Systems and methods for energetic particle synthesis and production - Patents.com

Abstract

A method and associated system for synthesizing energetic particles, the method including providing a metal powder, dispersing the metal powder in a first fluid to form a first suspension, contacting the first suspension with an oxide precursor, an aqueous ammonium hydroxide solution, and a second fluid to produce a first product, collecting product solids, and inductively heating the product solids to produce energetic core-shell particles.

Description

[Technical field]

[0001] FIELD OF THE DISCLOSURE Embodiments disclosed herein relate to energetic particles, and in particular to methods and systems for the synthesis and production of spherical energetic core-shell particles, such as Al / CuO particles having a core-shell structure.

[0002] Introduction Energetic particles such as metallic materials and / or fuels can be used for heating and combustion as an alternative energy source to meet energy needs on Earth and in space. Metals have high energy density and therefore can be used in many applications including batteries, energy materials, and / or propellants. Oxidation of metal powders can be used as an efficient energy carrier method and energy source for various applications. The exothermic reaction between the metal and the oxidizer releases heat and produces products such as metal oxides. In one application, this energy release can be used to generate thrust by accelerating a fluid in a rocket nozzle and / or generating heat for a heat engine. In another application, this energy release can be used to generate electricity by heating a fluid in a power generation system.

[0003] Thermite materials include fuels (e.g., Al, Mg, Si, etc.) and oxidizers (metal oxides, fluoropolymers, iodine oxide, etc.), and are widely applied in military and civilian fields. With the development of nanotechnology, submicron or nanothermit materials have also been developed and studied. Compared with traditional thermite materials, submicron and nanothermit materials have shown significantly improved energy performance, such as shorter reaction delay, reduced activation energy, faster reaction rate, and higher pressure, due to their significantly enlarged surface contact and shortened diffusion length. However, there are several problems that hinder the wider application of thermite materials to optimize their performance, including high sensitivity to external stimuli, reactive sintering of Al nanoparticles, and phase separation between fuel and oxidizer.

[0004] Researchers have developed a variety of thermite products with different structures, synthesis routes, and additives to overcome this problem. Surfactants or self-assembly methods were used to avoid the occurrence of phase separation and reactive sintering. Graphene has been used to reduce sensitivity to electrostatic discharge. Nanolaminates, nanosheets, and core-shell structures have been developed to tune the reactivity of thermite products. Among these different structures and synthesis methodologies, energetic core-shell structures show unique advantages. Due to the maximized surface contact and short diffusion length between the fuel and oxidizer, metal phase separation and reactive sintering are eliminated, resulting in improved energy performance.

[0005] Such energetic core-shell structured particles are difficult and / or complex to produce by currently known methods.

[0006] Thus, there is a need for improved methods and systems for producing metallic materials and / or fuels, such as energetic core-shell particles. Summary of the Invention

[0007] A system for the synthesis of energetic core-shell particles is provided herein, the system including a chamber for carrying out a particle synthesis reaction, an oxide source coupled to the chamber for supplying an oxide precursor to the chamber, a metal source coupled to the chamber for supplying a metal to the chamber, a nozzle coupled to the chamber for outputting the synthesized energetic core-shell particles from the chamber, and an induction heating source coupled to the chamber for inductively heating the chamber contents to synthesize the energetic core-shell particles.

[0008] The system may further include a supplemental material source coupled to the chamber for providing the supplemental material to the chamber.

[0009] The auxiliary material for supplying to the chamber may further include a gas, liquid, or another fluid.

[0010] The system can further include a capture and storage system coupled to the nozzle and configured to receive the energetic core-shell particles from the nozzle, the capture and storage system further configured to package the energetic core-shell particles in a storage container.

[0011] The capture and storage system may further include an inductive heating element for heating the stored energy core-shell particles.

[0012] The system may further include an electromagnetic suspension subsystem configured to suspend the energetic core-shell particles output by the nozzle.

[0013] The system can further include a gel packaging subsystem coupled to the nozzle, the gel packaging subsystem configured to receive the core-shell particles from the nozzle and encapsulate the core-shell particles in a gel capsule.

[0014] The nozzle may further include a number of sub-nozzles.

[0015] The system may further include an electromagnetic transmitter for exposing the contents of the chamber to electromagnetic radiation.

[0016] The system may further include an electromagnetic transmitter for exposing the energetic core-shell particles to electromagnetic radiation.

[0017] The system may further include an electromagnetic receiver for receiving the electromagnetic radiation emitted by the electromagnetic transmitter and recovering energy.

[0018] The system may further include a control system configured to adjust operating parameters of the system.

[0019] The control system may be configured to apply the trained machine learning model to adjust the operating parameters of the system.

[0020] Provided herein is a method for synthesizing energetic particles, the method including providing a metal powder, dispersing the metal powder in a first fluid to form a first suspension, contacting the first suspension with an oxide precursor, an aqueous ammonium hydroxide solution, and a second alcohol to produce a first product, collecting product solids, and inductively heating the product solids to produce energetic core-shell particles.

[0021] The method may further include stirring the first product for a first period of time.

[0022] The method may further include grinding the product solid prior to inductively heating the product solid.

[0023] The method may further include processing the product solids through a mesh screen prior to inductively heating the product solids.

[0024] The metal powder may be an aluminum powder.

[0025] The oxide precursor may be copper nitrate.

[0026] The first fluid may be an alcohol.

[0027] The second fluid may be an alcohol.

[0028] The method may further include inductively heating the product solid to 250°C.

[0029] The metal powder may have an average particle size of 1 micron.

[0030] The metal powder may have an average particle size of 40 nanometers.

[0031] The product solid can be collected by filtration.

[0032] The metal powder may be iron powder.

[0033] The ratio of metal powder to oxide precursor can be configured such that the method produces energetic core-shell particles having a particular equivalence ratio, and when the energetic core-shell particles are combusted, the combustion includes a predetermined ignition delay.

