Gas Generant Composition via In Situ Nitrate Formation
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Solution Overview
Problem
Current gas generant production methods for airbag systems are costly and complex due to the separate manufacturing and handling of fuels and oxidizers, which increases expenses and safety risks during shipping and processing.
Innovation Solution
A method of forming a gas generant in situ by mixing copper nitrate with melamine and guanidine carbonate, heating, and drying to produce melamine nitrate, guanidine nitrate, and basic copper nitrate, with optional additional fuels, oxidizers, or additives, and pressing into tablets or wafers for efficient and safer production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fuels and oxidizers are manufactured separately before mixing, then the gas generant can be produced with controlled composition, but the production cost and manufacturing complexity increase
Solution Approach 1:
The patent combines the manufacturing of fuels and oxidizers into a single integrated process. Instead of producing melamine nitrate, guanidine nitrate, and basic copper nitrate separately and then mixing them, the invention uses a one-step synthesis method where copper nitrate, melamine, and guanidine carbonate are mixed and heated together to directly form the complete gas generant composition with controlled stoichiometry and homogeneous distribution.
2Ease of manufacture
If fuels and oxidizers are shipped and handled separately, then inventory management is simplified, but shipping costs and safety risks increase
Solution Approach 1:
The patent applies preliminary action by pre-mixing the fuel components (melamine and guanidine carbonate) with the oxidizer (copper nitrate) in the desired stoichiometric ratios before storage and shipping. This creates a stable, non-sensitive precursor mixture that can be safely handled and stored, eliminating the need to ship and manage separate hazardous fuel and oxidizer inventories. The actual reactive gas generant is only formed when water is added at the point of use.
3Manufacturing precision
If separate manufacturing of gas generant components is used, then quality control of individual components is easier, but overall production efficiency decreases
Solution Approach 1:
The patent implements continuous useful action through an integrated one-step synthesis process. Instead of discontinuous separate manufacturing steps followed by mixing and drying, the invention continuously processes copper nitrate, melamine, and guanidine carbonate through a single heating and mixing operation that simultaneously forms all three active components (melamine nitrate, guanidine nitrate, and basic copper nitrate) in the correct proportions, significantly reducing production time and increasing throughput.
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 method reduces production costs and enhances safety by forming a high-quality gas generant in situ, with improved physical properties and manufacturing efficiency, as demonstrated by a >90% yield and confirmed through FTIR analysis.
Implementation Method 1
adding melamine and guanidine carbonate to the mixture comprising copper nitrate and water... heating and mixing the melamine, guanidine carbonate, copper nitrate, and water mixture to form a melamine nitrate, guanidine nitrate, basic copper nitrate, and water mixture
Implementation Method 2
heating and mixing the melamine, guanidine carbonate, copper nitrate, and water mixture
Implementation Method 3
providing a mixture comprising copper nitrate and water
Implementation Method 4
drying the melamine nitrate, guanidine nitrate, basic copper nitrate, and water mixture from step (c) to form the gas generant
Data Source
AI summary
A method of forming a gas generant according to various implementations includes the steps of providing a mixture of copper nitrate and water and adding melamine and guanidine carbonate to the copper nitrate and water mixture at room temperature. Next, the melamine, guanidine carbonate, copper nitrate, and water mixture is mixed and heated to form a melamine nitrate, guanidine nitrate, basic copper nitrate, and water mixture. The heating and mixing step may be performed at a temperature in the range of 50° C. to 60° C. for at least 20 minutes. Then, the melamine nitrate, guanidine nitrate, basic copper nitrate, and water mixture is dried to form the gas generant comprising melamine nitrate, guanidine nitrate, and basic copper nitrate. The method may further comprise a step of adding an additional fuel, an additional oxidizer, or an additive. Also disclosed is a gas generant made by the method described above.