Polymer ammunition having a MIM primer insert

1. An ammunition having an injection molded primer insert comprising:

an injection molded primer insert for polymer ammunition comprising

a top surface opposite a bottom surface,

a substantially cylindrical coupling element extending away from the bottom surface forming an interior surface inside the substantially cylindrical coupling element and

an exterior 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, and

a flange that extends circumferentially about an outer edge of the top surface, wherein the flange is adapted to receive a polymer overmolding;

a polymeric middle body extending from primer insert to a cylindrical middle body coupling region molded from a first polymer, wherein the first polymer is molded over the flange, the inner circumferential surface into the primer flash hole aperture and the outer surface and extends to the cylindrical middle body coupling region;

a primer inserted into the primer flash hole aperture;

a substantially cylindrical polymeric projectile end mated to the substantially cylindrical polymeric middle body, wherein the substantially cylindrical 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 end coupling region couples to the middle body coupling region;

a projectile frictionally fitted in the bullet-end aperture;

a propellant chamber defined between the primer flash aperture and the projectile aperture; and

a propellant at least partially filling the propellant chamber.

2. The ammunition cartridge of claim 1 , further comprising a primer flash aperture groove positioned in the primer recess around the primer flash aperture and the first polymer composition extends into the primer flash aperture to form a flash hole.

3. The ammunition cartridge of claim 1 , wherein the first polymer composition is the same as the second polymer composition.

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

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

6. The ammunition cartridge 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 ammunition cartridge of claim 1 , wherein the bullet aperture comprises one or more cannelures formed on an inner circumferential surface of the bullet aperture.

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

9. The ammunition cartridge 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-butadinen-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 ammunition cartridge of claim 1 , wherein the injection molded primer insert further comprises a flash hole groove that extends circumferentially about the primer flash aperture on the top surface in the primer recess.

11. The ammunition cartridge of claim 1 , wherein the bottom surface comprises a circumferential groove.

12. The ammunition cartridge of claim 1 , wherein the flange is a combination of a circumferential groove and one or more notches.

13. The ammunition cartridge of claim 1 , wherein the flange comprises 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15 notches positioned circumferential, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15 scallops positioned circumferential or both.

14. The ammunition cartridge of claim 1 , wherein the injection molded primer insert comprises 102, 174, 201, 202, 300, 302, 303, 304, 308, 309, 316, 316L, 316Ti, 321, 405, 408, 409, 410, 415, 416, 416R, 420, 430, 439, 440, 446 or 601-665 grade stainless steel.