Combustible structural composites and methods of forming combustible structural composites

• US 8,007,607 B2
• Filed: 09/19/2008
• Issued: 08/30/2011
• Est. Priority Date: 09/19/2008
• Status: Expired due to Fees

• Current Assignee: Battelle Energy Alliance LLC (Battelle Memorial Institute)
• Original Assignee: Battelle Energy Alliance LLC (Battelle Memorial Institute)
• Inventors: Swank, William D., Daniels, Michael A., Steffler, Eric D, Heaps, Ronald J.
• Primary Examiner(s): McDonough; James E
• Application Number:
  US12/233,639
• Publication Number:
  US 20100071813A1
• Time in Patent Office: 1,075 Days
• Field of Search: 149/15, 149/2, 149/17, 149/37, 149/108.2, 149/108.8, 149/109.2, 149/109.4, 149/109.6
• 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 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 combustible material comprising a fuel metal and a metal oxide, the fuel metal and the metal oxide present in the combustible material at a weight ratio of from 1;

9 to 1;

1 of the fuel metal to the metal oxide; and

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

2 to 2;

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

2. The combustible structural composite of claim 1, wherein the fuel metal is in an elemental form.

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

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

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

6. The combustible structural composite of claim 1, wherein the fuel metal comprises magnalium.

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

8. The combustible structural 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 combustible structural composite of claim 1, wherein the plurality of structural-reinforcing fibers comprises fibers selected from the group consisting of glass fibers, carbon fibers, aramid fibers, and combinations thereof.

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

11. The combustible structural composite of claim 1, wherein the plurality of structural-reinforcing fibers is received within the combustible material.

12. The combustible structural composite of claim 1, wherein the plurality of structural-reinforcing fibers is distributed homogenously within the combustible material.

13. The combustible structural composite of claim 1, wherein the plurality of structural-reinforcing fibers is provided in the combustible structural composite as at least one sheet.

14. The combustible structural composite of claim 13, wherein the structural-reinforcing fibers contact the combustible material.

15. The combustible structural composite of claim 13, wherein the at least one sheet is covered on opposing sides by the combustible material.

16. The combustible structural composite of claim 13, wherein:

the at least one sheet comprises a plurality of opposing major surfaces; and

the combustible material is provided to cover only a single surface among the plurality of opposing major surfaces.

17. The combustible structural composite of claim 13, wherein the at least one sheet comprises a plurality of sheets.

18. The combustible structural composite of claim 1, wherein 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.

24. The combustible structural composite of claim 1, wherein the plurality of structural-reinforcing fibers is distributed non-homogenously in the combustible material.

25. The combustible structural composite of claim 1, wherein the plurality of structural-reinforcing fibers comprises a non-combustible material.

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

combining a fuel metal and a metal oxide to form a liquid mixture of a combustible material, the fuel metal present in the combustible material at a weight ratio from 1;

9 to 1;

1 of the fuel metal to the metal oxide; and

adding structural-reinforcing fibers to the liquid mixture of the combustible material to form a liquid mixture of the combustible structural composite, the structural-reinforcing fibers present in the combustible structural composite at a weight ratio from 1;

2 to 2;

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

20. The method of claim 19, wherein combining a fuel metal and a metal oxide to form a liquid mixture of a combustible material comprises combining the fuel metal and the metal oxide with a solvent.

21. The method of claim 20, further comprising applying the liquid mixture of the combustible structural composite to a surface that is chemically inert to the solvent.

22. The method of claim 21, further comprising removing the solvent.

23. The method of claim 19, wherein adding structural-reinforcing fibers to the liquid mixture of the combustible material comprises combining the structural-reinforcing fibers, fuel metal, and metal oxide to form a homogeneous liquid mixture of the combustible structural composite.