Abstract:
Muzzleloader systems include a pre-packaged propellant charge and primer for providing efficient loading and unloading of the muzzleloader. The breech end accepts the propellant and means are provided to prevent breech loading of the projectile. A propellant cartridge conforms to a constriction portion to minimize ullage. A projectile is inserted in the muzzle end seats on the constriction portion. The propellant cartridge may be received in a removable breech plug. The constriction portion may be part of the breech plug or a separate component secured in the barrel by way of the breech plug. The cartridge may have a primer mechanism integrated into a proximal end. Projectiles have sliding components that have an axial elongate position and an axial shortened position and may be loaded with a ramrod having an engagement portion for each of the two pieces whereby the projectile doesn&#39;t prematurely collapse.

Description:
PRIORITY CLAIM 
       [0001]    This application claims priority to U.S. Provisional Application No. 61/707,520, filed Sep. 28, 2012, U.S. Provisional Application No. 61/852,480, filed Mar. 15, 2013, U.S. Provisional Application No. 61/802,264, filed Mar. 15, 2013, and U.S. Provisional Application No. 61/818,877, filed May 2, 2013, each of which is hereby fully incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention is directed to a system for muzzleloaders for improving safety, reliability, and performance. A muzzle loader has a breech that allows a breech plug and/or a propellant and pre-packaged propellant cartridges to be loaded therein and has features preventing the breach loading of bullets. 
       BACKGROUND OF THE INVENTION 
       [0003]    Muzzleloaders are a class of firearms in which the propellant charge and bullet are separately loaded into the barrel immediately prior to firing. Unlike modern breech loaded firearms where the bullet, propellant charge and primer are loaded as prepackaged cartridges, muzzleloaders are loaded by feeding a propellant charge through the muzzle of the barrel before ramming a bullet down the barrel with a ramrod until the bullet is seated against the propellant charge at the breech end of the barrel. A primer is inserted at the breech to be in communication with the propellant. The primer is then struck by an inline firing pin or an external hammer to ignite the propellant charge to create propellant gases for propelling the bullet. 
         [0004]    The loading process of muzzleloaders creates issues unique to muzzleloaders. Specifically, the muzzleloader loading process requires that, unlike conventional breech loaded firearms, the bullet travel through the barrel twice, once during loading and once during firing. The tight fit of the bullet to the barrel can create substantial friction as the bullet travels through the barrel and is etched by the barrel rifling. During firing, the expanding propellant gases can overcome the frictional forces to propel the bullet through the barrel. However, during loading, the user must overcome the frictional force by applying an axial force to the bullet with the ramrod until the bullet is seated against the propellant charge. The friction between the bullet and the barrel can complicate the determination as to whether the bullet has been pushed far enough down the barrel during loading and is properly seated against the propellant charge. The relative position of the bullet to the propellant charge changes the pressurization of the barrel behind the bullet from the ignited propellant gases impacting the ballistic performance and potentially creating a substantial safety risk. 
         [0005]    A concern with muzzleloaders is that the slower burning propellant required by muzzleloaders often foul the barrel with unconsumed residue requiring frequent cleaning of the barrel. The fouling can be severe enough that the barrel must be cleaned after every shot. The fouling can also interfere with the operation of the bullet and/or bullet with cup or sabot, causing damage to the cup and affect performance. In addition to contributing the fouling of the barrel, the deformation or damage to the sabot can impart wobble into the bullet or otherwise impact the ballistic performance of the bullet. 
         [0006]    A variability in muzzleloaders not present in cartridge based firearms is the quantity and type of the propellant charge. Unlike cartridge firearms where a cartridge is preloaded with a bullet and premeasured quantity of propellant is loaded into the firearm for firing, the bullet and propellant charge are combined within the firearm for firing. Accordingly, the muzzleloader operator can select the optimal bullet, propellant type and quantity combination for each shot, which is particularly advantageous given the long reloading time for muzzleloaders. While the variability of the bullet—propellant charge combination allows for an optimized shot, varying the bullet and in particular the propellant and quantity of propellant can significantly change the appropriate seating depth of the bullet. With loose or powdered propellant such as black powder, the amount of propellant is often varied between 80 and 120 volumetric grains. Similarly, propellants are often formed into cylindrical pellets that are stacked end-to-end within the barrel to form the propellant charges. The pellets are typically each about 1 cm in length and loaded in 1 to 3 pellet groups causing an even greater variation in the seating depth. Variability in the powder and bullet of course causes variability in performance including accuracy. 
         [0007]    A common approach to determining whether a bullet has been properly seated involves marking the ramrod with a visual indicator that aligns with the muzzle of the barrel when the end of the ramrod is at the appropriate depth with the barrel. The visual indicator is typically marked by loading the propellant charge and ramming a test bullet through the barrel. Once the user is certain that the bullet is properly seated against the propellant charge, the corresponding portion of the ramrod at the muzzle is marked. Although this approach is relatively easy to implement and widely used, the visual indicator approach detracts from the primary advantages of muzzleloaders. As the visual indicator approach is set based on a particular propellant charge and bullet combination, a variation in the propellant charge that changes the dimensions of the propellant charge can render the visual indicator at best useless or at worse a safety risk giving a false appearance of a properly seated bullet. 
         [0008]    In addition to the hazards posed by an improperly loaded propellant, the process for unloading an unfired muzzleloader can also pose a significant safety challenge. Typically, a ramrod with a bullet extractor tip is inserted into the muzzle and engaged to the bullet to pull the bullet out of the barrel. The propellant charge is then pulled or poured from the now open barrel. The bullet extraction and propellant charge removal process is highly dangerous as the user&#39;s hands and head are near the muzzle of the barrel and could be struck if the muzzleloader accidentally discharged. Moreover, the muzzleloader is typically not aimed at a particular target during unloading and can cause further injury if not aimed in a safe direction. The inherent risks associated with the conventional method of unloading muzzleloaders are such that the conventional wisdom for safely unloading a muzzleloader is to fire the muzzleloader into the ground or in a safe direction rather than attempt a risky extraction of the bullet and removal of the propellant charge. 
         [0009]    A similar consideration specific to hunting applications is that state and local laws typically require that the muzzleloader be unloaded while being transported in a motor vehicle from site to site. With certain types of game, hunters often check multiple sites in search of the targeted game. However, unloading the muzzleloader by firing the muzzleloader prior to leaving a site can spook the target game and other wildlife at that site and spoil the site for a period of time. Although certain laws are tailored to permit hunters to transport an otherwise loaded muzzleloader during hunting provided the primer is removed from the hole, the propellant charge and bullet are still seated within the barrel during transport posing a lessoned, but still substantial safety risk. As discussed above, the fouling can interfere with the safe operation of the muzzleloader as well as the ballistic performance of the bullet. While firing the muzzleloader can be comparatively safer method of unloading the bullet, the muzzleloader must often be cleaned after each firing. In a hunting situation where the muzzleloader may be fired several times to unload the muzzleloader for transport, the barrel may require cleaning, which can be difficult in the field. 
         [0010]    One approach to addressing the reloading problem is replacing the closed breech end of the muzzleloader barrel with a screw-in, removable breech plug. The breech plug is removable from the breech end of the muzzle to remove the propellant charge from behind the bullet rather than attempting the remove the bullet from the muzzle end of the barrel. While the approach is effective in safely separating the propellant charge from the bullet, a common problem with removable breech plugs is seizing of the breech plug within the barrel. The rapid temperature changes during firing as well as the corrosive nature of many of the propellants can result in seizing of the corresponding threads of the breech plug and the barrel. If not carefully maintained, the breech plug will become difficult to remove to efficiently unload of the muzzleloader. 
