Consumable weight components for flares and methods of formation

• US 10,155,700 B2
• Filed: 11/23/2015
• Issued: 12/18/2018
• Est. Priority Date: 11/04/2011
• Status: Active Grant

• Current Assignee: Northrop Grumman Systems Corporation (Northrop Grumman Corporation)
• Original Assignee: Northrop Grumman Innovation Systems, Inc. (Northrop Grumman Corporation)
• Inventors: Widener, Jeffrey F., Nielson, Daniel B.
• Primary Examiner(s): McDonough, James E
• Application Number:
  US14/949,702
• Publication Number:
  US 20160075614A1
• Time in Patent Office: 1,121 Days
• Field of Search: 149 196, 149 17, 149 18, 1491094, 1491096
• CPC Class Codes: B29C 39/22 Component parts, details or accessories; Auxiliary operations
• CPC Class Codes: B29C 43/32 Component parts, details or accessories; Auxiliary operations
• CPC Class Codes: B29C 48/0021 combined with joining, lining or laminating
• CPC Class Codes: B29C 65/48 using adhesives , i.e. using supplementary joining material; solvent bonding
• CPC Class Codes: B29K 2096/00 Use of specified macromolecular materials not provided for in a single one of main groups B29K2001/00 - B29K2095/00, as moulding material
• CPC Class Codes: B29K 2105/16 Fillers
• CPC Class Codes: B29K 2505/00 Use of metals, their alloys or their compounds, as filler
• CPC Class Codes: B29K 2995/0037 Other properties
• CPC Class Codes: B29L 2009/00 Layered products
• CPC Class Codes: B29L 2031/747 Lightning equipment
• CPC Class Codes: C06B 45/04 comprising solid particles dispersed in solid solution or matrix not used for explosives where the matrix consists essentially of nitrated carbohydrates or a low molecular organic explosive
• CPC Class Codes: C06B 45/10 the organic component containing a resin
• CPC Class Codes: C06C 15/00 Pyrophoric compositions; Flints chemical lighters C06C9/00; alloys in general C22C
• CPC Class Codes: F42B 12/42 of illuminating type, e.g. carrying flares
• CPC Class Codes: F42B 4/26 Flares; Torches mines for practice or training containing flares or illuminating charges F42B8/28; projectiles of illuminating type F42B12/42

Abstract

Flares with consumable weights connected to a forward end of the grain of the flare are disclosed. Also disclosed are consumable weight components for flares. The consumable weight components include a metal material within a matrix. Also disclosed are methods for fabricating a flare and methods for using a flare. Use of the consumable weights in the flares may reduce the amount of debris falling to ground.

Claims

1. A consumable weight component for a flare, the consumable weight component comprising a metal material within a polymer matrix, the polymer matrix comprising a solid continuous phase of the consumable weight component and the consumable weight component configured into a shape by at least one of casting, extrusion, molding, curing, or machining.

2. The consumable weight component of claim 1, wherein the metal material is essentially uniformly dispersed within the polymer matrix.

3. The consumable weight component of claim 1, wherein the metal material is more densely dispersed within the polymer matrix proximate to a front side of the consumable weight component.

4. The consumable weight component of claim 1, wherein the polymer matrix comprises an energetic binder.

5. The consumable weight component of claim 1, wherein the polymer matrix comprises a nonenergetic binder.

6. The consumable weight component of claim 1, wherein the metal material is suspended within the polymer matrix and the metal material comprises a metal, a metal alloy, or a metal oxide.

7. The consumable weight component of claim 1, wherein the metal material is a powdered metal material.

8. The consumable weight component of claim 1, wherein the metal material exhibits an average particle size not exceeding 60 micrometers.

9. A consumable weight component for a flare, the consumable weight component comprising a metal material dispersed within a matrix and defining at least one of:

an internal bore, or

at least one groove in at least one exterior lateral surface of the consumable weight component,

the metal material comprising from about 50 weight percent to about 98 weight percent of the consumable weight component and the matrix comprising from 2 weight percent to about 50 weight percent of the consumable weight component.

10. The consumable weight component of claim 9, wherein the consumable weight component defines the internal bore, the internal bore extending through a height of the consumable weight component.

11. The consumable weight component of claim 9, wherein the consumable weight component defines grooves in the exterior lateral surfaces of the consumable weight component.

12. The consumable weight component of claim 9, wherein the metal material comprises at least one of tungsten, bismuth, lead, or tantalum.

13. The consumable weight component of claim 9, wherein the metal material comprises a metal oxide selected from the group consisting of tungsten oxide, bismuth oxide, lead oxide, and tantalum oxide.

14. The consumable weight component of claim 9, wherein the matrix comprises a glycidyl azide polymer (GAP) binder and at least one of a GAP plasticizer, strontium nitrate, or iron oxide.

15. The consumable weight component of claim 14, wherein the metal material comprises tungsten.

16. A method of forming a flare having a consumable weight component, the method comprising:

forming a consumable weight component for a flare, the consumable weight component defining a cross-sectional shape, comprising;

dispersing a metal material within a polymer matrix, the polymer matrix forming a solid continuous phase of the consumable weight component and the consumable weight component configured into a shape by at least one of casting, extrusion, molding, curing, or machining; and

joining the consumable weight component to a forward end of a grain also defining the cross-sectional shape.

17. The method of claim 16, further comprising disposing a reactive foil about exterior lateral surfaces of the consumable weight component and the grain.

18. The method of claim 17, wherein disposing a reactive foil about exterior lateral surfaces of the consumable weight component and the grain comprises disposing the reactive foil to directly contact only some of the exterior lateral surfaces.

19. The method of claim 16, wherein forming a consumable weight component and joining the consumable weight component to a forward end of a grain comprise simultaneously co-curing material of the polymer matrix of the consumable weight component and material of the grain to form a unified flare comprising the consumable weight component seamlessly joined to the grain.

20. The method of claim 16, wherein forming a consumable weight component defining a cross-sectional shape comprises forming the cross-sectional shape exhibited by the polymer matrix containing the metal material.

21. A consumable weight component for a flare, the consumable weight component comprising a metal material within a polymer matrix in a solid phase of the consumable weight, the polymer matrix formulated to incinerate upon ignition of the consumable weight component, the metal material formulated not to incinerate during incineration of the polymer matrix, and the consumable weight component configured into a shape by at least one of casting, extrusion, molding, curing, or machining.

22. The consumable weight component of claim 21, wherein the polymer matrix is formulated to substantially incinerate upon ignition of the consumable weight component.