Abstract: An apparatus, system, and method utilizes at least two separate components during the process of producing the final product. At least one component during the process is produced using additive manufacturing, and additional components are components that are combined with the additively manufactured part. The apparatus, system, and method includes at least one energetic component and at least one second inert component. An additive manufacturing system produces a scaffold of said first energetic component(s). A system adds the second component(s) to the scaffold to produce the energetic material product.

Abstract: An end-burning grain of a solid rocket motor or other gas-generating device is supplemented with one or more sticks of high-burn-rate propellant embedded in a matrix of a relatively low-burn-rate propellant. The sticks increase the burning surface area as the grain burns by forming conical indentations in the surface.

Abstract: A gas generator includes an outer propellant, an inner propellant arranged inside the outer propellant, and a barrier membrane which isolates the outer propellant from the inner propellant. A forward end surface of the inner propellant faces a combustion space. A side surface of the inner propellant is isolated from the combustion space.

Abstract: A method of producing a propellant material element, such as an electrically-operated propellant material, includes extruding a propellant material through a heated nozzle. The nozzle may be heated to a temperature that is above the boiling point of a solvent that is part of the propellant material, yet is below a decomposition temperature of the propellant material. This allows some of the solvent to be driven off during the extruding process, while still preventing initiation of an energy-creating reaction within the material. The heating of the material in the extruding process, and especially the heating of the nozzle that the material is extruded through, may be controlled to remove an amount of solvent that results in the extruded material having desirable properties.

Abstract: A multi-pulse gas generator includes a pressure vessel, an outer propellant arranged in the pressure vessel and which has a tubular shape, an intermediate propellant arranged inside the outer propellant and which has a tubular shape, an inner propellant arranged inside the intermediate propellant and which has a tubular shape, an internal structure arranged inside the inner propellant and fixed to the pressure vessel, a first barrier membrane arranged between the outer propellant and the intermediate propellant so as to isolate the outer propellant and the intermediate propellant from each other, and a second barrier membrane arranged between the intermediate propellant and the inner propellant so as to isolate the intermediate propellant and the inner propellant from each other. The outer propellant is supported on its outer surface by the pressure vessel. The inner propellant is supported on its inner surface by the internal structure.

Abstract: Propellant compositions containing cyclic nitramines that are susceptible to unintentional detonation are desensitized by the incorporation of a linear nitramine having a backbone containing one to three ethylene groups and one or two nitramine groups.

Abstract: A solid fuel grain suitable for use in hybrid propulsion systems has a generally cylindrical shape and defines a center port. The solid fuel grain is formed as a series of concentric layers arrayed around the center port. When incorporated into a rocket, an oxidizer is introduced into the solid fuel grain along a pathway defined by the center port, with combustion occurring along the exposed surface area of the solid fuel grain section adjacent to the center port. Each concentric layer has a surface pattern that serves to increase the surface area for combustion, a surface pattern that persists even as the fuel burns. To achieve such a construction, the concentric layers of the solid fuel grain are preferably manufactured using any one of several available freeform-fabrication machines capable of fabricating articles in a polymeric material suitable for a hybrid propulsion system.

Abstract: A modular charge system based on a standard module fitted with a flying plate or a liner and axially coupled to other modules to configure the size and type of charge. The explosive is enclosed in a casing, which has a cylindrical wall with a plurality of external longitudinal rails that run lengthwise. The rails are substantially parallel, and approximately equidistantly spaced around the perimeter of the casing. The space between a pair of rails defines a channel. The casing rails function as a cylindrical tamper. The explosive is partitioned into removable portions and permanent portions, where the removable portions are separated from the permanent portions and any retained removable portions, therein enabling the module to be fitted with a variety of flying plates, liners and other hardware. Modules may be coupled utilizing internal slides, positioned in the channels to join modules.

