deadly force up to 300 yards and then die out quickly after that range, thereby reducing down-range liability. Up until now, they have not been able to find a satisfactory load to perform in such a manner. The present invention addresses this need as well.
Also, U.S. military and many law enforcement agencies have a minimum Power Factor (PF) (similar to KE—Kinetic Energy) for all ammunition in service or issue. That minimum PF is 125. Known frangible bullets typically cannot meet PF minimum requirements, with most known testing falling below the minimum PF of 125. It is believed that the present invention with a more efficient casing and effective projectile will achieve PF of greater than 125.
Optionally, the aluminum casing portion can be pure aluminum or can be an aluminum alloy. For example, advantageously, the aluminum alloy casing can comprise 7075 aluminum alloy. Also, the aluminum alloy casing can comprise 7068 aluminum alloy. Those skilled in the art will appreciate that other aluminum alloys or pure or nearly pure aluminum can be employed, as selected by the skilled designer.
Optionally, the non-lead matrix (Poly/Copper Matrix) can comprise one or more of the following materials: polymers; epoxies; nylon; copper particles; tungsten particles; depleted uranium; and/or other armor-piercing “heavy” metals and materials.
Optionally, the stainless steel non-brass casing (the stainless steel casing portion) can comprise one or more of: stainless steel; high nickel content stainless steel; high chromium stainless steel; and/or other non-brass metals and materials.
Optionally, the aluminum primer portion of the non-brass casing can comprise one or more of: aluminum; hardened aluminum; aircraft-grade 7XXX Series aluminum alloy(s) (zinc is a primary alloying agent for this series, and when magnesium is added in a smaller amount, the result is a heat-treatable, very high strength alloy. Other elements such as copper and chromium may also be added in small quantities. The most commonly known alloys are 7050 and 7075, which are widely used in the aircraft industry.) The aluminum could also be a more or less pure aluminum which is then nickel plated. The aluminum could also be replaced with other non-brass materials, such as chromium molybnium which is nickel plated; mild steel which is nickel plated; and stainless steel. Note that nickel plating of non-stainless steel base materials is performed to prevent electrolysis of dissimilar metals.
In an example commercial embodiment actually constructed and tested, the non-lead matrix (Poly/Copper Matrix) comprises 80% powdered copper, 20% polymer, epoxy and nylon. In that same example commercial embodiment actually constructed and tested, the stainless steel non-brass casing portion comprises a 316 grade of stainless steel. Further, in that same example commercial embodiment actually constructed and tested, the aluminum primer portion comprises 7078 aerospace grade aluminum alloy.
Optionally, the molded projectile could be made with an insert of a base material made of a solid, non-fragmenting material. In this case, a type of a “hybrid” frangible projectile could be provided, with an armor-piercing core or insert made of tungsten or depleted uranium, or other hardened or “heavy” metals and materials.
Optionally, the novel casing and projectile can be combined with hydrophilic lead-free primers. Such would result in an entirely lead-free ammunition, including the primer. As can be appreciated, the conventional ignition material contained in traditional primers contains lead and represents a serious environmental concern.