         [0011]    A related concern is that the performance of the hygroscopic propellant itself can be easily and often detrimentally impacted by the environmental conditions in which the propellant is stored. The sensitivity of the propellant can often result in “hang fires” where the ignition of the propellant charge is delayed or the propellant charge fails to ignite altogether. Hang fires are frequent occurrences and create a substantial risk for the user. The conventional approach to dealing with a hang fire is to point the muzzleloader in a safe direction until the muzzleloader fires or until sufficient time has passed to reasonably assume that the propellant charge failed to ignite altogether. The unloading process through the muzzle of the muzzleloader is particularly dangerous in hang fire situations as the propellant charge may ignite during the actual unloading process. Similarly, unloading through a breech plug can similarly be dangerous as the propellant charge may ignite as the breech plug is removed. 
         [0012]    Another safety concern unique to muzzleloaders is an undersized or oversized propellant charge. Unlike cartridge firearms where the amount of propellant loaded for each shot is limited by the internal volume of the cartridge, theoretically, the amount of propellant loaded for each shot in muzzleloaders is only limited by the length of the barrel. While measures are often used to provide a constant quantity of propellant for each propellant charge, the measures can be difficult to use in the field or in low light situation when hunting often occurs. Similarly, propellant can be formed into the pre-sized pellets that can be loaded one at a time until the appropriate amount of propellant is loaded. As with measuring the quantity of powder, errors can occur in loading the appropriate number of pellets. Embodiments of the invention address the above issues. 
       SUMMARY OF THE INVENTION 
       [0013]    A muzzle-loader bullet system includes a pre-packaged breech loaded propellant charge and primer for providing efficient loading and unloading of the muzzleloader. In embodiments, the muzzleloader has a breech portion, a projectile bore portion with a muzzle end, and a separator therebetween. The separator may be configured as a constrictor portion with a reduced diameter portion. The propellant containment vessel abuts against or is proximate the constriction portion with a reduced diameter portion. The propellant containment vessel may have an end portion with a tapered surface that conforms to the constriction portion surface. A projectile is inserted in the muzzle end and seats at the opposite side of the constriction portion from the propellant. A cup portion of the projectile may be injection molded, filled with propellant and then have a head portion that receives a primer fitted and adhered thereto. The ullage between the projectile and breech loaded propellant may be minimized with the configuration of the projectile and/or constriction portion. In other embodiments, propellant pellets or powder may be installed in the breech end. The projectile may have a cup portion that conforms to the ullage and is slidingly engaged with a bullet body. The projectile can be configured such that axially concentric sliding of the bullet body and cup portion shortening the axial length of the projectile radially and circumferentially expands the projectile, Ram rod means are provided for seating the projectile without axially compressing and shortening the projectile, whereby the projectile is readily loaded and upon firing is compressed and circumferentially expanded to provide enhanced sealing characteristics. In other embodiments, seating of the projectile may allow the axial reduction and radial expansion there by securing the bullet in position at its seat. This arrangement can facilitate loading powder in the breech end. 
         [0014]    A feature and advantage of the muzzleloader and bullet system is providing enhanced performance and safety. The muzzle loading system comprises an energetic system with a pre-packaged propellant charge that is breech loaded, providing efficient loading and unloading of the muzzleloader and with means that preclude loading of the bullet in the breech. 
         [0015]    A feature and advantage of embodiments of the invention is that the breech loading or unloading of the propellant charge allows for safe separation of the propellant charge from the bullet loaded within the barrel. When it is desired to unload the muzzleloader, the propellent containment vessel is removed, unfired, and the bullet can then be safely pulled or pushed down the barrel and removed from the muzzleloader without risk that the inadvertent or delayed ignition of the propellant charge will fire the projectile. 
         [0016]    A feature and advantage of embodiments of the invention the breech portion comprises a nozzle or constriction portion between the propellant containment vessel and the projectile. The nozzle or constriction portion focuses and accelerates the propellant gases generated from the ignited propellant charge to improve the acceleration of the bullet within the barrel. 
         [0017]    A feature and advantage of embodiments of the invention is that the containment vessel can comprise the integrated primer and be factory loaded or preloaded with a premeasured propellant charge. The primer and loaded containment vessel simplifies the loading process by combining the propellant measuring and loading steps with the primer positioning steps. The containment vessel can also serve to protect the propellant charge from environmental factors that could impact the ignition of the propellant charge. 
         [0018]    A muzzleloader, according to a present invention, comprises a barrel, a breech plug, an external hammer. The breech plug is insertable into the breech end of the barrel and defines an axial chamber extending through the breech plug and aligning with the internal bore of the barrel. A containment vessel comprising an integrated primer and a cup with a propellant charge is insertable into the axial chamber of the breech plug to define the breech end of the barrel, wherein the integrated primer is positioned to be struck with the external hammer to fire the muzzleloader. Similarly, the containment vessel can be removed from the axial chamber to unload the muzzleloader. 
         [0019]    A method of loading a muzzleloader, according an embodiment of the present invention, comprises providing a breech plug defining an axial chamber extending through the breech plug. The method further comprises inserting the breech plug into a breech end of a barrel, wherein the axial chamber aligns with the internal bore of the barrel when the breech plug is inserted into barrel. The method also comprises preloading a containment vessel having an integrated primer with a propellant charge. The method further comprises inserting the containment vessel with the loaded propellant charge into the axial chamber of the breech plug to load the muzzleloader. A feature and advantage of embodiments of the invention the method can also comprise removing the containment vessel from the axial chamber of the breech plug to unload the muzzleloader. 
         [0020]    A method, according to an embodiment of the present invention, of modifying a muzzleloading firearm to receive a breech loaded propellant charge, comprises: 
         [0021]    providing a muzzleloading firearm having a barrel having a bore running therethrough from a proximal end of the barrel to a distal end of the barrel, the bore including a proximal bore portion and a distal bore portion, with an axial channel defined in the proximal bore portion, 
         [0022]    sizing the axial channel in the proximal bore portion to define a chamber, wherein the chamber is sized to fittingly receive a containment vessel, the containment vessel being configured to receive a propellant charge, and 
         [0023]    modifying the barrel to provide a constriction portion at a position between the chamber and the distal bore portion, wherein the constriction portion prevents a muzzle loaded bore-diameter projectile from entering the chamber from the distal end of the bore. 
         [0024]    A method, according to an embodiment of the present invention, of modifying a muzzleloading firearm to receive a removable breech plug, comprises: 
         [0025]    providing a muzzleloading firearm having a barrel having a bore running therethrough from a proximal end of the barrel to a distal end of the barrel, the bore including a proximal bore portion and a distal bore portion, with an axial channel defined in the proximal bore portion, 
         [0026]    sizing the axial channel in the proximal bore portion to define a chamber, wherein the chamber is sized to fittingly receive a removable breech plug, and 
         [0027]    modifying the barrel to provide a constriction portion at a position between the chamber and the distal bore portion, wherein the constriction portion prevents a muzzle loaded bore-diameter projectile from entering the chamber from the distal end of the bore. 
