Patent Abstract:
An ammunition simulant including a first portion having a stud portion and a head portion. The stud portion is in coaxial alignment with the head portion, wherein the stud portion includes at least one engagement member. The simulant also includes a second portion formed by an injection molding process including a mold, wherein injection material is injected into the mold and the material flows about the base portion and the engagement member of the stud portion forming a union. Whereupon the ammunition simulant is formed upon hardening of the molten material and removal of the mold.

Full Description:
RELATED APPLICATIONS  
       [0001]    This application for letters patent is a continuation-in-part of pending application Ser. No. 09/239,126 filed on Jan. 28, 1999 (allowed).  
     
    
     
       FIELD OF THE INVENTION  
         [0002]    This invention relates generally to simulated ammunition devices. More particularly, this invention relates to simulated shotgun shells, simulated rimfire rounds and simulated centerfire rounds having a realistic appearance, feel and weight.  
         BACKGROUND AND SUMMARY OF THE INVENTION  
         [0003]    Law enforcement agencies, hunter safety organizations and others often provide firearm safety training in an effort to reduce the incidence of firearm related accidents. Safe use of shotguns, rifles and pistols is often demonstrated in such training, with such training including instruction in loading ammunition into the firearm and unloading unfired ammunition from firearm. It is undesirable to use actual live shotgun shells and rifle and pistol rounds for training in view of the inherent safety risks. In an attempt to simulate a shotgun shell, it is common for instructors to use previously fired and now empty shotgun shells, the casings of which have been re-crimped. However, empty shells do not adequately simulate a live round. Likewise, the use of empty centerfire pistol and rifle rounds is not adequate.  
           [0004]    With regard to the foregoing, the present invention is directed to a firearm ammunition simulant produced by an injection molding process.  
           [0005]    In a preferred embodiment, the ammunition simulant includes a first portion having a stud portion and a head portion. In accordance with the invention, the stud portion includes at least one engagement member having a structure extending towards or away from the stud portion, wherein the stud portion is in coaxial alignment with the head portion. The simulant also includes a second portion, and according to the invention is formed by an injection molding process. The injection molding process includes a mold and wherein injection material is injected into the mold. The injection material flows about the first portion and the engagement member of the stud portion forming a union. The ammunition simulant is formed upon hardening of the molten material and removal of the mold. The hardened mold material in the engagement member substantially prevents accidental separation of the first and second portions of the simulant.  
           [0006]    The first portion is preferably made of a metallic material, such as brass. The second portion is preferably molded from a polymeric material, such as plastic.  
           [0007]    In accordance with the invention, a method is provided for manufacturing the ammunition simulant. A solid, one piece base portion is provided having a longitudinal axis, a head which is substantially cylindrical in shape and includes a circumferential rim, and a stud including at least one engagement member extends co-axial to the longitudinal axis of the base portion. An injection mold device is provided to perform the injection molding, the device including a mold and mold material. The mold is located proximate to the base portion of ammunition simulant and a predetermined amount of mold material is injected by the device into the mold to form a mold portion. The mold portion encompasses the stud and engagement member of the base portion. Upon hardening of the mold, a union is formed between the base portion and mold portion substantially preventing accidental separation thereof. The mold is removed, providing the ammunition simulant.  
           [0008]    Simulated ammunition in accordance with the invention may be made to simulate shotgun shells, rimfire and centerfire rifle and pistol ammunition and other ammunition.  
           [0009]    To simulate a shotgun shell, the first portion is configured to resemble the case or hull of a shotgun shell and the second portion is configured to resemble the brass or base portion of a shotgun shell.  
           [0010]    To simulate rimfire ammunition, the first portion is configured to resemble the casing/bullet portion of rimfire ammunition and the second portion configured to resemble the base portion of rimfire ammunition where the primer is located.  
           [0011]    To simulate centerfire ammunition, the first portion is configured to resemble the casing/bullet portion of centerfire ammunition and the second portion configured to resemble the base portion of centerfire ammunition where the primer is located.  
           [0012]    The invention advantageously provides simulated ammunition which closely resembles the ammunition it simulates in appearance, feel and weight so as to give a realistic simulation experience. In addition, simulants in accordance with the invention are configured such that separation of the components are avoided.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]    The above and other features and advantages of the present invention will become further known from the following detailed description considered in conjunction with the accompanying drawings in which:  
         [0014]    [0014]FIG. 1 is an elevational side view of a shotgun shell simulant in accordance with a preferred embodiment of the invention.  
         [0015]    [0015]FIG. 2 is an exploded side view of the shotgun shell simulant of FIG. 1.  
         [0016]    [0016]FIG. 3 is a cross-sectional view of a hull portion of the shell simulant of FIG. 1.  
         [0017]    [0017]FIG. 4 is a cross-sectional view of a base portion of the shell simulant of FIG. 1.  
         [0018]    [0018]FIG. 5 is an elevational side view of a shotgun shell simulant in accordance with another embodiment of the invention.  
         [0019]    [0019]FIG. 6 is an exploded side view of the shotgun shell simulant of FIG. 5.  
         [0020]    [0020]FIG. 7 is a cross-sectional view of a hull portion of the shell simulant of FIG. 5.  
         [0021]    [0021]FIG. 8 is a cross-sectional view of a base portion of the shell simulant of FIG. 5.  
         [0022]    [0022]FIG. 9 is an elevational side view of a centerfire ammunition simulant in accordance with another embodiment of the invention.  
         [0023]    [0023]FIG. 10 is an exploded side view of the simulant of FIG. 9.  
         [0024]    [0024]FIG. 11 is a cross-sectional view of a casing/bullet portion of the shell simulant of FIG. 9.  
         [0025]    [0025]FIG. 12 is a cross-sectional view of a base portion of the shell simulant of FIG. 9.  
         [0026]    [0026]FIG. 13 is an exploded side view of another embodiment of a centerfire ammunition simulant.  
         [0027]    [0027]FIG. 14 is a side view of an alternative embodiment of the shell of FIG. 5 which enables a primer to be used in combination with the simulant.  
         [0028]    [0028]FIG. 15 is a side view of a rimfire ammunition simulant in accordance with yet another embodiment of the invention.  
         [0029]    [0029]FIG. 16 is an exploded side view of the rimfire ammunition simulant of FIG. to  15 .  
         [0030]    [0030]FIG. 17 is an exploded side view of another embodiment of a rimfire ammunition simulant in accordance with the invention.  
         [0031]    [0031]FIG. 18 is an isometric view of a centerfire ammunition simulant in accordance with yet another embodiment of the invention.  
         [0032]    [0032]FIG. 19 is a side view of the centerfire ammunition simulant of FIG. 18.  
         [0033]    [0033]FIG. 20 is a side view of a portion of the centerfire ammunition simulant of FIGS. 19 and 20, and FIG. 20 a  is a representative view of a mold for use in making the simulant.  
         [0034]    [0034]FIG. 20 b  is a side view of a portion of a centerfire ammunition simulant in accordance with another embodiment of the invention.  
         [0035]    [0035]FIG. 21 is a side view of a shotgun shell simulant in accordance with yet another embodiment of the invention.  
         [0036]    [0036]FIG. 22 is a side view of a portion of the shotgun shell simulant of FIG. 21, and FIG. 22 a  is a representative view of a mold for use in making the simulant.  
         [0037]    [0037]FIG. 23 is a side view of a rimfire ammunition simulant in accordance with yet another embodiment of the invention.  
         [0038]    [0038]FIG. 24 is a side view of a portion of the rimfire ammunition simulant of FIG. 23, and FIG. 24 a  is a representative view of a mold for use in making the simulant.  
     