Abstract: A cartridge may be loaded with a powder column containing stratified, stacked layers of propellant, each powder layer over-compressed to a specified degree, with the burn rate controlled by the specified degree of over-compression applied to each respective powder layer. The application of a highly compressed powder column reduces the burn rate, and may force one or more of the powder layers to launch with the projectile down the barrel. Accordingly, the powder column is forced to burn in a manner similar to fuel burning in a solid fuel rocket engine. This greatly reduces the pressure(s) developed in the chamber, and permits the force of the burning powder to be efficiently focused on forward propulsion. The rapidly increasing set of sequential ignitions provides higher and higher energy densities with each subsequent ignition, and creates a more uniform linear acceleration of the projectile for the full length of the target barrel.

Abstract: An end-burning grain of a solid rocket motor or other gas-generating device is supplemented with one or more sticks of high-burn-rate propellant embedded in a matrix of a relatively low-burn-rate propellant. The sticks increase the burning surface area as the grain burns by forming conical indentations in the surface.

Abstract: A hybrid rocket motor is manufactured by photopolymerizing the solid fuel grain in a stereolithography method, wherein fuel grains in a plastic matrix are deposited in layers for building a solid fuel rocket body in three dimensions for improved performance and for a compact design, the hybrid rocket motor including buried radial channels for defining a desired burn profile including the oxidizer to fuel burn ratio.

Abstract: In the two-pulse rocket motor in accordance with the present invention, the second propellant is set outside of the first propellant in a motor case, and the inner surface of the first propellant is exposed throughout the almost entire length in the axial direction of the motor case. Therefore, the initial burning area can be secured without deteriorating the performance. Also, by providing a weak part by bonding the barrier membranes or shaping slits on the barrier membrane, the breaking portion of barrier membrane and the behavior of barrier membrane after breakage can be controlled. Further, by setting an igniter charge having higher ignitability and a higher burning rate than the second propellant between the inner surface of the second propellant and the inner barrier membrane, the detachment of barrier membrane and the ignition of the second propellant can be assisted.

Abstract: A thermobaric self-sustaining reactive composition, method and device for defeating chemical or biological agents includes a first material including at least one of a Group IV or Group V metal; a second material reactive with the first material in an exothermic intermetallic reaction to generate heat sufficient to vaporize a third material; and the third material that when vaporized combusts with air producing an elevated temperature sufficient to destroy the chemical and biological agents. The device includes a container having a center core explosive driver with the self-sustaining reactive composition surrounding the center core explosive driver.

Abstract: A solid fuel rocket burn rate control employing electrical energy preheating of the fuel grain at a plurality of locations dispersed over the grain burn face cross-section as a thrust control arrangement. The electrical energy of the preheating is generated by electrical battery cells which are dispersed across the grain cross-section and are triggered from an inert state into energy generation by burn face heat. The preheating situs moves continually in response to movement of the grain burn face; this is achieved through the use of high temperature electrical battery cell materials responding to the approach of the grain burn face by increased chemical activity and decreased electrical resistance. Preferably, the preheating is directly accomplished by the heat from electrical and other losses in the battery cells.

Abstract: A hybrid rocket motor is formed from a single piece of material, such as, for example, by extrusion or injection molding. The rocket motor includes various components, such as casing, structure, oxidizer tank, combustion chamber, fuel, port and nozzle that are all formed from a single piece of material. The material can be, for example, a material that can be used as solid rocket fuel.

Abstract: A vehicle includes at least one polyoxymethylene structural support member. The polyoxymethylene structural support member includes a polyoxymethylene component that is a propellant that provides thrust to the vehicle upon pyrolysis or combustion of the polyoxymethylene component of the product of pyrolysis of the polyoxymethylene component. The vehicle can be a satellite or other type of spacecraft.

Abstract: A solid propellant rocket engine includes: a propellant formed into a predetermined shape having a combustion cavity and capable of deflagrating into hot, high-pressure gas upon ignition; and a nozzle configured and positioned to expand the hot, high-pressure gas into the atmosphere, where the propellant forms the nozzle as a part of the predetermined shape. A multi-stage rocket unit, a multi-engine rocket stage, and a super-staged rocket each has many rocket engines.

Abstract: A pyrotechnic charge structure, in particular for use as propellant in a rocket motor, is disclosed. The charge structure has a predetermined longitudinal extension and cross sectional area adapted to the intended purpose. The pyrotechnic charge structure (1; 2; 3; 4) is in cross sectional view in cellular form aimed at having similar wall thickness for all the cells of the charge structure. The wall (6) of the cells comprises the pyrotechnic charge, i.e. the propellant, and each cavity of the cells occupies air or oxygen-rich gas.