[0034] Other aspects and features will become apparent to those of ordinary skill in the art upon review of the following description of several exemplary embodiments. [Brief description of the drawings]

[0035] The drawings included herein are intended to illustrate various examples of the articles, methods, and apparatus herein. [Figure 1] 1 is a flow chart illustrating a method for synthesizing energetic core-shell particles, according to one embodiment. [Diagram 2] 1 is a flow chart illustrating an alternative method for synthesizing metal oxide core-shell particles according to another embodiment. [Diagram 3] FIG. 3 illustrates a synthesis method of FIGS. 1-2, according to one embodiment. [Figure 4] FIG. 1 is a block diagram illustrating a system for the synthesis of energetic core-shell particles, according to one embodiment. [Diagram 5] FIG. 1 is a block diagram illustrating a system for the synthesis of energetic core-shell particles, according to another embodiment. [Figure 6] FIG. 1 is a block diagram illustrating a system for the synthesis of energetic core-shell particles, according to another embodiment. [Figure 7] FIG. 1 is a block diagram illustrating a system for synthesis of thermite mixtures according to one embodiment. [Figure 8] FIG. 1 is a block diagram illustrating a system for the synthesis of energetic core-shell particles, according to another embodiment. [Figure 9] FIG. 1 is a block diagram illustrating a system for the synthesis of energetic core-shell particles, according to another embodiment. [Figure 10]FIG. 1 is a block diagram illustrating a system for measuring combustion parameters of energetic particles, according to one embodiment. [Figure 11] 1 is a graph showing ignition delay data captured for the combustion of energetic core-shell particles, according to one embodiment. [Figure 12] 1 is a graph illustrating ignition delay data measured for the combustion of energetic core-shell particles of various equivalence ratios and particle sizes, according to one embodiment. [Figure 13] FIG. 1 is a block diagram illustrating a laser focus assisted ignition system, according to one embodiment. [Figure 14] FIG. 1 is a block diagram illustrating a detachable tethered plate system, according to one embodiment. [Figure 15] FIG. 1 is a block diagram illustrating a laser assisted emission system according to one embodiment. [Figure 16] 16 is an additional block diagram illustrating the laser assisted emission system of FIG. 15, according to one embodiment. [Figure 17] 1 is a block diagram illustrating a system for multiple satellite operations, according to one embodiment. [Figure 18] 18 is an additional block diagram illustrating the system for multiple satellite operations of FIG. 17, according to one embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0036] Various devices or processes are described below to provide examples of each claimed embodiment. The embodiments described below are not intended to limit the claimed embodiments, which may cover processes or devices different from those described below. The claimed embodiments are not limited to devices or processes having all the features of any one device or process described below, or to features common to multiple or all of the devices described below.

[0037] Described herein are methods and systems for synthesizing energetic core-shells, such as metal-metal oxide core-shell particles, Al-CuO particles, which can be used to produce either micron core-shell particles or nano core-shell particles. The Al-CuO energetic core-shell products produced by the methods described herein exhibit a uniform core-shell structure with small CuO grains on the surface of the Al particles. The methods described herein can be extended to other metals and metal oxides, so that Al particles with oxide core-shells of metals or non-metals other than copper can be produced, or metal particles other than aluminum particles with oxide core-shells of any material known in the art can be produced.

[0038] 1, a flow chart is shown illustrating a method 100 of synthesizing energetic core-shell particles. Method 100 includes steps 102, 104, 106, 108, and 110. Although the steps are listed in order, in some embodiments, the method steps may be performed in any order.

[0039] In step 102, a metal powder is provided. In some examples, the metal powder may be aluminum metal powder. In some examples, the metal powder may include spherical particles. In some examples, the metal powder may include an average particle size of 1 micron. In some examples, the metal powder may include an average particle size of 40 nanometers. In some examples, the metal powder may include an average particle size of up to 100 microns. In some examples, the metal powder may include an average particle size of up to 100 nanometers. In other examples, metal powders of various sizes may be used to meet user-defined criteria.

[0040] In other examples, metal powders of other metals may be used, including iron, titanium, zirconium, magnesium, zinc, lithium, silicon, boron, tin, tungsten, molybdenum, or any other metal known in the art.

[0041] In some embodiments, the metal powder may be sourced from Earth. In other embodiments, the source may include recycling space debris, orbiting satellites, or other materials transported from Earth to space. In other embodiments, the metal powder may be sourced from space. Sources may also include in situ resource utilization, such as materials from the Moon (lunar regolith), Mars (Mars regolith), and / or asteroidal sources.

[0042] In some examples, the metal powder may be sourced from waste products of industrial processes, or products of other combustion processes, or waste disposal from human or robotic activity.

[0043] In step 104, the metal powder is dispersed in a first alcohol to form a first suspension. In some embodiments, the first alcohol may include ethanol. In other embodiments, the alcohol may be selected from the group including methanol, ethanol, propanol, butanol, pentanol, or combinations thereof.

[0044] In other embodiments, liquids other than alcohol may be used to form the dispersion in step 104. For example, the metal powder may be dispersed in water instead of alcohol, or any other liquid or fluid known in the art.

[0045] In some examples, the dispersion of step 104 may include agitating a mixture of the metal powder and the first alcohol, or subjecting such mixture to ultrasonic treatment. In some examples, the first suspension produced in step 104 may include 0.5 grams of aluminum and 100 mL of alcohol.

[0046] In step 106, the first suspension is contacted with an oxide precursor, an aqueous ammonium hydroxide solution, and a second alcohol to produce a first product. In some embodiments, the first suspension may include 0.5 grams of aluminum and 100 mL of alcohol, and in step 106, 1 g of Cu(NO3)2·2.5H2O (the oxide precursor) may be added, 2 mL of an aqueous ammonium hydroxide solution (NH4OH, 15%) may be added, and 10 mL of the second alcohol may be added.

[0047] In some embodiments, other ratios of metal (e.g., aluminum) to oxide precursor (e.g., Cu(NO3)2·2.5H2O) may be applied in step 106 to obtain final energetic core-shell particles with various equivalence ratios.

