PFPE-Based Flare Compositions for Safer Grain Casting

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Solution Overview

Problem

Conventional decoy flare compositions, such as those using magnesium, TEFLON®, and VITON®, are highly reactive and pose safety issues due to the use of flammable solvents and electrostatic discharge sensitivity, making the manufacturing process time-intensive and hazardous.

Innovation Solution

A composition comprising a fuel, a perfluoropolyether (PFPE) with a high fluorine content, and a curative, which is cast into grains without solvents, reducing reactivity and improving processing safety, and an alloy of magnesium and aluminum with PFPE, providing improved energetic performance and reduced sensitivity to electrostatic discharge.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional MTV compositions are prepared using flammable solvents and high shear mix equipment, then the compositions can be formed into grains, but the process creates safety hazards due to flammability and electrostatic discharge sensitivity

Engineering Contradiction:

Improvemanufacturing process safetyVSAvoidelectrostatic discharge sensitivity

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent changes the chemical composition parameters by substituting conventional VITON® polymer with perfluoropolyether (PFPE) and modifying the binder system. This compositional change fundamentally alters the electrostatic properties of the mixture, reducing sensitivity to electrostatic discharge while maintaining grain formation capability through casting instead of high shear mixing

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The use of perfluoropolyether creates an inherently safer, less reactive environment compared to conventional MTV compositions. The PFPE-based system reduces flammability hazards and electrostatic sensitivity, effectively creating a more inert processing environment that eliminates the need for specialized safety measures during manufacturing

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

2Productivity

If conventional MTV compositions undergo solvent evaporation and high pressure pressing/extrusion, then grains can be formed, but the process becomes time-intensive with multiple steps

Engineering Contradiction:

Improvegrain formation speedVSAvoidmanufacturing cycle time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent extracts and eliminates the solvent evaporation step entirely by using a solvent-free casting process. The PFPE-based composition can be directly cast into grains without requiring solvent removal, high pressure pressing, or extrusion, dramatically reducing manufacturing cycle time while maintaining grain quality

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical high shear mixing and high pressure extrusion system with a simpler casting process. This substitution of mechanical processing with a phase-change-based casting method reduces both equipment complexity and processing time while achieving the same grain formation objective

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If conventional MTV compositions are used, then the flare can defeat heat-seeking missiles, but the reactivity to energy inputs creates safety issues

Engineering Contradiction:

Improvemissile defeat effectivenessVSAvoidreactivity to electrostatic discharge and impact

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent creates a composite material system using perfluoropolyether as the base polymer combined with specific fuels and additives. This composite structure maintains the infrared emission properties necessary for missile defeat while the PFPE matrix provides inherent protection against electrostatic discharge and impact sensitivity, achieving both effectiveness and safety

Inventive Principle:

Principle #40Composite materials

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 PFPE-based composition exhibits comparable or improved effectiveness in defeating heat-seeking missiles, with enhanced IR intensity, burn time, and rise time, while reducing safety hazards and processing time compared to conventional MTV compositions.

Implementation Method 1

The IR emissions of the decoy flare are produced by combustion of a flare composition

Methodology Applied

Scientific EffectCombustion: Combustion

Implementation Method 2

The PFPE-based composition exhibits comparable or improved effectiveness in defeating heat-seeking missiles, with enhanced IR intensity

Methodology Applied

Scientific EffectInfrared radiation: Infrared Radiation

Data Source

PatentUS10479738B2Compositions usable as flare compositions

Publication Date: 2019.11.19 NORTHROP GRUMMAN SYSTEMS CORP

AI summary

A composition that includes a fuel and a perfluoropolyether (PFPE) is disclosed. The composition may be used as a flare composition in a countermeasure device. Countermeasure devices including the flare composition are also disclosed, as are methods of forming grains of the countermeasure device.