COMBUSTIBLE STRUCTURAL COMPOSITES AND METHODS OF FORMING COMBUSTIBLE STRUCTURAL COMPOSITES

• US 20100071813A1
• Filed: 09/19/2008
• Published: 03/25/2010
• Est. Priority Date: 09/19/2008
• Status: Active Grant

• Current Assignee: Battelle Energy Alliance LLC (Battelle Memorial Institute)
• Original Assignee: Battelle Energy Alliance LLC (Battelle Memorial Institute)
• Inventors: DANIELS, MICHAEL A., STEFFLER, ERIC D., SWANK, W. DAVID, HEAPS, RONALD J.
• Granted Patent: US 8,007,607 B2
• Time in Patent Office: Days
• US Class Current: 149/15
• CPC Class Codes: C06B 23/001 Fillers, gelling and thickening agents (e.g. fibres) , absorbents for nitroglycerine binders, plasticisers for propellants C06B45/10; crosslinking or curing agents C06B45/10
• CPC Class Codes: C06B 33/00 Compositions containing particulate metal, alloy, boron, silicon, selenium or tellurium with at least one oxygen supplying material which is either a metal oxide or a salt, organic or inorganic, capable of yielding a metal oxide
• CPC Class Codes: C06B 45/00 Compositions or products which are defined by structure or arrangement of component of product explosive charges of particular form or shape F42B1/00, F42B3/00
• CPC Class Codes: C06B 45/14 a layer or zone containing an inorganic explosive or an inorganic explosive or an inorganic thermic component
• CPC Class Codes: Y10T 29/49826 Assembling or joining
• CPC Class Codes: Y10T 428/249953 Composite having voids in a component [e.g., porous, cellular, etc.]

Abstract

Combustible structural composites and methods of forming same are disclosed. In an embodiment, a combustible structural composite includes combustible material comprising a fuel metal and a metal oxide. The fuel metal is present in the combustible material at a weight ratio from 1:9 to 1:1 of the fuel metal to the metal oxide. The fuel metal and the metal oxide are capable of exothermically reacting upon application of energy at or above a threshold value to support self-sustaining combustion of the combustible material within the composite. Structural-reinforcing fibers are present in the composite at a weight ratio from 1:20 to 10:1 of the structural-reinforcing fibers to the combustible material. Other embodiments and aspects are disclosed.

Claims

1. A combustible structural composite, comprising:

a combustible material comprising a fuel metal and a metal oxide, the fuel metal being present in the combustible material at a weight ratio from 1;

9 to 1;

1 of the fuel metal to the metal oxide, the fuel metal and the metal oxide being capable of exothermically reacting upon application of energy at or above a threshold value to support self-sustaining combustion of the combustible material within the composite; and

a plurality of structural-reinforcing fibers present in the composite at a weight ratio from 1;

20 to 10;

1 of the structural-reinforcing fibers to the combustible material form.

2. The composite of claim 1 wherein the fuel metal is in an elemental

3. The composite of claim 1 wherein the fuel metal is an alloy of elemental metals.

4. The composite of claim 1 wherein the fuel metal comprises at least one selected from the group consisting of aluminum, titanium, zirconium, and magnesium.

5. The composite of claim 1 wherein the fuel metal comprises aluminum in alloy form.

6. The composite of claim 5 wherein the fuel metal comprises magnalium.

7. The composite of claim 1 wherein the metal oxide comprises an oxide of at least a metal selected from the group consisting of iron, copper, boron, chromium, manganese, lead, and silicon.

8. The composite of claim 1 wherein the fuel metal is present in the combustible material at a weight ratio from 1:

4 to 3;

7 of the fuel metal to the metal oxide.

9. The composite of claim 1 wherein the structural-reinforcing fibers are present in the composite at a weight ratio from 1:

2 to 2;

1 of the structural-reinforcing fibers to the combustible material.

10. The composite of claim 1 wherein the structural-reinforcing fibers comprise at least one selected from the group consisting of glass fibers, carbon fibers, and aramid fibers.

11. The composite of claim 1 wherein the structural-reinforcing fibers contact the combustible material.

12. The composite of claim 11 wherein the structural-reinforcing fibers are received within the combustible material.

13. The composite of claim 12 wherein the structural-reinforcing fibers are distributed homogenously within the combustible material.

14. The composite of claim 1 wherein the structural-reinforcing fibers are provided in the composite as a sheet.

15. The composite of claim 14 wherein the structural-reinforcing fibers contact the combustible material.

16. The composite of claim 15 wherein the sheet is covered on opposing sides by the combustible material.

17. The composite of claim 14 wherein the sheet comprises a plurality of opposing major surfaces, the combustible material being provided to cover only a single surface among the opposing major surfaces.

18. The composite of claim 14 wherein the structural-reinforcing fibers are provided in the composite as a plurality of sheets.

19. A combustible structural composite, comprising:

a combustible material comprising a fuel metal and a metal oxide, the fuel metal being present in the combustible material at a weight ratio from 1;

9 to 1;

1 of the fuel metal to the metal oxide, the fuel metal and the metal oxide being capable of exothermically reacting upon application of energy at or above a threshold value to support self-sustaining combustion of the combustible material within the composite; and

a metal wire present in the composite at a weight ratio from 1;

20 to 10;

1 of the metal wire to the combustible material.