[0048] In some embodiments, the second alcohol may include ethanol, hi other embodiments, the second alcohol may be selected from the group including methanol, ethanol, propanol, butanol, pentanol, or combinations thereof.

[0049] In step 106 of method 100, Cu(NO3)2·2.5H2O was used as an oxide precursor to form Al-Cu metal oxide core-shell particles with a copper oxide shell. In other examples, other oxide precursors may be added to form other Al-Cu metal oxide core-shell particles, or metal oxide core-shell particles of other metals and / or oxides. For example, oxide precursors may be selected to produce the following oxides for application in the synthesis of energetic core-shell particles: CuO, NiO, TiO2, WO3, MoO3, Fe2O3, KMnO 4, Or any other oxide known in the art.

[0050] In some embodiments, the metal oxide or oxide precursor may be sourced from Earth. Such sources may include recycling space debris, orbiting satellites, or other materials transported from Earth to space. In other embodiments, the metal oxide or oxide precursor may be sourced from space. Such sources may include the Moon (lunar regolith), Mars (Mars regolith), and / or asteroid sources.

[0051] In some embodiments, the metal oxide or oxide precursor may be sourced from the waste output of industrial processes, or the products of other combustion processes, or waste disposal from human or robotic activity.

[0052] In an embodiment involving the production of an Al-Cu metal oxide, after the contacting process of step 106 of method 100, [Cu(NH)] and OH - A shell containing 1,2-dichlorophenyl 1,3-dichlorophenyl 1,4-trifluorophenyl 1,5-trifluorophenyl 1,6-trifluorophenyl 1,7 ...

[0053] In step 108, the first product is filtered to collect product solids. The first product is [Cu(NH)] and OH. - The aluminum particles may include a shell comprising:

[0054] The filtration of step 108 may be performed using vacuum assisted filtration. In some embodiments, this vacuum assisted filtration may be performed using Whattman™, Grade 42 filter paper.

[0055] In other examples, methods other than filtration may be utilized to separate the product solids from the solution in step 108. Such methods may include centrifugation, evaporation, or any other method known in the art for separating solids from liquids.

[0056] In step 110, the product solid is inductively heated to produce energetic core-shell particles. The product solid is then heated to produce energetic core-shell particles, which are then heated to produce energetic core-shell particles.- During the induction heating process of step 110, the aluminum particles may include an aluminum particle having a shell formed thereon that includes [Cu(NH)] and OH. - The shell containing is oxidized and converted to CuO.

[0057] In some embodiments, the induction heating process of step 110 may be performed in air. In such embodiments, the gaseous oxygen in air may include a source of oxygen for oxidation of the [Cu(NH)] and OH shells. In other embodiments, the heating may be performed in any other oxygen-containing atmosphere or any other atmosphere.

[0058] The heating process of step 110 may be carried out at or near 250° C. for a period of two hours.

[0059] The induction heating process in step 110 advantageously allows for precise temperature control and may produce higher quality core-shell particles relative to non-inductive heating methods. In some embodiments, induction heating may directly heat ferromagnetic particles (e.g., iron), which may result in reduced waste heat during operation of method 100 because heat may be more precisely directed.

[0060] 2, a flow chart is shown illustrating a method 200 of synthesizing energetic core-shell particles. Method 200 may include any or all of the steps of method 100, and further includes steps 202, 204, and 206. Although the steps are listed in order, in some embodiments, the method steps may be performed in any order.

[0061] In step 202, the first product is stirred for a first period of time. In some examples, this first period of time may include 4 hours. The first product may be stirred in a flask using a magnetic stir bar. In other examples, any other method known in the art may be used to stir the first product in step 202, such as an integrated stirrer or stirring attachment in a chemical reaction vessel or tank. Step 202 may be performed between steps 106 and 108.

[0062] In step 204, the product solids are processed through a mesh sieve. In some embodiments, the mesh sieve comprises a 140 mesh sieve. The product solids may be extruded or forced through a single mesh sieve, or a series of mesh sieves of specifically configured mesh size and parameters. In some embodiments, the product solids may be placed on the mesh sieve and vibrated or shaken to allow product solids that may pass through the sieve (e.g., having a particle size smaller than the mesh hole size) to pass through.

[0063] Step 204 may be performed after completion of step 108, in which the product solids are collected.

[0064] After completion of method 100 and / or method 200, metal oxide core-shell particles are produced. Metal oxide core-shell particles include a core of metal surrounded by a thin layer of an oxide material, such as a metal oxide. In some examples, metal oxide core-shell particles may include a core of metallic aluminum and a thin layer of CuO (copper oxide). Such particles may be used in thermite reactions, including any application of such reactions described herein.

[0065] 3, there is shown a schematic diagram 300 of the synthesis method 100 / 200 for Al / CuO energetic core-shell particles. As shown in FIG. 3, Al particles 302 undergo hydrolysis in step 1 to form [Cu(NH)] and OH shells 304, and are then heat treated to oxidize the [Cu(NH)] and OH shells to CuO 306.

[0066] Particles generated using the methods (eg, method 100 and method 200) and / or systems described herein were analyzed to measure ignition delay under laser-induced ignition.

[0067] Particles with various equivalence ratios were investigated using laser ignition. The samples used for laser ignition were prepared according to methods such as method 100 and method 200 described herein. The sample mass was about 3.5 mg and 1.75 mg for microparticles and nanoparticles, respectively. The samples were held loosely. There were three samples for each equivalence ratio to reduce possible experimental errors. All results described herein are average values ​​calculated from these three samples.

[0068] The experimental setup used for laser ignition and high-speed imaging analysis is shown in the system 1000 in Fig. 10. A diode laser 1002 (3.5 W) with a pulse duration of 100 ms is utilized to ignite the sample 1004, together with a focusing lens 1006 to increase the power density of the laser from 225 W / cm2 to 40 kW / cm2. The sample 1004 was heated from above. A photodiode 1008 with a response time of 1 ns was configured to send a signal to trigger a phantom high-speed camera 1010 to record at 200,000 fps and 500 ns exposure time with extreme dynamic range (EDR). To capture the high-time resolution signal, two oscilloscopes are used to capture the signal.

