Membrane Emulsification for Energetic Material Particle Control
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Solution Overview
Problem
Existing methods for producing particulate energetic material compositions struggle to achieve consistent, narrow particle size distributions, which is crucial for controlling burn rate and ballistic performance, and often involve hazardous handling of solid materials.
Innovation Solution
A method involving the formation of a dispersed phase with an energetic material dissolved in a solvent, followed by the creation of a continuous phase using a porous membrane to exert shear forces on droplets, allowing controlled precipitation and surface coating, resulting in uniform particulate sizes between 1 to 100 microns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to produce particulate energetic material compositions, then production is simpler, but particle size distribution is wide and inconsistent
Solution Approach 1:
The process segments particle formation into distinct phases: droplet formation through porous membrane, shear force application for size control, and separate precipitation/stabilization steps. This segmentation enables precise control over particle size distribution while maintaining manageable process complexity through modular operation
Solution Approach 2:
A porous membrane acts as an intermediary device between the dispersed phase and continuous phase, enabling controlled droplet formation. The membrane's pore structure serves as a physical mediator that standardizes initial droplet sizes, which then undergo further refinement through shear forces to achieve the desired narrow particle size distribution
2Object-affected harmful factors
If solid energetic materials are handled directly, then processing is straightforward, but handling risks and hazards increase
Solution Approach 1:
The energetic material is transformed from solid state to dissolved state in a solvent, fundamentally changing its physical parameters. This parameter change (solid→dissolved) eliminates handling risks associated with solid energetic materials while maintaining ease of manufacture through liquid-phase processing, which is inherently safer and more controllable
Solution Approach 2:
Direct mechanical handling of solid energetic materials is replaced with liquid-phase processing operations. The material is processed in dissolved form through mixing, droplet formation, and precipitation, eliminating the need for mechanical manipulation of sensitive solid particles and thereby reducing handling risks
3Productivity
If particle size is not controlled, then production is faster, but burn rate and ballistic performance cannot be controlled
Solution Approach 1:
The process applies preliminary action by first forming droplets of controlled size through the porous membrane before precipitation occurs. This preliminary droplet formation step establishes the particle size framework early in the process, enabling subsequent rapid precipitation to proceed while maintaining precise size control, thus achieving both productivity and manufacturing precision
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 enables the production of energetic material compositions with precise, mono-sized particulates, reducing handling risks and improving performance by controlling particle size and morphology, thus enhancing the safety and effectiveness of energetic formulations.
Implementation Method 1
a shear force is exerted on the forming droplet of dispersed phase material, to furnish a droplet
Implementation Method 2
optionally causing removal of the at least one first solvent to cause precipitation of said energetic material composition in the continuous phase
Implementation Method 3
passing the dispersed phase via a micro porous membrane, preferably there is a membrane separating the dispersed phase and continuous phase
Implementation Method 4
forming a continuous phase, comprising at least one second solvent which is substantially immiscible with said dispersed phase
Data Source
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AI summary
The invention relates to a method of producing a range of particulate energetic materials with tailored particle sizes and extremely narrow particle size distributions. The use of membrane emulsification apparatus provides a means of formulating explosives with a selectable particle size, without the use of milling techniques to physically reduce the size of the particulates.