PRE-FORMED DIFFUSER DISK FOR PRIMER POCKET INSERTION

Abstract

A process for loading a primer into an ammunition cartridge while concurrently forming a diffuser disk includes stamping a sheet to pre-form a diffuser disk therein. The primer, pre-formed diffuser disk and primer pocket of the cartridge are aligned with one another and thereafter, the primer is pressed through the pre-formed diffuser disk into the primer pocket. As the primer is pressed into the pre-formed diffuser disk, the primer severs one or more attachment points to release the pre-formed disk from the sheet and form the diffuser disk while the primer is loaded.

Description

BACKGROUND OF THE INVENTION

Field of the Invention

The present disclosure relates generally to ammunition cartridges, and, more particularly to improved diffuser disks and processes for loading the improved diffuser disks into ammunition cartridges.

Description of Related Art

Conventional ammunition cartridges have long been made from brass, which is expensive, heavy, and potentially hazardous. In terms of military use, the weight of brass cartridges en masse adds to the overall weight a soldier or vehicle must carry. The combined weight limits the amount of brass cartridges that the individual soldier can carry on their person and presents further logistical issues for transportation and use by military vehicles. For instance, a box of .50 caliber brass ammunition cartridges plus links can weigh about 35 pounds (100 brass cartridges plus links). Military personnel and vehicles, especially winged and rotary vehicles such as fighter jets or helicopters, are therefore limited in the quantity of cartridges they can carry due to the significant weight of these cartridges when considered en masse.

Thus, there has long been a need for a lighter weight alternative to the conventional brass ammunition cartridge. Polymer cartridges have been considered a desirable alternative to brass cartridges for decades but prior polymer cartridges have not yet met industry and military performance standards.

To ensure polymer-based ammunition cartridges are safe and reliable during a firing event and the subsequent extraction from the firearm, the materials chosen to form the case must be sufficiently durable to withstand the pressure and heat exerted during and after the firing event.

In some instances, the cartridge body may be molded from a polymer material while a separate base-insert is formed from metal and attached to the cartridge body. For example, Applicant's U.S. Pat. No. 8,561,543 teaches a multi-piece polymer-based cartridge body that is engaged to a metallic base-insert. A problem that was discovered with regard to Applicant's U.S. Pat. No. 8,561,543 is that detonation of the primer in the base-insert tended to weaken the connection between the base and the cartridge body. Therefore, Applicant invented the diffuser disk, which is inserted into a primer pocket of the base-insert to provide additional protection around the flash hole, where a major portion of the connection between the cartridge body and the base-insert is concentrated.

However, additional problems with the diffuser disk and loading of the polymer-based cartridge have persisted. Therefore, what is needed is an improved process for loading polymer-based ammunition cartridges that can be implemented on conventional ammunition loading equipment.

SUMMARY OF THE INVENTION

The inventive concepts disclosed herein relate generally to improved processes for loading primers concurrently with diffuser disks into ammunition cartridges, particularly polymer-based ammunition cartridges. Further disclosed are pre-formed disks for use in the improved loading process, where the pre-formed disks are engineered to add a layer of protection to the primer pocket of polymer-based cartridges after being loaded therein with the primer. The improved process and pre-formed disks can be used for virtually all calibers of ammunition cartridges, including pistol, rifle, and shotgun ammunition for military and civilian use. Conventional ammunition loading equipment may be implemented with the disclosed process to streamline primer loading in polymer-based ammunition cartridges. The disclosed process and devices thereof, particularly the pre-formed diffuser disk, can be implemented on industrial sized ammunition loading equipment found in many ammunition manufacturer's plants as well as with at-home loading equipment typically used by individuals for reloading ammunition cartridges. The at-home equipment may be small, handheld devices for manually loading a primer into the cartridge or small automated machines that accomplish such. The disclosed process and devices thereof can be used similarly in both scenarios for at-home reloading of polymer-based ammunition cartridges.