Example Calibers

The present invention can be provided in a variety of small arms calibers, including:
9 mm Luger (9×19 mm)
.22 LR
.22 WMR
.380 Auto
38 Special
.357 Sig
.357 Magnum
.40 S&W
10 MM
.45 ACP
4.6 mm×30 mm
5.56 mm/.223R
6.5 mm Grendel
6.5 Creedmoor
6.8 mmR
.300 AAC B/O
7.62../.308W
.30-06 Sgfd.
.338 Lapua
.338 Norma
.50 BMG
.50 Russian
20 MM A/A (Anti-Aircraft)
30 MM A/A
Testing, Generally:
The novel ammunition has completed the approval process of the novel 9 mm Engagement Extreme (EE) and 9 mm Cross Trainer (CT) ammunition. This testing included shooting 11,400 cartridges of the novel 9 mm EE and 11,600 cartridges of the novel 9 mm CT through a total of 18 pistols and 8 shooters. The shooters represented a range of consumers including experienced and inexperienced men and women of varying ages. The novel 9 mm EE passed with an overall pass rate of 99.96% and the novel 9 mm CT passed with an overall pass rate of 99.96%, as well.
The ammunition passed the Pressure and Velocity threshold testing. After 100 cartridges, the novel 9 mm EE recorded an average velocity of 1,552 FPS with a SD of 11 and ES of 40 FPS. The novel 9 mm CT recorded an average pressure of 37,541 PSI with a SD of 811 and ES of 3,837 PSI. After 100 cartridges, the novel 9 mm EE recorded an average velocity of 1,575 FPS with a SD of 11 and ES of 42 FPS. The novel 9 mm EE recorded an average pressure of 36,740 PSI with a SD of 816 and ES of 3,338 PSI.
Pressure and Velocity Testing:
Pressure:
A testing standard for pressure is that the pressure should not exceed a Maximum Probably Sample Mean (MPSM) and also should not exceed Maximum Extreme Variation (MEV). As defined by the Sporting Arms and Ammunition Manufacturer's Institute (SAAMI), the MPSM for standard pressure 9 mm Luger is 37,800 PSI. The novel 9 mm CT averaged 37,541 PSI and the novel 9 mm EE averaged 36,740 PSI, which is below the MPSM. The MEV is defined by SAAMI as 5.16 times the standard deviation of the sample. MEV for the novel 9 mm CT is calculated to be 4,189 PSI, but our ES was 3,837 PSI. The MEV for the novel 9 mm EE is calculated to be 4,211 PSI, but our ES was 3,338 PSI. Both standards of MPSM and MEV were met.
Velocity:
A testing standard for velocity is that the velocity should not vary more than 5% of the mean. 5% of the average velocity for the novel 9 mm CT is 78 FPS and for the novel 9 mm EE is 79 FPS. The tested extreme spreads for velocity were 40 and 42, respectively.
Accuracy Testing:
A testing standard for accuracy is that the ammunition must be capable of grouping five consecutive shots in a group 6″ or less at 25 yards, from a rest with optical magnification allowed.
Weapon Used:
The test weapon used was an STI DVC Open chambered in 9 mm. This pistol has a 5.4″ barrel and has mounted C-More 6MOA Dot Sight. This gun was chosen due to the sight and ease of aim.
Set Up:
At a local shooting range, targets were mounted to shoot out to 25 yards. We used the STI DVC Open, and the range tray as a rest (resting the bottom of the magazine on the tray with no muzzle support). Five consecutive shots were then fired.
Results:
Using the STI DVC Open, we were able to obtain a 3¼″ group with the novel 9 mm CT and a 1¼″ group with the novel 9 mm EE. The novel 9 mm+P EE came in with a 1⅞″ group and the novel 9 mm+P CT shot a 3⅙″ group. The accuracy of these cartridges passes the standard.
Function/Jury Testing:
A testing standard for Function/Jury Testing is that for each new product, a minimum of 10,000 cartridges is to be shot, through a minimum of ten weapons, with at least 6 testers/jurors. To meet the standard, the overall pass rate must be at or above 99.83%. Shooters are to be representative of the typical consumer, ranging from inexperienced men and women, to experienced men and women of varying sizes. Shooters are to shoot from four positions, for a total of 200 cartridges per shooter (50 per position). We used a total of eight jurors and a total of 18 pistols.
Positions (CT & EE):
50 Cartridges two handed, arms extended; 50 Cartridges two handed, arms slightly bent; 50 Cartridges one handed, strong hand; 50 Cartridges one handed, weak hand.
Results:
A total of 11,600 cartridges of the novel 9 mm CT were fired. In those cartridges, there were a total of five failures. No one gun had more than one failure. This gives a 99.96% pass rate.
A total of 11,400 cartridges of the novel 9 mm EE were fired. In those cartridges, there were a total of five failures. No one gun had more than one failure. This gives a 99.96% pass rate.
Ballistic Gel Testing:
