Gas generating charge and a process for producing the same

Claim 2

A propellant charge capable of rapid combustion to generate a large volume of combustion gas in a short time, comprising: a stack of a plurality of relatively thin layers of relatively large surface area and which are joined to each other to form the propellant charge, said layers being made of a solid combustible propellant composition and having substantially parallel upper and lower surfaces, the lower surface of each of said layers being opposed to, spaced from and extending substantially parallel with the upper surface of the adjacent lower layer in said stack, each of said layers having a plurality of projections of relatively small surface area and height on at least one of said surfaces thereof and extending into contact with the opposing surface of the adjacent layer in said stack so that said layers are maintained spaced from each other, the surface areas of said projections being small relative to the surface areas of said surfaces of said layers to provide gaps of large area between adjacent layers so that said layers have large surface areas exposed for uniform ignition and burning to generate a large volume of combustion gas in a short time.

Claim 3

A propellant charge as claimed in claim 1, wherein said upper and lower surfaces of said layers are planar, the thickness of each of said layers, measured between said upper and lower surfaces thereof, is a uniform thickness in the range of from 0.4 to 4.0 mm, the height of said projections is in the range of from 0.2 to 2.0 mm and said projections are arranged in a regularly repeating pattern and are spaced apart from each other across said one surface of each layer.

Claim 4

A propellant charge as claimed in claim 1, wherein said projections are arranged in a rectangular grid.

Claim 5

A propellant charge as claimed in claim 1, wherein said projections are of pyramidal shape, are arranged in a regularly repeating pattern and are spaced from each other across said one surface of each layer.

Claim 6

A propellant charge as claimed in claim 1, wherein said projections are of trigonal shape, are arranged in a regularly repeating pattern and are spaced from each other across said one surface of each layer.

Claim 7

A propellant charge as claimed in claim 1, wherein said projections are of hemispherical shape, are arranged in a regularly repeating pattern and are spaced from each other across said one surface of each layer.

Claim 8

A propellant charge as claimed in claim 1, wherein said projections are of cylindrical shape, are arranged in a regularly repeating pattern and are spaced from each other across said one surface of each layer.

Claim 9

A propellant charge as claimed in claim 1, wherein said layers are annular, coaxial disks.

Claim 10

A propellant charge as claimed in claim 1, wherein said layers are united to each other by a bonding agent compatible with and inert to said propellant composition, said bonding agent being applied to said projections and bonding said projections to the portions of the opposing surface of the adjacent layer that contacts said projections.

Claim 11

A propellant charge as claimed in claim 9, wherein said bonding agent is a polar solvent having a boiling point in the range of 50° to 150° C. which is capable of dissolving said propellant composition.

Claim 12

A propellant charge as claimed in claim 1, wherein said propellant composition consists essentially of 20 to 70 wt. % of nitrocellulose, 10 to 50 wt. % of a nitroplasticizer, 0 to 20 wt. % of a plasticizer, 0 to 70 wt. % of an oxidizing agent, and a total of 1 to 10 wt. % of a stabilizer and a combustion catalyst.

Claim 13

A process for producing a propellant charge comprising: (a) forming a propellant composition comprising nitrocellulose and a nitroplasticizer into a sheet; (b) passing said sheet between a pair of rotating, parallel molding rolls so that said sheet passes in a direction transverse to the axes of rotation of said rolls, the outer surface of at least one of said rolls having a plurality of recesses formed therein, whereby said sheet is molded between said rolls and projections corresponding to said recesses are formed on said sheet; (c) then cutting said sheet into a plurality of layers having upper and lower substantially planar surfaces, at least one of said surfaces having said projections formed thereon and projecting therefrom; (d) stacking said layers in face-to-face order, such that the upper and lower surfaces of each of said layers are spaced apart from corresponding surfaces of adjacent layers by means of said projections; and (e) joining said layers such that said stack forms a united body, said stack of joined layers comprising said propellant charge.