         [0028]    A method, according to an embodiment of the present invention, of modifying a firearm to receive an adapter breech plug, comprises the steps of: 
         [0029]    providing a firearm having a barrel having a bore running therethrough from a proximal end of the barrel to a distal end of the barrel, the bore including a proximal bore portion and a distal bore portion, with an axial channel defined in the proximal bore portion, 
         [0030]    sizing the axial channel in the proximal bore portion to define a chamber, wherein the chamber is sized to fittingly receive an adapter breech plug, the adapter breech plug being configured to receive a propellant charge, and 
         [0031]    modifying the barrel to provide a constriction portion at a position between the chamber and the distal bore portion, wherein the constriction portion prevents a muzzle loaded bore-diameter projectile from entering the chamber from the distal end of the bore. 
         [0032]    A method, according to an embodiment of the present invention, of modifying an adapter breech plug to be breech received by a muzzleloading firearm, comprises the steps of: 
         [0033]    providing a muzzleloading firearm having a barrel having a bore running therethrough from a proximal end of the barrel to a distal end of the barrel, the bore including a proximal bore portion and a distal bore portion, with an axial channel defined in the proximal bore portion, the axial channel in the proximal bore portion defining a chamber, 
         [0034]    preparing an adapter breech plug having a diameter and outer surface, the adapter breech plug being configured to receive a propellant charge, 
         [0035]    sizing and shaping the diameter and outer surface of the adapter breech plug to conform to the chamber, wherein the adapter breech plug is sized to be fittingly received in the chamber, and 
         [0036]    modifying the barrel to provide a constriction portion at a position between the chamber and the distal bore portion, wherein the constriction portion prevents a muzzle loaded bore-diameter projectile from entering the chamber from the distal end of the bore. 
         [0037]    In embodiments of the invention, moisture concerns normally associated with the very hygroscopic black powder (and black powder substitute) propellants are minimized due to the sealed vessel design. Embodiment provide enhanced ease of use in unloading all energetics from system at any time compared to most conventional muzzleloaders that require the removal of the breech plug in order to remove propellant, and precise loading compaction of the black powder propellant. 
         [0038]    In an embodiment of the invention, propellant containment vessel comprises an integral cylindrical wall and conical tapering portion and a disk portion all unitary and formed of a polymer. Such may be advantageously injection molded and filled with propellant and then have a head portion secured thereto. The head portion having or receiving a primer. Advantageously, the head portion may be formed of brass or a polymer and may be adhered by adhesives or welding. 
         [0039]    Embodiments herein are specifically addressed to muzzleloading projectiles from 45 caliber to 50 caliber. Also the propellant packages may be sized from 20 gauge to 12 gauge and may be an intermediate, non standardized size. 
         [0040]    A feature and advantage of embodiments of the invention is minimal ullage between the propellant charge and the projectile in a breech loaded propellant configuration that precludes breech loading of the projectiles Such is conducive to enhanced firing performance. The minimal ullage may be provided by an angled constriction portion that correlates to the propellant vessel. 
         [0041]    A feature and advantage of embodiments of the invention is a projectile with a metal projectile body and a separate axially slidable component, the body and component having a common axis, and respective annular sliding engagement surfaces. The sliding from one defined position to another position having a hard stop defined by respective surfaces of the components. 
         [0042]    In embodiments as described immediately above certain embodiments will affect a radial expansion at the another position. In embodiments the expansion is caused by cam surfaces, in embodiments, the expansion is caused by axial compression of a member causing is to bulge radially outward. 
         [0043]    The above summary of the various representative embodiments of the invention is not intended to describe each illustrated embodiment or every implementation of the invention. Rather, the embodiments are chosen and described so that others skilled in the art can appreciate and understand the principles and practices of the invention. The Figures in the detailed description that follow more particularly exemplify these embodiments. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0044]    The invention can be completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which: 
           [0045]      FIG. 1  is a cross-sectional side view of a muzzleloader barrel for use with the present invention. 
           [0046]      FIG. 2  is a cross-sectional side view of a muzzleloader barrel with a propellant charge positioned at a breech end of the barrel and a conventional bullet positioned at a muzzle end of the barrel. 
           [0047]      FIG. 3  is a cross-sectional side view of the muzzleloader barrel depicted in  FIG. 2 , with the conventional bullet pushed partially through the barrel with a ramrod. 
           [0048]      FIG. 4  is a cross-sectional side view of the muzzleloader barrel depicted in  FIG. 2  with the conventional bullet seated against the propellant charge in the breech end of the barrel. 
           [0049]      FIG. 5  is a cross-sectional side view of a breech end of a muzzleloader according to an embodiment of the present invention in the pre-fired condition. 
           [0050]      FIG. 6  is a cross-sectional side view of a breech end of a muzzleloader according to an embodiment of the present invention. 
           [0051]      FIG. 7  is a cross-sectional side view of a containment vessel according to an embodiment of the present invention. 
           [0052]      FIG. 8  is a cross-sectional side view of a containment vessel according to an embodiment of the present invention. 
           [0053]      FIG. 9  is a cross-sectional side view of a breech end of a muzzleloader according to an embodiment of the present invention in the pre-fired condition. 
           [0054]      FIG. 10  is a cross-sectional side view of a breech end of a muzzleloader according to an embodiment of the present invention in the pre-fired condition. 
           [0055]      FIG. 11  is an end view of a constriction portion according to an embodiment of the invention. 
           [0056]      FIG. 12  is an end view of a constriction portion according to an embodiment of the invention. 
           [0057]      FIG. 13  is an end view of a constriction portion according to an embodiment of the invention. 
           [0058]      FIG. 14  is a cross-sectional side view of a breech end of a muzzleloader in the pre-fired condition. 
           [0059]      FIG. 15  is a cross-sectional side view of a breech end of a muzzleloader according to an embodiment of the present invention in the pre-fired condition. 
           [0060]      FIG. 16  is a cross-sectional side view of a breech end of a muzzleloader in the pre-fired condition. 
           [0061]      FIG. 17  is a cross-sectional side view of a breech end of a muzzleloader according to an embodiment of the present invention in the pre-fired condition. 
           [0062]      FIG. 18  is a cross-sectional side view of a breech end of a muzzleloader in the pre-fired condition. 
           [0063]      FIG. 19  is a cross-sectional side view of a breech end of a muzzleloader according to an embodiment of the present invention wherein the breech plug secures a constriction portion and a propellant cartridge is in place in a bore sized to the constriction portion. 
           [0064]      FIG. 20  is a perspective view of a propellant package configured as a cartridge with a primer. 
           [0065]      FIG. 21  is a perspective view with a partial cut-away cross section of the propellant cartridge of  FIG. 20 . 
           [0066]      FIG. 22  is a cross section of the propellant cartridge of  FIG. 20 . 
           [0067]      FIG. 23  is an end view of the propellant cartridge of  FIG. 20 . 
           [0068]      FIG. 24  is a cross section of the propellant cartridge of  FIG. 20 . 
           [0069]      FIG. 25  is a cross section of the propellant cartridge of  FIG. 20 . 
           [0070]      FIG. 26  is a side elevational view of a projectile according to embodiments of the invention. 
           [0071]      FIG. 27  is a cross sectional view of a projectile according to embodiments of the invention. 
           [0072]      FIG. 28A  is a front perspective view of a projectile according to embodiments of the invention in an axial elongated state. 
           [0073]      FIG. 28B  is a front perspective view of the projectile of  FIG. 28A  in an axial shortened state and illustrating grooves engraved on the cup by rifling. 
           [0074]      FIG. 28C  is a rear perspective view of the projectile of  FIG. 28A  in an axial shortened state. 
           [0075]      FIG. 29  is a front perspective view of the projectile of  FIG. 28A . 
