Porous propellant grain and method of making same
First Claim
Patent Images
1. A process for preparing a porous propellant grain which comprises:
- blending a predetermined amount of at least two combustible materials, said materials being capable of rapidly reacting to generate a gaseous product, and a liquid dispersant to form a slurry; and
flash drying said slurry to substantially evaporate said dispersant and form a porous propellant grain.
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Accused Products
Abstract
A process for preparing a porous propellant grain which comprises blending at least two combustible materials to form a homogeneous mixture, adding a predetermined amount of a liquid dispersant to said mixture to form a slurry, and flash drying the slurry in order to form a porous, single grain propellant having a greatly increased burning surface. A single grain propellant is produced having a flat, torroidal shape with a central cylindrical core and honeycombed with a plurality of porous channels extending entirely through the grain to increase the burning surface thereof.
62 Citations
46 Claims
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1. A process for preparing a porous propellant grain which comprises:
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blending a predetermined amount of at least two combustible materials, said materials being capable of rapidly reacting to generate a gaseous product, and a liquid dispersant to form a slurry; and flash drying said slurry to substantially evaporate said dispersant and form a porous propellant grain. - View Dependent Claims (3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 16, 17, 18, 19, 20, 21, 35)
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2. A process for preparing a porous propellant grain which comprises:
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blending a predetermined amount of at least two combustible materials to form a homogeneous mixture, said materials capable of rapidly reacting to generate a non-toxic, non-noxious gas; adding a predetermined amount of a liquid dispersant to said mixture to form a slurry; and flash drying said slurry in order to evaporate said dispersant and form a porous propellant grain having a burning surface capable of producing a desired amount of gaseous product to substantially fully inflate an automobile air bag in about 30-60 milliseconds. - View Dependent Claims (36)
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15. A process for preparing a porous propellant grain which comprises:
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dry blending a mixture of 40-80 parts per hundred by weight of a sodium azide and from about 20-60 parts per hundred by weight of a mixture of ferric oxide and cupric oxide, said metal oxide being added in an amount slightly in excess of the stoichiometric requirement, with an oxidizing agent selected from among an alkaline nitrate, an alkaline chlorate, an alkaline perchlorate and mixtures thereof, to form a homogeneous mixture; adding a predetermined amount of a solution of sodium silicate in water to said mixture to form a slurry; and flash drying said slurry in order to evaporate water from the slurry and form a porous, single-grain propellant composition with a sufficient burning surface capable of producing a desired amount of gaseous product to substantially fully inflate an automobile air bag in about 30-60 milliseconds. - View Dependent Claims (37)
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22. A process for preparing a porous propellant grain which comprises:
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dry blending 40-80 parts per hundred by weight of an alkali metal azide selected from among sodium azide, potassium azide, lithium azide and mixtures thereof together with about 20-60 parts per hundred by weight of a metal oxide selected from among iron oxide, copper (II) oxide, manganese oxide, tin oxide, titanium oxide, nickel oxide and mixtures thereof, said amount of metal oxide being slightly in excess of the stoichiometric requirement and an additional oxidizing agent selected from among an alkaline nitrate, an alkaline chlorate, an alkaline perchlorate and mixtures thereof, to form a homogeneous mixture; adding a predetermined amount of a sodium slicate solution in water to said mixture to form a slurry wherein the percentage of said sodium silicate ranges between 10-70% by weight; placing said slurry into an automobile gas generator combuster cup in an amount sufficient to substantially fill said cup so as to mold the slurry into a predetermined shape; and irradiating said slurry with a source of microwave radiation for a period of about 3-5 minutes, wherein said period is comprised of a plurality of discrete radiation treatments, each lasting about 30 seconds, to evaporate substantially all of the water from the slurry and form a porous, single grain propellant having a burning surface capable of producing a desired amount of gaseous product to substantially fully inflate an automobile air bag in about 30-60 milliseconds. - View Dependent Claims (38)
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23. A process for rapidly generating a quantity of a gaseous product which comprises:
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preparing a porous propellant grain by blending a predetermined amount of at least two combustible materials, said materials capable of rapidly reacting to generate a gaseous product, and a liquid dispersant to form a slurry; and flash drying said slurry to substantially evaporate said dispersant, thus forming said porous grain; and igniting said grain so as to produce a desired quantity of gaseous product. - View Dependent Claims (24, 25, 26, 27, 28, 29, 30, 31, 32, 33)
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34. A process for rapidly generating a desired quantity of a gaseous product to substantially fully inflate an automobile air bag in between about 30-60 milliseconds which comprises:
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preparing a porous propellant grain by blending a predetermined amount of at least an alkali metal azide and a metal oxide, said azide and said oxide capable of rapidly reacting to generate a nonnoxious, non-toxic gaseous product, and an aqueous dispersant to form a slurry; and flash drying said slurry to substantially evaporate said dispersant, thus forming said porous grain; placing said porous grain within a combustion chamber portion of an automotive air bag gas generator assembly; and igniting said porous grain to generate said gas.
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- 39. A porous propellant grain wherein said grain has a plurality of randomly oriented, radial and longitudinally interconnected porous channels having a variety of diameters, extending entirely through said grain to increase the burning surface of said grain.
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44. A porous propellant grain resistant to abrasion and breakup during loading into a gas generator and upon ignition thereof, wherein said grain has a plurality of randomly oriented uniformly distributed porous channels extending entirely therethrough, having a variety of diameters, said channels being radially and longitudinally interconnected to increase the burning surface of said grain, said grain having a density of between about 0.85-1.45 grams/cm3, and having a flat, torroidal shape.
- 45. A porous propellant grain resistant to abrasion and breakup during loading into a gas generator and upon ignition thereof, comprising a homogeneous mixture of at least two combustible reactants, said mixture containing a plurality of randomly oriented porous channels having a variety of diameters, uniformly distributed therethrough, said channels being radially and longitudinally interconnected to provide a sufficient burning surface for rapidly producing a large quantity of gaseous product upon ignition of said propellant.
Specification