Propellant composition and methods of preparation and use thereof

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 rocket engine comprising: 
 a case having a tensile strength of less than about 5,000 KPa; and    a composite propellant grain disposed in the case, the composite propellant grain comprising an oxidizer, a burn rate catalyst, and a binder comprising a vinyl resin, and a polyfunctional ether.    
   
   
       2 . The rocket engine of  claim 1 , wherein the burn rate catalyst is acicularly-shaped.  
   
   
       3 . The rocket engine of  claim 2 , wherein the burn rate catalyst comprises iron oxide.  
   
   
       4 . The rocket engine of  claim 1 , wherein the oxidizer comprises potassium perchlorate.  
   
   
       5 . The rocket engine of  claim 1 , wherein the polyfunctional ether comprises a triglycidyl ether.  
   
   
       6 . The rocket engine of  claim 5 , wherein the triglycidyl ether comprises a polyepoxide resin.  
   
   
       7 . The rocket engine of  claim 6 , wherein the binder further comprises an amide.  
   
   
       8 . The rocket engine of  claim 7 , wherein the amide comprises dicyandiamide.  
   
   
       9 . The rocket engine of  claim 1 , wherein the vinyl resin comprises a hydroxyl-functional polymer selected from the group consisting of vinylchloride, vinylacetate, hydroxyalkylacetate, and mixtures thereof.  
   
   
       10 . The rocket engine of  claim 1 , wherein the case has a bursting strength of less than about 1,000 KPa.  
   
   
       11 . The rocket engine of  claim 1 , wherein the case comprises paper or paperboard.  
   
   
       12 . The rocket engine of  claim 1 , wherein the case is comprised of a material that is free of metals or metal alloys.  
   
   
       13 . The rocket engine of  claim 1 , wherein the composite propellant grain comprises: 
 an oxidizer consisting essentially of potassium perchlorate;    a burn rate catalyst consisting essentially of acicularly-shaped iron oxide nanoparticles; and    a binder consisting essentially of a vinyl resin and a triglycidyl ether cross-linked with dicyandiamide.    
   
   
       14 . A method of preparing a pressable composite propellant formulation comprising: 
 mixing a vinyl resin, a vegetable oil, and a solvent to provide a binder mixture;    adding a burn rate catalyst to the binder mixture;    adding an amide to the binder mixture; and    reducing the solvent from the binder mixture to about 7 wt % to provide a mixed formulation.    
   
   
       15 . The method of  claim 14 , wherein the vegetable oil comprises epoxidized castor oil.  
   
   
       16 . The method of  claim 14 , wherein the vinyl resin comprises a hydroxyl-functional polymer selected from the group consisting of vinylchloride, vinylacetate, hydroxyalkylacetate, and mixtures thereof.  
   
   
       17 . The method of  claim 14 , wherein the burn rate catalyst comprises acicularly-shaped iron oxide nanoparticles.  
   
   
       18 . The method of  claim 14 , wherein the amide comprises dicyandiamide.  
   
   
       19 . The method of  claim 14 , wherein the solvent comprises an ester.  
   
   
       20 . The method of  claim 19 , wherein the solvent comprises ethyl acetate.  
   
   
       21 . The method of  claim 14 , further comprising an act of drying the burn rate catalyst prior to performing the act of adding the burn rate catalyst to the binder mixture.  
   
   
       22 . The method of  claim 14 , further comprising an act of extruding the mixed formulation to form pellets thereof.  
   
   
       23 . The method of  claim 22 , further comprising an act of drying the pellets to reduce the amount of solvent present therein.  
   
   
       24 . The method of  claim 23 , further comprising an act of encasing at least one pellet in a case comprising a case material having a tensile strength of less than about 2,000 KPa.  
   
   
       25 . The method of  claim 24 , wherein the case material has a specific gravity of less than about 2.