Synthetic Polymer Igniter Device Sealing
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Solution Overview
Problem
The construction of conventional igniter devices for munitions using cotton primer bags is time-consuming, labor-intensive, and lacks flexibility, with potential issues in material dispersion during transport leading to inefficient burns or failure in initiation, and existing synthetic polymer solutions face compatibility problems with certain energetic materials.
Innovation Solution
An igniter device using two synthetic polymer layers that envelop energetic materials, with through holes and separator structures to ensure consistent distribution and uniform ignition, utilizing heat, pressure, or UV for sealing, and allowing for mechanized production and adaptable shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cotton primer bags are used to encase energetic material, then the energetic material can be contained, but the construction process becomes time-consuming and labor-intensive requiring hand sewing
Solution Approach 1:
The patent replaces the mechanical hand-sewing process with a thermal sealing process using synthetic polymer layers. The polymer layers are sealed together through application of heat, pressure, or UV radiation, eliminating the need for manual sewing operations and significantly increasing production speed while maintaining reliable containment.
Solution Approach 2:
The patent changes the material parameter from natural cotton to synthetic polymer, which enables mechanized sealing processes. The synthetic polymer's ability to be sealed through heat, pressure, or UV radiation transforms the construction process from manual sewing to automated thermal sealing, improving productivity.
2Reliability
If hand sewing is used to seal cotton primer bags, then the energetic material can be contained, but the workload and production time increase
Solution Approach 1:
The patent substitutes the manual mechanical sewing action with an automated thermal sealing process. The synthetic polymer layers are sealed through application of heat, pressure, or UV radiation, which can be performed rapidly and consistently, reducing production time while maintaining reliable sealing.
Solution Approach 2:
The synthetic polymer material itself provides the sealing function through its inherent properties. When exposed to heat, pressure, or UV radiation, the polymer melts and self-seals the layers together, eliminating the need for external sewing operations and reducing production time.
3Reliability
If cotton primer bags of set dimensions are used, then the energetic material can be contained, but the energetic material may disperse during transport leading to inefficient burns
Solution Approach 1:
The patent incorporates separator structures that divide the interior space into separate compartments. These separators prevent the energetic material from dispersing during transport and ensure uniform distribution, which is critical for consistent burn performance and reliable ignition.
Solution Approach 2:
The patent uses separator structures to create localized zones within the igniter device. These separators ensure that the energetic material remains in specific locations and maintains uniform distribution, preventing dispersion while allowing the overall device to maintain its containment structure.
4Ease of manufacture
If adhesives are used to seal polymer layers, then the sealing process is simplified, but compatibility problems arise with certain energetic materials
Solution Approach 1:
The patent replaces adhesive bonding with thermal sealing processes. The synthetic polymer layers are sealed through application of heat, pressure, or UV radiation, which melts and fuses the polymer layers together without requiring adhesives. This eliminates compatibility issues between adhesives and energetic materials while maintaining ease of manufacture.
Solution Approach 2:
The patent changes the sealing mechanism from chemical adhesion to thermal fusion. By applying heat, pressure, or UV radiation to the synthetic polymer layers, the material melts and self-fuses, eliminating the need for adhesives and avoiding compatibility problems with energetic materials.
5Productivity
If machine sewing or stapling is used to seal polymer layers, then production speed increases, but the risk of initiating the material increases
Solution Approach 1:
The patent substitutes mechanical sealing methods (sewing, stapling) with a thermal sealing process. The synthetic polymer layers are sealed through application of heat, pressure, or UV radiation, which eliminates the mechanical actions that could generate sparks or friction heat capable of initiating the energetic material, while maintaining high production speed.
Solution Approach 2:
The patent converts the potential harm of mechanical sealing (sparks, friction heat causing initiation) into a beneficial thermal process. By using controlled application of heat, pressure, or UV radiation to melt and fuse the polymer layers, the process achieves fast sealing without the initiation risks associated with mechanical methods.
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 solution provides a faster, more controlled, and flexible method for producing igniter devices with consistent explosive energy output, reducing labor and material dispersion issues, while avoiding compatibility problems with adhesives and enabling uniform thermal output and flame propagation.
Implementation Method 1
the seal is created when the fused first and second layers re solidify
Implementation Method 2
the seal is caused by the application of pressure, heat, or UV
Implementation Method 3
This provides a number of areas which will provide paths for thermal output and flame propagation
Data Source
Figure 1a~1c
Figure 2a~2c
Figure 3a~3b
AI summary
The invention relates to an igniter device (5a) for igniting energetic materials, more specifically to the area of the initiation of munitions, and methods of forming said ignition devices. There is provided an igniter device (5a), for use in an explosive train, comprising a first synthetic polymer layer (4), a second synthetic polymer layer (4a), wherein said first layer (4) and second layer (4a) envelope a portion of an energetic material (3), wherein said synthetic polymer is capable of being sealed (1).