    
     DETAILED DESCRIPTION  
       [0039]    With initial reference to FIG. 1, there is shown a shotgun shell simulant  10  having a case or hull portion  12  and a base portion  14 . The simulant  10  has an appearance, feel and weight which provides realistic simulation of a live or loaded shotgun shell. Advantageously, the hull portion  12  is fixedly secured to the base portion  14  in a manner that avoids accidental separation of the hull portion  12  from the base portion  14 .  
         [0040]    Avoidance of accidental separation is desirable to render the shell simulant  10  suitable for training purposes with a variety of shotguns including those having a pump action wherein shells are cycled from a magazine of a shotgun to a firing chamber and then ejected by operation of the pump action by a user. It would be undesirable for separation of the components to occur, i.e., separation of the hull and base portions, since one or both of the components could remain in the shotgun and render it unusable or unsafe for subsequent use with live ammunition.  
         [0041]    Turning to FIGS. 2, 3 and  4 , the hull portion  12  is preferably of solid, one-piece construction, preferably made of a plastic or polymeric material, most preferably nylon, using known molding techniques. The hull portion  12  is substantially cylindrical in shape to correspond in size and shape to the hull portion  12  of a shotgun shell. The hull portion  12  includes a threaded, preferably blind bore  16  co-axial to the center line of the hull portion and open at one end of the hull portion  12  for receiving a corresponding portion of the base  14 . The bore  16  may be provided, as by drilling and threading.  
         [0042]    The base portion  14  is preferably of solid, one-piece construction, preferably made of a metallic material, most preferably brass, using known milling or turning techniques. The base portion  14  includes a head  18  which is substantially cylindrical in shape and includes a circumferential rim  20  to simulate the appearance and external structure of the base portion of a shotgun shell. The base portion  14  includes a stud  22  extending co-axial to the center line of the base portion and threaded so as to be threadably receivable within the blind bore  16  of the hull portion  12 .  
         [0043]    A bore  24  is also preferably centrally provided on the head  18  opposite the stud  22  as clearance for a firing pin of a shotgun so that the shotgun may be dry fired when the simulated shell  10  is positioned within a firing chamber of the shotgun. Additionally, a resilient energy absorbing material, such as foam or a spring, may be placed within the bore  24  for dry firing purposes for avoiding damage to the firing pin of the shotgun.  
         [0044]    For the purpose of an example, the hull  12  is preferably dimensioned as set forth in Table 1 below to simulate the hull of a 12 gauge shotgun shell. It will be appreciated that the hull  12  may be provided in various dimensions to enable its use with various other gauges such as 16 gauge, 20 gauge, 28 gauge and 410 bore shotguns.  
                           TABLE 1                                   Dimension   Inches                           A   1.0 length, 0.3125 inch diameter and               threaded (3/8-16 thread)           B   0.78           C   1.95                      
 
