Abstract: A rocket motor comprises at least two propellant grains/grain segments; a case comprising the propellant grains/grain segments, stacked within the case; and a resin for substantially maintaining the grains/grain segments in position within the case. In another aspect, a rocket motor comprises at least two propellant grains/grain segments, each having an aft-end face and a fore-end face. At least two of the propellant grains/grain segments comprise a sleeve having propellant cast therein. The motor further comprises a case comprising the propellant grains/grain segments, stacked within the case, wherein the sleeve of one propellant grain/grain segment is coupled to the sleeve of an adjacent propellant grain/grain segment such that the fore-end face of one grain/grain segment is spaced from the aft-end face of an other grain/grain segment creating a gap therebetween. Methods for making the rocket motors are described.

Abstract: An ammunition cartridge case comprising polycycloolefin derived from ring-opening metathesis polymerization (ROMP) reaction of a cyclic olefin. Methods, apparatus and systems for manufacturing the ammunition cartridge case.

Abstract: A surface skimming munition comprises a hull, a traction propulsion motor positioned in the hull and having a combustion chamber for combustion of a propellant, at least one aft directed nozzle coupled to the hull at a position forward of a center of gravity of the hull and comprising an inlet section and an outlet section, the inlet section in fluid communication with the combustion chamber and the outlet section directing combustion gas received from the combustion chamber through the inlet section in the aft direction, and at least one stabilizing plane coupled to the hull and moveable between a stowed position and a deployed position.

Abstract: A surface skimming munition comprises a hull, a traction propulsion motor positioned in the hull and having a combustion chamber for combustion of a propellant, at least one aft directed nozzle coupled to the hull at a position forward of a center of gravity of the hull and comprising an inlet section and an outlet section, the inlet section in fluid communication with the combustion chamber and the outlet section directing combustion gas received from the combustion chamber through the inlet section in the aft direction, and at least one stabilizing plane coupled to the hull and moveable between a stowed position and a deployed position.

Abstract: A surface skimming munition comprises a hull, a traction propulsion motor positioned in the hull and having a combustion chamber for combustion of a propellant, at least one aft directed nozzle coupled to the hull at a position forward of a center of gravity of the hull and comprising an inlet section and an outlet section, the inlet section in fluid communication with the combustion chamber and the outlet section directing combustion gas received from the combustion chamber through the inlet section in the aft direction, and at least one stabilizing plane coupled to the hull and moveable between a stowed position and a deployed position.

Abstract: A surface skimming munition comprises a hull, a traction propulsion motor positioned in the hull and having a combustion chamber for combustion of a propellant, at least one aft directed nozzle coupled to the hull at a position forward of a center of gravity of the hull and comprising an inlet section and an outlet section, the inlet section in fluid communication with the combustion chamber and the outlet section directing combustion gas received from the combustion chamber through the inlet section in the aft direction, and at least one stabilizing plane coupled to the hull and moveable between a stowed position and a deployed position.

Abstract: The present invention comprises a heat exchanger and method for sealing a heat exchanger tube to a header of the heat exchanger. The method comprises melt-bonding the tube to a header of the heat exchanger to form a bond and sealing the bond with a sealant material to form a seal.

Abstract: A lead-free projectile having a metal jacket (10) with a tip in the form of a truncated parabellum. The metal jacket (10) is partially filled with cold-pressed metal powder (18), the remainder of the metal jacket being filled with metal-filled polymer (26). The metal-filled polymer (26) extends through the truncated parabellum and forms a tip on the projectile. A projectile (bullet) having a higher grain is obtained. Methods of manufacture are also disclosed.

Abstract: An oxidizer package for a propellant system for a motor in which the oxidizer is separated from fuel grain, the oxidizer package comprising oxidizer material and an ignition system therefor in a wrapping or sealing material. A hybrid rocket comprising oxidizer material and fuel grain, the oxidizer material being separated from the fuel grain and being in the form of a single package or plurality of packages of oxidizer material and an ignition system therefor, said packages generally conforming to the shape of the rocket. A grid of a pyrotechnic material. A propulsion system for a hybrid rocket comprising oxidizer material in a matrix, mesh, wool, foamed metal or wires of structural or pyrotechnic material.

Abstract: A lead-free projectile having a metal jacket (10) with a tip in the form of a truncated parabellum. The metal jacket (10) is partially filled with cold-pressed metal powder (18), the remainder of the metal jacket being filled with metal-filled polymer (26). The metal-filled polymer (26) extends through the truncated parabellum and forms a tip on the projectile. A projectile (bullet) having a higher grain is obtained. Methods of manufacture are also disclosed.