[0069] The ignition delay is measured from the difference between the illumination photodiode signal and the ignition photodiode signal. The first "jump" in the photodiode signal signifies the start of the laser irradiation, and the second "jump" indicates the start of the thermite reaction, which are shown in graph 1100 of FIG. 11. Between the point of laser irradiation on the curve and the start of the thermite reaction there is a linear section indicating the ignition delay. The time gap between the moment the laser hits the sample and the moment the sample becomes brighter in the associated high-speed camera video also corresponds to the ignition delay. The two measurement methods were compared to confirm the results. All results returned comparable values ​​between the two methods.

[0070] The ignition delays for the different samples were calculated and are shown in Table 1 below.

[0071] [Table 1]

[0072] The results are quite different for microparticles and nanoparticles, so they are considered separately. As shown in the above table, as well as in the graph 1200 of FIG. 12, the ignition delay increases with increasing equivalence ratio of microparticles, but the ignition delay is shortest for the nanoparticle sample with an equivalence ratio of 2. The ignition delays for microparticles with equivalence ratios of 1, 3, and 5 are 5.832 ms, 7.209 ms, and 9.065 ms, and for nanoparticles with equivalence ratios of 1, 2, and 3, they are 0.542 ms, 0.325 ms, and 1.847 ms. The ignition delays for the nanosamples are about an order of magnitude smaller than those for the microsamples, indicating that the smaller diffusion distance plays an important role during the initiation phase.

[0073] In some embodiments of the systems and methods described herein, the equivalence ratio of the synthesized energetic core-shell particles can be specifically configured to produce particles with specific ignition delays. Particles with different ignition delays can be beneficial depending on the end use of the particles.

[0074] Referring now to FIG. 4, a schematic diagram of a system 400 for the synthesis of energetic core-shell particles is shown, according to one embodiment. The system 400 can be operated to perform a method, such as method 100 or method 200 described herein, or other methods for the synthesis of energetic core-shell particles. The system 400 includes a chamber 402, a metal source 404, an oxide precursor source 406, a nozzle 408, and an induction heating source 410. In some examples, the system 400 can optionally further include any or all of an electromagnetic transmitter 418, an electromagnetic receiver 424, a supplemental material source 412, a capture and storage system 414, a control system 422, a valve 420, and a magnetic suspension system 426, as shown in FIG. 4.

[0075] The chamber 402 includes a mechanical structure configured to receive synthesis reactants. The chamber 402 may include a tubular structure constructed from stainless steel. In other embodiments, the chamber 402 may include any other shape known in the art and may be constructed from any material suitable for application of the synthesis processing system 400.

[0076] The chamber 402 may further comprise features for stirring or agitating the contents within the chamber 402, such as a magnetic stirring system, a sonication system, and / or an integrated stirrer, or combinations thereof.

[0077] The metal source 404 includes a supply of metal particles for the production of energetic core-shell particles by the system 400. The metal source 404 can supply any metal required for the desired core-shell synthesis process into the chamber 402. The metal provided by the metal source 404 can vary in morphology, particle size, and other parameters depending on the process parameters. The metal source 404 can be configured to supply the metal into the chamber 402 continuously or discretely.

[0078] The oxide precursor source 406 includes a supply of oxide precursor material for the production of energetic core-shell particles by the system 400. The oxide precursor source can provide any oxide precursor material required for the desired core-shell synthesis process into the chamber 402. The oxide precursor material ultimately forms or contributes to an oxide shell layer. The oxide precursor material can include an oxide, such as copper oxide, or a material that can ultimately be converted to an oxide, such as copper nitrate, as applied in the method 100 described herein. The oxide precursor source 406 can be configured to continuously or discretely supply the oxide precursor into the chamber 402.

[0079] The nozzle 408 comprises a mechanical structure coupled to the chamber 402 for outputting material from the chamber 402. The nozzle 408 may comprise a tapered profile such that the material may be output from the chamber 402 at a precise output location. The nozzle 408 may be constructed from any material that is compatible with the material to be delivered by the nozzle 408. In some embodiments, the nozzle 408 may be constructed from stainless steel.

[0080] The induction heating source 410 includes a device capable of inductively heating ferromagnetic materials. The induction heating source 410 may be coupled to the chamber 402, the nozzle 408, or other structures of the system 400 to heat synthesis reactants as needed. The induction heating source 410 may be precisely controlled so that materials heated by the induction heating source 410 may be heated to precise and consistent temperatures. Such precise temperature control may be particularly advantageous in a space environment, since excess heat is difficult to remove (e.g., excess heat must be dissipated). The high precision of the induction heating may reduce the amount of excess heat generated.

[0081] The auxiliary material source 412 includes components similar to those of the metal source 404 and the oxide precursor source 406, and may provide additional materials into the chamber 402 to facilitate the mechanical, physical, and chemical processes required to produce energetic core-shell particles. The auxiliary materials may include alcohols such as ethanol, other reactants such as ammonium hydroxide, carrier fluids including air, inert gases, water, and other fluids, or any other substance known in the art that may be introduced into the chamber 402 to improve or facilitate energetic core-shell synthesis.

[0082] In some embodiments, a photosensitive polymer or monomer may be introduced into the chamber 402 by a supplemental material source 412 such that a photopolymerization reaction may be initiated by application of visible light or other radiation.

[0083] Capture and storage system 414 comprises a system that can receive the energetic core-shell particles produced by system 400 and package these particles for storage or further use. The particles may be stored in inert gases, liquids, gels, waxes, and the like.

[0084] The capture and storage system 414 may further include an inductive heating element 416 for applying heat during the storage process and operation.