         [0045]    Likewise, the base  14  is preferably dimensioned as set forth in Table 2 below to simulate the base or brass portion of a 12 gauge shotgun shell.  
                           TABLE 2                                   Dimension   Inches                           D   0.975           E   0.375           F   0.650 (3/8-16 thread)           α   95°           G   0.050           H   0.325           I   0.800           J   0.881                      
 
         [0046]    The hull portion  12  as configured above preferably has a weight of from about 13 grams to about 19 grams and the base portion  14  as configured above preferably has a weight of from about 32 grams to about 36 grams, such that the overall weight of the simulated shell is from about 47 grams to about 53 grams. It has been observed that this range substantially approximates the typical weight range of shotgun shells, whose weight generally varies from about 41 grams to about 67 grams, depending on the powder and shot charge and other characteristics of the shotgun shell.  
         [0047]    With reference now to FIG. 5, there is shown an alternate embodiment of a shotgun shell simulant  50  having a hull portion  52  and a base portion  54 . The simulant  50  also has an appearance, feel and weight which provides realistic simulation of a live shotgun shell. Advantageously, the hull portion  52  is fixedly secured to the base portion  54  in a manner that avoids accidental separation of the hull portion  52  from the base portion  54 .  
         [0048]    Turning to FIGS. 6, 7 and  8 , the hull portion  52  is preferably of solid, one-piece construction, preferably made of a plastic or polymeric material, most preferably nylon, using known molding techniques. The hull portion  52  is substantially cylindrical in shape to correspond in size and shape to the hull portion of a shotgun shell. The hull portion  52  includes a blind bore  56  co-axial to the center line of the hull portion and open at one end of the hull portion  52  for receiving a corresponding portion of the base  54 . The bore  56  may be provided, as by drilling, and is preferably of smooth bore.  
         [0049]    The base portion  54  is preferably of solid, one-piece construction, preferably made of a metallic material, most preferably brass, using known turning or milling techniques. The base portion  54  includes a head  58  which is substantially cylindrical in shape and includes a circumferential rim  60  to simulate the appearance of the base portion of a shotgun shell. The base portion  54  includes a stud  62  extending co-axial to the center line of the base portion and configured so as to be receivable within the blind bore  56  of the hull portion  52 . In this regard, the stud  62  preferably includes a plurality of projections or protrusions such as annular rings, serrations or angled barbs  63  for frictionally and mechanically engaging the sidewalls of the bore  56  of the hull portion  52  to retain the stud  62  within the bore  56 . The shell simulant  50  may be readily assembled by press-fitting the stud  62  into the bore  56 , the barbs  63  being of sufficient dimension to provide a fit sufficient to maintain the assembly of the shell  50  during use of the shell as a training device with shotguns.  
         [0050]    A blind bore  64  is also preferably centrally provided on the head  58  opposite the stud  62  as clearance for a firing pin of a shotgun so that the shotgun may be dry fired when the simulated shell  50  is positioned within the firing chamber of the shotgun.  
         [0051]    The bore  64  (and blind  24 ) is preferably blind. However, it will be understood that the bore  64  may be made contiguous through the stud  62  and communicate with the bore  56 , which may be extended to communicate with the other end of the hull portion. This would provide a continuous open bore  55  such that a live primer could be seated in the bore  64  (or bore  24 ) and fired to simulate firing of the shotgun. See, FIG. 14.  
         [0052]    For the purpose of an example, the hull  52  is preferably dimensioned as set forth in Table 3 below to simulate the hull of a 12 gauge shotgun shell. It will be appreciated that the hull  52  may be provided in various dimensions to enable its use with various other gauges such as 16 gauge, 20 gauge and 410 bore shotguns.  
                           TABLE 3                                   Dimension   Inches                           K   1.0 length, 0.3125 inch diameter           L   0.78           M   1.95                      
 
         [0053]    Likewise, the base  54  is preferably dimensioned as set forth in Table 4 below to simulate the base or brass portion of a 12 gauge shotgun shell.  
                           TABLE 4                                   Dimension   Inches                           N   0.975           O   0.375           P   0.650           β   95°           Q   0.050           R   0.325           S   0.800           T   0.881                      
 