Various examples of the novel ammunition were tested in gel, including the novel 9 mm CT, the novel 9 mm EE, the novel 9 mm+P CT, and the novel 9 mm+P EE, all through bare 10% Ballistic Ordinance Gelatin. The novel 9 mm+P EE ammunition was then tested through two intermediate barriers—6061 T6 Aluminum and car windshield. The aluminum was positioned 10″ in front of the gel. The windshield was positioned 10″ in front of the gel at a compound angle.
Results:
The novel 9 mm EE—Bare Gel obtained 16¾″ of penetration, with 3″ in diameter cavitation, and 100% weight retention (no fragmentation).
The novel 9 mm CT—Bare Gel obtained 19¼″ of penetration, 1⅞″ in diameter cavitation, and 100% weight retention (no fragmentation).
The novel 9 mm EE+P—Bare Gel obtained 16¾″ of penetration, 3¾″ in diameter cavitation, and 100% Weight retention (no fragmentation).
The novel 9 mm CT+P—Bare Gel obtained 19¼″ of penetration, approximately 2″ in diameter cavitation, and 100% Weight retention (no fragmentation).
The novel 9 mm EE+P—6061 T6 Aluminum obtained 13¾″ of penetration, approximately 3″ in diameter cavitation, and 91% Weight retention (some fragmentation).
The novel 9 mm EE+P—Car Windshield obtained 12¼″ of penetration, approximately 1¾″ in diameter cavitation, and 70.5% Weight retention (fragmentation). Note: While shooting the windshield, it is possible to shoot through the same hole, or a weakened area of the windshield of glass and the bullet does not fragment.
Testing Summary:
After firing a total of 23,000 cartridges, with 18 pistols, and 8 shooters, the novel 9 mm CT and the novel 9 mm EE successfully passed the jury test. Between the two tested cartridges, there was an overall pass rate of 99.9565% pass rate. This ammunition has also passed the consistency and accuracy standards. These both are solid cartridges.
The novel ammunition described herein provides high performance in part due to elimination of the brass shell. Brass, because of its soft, malleable nature, absorbs a significant amount of energy at the time of the round being fired. The thick brass case walls and shell base stretch and expand, resulting in somewhat compromised velocity. The novel stainless steel case, being less prone to stretching and deforming, and exhibiting superior hardness and having a greater modulus of elasticity, does not absorb nearly as much energy from the shot, resulting in more energy pushing the projectile and much higher velocities without increased pressures.
As described herein, the novel ammunition achieves a synergistic advantageous result. For example, if a standard 5.56/223 brass case is charged with a maximum amount of gunpowder (SAAMI max psi) and the 35 gr poly/copper projectile is loaded, the 35 gr bullet produces 3810 fps out of a test receiver rifle. That is what testing revealed.
Now, the novel ammunition, charged with the identical type and weight of gunpowder, loaded with the same 35 gr poly/copper bullet, achieves a significant improvement in performance. Using the same test gun, the same gunpowder, everything as identical as can be achieved—the novel ammunition fires at a speed of 4120 fps with slightly less pressure. This is an increase of 310 fps, which is more than an 8% increase in performance gained from superior cartridge components, while using the same gunpowder. An 8% increase is very significant.
As is well known in the art, to achieve a performance of about 2% in increased velocity usually requires a “magnum” version of ammo (greater gunpowder load). Example: 30-06 Sgfd shoots a 180 grain bullet at 2810 fps. But the venerable 300WSM shoots the same bullet at 3090 fps, an increase of 280 fps or 9% increase in velocity.
The novel ammunition achieves this performance increase with the same caliber, same powder, same bullet (projectile mass) and same gun, achieving 8% improvement in velocity performance.
The present invention combines various disparate technologies to achieve an all stainless steel/aluminum cased, polycarbonate/copper tipped, high-performance cartridge (small arms round). Notably, in example forms, the present invention accomplishes one or more of the following: (1) replaces brass shells with stainless steel and/or aluminum; (2) replaces lead-core copper-plated bullets (projectiles) with matrix projectiles, such as polycarbonate bullets; (3) employs fluid dynamics (ARX) instead of hydrostatic shock (mushroomed, fragmented, shrapnel lead); (4) achieves lightweight hi-performance cartridges that reduce weight compared to heavy traditional ammo, saving as much as 30-60% in weight; (5) increases projectile velocity 15-30%; (6) reduces recoil 10-25%; and (7) eliminates lead and copper fouling in gun barrels, and in the air.

