Composite propellant compositions

Abstract

The invention relates to propellant compositions comprising a solid inorganic perchlorate oxidizing agent, a nitrogen-containing fuel, and a burn rate catalyst. Such compositions may be used as a propellant material, (e.g., in rocketry), a pyrotechnic material, an explosive material, a light generating material, a heat generating material, or a sound generating material.

1 . A propellant composition comprising a solid inorganic oxidizing agent; a nitrogen-containing fuel; and a burn rate catalyst, wherein said burn rate catalyst is nanoparticulate.  
     
     
         2 . The composition of  claim 1  wherein said burn rate catalyst is an oxide selected from the group consisting of copper, chromium, cobalt, manganese, iron, vanadium, and mixtures thereof.  
     
     
         3 . The composition of  claim 1 , wherein said material is a propellant material, a pyrotechnic material, an explosive material, a light generating material, a heat generating material, or a sound generating material.  
     
     
         4 . The composition of  claim 1 , wherein said nanoparticles are irregularly shaped.  
     
     
         5 . The composition of  claim 2 , wherein said burn rate catalyst is about 0.1-15 wt % oxide.  
     
     
         6 . The composition of  claim 2 , wherein said burn rate catalyst is about 0.5-10 wt % oxide.  
     
     
         7 . The composition of  claim 1 , further comprising a binder.  
     
     
         8 . The composition of  claim 7 , wherein said binder is a combustible organic polymer selected from the group consisting of polyvinylchloride, polyvinylacetate, polyvinylalcohol, and copolymers thereof including VAAR, VROH, VAGH, Geon-121, poly (2-ethyl-2-oxazoline), and epoxy or acrylate resin.  
     
     
         9 . The composition of  claim 7 , wherein said composition is about 0.5%-15% binder.  
     
     
         10 . The composition of  claim 7 , wherein said composition is about 0.75%-12% binder.  
     
     
         11 . The composition of  claim 7 , further comprising a plasticizer.  
     
     
         12 . The composition of  claim 11 , wherein said plasticizer is selected from the group consisting of dioctyl adipate, dioctyl sebacate, hydrocarbon ester tackifier, and combinations thereof.  
     
     
         13 . The composition of  claim 1 , wherein said solid inorganic oxidizing agent is selected from the group consisting of potassium perchlorate and ammonium perchlorate.  
     
     
         14 . The composition of  claim 1 , wherein said composition is about 60-75 wt % solid oxidizing agent.  
     
     
         15 . The composition of  claim 1 , wherein said composition is about 64-72 wt % solid oxidizing agent.  
     
     
         16 . The compositions of  claim 1 , wherein said nitrogen-containing fuel comprises a cyano-, amide-, or amine-containing material.  
     
     
         17 . The composition of  claim 16 , where said nitrogen-containing fuel is selected from the group consisting of acrylonitrile, amino tetrazole, aminoguanidinium bitetrazole, ammonium dicyanamide, bistriaminoguanidiniumdecacarborane, bis(trinitroethyl)nitramine, calcium bitetrazole, dicyandiamide, nitroaminoguanidine, triaminoguanidine, and triaminoguanidinedicyanamide.  
     
     
         18 . The composition of  claim 1 , wherein said composition is about 10-30 wt % nitrogen-containing fuel.  
     
     
         19 . The composition of  claim 1 , wherein said composition is about 15-23 wt % nitrogen-containing fuel.  
     
     
         20 . The composition of  claim 7 , wherein said binder is selected from the group consisting of epoxidized trimethylolpropane, trimethylol ethane trigylcidyl ether, epoxidized soybean oil and combinations thereof.  
     
     
         21 . The composition of  claim 1 , wherein said composition has a specific impulse of at least 100 seconds at 100 psia.  
     
     
         22 . The composition of  claim 1 , wherein said composition has a specific impulse of at least 120 seconds at 100 psia.  
     
     
         23 . The composition of  claim 1 , wherein the average molecular weight of the exhaust gases of said composition is less than about 45.  
     
     
         24 . The composition of  claim 1 , wherein the average molecular weight of the exhaust gases of said composition is less than about 40.  
     