In one embodiment of the invention, a process for loading a diffuser disk into an ammunition cartridge is disclosed. The process involves stamping a sheet to pre-form the diffuser disk therein. In preferred embodiments, the sheet is a metal sheet having a thickness of substantially about 0.005 inches. The sheet may be a copper sheet or a different metal with similar physical properties to copper. The pre-formed diffuser disk remains connected to the sheet by at least one attachment point formed about an outer perimeter of the pre-formed disk. A diffuser aperture is stamped through the sheet concurrently with the stamping of the pre-formed disk therein. The diffuser aperture is next aligned between a primer and a primer pocket of the ammunition cartridge. Preferably, the primer is positioned below the pre-formed disk and the primer pocket is positioned above the pre-formed disk. Thereafter, the primer and the pre-formed disk are pressed into the primer pocket. Pressing the primer through the pre-formed disk cuts the one or more attachment points to concurrently form and release the diffuser disk from the sheet while loading the primer and diffuser disk into the primer pocket.

In some embodiments of the process, the stamping step may involve stamping a plurality of attachment points about the outer diameter of the pre-formed disk. In preferred embodiments, each attachment point is stamped to be separated from an adjacent attachment point by a semi-circular recessed arc defined through the sheet. Each of the semi-circular recessed arcs define an outer perimeter of the pre-formed disk and an inner perimeter of the sheet. The outer perimeter of the pre-formed disk sets the maximum outer diameter of the final diffuser disk. The plurality of attachment points are preferably radially symmetrically disposed about the outer perimeter of the pre-formed disk. In some embodiments comprising three attachment points, each of the attachment points may be separated from an adjacent attachment point by a substantially 120-degree semi-circular recessed arc.

In alternative embodiments, the stamping step may also include stamping one or more alignment aids in the sheet concurrently with stamping the pre-formed disk therein. The alignment aids are designed to aid in aligning the pre-formed disk concentrically with a primer and a primer pocket. Preferably, the alignment aids are stamped proximate to the outer perimeter of the sheet In some embodiments, the alignment aids are apertures defined through the sheet that are engineered to engage gears on the ammunition loading equipment utilized. Alternatively, the alignment aids may be stamped studs extending upward from the sheet. The studded alignment aids may be used to box-in an ammunition cartridge on the sheet to align the primer pocket concentrically with the pre-formed disk. In such embodiments, a diagonal distance between any two non-adjacent alignment aids is substantially equal to the maximum outer diameter of the base-end of the ammunition cartridge being loaded.

In further embodiments of the inventive concepts disclosed herein, a pre-formed diffuser disk is disclosed. The pre-formed diffuser disk includes a sheet and a disk formed in and retained to the sheet by at least one attachment point. The attachment point connects the perimeter of the disk to the sheet. A center hole is defined through the disk. The pre-formed diffuser disk further includes a means, formed in the sheet, for aligning the center hole with a primer pocket of an ammunition cartridge. In some embodiments, the alignment means includes at least one alignment aid formed proximate the outer perimeter of the sheet. The alignment aids can be apertures configured to engage a gear of the ammunition loading equipment utilized to concentrically align the center hole between a primer and a primer pocket. In some embodiments, there may be a plurality of alignment aids formed about the outer perimeter of the sheet.

In further embodiments, the pre-formed diffuser disk can include a plurality of attachment points. Each of the plurality of attachment points may be separated from an adjacent attachment point by a semi-circular recessed arc. Preferably, the recessed arc has a curvature of substantially about 120-degrees.

In further embodiments, one or more indents may be formed in the bottom surface of the disk. The one or more indents are designed to engage a leg of an anvil in a conventional primer. In preferred embodiments, there are three indents formed about the disk bottom surface to engage a corresponding three-legged anvil typically found in a conventional primer. The indents further aid in concentrically aligning the primer with the pre-formed diffuser disk.

In more elaborate embodiments of the inventive concepts, a pre-formed diffuser disk is disclosed. The pre-formed diffuser disk includes a thin metal sheet having one or more disks formed therein. Each of the disks is connected to the metal sheet by two or more attachment tabs. Each attachment tab for each disk is separated from an adjacent attachment tab of that disk by a recessed curvature defined through the metal sheet. Each disk includes a center hole defined therethrough. One or more indents are formed in the bottom surface of each disk and are engineered to engage an anvil leg extending upwards from a conventional primer. The sheet further includes two or more alignment aids formed therein and designed to concentrically align the center hole with a primer pocket of a cartridge to be loaded. In preferred embodiments, the outer diameter of the disk is substantially equal to the inner diameter of the primer pocket so that the disk can be frictionally retained therein along with the primer.