Additional Considerations

When making a shell casing of stainless steel, the stainless steel is harder, stiffer and less malleable than commonly used brass. This can cause unexpected problems when attempting to flare the case mouth as is a common practice in preparation to load a brass pistol case. First of all, the stainless steel case mouth can be more difficult to flare or “bell” in the traditional manner.
Once the case mouth is flared to accommodate loading the projectile into the case, it has been found that it can be very difficult to finish the case into a crimp that is smooth and professional looking. In order to smooth out the flare, a significant crimp may be required. In a Poly/Copper cast or molded bullet, the crimping can often result in a hairline fracture in the poly/copper projectile, which can cause the projectile to break off flush with the crimp line at the case mouth during loading and/or firing mode. This difficulty was overcome by a newly-developed loading method. In this new loading method, first, the stainless steel case mouth is not belled or flared, but left straight-walled. To insert the projectile into the case without a flare typically requires precision alignment and very tight tolerances.
5. Additionally, almost all loading information heretofore has been based upon a substantially crimped bullet. Without a crimp, case mouth tension alone can greatly affect internal cartridge pressure and desired velocity. This crimpless design led the inventors to develop some completely new and unique ballistic loading data. The inventors in the end settled on the use of non-customary powder types with faster burning rates not usually associated with cartridges.
Another unforeseen problem was the use of 6061 and 7075 aluminum alloys for the base of the two-piece case. As rifle caliber cases were developed, several problems emerged which led the inventors to switch to a chrome molybdenum steel base component. While this steel alloy is relatively expensive, the chrome moly steel accommodates higher operating pressures of rifle calibers. Various other types of stainless steel can work well for the base as well.
The steel base, being considerably stronger than aluminum alloy, made it possible and/or feasible to cut a deeper extractor groove into the shell base. This feature has been found to be especially beneficial when firing full-auto fire military weapons and belt-fed weapons.
Ideally, a stainless steel should be chosen that is soft enough to stamp-form into a rifle casing, yet hard enough and strong enough to withstand the high pressures of a rifle cartridge. Finally, a custom, proprietary stainless steel similar to 316 stainless, with a 9.75% nickel content has been determined to be most suitable for this application. The stainless steel for the casing could also be of other alloys, such as 304, 305, 306, or 316 alloys.
The original poly/copper resin, manufactured and supplied by PolyOne Corporation, has been used satisfactorily in traditional brass-cased ammo in the past. Upon the investigation of using PolyOne's resin in the small arms ammunition according to the present invention, projectile integrity issues and deformation immediately became apparent at the higher velocities produced by the new ammo. A new, higher strength resin, consisting of a proprietary blend of nylon, epoxies and polymers was formulated specifically for this new ammo.
Optionally, one can utilize metallics and heavy metals (other than copper) in the resin compound. For example the use of a zinc-based resin, an iron-oxide-based resin, a tungsten carbide-based resin, a depleted uranium based-resin, etc. all can be employed. This utilizes a new technique to create a homogenous blending of more than one heavy metal in the projectile resin.
Optionally, the primer base could also be made of stainless steel, such as a 416 stainless steel alloy, for example. Optionally, the primer base and the shell housing can both be made of 416 stainless steel alloy. Optionally, these two component portions of the casing can be made of different metals, such as having the shell housing made of one stainless steel alloy and the primer base made of aluminum or a different stainless steel alloy (such as the 416 stainless steel alloy).
Also optionally, the projectile can be constructed with hBN (hexagonal Boron Nitride) powder to achieve a poly/molded projectile. This ultra fine hBN powder acts as a friction-reduction agent when applied, through an optional steel/ceramic shot vibration/peening process, into the pores of the projectile. The use of hBN powder can provide multiple advantages in this application, including: less friction between the projectile and the barrel rifling, thus decreasing pressure, reducing barrel wear, increasing velocity, improving accuracy and minimizing the extreme velocity spread between many rounds. Optionally, other types of anti-friction coatings or lubricants can be employed to provide similar characteristics or benefits to the projectile as the hBN, although the hBN is preferred.