     
         25 . The composition of  claim 1 , wherein the combustion temperature is at least about 3000° F.  
     
     
         26 . The composition of  claim 1 , wherein the combustion temperature is at least about 4000° F.  
     
     
         27 . The composition of  claim 1 , wherein the burn rate of said composition is r h =a(P c ) n , wherein a is the burn rate coefficient, P c  is the chamber pressure, and n is the burn rate exponent having a value of less than about 0.5.  
     
     
         28 . The composition of  claim 1 , wherein the burn rate of said composition is r h =a(P c ) n , wherein a is the burn rate coefficient, P c  is the chamber pressure, and n is the burn rate exponent having a value of less than about 0.35.  
     
     
         29 . The composition of  claim 1 , wherein the burn rate of said composition is r h =a(P c ) n , wherein a is the burn rate coefficient having a value of greater than about 0.1, P c  is the chamber pressure, and n is the burn rate exponent.  
     
     
         30 . The composition of  claim 1 , consisting of about 62-72% wt. potassium perchlorate, about 15-30% wt. dicyandiamide, about 2-10% wt. iron oxide, and about 3-12% wt. VROH base stock, wherein said VROH base stock comprises a mixture of VROH and dioctyl sebacate.  
     
     
         31 . The composition of  claim 30 , wherein the relative amounts of VROH and dioctyl sebacate are about 3:2.  
     
     
         32 . The composition of  claim 1 , consisting of about 68% wt. potassium perchlorate, about 19% wt. dicyandiamide, about 5% wt. iron oxide, and about 7.5% wt. VROH base stock, wherein said VROH base stock comprises a mixture of VROH and dioctyl sebacate.  
     
     
         33 . The composition of  claim 32 , wherein the relative amounts of VROH and dioctyl sebacate are about 3:2.  
     
     
         34 . The composition of  claim 1 , having a specific impulse of at least about 120% of the specific impulse of black powder.  
     
     
         35 . The composition of  claim 1 , wherein the molar %. of non-expandable solid by-products in the exhaust stream is less than about molar 5%.  
     
     
         36 . The composition of  claim 1 , wherein said composition is adapted to be pressed or molded in the form of a grain.  
     
     
         37 . The composition of  claim 36 , wherein said composition is adapted to be pressed directly into a rocket engine casing or molded to fit an engine by means of a mold.  
     
     
         38 . A method of manufacturing a rocket engine comprising a step of loading a rocket engine chamber with a propellant composition according to  claim 1 .  
     
     
         39 . A method of manufacturing a rocket engine comprising a step of loading a rocket engine chamber with a propellant composition according to  claim 32 .  
     
     
         40 . The method according to  claim 38 , wherein said method is automated.  
     
     
         41 . A rocket engine packed with a propellant composition comprising a solid inorganic perchlorate oxidizing agent; a nitrogen-containing fuel; and a burn rate catalyst, wherein said burn rate catalyst is particulate.  
     
     
         42 . The rocket engine of  claim 41 , wherein said burn rate catalyst is nanoparticulate.  
     
     
         43 . The rocket engine of  claim 41  wherein said burn rate catalyst is an oxide selected from the group consisting of copper, chromium, cobalt, manganese, iron, vanadium, and mixtures thereof.  
     
     
         44 . The rocket engine of  claim 41 , wherein said composition further comprises a binder.  
     
     
         45 . The rocket engine of  claim 44 , wherein said binder is a combustible organic polymer selected from the group consisting of polyvinylchloride, polyvinylacetate, polyvinylalcohol and copolymers thereof including VAAR, VROH, VAGH, Geon-121, poly (2-ethyl-2-oxazoline), and epoxy or acrylate resin.  
     
     
         46 . The rocket engine of  claim 41 , wherein said composition further comprises a plasticizer.  
     
     
         47 . The compositions of  claim 46 , wherein said plasticizer is selected from the group consisting of dioctyl adipate, dioctyl sebacate, hydrocarbon ester tackifier, and combinations thereof.  
     
     
         48 . The rocket engine of  claim 41 , wherein said solid inorganic oxidizing agent is selected from the group consisting of potassium perchlorate and ammonium perchlorate.  
     