BRIEF DESCRIPTION OF THE DRAWINGS

Other systems, methods, features and advantages of the invention will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the invention, and be protected by the accompanying claims. Component parts shown in the drawings are not necessarily to scale, and may be exaggerated to better illustrate the important features of the invention. Dimensions shown are exemplary only. In the drawings, like reference numerals may designate like parts throughout the different views, wherein:

FIG. 1 is a cross-sectional perspective view of an ammunition cartridge loaded with an embodiment of a diffuser disk according to the present invention.

FIG. 2 is a top view of an embodiment of a pre-formed diffuser sheet according to the present invention.

FIG. 3 is an end view of an embodiment of the pre-formed diffuser sheet of FIG. 2.

FIG. 4A is a bottom view of the embodiment of a pre-formed diffuser sheet of FIG. 2.

FIG. 4B is a top view of a conventional primer that can be used with embodiments of the inventive concepts disclosed herein.

FIG. 5 is a top view of an alternative embodiment of a pre-formed diffuser plate according to the present invention.

FIG. 6 is a flow chart diagraming salient steps for a process of forming and loading a diffuser disk into an ammunition cartridge according to aspects of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

The following disclosure presents exemplary embodiments of a novel process for loading a diffuser disk into ammunition cartridges concurrently with a primer. Further, the disclosure presents exemplary embodiments of a pre-formed diffuser disk that is specially engineered to be used in the processes disclosed herein. The process and pre-formed diffuser disk disclosed herein are particularly useful with polymer-based ammunition cartridges but may similarly be used in conventional brass or other metal-based ammunition cartridges. The inventive process and pre-formed diffuser disk allow a manufacturer to utilize conventional ammunition loading equipment for purposes of seating a primer in the cartridge and loading propellant therein.

FIG. 1 is a cross-sectional perspective view of one embodiment of an ammunition cartridge 10 loaded with an embodiment of a diffuser disk 24 according to the present invention. The cartridge 10 can be a polymer-based cartridge or a conventional brass or metal-based cartridge. As is typical for most ammunition cartridges, the cartridge 10 includes a cartridge body 12 with a bullet aperture 18 at a forward end thereof. The cartridge body 12 is connected to a base-insert 14 opposite the bullet aperture 18. The base-insert 14 forms the base end 15 of the cartridge 10 and defines the largest outer diameter for the cartridge 10. An internal powder chamber 16 is formed by the cartridge body 12 between the bullet aperture 18 and the base insert 14. A primer 26 loaded into the primer pocket 20 formed in the base-insert 14 is in fluid communication with the powder chamber 16 via a flash hole 22. The flash hole 22 is defined through an upper surface 28 of the primer pocket 20 and opens into the powder chamber 16. In some preferred embodiments of polymer-based cartridges 10, the flash hole 22 is overmolded at 29 to provide a more secured connection between the insert 14 and the body 12 of the cartridge 10. The diffuser disk 24 provides protection about the overmolded area 29 by providing a physical barrier between the primer 26 and overmolded area.

The illustrated diffuser disk 24 is one example of a formed diffuser or blast shield, according to the present invention, that may be used in polymer-based ammunition cartridges, e.g., cartridge 10. The diffuser disk 24 provides added protection about the upper surface 28 of the primer pocket 20, in particular the overmolded area 29 in the primer pocket, to divert the pressure and explosive gases generated by detonation of the primer 26 through the flash hole 22 and into the powder chamber 16. The added protection about the overmolded area 29 in the base-insert 14 ensures the pressure and gases do not weaken or otherwise diminish the structural integrity of the cartridge 10, in particular at the overmolded areas 29 about the flash hole 22. In preferred embodiments, the diffuser disk 24 is a thin metal disk, as discussed in more detail below.