Additional Benefits and Advantages

Initially, an observed advantage of the stainless steel case was a less expensive option to the common brass cased ammunition. (Brass is generally more expensive than stainless steel.) However, as pressure and velocity tests were conducted, completely new loading data developed, and new loading techniques were adapted, more advantages began to be realized. First, the stainless steel casing can be made much thinner than a brass casing. The consistent outside dimension of each caliber is critical as prescribed by SAAMI. The result with thinner stainless is a larger internal capacity in each caliber utilizing stainless steel. This allows for more powder, higher velocities and greater performance.
Additionally, previously it was not apparent how much energy the brass case absorbs during the shot, as there was nothing else with which to compare it. Testing of the new cartridge established that far less energy is absorbed by the stainless case, resulting in more energy available to propel the projectile down the barrel. The results have been impressive, often yielding more than a 10% increase in performance over the exact same cartridge with a brass case.
Additionally, it was previously considered that poly/copper bullets, previously only used when loaded into a brass case, were rather inaccurate, even at 100 yards. Upon testing the new ammo, yielding higher velocities, the projectiles were extremely accurate out to ranges in excess of 500 yards. Also contributing to this accuracy is the stainless case and the poly/copper bullet combination which produces an optimum performance, which is not duplicated by any known combination of brass cases and poly/copper projectiles.
Other Observations:
The novel ammo results in less recoil due to the lighter weight poly/copper projectile. Perceived recoil reduction was estimated at 20-25%. However, actual reduction (measured) in recoil varied between about 15% and 25%.
The novel ammo delivers much higher energy from each specific caliber because of the higher speed of the projectiles. For example, a normal 9 mm defensive round, say a Hornady Critical Defense round, delivers a 124 grain bullet at 1140 fps and creates approx. 332 ft lbs of energy. The equivalent 9 mm round according to the invention delivers nearly 1800 fps with a fluted 65 grain bullet, creating 460 ft/lbs of energy—more energy than a full-power 45 ACP (352 ft lbs). (This performance cannot be duplicated by a brass-cased cartridge within safe and standard SAAMI pressures.
The novel ammo causes less barrel fouling or barrel wear. The ammo is rather “clean”. Bore inspection after thousands of rounds prove to be virtually clean, showing no evidence of any wear or tear on the chamber, barrel, or rifling.
The novel ammo allows for excellent terminal performance from the combination of hydrostatic shock and dynamic fluid displacement. It is also rather precise and accurate ammunition, far more so than brass-cased ammo with the same projectiles.
Advantageously, the ammo with its Poly/Copper projectile would be considered to be lead-free by the shooting industry and all known state regulatory agencies.
While the invention has been shown and described in exemplary forms, it will be apparent to those skilled in the art that many modifications, additions, and deletions can be made therein without departing from the spirit and scope of the invention as defined by the following claims.

Claims

What is claimed is:

1. A small arms ammunition round, comprising:

a non-brass casing comprising stainless steel; and

a non-lead projectile housed within the casing, the non-lead projectile comprising a matrix of at least one epoxy, at least one non-epoxy polymer, and copper.

