Advanced Muzzle Loader Ammunition

Abstract

A muzzle loaded ammunition round having a bullet and a consumable cartridge case. The cartridge case is hollow and is filled with at least one propellant composition, the cartridge case being constructed from a consumable material, such as foamed celluloid. The bullet is commonly engaged to the propellant composition at least via the cartridge case, the propellant composition having a charge weight.

1 . A muzzle loaded ammunition round comprising:
 a fixed round comprising a bullet and a consumable cartridge case; the cartridge case is hollow and is filled with at least one propellant composition, the cartridge case being constructed from a consumable material; the bullet is commonly engaged to the propellant composition at least via the cartridge case, the propellant composition having a charge weight, wherein the consumable material is a foamed celluloid.   
     
     
         2 . The muzzle loaded ammunition round of  claim 1  further comprising an igniter which extends into the propellant composition inside the case at the time of ignition. 
     
     
         3 . The muzzle loaded ammunition round of  claim 1  in which the bullet is positioned within a sabot and the sabot is engaged to the cartridge case. 
     
     
         4 . The muzzle loaded ammunition round of  claim 3  in which the sabot is constructed at least in part out of a thermoplastic material. 
     
     
         5 . The muzzle loaded ammunition round of  claim 1  in which the propellant composition is one selected from the list consisting of: smokeless propellant, single base nitrocellulose, nitrocellulose propellant, black powder propellant, pyrotechnic propellant, non-pyrotechnic propellant, and any combination thereof. 
     
     
         6 . The muzzle loaded ammunition round of  claim 1  in which the propellant composition occupies a volume substantially equal to at least 90% of the volume of the cartridge case. 
     
     
         7 . The muzzle loaded ammunition round of  claim 7  in which the propellant composition includes at least one energy modifying material. 
     
     
         8 . The muzzle loaded ammunition round of  claim 7  in which the at least one energy modifying material is an energy reducing material. 
     
     
         9 . The muzzle loaded ammunition round of  claim 1  in which the propellant composition includes a pyrotechnic material. 
     
     
         10 . The muzzle loaded ammunition round of  claim 1  in which the propellant composition includes a stabilizer compound. 
     
     
         11 . The muzzle loaded ammunition round of  claim 10  in which the stabilizer compound is no greater than 1% by volume of the propellant composition. 
     
     
         12 . A method of manufacturing a muzzle loaded ammunition round comprising a bullet and a consumable cartridge case, the method comprising:
 heating at least one sheet of a foamed celluloid to a predetermined softening temperature;   stretching the at least one sheet about a cylindrical mandrel of a desired diameter of the consumable cartridge case;   using a vacuum to pull the sheet into a desired shape of the consumable cartridge case;   closing a first end of the consumable cartridge case;   filling the consumable cartridge case with at least one propellant composition; and   closing the second end of the consumable cartridge case.   
     
     
         13 . The method of  claim 12 , further comprising applying pressure to the sheet of a forming die can be used with pressure to finalize the desired shape or dimensions of the cartridge case. 
     
     
         14 . The method of  claim 12 , wherein a seam is formed where two ends of the sheet of foamed celluloid method and the seam is glued with a cyanoacrylate. 
     
     
         15 . A method of manufacturing a muzzle loaded ammunition round comprising a bullet and a consumable cartridge case, the method comprising:
 extruding foamed celluloid material in a long tube using a thermoplastic extrusion process;   cutting the tube to a desired length of the consumable cartridge case; closing a first end of the consumable cartridge case;   filling the consumable cartridge case with at least one propellant composition; and   closing the second end of the consumable cartridge case.   
     
     
         16 . The method of  claim 15 , wherein the first and second ends are closed with small end caps that are attached to the cut cylindrical tube.