FIG. 2 is a top view of one embodiment of a pre-formed diffuser strip 100 according to the present invention. The pre-formed diffuser strip 100 has a sheet 102 with a defined thickness T (e.g., FIG. 3). The top surface 101 of the sheet 102 is substantially flat. Preferably, the sheet 102 is a copper sheet with a thickness T substantially equal to about 0.005 inches. However, other materials of various other thicknesses may also be suitable for purposes of the disclosed invention. Larger caliber ammunition cartridges, for example some artillery cartridges, may require an increased thickness for the sheet 102 to ensure the increased pressure generated by such cartridges does not damage or otherwise weaken the diffuser disk 24 therein. Copper was selected for the sheet 102 due to its familiarity in the ammunition industry and the relatively high melting point in comparison to the polymer materials used in the overmolding process. Further, copper has good malleability properties, making copper sheet metal particularly well suited for the invention disclosed herein.

At least one pre-formed diffuser disk 104 is formed in the sheet 102. The pre-formed diffuser disk 104 has a diffuser aperture 114 defined substantially through a center point of the disk. The pre-formed diffuser disk 104 is retained in the sheet 102 by at least one attachment point 106, which is a portion of the sheet 102 that was not stamped during the formation of the pre-formed disk 104 and integrally retains the disk in the sheet. Preferably, there are multiple attachment points 106 retaining the pre-formed diffuser disk 104 within the sheet 102. As illustrated, the pre-formed diffuser strip 100 may utilize three attachment points 106 per pre-formed diffuser disk 104, where each attachment point 106 is separated from an adjacent attachment point by about 120-degree curvature. A recessed arc 108, defined through the sheet 102, is defined between each adjacent attachment point 106. The recessed arc 108 is an area of the sheet 102 that has had its material stamped out so that it is void of any sheet material. The attachment points 106 may be a thin rectangular strip of the sheet 102 that integrally connects a distinct point of the outer perimeter 110 of the pre-formed diffuser disk 104 to the inner perimeter 112 of the recessed arc 108. In this way, each of the subcomponents forming the pre-formed diffuser strip 100 can be produced in a single stamping action according to one aspect of the present invention, as discussed further below. In alternative embodiments, there may be more than three attachment points 106 formed with a different shape, e.g., triangular. In further alternative embodiments, the outer perimeter 110 may be defined by a plurality of attachment points 106 configured as a perforated seam fully circumvolving the pre-formed diffuser disk 104.

The pre-formed diffuser strip 100 also includes a means for aligning the diffuser aperture 114 with a primer pocket 20 of an ammunition cartridge 10. In some embodiments, the alignment means may be one or more alignment aids 116 formed in the sheet 102. The alignment aids 116 may be holes defined through the sheet 102 that can be grabbed by gears to move the pre-formed diffuser strip 100 into position on the ammunition loading equipment being utilized. The pre-formed diffuser strip 100 can be pulled down an assembly line by the gears engaged to two or more of the alignment aids 116 and, once in position over a primer 26 and aligned with the ammunition cartridge 10, the same loading equipment can press the primer 26 into the primer pocket 20. In preferred embodiments, the pre-formed diffuser strip 100 includes at least two alignment aids 116 per pre-formed diffuser disk 104 formed therein. In this manner, the ammunition loading equipment can concurrently engage the two alignment aids 116 at one time to ensure the pre-formed diffuser strip 100 is moved smoothly and evenly into position on the loading equipment.

Alternatively, the alignment aids 116 may be used by the loading equipment as reference points for properly aligning an ammunition cartridge on top of the pre-formed diffuser disk, e.g., sensors configured to detect when two or more alignment aids 116 are in proper alignment for loading of a primer. In a further alternative embodiment, the alignment aids 116 may be formed as small studs or protrusions which define a boxed area for properly aligning an ammunition cartridge on top of the pre-formed diffuser strip 100. Preferably, the alignment aids 116 are formed outside the perimeter 112 defining the recessed arc 108 and proximate to an outer sheet perimeter 118.