           [0076]      FIG. 30  is a rear perspective view of the projectile of  FIG. 28A   FIG. 30  is a rear end view of a projectile according to embodiments of the invention. 
           [0077]      FIG. 30A  is a front elevational view of a projectile according to embodiments of the invention in an axially elongated state. 
           [0078]      FIG. 30B  is a front elevational view of a projectile according to embodiments of the invention in an axially shortened state. 
           [0079]      FIG. 30C  is a front elevational view of a projectile according to embodiments of the invention in an axially shortened state with grooves engraved thereon from rifling in a barrel. 
           [0080]      FIG. 30D  is a side elevational view of a projectile body according to embodiments of the invention utilizing raised and recessed surfaces for radially expanding the cup. 
           [0081]      FIG. 30E  is a side elevational view of a projectile body according to embodiments of the invention utilizing nodules as the radial expansion means for the cup. 
           [0082]      FIG. 30F  is a side elevational view of a projectile body according to embodiments of the invention utilizing ribs extending around the tail portion. 
           [0083]      FIG. 30G  is a side elevational view with the tail portion and cup in cross section should the projectile body of  FIG. 30F  with a cup in place in an axially elongated position. 
           [0084]      FIG. 30H  is a partial side elevational view of the projectile body and cup of  FIG. 30G  in the axially shortened configuration. 
           [0085]      FIG. 31  is a side elevational view of a projectile body with a cup engaged thereon in an axially elongated position, the cup having an aperture therein. 
           [0086]      FIG. 32  is a cross sectional view of a breech end of a muzzleloader barrel with a propellant package and a projectile abutting up to a constriction portion. 
           [0087]      FIG. 33  is an elevational view of the constrictor of  FIG. 32 . 
           [0088]      FIG. 34  is a cross sectional view of a constrictor similar to that of  FIG. 33 . 
           [0089]      FIG. 34A  is an alternative constriction portion that conforms to the propellant cartridge of  FIG. 35A . 
           [0090]      FIG. 34B  is another constriction portion in place in a barrel. 
           [0091]      FIG. 35  is an alternative view of a muzzleloader propellant cartridge. 
           [0092]      FIG. 35A  is an alternative view of a muzzleloader propellant cartridge. 
           [0093]      FIG. 35B  is a cross sectional view of the cartridge of  FIG. 35A . 
           [0094]      FIG. 36  is a cross sectional view of a breech end of a muzzle loader with the propellant cartridge of  FIG. 35  therein and with minimal or no ullage between the projectile and the propellant cartridge. 
           [0095]      FIG. 37  is a ramrod according to an embodiment of the invention. 
           [0096]      FIG. 38A  is a cross sectional view of a projectile being inserted in a muzzleloader. 
           [0097]      FIG. 38B  is a cross sectional view of a projectile being inserted in a muzzleloader in an axially elongated state by a ramrod the maintains the elongated state. 
           [0098]      FIG. 38C  is a cross sectional view of a projectile being seated in a muzzleloader in an axially elongated state by a ramrod the maintains the elongated state. 
           [0099]      FIG. 39A  is a saboted projectile according to embodiments of the invention in an axially elongated state. 
           [0100]      FIG. 39B  is the saboted projectile of  FIG. 39A  in an axially shortened state affecting bulges. 
           [0101]      FIG. 40A  is the projectile of  FIG. 39A  confronting a ramrod with capability of seating the projectile without shifting it to the axial shortened position. 
           [0102]      FIG. 40B  is a side elevational view of a ramrod. 
           [0103]      FIG. 40C  is another embodiment of a ramrod according to an invention. 
           [0104]      FIG. 41  illustrates components of the barrel assembly of  FIG. 42  including propellant package and a primer retainer piece 
           [0105]      FIG. 42A  is a cross section of a barrel assembly with a projectile in place. 
           [0106]      FIG. 42B  is a cross section of a barrel assembly with a projectile seated and in its axial shortened position thereby better securing the bullet in place, and a propellant powder in the breech cavity, retained by the primer retainer. The securement of the projectile provides a secure containment for the powder propellant. 
           [0107]      FIG. 42C  is a cross section of a barrel assembly with a projectile in place and without a constrictor portion that narrows the breech, rather relying on the larger diameter of the barrel compared to the breech to prevent breech loading of the projectile. 
           [0108]      FIGS. 43A-43C  illustrate an axially shiftable components with respect to one another of a projectile that affects a radial expansion. 
           [0109]      FIGS. 44A-43C  illustrate an axially shiftable components with respect to one another of a projectile that affects a radial expansion 
           [0110]      FIG. 45  is a FLOW CHART of the methodologies illustrated in  FIG. 46 . 
           [0111]      FIG. 46  is a diagrammatic view of a method of assembling a propellant cartridge for a muzzleloader. 
       
    
    
       [0112]    While the invention is amenable to various modifications and alternative forms, specifics thereof have been depicted by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0113]    As depicted in  FIGS. 1-4 , a muzzleloader  20 , for use with the present invention, generally comprises a barrel  22  having a breech  23  (or breech cavity), a breech end  26 , and a muzzle end  24 . The barrel  22  can comprise a smooth bore (not shown) or a rifled bore  31  as depicted in  FIGS. 2-4 . Referring to  FIG. 2 , the muzzleloader  20  is conventionally loaded with a projectile  25  at the muzzle end by pushing the projectile down the bore towards the breech end  26  until the projectile is seated. The breech is accessed for loading of the propellant as shown in  FIG. 3  and a propellant containment vessel  32  or cartridge is inserted into the breech. The breech is closed as shown in  FIG. 4  and is ready for firing. 
         [0114]    As depicted in  FIGS. 4 and 5 , the muzzleloader  20 , according to an embodiment of the present invention, can comprise the barrel  22  having an open breech end  26 , a breech portion  27 , and a projectile bore portion  29 , and a projectile bore  31 . In this configuration, the muzzleloader  20  can further comprise a breech plug  30  and a propellant containment vessel  32 . The breech plug  30  defines an axial channel  34  extending through the breech plug  30 . The axial channel  34  extends the effective length of the bore of the barrel  22  when the breech plug  30  is placed in the breech end  26  of the barrel  22 . The containment vessel  32  further defines an axial cavity  36  having an open end  38  and a closed end  40 . In some aspects of the invention, the open end  38  may be closed so as to wholly contain and seal the propellant charge for easier handling of the containment vessel  32  as more fully described below.  FIG. 7  shows a containment vessel  32  having and open end  38 .  FIG. 8  shows an aspect of the invention, wherein the containment vessel  32  comprises containment mechanism  62 . In the embodiment shown, the containment mechanism is crimping. 
         [0115]    In operation, a propellant charge  28  can be loaded into the axial cavity  36  of the containment vessel  32 . A feature and advantage of embodiments of the invention the open end  38  of the containment vessel  32  can comprises a containment mechanism, such as inward crimping  62  (shown in  FIG. 8 ), can be crimped inwards after the propellant charge  28 , as depicted in  FIG. 5 , to maintain the propellant charge  28  with the containment vessel  32  following loading of the propellant charge  28 . The loaded containment vessel  32  can then be positioned within the axial channel  34  with the open end  38  oriented toward the projectile bore portion  29  of the barrel  22 . Wherein the closed end  40  of the containment vessel  32  operates as effective breech end  26  of the barrel  22 . A feature and advantage of embodiments of the invention the containment vessel  32  can comprise an integrated primer  42  in the closed end  40  of the containment vessel  32  that can be struck with an external hammer to ignite the propellant charge  28  and fire the muzzleloader  20 . In this configuration, the primer  42  and propellant charge  28  can be loaded as a single energetic system for firing the muzzleloader  20 . After firing or during unloading, the containment vessel  32  can be removed from the breech  23  and replaced with a new containment vessel  32  or remain unloaded. A feature and advantage of embodiments of the invention the containment vessel  32  further comprises a rim  56  for gripping the containment vessel  32  for removal of the containment vessel  32 . 
