Binder-Free Pyrotechnic Payloads via Dry Blending
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Solution Overview
Problem
Legacy flash/bang formulations for non-lethal devices are labor-intensive to produce and prone to component segregation, leading to inconsistent performance and reduced efficiency due to the use of binders in the pyrotechnic granulation process.
Innovation Solution
A non-lethal payload formulation comprising boron or silicon, combined with a fuel and oxidizer through a dry blending process without solvents, which produces a homogeneous mixture that is less labor-intensive and more stable, enhancing light and sound output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If legacy flash/bang formulations use binders and pyrotechnic granulation process, then the formulation can be produced, but the production becomes labor-intensive and component segregation occurs leading to inconsistent performance
Solution Approach 1:
The patent removes binders from the pyrotechnic formulation entirely, extracting the problematic component that caused labor-intensive processing and component segregation. The binder-free formulation eliminates the need for complex granulation processes while maintaining formulation integrity through proper particle size control and blending techniques.
Solution Approach 2:
The patent changes the physical parameters of the formulation by eliminating binders and adjusting particle size distributions of the pyrotechnic components. This parameter change transforms the formulation from a binder-dependent granulated structure to a binder-free powdered mixture, simplifying production and preventing component segregation.
2Ease of manufacture
If binders are used in the pyrotechnic granulation process, then the formulation can be manufactured, but component segregation occurs leading to reduced efficiency
Solution Approach 1:
The patent extracts binders from the formulation to eliminate the source of component segregation. This removal improves reaction efficiency by ensuring uniform distribution of pyrotechnic components without the interfering presence of binder materials that cause heterogeneous mixing and reduced combustion efficiency.
3Quantity of substance
If traditional pyrotechnic granulation process is used, then the formulation can be produced, but the process is labor-intensive and complex
Solution Approach 1:
The patent removes binders from the formulation, which eliminates the need for complex pyrotechnic granulation processes. This extraction simplifies the production process from multi-step granulation and drying operations to straightforward mixing and blending, reducing both labor intensity and process complexity while maintaining full formulation production capability.
Solution Approach 2:
Instead of following the traditional approach of adding binders to enable granulation, the patent inverts the approach by eliminating binders entirely and using alternative methods (particle size control, blending techniques) to achieve proper formulation integrity. This inversion simplifies the production process while maintaining manufacturability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The dry blended formulations result in improved light and sound output with increased reliability and reduced sensitivity to handling, while eliminating the need for binders, thus simplifying production and reducing labor costs.
Implementation Method 1
The formulation includes at least one of boron and silicon, at least one fuel, and at least one oxidizer
Implementation Method 2
The formulations are produced by a dry blending process
Data Source
AI summary
Non-lethal payloads including at least one of boron and silicon, at least one fuel, and at least one oxidizer. The non-lethal payload may be a single-component or dual-component payload. Methods of producing the non-lethal payloads are also disclosed.