[0085] Electromagnetic transmitter 418 comprises a device capable of emitting electromagnetic radiation. The electromagnetic radiation emitted by transmitter 418 can include ultraviolet radiation, visible light radiation, x-ray radiation, infrared radiation, or any other wavelength of radiation required for the process applied by system 400.

[0086] The contents, products, or reactants provided to system 400 may be sensitive to certain forms of electromagnetic radiation. The presence of electromagnetic transmitter 418 enables system 400 to expose these contents, products, or reactants of system 400 to the desired electromagnetic radiation.

[0087] Electromagnetic receiver 424 comprises a device capable of absorbing electromagnetic radiation and converting the electromagnetic radiation into electrical energy. Electromagnetic receiver 424 can be configured to match the form and wavelength of the electromagnetic radiation emitted by electromagnetic transmitter 418. Electromagnetic receiver 424 can capture stray electromagnetic radiation generated by electromagnetic transmitter 418 and convert the captured radiation back into electricity for recycling, thereby reducing the energy wasted by system 400.

[0088] In system 400, the electromagnetic receiver 424 and the electromagnetic transmitter 418 are depicted outside of the chamber 402, however, in other embodiments, the electromagnetic receiver 424 and the electromagnetic transmitter 418 may be positioned such that contents within the chamber 402 may be exposed to electromagnetic radiation by the electromagnetic transmitter 418 before exiting the chamber 402.

[0089] Valves 420 are present between components of system 400, including between metal source 404 and chamber 402, between oxide precursor source 406 and chamber 402, between supplemental material source 412 and chamber 402, and any other part of system 400 where material flow may preferably be controlled. In some embodiments, additional valves may be integrated into nozzle 408. Valves 420 may be of any form known in the art that may be compatible with the materials to be processed by system 400. Valves 420 may preferably be electronically and / or computer controlled.

[0090] Electromagnetic suspension system 426 comprises a system configured to receive the energetic core-shell particles output by system 400 through nozzle 408. Magnetic suspension system 426 may use electromagnets to apply and modify a magnetic field to conductive and / or magnetic particles to magnetically suspend the particles in position, move the particles to a desired location, and maintain particle dispersion through application of electromagnetic suspension and / or magnetohydrodynamics.

[0091] The magnetic suspension system 426 may be particularly useful in space applications of the system 400, as alternative methods of transporting energetic core-shell particles may be rendered ineffective in the microgravity environment.

[0092] The control system 422 comprises a set of components coupled to other components of the system 400, which can adjust process parameters to improve yield, reduce waste, reduce energy usage, or modify energy core-shell particle parameters and / or characteristics. The control system 422 can be coupled to the metal source 404, the oxide precursor source 406, the valves 420, the nozzles 408, or any other components of the system 400.

[0093] In some embodiments, the control system 422 can apply artificial intelligence (AI) and / or machine learning (ML) methods in controlling the system 400. The control system 422 may apply trained AI / ML models and algorithms (including, but not limited to, neural networks, deep learning, etc.). Such models can correlate or receive multiple user-driven inputs including oxide precursor type, metal type, auxiliary material type, flow rate, temperature, frequency, gravity, mixing, viscosity, time, equivalence ratio, morphology, domain (e.g., land, air, water space, etc.), or other input parameters. Such models can correlate or generate the following outputs: particle shape, core content, shell content, distribution and energetics, or other outputs based on the user-driven inputs.

[0094] In other embodiments, the control system 422 may apply other optimization schemes and methods to optimize the operation of the system 400 .

[0095] During operation, metal and oxide precursor materials may be introduced into the chamber 402 from a metal source 404 and an oxide precursor source 406, respectively. Other materials may be introduced into the chamber 402 by a supplemental material source 412. The contents within the chamber 402 may react to form intermediate products or final core-shell particles. In some embodiments, the contents of the chamber 402 may be heated within the chamber 402 or as they exit the nozzle 408 using an inductive heating source 410. The particles may exit the nozzle 410. After exiting the nozzle 410, the particles may be further exposed to electromagnetic radiation by an electromagnetic transmitter 418, magnetically suspended by a magnetic suspension system 428, and / or packaged or stored by a capture and storage system 414 for further use.

[0096] 5, there is illustrated a system 500 for the production of energetic core-shell particles, according to another embodiment. System 500 is similar to system 400, with similar components having their reference numbers increased by 100.

[0097] Nozzle 510 differs from nozzle 410 in that nozzle 510 includes multiple outlets. The multiple outlets of nozzle 510 allow for the output of energetic core-shell particles from chamber 502 to multiple locations. This may allow for packaging of the energetic core-shell particles into multiple separate packages, storage containers, or subsequent systems, machines, or processes.

[0098] 6, a system 600 for producing energetic core-shell particles is illustrated according to another embodiment. System 600 comprises subsystems including components of system 400, and a gel packaging subsystem 602. Subsystem 602 includes a body 604, a die roll 606, a gel ribbon 608, and waste gelatin 612.

[0099] Particles produced by system 400 as described above may be provided to body 604 of subsystem 602. The particles may be disposed on a gel ribbon 608 (made of gelatin) and passed through die roll 606 to form gel 610. Gel 610 includes energetic core-shell particles encapsulated in the gel. System 600 may further produce waste gelatin 612 as a by-product of the operation.

[0100] In other embodiments, materials other than gelatin may be used within the gel ribbon 608, such as, but not limited to, gelatin infused with other energetic particles, such as wax or other energetic core-shell particles.

[0101] The creation of gel 610 may advantageously store the particles in a non-reactive form and, in some configurations, improve the combustion characteristics of the energetic core-shell particles by increasing the spacing between particles within gel 610.

[0102] 7, a system 700 for the production of thermite mixtures (nanothermite and / or microthermite) is shown, according to one embodiment. System 700 includes a metal source 704, a metal oxide source 706, a mixing chamber 702, a heating chamber 708, and a desiccator 710.