         [0116]    As depicted in  FIG. 6 , a muzzleloader  20 , according to an embodiment of the present invention, can comprise a barrel  44  having an axial channel  46  or breech  23  through the breech end  48  of the barrel  44 , wherein the axial channel  46  is adapted to receive a containment vessel  32 . In this embodiment, the constriction portion  54  is unitary with the barrel defining a reduced diameter channel portion  55  that leads to a projectile bore portion  58 . In this configuration, the barrel  44  can further comprise an engagement mechanism  50  for securing the barrel  44  to the mount assembly for a conventional firearm or muzzleloader such that the barrel  44  can be interchanged with a conventional muzzleloader barrel  22 . 
         [0117]    As depicted in the Figures, the breech plug  30  or the barrel  44  can be operated with a break action muzzleloader or a reconfigured break action rifle or a bolt action muzzleloader, not shown. In this configuration, the hammer receiver portion  57  secures the breech at the propellant containment vessel  32  to prevent the containment vessel  32  from moving rearward from the breech end  26 , during firing. 
         [0118]    As depicted in  FIGS. 5-8 , the axial channel  34  may comprise a vessel chamber  52  for receiving the containment vessel  32  and a nozzle or constriction portion  54 . The constriction portion  54  is positioned between the propellant charge  28  and the bullet  25  when the containment vessel  32  is loaded into the vessel chamber  52 . The constriction portion  54  accelerates the propellant gases generated from the ignition of the propellant charge  28  to improve the propulsion of the bullet from the barrel  44 . In an aspect of the invention, the vessel chamber  52  which receives the containment vessel  32  is formed in the axial chamber  46  of the breech plug  30 , as shown in  FIG. 5  and, in another aspect, the vessel chamber  52  which receives the containment vessel  32  is formed in the axial chamber  46  of the breech end  48  of the barrel  44 , as shown in  FIG. 6 . 
         [0119]    As depicted in  FIG. 5 , a muzzleloader  20 , according to an embodiment of the present invention, can further comprise a barrel  22  having an open breech end  26 . In this configuration, the muzzleloader  20  can further comprise a breech plug  30  and a containment vessel  32 . The breech plug  30  defines an axial channel  34  extending through the breech plug  30 . The axial channel  34  extends the effective length of the bore of the barrel  22  when the breech plug  30  is placed in the breech end  26  of the barrel  22 . The containment vessel  32  further defines an axial cavity  36  having an open end  38  and a closed end  40 . 
         [0120]    In operation, a propellant charge  28  can be loaded into the axial cavity  36  of the containment vessel  32 . A feature and advantage of embodiments of the invention the open end  38  of the containment vessel  32  can be crimped inwards after the propellant charge  28 , as depicted in  FIG. 5 , to maintain the propellant charge  28  with the containment vessel  32  following loading of the propellant charge  28 . The loaded containment vessel  32  can then be positioned within the axial channel  34  with the open end  38  distally oriented toward the barrel  22 , wherein the closed end  40  of the containment vessel  32  operates as the effective breech end  26  of the barrel  22 . A feature and advantage of embodiments of the invention the containment vessel  32  can comprise an integrated primer  42  in the closed end  40  of the containment vessel  32  that can be struck with an external hammer to ignite the propellant charge  28  and fire the muzzleloader  20 . In this configuration, the primer  42  and propellant charge  28  can be loaded as a single energetic system for firing the muzzleloader  20 . After firing or during unloading, the containment vessel  32  can be removed axial channel  46  and replaced with a new containment vessel  32  or remain unloaded. A feature and advantage of embodiments of the invention the containment vessel  32  further comprises a rim  56  for gripping the containment vessel  32  for removal of the containment vessel  32 . 
         [0121]    As depicted in  FIG. 6 , a muzzleloader  20 , according to an embodiment of the present invention, can comprise a barrel  44  having an axial channel  46  through the breech end  48  of the barrel  44 , wherein the axial channel  46  is adapted to receive a containment vessel  32 . In this configuration, the barrel  44  can further comprise an engagement mechanism  50  for securing the barrel  44  to the mount assembly for a conventional firearm or muzzleloader such that the barrel  44  can be interchanged with a conventional muzzleloader barrel  22 . 
         [0122]    As depicted in  FIGS. 5-8 , the breech plug  30  or the barrel  44  can be operated with a break action muzzleloader or a reconfigured break action rifle. In this configuration, the hammer block engages at least the rim  56  of the containment vessel  32  to prevent the containment vessel  32  from moving rearward from the breech end  26 ,  48  of the barrel  22 ,  44  during firing as a result of the back blast from ignited propellant charge  28 . 
         [0123]    As depicted in both  FIGS. 5-8 , the axial channel  34  can further comprise a vessel chamber  52  for receiving the vessel  32  and a constriction portion  54 . The constriction portion  54  is positioned between the propellant charge  28  and the bullet when the containment vessel  52  is loaded into the vessel chamber  52 . The constriction portion  54  may accelerate the propellant gases generated from the ignition of the propellant charge  28  to improve the propulsion of the bullet from the barrel  22 ,  44 . 
         [0124]    As depicted in  FIG. 9 , a containment vessel receiving muzzleloader  120 , according to an embodiment of the present invention, is configured to receive a containment vessel  132  within the breech region  101  of the muzzleloader instead of a breech plug. The containment vessel is a propellant cartridge, as illustrated with a unitary casing and crimped end. The muzzleloader  120  can further comprise a barrel  122  having a distal end  123  and having an open breech end  126  at a proximal end  127 . In this configuration, the muzzleloader  120  can further comprise an axial channel  134  or breech  23  in the proximal end  127  of the barrel  122 . The breech  23  defines a vessel chamber  152  and as illustrated a containment vessel  132  is contained within the vessel chamber  152 . The containment vessel  132  further defines an axial cavity  136  having a distal closed end  162  and a proximal closed end  140  configured to receive the propellant charge  128 . The breech chamber  159  and vessel chamber  152  defined therein are separated from a distal bore portion  160  by a narrowing internal shoulder  162  at the distal end of axial channel  134  and at the proximal end of the distal bore portion  160 . 
         [0125]    In operation, a propellant charge  128 ,  28  can be loaded into the axial cavity  136 ,  438  of the containment vessel  132 ,  432 . A feature and advantage of embodiments of the invention the containment vessel has an open end  438  and, in another aspect, has a closed end  462  to contain the propellant charge  128 ,  28  within the containment vessel  132 ,  432  following loading of the propellant charge  128 ,  28 , as depicted in  FIGS. 7-8 . The loaded containment vessel  132  can then be positioned within the axial channel  134  with the end  162  (in the case shown in  FIG. 9 , closed end  162 ,  462 ) oriented distally toward the barrel  22 , wherein the closed end  162  of the containment vessel  132  operates as effective breech end of the barrel  122 . A feature and advantage of embodiments of the invention the containment vessel  132  can comprise an integrated primer  142  in the closed end  140  of the containment vessel  132  that can be struck with an external hammer  174  to ignite the propellant charge  128  and fire the muzzleloader  120 . In this configuration, the primer  142  and propellant charge  128  can be loaded as a single energetic system for firing the muzzleloader  120 . After firing or during unloading, the containment vessel  132  can be removed via the axial channel  134  and replaced with a new containment vessel  132  or remain unloaded. A feature and advantage of embodiments of the invention the containment vessel  132  further comprises a rim  156  for gripping the containment vessel  132  for removal of the containment vessel  132 . 
