COMBUSTIBLE STRUCTURAL COMPOSITES AND METHODS OF FORMING COMBUSTIBLE STRUCTURAL COMPOSITES

• US 20110281101A1
• Filed: 07/28/2011
• Published: 11/17/2011
• 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., SWANK, W. David, HEAPS, Ronald J., STEFFLER, Eric D.
• Granted Patent: US 8,409,377 B2
• Time in Patent Office: Days
• US Class Current: 428/304.4
• 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 combustible structural 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 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 plurality of combustible material masses comprising a fuel metal and a metal oxide, the fuel metal being present in the plurality of combustible material masses 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 plurality of combustible material masses within the combustible structural composite.

2. The combustible structural composite of claim 1, wherein the plurality of combustible material masses are spherical.

3. The combustible structural composite of claim 1, wherein the foam-comprising core comprises opposing major surfaces each of which is received proximate different of the respective structural load-bearing sheets of the pair, the plurality of combustible material masses extending completely through the foam from one of the opposing major surfaces to the other.

4. The combustible structural composite of claim 1, wherein the plurality of combustible material masses are cylindrical.

5. 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 mass 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 mass within the combustible structural composite; and

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

6. The method of claim 5, further 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.

7. The method of claim 5, wherein the combustible material mass is placed within the plurality of holes and glued to the foam-comprising sheet.