Claim 14

A process for producing a propellant charge comprising: (a) forming a propellant composition comprising nitrocellulose and a nitroplasticizer into a sheet; (b) passing said sheet between a pair of rotating, parallel molding rolls so that said sheet passes in a direction transverse to the axes of rotation of said rolls, the outer surface of at least one of said rolls having a plurality of recesses formed therein, whereby said sheet is molded between said rolls and projections corresponding to said recesses are formed on said sheet; (c) then cutting said sheet into a plurality of layers having upper and lower substantially planar surfaces, at least one of said surfaces having said projections formed thereon and projecting therefrom; (d) stacking said layers in face-to-face order, such that the upper and lower surfaces of each of said layers are spaced apart from corresponding surfaces of adjacent layers by means of said projections; and (e) joining said layers such that said stack forms a united body, said stack of joined layers comprising said propellant charge.

Claim 15

A process as claimed in claim 12, wherein the rotation speed ratio of said pair of parallel molding rolls is in the range of 1:1 to 1:1.1.

Claim 16

A process as claimed in claim 12, wherein said recesses are formed in one of said rolls, the other of said rolls being free of said recesses.

Claim 17

A process as claimed in claim 12, wherein said projections comprise rectangular bars.

Claim 18

A propellant charge as claimed in claim 12, wherein said projections are of pyramidal shape.

Claim 19

A propellant charge as claimed in claim 12, wherein said projections are of trigonal shape.

Claim 20

A propellant charge as claimed in claim 12, wherein said projections are of hemispherical shape.

Claim 21

A propellant charge as claimed in claim 12, wherein said projections are of cylindrical shape.

Claim 22

A process for producing a propellant charge capable of rapid gas generation when said propellant charge is subjected to combustion, comprising the steps of: (a) forming a propellant composition consisting essentially of 20 to 70 wt. % of nitrocellulose, 10 to 50 wt. % of a nitroplasticizer, 0 to 20 wt. % of a plasticizer, 0 to 70 wt. % of an oxidizing agent and 1 to 10 wt. % of a stabilizer and a combustion catalyst, into a sheet; (b) passing said sheet between a pair of rotating, parallel molding rolls so that said sheet passes in a direction transverse to the axes of said rolls, said rolls rotating at approximately the same speed, said propellant and said rolls being at a temperature in the range of 15° to 90° C., the outer surface of at least one of said rolls having a plurality of regularly spaced recesses formed therein, whereby said sheets are molded between said rolls and a regular pattern of projections corresponding to said recesses is formed on said sheet, said projections having a height in the range of 0.2 to 2.0 mm; (c) cutting said molded sheet into a plurality of thin annular disks having central holes therein and upper and lower planar faces, at least one of said faces of each of said disks having said projections formed thereon, said disks having a thickness in the range of 0.4 to 4.0 mm, as measured between the respective upper and lower faces thereof; (d) stacking said disks coaxially and in face-to-face order, such that the upper and lower faces of each of said disks are spaced apart from corresponding faces of adjacent disks by means of said projections; and (e) joining said disks so that said stack forms a united body, said stack of joined disks comprising said propellant charge.

Claim 23

A process for producing a propellant charge capable of rapid gas generation when said propellant charge is subjected to combustion, comprising the steps of: (a) forming a propellant composition consisting essentially of 20 to 70 wt. % of nitrocellulose, 10 to 50 wt. % of a nitroplasticizer, 0 to 20 wt. % of a plasticizer, 0 to 70 wt. % of an oxidizing agent and 1 to 10 wt. % of a stabilizer and a combustion catalyst, into a sheet; (b) passing said sheet between a pair of rotating, parallel molding rolls so that said sheet passes in a direction transverse to the axes of said rolls, said rolls rotating at approximately the same speed, said propellant and said rolls being at a temperature in the range of 15° to 90° C., the outer surface of at least one of said rolls having a plurality of regularly spaced recesses formed therein, whereby said sheets are molded between said rolls and a regular pattern of projections corresponding to said recesses is formed on said sheet, said projections having a height in the range of 0.2 to 2.0 mm; (c) cutting said molded sheet into a plurality of thin annular disks having central holes therein and upper and lower planar faces, at least one of said faces of each of said disks having said projections formed thereon, said disks having a thickness in the range of 0.4 to 4.0 mm, as measured between the respective upper and lower faces thereof; (d) stacking said disks coaxially and in face-to-face order, such that the upper and lower faces of each of said disks are spaced apart from corresponding faces of adjacent disks by means of said projections; and (e) joining said disks so that said stack forms a united body, said stack of joined disks comprising said propellant charge.