20. The composite of claim 19 wherein the metal wire comprises a sheet.

21. The composite of claim 20 wherein the metal wire comprises a screen mesh.

22. The composite of claim 20 wherein the composite comprises a plurality of opposing major surfaces, the sheet being substantially centered between the opposing major surfaces.

23. The composite of claim 19 wherein the composite is cylindrical.

24. The composite of claim 19 wherein the metal wire is of a composition comprising the fuel metal.

25. The composite of claim 19 wherein the metal wire is of a composition consisting essentially of the fuel metal.

26. A combustible structural composite, comprising:

a combustible material comprising a fuel metal and a metal oxide, the fuel metal being present in the combustible material at a weight ratio from 1;

9 to 1;

1 of the fuel metal to the metal oxide, the fuel metal and the metal oxide being capable of exothermically reacting upon application of energy at or above a threshold value to support self-sustaining combustion of the combustible material within the composite; and

a structural load-bearing sheet bonded to the combustible material, the structural load-bearing sheet being present in the composite at a weight ratio from 1;

20 to 10;

1 of the structural load-bearing sheet to the combustible material.

27. The composite of claim 26 comprising a plurality of layers of structural load-bearing sheets collectively present in the composite at a weight ratio from 1:

20 to 10;

1 of the structural load-bearing sheets to the combustible material.

28. The composite of claim 27 comprising a plurality of layers of the combustible material being alternatingly disposed with at least a layer of the plurality of structural load-bearing sheets.

29. The composite of claim 26 wherein the structural load-bearing sheet comprises metal.

30. The composite of claim 26 wherein the composite comprises a plurality of opposing major surfaces, the structural load-bearing sheet being centered between the plurality of opposing major surfaces.

31. The composite of claim 26 wherein the composite comprises a plurality of opposing major surfaces, the structural load-bearing sheet comprising an opposing major surface among the plurality of opposing major surfaces.

32. A combustible structural composite, comprising:

a pair of structural load-bearing sheets having a foam-comprising core received therebetween; and

the foam-comprising core comprising a plurality of combustible material masses received within a foam, the combustible material masses comprising a fuel metal and a metal oxide, the fuel metal being present in the combustible material at a weight ratio from 1;

9 to 1;

1 of the fuel metal to the metal oxide, the fuel metal and the metal oxide being capable of exothermically reacting upon application of energy at or above a threshold value to support self-sustaining combustion of the combustible material within the composite.

33. The composite of claim 32 wherein the masses are spherical.

34. The composite of claim 32 wherein the core comprises opposing major surfaces each of which is received proximate different of the respective structural load-bearing sheets of the pair, the combustible material masses extending completely through the foam from one of the opposing major surfaces to the other.

35. The composite of claim 34 wherein the masses are cylindrical.

36. A method of forming a combustible structural composite, comprising:

forming a plurality of holes extending into a foam-comprising sheet;

inserting a combustible material mass into a hole among the plurality of holes in the foam-comprising sheet, the combustible material mass comprising a fuel metal and a metal oxide, the fuel metal being present in the combustible material at a weight ratio from 1;

9 to 1;

1 of the fuel metal to the metal oxide, the fuel metal and the metal oxide being capable of exothermically reacting upon application of energy at or above a threshold value to support self-sustaining combustion of the combustible material within the composite; and

disposing the foam-comprising sheet containing the combustible material mass between a pair of structural load-bearing sheets.

37. The method of claim 36 comprising forming the plurality of holes to extend transversally and completely through the foam-comprising sheet, the combustible material mass being disposed completely through the foam-comprising sheet from a first major opposing surface of the foam-comprising sheet to a second major opposing surface of the foam-comprising sheet.

38. The method of claim 36 wherein the combustible material mass is placed within the hole and glued to the foam-comprising sheet.

39. A method of forming a combustible structural composite, comprising:

spraying a liquid mixture onto and through a screen mesh; and

solidifying the sprayed liquid mixture into a combustible material covering a plurality of opposing surfaces of the screen mesh, the combustible material comprising a fuel metal and a metal oxide, the fuel metal being present in the combustible material at a weight ratio from 1;

9 to 1;

1 of the fuel metal to the metal oxide, the fuel metal and the metal oxide being capable of exothermically reacting upon application of energy at or above a threshold value to support self-sustaining combustion of the combustible material within the composite.

40. The method of claim 39 wherein the screen mesh comprises a metal.

41. The method of claim 39 wherein the liquid mixture is molten and at a temperature above that of the screen mesh during the spraying.

42. The method of claim 39 wherein the screen mesh is planar.

43. The method of claim 39 wherein the screen mesh is cylindrical.

44. The method of claim 39 wherein the screen mesh comprises a cylinder, the cylinder being rotated about a longitudinal axis of the cylinder during spraying such that the combustible material lines an internal surface and an external surface of the cylinder.