Regardless of the embodiment for the alignment aids 116, the diagonal distance D between any two non-adjacent alignment aids 116 is preferably substantially equal to or greater than the diameter of the base end 15 of the ammunition cartridge 10 being loaded. This will ensure that the ammunition cartridge 10 can be properly aligned over the pre-formed diffuser disk 104 and within the confines of the alignment aids 116 to ensure the diffuser aperture 114 is aligned with the primer pocket 20 in the cartridge.

FIG. 4A is a bottom view of an embodiment of the pre-formed diffuser strip 100 according to the present invention and FIG. 4B is a top perspective view of a conventional primer 26 that may be used in conjunction with the invention disclosed herein. The bottom surface 103 of the sheet 102 is substantially flat, similar to the top surface 101. The disk bottom surface 105 may have one or more indents 120 formed therein. In preferred embodiments, the pre-formed diffuser disk 104 has three indents 120 formed in the disk bottom surface 105. The indents 120 are positioned a substantially equal distance from one another and proximate to the outer perimeter 110. The indents 120 are configured to receive the legs 121 of the internal anvil 123 in a conventional primer 26.

Conventional primers, such as the one illustrated at FIG. 4B, typically include three legs 121 extending from a central point of the anvil 123. Similarly, the disk bottom surface 105 can include three indents 120 to receive the legs 121 of a primer. The relative positioning of the indents 120 about the disk bottom surface 105 will thus be dependent on the primer 26 being used in the assembly process for the ammunition cartridge 10. There may be more than or less than three indents 120 depending on the number of legs 121 in the primer 26 being used. The depth of the indents 120 is minimal as the height of the legs 121 beyond the outer edge 127 of a primer cup 125 is also minimal. The depth of the indents 120 may be approximately 0.001 to 0.002 inches. The indents 120 help to properly align a primer 26 with the disk bottom surface 105 by engaging the anvil legs 121 with indents 120, which ensures the primer 26 is concentrically aligned about the disk bottom surface 105.

FIG. 5 is a top view of an alternative embodiment of a pre-formed diffuser plate 200 according to the present invention. The pre-formed diffuser plate 200 includes substantially the same components as the pre-formed diffuser strip 100. The primary difference between the strip 100 and the plate 200 is that the pre-formed diffuser plate 200 includes only a single pre-formed diffuser disk 104 formed in plate 202. The pre-formed diffuser plate 200 may be better suited for at-home reloading of ammunition cartridge 10 where it is more likely that an operator will load one cartridge at a time. The pre-formed diffuser plate 200 allows the operator to readily align a primer 26 with the pre-formed diffuser disk 104 and position the ammunition cartridge 10 there above. The operator can be assured that all components are properly aligned by visually inspecting the components and making small adjustments as needed. This can all be done at home without the need for expensive industrial sized ammunition loading equipment. After ensuring the proper alignment of the component pieces, an operator can use a conventional hand-held primer loading device or other types of at-home loading equipment to form the diffuser disk 24 concurrently while pressing the primer 26 into the primer pocket 20 through the pre-formed diffuser plate 200.

FIG. 6 is a flow chart diagraming salient steps for a process 300 for loading a primer 26 and a diffuser disk 24 into an ammunition cartridge 10 according to aspects of the present invention. The first step 302 in the process 300 is to stamp a sheet 102 to pre-form the diffuser disk 104. This can involve stamping a sheet 102 or a plate 202, depending on the number of pre-formed diffuser disks 104 desired. In industrial sized operations, it is more likely that a sheet 102 will be stamped at step 302 to continuously form the pre-formed diffuser disks 104 in as high a volume as needed to streamline loading of the ammunition cartridge 10. As described above, the sheet 102 is preferably a copper sheet with a thickness of about 0.005 inches. A mechanical dye press may be used to stamp the pre-formed diffuser disk 104 out of the sheet 102 (or plate 202). The profile of the dye press punch is a negative image of the corresponding pre-formed diffuser disk 104. Depending on the embodiment of the process 300, the stamping step 302 may be repeated numerous times along a significant length of copper sheet metal 102 to form a plurality of pre-formed diffuser disks 104 usable in the loading process 300. The dye press will include at least one cutting edge having a profile of less than 360-degrees so as to define one or more of the recessed arcs 108 through the sheet 102 and form the at least one attachment point 106 for retention of the pre-formed diffuser disk 104 to the sheet 102 or plate 202. Further, one or more indents 120 may be formed in the disk bottom surface 105 during the stamping of the pre-formed diffuser disk 104. The indents 120 may be formed as a result of small studs or protrusions on a stamping surface that will be pressed into the disk bottom surface 105 while the pre-formed diffuser disk 104 is stamped into the sheet 102. The arrangement of the studs or protrusions on the stamping surface is such that the indents 120 formed in the disk bottom surface 105 are appropriately positioned to engage the anvil legs 121 of a conventional primer 26.

