Multi-Stack Decoy Cartridge with Segmented Impulse Control
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Solution Overview
Problem
Current pyrophoric decoy devices release multiple foils simultaneously, lacking a controlled, timed mechanism for multiple discrete bursts of infrared energy and are susceptible to Hazard from Electromagnetic Radiation (HERO) within sealed aluminum cartridges.
Innovation Solution
A multi-stage thruster technology is employed to package propellants in a single thruster with alumina powder separation and scored metal diaphragms, allowing for controlled, timed ejection of multiple pyrophoric foil stacks using electrically initiated impulse cartridges or propellant charges, ensuring HERO-safe design and efficient volume utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If multiple pyrophoric foils are released simultaneously from a single impulse cartridge, then the device structure is simple, but the ability to produce controlled timed bursts of infrared energy is lost
Solution Approach 1:
The single impulse cartridge system is segmented into multiple independent impulse cartridges, each capable of firing separately to eject individual pyrophoric foil stacks at controlled time intervals. This segmentation enables timed bursts of infrared energy while maintaining relatively simple device architecture.
2Quantity of substance
If multiple pyrophoric foil stacks are contained in a single cartridge, then payload density increases, but the risk of HERO (Hazard from Electromagnetic Radiation to Ordnance) increases
Solution Approach 1:
Multiple impulse cartridges are positioned in separate compartments within the housing, physically isolating each pyrophoric foil stack. This spatial segmentation reduces electromagnetic coupling between stacks, thereby maintaining high payload density while minimizing HERO susceptibility.
Solution Approach 2:
Dielectric material is introduced as an intermediary substance between adjacent pyrophoric foil stacks and impulse cartridges. This dielectric barrier blocks electromagnetic radiation propagation, preventing HERO effects while allowing the compact arrangement of multiple stacks within the single cartridge.
3Ease of operation
If a single impulse cartridge is used to eject all pyrophoric foils, then the device is simpler to operate, but control over the timing of infrared bursts is lost
Solution Approach 1:
The system employs periodic action through separately controllable impulse cartridges that can be fired at predetermined time intervals. Each cartridge can be triggered independently or in sequence, enabling automated timed ejection of pyrophoric stacks while maintaining operational simplicity through centralized control.
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
Enables reliable, consistent, and controllable timed release of pyrophoric material, optimizing the timing of individual foil stacks and maximizing payload volume while maintaining HERO immunity and compatibility with existing dispenser systems.
Implementation Method 1
Pyrophoric decoys utilize a special, high surface area metal foil, which rapidly oxidizes when exposed to oxygen. When dispensed from the host aircraft, the special pyrophoric alloy material payload reacts with air to emit intense IR radiation
Implementation Method 2
After a firing signal is sent to the impulse cartridge through an aircraft's on-board deployment system, the expansion of generated gases forces the piston forward, causing the end cap to rupture, and eject the pyrophoric material
Data Source
AI summary
A decoy device including: a cartridge casing; and two or more pyrophoric assemblies disposed longitudinally in the casing for sequential ejection from the casing, the two or more pyrophoric assemblies including: a pyrophoric material; a piston positioned rearward in an ejection direction relative to the pyrophoric material, the piston being movable in the ejection direction upon application of ejection force to eject the pyrophoric material from the casing; one or more energetic materials positioned rearward in an ejection direction relative to the piston, the one or more energetic materials being initiated by electrical impulse to provide the ejection force to the piston; and an inert barrier layer positioned rearward in an ejection direction relative to the impulse cartridge.