2. A small arms ammunition round as claimed in claim 1 wherein the non-lead projectile comprises copper particles.

3. A small arms ammunition round as claimed in claim 1 wherein the matrix projectile comprises pure copper.

4. A small arms ammunition round as claimed in claim 1 wherein the matrix projectile comprises tungsten.

5. A small arms ammunition round as claimed in claim 1 wherein the matrix projectile comprises a copper alloy.

6. A small arms ammunition round as claimed in claim 1 wherein the matrix projectile comprises a blend of copper and tungsten.

7. A small arms ammunition round as claimed in claim 1 wherein the casing comprises a stainless steel shell housing and an aluminum primer housing press-fit together.

8. A small arms ammunition round as claimed in claim 1 wherein the casing comprises a stainless steel shell housing and an chrome moly steel primer housing press-fit together.

9. A small arms ammunition round as claimed in claim 1 wherein the projectile has a tapered nose with spiral flutes.

10. A small arms ammunition round as claimed in claim 1 wherein the copper/polymer matrix comprises a matrix of at least one epoxy, at least one metal, and at least one non-epoxy polymer.

11. A small arms ammunition round as claimed in claim 1 wherein the casing comprises a first portion and a primer portion press-fit together.

12. A small arms ammunition round as claimed in claim 1 wherein at least a portion of the casing comprises a 416 stainless steel alloy.

13. A small arms ammunition round as claimed in claim 1 wherein at least a primer portion of the casing comprises a 416 stainless steel alloy.

14. A small arms ammunition round as claimed in claim 1 wherein the projectile comprises hBN (hexagonal Boron Nitride) powder.

15. A small arms ammunition round as claimed in claim 14 wherein the hBN powder is incorporated into the projectile by a shot vibration/shot peening process.

16. A small arms ammunition round as claimed in claim 1 wherein the at least one non-epoxy polymer comprises nylon.

17. A small arms ammunition round, comprising:

a multi-piece, non-brass casing; and

a non-lead projectile housed within the casing.

18. A small arms ammunition round as claimed in claim 17 wherein the non-brass casing comprises a stainless steel casing.

19. A small arms ammunition round as claimed in claim 17 wherein the non-brass casing comprises an aluminum casing.

20. A small arms ammunition round as claimed in claim 19 wherein the aluminum casing comprises an aluminum alloy.

21. A small arms ammunition round as claimed in claim 19 wherein the aluminum alloy casing comprises 7075 aluminum.

22. A small arms ammunition round as claimed in claim 19 wherein the aluminum alloy casing comprises 7078 aluminum.

23. A small arms ammunition round as claimed in claim 19 wherein the aluminum casing comprises substantially pure aluminum.

24. A small arms ammunition round as claimed in claim 17 wherein the non-lead projectile comprises a metal/polymer matrix.

25. A small arms ammunition round as claimed in claim 24 wherein the metal/polymer matrix comprises a matrix of at least one epoxy, at least one metal, and at least one non-epoxy polymer.

26. A small arms ammunition round as claimed in claim 24 wherein the metal/polymer matrix comprises a matrix comprising epoxy and copper.

27. A small arms ammunition round as claimed in claim 17 wherein the projectile has a tapered nose with spiral flutes.

28. A small arms ammunition round as claimed in claim 17 wherein the projectile has a smooth tapered nose.

29. A small arms ammunition round as claimed in claim 25 wherein the at least one non-epoxy polymer comprises nylon.

31. A small arms ammunition round as claimed in claim 17 wherein at least a portion of the casing comprises a 416 stainless steel alloy.

32. A small arms ammunition round as claimed in claim 17 wherein at least a primer portion of the casing comprises a 416 stainless steel alloy.

33. A small arms ammunition round as claimed in claim 17 wherein the projectile comprises hBN (hexagonal Boron Nitride) powder.

34. A small arms ammunition round as claimed in claim 34 wherein the hBN powder is incorporated into the projectile by a shot vibration/shot peening process.