One piece polymer ammunition cartridge having a primer insert and method of making the same

1. A method of making a polymeric ammunition cartridge comprising the steps of:

providing a polymer ammunition cartridge blank comprising an unformed top end connected to a cartridge bottom by a polymer middle body to form a propellant chamber, wherein the unformed top end comprises a nose end aperture, wherein the cartridge bottom comprises

a primer insert comprising

a top surface opposite a bottom surface and a coupling element that extends from the bottom surface,

a primer recess in the top surface that extends toward the bottom surface,

a primer flash hole aperture positioned in the primer recess to extend through the bottom surface and

a groove in the primer recess positioned around the flash hole aperture, wherein the middle body is overmolded through the primer flash hole aperture into the groove;

providing a thermal form comprising a body segment extending to a shoulder segment that transitions to a neck segment that terminates at a tip segment end and a mandrel extendable into the neck segment at the tip segment end;

heating the thermal form;

inserting the unformed top end into the thermal form;

extending the mandrel into the nose end aperture;

contacting the unformed top end with the tip segment end to form a polymer ammunition cartridge having a shoulder that terminates with the nose end aperture forms a projectile aperture, wherein the polymer ammunition cartridge is a neckless polymer ammunition cartridge; and

removing the polymer ammunition cartridge from the thermal form.

2. The method of claim 1 , wherein the polymer ammunition cartridge blank is formed from a ductile polymer.

3. The method of claim 1 , wherein the polymer ammunition cartridge blank comprise a nylon polymer.

4. The method of claim 1 , wherein the polymer ammunition cartridge blank is formed from a fiber-reinforced polymeric material.

5. The method of claim 4 , wherein the fiber-reinforced polymeric composite contains between about 10 and about 70 wt % glass fiber fillers, mineral fillers, or mixtures thereof.

6. The method of claim 1 , wherein the polymer ammunition cartridge blank comprise a polymers selected from the group consisting of 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.

7. The method of claim 1 , wherein the polymer ammunition cartridge blank comprises one or more polymers selected from the group consisting of polybutylene, polybutylene terephthalates, polyphenyl sulfones, polyether sulfones, and polycarbonates.

8. The method of claim 1 , wherein the polymer ammunition cartridge blank is a .17 HMR, .17 Hornet, .17 Ackley Hornet, .17 Winchester Super Magnum, .17-32 Magnum, .17 VHA, .17 Remington, .17/222, .17 Mach .17 Ackley Improved Bee, .17-357 RG, .17 Remington Fireball, .17 Incinerator, 4.39×39Rmm SPS, .204 Ruger, 5 mm Remington Rimfire Magnum, 5.45×39 mm Russian family, .22 Short, .22 Long, .22 Long Rifle, .22 Stinger, 22 Extra Long, .297/230 Morris Extra Long, .22 Hornet, .22 Rem Automatic, 5.66 ×39 MPS, .22 Rem Jet, .218 Bee, .219 Zipper, .22 Hornet-K, .220 Swift, .222 Remington, .222 Remington Magnum, .223 Remington, 5.56×45 mm NATO, 5.7×28 mm, .22 TCM, 5.8×42 Chinese, .224 Weatherby Magnum, .225 Winchester, .223 Winchester Super Short Magnum (Obsolete) .223 Ackley Improved, .219 Donaldson Wasp, .221 Remington Fireball, .22-250 Remington and many more, .243 Winchester, .244 Remington, 6 mm Remington, 6 mm plastic airsoft BBs, 6 mm Whisper, 6 mm PPC, 6 mm Bench Rest Remington, 6×45 mm, 6×47 mm, 6 mm Cheetah, .240 Weatherby, 6×62 Freres, 6 mm Norma BR, 6XC Tubb, 6 mm JDJ, 6 mm SAW, 6-250 Walker, 6.17 Spitfire, 6.17 Flash, 6 mm Lee Navy, and more, .25 ACP (.251″), 250/3000 Savage, 257 Roberts, 25-06 (.257″), .277, 6.5 ×55 mm, .260 Remington, 26 Nosler, 6.5 Creedmoor, 6.5×47 Lapua, .270 Winchester, 6.8, 6.8 SPC, .280 Remington, 7 mm-08 Remington, 7 mm Remington Magnum, 7×57 mm Mauser, 7x 64 mm, .30 Luger (7.65×21 mm Luger), .30-30 Win, 30 Herrett, .300 Whisper, .30-378 Weatherby, 7.63 Mannlicher-Schoenauer, 7.63 Mauser, .30 USA Rimless, .308 Corbon, .3-9 Savage, .30 Kurz, 300 AAC Blackout (7.62×35 mm), 7.5 mm Schmidt-Rubin, .300 Winchester Magnum, .30 Carbine, 309 JDJ, .30-03, .30-06 Springfield, .30-06 JDJ, .307 GNR, .308 Winchester (7.62×51 mm NATO), .300 Weatherby Magnum, .30 Army (.30-40 Krag), 7.82 mm Lazzeroni, and dozens more, .303 British, 7.62×39 mm Soviet, 7.62×54mmR, 7.62×25 mm, 7.7×58 mm, .32 ACP, 8×57 mm IS, .325 WSM, 8 mm Remington Magnum, 8 mm plastic (airsoft) BBs, .338 Lapua, .338 Norma Magnum, .338 Winchester Magnum, .338-378 Weatherby Magnum, 9 mm Luger, 9 mm Ultra, 9 mm Bayard Long, 9 mm Browning Long, 9 mm Mauser, 9 mm Winchester Magnum, 9 mm Glisenti, 9×21 mm, 9×23 mm Winchester, 9 mm Mi-Bullet, 9 mm Steyr, .356 Team Smith & Wesson, 9 mm Federal, 9 mm×25 mm Dillon, 9 mm Action Express, .380 ACP (9 mm Short), 9x 56 mm MannlicherSchoenauer, 9 mm×57 mm Mauser, .38 Super, .38 Special, .357 Magnum, .357 SIG, .35 Remington, 9×18 mm Makarov, 9.3×62 mm, 9.3×64 mm Brenneke, 9.3×72mmR, 9.3×74 mm, .375 H&H Magnum, 9.5×57 mm MannlicherSchonauer (.375 Rimless Nitro Express (RNE)×2¼), .40 S&W, 10 mm Auto, .444 Marlin, .44 S&W Russian, .44 S&W Special, .44 Remington Magnum, .44 Auto Mag, .440 Cor-Bon, 44/454 JDJ Woodswalker, .45 ACP, .45 GAP, .454 Casull, .45 Long Colt, .455 Webley, .50 BMG, .50 Action Express, 12.7×108 mm polymer ammunition cartridge blank.