         [0054]    The shell  50  (and the components thereof) has a weight which substantially corresponds to that of the shell  10  (and components thereof) as previously described.  
         [0055]    With reference now to FIG. 9, there is shown an alternate embodiment of an ammunition simulant  80  having a casing/bullet portion  82  and a base portion  84 . The simulant  80  also has an appearance, feel and weight which provides realistic simulation of live centerfire ammunition. Advantageously, the casing/bullet portion  82  is fixedly secured to the base portion  84  in a manner that avoids accidental separation of the casing/bullet portion  82  from the base portion  84 .  
         [0056]    Turning to FIGS. 10, 11 and  12 , the casing/bullet portion  82  is preferably of solid, one-piece construction, preferably made of a plastic or polymeric material, most preferably nylon, using known molding techniques. The casing/bullet portion  82  has a substantially cylindrical casing portion  82   a,  the exterior of which corresponds in size and shape to the exterior of the casing portion of a conventional centerfire ammunition round and a bullet portion  82   b  which corresponds in size and shape to the exposed portion of a bullet as seated in a conventional centerfire round. The casing/bullet portion  82  includes a preferably blind bore  86  co-axial to the center line of the casing/bullet portion and open at one end of the casing/bullet portion  82  for receiving a corresponding portion of the base  84 . The bore  86  may be provided, as by drilling, and is preferably of smooth bore.  
         [0057]    The base portion  84  is preferably solid, one-piece construction, preferably made of a metallic material, most preferably brass, using known milling and turning techniques. The base portion  84  includes a head  88  having a circumferential groove/rim  90  to simulate the appearance of the base portion of centerfire ammunition. The base portion  84  includes a stud  92  extending co-axial to the center line of the base portion and configured so as to be receivable within the bore  86  of the casing/bullet portion  82 . In this regard, the stud  92  preferably includes a plurality of protrusions such as annular rings or angled barbs  93  for frictionally and mechanically engaging the sidewalls of the bore  86  of the casing/bullet portion  82  to retain the stud  92  within the bore  86 . The shell simulant  80  may be readily assembled by press-fitting the stud  92  within the bore  86  to provide a fit sufficient to maintain the assembly of the shell  80  during use of the shell as a training device with centerfire firearms. Alternatively, as shown in FIG. 13, the simulant  80  may include a stud  92 ′ which is threaded and a bore  86 ′ having receiving threads in the manner previously described in connection with the simulant  10 .  
         [0058]    A blind bore  94  is also preferably centrally provided on the head  88  opposite the stud  92  as clearance for a firing pin of a centerfire pistol or rifle so that the pistol or rifle may be dry fired when the simulated shell  80  is positioned within the firing chamber of the firearm. The bore  94  may also be made contiguous with the bore  86  to provide a continuous bore for enabling use of a primer.  
         [0059]    For the purpose of an example, the casing/bullet  82  is preferably dimensioned as set forth in Table 5 below to simulate the casing/bullet of a 9 mm Luger centerfire pistol round. It will be appreciated that the casing/bullet  82  may be provided in various dimensions to enable its use with various other centerfire pistol and rifle calibers, e.g., 45 cal., 30-06 Springfield and the like.  
                           TABLE 5                                   Dimension   Inches                           U   0.5 - depth, .221 - diameter           V   0.387           W   0.545           X   0.800           Y   0.335           Z   0.325                      
 
         [0060]    Likewise, the base  84  is preferably dimensioned as set forth in Table 6 below to simulate the base of a 9 mm centerfire pistol round.  
                           TABLE 6                                   Dimension   Inches                           AA   0.370           BB   0.160           CC   0.387           DD   0.530           EE   0.224           FF   0.187                      
 
         [0061]    The casing/bullet portion  82  as configured above preferably has a weight of from about 0.03 oz. to about 0.07 oz. and the base portion  84  as configured above preferably has a weight of from about 0.015 oz. to about 0.025 oz., such that the overall weight of the simulated shell is from about 0.02 oz. to about 0.03 oz. It has been observed that this range substantially approximates the typical weight of 9 mm centerfire pistol rounds, which generally weigh from about 0.03 oz. to about 0.04 oz., depending on the bullet weight.  
         [0062]    With reference now to FIG. 15, there is shown yet an alternate embodiment of an ammunition simulant  96  having a casing/bullet portion  98  and a base portion  100  The simulant  96  also has an appearance, feel and weight which provides realistic simulation of live rimfire ammunition, e.g. 22 long rifle ammunition. Advantageously, the casing/bullet portion  98  is fixedly secured to the base portion  100  in a manner that avoids accidental separation of the casing/bullet portion  98  from the base portion  100 .  
         [0063]    With additional reference to FIG. 16, the casing/bullet portion  98  is preferably of solid, one-piece construction, preferably made of a plastic or polymeric material, most preferably nylon as by injection molding. The casing/bullet portion  98  has a substantially cylindrical casing portion  102  and a bullet portion  104 . The casing/bullet portion  98  is attached to the base portion  100  to yield the simulant  96 , having a size and shape corresponding to the size and shape of a conventional rimfire round. The casing/bullet portion  98  includes a preferably blind bore  106  co-axial to the center line of the casing/bullet portion and open at one end of the casing/bullet portion  98  for receiving a corresponding portion of the base  100  The bore  106  may be provided, as by drilling, and is preferably of smooth bore.  
         [0064]    The base portion  100  is preferably solid, one-piece construction, preferably made of a metallic material, most preferably brass, as by milling. The base portion  100  includes a head  108  having a circumferential rim  110  to simulate the appearance of the base portion of rimfire ammunition. The base portion  100  includes a stud  112  extending co-axial to the center line of the base portion  100  and configured so as to be receivable within the bore  106  of the casing/bullet portion  98 . In this regard, the stud  112  preferably includes a plurality of protrusions such as annular rings or angled barbs  114  for frictionally and mechanically engaging the sidewalls of the bore  106  of the casing/bullet portion  98  to retain the stud  112  within the bore  106 . The shell simulant  96  may be readily assembled by press-fitting the stud  112  within the bore  106  to provide a fit sufficient to maintain the assembly of the shell  96  during use of the shell as a training device with rimfire firearms.  
         [0065]    Alternatively, as shown in FIG. 17, base portion  100 ′ may include a threaded stud  116  and casing/bullet portion  98 ′ include a corresponding threaded bore  118  for receiving the stud  116 .  
         [0066]    For the purpose of an example, the casing/bullets  98  and  98 ′ and base portions  100  and  100 ′ are preferably dimensioned as set forth in Table 7 below and FIG. 16, so that when assembled they simulate a 0.22 long rifle rimfire round. It will be appreciated that the casing/bullets  98  and  98 ′ and base portions  100  and  100 ′ may be provided in various dimensions to enable its use with various other rimfire pistol and rifle calibers, e.g., 0.22 short, long, 22 WMR and the like.  
                           TABLE 7                                   Dimension   Inches                           A4   .375 depth, .110 - diameter           B4   .221           C4   .035           D4   .325           E4   .175           F4   .095           G4   .120           H4   .270                      
 