         [0126]    A method of manufacturing or retrofitting a containment vessel receiving muzzleloader  120  which utilizes a containment vessel  132  comprises providing a muzzleloader having a barrel  122  which has a bore running therethrough from a proximal end of the bore to a distal end of the bore. The bore includes a proximal bore portion  159  and a distal bore portion  137 , with an axial channel  134  defined in the proximal bore portion  159 , and a narrowing internal shoulder  162  within the bore separating the proximal bore portion from the distal bore portion. The method also comprises sizing the axial channel  134  to define a vessel chamber  152 , wherein the vessel chamber is sized to fittingly receive a containment vessel  132 . The method further comprises inserting or integrally forming within the bore a forcing cone  164  at a position within the bore proximally adjacent the narrowing shoulder  162 . 
         [0127]    As depicted in  FIG. 10 , the containment vessel receiving muzzleloader  120  shown in  FIG. 9 , according to an embodiment of the present invention, can comprise a removable breech plug  176  instead of a containment vessel  132 . The removable breech plug is sized to be fittingly received within the vessel chamber  152  and allow the muzzlerloader to be loaded in a conventional manner. The removable breech plug  176  has a distal end  178  and a proximal end  180 , wherein, when fitted into the vessel chamber  152 , the distal end  178  abuts against the forcing cone  164 . The removable breech plug  176  can include an integrated primer  142  in its proximal end  180 , a flash passage  182  extending from the primer  142  to and opening up at the distal end  178 , and an otherwise solid body  181 . In an aspect of the invention the removable breech plug does not have any outer threads and is installed with a slidable fit. The primer  142  can be struck with an external hammer  174  to ignite the propellant charge  128 , which is loaded through the distal end  123  of the barrel  122  with the bullet and fire the muzzleloader  120 . In this embodiment, the propellant charge  128  is loaded with the bullet and is positioned distal to the internal shoulder  162  and the forcing cone  164 . After firing or during unloading, the removable breech plug  176  can remain and be used with a further load or can be removed via the axial channel  134  and replaced with a containment vessel  132  or remain unloaded. A feature and advantage of embodiments of the invention the removable breech plug  176  further comprises a rim  157  for gripping the removable breech plug  176  and insertion of a containment vessel  132 . 
         [0128]      FIGS. 14 and 15  illustrate the breech region of a representative muzzleloader barrel  119  having a conventional breech plug  186  ( FIG. 14  illustrates a ‘ 209  primer adapter’) with a securing plug  129 , and a muzzleloader  120 , according to an embodiment of the present invention, having a containment vessel  132  ( FIG. 15 ). The Figures illustrate differences between the two, including the construction or retrofit of the axial channel  134  in muzzleloader  120  and the inclusion of a conventional, threaded-in  187  breech plug  186  in the commercial muzzleloader  119 , as opposed to the slidably received containment vessel  132  of inventive muzzleloader  120 . A further difference is the inclusion of the separator configured as a forcing cone  164  in the present invention, as shown in  FIG. 15 . In the convention muzzleloader  119 , the propellant  128  and bullet are loaded at the distal barrel end, resulting in the propellant sitting directly on the breech plug  186  and the bullet seated right on the propellant. After firing, the propellant residue remains in the barrel in the position where the next propellant and bullet are to be placed. Cleaning may need to be accomplished by removing the plug  186 . In contrast, in the inventive muzzleloader  120 , the propellant  128  in the containment vessel  132  is in the vessel chamber  152  within the axial channel  134 , which is spaced and separated from the bullet by the internal shoulder  162  and the forcing cone  164 . Further, after firing the propellant casing is easily removable out the proximal end of the barrel, minimizing cleaning and allowing for quicker reload. The present invention provides ease of use, minimizes moisture concerns with the very hygroscopic black powder (and black powder substitute) propellants with the sealed vessel designs. 
         [0129]    In a method, commercial barrels, such as the one shown in  FIG. 14 , can be altered and retrofitted to receive a containment vessel  132  or removable plug  176  according to the invention by resizing the axial channel of the breech end of the barrel so as to receive a containment vessel  132  or removable plug  176  and include an internal shoulder  162 , and fitting the distal end of the resized axial channel  134  with a forcing cone  164  and abutting said forcing cone  164  proximally against the internal shoulder within the axial channel  134 . A further aspect of the present inventive method is inserting an adapter breech plug that is fittingly receivable into the axial channel of the commercial barrel, wherein the adapter breech plug includes an axial channel sized to receive a containment vessel  132  and wherein a forcing cone  164  is positioned within the distal end of the axial channel  134  of the commercial barrel  119  or within the distal end of the axial channel of the adapter breech plug. An embodiment of an adapter breech plug is illustrated in  FIG. 18 . 
         [0130]    As further depicted in  FIG. 15 , the muzzleloader  120 , according to an embodiment of the present invention, comprises a barrel  122  having an axial channel  134  through the breech end  126  of the barrel  122 , wherein the axial channel  134  is adapted to receive a containment vessel  132 . In this configuration, the barrel  122  can further comprise an engagement mechanism  150  for securing the barrel  122  to the mount assembly  151  (seen in  FIG. 17 ) for a conventional firearm or muzzleloader such that the barrel  444  can be interchanged with another muzzleloader barrel. 
         [0131]      FIGS. 16 and 17  illustrate the barrels of  FIGS. 14 and 15 , respectively, with the barrels engaged and secured to mount assemblies  151  via the engagement mechanisms  150  and the break actions open. 
         [0132]    As depicted in  FIG. 17 , barrel  122  shown in  FIG. 15  can be operated with a break action muzzleloader or a reconfigured break action rifle utilizing either a containment vessel  134 , a removable plug  176  or an containment vessel containing adapter plug (as shown in  FIG. 18 ). In this configuration, the hammer block  175  engages at least the rim  156  of the containment vessel  132  to prevent the containment vessel  132  from moving rearward from the breech end  126  of the barrel  122  during firing as a result of the back blast from ignited propellant charge  128 . 
         [0133]    As depicted in  FIG. 18 , in a further embodiment of the invention, the containment vessel  132  within the vessel chamber  152  can be replaced with an adapter breech plug  190 . As shown in  FIG. 18 , the adapter breech plug  190  is sized to be received within the vessel chamber  152  like the containment vessel  132 . The adapter breech plug  190  further defines an axial cavity  192  having a proximal closed end  194  and a distal open end  196  configured to receive a propellant charge  128  of a smaller size. The distal end  196  of the adapter breech plug  190  can be formed to be fittingly received into the conical portion of the forcing cone through the top end  168 . The axial cavity  192  extends the effective length  135  of the bore  137  of the barrel  122  at a proximal bore portion  159  to the forcing cone  164 . The wall  198  of the adapter breech plug  190  can be varied to alter the diameter of the axial cavity  192  allowing for the snug fit of propellant charges of different sizes. A feature and advantage of embodiments of the invention the adapter breech plug  190  can comprise an integrated primer  142  in the closed end  140  of the adapter breech plug  190  that can be struck with an inline firing pin  191  to ignite the propellant charge  128  and fire the muzzleloader  120 . In this configuration, in use, the primer  142  and propellant charge  128  can be loaded as a single energetic system for firing the muzzleloader  120 . After firing or during unloading, the adapter breech plug  190  can be removed via the axial channel  134  and the propellant charge can be replaced with a propellant charge or remain unloaded. A feature and advantage of embodiments of the invention the adapter breech plug  190  further comprises a rim  156  for gripping the adapter breech plug  190  for removal of the adapter breech plug  190 . 