Abstract: An initiator (14c) for a secondary explosive receptor charge is provided by forming a length of detonating cord (14) into a helical coil containing a plurality of windings with a cut-off barrier provided by, e.g., a separating rib (46) between adjacent windings. The adjacent windings may be not more than about 0.5 inch (12.7 mm) apart. The detonating cord (14) may be wound about a spindle (16) which may optionally provide the separating rib (46). The coil may be a tapered coil which may define a taper angle of e.g., from about 2 to 4 degrees. Alternatively, the coil may be a cylindrical coil, or the cord may be configured in a planar spiral. Optionally, the detonating cord in the helical coil may have a core of explosive material with a loading of less than 15 grains per foot of the cord, e.g., less than 12 grains per foot of the cord, or a loading in the range of from 8 to 12 grains per foot of the cord. The coil may consume about six inches of the cord.

Abstract: High temperature incendiary (HTI) devices and methods destroy biological and/or chemical agents. Preferably, such HTI devices include dual modal propellant compositions having low bum rate propellant particles dispersed in a matrix of a high burn rate propellant. Most preferably, the HTI device includes a casing which contains the dual modal propellant and a nozzle through which combustion gases generated by the ignited high burn rate propellant may be discharged thereby entraining ignited particles of the low burn rate propellant. In use, therefore, the high burn rate propellant will be ignited using a conventional igniter thereby generating combustion gases which are expelled through the nozzle of the HTI device. As the ignition face of the propellant composition regresses, the low burn rate particles will similarly become ignited.

Abstract: A case-burning rocket booster includes a combustible case containing a solid rocket fuel, a combustion chamber adjustably coupled to the case for burning the case and the solid rocket fuel, a nozzle connected to the combustion chamber for expelling the burned case and fuel to generate thrust, and a drive system for pulling the combustion chamber and nozzle up the case as the case and fuel burn. A hybrid version of the case-burning rocket also includes an oxygen supply system for supplying varying amounts of oxygen to the combustion chamber to vary the thrust generated by burning the case and the fuel.

Abstract: High temperature incendiary (HTI) devices and methods destroy biological and/or chemical agents. Preferably, such HTI devices include dual modal propellant compositions having low burn rate propellant particles dispersed in a matrix of a high burn rate propellant. Most preferably, the HTI device includes a casing which contains the dual modal propellant and a nozzle through which combustion gases generated by the ignited high burn rate propellant may be discharged thereby entraining ignited particles of the low burn rate propellant. In use, therefore, the high burn rate propellant will be ignited using a conventional igniter thereby generating combustion gases which are expelled through the nozzle of the HTI device. As the ignition face of the propellant composition regresses, the low burn rate particles will similarly become ignited.

Abstract: High temperature incendiary (HTI) devices and methods destroy biological and/or chemical agents. Preferably, such HTI devices include dual modal propellant compositions having low burn rate propellant particles dispersed in a matrix of a high burn rate propellant. Most preferably, the HTI device includes a casing which contains the dual modal propellant and a nozzle through which combustion gases generated by the ignited high burn rate propellant may be discharged thereby entraining ignited particles of the low burn rate propellant. In use, therefore, the high burn rate propellant will be ignited using a conventional igniter thereby generating combustion gases which are expelled through the nozzle of the HTI device. As the ignition face of the propellant composition regresses, the low burn rate particles will similarly become ignited.

Abstract: A nitrate ester plasticized energetic composition in which the binder is made of, prior to curing, lower alkylene glycol prepolymer blocks end-capped with ethylene glycol monomers and/or oligomers. The end-capped prepolymer blocks are preferably difunctional or trifunctional. The lower alkylene glycol are preferably propylene glycol, butylene glycol, and/or copolymers thereof. The difunctional end-capped alkylene glycol prepolymer blocks are cured with a diisocyanate or polyisocyanate. In the case of a trifunctional (or higher functional) end-capped alkylene glycol prepolymer block, preferably a diisocyanate is used to effect crosslinking.