[0103] System 700 may be adapted for mechanical mixing methods of thermite mixture production. Reactants are provided to a mixing chamber 702 from a metal oxide source 706 and a metal source 704. The metal oxide and metal may be mixed (e.g., by sonication) in the chamber 702. In some embodiments, a solvent such as ethanol may be introduced into the chamber 702 to facilitate mixing. In some embodiments, a magnetic stirring system, a sonication system, and / or an integrated stirrer or combinations thereof may be integrated into the system 700.

[0104] Once mixed, the contents of chamber 702 may be provided to a heating chamber 708. The heating chamber 708 may apply inductive heating to directly heat either the walls of the chamber 708 or the contents of the chamber 708 (e.g., if the contents are ferromagnetic). Heating the chamber 708 may encourage evaporation of the solvent provided within the chamber 702. Inductive heating may provide greater temperature precision and control and / or reduced energy usage over other heating methods.

[0105] The contents may be transferred from the heating chamber 708 to a desiccator 710 to dry the contents. The contents may be dried under vacuum with the aid of inductive heating, which may provide greater temperature precision and control and / or reduced energy usage over other heating methods.

[0106] 8, a system 800 for producing energetic core-shell particles is shown, according to one embodiment. The system 800 includes a metal source 804, a metal oxide source 806, a mixing chamber 802, an inductively heated chamber 808, and a desiccator 810.

[0107] The system 800 can apply a precipitation method of energetic core-shell particle synthesis. The precipitation method forms copper complexes on the Al particles. The copper complexes are further converted to CuO by annealing. The copper complexes can also be precipitated in the solution, so the final Al / CuO thermite is a mixture of CuO and Al / CuO core / shell particles.

[0108] Metal and metal oxide, Al and CuO, are provided from metal source 804 and metal oxide source 806, respectively, and fed into mixing chamber 802. Al and CuO are mixed, dispersed in ethanol, and sonicated in chamber 802. Ammonium hydroxide solution and copper nitrate hemi(pentahydrate) ethanol solution are then added to the suspension in chamber 802. After stirring the contents in chamber 802, copper complexes are formed on the surface of the aluminum particles. The suspension is filtered and then dried in desiccator 810. Finally, the dried particles are annealed using induction heating chamber 808 to convert the copper complex layer to copper oxide, forming aluminum, copper oxide core-shell particles.

[0109] The application of inductive heating by chamber 808 may provide greater temperature precision and control, and / or reduced energy usage over other heating methods.

[0110] 9, a system 900 for producing energetic core-shell particles is shown, according to one embodiment. The system 900 includes a metal source 904, a metal oxide source 906, a mixing chamber 902, an inductively heated chamber 908, and a solution source 910.

[0111] The system 900 can apply a displacement method of energetic core-shell particle synthesis, in which copper is electrically displaced by aluminum to form aluminum / copper core-shell particles, which are then further annealed to form copper oxide to form energetic core-shell particles.

[0112] In the operation of the system 900, a CuSO4-based stock solution is prepared by dissolving CuSO4, ethylenediaminetetraacetic acid, and triethanolamine in deionized water. This solution is fed into the chamber 902 from an oxide source 906. Then, an aqueous NH4OH solution is dripped into the CuSO4 solution in the chamber 902 from a solution source 910. Next, aluminum particles are added from a metal source 904 into the solution in the chamber 902 and sonicated in the chamber 902 to form a well-dispersed suspension. The solution is filtered, washed with alcohol, and then dried in a vacuum desiccator. The particles are then annealed in an induction heating chamber 908 under ventilation to form energetic core-shell particles.

[0113] The application of inductive heating by chamber 908 may provide greater temperature precision and control, and / or reduced energy usage over other heating methods.

[0114] Referring now to FIG. 13, a laser focus assisted ignition system 1300 is shown according to an embodiment. The system 1300 can be applied to clean up space debris 1302 and space junk in orbit. A number of satellites 1304 constituting the system 1300 can be launched into low earth orbit to help remove space debris. The system 1300 can apply a laser assisted ignition system and energetic particles such as metal oxide core-shell particles synthesized by the methods described herein. Ignition can be initiated by a laser and / or an inductive ignition system.

[0115] 14, there is shown a detachable tethered plate system 1400, according to one embodiment. The system 1400 may be applied to tether an object 1402 in space to a spacecraft 1404. The system 1400 may further comprise elements for mechanical functions such as mechanical connections, tracks, and joints.

[0116] The system 1400 may be used for operations, logistics, maintenance, point-to-point transportation, and / or orbit raising. In other implementations, the deployable plate may be detachable on the tethered satellite subsystem and released to be attached to a free flying object in space. The satellite system acting as part of a network of satellites may use situational awareness to best position itself relative to the target object and may use AI / ML algorithms and / or autonomous systems for docking. The tethered satellite subsystem may be equipped with its own propulsion system for thrust. The deployable plate may be attached to the tethered satellite subsystem and may attach itself to multiple surfaces on the target object, for example, to capture space debris. Using a laser-assisted ignition system, the deployable plate may attach to the surface via welding and / or sintering of fillers and / or energetic particles. Using the tethered system, the satellite system may reel back into place with the tethered satellite subsystem and provide propulsion to the target object for orbit raising, which may continue in space servicing and / or de-orbit applications. Multiple space debris may be linked using deployable plates to link objects in space to be collected and assembled for recycling and / or reuse.

[0117] In other implementations, the deployable plate and / or tethered satellite system and / or satellite system can be attached to the satellite in orbit and in transit for orbit raising or de-orbiting, maintenance by astronauts and / or robotic systems. In other implementations, the detachable plate used for capture and release operations can have multiple mechanical connections, such as hooks and rods, and can be linearly actuated to attach to and detach from the target object.

[0118] 15, a laser assisted release system 1500 is shown according to one embodiment. The system 1500 may be on a satellite for rendezvous and docking with objects in space. In some embodiments, the system 1500 may be on board a refueling satellite system to capture, refuel, and release the satellite for continued operation. The system 1500 may be attached to a satellite in orbit and may be transported for orbit raising or de-orbiting or maintenance by astronauts and / or robotic systems.