         [0134]    A further aspect of the invention and method of the present inventive is that the adapter breech plug  190  and forcing cone  164  can be sized with regard to their outer diameters, lengths and outer surfaces to accommodate axial channels of other commercially available muzzleloaders. By way example, as shown in  FIG. 16  (which shows the commercial barrel  119  of  FIG. 19 ); the adapter breech plug  190  can be adjusted in a size and configuration to conform to the axial channel  134  of the barrel  119 . In this case, the adapter breech plug is adapted by increase its diameter, which in this case results in a thicker wall  198 , and conform the outer surface  600  to the inner surface of the axial channel  134  of the barrel  119 . In this case, the outer surface  600  is threaded. For the conversion of the energetic system to conform to barrel  119 , the forcing ring  164  can also be altered to conform to the distal end  602  of the axial channel  134  of the barrel  119 . The distal end  196  of the adapter breech plug  190  can be similarly adjusted to form fit into the conical portion of the forcing cone through the top end  168 . The axial cavity  192  can also be increased in diameter to receive a larger containment vessel  132 . 
         [0135]    In a method, providing a muzzleloader having an axial channel in its barrel at its proximal breech end and providing an adapter breech plug having or constructing it to have an outer surface that is fittingly receivable into the axial channel of the barrel, wherein the adapter breech plug includes an axial channel sized to receive a containment vessel and wherein a forcing cone is positioned within the distal end of the axial channel of the barrel or within the distal end of the axial channel of the adapter breech plug. 
         [0136]    Referring to  FIGS. 20-25  several views of propellant cartridges  200  comprising containment vessels  232  and propellant  228  are illustrated. The cartridges each have a cup portion  257  comprising a tubular wall portion  232 , a converging portion at a closed end  236 , and an open end  238 . A head portion  244  connects to the open end  238  of the cup portion tubular portion  242 . A disk shaped portion  246  is unitary with the tubular portion  242  and has a recess  250  for receiving a primer  254  and a flange portion  256 . The tubular portion and closed end are unitarily formed as the cup portion  257 . Such may be injection molded from polymers such as polyethylenes or fabricated from metals. The head portion may also be injection molded or formed from convention materials such as brass. The head portion and cup portion may be press fit together and joined by way of crimping, welding, adhesives, or other securement means. As illustrated in  FIGS. 24 and 25 , the wall portion and head portion may have different configurations. Specifically, different wall thicknesses for the cup portion allows for different quantities of propellant and can provide structural enhancements. Also, the head portions may have different volumetric displacement portions  258  which, when attaching to a propellant filled cup portion, allows different levels of compaction. Although not shown, the tubular portions can have, in cross section, regular polygon shapes as well as the circular shape shown. 
         [0137]    Referring to  FIGS. 26-31 , projectiles  259 , including projectile bodies  261  and cups  266 . according to the inventions herein are illustrated. These particular embodiments have a head portion  260 , a tail portion  263 , a slidable component  266  configured as the cup. The cup may further have a cutting ring  268 . A polymer nose insert  268  fits into a recess  270  in the head portion in particular embodiments. Referring to  FIGS. 27 ,  30 D,  30 E- 30 H, and  31 , the tail portion and tubular portion of the cup have cooperating surfaces to affect a radial expansion as the cup moves axially on the tail. The surfaces can be a tapered portion  272  upon which the lip  274  of the cup rides increasing the radial expansion of the projectile. The projectile body can have circumferential recesses  273  and circumferential projections  275 . As illustrated in  FIG. 30E  the circumferential projections do not need to be continuous circumferentially, the can be, for example circumferentially spaced bumps  278  or nodules. Also, the cup can have thickened portions  282  that extend radially inward. In an embodiment, the projectile body is metal, such as lead, copper, steel, or other alloys or other metals. The tail can have circumferential ribs  283  and a cup  285  with recesses corresponding to the ribs as illustrated in  FIGS. 30F and 30G . When compressed, as illustrated in  FIG. 30H , the ribs force portions of the cup axially offset from the recesses to bulge outwardly affecting the radial expansion. The cup may be polymers or metals in some embodiments. 
         [0138]    Referring to  FIGS. 32-34 , a minimal ullage configuration is illustrated with the propellant package or cartridge  200  abutting a constriction portion  264  and the projectile  259  also abutting up against the constriction portion. In this embodiment the projectile tail portion  265  can have a conical surface  267  to conform to the muzzle facing surface  270  of the constriction portion  264 . This surface is conical in  FIGS. 32 and 34  and may have other shapes that converge or have a face perpendicular to the axis. This facilitates the minimal ullage between the projectile  259  and the propellant which is believed to provide enhanced propellant and projectile performance. 
         [0139]    Referring to  FIGS. 34A ,  35 ,  35 A,  35 B, and  36 , other means of minimizing ullage is illustrated. In  FIG. 35 , the propellant cartridge  201  has the conical portion  279  that corresponds to and engages the conical portion  281  of the constriction portion  264  that faces the breech opening. The cartridge also has a neck portion  284  that has a cylindrical shape and a disk  286  perpendicular to the axis a of the cartridge. As illustrated in  FIG. 36  the neck portion can extend into and conform to the reduced diameter portion  287  of the constriction portion  264 , also presenting minimal ullage.  FIGS. 35A and 35B  illustrate another configuration of a propellant cartridge according to embodiments of the invention with the cartridge having a rounded tip. The constriction portion  264  can have the surface that faces the breech end have a curvature that corresponds to the rounded tip. In embodiments the tip can extend beyond the converging portion, to confront or engage the projectile. In  FIG. 34B , the constriction portion  264  can be rectilinear such as a conventional washer with two planar faces, and cylindrical outer surface and a cylindrical inner surface. In such an embodiment, the cup of the cartridge may have outer walls such that the inner surface of the outer wall is in alignment with the inner surface of the constriction portion or separator portion. A polymer cartridge casing can have weakening structure  255 , such as scoring or grooves, in alignment with the inner cylindrical surface of the constriction portion to facilitate uniform separation of the disk  257 . 
         [0140]    Referring to  FIGS. 37-38C , a ramrod  288  has a pair of stop surfaces  289 ,  290 , a shaft  291 , and a handle  292 . The projectile  300  has bullet body  310  and a cup portion  312 , the cup portion slidably engaged on the bullet body. In order to maintain the gap G between the cup and bullet body, the ramrod engages both the cup portion  312  and the tip  314  of the bullet body  310  by respective engagement portions  318 ,  320  when the ramrod is pushing the projectile in the barrel, as illustrated by  FIGS. 39 and 40 . In  FIG. 40  the projectile is seated at the seating position  320  next to the propellant  324 . The projectile is thus positioned to be fired and moved from the axially extended position to the axially shortened position that will also expand the radius of the projectile. 