         [0067]    The casing/bullet portion  98  as configured above preferably has a weight of from about ⅛oz. to about ¼oz. and the base portion  100  as configured above preferably has a weight of from about ¼oz. to about ½oz., such that the overall weight of the simulated shell is from about ⅜oz. to about ¾oz. It has been observed that this range substantially approximates the typical weight of 0.22 long rifle rimfire rounds, which generally weigh from about ½oz. to about ¾oz., depending on the bullet weight.  
         [0068]    Referring now to FIG. 18, there is shown an injection molded centerfire ammunition simulant  210  in accordance with still another embodiment of the invention. The simulant  210  includes a casing/bullet portion  212  and a base portion  214 . The injection molding process is suitable for providing a variety of simulants, including but not limited to centerfire and rimfire ammunition, and shotgun shell simulants. The simulants in accordance with the invention have an appearance, feel and weight which provides realistic simulation of live ammunition. Simulants  210  manufactured in accordance with the invention advantageously have the casing/bullet portion  212  fixedly secured to the base portion  214  in a manner that helps to avoid accidental separation of the casing/bullet portion  212  from the base portion  214  together with a permanent in-situ portion for dissipating shock on a firing pin for dry-firing purposes.  
         [0069]    Preferably, the base portion  214  of the centerfire simulant  210  is of a solid, one-piece construction, preferably made of a metallic material, most preferably brass, using known milling or turning techniques. As described further below, an injection molding process is used to fixedly secure the casing/bullet portion  212  to the base portion  214  in a manner that helps to avoid accidental separation of the casing/bullet portion  212  from the base portion  214 .  
         [0070]    With additional reference to FIG. 19, the base portion  214  includes a head  216  having a circumferential groove/rim  218  to simulate the appearance of the base portion of centerfire ammunition. The groove/rim  218  enables the extractor mechanism of the centerfire weapon to engage the simulant  210  when the simulant  210  is loaded from an ammunition cartridge into the firing chamber of the weapon. The base portion  214  includes a stud  220  that preferably extends co-axially to the center line of the base portion  214 . The stud  220  preferably has a diameter which is less than the diameter of the base portion  214 , and as described further below, the injection molded casing/bullet portion  212  encompasses the difference once the molded casing/bullet portion is injection molded to the stud  220 .  
         [0071]    The stud  220  includes a circumferential recess  222  having a width and a depth, which is preferably proximately located with respect to the head  216 . However, the circumferential recess  222  can be located at various locations along the length of the stud  220 . Moreover, more than one circumferential recess  222  can be located along the length of the stud  220 , wherein the width of each circumferential recess  222  preferably decreases as the number of circumferential recesses increases along the length of the stud  220 . As described further below, as the length of the stud  220  increases, it is preferred that more than one circumferential recess  222  be located along the length of the stud  220 .  
         [0072]    The base portion  214  also preferably includes a coaxial bore  224  having a diameter, extending therethrough. The centerfire base portion  214  is dimensioned according to the desired ammunition simulant  210 . With additional reference to FIGS. 20 and 20 b,  Table 8 lists examples of dimensions (in inches) for the base portion  214  and the casing/bullet portion  212  according to various centerfire ammunition types.  
                                                                                                     TABLE 8                       Dimension                                               (millimeters)   A1   B1   C1   D1   E1   F1   G1   H1   J1   K1                                Simulant                                               9 mm   .462   .218   .258   .690   .335   .140   .387   .300   .500   .300       .270   1.740   .200   .250   1.948   .394   .140   .468   .300   1.957   1.045       .30-06   1.750   .200   .260   1.948   .399   .170   .468   .310   1.986   1.132       .44 mag   1.050   .200   .250   1.270   .450   .170   .508   .300   1.070   .300                  
 