     
         49 . The rocket engine of  claim 41 , wherein said nitrogen-containing fuel comprises a cyano-, amide-, or amine-containing material.  
     
     
         50 . The rocket engine of  claim 49 , where said nitrogen-containing fuel is selected from the group consisting of acrylonitrile, amino tetrazole, aminoguanidinium bitetrazole, ammonium dicyanamide, bistriaminoguanidiniumdecacarborane, bis(trinitroethyl)nitramine, calcium bitetrazole, dicyandiamide, nitroaminoguanidine, triaminoguanidine, and triaminoguanidinedicyanamide.  
     
     
         51 . A high burn rate, high combustion temperature propellant composition comprising a solid inorganic perchlorate oxidizing agent; a nitrogen-containing fuel consisting essentially of dicyandiamide; a burn rate catalyst; and a binder.  
     
     
         52 . The composition of  claim 51  wherein said burn rate catalyst is selected from the group consisting of oxides of copper, chromium, cobalt, manganese, iron, vanadium, and mixtures thereof.  
     
     
         53 . The composition of  claim 52 , wherein said oxide is particulate.  
     
     
         54 . The composition of  claim 53 , wherein said particles are irregularly shaped.  
     
     
         55 . The composition of  claim 52 , further comprising a plasticizer.  
     
     
         56 . The composition of  claim 51 , wherein said solid inorganic perchlorate oxidizing agent is selected from the group consisting of potassium perchlorate and ammonium perchlorate.  
     
     
         57 . The composition of  claim 51 , wherein said binder is selected from the group consisting of polyvinylchloride, polyvinylacetate, polyvinylalcohol and copolymers thereof including VAAR, VROH, VAGH, Geon-121, poly (2-ethyl-2-oxazoline), and epoxy or acrylate resin.  
     
     
         58 . The composition of  claim 51 , wherein said composition is about 60-75 wt % solid oxidizing agent.  
     
     
         59 . The composition of  claim 51 , wherein said composition is about 10-30 wt % nitrogen-containing fuel.  
     
     
         60 . The composition of  claim 52 , wherein said composition is about 0.1-15 wt % oxide.  
     
     
         61 . The composition of  claim 51 , wherein said composition is about 0.5%-15% binder.  
     
     
         62 . A high burn rate, high combustion temperature propellant composition comprising about 64-72 wt. % solid inorganic perchlorate; about 15-23 wt. % nitrogen-containing fuel; about 0.5-10 wt. % oxide of copper, chromium, cobalt, manganese, iron, vanadium, or a mixture thereof; and about 0.75-12 wt. % binder.  
     
     
         63 . The composition of  claim 62 , wherein said oxide is particulate.  
     
     
         64 . The composition of  claim 63 , wherein said oxide particles are irregularly shaped.  
     
     
         65 . The composition of  claim 62 , further comprising a plasticizer.  
     
     
         66 . The composition of  claim 65 , wherein said plasticizer is selected from the group consisting of dioctyl adipate, dioctyl sebacate, hydrocarbon ester tackifier, and combinations thereof.  
     
     
         67 . The composition of  claim 62 , wherein said solid inorganic perchlorate is selected from the group consisting of potassium perchlorate and ammonium perchlorate.  
     
     
         68 . The composition of  claim 62 , wherein said nitrogen-containing fuel comprises a cyano-, amide-, or amine-containing material.  
     
     
         69 . The composition of  claim 68 , where said nitrogen-containing fuel is selected from the group consisting of acrylonitrile, amino tetrazole, aminoguanidinium bitetrazole, ammonium dicyanamide, bistriaminoguanidiniumdecacarborane, bis(trinitroethyl)nitramine, calcium bitetrazole, dicyandiamide, nitroaminoguanidine, triaminoguanidine, and triaminoguanidinedicyanamide.  
     
     
         70 . The composition of  claim 62 , wherein said binder is selected from the group consisting of polyvinylchloride, polyvinylacetate, polyvinylalcohol and copolymers thereof including VAAR, VROH, VAGH, Geon-121, poly (2-ethyl-2-oxazoline), and epoxy or acrylate resin.  
     