         [0141]    Referring to  FIGS. 39 ,  40 A, and  40 B, a saboted projectile with aspects of the invention are illustrated. Specifically, the saboted projectile has an axially elongated or extended position as shown in  FIGS. 39A and 40A  and an axially shortened position as shown in  FIG. 39B . A cup  360 , termed a sabot in that it separates from the projectile upon exiting the barrel, is engaged with a projectile body  310 . The sabot has a base portion  364  and a plurality of forward extending wings or fingers  366  that are unitary with the base portion. Internally, the sabot has an inwardly extending annular ridge  368  that seats within an circumferential recess  370  on the tail portion  372  of the projectile body. Additionally an outwardly extending circumferential projection  376  on the tail of the bullet body seats in a recess  378  in the sabot. In this configuration the thickened portions  380  of the fingers that initially seat in recesses or a projectile void  381  then ride up widened portions  383 ,  384  of the projectile body providing radially expanded portions  388  configured as bands on the sabot. The projectile body and sabot have confronting hard stops  391 ,  392  to definitively seat the projectile in the second position, the axially shortened position. 
         [0142]    Referring to  FIGS. 40A-40C , ramrod configurations suitable for saboted projectiles such as illustrated in  FIGS. 39A-40A . The ramrod  393  of  FIGS. 40A and 40B  has a cup portion  394  with a bullet tip engagement portion  395 . The ramrod  396  of  FIG. 40C  has cup/sabot engagement portions  397  on fingers  398 . Similar to the ramrod of  FIGS. 37-38C , the ramrods two engagement portions simultaneously engage and push down the barrel the projectile body and the cup. The dashed lines in  FIG. 40A  indicate that a central rod  399  may be sildable in the shaft to engage the tip of the projectile body to axially shorten the projectile after it is seated. This facilitates pushing the projectile down the barrel at the radially reduced configuration and then radially expanding the projectile once it is seated before it is fired. 
         [0143]    Referring to  FIGS. 41 to 42B , two alternative embodiments are illustrated in which the propellant package is a discrete packet  326  in  FIGS. 41 and 42 . The separator  330  is a constriction portion with a conical surface  328  facing the breech chamber  329 . The primer  331  is secured in a primer retainer  334  that fits into the breech chamber. The fit can be snug and it may be held in place by the hammer receiver portion  58  of the gun when closed. The packaging for the packet can be, for example, polymer sheet material formed in a cylindrical shape, or materials also are suitable. As an alternative to the propellant powder, propellant pellets may also be used in the same manner, although the constriction portion can be sized, or the pellets sized to prevent their passage out of the breech chamber into the projectile bore. 
         [0144]      FIG. 42B  illustrates usage of the primer retainer  334  and the non-packaged propellant  338  in the breech chamber. The chamber may be contained on the projectile bore  337  side, opposite the constriction portion  330 , by the projectile  342 . The projectile as illustrated is in the axial shortened position causing the radial expansion thereby securing the projectile in the projectile seat  342  at the constriction portion  330 . The projectile can be shortened with a radius increase by the user axially compressing the projectile with the ramrod. 
         [0145]      FIG. 42C  illustrates an embodiment with the projectile bore portion of the barrel having a diameter d1 greater than the diameter d2 of the breech chamber. This precludes loading of the projectiles sized for the projectile bore portion through the breech chamber. 
         [0146]      FIGS. 43A-43C  illustrate another embodiment where a projectile  341  has an axial elongated position and an axially shortened position shown in  FIG. 43C . In this embodiment, an axially sliding component  342 , shaped as a cup, slides on the tail  343  of the projectile body  344  to affect the axial compression of a ring shaped polymer member  345  that is essentially incompressible from a volumetric perspective. The polymer member expands radially when compressed axially as it is constrained by the tail  343 . The polymer member may be elastomeric or may be formed of more than one component, for example, that is an outer skin and a different inner material, for example a gel material constrained by an impervious polymer material. 
         [0147]      FIGS. 44A-44C  illustrate another embodiment where a projectile  351  has an axial elongated position in  FIG. 44B  and an axially shortened position shown in  FIGS. 44A and 44C . In this embodiment, an axially sliding component  352 , having a T-shape in cross section, slides in a recess of the tail portion  353  of the projectile body  354  to affect the axial compression of a ring shaped polymer member  355  that is essentially incompressible from a volumetric perspective. The polymer member expands radially when compressed axially as it is constrained by the tail  353  and T-shaped member  252 . The dashed lines in  FIG. 44C  indicate that the T-shaped member may have structure to cooperate with the recess to lock the projectile in the axial shortened position. A circumferential rib that is slid into a matching recess in the tail recess would accomplish such a locking. The polymer member may be elastomeric or may be formed of more than one component, for example, an outer skin and a different inner material, for example a gel material constrained by an impervious polymer material. 
         [0148]      FIGS. 45 and 46  illustrate embodiments of a manufacturing system conducive to use with the muzzleloading propellant cartridges described herein, particularly those cartridges shown in  FIGS. 20-25 , and  35 - 35 B. First, a size of a cartridge cup is selected from a plurality of stockpiles  400  of various sizes of the cartridge cups that corresponds to a specific volumetric quantity of propellant. As shown in  FIG. 46 , the “J” size reflecting the minimal side wall thickness of the illustrated options that corresponds to the maximal volumetric capacity of the three sizes illustrated and identified as J, K, and L. A specific propellant having desired characteristics is then selected and the cartridge is then filled from the specific one of the plurality of reservoirs  408  corresponding to the selected propellant. Then, a specific compaction level is selected and the head with the specific sized volumetric displacement portion corresponding to the compaction level is selected from the stockpiles  410  of the cartridge heads. The selected head is then assembled on to the cartridge cup with corresponding selected compaction of the propellant and the head is secured thereon providing the cartridge. The methodology as illustrated is particularly suitable for muzzleloading propellant cartridges where compaction of the propellant can provide enhanced burn characteristics, which is generally contrary to traditional loading of propellants in firearm cartridges. Of course, different methodologies of assembling the propellant cartridges do not require all of the above steps. For example, the step of selecting the particular cartridge cup size could eliminated from a particular method. Similarly, selecting the head compaction size could be eliminated in a particular methodology. The above methodologies are suitable for instituting in a factory setting to provide a variety of propellant cartridges with different performance characteristics. 
         [0149]    As used herein, propellant and propellant charges can be any propellant suitable for muzzleloader firing, including, propellant powder, flakes, and propellant pellets. The cartridge cups are illustrated as having a cylindrical exterior and interior walls but it is recognized that other shapes, in a cross section perpendicular to the cartridge cup axis, such as regular polygons, are also suitable and the inventions herein are not limited to circular tubular cartridge configurations unless specifically claimed. 
         [0150]    While the invention is amenable to various modifications and alternative forms, specifics thereof have been depicted by way of example in the drawings and described in detail. It is understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims. 
         [0151]    The above references in all sections of this application are herein incorporated by references in their entirety for all purposes. 
         [0152]    All of the features disclosed in this specification (including the references incorporated by reference, including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. 
         [0153]    Each feature disclosed in this specification (including references incorporated by reference, any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features. 
         [0154]    The invention is not restricted to the details of the foregoing embodiment (s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any incorporated by reference references, any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed The above references in all sections of this application are herein incorporated by references in their entirety for all purposes. 
         [0155]    Although specific examples have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement calculated to achieve the same purpose could be substituted for the specific examples shown. This application is intended to cover adaptations or variations of the present subject matter. Therefore, it is intended that the invention be defined by the attached claims and their legal equivalents, as well as the following illustrative aspects. The above described aspects embodiments of the invention are merely descriptive of its principles and are not to be considered limiting. Further modifications of the invention herein disclosed will occur to those skilled in the respective arts and all such modifications are deemed to be within the scope of the invention.