         [0073]    The base portion  214  and its constituent elements provide a structure for adhering molten plastic to the base portion  214 , forming the casing/bullet  212 , thereby operating to replicate various ammunition types according to the specific mold used for a desired centerfire simulant  210 . The casing/bullet portion  212  has a substantially cylindrical casing portion  226 , the exterior of which corresponds in size and shape to the exterior of the casing portion of a conventional centerfire ammunition round and a bullet portion  228  which corresponds substantially in size and shape to the exposed portion of a bullet as seated in a conventional centerfire round.  
         [0074]    Once it is decided to which type or types of ammunition simulants are desired, in accordance with the invention a specific mold  229  (FIG. 20 a ) is provided for the casing/bullet portion  212  having dimensions which are substantially the same as the live ammunition to which the simulant  210  is modeled. Referring again to FIG. 19 and Table 8, various dimensions are shown for different casing/bullet types according to the centerfire ammunition simulant.  
         [0075]    The injection molding process utilizes the mold to inject a mold material such as a plastic or polymeric material, such as nylon, for example. Once a particular mold is selected according to the desired ammunition type along with the corresponding base portion  214 , the mold is placed about the base portion  214  so that the stud  220  is substantially completely encompassed by the mold abutting against the head  216 . Once the mold is in place, the injection molding equipment is preferably operated to inject molten polymeric material into the mold through an orifice provided with the mold. The molten material flows through the orifice and into the mold encompassing the stud  220  and filling in the space defined by the differing stud and head diameters. The molten material also flows into and throughout the coaxial bore  224  and circumferential recess  222 .  
         [0076]    After a predetermined amount of time, the mold material hardens and the mold is removed. Any excess mold material may be removed by grinding or cutting, leaving a simulant, such as the centerfire ammunition simulant  210  of FIG. 18. Preferably, the machining of the base portion  214  and the injection molding process is automated so that all that is required is for a user to input a desired ammunition simulant type, for example through a peripheral device, such as a handheld computer, and one or more ammunition simulants are produced according to the input. Preferably, the peripheral device includes the various dimensional characteristics of each simulant type in memory or can be input by the user.  
         [0077]    Once the mold sets, the casing/bullet portion  212  is frictionally and mechanically engaged to the base portion  214 . More specifically, a “lock” is formed between the set mold and the circumferential recess  222 , so that the casing/bullet portion  212  is substantially permanently attached to the base portion  214 , providing a fit sufficient to maintain the assembly of the casing/bullet portion  212  during use of the simulant  210  as a training device with centerfire firearms. Furthermore, a dampening mechanism is provided by the mold material encompassing the bore  224  of the base portion. More specifically, when the simulant  210  is chambered in a weapon and “dry fired”, the material in the bore  224  acts to dissipate the shock conveyed by the firing pin of the weapon, thereby substantially reducing the damage to the firing pin of the weapon.  
         [0078]    As an example, the casing/bullet portion  212  for a 9 mm simulant  210  as configured above preferably has a weight of from about 0.03 oz. to about 0.07 oz. and the base portion  214  for a 9 mm simulant  210  as configured above preferably has a weight of from about 0.015 oz. to about 0.025 oz., such that the overall weight of the simulated centerfire ammunition is from about 0.02 oz. to about 0.03 oz. It has been observed that this range substantially approximates the typical weight of 9 mm centerfire pistol rounds, which generally weigh from about 0.03 oz. to about 0.04 oz., depending on the bullet weight.  
         [0079]    Referring now to FIGS. 21 and 22, and with additional reference to Table 9, a description of an injected molded shotgun shell simulant  230  follows. The shotgun shell simulant  230  includes a base portion  232  and a hull portion  234 . The base portion  234  includes a head  236  which is substantially cylindrical in shape and includes a circumferential rim  238  to simulate the appearance and external structure of the base portion of a shotgun shell. The base portion  232  includes a stud  240  extending co-axial to the center line of the base portion  232  and includes one or more, most preferably two circumferential recesses  242 . The base portion  232  also preferably includes a bore  244  coaxially located therethrough.  
                                                   TABLE 9                       Dimension                                           (inches)   A2   B2   C2   D2   E2   F2   G2   H2   J2                   Simulant                                           12 gauge   1.0   .450   .540   1.450   .795   .175   .880   .600   1.825       16 gauge   1.0   .450   .500   1.450   .730   .175   .809   .550   1.850       20 gauge   1.0   .450   .320   1.450   .690   .175   .756   .380   1.850       28 gauge   1.0   .380   .260   1.450   .615   .175   .681   .440   1.850       .410 bore   1.0   .450   .260   1.450   .472   .150   .528   .300   1.790                  
 