Abstract: A propellant is disclosed, comprising, as binder, an ethylene copolymer especially ethylene/vinyl acetate copolymer. The binder may be silane-grafted and moisture curable. A solid propellant composition may contain a plasticizer that is solid or semi-solid at 20° C., and an additive to increase one or more of elongation, adhesion and tack. Examples of the solid or semi-solid plasticizer are selected from microcrystalline wax, macrocrystalline wax, an oxidized hydrocarbon polyolefin and a polyketone wax. Examples of the additive are selected from an aliphatic hydrocarbon, an aromatic, a hydrogenated hydrocarbon resin and a derivative of a rosin. Preferably, the binder composition contains 10-30% by weight of liquid plasticizer, 0-30% by weight of solid or semi-solid plasticizer and 20-40% by weight of at least one said additive. The propellant is particularly useful as a rocket propellant. A method of manufacture is disclosed.

Abstract: A flame holder is provided at a head end of a combustion chamber of a hybrid rocket motor. The flame holder includes a high-temperature casing defining a cavity, and a solid propellant within cavity around or near the injector. The propellant may be provided in an annulus within the casing, such that the flame plume from the burning propellant is substantially parallel to the flow of the oxidizer, or may be generally cylindrical within a cylindrical casing such that the flame plume of the burning propellant is substantially perpendicular to the oxidizer flow. The solid propellant is preferably ignited substantially simultaneously with the ignition of the hybrid motor. The burning of the solid propellant prevents the flame from combustion of the fluid oxidizer and solid fuel in the hybrid motor from drifting and thereby stabilizes the flame front.

Abstract: This invention relates to fabrication of tube bank style heat exchangers and similar assemblies. It provides a novel apparatus and a method for trimming polymeric tubes disposed within a core structure (such as a heat exchanger core) and securing these tubes within the core structure.

Abstract: An oxidizer package for a propellant system for a motor in which the oxidizer is separated from fuel grain, the oxidizer package comprising oxidizer material and an ignition system therefor in a wrapping or sealing material. A hybrid rocket comprising oxidizer material and fuel grain, the oxidizer material being separated from the fuel grain and being in the form of a single package or plurality of packages of oxidizer material and an ignition system therefor, said packages generally conforming to the shape of the rocket. A grid of a pyrotechnic material. A propulsion system for a hybrid rocket comprising oxidizer material in a matrix, mesh, wool, foamed metal or wires of structural or pyrotechnic material.

Abstract: A flame holder is provided at a head end of a combustion chamber of a hybrid rocket motor. The flame holder includes a high-temperature casing defining a cavity, and a solid propellant within cavity around or near the injector. The propellant may be provided in an annulus within the casing, such that the flame plume from the burning propellant is substantially parallel to the flow of the oxidizer, or may be generally cylindrical within a cylindrical casing such that the flame plume of the burning propellant is substantially perpendicular to the oxidizer flow. The solid propellant is preferably ignited substantially simultaneously with the ignition of the hybrid motor. The burning of the solid propellant prevents the flame from combustion of the fluid oxidizer and solid fuel in the hybrid motor from drifting and thereby stabilizes the flame front.

Abstract: A process of producing a plastic heat exchanger where a multiplicity of tubes are welded to tube headers having raised collars surrounding each of the tubes, using an infrared energy source such as a laser to melt-bond the tubes to the collars.

Abstract: An oxidizer package for use in a solid fuel propellant system. The oxidizer package comprises a solid oxidizer in the form of discrete pellets of predetermined geometric shape. The pellets are arranged in an array with spaces amongst the pellets. A holder is provided for maintaining the pellets in the array for receipt of a binder introduced to spaces amongst the array of pellets. Preferred propellants include hydrazinium nitroformate and nitronium perchlorate. This arrangement for the pellets can achieve loadings as high as 85% by weight for the pellets.

Abstract: An apparatus and method for making thermotropic liquid crystalline polymer films with improved transverse direction properties comprises two preferably embossed rollers which oscillate oppositely with respect to each along their respective rotational axes. Film made by passing a liquid crystalline polymer between such rolls has improved transverse direction properties. Such films are useful in multilayer containers and for circuit boards.

Abstract: A heat exchanger comprising plates of thermoplastic tubes arranged in a way which minimizes the thermal resistance at the outer surface of the tubes preferably to not more than 5 times the resistance to heat transfer at the inside of the tubes. The tubes are arranged in the tube plates in groups that can be flat or slightly wavy, such as undulating in a periodic manner, or offset with open spaces facing groups of tubes in alternating rows. This is done in a way that maximizes turbulence outside the tubes and minimizes vortices which can trap coolant in the interstices between tubes.

Abstract: A method for bonding a tube into a device each of which is formed from a thermoplastic polymer. The device has first and second solid members in spaced apart relationship to form a hollow cavity therebetween. At least one linear channel extends through each of said solid members in an aligned relationship, such that a tube may be passed through in sliding engagement, including through the hollow cavity. Molten polymeric composition is injected into the hollow cavity at a temperature lower than the melting point of the thermoplastic polymer so as to bond to the thermoplastic polymer and to the tube to form fluid-tight bonds therewith.