METHOD OF MAKING POLYMER AMMUNITION HAVING A WICKING TEXTURING

1 . A method of making polymeric ammunition having wicking texturing comprising the steps of:

molding a primer insert by injection molding, wherein the primer insert comprising a top surface opposite a bottom surface and a coupling element that extends from the bottom surface, wherein the coupling element forms an outer surface opposite an inner circumferential surface, a primer recess in the top surface that extends toward the bottom surface, a primer flash aperture positioned in the primer recess to extend through the bottom surface, a primer flash aperture groove positioned in the primer recess around the primer flash aperture, and a locking groove that extends circumferentially about the top surface;

molding from a first polymer composition a polymer ammunition cartridge by overmolding a polymeric middle body over the primer insert at a first end and a polymeric coupling region at a second end, wherein the first polymer composition is overmolded and extends over an outer surface of the primer insert to the flange and extends over an interior surface of the coupling region to the primer flash hole aperture, wherein the first polymer composition extends from the polymeric coupling region to the primer flash hole aperture and to the primer flash aperture groove to form a flash hole;

inserting a primer into the primer recess;

forming a polymeric projectile end component from a second polymer composition, wherein the polymeric projectile end comprises a projectile end coupling region that extends to a shoulder region that reduces to a neck region having a projectile aperture, wherein the projectile aperture is textured about an inner surface of the neck to form a textured projectile aperture surface;

coupling the projectile end coupling region to the textured surface to form a propellant chamber that extends from the primer flash hole aperture to the projectile aperture;

filling at least partially the propellant chamber with a propellant;

applying an adhesive to at least a portion of the projectile; and

fitting a projectile in the projectile aperture, wherein the textured projectile aperture surface provides wicking of the adhesive down the textured projectile aperture surface.

2 . The method of claim 1 , wherein the first polymer composition is the same as the second polymer composition.

3 . The method of claim 1 , wherein the first polymer composition is a ductile polymer.

4 . The method of claim 1 , wherein the first polymer composition, the second polymer composition or both comprise a nylon polymer.

5 . The method of claim 1 , wherein the first polymer composition, the second polymer composition or both comprise a fiber-reinforced polymeric composite.

6 . The method of claim 1 , wherein the first polymer composition, the second polymer composition or both comprise between about 10 and about 70 wt % glass fiber fillers, mineral fillers, or mixtures thereof.

7 . The method of claim 1 , wherein the projectile end coupling region, the polymeric coupling region, or both are textured.

8 . The method of claim 1 , wherein the substantially cylindrical coupling region and the polymeric bullet-end coupling are welded or bonded together.

9 . The method of claim 1 , wherein the first polymer composition, the second polymer composition or both comprise polyurethane prepolymer, cellulose, fluoro-polymer, ethylene inter-polymer alloy elastomer, ethylene vinyl acetate, nylon, polyether imide, polyester elastomer, polyester sulfone, polyphenyl amide, polypropylene, polyvinylidene fluoride or thermoset polyurea elastomer, acrylics, homopolymers, acetates, copolymers, acrylonitrile-butadiene-styrene, thermoplastic fluoro polymers, inomers, polyamides, polyamide-imides, polyacrylates, polyatherketones, polyaryl-sulfones, polybenzimidazoles, polycarbonates, polybutylene, terephthalates, polyether imides, polyether sulfones, thermoplastic polyimides, thermoplastic polyurethanes, polyphenylene sulfides, polyethylene, polypropylene, polysulfones, polyvinylchlorides, styrene acrylonitriles, polystyrenes, polyphenylene, ether blends, styrene maleic anhydrides, polycarbonates, allyls, aminos, cyanates, epoxies, phenolics, unsaturated polyesters, bismaleimides, polyurethanes, silicones, vinylesters, urethane hybrids, polyphenylsulfones, copolymers of polyphenylsulfones with polyethersulfones or polysulfones, copolymers of poly-phenylsulfones with siloxanes, blends of polyphenylsulfones with polysiloxanes, poly(etherimide-siloxane) copolymers, blends of polyetherimides and polysiloxanes, and blends of polyetherimides and poly(etherimide-siloxane) copolymers.

10 . The method of claim 1 , further comprising one or more internal structures in the neck to support the projectile.

11 . The method of claim 1 , wherein the bullet aperture comprises one, two, three, or more annular rings that mates with one, two, three, or more corresponding annular grooves positioned on a bullet.

12 . The method of claim 1 , further comprising the step of positioning a diffuser in the primer cavity before inserting the primer.

13 . The method of claim 1 , wherein the texture is a groove texture, a knurled texture, a random texture, a striped texture, a spiral texture, or other texture.

14 . The method of claim 1 , wherein the adhesive is applied by dipping at least a portion of the projectile into the adhesive.

15 . The method of claim 1 , wherein the adhesive is applied by spraying the adhesive onto at least a portion of the projectile.

16 . The method of claim 1 , wherein at least a portion of the projectile is the portion of the projectile that is inserted into the projectile aperture.

17 . The method of claim 1 , further comprising the step of applying adhesive to the projectile aperture.

18 . The method of claim 1 , wherein the injection molding includes polymer injection molding, metal injection molding or both.

19 . The method of claim 1 , wherein the injection molding includes metal injection molding.