[0119]

[00136] Referring now to Figure 16, additional components of the laser assisted release system 1500 of Figure 15 are shown, according to one embodiment. As seen in Figure 16, a removable disposable welding plate 1502 is present for the capture and release operations. Additionally, as shown in Figure 16, a rod 1504 can be linearly actuated to release the hook and remove it from the target.

[0120] 17, a multiple satellite operation system 1600 is shown according to one embodiment. The system 1600 may include a satellite 1602 that may be coupled to other satellites or to each other. In some examples, a mother ship with multiple small engines may be connected to other satellites for logistics and maintenance operations.

[0121]

[00136] Referring now to Figure 18, there is shown additional components of the multiple satellite operations system 1600 of Figure 17, according to one embodiment. In Figure 18, there is an additional satellite 1602. The satellite 1602 can use a laser source to ignite energetic particles on the ground, in the air, in the water, or in space.

[0122] In some examples, the systems and methods described herein can be modified to produce energetic core-shell particles with different properties, such as different core-shell structures. Such core-shell structures may include core-shell, multiple core-shell, multiple core-hollow structures, yolk-shell, multiple core-hollow, core mesopore, sandwich core-shell, and embedded structures. In other examples, the core-shell structures or configurations may include core-shell, double shell, multiple shell, concentration gradient, and full concentration gradient.

[0123] Microthermites, nanothermites, nanoenergetic core-shell particles, and thermite mixtures including microenergetic core-shell particles, such as those synthesized by the methods and systems described herein, can be applied in a number of applications requiring high density stored energy, high intensity energy, low carbon emission energy or combustion sources, remote operation (including Earth orbit and outer space), and other requirements.

[0124] In some examples, the metal may be combined with an oxidizer, such as air and / or water. The oxidizer may be used as a carrier and as a source of oxidation for the metal. In other examples, the fuel in the form of a thermite and the oxidizer may both be located on the same metal particle (e.g., a metal oxide coating on the outside of a metal particle). In some examples, these particles may be referred to as metal fuels (metal, metallic, and / or energetic particles, thermite and / or microthermite, and / or nanothermite, etc.).

[0125] Metallic materials may contain energetic particles composed of fuel and oxidizer, typically metal and metal oxide, respectively. Nanothermites are composed of both oxidizer and fuel within each particle, on the scale of 100 nanometers or less. The energy release per mass of particle is very large. In one embodiment, the use of metal fuel propellants including nanothermites or microthermites, or combinations thereof, allows the propellants to be dispersed within a chamber in combination with an inert carrier gas and / or liquid or fluid for effective heating and / or combustion, resulting in well-controlled heating, formation, power and thrust generation.

[0126] Metallic materials and / or fuels (e.g., thermite, microthermites, nanothermites) have high energy density and, when mixed with inert gases, liquids and / or carrier fluids, are generally safer to handle and transport than traditional fuels. They can be synthesized and manufactured, transported for use, and / or stored for future use. Propellant can be manufactured, stored and transported for powerable electricity. Stored energy can be in the form of matter. Fuels can be used to generate heat for construction, power and propulsion applications.

[0127] In some examples, the energetic core-shell particles can be used as a source for catalytic conversion of carbon dioxide (e.g., atmospheric carbon dioxide), such as thermal catalysis, photocatalysis, and electrocatalysis processes for the conversion of carbon dioxide to produce products such as CO, H2, Ch3OH, C2, and / or CH, or other desired products derived from the CO2 conversion process. In some examples, the energetic core-shell particles can be used as a source for catalytic conversion of methane. In other examples, the energetic core-shell particles can be used as a source for catalytic conversion of other greenhouse gases.

[0128] In some examples, nanothermites may be used for propulsion, power generation, energy storage, and energy distribution. In some examples, nanothermites may be used for construction, including welding, additive manufacturing, and 3D printing, such as the inclusion of a core-shell in a material for 3D printing to create a 3D printable material with user-defined properties. In some examples, nanothermites may be used as battery cathodes. In some examples, nanothermites may be used as filters, such as mesh filters, with specific geometries that may specifically target certain particles such that these particular particles cannot pass through the filter, or vice versa.

[0129] In some embodiments, the nanothermites may be applied in an ignition system, where the nanothermites are heated by a laser or an inductive heating system to initiate ignition of another substance. Such ignition devices are more portable than other ignition systems and are suitably disposable.

[0130] In some embodiments, the spacecraft can synthesize energetic particles that can be applied to an ignition system, where the energetic particles are heated with a laser or induction heating system to initiate ignition of another material. The spacecraft can rendezvous and attach to uncontrolled objects in space, such as space junk, space debris, satellites at the end of their life cycle, satellites that have run out of fuel, second stages, asteroids, or other space objects that provide motility and / or additional propulsion capabilities.

[0131] In some embodiments, a spacecraft may transport multiple other spacecraft for operations, logistics, maintenance, transportation from a point and / or orbit raising.

[0132] In some embodiments, multiple satellites can be launched and deployed into low Earth orbit to aid in space debris removal and space traffic management using laser-assisted ignition systems and energetic particles. Ignition assistance can be provided by laser and / or induction heating systems. Sub-satellites with a deployable plate with a first layer of weld filler and / or energetic particles and / or a second layer with energetic particles can be used to act as a catalyst that can be ignited using laser and / or induction heating assisted ignition. The deployable plate can be ignited at a distance using multiple other satellites in different orbits. In other implementations, ignition can occur from multiple fixed and mobile sources on the ground, in the air (e.g., from drones and / or airships), on water, and / or in space.

[0133] In one embodiment, in order to capture and release uncontrollable space objects, including but not limited to space debris, a satellite without a propulsion system can capture a second stage or other space object larger than 10 cm, or an asteroid, allowing the uncontrollable space object to be fitted with a new propulsion system and / or refueled or receive in-orbit servicing.

