Electrophoretic Deposition of Energetic Materials

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Solution Overview

Problem

Current electrophoretic deposition (EPD) processes have not been effectively applied to create products containing energetic materials due to the hazardous and sensitive nature of these materials, limiting their precision and control in applications such as national defense, materials research, and pyrotechnics.

Innovation Solution

The method involves suspending energetic materials like thermite, high explosives, and intermetallic materials in a dispersion liquid with secondary agents to confer surface charges, and using EPD to deposit these materials onto substrates with controlled electric fields, allowing for precise and tunable combustion behavior.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If EPD process is applied to create products containing energetic materials, then manufacturing precision and control of combustion behavior are improved, but the hazardous and sensitive nature of energetic materials creates safety risks and operational difficulties

Engineering Contradiction:

Improveprecision and control of combustion behaviorVSAvoidhazardous and sensitive nature of energetic materials

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent employs an electrophoretic deposition system that operates in a controlled environment with specific pH buffers and dispersion media that stabilize energetic material particles, effectively creating a chemically inert processing environment that mitigates the hazardous nature of these materials during manufacturing

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

Solution Approach 2:

The patent replaces traditional mechanical mixing and deposition methods with an electrophoretic system that uses electric fields to control particle movement and deposition. This substitution provides precise control over combustion behavior while reducing the physical handling and mechanical processing of hazardous energetic materials

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If traditional methods are used to handle energetic materials, then safety risks are reduced, but manufacturing precision and flexibility in designing products are limited

Engineering Contradiction:

ImprovesafetyVSAvoidprecision and flexibility in designing products

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent changes the fundamental parameters of the deposition process by using electrophoretic mobility controlled through pH adjustment and electric field strength variation. This allows precise control of combustion behavior and product design flexibility while maintaining safety through non-contact processing and stable suspension chemistry

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If electrophoretic deposition is used to deposit energetic materials, then deposition precision and homogeneity are improved, but the complexity of the EPD system and process control increases

Engineering Contradiction:

Improvedeposition precision and homogeneityVSAvoidcomplexity of EPD system and process control

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent achieves homogeneous deposition of energetic materials by formulating stable suspensions with appropriate pH buffers and dispersion media that ensure uniform particle charge distribution. This homogeneity in the suspension state translates to uniform electrophoretic deposition without requiring complex multi-step processes

Inventive Principle:

Principle #33Homogeneity

Solution Approach 2:

The patent introduces pH buffers and dispersion media as intermediary substances that mediate between the electric field and energetic material particles. These intermediaries control particle surface charge and stability, simplifying the overall process control while achieving precise deposition

Inventive Principle:

Principle #24Intermediary (Mediator)

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

This approach enables the creation of energetic materials with precise combustion behavior and flexible application in various fields by achieving controlled and homogeneous deposition of energetic materials, enhancing their reactivity and reliability.

Implementation Method 1

The electrophoretic deposition (EPD) process utilizes electric fields to mobilize particles within a solution or suspension and deposit those particles from a solution onto a substrate by taking advantage of particle surface charge

Methodology Applied

Scientific EffectElectrophoresis: Electrophoresis

Implementation Method 2

The electrophoretic deposition (EPD) process utilizes electric fields to mobilize particles within a solution or suspension and deposit those particles from a solution onto a substrate

Methodology Applied

Scientific EffectElectrophoretic deposition: Electrophoretic Deposition

Data Source

PatentUS10358737B2Methods and systems for electrophoretic deposition of energetic materials and compositions thereof

Publication Date: 2019.07.23 LAWRENCE LIVERMORE NAT SECURITY LLC

AI summary

A method includes providing a plurality of particles of an energetic material suspended in a dispersion liquid to an EPD chamber or configuration; applying a voltage difference across a first pair of electrodes to generate a first electric field in the EPD chamber; and depositing at least some of the particles of the energetic material on at least one surface of a substrate, the substrate being one of the electrodes or being coupled to one of the electrodes.