     
         71 . An energetic composition comprising a solid inorganic oxidizing agent selected from the group consisting of potassium perchlorate and ammonium perchlorate; a nitrogen-containing fuel; and a burn rate catalyst, wherein said burn rate catalyst is nanoparticulate.  
     
     
         72 . The composition of  claim 71 , wherein said burn rate catalyst is an oxide selected from the group consisting of copper, chromium, cobalt, manganese, iron, vanadium, and mixtures thereof.  
     
     
         73 . The composition of  claim 71 , wherein said material is a propellant material, a pyrotechnic material, an explosive material, a light generating material, a heat generating material, or a sound generating material.  
     
     
         74 . The composition of  claim 71 , wherein said nanoparticles are irregularly shaped.  
     
     
         75 . The composition of  claim 72 , wherein said burn rate catalyst is about 0.1-15 wt % oxide.  
     
     
         76 . The composition of  claim 71 , further comprising a binder.  
     
     
         77 . The composition of  claim 76 , wherein said binder is a combustible organic polymer selected from the group consisting of polyvinylchloride, polyvinylacetate, polyvinylalcohol, and copolymers thereof including VAAR, VROH, VAGH, Geon-121, poly (2-ethyl-2-oxazoline), and epoxy or acrylate resin.  
     
     
         78 . The composition of  claim 76 , wherein said composition is about 0.5%-15% binder.  
     
     
         79 . The composition of  claim 76 , further comprising a plasticizer.  
     
     
         80 . The composition of  claim 79 , wherein said plasticizer is selected from the group consisting of dioctyl adipate, dioctyl sebacate, hydrocarbon ester tackifier, and combinations thereof.  
     
     
         81 . The composition of  claim 71 , wherein said composition is about 60-75 wt % solid oxidizing agent.  
     
     
         82 . The compositions of  claim 71 , wherein said nitrogen-containing fuel comprises a cyano-, amide-, or amine-containing material.  
     
     
         83 . The composition of  claim 82 , where said nitrogen-containing fuel is selected from the group consisting of acrylonitrile, amino tetrazole, aminoguanidinium bitetrazole, ammonium dicyanamide, bistriaminoguanidiniumdecacarborane, bis(trinitroethyl)nitramine, calcium bitetrazole, dicyandiamide, nitroaminoguanidine, triaminoguanidine, and triaminoguanidinedicyanamide.  
     
     
         84 . The composition of  claim 71 , wherein said composition is about 10-30 wt % nitrogen-containing fuel.  
     
     
         85 . The composition of  claim 76 , wherein said binder is selected from the group consisting of epoxidized trimethylolpropane, trimethylol ethane trigylcidyl ether, epoxidized soybean oil and combinations thereof.  
     
     
         86 . The composition of  claim 71 , wherein said composition has a specific impulse of at least 100 seconds at 100 psia.  
     
     
         87 . The composition of  claim 71 , wherein the average molecular weight of the combustion gases of said composition is less than about 45.  
     
     
         88 . The composition of  claim 71 , wherein the combustion temperature is at least about 3000° F.  
     
     
         89 . The composition of  claim 71 , wherein the burn rate of said composition is r h =a(P c ) n , wherein a is the burn rate coefficient, P c  is the chamber pressure, and n is the burn rate exponent having a value of less than about 0.5.  
     
     
         90 . The composition of  claim 71 , wherein the burn rate of said composition is r h =a(P c ) n , wherein a is the burn rate coefficient having a value of greater than about 0.1, PC is the chamber pressure, and n is the burn rate exponent.  
     
     
         91 . The composition of  claim 71 , consisting of about 62-72% wt. potassium perchlorate, about 15-30% wt. dicyandiamide, about 2-10% wt. iron oxide, and about 3-12% wt. VROH base stock, wherein said VROH base stock comprises a mixture of VROH and dioctyl sebacate.  
     
     
         92 . The composition of  claim 71 , having a specific impulse of at least about 120% of the specific impulse of black powder.  
     
     
         93 . The composition of  claim 71 , wherein the molar %. of non-expandable solid by-products in the combustion gas is less than about molar 5%.  
     
     
         94 . The composition of  claim 71 , wherein said composition is adapted to be pressed or molded in the form of a grain.