Bridge Wire Initiator Slurry Application via Sealed Viscosity Control

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Solution Overview

Problem

Existing methods for preparing and applying a slurry mixture to a bridge wire initiator are complex, unreliable, and hazardous due to the use of open containers, which can lead to premature detonation or ignition, and result in limited manufacturing reliability and unwanted voids, especially when handling energetic materials over a wide temperature range.

Innovation Solution

A method involving the preparation of a slurry mixture in a sealed container using a gyrating mixer, filtration, and application via a dispensing syringe with precise viscosity control and air-pressure controlled dispensing to ensure safe handling and reliable application over a large temperature range.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the slurry mixture is prepared and applied using an open container, then the application process is simpler, but the solvent evaporates quickly causing the slurry to dry out and potentially detonate or ignite prematurely

Engineering Contradiction:

Improvesimplicity of application processVSAvoidsafety of handling slurry mixture

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent uses a sealed container system that creates a controlled environment for the slurry mixture, preventing solvent evaporation and eliminating the hazard of premature detonation or ignition that occurs with open container methods. The sealed environment maintains the slurry in a safe, handleable state throughout the application process.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

2Quantity of substance

If a high viscosity slurry mixture is used with a positive displacement rotary pump, then the slurry can be applied in large amounts, but unwanted voids are created or left in the slurry mixture

Engineering Contradiction:

Improveamount of slurry appliedVSAvoidquality of slurry application

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The patent controls the viscosity parameter of the slurry mixture to optimize both application quantity and quality. By maintaining viscosity within a specific range and using a sealed container system, the method enables application of adequate slurry amounts while preventing void formation that occurs with high viscosity slurries and rotary pumps.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If the slurry mixture is prepared over a long duration with complex procedures, then the application can be thorough, but the process becomes more complex and time-consuming

Engineering Contradiction:

Improvemanufacturing reliabilityVSAvoidduration of preparation and application

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent enables rapid application of the slurry mixture through a streamlined sealed container system. The method skips the lengthy, complex procedures of traditional open container methods while maintaining or improving reliability, reducing the overall preparation and application time significantly.

Inventive Principle:

Principle #21Skipping (Rushing through)

4Productivity

If the slurry mixture is handled without proper controls, then the process is faster, but the solvent evaporation causes the slurry to detonate or ignite prematurely

Engineering Contradiction:

Improvespeed of applicationVSAvoidrisk of premature detonation or ignition

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The sealed container system creates a protected environment that prevents solvent evaporation and eliminates the hazard of premature detonation or ignition. This allows rapid application procedures to be performed safely without the risks associated with uncontrolled handling of the slurry mixture.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

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 method significantly reduces the complexity and duration of the process, enhances safety, and improves reliability by maintaining the slurry mixture's viscosity and preventing premature drying, resulting in consistent and efficient application with reduced risk of failures and costs.

Implementation Method 1

mixing the solvent and energetic powder to form a slurry mixture

Methodology Applied

Scientific EffectMixing: Stirring

Implementation Method 2

The slurry mixture is filtered

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Implementation Method 3

air-pressure controlled dispensing

Methodology Applied

Scientific EffectPressure-driven flow: Pressure Gradient

Implementation Method 4

The applied slurry mixture is then dried

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS11624592B2Method of preparing and applying a slurry mixture to a bridge wire initiator

Publication Date: 2023.04.11 ENSIGN BICKFORD AEROSPACE & DEFENSE CO

AI summary

Embodiments include a method of forming an initiator. The method includes placing an energetic powder in a container. A solvent is added to the container and the solvent and energetic powder are mixed to form a slurry mixture. The slurry mixture is filtered. The filtered slurry mixture is placed in a transfer tube. The slurry mixture is applied to a bridge wire. The slurry mixture applied to the bridge wire is then dried.