[0134] In other implementations, energetic particles can be used in conjunction with multiple shaping methods, including but not limited to microemulsion, wet spinning, roll-to-roll casting, spin coating, and / or molding. In some embodiments, shapes such as microspheres, fibers, sheets, coatings, complex shapes, layered shapes, and / or monoliths can be produced.

[0135] In other embodiments, energetic core-shells can be used in addition to molecular precursors, nanoparticles, nanofibers, nanotubes, nanosheets, etc. In some examples, microstructures such as particle chains, fiber structures, and / or laminated flake structures may be added.

[0136] In other implementations, the satellite system may carry multiple other satellites for in-space applications and services. In some implementations, the satellite subsystem may be on board a refueling satellite system to capture and refuel other satellites in space for servicing and release those satellites for continued operation or servicing beyond low Earth orbit.

[0137] In some embodiments, energetic core-shell particles can be embedded into the structure of the system under reaction and / or sintering and hardening processes.

[0138] In some embodiments, energetic core-shell particles can be reacted in a gas for propulsive application by heating and expanding the gas to generate thrust.

[0139] In some examples, the energetic core-shell particles may be applied in space-based applications such as space manufacturing for products such as the synthesis of compounds and mixtures that benefit from a microgravity environment, and may result in improved conditions such as the production of materials related to pharmaceuticals and / or other medical applications.

[0140] In some embodiments, energetic core-shell particles may be applied to drive reactions on Earth and / or in space.

[0141] In some embodiments, the energetic core-shell particles may be applied to refueling satellites in space. In some embodiments, magnetic fuel may be added to the material to make it more magnetic and allow the particles to move at different gravitational forces, and the particles may be moved within the system using magnetohydrodynamics. The magnetic properties of the fuel may be used to replenish the system in space.

[0142] Although the above description provides examples of one or more devices, methods, or systems, it will be understood that other devices, methods, or systems may be within the scope of the claims as interpreted by one of ordinary skill in the art.

Claims

1. A system for the synthesis of energy core-shell particles, A chamber for carrying out particle synthesis reactions, An oxide source connected to the chamber for supplying an oxide precursor to the chamber, A metal source connected to the chamber for supplying metal to the chamber, A nozzle connected to the chamber for outputting the synthesized energy core shell particles from the chamber, A system comprising: an induction heating source connected to a chamber for induction heating of the contents of the chamber to synthesize energy core shell particles.

2. The system according to claim 1, further comprising an auxiliary material source connected to the chamber for supplying auxiliary material to the chamber.

3. The system according to claim 2, wherein the auxiliary material supplied to the chamber includes a fluid.

4. The aforementioned system, The system further comprises a capture and storage system connected to the nozzle and configured to receive energy core shell particles from the nozzle, The system according to any one of claims 1 to 3, wherein the capture and storage system is further configured to package energy core-shell particles within a storage container.

5. The capture and storage system according to claim 4, wherein the capture and storage system includes an induction heating element for heating the stored energy core-shell particles.

6. The system further comprises an electromagnetic suspension subsystem, The system according to any one of claims 1 to 3, wherein the electromagnetic suspension subsystem is configured to suspend energy core-shell particles output by the nozzle.

7. The system further comprises a gel packaging subsystem connected to the nozzle, The system according to any one of claims 1 to 3, wherein the gel packaging subsystem is configured to receive core-shell particles from the nozzle and encapsulate the core-shell particles in a gel capsule.

8. The system according to any one of claims 1 to 3, wherein the nozzle includes a plurality of sub-nozzles.

9. The system according to any one of claims 1 to 3, further comprising an electromagnetic transmitter for exposing the contents of the chamber to electromagnetic radiation.

10. The system according to any one of claims 1 to 3, further comprising an electromagnetic transmitter for exposing energy core shell particles to electromagnetic radiation.

11. The system according to claim 9, further comprising an electromagnetic receiver for receiving electromagnetic radiation emitted by the electromagnetic transmitter in order to recover energy.

12. The system according to any one of claims 1 to 3, further comprising a control system configured to adjust the operating parameters of the system.

13. The system according to claim 12, wherein the control system is configured to apply a trained machine learning model to adjust the operating parameters of the system.

14. A method for synthesizing energy particles, To provide metal powder, Dispersing the metal powder in a first fluid to form a first suspension, The first suspension is brought into contact with an oxide precursor, an aqueous solution of ammonium hydroxide, and a second alcohol to produce a first product. Collecting the product solid, A method comprising generating energy core-shell particles by induction heating of the product solid.

15. The method according to claim 14, further comprising stirring the first product over a first period of time.

16. The method according to claim 14 or 15, further comprising grinding the product solid before induction heating the product solid.

17. The method according to claim 14 or 15, further comprising treating the product solid by passing it through a mesh sieve before induction heating the product solid.

18. The method according to claim 14 or 15, wherein the metal powder is aluminum powder.

19. The method according to claim 14 or 15, wherein the oxide precursor is copper nitrate.

20. The system according to claim 14 or 15, wherein the first liquid is an alcohol.

21. The method according to claim 14 or 15, wherein the second liquid is an alcohol.

22. The method according to claim 14 or 15, wherein the product solid is induction heated to 250°C.

23. The method according to claim 14 or 15, wherein the metal powder has an average particle size of 1 micron.

24. The method according to claim 14 or 15, wherein the metal powder has an average particle size of 40 nanometers.

25. The method according to claim 14 or 15, wherein the product solid is collected by filtration.

26. The method according to claim 14 or 15, wherein the metal powder is iron powder.

27. The method according to claim 14 or 15, wherein the method generates energy core-shell particles having a specific equivalence ratio, and the ratio of metal powder to oxide precursor is configured such that when the energy core-shell particles are burned, the combustion includes a predetermined ignition delay.

28. The method according to claim 14 or 15, wherein the energy core-shell particles are improved by induction heating of the product solid to produce energy core-shell particles.

Images