Flares with a consumable weight and methods of fabrication and use

• US 9,194,669 B2
• Filed: 11/04/2011
• Issued: 11/24/2015
• Est. Priority Date: 11/04/2011
• Status: Active Grant

• Current Assignee: Northrop Grumman Systems Corporation (Northrop Grumman Corporation)
• Original Assignee: Orbital ATK Inc.
• Inventors: Widener, Jeffrey F., Nielson, Daniel B.
• Primary Examiner(s): Bergin, James S
• Application Number:
  US13/289,669
• Publication Number:
  US 20130112099A1
• Time in Patent Office: 1,481 Days
• Field of Search: 102/335, 102/336, 102/341, 102/345, 102/352, 102/360, 102/285, 102/286, 102/291, 102/292
• US Class Current: 1/1
• 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 flare comprising:

a grain comprising a combustible material; and

a consumable weight bonded directly to a forward end of the grain, the consumable weight comprising metal material suspended within a matrix, the matrix constraining the metal material therein and exhibiting a solid, continuous phase of the consumable weight.

2. The flare of claim 1, wherein the consumable weight has a density greater than or equal to about 8.4 grams per cubic centimeter.

3. The flare of claim 1, wherein the metal material comprises a metal-containing material selected from the group consisting of tungsten, bismuth, lead, tantalum, tungsten oxide, bismuth oxide, lead oxide, tantalum oxide, tungsten carbide, alloys thereof, and combinations thereof.

4. The flare of claim 1, wherein the consumable weight is formulated to produce at least one of gaseous byproducts, a friable material, and unreacted metal material upon combustion.

5. The flare of claim 1, wherein the metal material comprises between about 50 weight percent and about 98 weight percent of the consumable weight.

6. The flare of claim 1, wherein the matrix comprises a polymer binder formed from a curable polymer binder.

7. The flare of claim 6, wherein the curable polymer binder comprises at least one of glycidyl azide polymer, nitrocellulose, polyethylene glycol, polypropylene glycol, polybutadiene acrylonitrile, hydroxyl-terminated polybutadiene, cellulose acetate butyrate, and a fluoroelastomer.

8. The flare of claim 6, wherein the curable polymer binder is a liquid at a processing temperature of the consumable weight.

9. The flare of claim 1, wherein the combustible material and the matrix comprise essentially identical compositions.

10. The flare of claim 1, wherein the matrix further comprises at least one of a plasticizer, an oxidizer, and a burn rate catalyst.

11. The flare of claim 1, wherein the consumable weight comprises tungsten particles in a glycidyl azide polymer matrix.

12. The flare of claim 1, wherein the consumable weight is attached to the grain.

13. The flare of claim 1, wherein:

the flare is configured to be released from an airborne aircraft; and

the matrix is formulated to be fully consumed before combustion products of the consumable weight contact another aircraft or an earth-supported object.

14. The flare of claim 1, wherein the metal material is essentially uniformly dispersed within the matrix.

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

16. The flare of claim 1, wherein the matrix comprises a cured energetic binder.

17. The flare of claim 1, wherein the matrix comprises a cured nonenergetic binder.

18. The flare of claim 1, wherein the metal material comprises a metal, a metal alloy, or a metal oxide.

19. The flare of claim 1, wherein the metal material is a powdered metal material.

20. The flare of claim 1, wherein the metal material exhibits an average particle size not exceeding 60 micrometers.

21. A method for fabricating a flare, comprising:

suspending a metal material within a matrix to form a consumable weight, the matrix constraining the metal material therein and exhibiting a solid, continuous phase of the consumable weight; and

bonding the consumable weight directly to a forward end of a grain comprising a combustible material.

22. A method for using a flare, comprising:

providing a flare comprising a combustible grain and a consumable weight bonded directly to a forward end of the combustible grain and comprising a metal material suspended within a matrix, the matrix constraining the metal material therein and exhibiting a solid, continuous phase of the consumable weight; and

combusting the consumable weight to produce combustion products comprising gaseous byproducts, a friable material, and unreacted metal material.

23. The method of claim 22, wherein combusting the consumable weight comprises incinerating the matrix before the friable material and unreacted metal material impact an airborne aircraft or an earth-supported object.

24. The method of claim 22, wherein combusting the consumable weight comprises producing an ash.

25. The method of claim 22, wherein combusting the consumable weight to produce combustion products comprises producing the friable material and unreacted metal material having an average particle size of less than or equal to about 60 micrometers.

26. A flare comprising:

a grain comprising a combustible material; and

a consumable weight seamlessly integrated directly with a forward end of the grain, the consumable weight comprising metal material suspended within a matrix, the matrix constraining the metal material therein and exhibiting a solid, continuous phase of the consumable weight.