Abstract: An initiator (14c) for a secondary explosive receptor charge is provided by forming a length of detonating cord (14) into a helical coil containing a plurality of windings with a cutoff barrier provided by, e.g., a separating rib (46) between adjacent windings. The adjacent windings may be not more than about 0.5 inch (12.7 mm) apart. The detonating cord (14) may be wound about a spindle (16) which may optionally provide the separating rib (46). The coil may be a tapered coil which may define a taper angle of e.g., from about 2 to 4 degrees. Alternatively, the coil may be a cylindrical coil, or the cord may be configured in a planar spiral. Optionally, the detonating cord in the helical coil may have a core of explosive material with a loading of less than 15 grains per foot of the cord, e.g., less than 12 grains per foot of the cord, or a loading in the range of from 8 to 12 grains per foot of the cord. The coil may consume about six inches of the cord.

Abstract: A propellant grain for a cylindrical casing has a cavity including an axially central opening with a combustion product exit port at one end. The grain bears a plurality of surfaces extending circumferentially about and disposed normally or helically to this opening so as to define, between these surfaces and axially of the casing, alternating sections of propellant and sections of a groove or grooves in the propellant. The groove sections extend radially from the opening to a distance selectable to provide the grain with a large initial surface area while providing a high propellant volume.

Abstract: A modular solid-fuel rocket propellent charge has a combustion-chamber wall, a plurality of separate elements including frozen fuel or oxidizer, and respective rigid casings completely surrounding and enclosing the elements. Respective formations on the casing and on the casings directly engage each other for supporting the elements via the respective casings directly an the wall.

Abstract: A propellant cutting assembly and method of using the assembly to cut samples of solid propellant in a repeatable and consistent manner is disclosed. The cutting assembly utilizes two parallel extension beams which are shorter than the diameter of a central bore of an annular solid propellant grain and can be loaded into the central bore. The assembly is equipped with retaining heads at its respective ends and an adjustment mechanism to position and wedge the assembly within the central bore. One end of the assembly is equipped with a cutting blade apparatus which can be extended beyond the end of the extension beams to cut into the solid propellant.

Abstract: A gas generating eject motor includes a case containing an ignitable low temperature gas generant material that does not produce toxic gases upon the combustion thereof. The gas generant material is generally contained with a screen enclosure housed within the case. An igniter is disposed within the gas generant material for selectively igniting the gas generant to thereby generate combustion gases. A nozzle is disposed within an open aft end of the case for focusing and directing the combustion gases generated by the ignited gas generant material. The case is constructed and arranged to be separably attached to the aft end of a rocket to be launched from a launch platform, so that, upon ignition of the gas generant, the combustion gases focused by the nozzle will apply a thrust to the rocket and thereby propel, or eject, the rocket from the launch platform, at which time the combustible propellant of the rocket motor will ignite and the eject motor will be separated from the rocket.

Abstract: A flashless rocket propellent has a continuous potassium sulfate rod extending though the length of the propellent component. The flashless rocket propellent is particularly useful in the MK 66 Rocket Motor.

Abstract: A retainer for model rocket motors having a flange (10) with a concavity (18). Several supports (12) extend perpendicular from the flange (10) and extend to the rocket frame (20). Mounts (14), parallel to the flange (10), abut each of the supports (12). Each mount (14) contains a longitudinal through-hole (16) as a means for attachment to the rocket frame (20).

Abstract: A solid propellant charge for a propulsion unit (1). The latter includes a casing (2) containing the solid propellant charge (3), in the form of an elongated body having a longitudinal axis (X--X), which charge (3) has, over part of its longitudinal extent, a propellant charge profile (4) of large combustion area and is subdivided, along the longitudinal axis (X--X), into at least two segments abutting one another with their respective mutually confronting faces. The propulsion unit furthermore includes a nozzle (5) and means (6) for igniting said charge. The propellant charge profile (4) of large combustion area is provided in that part of the propellant charge (3) which is intermediate along the longitudinal axis (X--X).

