Abstract: A nonsolvent process of synthesizing bis(2,2-dinitropropyl)formal (BDNPF) is disclosed. In the process, 2,2-dinitropropanol (DNPOH) is reacted at low temperature with a formaldehyde source in the presence of a protic acid catalyst, such as H.sub.2 SO.sub.4, HCl, H.sub.3 PO.sub.4, or HBr. To inhibit byproduct formation, the reaction temperature is maintained from about -30.degree. C. to 30.degree. C. Upon completion of the reaction, the reaction solution is quenched with water and washed with an aqueous hydroxide ion solution. The hydroxide ion concentration should be sufficient to neutralize the protic acid catalyst during the quenching step and to solubilize unreacted 2,2-dinitropropanol as well as other aqueous soluble byproducts in the reaction solution. The BDNPF product is extracted with a low boiling temperature polar organic solvent, such as methyl tert-butyl ether (MTBE) or equivalent solvent. The organic solvent is evaporated to yield usable BDNPF product.

Abstract: Polyether organic compounds are described which have both imine and hydroxyl functionality. These materials are synthesized by reacting a primary amine with an aldehyde or ketone to form a Schiff base. By definition, a Schiff base comprises the reaction product of a primary amine and an aldehyde. In this case, however, unlike conventional Schiff bases, the reaction product possesses both hydroxyl and Schiff base functionality. In one embodiment of the invention, such a product is produced by the reaction of a polyoxyalkyleneamine (Jeffamine) with p-nitrobenzaldehyde and glycidol. The result is a polyether having both hydroxyl and Schiff base functionality. The compounds produced in this manner are particularly useful as bonding agents in the formulation of solid propellants. The bonding agents provide superior performance, while avoiding the problems encountered when using existing bonding agents.

Abstract: Oxazolines useful as bonding agents in solid rocket propellants are disclosed. The oxazoline bonding agents are capable of polymerizing in the presence of ammonium perchlorate. The bonding agents of the present invention are added to the propellant in a range from about 0.1% to about 3% concentration. Importantly, there is no increase in ammonia liberated above baseline propellant values and no increase in end of mix viscosities by using the oxazolines according to the present invention which provides substantial processing savings.

Abstract: Vinyl ethers for use as bonding agents in solid rocket propellants are disclosed. The vinyl ether bonding agents are capable of polymerizing in the presence of and around the surface of ammonium perchlorate particles. The bonding agents of the present invention are added to the propellant in a range from about 0.1% to about 3% by weight concentration. Importantly, there is no increase in ammonia liberated above baseline propellant values and no increase in end of mix viscosities by using the vinyl ethers according to the present invention which provides substantial processing savings.