         [0080]    The injection molding process is substantially the same for a shotgun shell simulant  230  as for the centerfire simulant  210  described above. The base portion  232  and its constituent elements provide a structure for adhering molten plastic to the base portion  232 , forming the hull  234 , thereby operating to replicate various shell types according to the specific mold used for a desired shotgun shell simulant  230 . The hull  234  is substantially cylindrical, the exterior of which corresponds in size and shape to the exterior of the hull portion of a conventional shotgun shell.  
         [0081]    Once it is decided to which type or types of shotgun shell simulants  230  are desired, according to the invention, a specific mold  235  (FIG. 22 a ) is provided for the hull  234  having dimensions which are substantially the same as the shotgun shell hull to which the simulant  230  is modeled. Referring again to FIG. 21 and Table 9, various dimensions are shown for different hull types according to the shotgun shell simulant  230 .  
         [0082]    As described above, the injection molding process utilizes the mold to inject a mold material such as nylon. Once a particular mold is selected according to the desired shell type along with the corresponding base portion  232 , the mold is placed about the base portion  232  so that the stud  240  is completely encompassed by the mold abutting against the head  236 . Once the mold is in place, the injection molding equipment injects molten mold material into the mold through an orifice provided with the mold. The molten material flows through the orifice and into the mold encompassing the stud  240  and filling in the space defined by the differing stud and head diameters. The molten material also flows into and throughout the coaxial bore  244  and the circumferential recesses  242 .  
         [0083]    After a predetermined amount of time, the mold material hardens and the mold is removed. Any excess mold material may be removed by grinding or cutting, leaving a simulant, such as the shotgun shell simulant of FIG. 21. Preferably, the machining of the base portion  232  and the injection molding process is automated so that all that is required is for a user to input a desired shell simulant type, for example through a peripheral device, such as a handheld computer, and one or more shell simulants are produced according to the input. Preferably, the peripheral device includes the various dimensional characteristics of each simulant type in memory or can be input by the user.  
         [0084]    According to the invention, once the mold sets, the hull  234  is frictionally and mechanically engaged to the base portion  232 . More specifically, a “lock” is formed between the set mold and the circumferential recesses  242 , so that the hull  234  is substantially permanently attached to the base portion  232 , providing a fit sufficient to maintain the assembly of the hull  234  during use of the shotgun shell simulant  230  as a training device with shotguns. Furthermore, a dampening mechanism is provided by the mold material encompassing the bore  244  of the base portion  232 . More specifically, when the shell simulant  230  is chambered in a shotgun and “dry fired”, the material in the bore  244  acts to dissipate the shock conveyed by the firing pin of the shotgun, thereby substantially reducing the damage to the firing pin.  
         [0085]    The hull  234  configured above preferably has a weight of from about 13 grams to about 19 grams and the base portion  232  as configured above preferably has a weight of from about 32 grams to about 36 grams, such that the overall weight of the shotgun shell simulant  230  is from about 47 grams to about 53 grams. It has been observed that this range substantially approximates the typical weight range of live shotgun shells, whose weight generally varies from about 41 grams to about 67 grams, depending on the powder and shot charge and other characteristics of the shotgun shell.  
         [0086]    Referring now to FIG. 23, there is shown a side view of an injection molded rimfire ammunition simulant  310  in accordance with yet another embodiment of the invention. The simulant  310  includes a casing/bullet portion  312  and a base portion  314  formed according to an injection molding process as described in greater detail below. As described above with respect to centerfire and shotgun simulants, the injection molding process is further operable to provide rimfire ammunition simulants. The rimfire simulant  310  has an appearance, feel and weight which provides realistic simulation of live rimfire ammunition. Simulants  310  manufactured in accordance with the invention advantageously have the casing/bullet portion  312  fixedly secured to the base portion  314  in a manner that helps to avoid accidental separation of the casing/bullet portion  312  from the base portion  314 .  
         [0087]    Preferably, the base portion  314  of the rimfire simulant  310  is of a solid, one-piece construction, preferably made of a metallic material, most preferably brass, using known milling or turning techniques. As described further below, an injection molding process is used to fixedly secure the casing/bullet portion  312  to the base portion  314  in a manner that helps to avoid accidental separation of the casing/bullet portion  312  from the base portion  314 .  
         [0088]    With additional reference to FIG. 24, the base portion  314  includes a head  316  having a circumferential rim  318  to simulate the appearance of the base portion of rimfire ammunition. The rim  318  enables the extractor mechanism of the rimfire weapon to engage the simulant  310  when the simulant  310  is loaded from an ammunition cartridge into the firing chamber of the weapon. The rim  318  further provides the necessary structure for the firing mechanism of a rimfire weapon to strike the rim when ‘fired’. The base portion  314  includes a stud  320  that preferably extends co-axially to the center line of the base portion  314 . The stud  320  preferably has a diameter which is less than the diameter of the base portion  314 , and to as described further below, the injection molded casing/bullet portion  312  encompasses the difference once the molded casing/bullet portion is injection molded to the stud  320 .  
         [0089]    The stud  320  includes a circumferential recess  322  having a width and a depth, which is preferably proximately located with respect to the head  316 . However, the circumferential recess  322  can be located at various locations along the length of the stud  320 . Moreover, more than one circumferential recess  322  can be located along the length of the stud  320 , wherein the width of each circumferential recess  322  preferably decreases as the number of circumferential recesses increases along the length of the stud  320 . As the length of the stud  320  increases, it is preferred that more than one circumferential recess  322  be located along the length of the stud  320 .  
         [0090]    The rimfire base portion  314  is dimensioned according to the desired ammunition simulant  310 . Table 10 lists examples of dimensions (in inches) for the base portion  314  and the casing/bullet portion  312  according to various rimfire ammunition types.  
                                                                                     TABLE 10                       Dimension                                       (millimeters)   A3   B3   C3   D3   E3   F3   G3   H3                                Simulant                                       .22 short   .300   .150   .119   .450   .223   .149   .270   .532       .22 long   .400   .150   .119   .550   .223   .149   .270   .720       .22 long rifle   .400   .150   .119   .550   .223   .149   .270   .825       .22 Mag.   .850   .150   .139   1.0   .237   .159   .288   1.180                  
 
