Layered reactive particles with controlled geometries, energies, and reactivities, and methods for making the same

Patent metadata

Field	Value
Publication number	US-9382167-B2
Application number	US-201313850064-A
Country	US
Kind code	B2
Filing date	Mar 25, 2013
Priority date	Oct 23, 2008
Publication date	Jul 5, 2016
Grant date	Jul 5, 2016

Abstract

An energetic composite having a plurality of reactive particles each having a reactive multilayer construction formed by successively depositing reactive layers on a rod-shaped substrate having a longitudinal axis, dividing the reactive-layer-deposited rod-shaped substrate into a plurality of substantially uniform longitudinal segments, and removing the rod-shaped substrate from the longitudinal segments, so that the reactive particles have a controlled, substantially uniform, cylindrically curved or otherwise rod-contoured geometry which facilitates handling and improves its packing fraction, while the reactant multilayer construction controls the stability, reactivity and energy density of the energetic composite.

First claim

We claim:

1. A method for fabricating a plurality of reactive multilayer particles, the method comprising:
(a) providing a polymer mesh substrate, wherein the mesh substrate comprises a plurality of members arranged in space to be approximately parallel to at least one other member and approximately perpendicular to at least one other member so as to form a mesh opening ranging from about 50 micrometers to about 100 micrometers and defined by at least one dimension between two parallel members and two perpendicular members;
(b) successively depositing two or more reactive materials onto one side of the mesh substrate to form thereon a reactive multilayer having a trough shape; and
(c) removing the reactive multilayer from the mesh substrate to provide a plurality of reactive multilayer particles, wherein each reactive multilayer particle has a range of heats of reaction between 500 J/g to 4300 J/g, a substantially uniform geometry, and a cylindrically-curved body radially spaced from a corresponding cylindrical axis, wherein the cylindrically-curved body has a trough shape and a reactive multilayer construction with successive reactive layers stacked in a radially outward direction from the cylindrical axis.

2. The method of claim 1 , wherein at least one of the one or more materials is deposited onto the mesh substrate by a deposition method selected from the group consisting of physical vapor deposition, chemical vapor deposition, electrochemical deposition, electrolytic deposition, and atomic layer epitaxy.

3. The method of claim 1 , wherein the physical vapor deposition comprises magnetron sputter deposition.

4. The method of claim 1 , wherein the reactive multilayer particle is removed from the mesh substrate by bending the mesh substrate.

5. The method of claim 4 wherein the reactive multilayer particle is removed from the mesh substrate while the mesh substrate, or a portion thereof, is submerged in a liquid.

6. The method of claim 1 , wherein the polymer is selected from the group consisting of polyester and nylon.

7. The method of claim 1 , wherein the reactive multilayer particle comprises a material selected from the group consisting of aluminum, nickel, titanium, carbon, iron, zirconium, palladium, silicon, molybdenum, rhodium, boron, zinc, magnesium, vanadium, iron oxide (Fe 2 O 3 ), copper oxide (CuO x ), and molybdenum oxide (MoO 3 ).

8. The method of claim 1 , wherein the reactive multilayer particle comprises at least a bilayer comprising a combination of materials selected from the group consisting of Zr/Al, Ni/Al, Al/Cu(0.3)Ni(0.7), Ni/Si, Mo/Si, Pd/Al, Rh/Al, Ti/B, Zr/B, Ti/B 4 C, and Zr/B 4 C.

9. The method of claim 1 , wherein the successive deposition of the one or more materials is controlled so that the reactive multilayer particles have a predetermined layer thickness and total thickness and a predetermined chemistry.

10. The method of claim 1 , wherein the plurality of reactive multilayer particles has a length approximately equal to two times a dimension of the mesh substrate opening plus a diameter of a member of the mesh substrate and a width approximately equal to a diameter of a member of the mesh substrate.

Assignees

• Univ Johns Hopkins

Inventors

• Fritz Gregory M
• Weihs Timothy P
• Grzyb Justin A

Classifications

• C23C16/01

  on temporary substrates, e.g. substrates subsequently removed by etching · CPC title

• Y10T428/131

  Glass, ceramic, or sintered, fused, fired, or calcined metal oxide or metal carbide containing [e.g., porcelain, brick, cement, etc.] · CPC title

• Y10T428/25

  Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles · CPC title

• Y10T428/2975

  Tubular or cellular · CPC title

• B32B1/08

  Tubular products · CPC title