Polymer ammunition having an alignment aid, cartridge and method of making the same

1. A polymeric ammunition cartridge comprising:

a substantially cylindrical insert comprising a top surface opposite a bottom surface and a substantially cylindrical 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 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; and

a substantially cylindrical polymeric middle body comprising a substantially cylindrical polymeric coupling end connected by a powder chamber, wherein the substantially cylindrical polymeric coupling end extends over the substantially cylindrical coupling element and covers a circumferential surface of the primer flash hole; and

a substantially cylindrical polymeric nose comprising a projectile aperture formed in a neck, a shoulder extending from the neck and nose junction adapted to connect to the substantially cylindrical polymeric middle body and an alignment aid configured to prevent rotational movement of the ammunition cartridge in a chamber of a firearm, the alignment aid comprising a plurality of radially extending tabs formed on an outer surface of the nose and below the shoulder, a top surface of each of the radially extending tabs slanting angularly from a proximal end of the shoulder to an outer tab surface defining an outer diameter substantially equal to an outer diameter of the substantially cylindrical polymeric middle body, wherein each of the radially extending tabs is separated from an adjacent one of the radially extending tabs by a recessed surface.

2. The polymeric ammunition cartridge of claim 1 , wherein the substantially cylindrical polymeric middle body is formed from a ductile polymer.

3. The polymeric ammunition cartridge of claim 1 , wherein the substantially cylindrical polymeric middle body comprise a nylon polymer.

4. The polymeric ammunition cartridge of claim 1 , wherein the substantially cylindrical polymeric middle body is formed from a fiber-reinforced polymeric composite.

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

7. The polymeric ammunition cartridge of claim 1 , wherein a bullet is adhesively fitted to the forward opening end.

8. The polymeric ammunition cartridge of claim 1 , further comprising a groove positioned around the primer flash aperture in the primer recess.

9. The polymeric ammunition cartridge of claim 1 , wherein the alignment aid comprises one or more first tabs surface each separated by a second cut surface.

10. The polymeric ammunition cartridge of claim 1 , wherein the alignment aid comprises at least four first tabs surface each separated by a second cut surface.

11. The polymeric ammunition cartridge of claim 1 , wherein the substantially cylindrical polymeric middle body 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, polyarylsulfones, 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(etherimidesiloxane) copolymers.

12. The polymeric ammunition cartridge of claim 1 , wherein the forward opening end comprises a neck with a plurality of internal structures for supporting a bullet.

13. The polymeric ammunition cartridge of claim 1 , wherein the substantially cylindrical coupling element is a male coupling element with a straight skirt interlock surface that tapers to a smaller diameter at the forward portion on the skirt tip to mate with a female coupling element of the substantially cylindrical polymeric coupling end.

14. The polymeric ammunition cartridge of claim 1 , further comprising a diffuser positioned in the primer recess comprising a diffuser flash hole aligned with the primer flash hole.

15. A chamber adapted to accept the ammunition cartridge of claim 1 .

16. The polymeric ammunition cartridge of claim 1 , wherein the slanted angular top surface of the radially extending tabs extends fully about the circumference of a junction of the proximal end of the shoulder and the alignment aid to define a slanted angular lip.