         [0091]    The base portion  314  and its constituent elements provide a structure for adhering molten plastic to the base portion  314 , forming the casing/bullet  312 , thereby operating to replicate various ammunition types according to the specific mold used for a desired rimfire simulant  310 . The casing/bullet portion  312  has a substantially cylindrical casing portion  326 , the exterior of which corresponds in size and shape to the exterior of the casing portion of a conventional rimfire ammunition round and a bullet portion  328  which corresponds substantially in size and shape to the exposed portion of a bullet as seated in a conventional rimfire round.  
         [0092]    Once it is decided to which type or types of rimfire ammunition simulants are desired, in accordance with the invention a specific mold  329  (FIG. 24 a ) is provided for the casing/bullet portion  312  having dimensions which are substantially the same as the live ammunition to which the simulant  310  is modeled. Referring again to FIG. 23 and Table 10, various dimensions are shown for different casing/bullet types according to the rimfire ammunition simulant.  
         [0093]    The injection molding process utilizes the mold to inject a mold material such as a plastic or polymeric material, such as nylon, for example. Once a particular mold is selected according to the desired ammunition type along with the corresponding base portion  314 , the mold is placed about the base portion  314  so that the stud  320  is substantially completely encompassed by the mold abutting against the head  316 . Once the mold is in place, the injection molding equipment is preferably operated to inject molten polymeric material into the mold through an orifice provided with the mold. The molten material flows through the orifice and into the mold encompassing the stud  320  and filling in the space defined by the differing stud and head diameters. The molten material also flows into and throughout the circumferential recess  322 .  
         [0094]    After a predetermined amount of time, the mold material hardens and the mold is removed. Any excess mold material may be removed by grinding or cutting, leaving a simulant, such as the rimfire ammunition simulant  310  of FIG. 23. Preferably, the machining of the base portion  314  and the injection molding process is automated so that all that is required is for a user to input a desired ammunition simulant type, for example through a peripheral device, such as a handheld computer, and one or more ammunition simulants are produced according to the input. Preferably, the peripheral device includes the various dimensional characteristics of each simulant type in memory or can be input by the user.  
         [0095]    According to the invention, once the mold sets, the casing/bullet portion  312  is frictionally and mechanically engaged to the base portion  314 . More specifically, a “lock” is formed between the set mold and the circumferential recess  322 , so that the casing/bullet portion  312  is substantially permanently attached to the base portion  314 , providing a fit sufficient to maintain the assembly of the casing/bullet portion  312  during use of the simulant  310  as a training device with rimfire firearms.  
         [0096]    As an example, the casing/bullet portion  314  for a .22 long rifle simulant  310  as configured above preferably has a weight of from about ⅛oz. to about ¼oz. and the base portion  314  for a .22 long rifle simulant  310  as configured above preferably has a weight of from about ¼oz. to about ½oz., such that the overall weight of the simulated rimfire ammunition is from about ⅜oz. to about ¾oz. It has been observed that this range substantially approximates the typical weight of .22 long rifle rimfire rounds, which generally weigh from about ½oz. to about ¾oz., depending on the bullet weight.  
         [0097]    Ammunition simulants in accordance with the invention are suitable for use in conventional firearms for training purposes and are compatible with the mechanisms thereof. That is, the simulants are configured so that they mechanically cooperate with magazine, feed and ejection mechanisms of conventional firearms in the same manner as ammunition does. This enables the actions of the firearms, such as the pump or lever action of a firearm, to be operated to cycle the simulants through the firearm in the same manner as live ammunition for the purpose of training. It should be noted that the examples described herein are not intended to limit the invention in any way, and furthermore, the invention is operable to provide ammunition simulants for virtually any weapon type.  
         [0098]    The foregoing description of certain embodiments of the present invention has been provided for purposes of illustration only, and it is understood that numerous modifications or alterations may be made in and to the illustrated embodiments without departing from the spirit and scope of the invention as defined in the following claims.

Technology Classification (CPC): 5