PFPE Flare Composition Grain Casting

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

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, requiring time-intensive and hazardous processing methods.

Innovation Solution

A composition comprising a fuel, a perfluoropolyether (PFPE) with a high fluorine content, and a curative, which is cast into grains, reducing reactivity and processing hazards while maintaining or improving IR emissions and burn performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional MTV compositions are used with flammable solvents and high shear mix equipment, then the composition can be formed into grains, but safety issues arise due to high reactivity to electrostatic discharge, impact, and friction

Engineering Contradiction:

Improvegrain formation capabilityVSAvoidreactivity to electrostatic discharge and impact

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent changes the chemical composition parameters by replacing conventional VITON® with perfluoropolyether (PFPE) and adjusting the magnesium particle size distribution. This composition modification reduces the material's sensitivity to electrostatic discharge, impact, and friction while maintaining grain formation capability through casting processes

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The use of perfluoropolyether creates a more chemically inert composition environment that reduces reactivity to external energy inputs such as electrostatic discharge and impact. The PFPE acts as a safer binder matrix compared to conventional VITON®, lowering the overall hazard profile during manufacturing and handling

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

2Ease of manufacture

If flammable solvents are used to dissolve and precipitate VITON®, then the MTV composition can be prepared, but time-intensive drying processes are required and safety hazards increase

Engineering Contradiction:

Improvecomposition preparationVSAvoiddrying process time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The patent extracts and eliminates the flammable solvent step from the manufacturing process by using perfluoropolyether, which does not require solvent dissolution and precipitation. This direct formulation approach removes the time-consuming drying工序 and eliminates associated safety hazards while maintaining composition integrity

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent adopts a formulation approach that eliminates the need for reusable drying equipment and extensive processing infrastructure. The PFPE-based composition can be directly cast and cured without requiring complex solvent removal infrastructure, simplifying the manufacturing setup

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Productivity

If high pressure pressing or extrusion is used to form MTV compositions, then grains can be produced, but the process is time intensive and creates safety issues with flashing remnants

Engineering Contradiction:

Improvegrain production rateVSAvoidflashing remnants from pressing

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the high-pressure mechanical forming process with a casting process. The PFPE-based composition is cast into grain shapes using minimal pressure, eliminating the flashing and safety hazards associated with high-pressure extrusion while maintaining production efficiency through direct casting methods

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the processing parameters from high-pressure mechanical forming to low-pressure casting. This parameter change in the forming process eliminates flashing remnants while maintaining grain production rates, as the PFPE-based composition can be directly cast into final shapes without requiring high-pressure extrusion

Inventive Principle:

Principle #35Parameter changes

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 improved safety, processing efficiency, and energetic performance, with reduced sensitivity to ignition and off-gassing, achieving comparable or enhanced IR intensity, burn time, and rise time compared to conventional MTV compositions.

Implementation Method 1

The PFPE is a liquid at room temperature and has a flash point of greater than 200° F.

Methodology Applied

Scientific EffectFlash point:

Implementation Method 2

The IR emissions of the combusting flare composition are intended to confuse the heat-seeking missile

Methodology Applied

Scientific EffectCombustion: Combustion

Data Source

PatentUS11014859B2Compositions usable as flare compositions, countermeasure devices containing the flare compositions, and related methods

Publication Date: 2021.05.25 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.