Abstract: A rocket according to the invention includes a motor having a fuel chamber and an oxidizer tank, a nose portion provided forward of the motor, and a nozzle surrounded by fins provided aft of the motor. The fuel chamber is provided with a relatively central solid propellant, and a hybrid fuel surrounds the solid propellant. The oxidizer tank is filled with a reactant and coupled to the forward end of the fuel chamber. A pathway is provided between the tank and the fuel chamber for the passage of reactant therethrough. At least one of a valve and a barrier is coupled in the pathway to prevent passage of the reactant into the fuel chamber until after the solid propellant is at least partially consumed. After the solid propellant is at least partially consumed, the valve is opened and/or the barrier is removed to permit the passage of reactant into the fuel chamber.

Abstract: A method for manufacturing solid rocket motors comprises placing a mandrel having at least one collapsible solid slot former positioned thereon substantially centrally along the axis of a rocket case, casting uncured solid rocket propellant about the mandrel and the collapsible solid slot former, curing the solid propellant, removing the mandrel and pressurizing the propellant and slot former, causing the slot former to collapse, and easily removed from the cured propellant.

Abstract: The present invention relates to a gas generator for motor vehicle safety.The generator (1) comprises a hollow cylindrical body (2) containing an igniter (8), a pyrotechnic charge (20) and a nozzle (16,19). The pyrotechnic charge is in the form of a lobed block perforated with channels (24) which are parallel to the axis of the generator.The generator (1) is extended by a diffuser (30) which has a lateral vent (33) for discharging the gases.The generator (1) is particularly suited for inflating side bags for protecting the occupants of a motor vehicle.

Abstract: There is disclosed a propellent having a deterred burn rate. The propellent is a particulate containing an energetic binder base and a thermoplastic burn deterrent. The energetic binder has in impetus (energy) in excess of 200,000 foot pounds per pound (mass) and the thermoplastic burn deterrent is both a solid at room temperature and soluble in an organic solvent. The burn deterrent is gradationally dispersed within the particulate with the greatest concentration of burn deterrent at the particulate periphery.

Abstract: A rocket propellant of improved Isp and thrust is provided by modifying a rocket fuel of RP-1 (a kerosene fraction). Such fuel is combined with an oxidizer (e.g. liquid oxygen, LOX) which defines a rocket propellant of the prior art. Such propellant is modified per the invention by addition to or replacement of, the RP-1 with quadricyclane. In another embodiment, quadricyclane is added to n-Hexane as a fuel composition which is then combined with an oxidizer to define a rocket propellant per the invention. The invention thus provides a number of rocket fuels which upon combination with an oxidizer, provides a high energy density propellant, which can permit increases of over 10 wt % in additional payload for rocket launch vehicles.

Abstract: There is disclosed a propellent having a deterred burn rate. The propellent is a particulate containing a nitrocellulose base and a cellulosic thermoplastic deterrent, preferably cellulose acetate butyrate or cellulose acetate propionate. The deterrent is gradationally dispersed within the particulate with the greatest concentration of deterrent at the particulate periphery.

Abstract: In a gas generant composition for automotive airbag inflation, a gas generant composition comprises a fuel and an oxidizer the composition includes a metal oxide or metalloid oxide and a processing aid which is a mixture of mica and a salt of a fatty acid.

Abstract: A galvanically conductive explosive is formed by the admixture of a small proportion of precious metal-containing platelets to a binder. The resulting blend is combined with explosive granules to form a homogeneous mixture which, after press-forming, produces galvanically conductive bodies.

Abstract: A gas generant composition contains as a fuel a mixture of a major portion of a triazole or tetrazole and a minor portion of a water soluble fuel; and an oxidizer component, at least 20 wt % of said oxidizer component being a transition metal oxide, such as CuO. Generant compositions in accordance with the invention autoignite in a range around 170.degree. C., providing autoignition of the generant without the need for separate autoignition devices. Also, the generant compositions are useful as autoignition pyrotechnic in autoignition devices.

Abstract: Compositions and methods for increasing the storage life of a propellant grain by reducing the rate of decomposition of its nitrate ester components. A nitrate ester stabilizer is placed in a layer adjacent to a nonburning surface of the propellant grain. The stabilizer migrates from the layer into the grain's nonburning surface to provide additional stabilization for the entire grain, especially portions of the grain adjacent to the protected nonburning surface.