Further, at the same time the pre-formed diffuser disk 104 is stamped in the sheet 102, the one or more alignment aids 116 may similarly be stamped in the sheet. Again, depending on the embodiment, this may involve stamping one or more alignment holes through the sheet 102 at positions sufficient for geared engagement with an ammunition loading machine. Alternatively, the mechanical dye press may have one or more protrusions defined on a stamping surface that will form studded alignment aids in the sheet 102 as the dye press punch pushes the sheet against the stamping surface.

After the pre-formed diffuser disk 104 is formed during the stamping step 302, the next step 304 is to align the pre-formed diffuser disk 104 with the remaining components of the ammunition cartridge. This involves concentrically aligning the primer 26, the pre-formed diffuser disk 104 and the primer pocket 20 with one another, preferably on the loading equipment. In preferred embodiments, the process 300 allows an operator to utilize conventional ammunition loading equipment, which loads a primer into the primer pocket by pressing upwards. Thus, the alignment step 304 preferably involves the primer 26 concentrically aligned below the pre-formed diffuser disk 104 and the primer pocket 20 of the ammunition cartridge 10 concentrically aligned above the pre-formed diffuser disk 104. Alignment of the primer 26 about the disk bottom surface 105 is readily accomplished through the engagement of the anvil legs 121 of a primer 26 with the indents 120 formed with the pre-formed diffuser disk 104. The indents 120 may be formed during the stamping step 302, as described above.

With the component pieces properly aligned, the final step 306 requires pressing the primer 26 into the primer pocket 20 through the pre-formed diffuser disk 104. The pressing step 306 loads the primer 26 into the primer pocket 20 while concurrently forming the diffuser disk 24 from the pre-formed diffuser disk 104. The outer edges 127 of the primer cup 125 in a conventional primer 26 will cut each attachment point 106 about the pre-formed diffuser disk 104 as the primer is pressed into the primer pocket 20 through the pre-formed diffuser disk 104. The cutting of the one or more attachment points 106 thereby releases the pre-formed diffuser disk 104 from the sheet 102 (or plate 202) to concurrently form the diffuser disk 24 while loading the primer 26 and disk 24 into cartridge 10.

The process 300 has been described in stepwise fashion but it should be understood that many of the steps may be accomplished concurrently in an automated loading assembly line. The automated assembly line may include conventional loading equipment that can simultaneously align the component pieces while pressing the primer into the primer pocket and thereby release the diffuser disk from the sheet.

The process 300 allows an operator to readily use conventional ammunition loading equipment with minimal modifications required to accommodate the pre-formed diffuser disk 104 therein. The process 300 reduces manufacturing costs associated with polymer-based ammunition cartridges by allowing use of conventional equipment with minimal modification. The disclosed process 300 and accompanying pre-formed diffuser disk 104 disclosure can be implemented with virtually all small and medium sized caliber ammunition, including pistol, rifle and shotgun ammunition cartridges of both military and civilian grades. While the disclosed invention is particularly useful in polymer-based ammunition cartridges, it can be readily implemented in more conventional metal-based cartridges, as the need may arise.

Exemplary embodiments of the invention have been disclosed in an illustrative style. Accordingly, the terminology employed throughout should be read in a non-limiting manner. Although minor modifications to the teachings herein will occur to those well versed in the art, it shall be understood that what is intended to be circumscribed within the scope of the patent warranted hereon are all such embodiments that reasonably fall within the scope of the advancement to the art hereby contributed, and that that scope shall not be restricted, except in light of the appended claims and their equivalents.

