Composite polymer based cartridge case having an overmolded metal cup, polymer plug base assembly

1. A cup and plug base assembly of a lead-free cartridge case configured to hold a projectile that has a cannelure formed along an outer circumferential surface thereof, the cartridge case including a cylindrical sleeve joined to the base, the sleeve being manufactured from a composite polymer and has a front end and a rear end opposite the front end, a mouth is defined by the front end of the sleeve and the rear end of the sleeve has an outer diameter that is less than an outer diameter of a main cartridge case holding chamber located intermediate the front and rear ends of the sleeve, the base assembly comprising:

a cup having a web with a flash hole defined therein, a first annular cup portion extending in a first direction away from the web toward the sleeve and a second annular cup portion extending in a second direction away from the web and away from the sleeve in a direction opposite to the first direction in which the first annular cup portion extends; and

a plug molded over the cup, the plug comprising a first annular portion extending from a first end of the base to a second end of the base and a second annular portion extending from the first annular portion and covers at least an entire inner surface of the first annular cup portion.

2. The base assembly according to claim 1 , wherein the second annular portion of the plug extends from a region located intermediate the first and second ends of the base.

3. The base assembly according to claim 1 , wherein the second annular portion of the plug extends in a direction from the first end of the base toward the second end of the base.

4. The base assembly according to claim 1 , wherein the web extends radially inward relative to the body and is disposed intermediate the first and second ends of the base, the web separating the main holding chamber of the sleeve from a primer pocket defined in the second end of the base.

5. The base assembly according to claim 4 , wherein the second annular portion of the plug covers at least a portion of an end face of the web facing the first end of the base.

6. The base assembly according to claim 4 , wherein the main holding chamber of the sleeve communicates with the primer pocket of the base via the flash hole.

7. The base assembly according to claim 1 , wherein an inner diameter of the plug at the first end of the base is greater than an outer diameter of the sleeve and the rear end thereof, and wherein the rear end of the sleeve is engaged by the plug.

8. The base assembly according to claim 1 , wherein the cup is manufactured from one of a metal and a suitable non-metal and the plug is manufactured from polymer.

9. The base assembly according to claim 8 , wherein the polymer may consist of additives and/or stabilizers.

10. The base assembly according to claim 1 , wherein the front end of the sleeve also includes a neck having engaging means defined therein for engaging the cannelure formed along the outer circumferential surface of the projectile, and wherein a groove is formed along an outer circumferential surface of the base near the second end of the base.

11. The base assembly according to claim 10 , wherein the engaging means is an annular projectile locking lip extending radially inward relative to an outer surface of the sleeve.

12. The base assembly according to claim 10 , wherein the groove defines a rim extending radially outward away from the outer circumferential surface of the base.

13. The base assembly according to claim 1 , wherein an inner diameter of the first annular cup portion is greater than an inner diameter of the second annular cup portion.

14. The base assembly according to claim 1 , wherein the sleeve and base are joined together by one of an adhesive and a welding process.