Abstract: The present invention is directed to a continuous process for producing a foamable celluloid product by introducing a solid component (comprising nitrocellulose, chemical blowing agent (CBA), stabilizer and alcohol) and a liquid component (comprising camphor and acetone) into a mixer/devolatilizer machine where the chamber is under atmospheric pressure and having significant overhead space. The chamber is comprised of two zones wherein the first zone has a temperature that is less than the second zone and at least one rotor comprising hollow, temperature-controlled arms having a tilted angle affixed to the rotors. The rotors of the mixer/devolatilizer machine act to mix the solid and liquid components under lower shearing forces, lower mechanical stress and longer residence times than those used by twin-screw extruders.

Abstract: The present invention is directed to a process for making combustible foam celluloid munition parts having high aspect ratios, different densities or having an insert embedded into the foam celluloid munition part. The process for making such foam celluloid munition part requires pre-soaking dry particles of celluloid, placing the celluloid particles into a munition part mold, exposing the celluloid particles to high heat and pressure until the celluloid particles expand and fuse into the shape of the mold. Varying the density or the size of the celluloid particles used in the process produces munition parts having different densities. In addition, the placement of inserts into the particles prior to exposure to high heat and pressure produces munition parts having inserts that are useful for identification and tracking of such parts.

Abstract: A wet chemistry method for preparing spherical celluloid beads by mixing a water-based suspension solution and a solvent based celluloid solution that is immiscible in the suspension solution. The two combined solutions create an “oil-in-water” type mixture where the dispersed phase consists of celluloid dissolved in solvent and co-solvent that is suspended in the continuous water phase. Agitation and removal of the solvent and co-solvent mixture produces spherical shaped celluloid beads.

Abstract: A safety fuze for use in military and commercial applications, includes a fuze body that is attached to a trigger mechanism, an energetic train contained within the fuze body, and a non-energetic fuze delay mixture that is formed in a rod form so that it can dropped inside the fuze body, without modification to the other components of the safety fuze. Preferably, the non-energetic fuze delay mixture is made of foamed celluloid.

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

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

Abstract: An encapsulated propellant charge comprised a sealed combustible container comprised of a consumable material and having a substantially cylindrical shape. The sealed combustible container comprises a top wall, a bottom wall, and a side wall therebetween. The top wall, the bottom wall and the side wall define a chamber; which contains a propellant composition.

Abstract: A method of manufacture of foamed celluloid molded products, involving three steps for the manufacture of higher density (0.7 to 1.25 gm/cc) foamed celluloid products or simple geometry lower density (0.2 to 0.7 gm/cc) foamed celluloid products, and four steps for the manufacture of lower density foamed celluloid products of any geometry. The three step process involving: (1) providing small, uniform, pieces of celluloid; (2) presoaking the pieces in a physical blowing agent (PBA) under pressure; and (3) foaming at raised temperature a controlled quantity of the presoaked pieces in a mold—to obtain the desired shape and density. For a lower density foamed celluloid product, of any moldable geometry, the steps are to: (1) small pieces of celluloid, that (2) have been presoaked in a PBA, are (3) pre-expanded to an intermediate density, and then (4) foam the desired lower density foamed product in a mold at raised temperature.

Abstract: An economical, low residue, mortar increment propellant container manufactured of foamed celluloid, which is composed of 50 to 84% nitrocellulose, having a nitrogen content of from about 10.5 to about 13.5%, and about 15 to about 50% camphor. The burn rate of the foamed celluloid can be enhanced by the addition of energetic additives, such as energetic plasticizers.

Abstract: By using generally known chemically, physically, or a combination thereof, means to foam celluloid, a foamed celluloid material is invented with a density of less than about 1.25 gm/cm3, which material is relatively low cost, very fast burning, very low residue, easily moldable, and which material exhibits good mechanical strength, and provides a good water barrier. These characteristics make this foamed celluloid a preferred choice for military artillery propellant charge bags, military mortar and civilian fireworks increment charges, combustible cartridges, flare housings, igniter tubes, as well as, closure disks, combustible enclosures and components thereof, among other applications.

Abstract: A method for the continuous production of finely ground particulates coated with a barrier, or other desirable film wherein the coated particulates exhibit a diameter of less than 10 microns. In an exemplary embodiment, large coated particulates are introduced into a fluid energy, or jet mill, along with smaller, uncoated particulates. As the particulates collide within the mill they are comminuted, and an amount of coating is transferred from the coated particulates to the uncoated ones such that they become sufficiently coated and size-reduced to a desired size. Alternatively, uncoated particulates are milled and coated during their milling. Still alternatively, uncoated particulates are milled and subsequently directed through an atomized mist of coating material wherein the size of the mist droplets are as large, or larger than the directed particulates.

Abstract: Techniques and processes that combine particulate coating processes with particulate handling steps resulting in the formation of free-flowing particulates for introduction into energetic product vessels to affect an in-situ, net-shape manufactured product. The processes involve selecting suitably sized materials, processing such materials such that they are surface-coated and/or locally “structured” particulates, and pouring, preferably “dry” pouring, these processed materials into an energetic product vessel and infusing the filled vessel with a polymerizable and surface-compatible monomer or oligomer which flows into the unoccupied volume, followed by polymerization of the monomer, which then becomes the binder giving mechanical integrity to the final, net-shape energetic composition.

Abstract: Techniques and processes that combine particulate coating processes with particulate handling steps resulting in the formation of free-flowing particulates for introduction into energetic product vessels to affect an in-situ, net-shape manufactured product. The processes involve selecting suitably sized materials, processing such materials such that they are surface-coated and/or locally “structured” particulates, and pouring, preferably “dry” pouring, these processed materials into an energetic product vessel and infusing the filled vessel with a polymerizable and surface-compatible monomer or oligomer which flows into the unoccupied volume, followed by polymerization of the monomer, which then becomes the binder giving mechanical integrity to the final, net-shape energetic composition.

Abstract: Techniques and methods of formation of ordered mixtures of particles by “clustering”. Clustering comprises local “structuring” consisting of a large “host” and smaller “guest” particles by various techniques. Small amounts of polymer are coated onto solid particles by various means. In one embodiment, an ordered mixture is created wherein the material that is of lesser quantity is of small particle size (the “B” particles) and the “A” particles are of larger size. The “B” particles are then coated onto a single A particle. By creating this ordered structure, each composite particle has the proper or stoichiometric amount of all ingredients.

Abstract: Particle coating processes and systems employ UV curable materials to form tack-free surfaces rapidly. By applying UV curable compositions on well suspended particles a UV particle coating technology enables a scalable process of coating fine particles at desirable coating thicknesses with a wide spectrum of obtainable properties. Processes in accordance with the present invention decouple the particle suspension and film formation steps, enabling ample time to first deliver evenly the coating materials to the particle surfaces, followed by rapid polymerization/curing reaction induced by the UV light to rapidly create tack-free surfaces, thus preventing particles agglomeration while achieving uniform and thin-layer coating.