Claims

1. A process for loading a diffuser disk into an ammunition cartridge, comprising:

stamping a sheet to pre-form a disk having a diffuser aperture, wherein the pre-formed disk remains connected to the sheet by an attachment point;

centering the diffuser aperture between a primer and a primer pocket of the ammunition cartridge; and

pressing the primer and the pre-formed disk into the primer pocket thereby cutting the attachment point to form the diffuser disk concurrently with installation of the primer.

2. The process of claim 1, wherein the stamping of the pre-formed disk comprises forming the attachment point about an outer perimeter of the pre-formed disk by stamping at least one semi-circular recessed arc between the outer perimeter of the pre-formed disk and an inner perimeter of the sheet.

3. The process of claim 1, wherein the stamping step further comprises stamping the pre-formed disk with a plurality of attachment points about an outer perimeter of the pre-formed disk.

4. The process of claim 3, wherein the plurality of attachment points are radially symmetrically disposed about the outer perimeter.

5. The process of claim 3, comprising stamping three attachment points spaced apart from one another around the outer perimeter by substantially 120 degrees.

6. The process of claim 1, wherein the sheet is a copper sheet.

7. The process of claim 1, wherein the sheet has a thickness of substantially about 0.005 inches.

8. The process of claim 1, wherein the centering step comprises positioning the primer pocket above the diffuser aperture.

9. The process of claim 1, wherein the stamping step further comprises stamping at least one alignment aid in the sheet, wherein the alignment aid is configured to aid in centering the diffuser aperture with the primer pocket.

10. The process of claim 9, further comprising stamping a plurality of alignment aids in the sheet.

11. The process of claim 10, wherein each of the plurality of alignment aids are stamped proximate to an outer perimeter of the sheet.

12. A pre-formed diffuser disk configured for insertion into a primer pocket of an ammunition cartridge, the pre-formed diffuser disk comprising:

a sheet;

a disk formed in the sheet and retained therein by at least one attachment point connecting a perimeter of the disk to the sheet;

a center hole defined through the disk; and

a means, formed in the sheet, for aligning the center hole to the primer pocket.

13. The pre-formed diffuser disk of claim 12, comprising a plurality of attachment points.

14. The pre-formed diffuser disk of claim 13, wherein each of the plurality of attachment points is separated from an adjacent attachment point by a semi-circular recessed arc defined through the sheet.

15. The pre-formed diffuser disk of claim 14, wherein each semi-circular recessed arc has a curvature substantially equal to about 120 degrees.

16. The pre-formed diffuser disk of claim 12, wherein the alignment means comprises at least one alignment aid formed proximate an outer perimeter of the sheet.

17. The pre-formed diffuser disk of claim 16, comprising a plurality of alignment aids, each alignment aid positioned substantially equally from an adjacent alignment aid about the outer perimeter of the sheet.

18. The pre-formed diffuser disk of claim 16, comprising a plurality of alignment aids defined substantially an equal distance from one another and proximate an outer perimeter of the sheet, each alignment aid defining a hole configured to engage a gear of a primer loading machine, wherein the primer loading machine engaged to one or more alignment aids substantially concentrically aligns a primer below the center hole and substantially concentrically aligns the primer pocket above the center hole.

19. The pre-formed diffuser disk of claim 12, further comprising one or more indents formed in a bottom surface of the disk, wherein the one or more indents are configured to engage one or more anvil legs of a primer.

20. A pre-formed diffuser disk for insertion into a primer pocket of an ammunition cartridge, comprising:

a thin metal sheet;

one or more disks formed in the sheet, wherein each disk is connected to the sheet by two or more attachment tabs, each attachment tab separated from an adjacent attachment tab by a recessed curvature defined through the sheet forming an outer disk perimeter;

a center hole defined through each of the one or more disks;

two or more alignment tabs formed in the sheet and configured to concentrically align each center hole with a primer pocket, wherein an outer diameter of each disk is substantially equal to a maximum inner diameter of the primer pocket; and

one or more indents formed in a bottom surface of each of the disks, wherein the one or more indents are configured to engage at least one anvil leg of a primer.