Abstract: Methods and materials for modifying rocket motors to render them safer are disclosed. The invention is primarily related to placing within the bore of a rocket motor a sufficient quantity of a material mitigant such that if the rocket motor receives an unintended impact, the material mitigates the effects of the impact, and prevents ignition or explosion of the propellant. The material mitigant may take a number of forms; however, polymer foams and fibers of various types have been found to work well. It is presently preferred that the material mitigants have a density of not less than approximately 0.04 grams/cc. Examples of such materials include polyurethane foam, polystyrene, and Kevlar.RTM. fibers. It is also preferred that the material mitigant not be reactive with the propellant in the rocket motor.

Abstract: An igniter for solid fuel rockets in which hot gases from an initiator are hanneled to drive a piston against a reservoir of combustion modifying fluid, like ethylene glycol, so as to spray the fluid onto the propellant grain just before ignition. After the piston moves, the hot gases escape the igniter as to ignite the propellant directly or through an intermediate main ignition charge.

Abstract: A solid propellant component grain is supported in a combustion chamber. A liquid propellant component container is mounted forward of the combustion chamber. The liquid propellant component is supplied through conduits from the container into the combustion chamber, and ignited to form combustion gas which is discharged out the rear of the combustion chamber to generate thrust for propelling a rocket. A high pressure tank containing a non-flammable gas such as helium is at least partially embedded in the grain. A conduit leads from the tank into the container, such that the high pressure gas pressurizes the container and urges the liquid propellant component to flow from the container into the combustion chamber. The tank provides internal structural support for the grain, with the wall of the combustion chamber constituting a safety barrier in the event of structural failure of the tank after the tank is filled with high pressure gas.

Abstract: A method of making an elastomer lined composite vessel or portion of such vessel is disclosed. The method comprises causing a thin, tacky ribbon comprising an elastomer (preferably curable) to continuously so encircle a center rotational axis of a madrel as to adjacently position and tack together integral segments of the ribbon substantially circumferentially relative to this center rotational axis thereby forming a layer of the elastomer about the mandrel which may be the shell of the pressure vessel in case of internal application of the insulator or may be a workpiece around which the shell is built over the so-layed ribbon.

Abstract: The trimer of 1,6-hexanediisocyanate, which has the chemical name in acconce with (International Union of Pure and Applied Chemistry) (IUPAC) nomenclature of 7-aza-8-oxo-7[1-isocyanato-6-oxohexyl]pentadecanediisocyanate, is employed in a method of chemical bonding of solid propellant grains to the internal insulation of an interceptor motor. Both the propellant composition and the insulation are chemically reactive with the trimmer identified hereinabove. The method comprises providing a solid propellant rocket motor case having the internal insulation installed therein. Following degreasing of the insulation outer surface, the trimer identified hereinabove is spray coated onto the insulation, and the solid propellant composition is placed onto the trimer. A chemical bond is formed between the propellant and the trimer and the insulation to achieve the chemical bonding of an isocyanate curable solid propellant composition to the internal insulation.

Abstract: A thermal insulator for a rocket motor body comprises a member adapted to be fitted as a sleeve on the outer surface of the body the member comprising a composite of cork having on its outer surface a layer of fibre reinforced polymeric material wherein a substantial proportion of the fibre reinforcement comprises fibres of low-conducting material.

Abstract: Sectors of tubes are adhesively fixed around a prefabricated propellant, the sectors being juxtaposed edge to edge to constitute a cylindrical tube, and a winding is formed around the tube at least in circumferential direction. The front and rear walls which are equipped with a seating and a tuyere, can be joined to the tubular structure formed by the tube sectors, by adhesive means on the inside of that structure, or as a variant, by means of a helical winding formed simultaneously on the wall and on the tubular structure.

Abstract: A low freezing point eutectic solid propellant plasticizer composition component comprising a mixture of 1,5-dinitrato-3-nitrazapentane and 1,5-diazido-3-nitrazapentane having a eutectic freezing point below about -25.degree. C.