Additive Manufacturable Energetic Material Using UV Curable Binder
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Solution Overview
Problem
Energetic materials like XTX-8003 are unsuitable for additive manufacturing due to storage requirements and limited shelf life, necessitating improvements for processing using such techniques.
Innovation Solution
Development of an optically curable energetic material, specifically using a UV curable binder with energetic materials like PETN, allowing for additive manufacturing through processes involving mixing, extrusion, and UV light curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional energetic materials like XTX-8003 are used, then the material has good flowability and low critical propagation diameter, but the material requires cold storage below zero degrees Centigrade and has limited shelf life
Solution Approach 1:
The patent changes the chemical composition parameters by incorporating optically curable binder components and photopolymerization catalysts into the energetic material formulation. This modifies the material's storage and processing parameters, allowing it to remain stable at ambient temperatures while maintaining explosive performance characteristics.
Solution Approach 2:
The patent replaces the mechanical cold storage system (requiring temperatures below zero degrees Centigrade) with an optical curing system. Instead of using cold storage to prevent resin crosslinking, the material uses UV light activation to trigger controlled polymerization only when needed, eliminating the need for complex refrigeration infrastructure.
2Stability of the object's composition
If traditional energetic materials are stored at low temperatures, then the material maintains stability, but the material must be introduced to the intended fixture immediately and any unused material is discarded
Solution Approach 1:
The patent incorporates photopolymerization catalysts and optically curable binders that remain dormant until activated by UV light. This preliminary preparation allows the material to be stored stably in an uncured state and then rapidly transformed into its functional form only when needed, eliminating waste from unused material.
Solution Approach 2:
The material contains self-contained photopolymerization catalysts and optically curable components that automatically activate and cure when exposed to UV light during the additive manufacturing process. This self-service mechanism eliminates the need for external curing systems or immediate fixture introduction, allowing material to be stored and processed flexibly.
3Ease of manufacture
If existing energetic materials are used for additive manufacturing, then the material can be processed, but the material requires immediate use after removal from cold storage and has limited shelf life
Solution Approach 1:
The patent modifies the material's chemical parameters by incorporating optically curable binders and photopolymerization catalysts, changing the material from a cold-storage required formulation to a light-activated formulation. This extends shelf life by allowing stable storage at ambient temperatures while maintaining manufacturability through UV-triggered curing.
Solution Approach 2:
The patent substitutes the mechanical cold storage and immediate processing requirement with an optical activation system. The material can be stored indefinitely at ambient temperatures in an uncured state and then rapidly cured by UV light exposure during additive manufacturing, eliminating the limited shelf life constraint.
4Ease of operation
If UV curable binder is used instead of traditional resin systems, then the material can be processed at ambient temperature, but the material requires optical curing equipment
Solution Approach 1:
The patent replaces the complex mechanical cold storage and heating systems with a relatively simple optical curing system. UV light sources can be integrated directly into additive manufacturing printers, providing a more versatile and easier-to-implement solution for controlling the curing process at ambient temperatures.
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
Enables the fabrication of energetic devices via additive manufacturing, overcoming storage and shelf life limitations, and providing improved processability and versatility.
Implementation Method 1
The optically curable binder is an ultraviolet curable binder
Data Source
AI summary
An additively manufactured energetic material, a method of producing an additively manufactured energetic material, and a method of making an injection moldable plastic bonded energetic material are provided. The energetic material comprises a liquid optically curable binder and an energetic material suspended in the optically curable binder.