US 5,798,480 AGrant

High Performance Space Motor Solid Propellants

Issue Date:1998-08-25

•14 Claims

Abstract

A family of high performance, space motor, solid propellants based on polyglycidyl nitrate elastomer binder, ammonium perchlorate oxidizer and beryllium or beryllium hydride fuel which do not require the presence of plasticizers. A high performance, space motor, solid propellant based on a polyglycidyl nitrate elastomer binder, ammonium perchlorate or hydroxy ammonium perchlorate and beryllium or beryllium hydride optimizes performance at low solids levels.

Metadata

Assignee

Cordant Technologies Inc.

Inventors

Rodney L. Willer
David K. McGrath

Application Information

Application Number:US 5619734

Filing Date:1990-08-02

Priority Date:1990-08-02

Art Unit:224

Classifications

IPC:

C06B 4510

Field of Search:

14919.4;19.6

Patent Drawings

This patent does not have any drawings.

Description

Field of the Invention

This invention relates to improved high performance, space motor solid propellants based on a polyglycidyl nitrate elastomer binder, ammonium perchlorate or hydroxy ammonium perchlorate oxidizer and beryllium or beryllium hydride fuel which do not require the presence of plasticizer and which optimize performance at low solids levels.

Background of the Invention

Solid high-energy compositions, such as propellants, explosives, gasifiers, or the like, comprise solid particulates, such as fuel particulates and/or oxidizer particulates, dispersed and immobilized throughout a binder matrix comprising an elastomeric polymer.

Binders previously used in composite solid propellant formulations have generally been non-energetic polymers such as polycaprolactones, polyethyleneglycols or polybutadienes. Since about 1950 there has been a considerable need to develop energetic binders with satisfactory mechanical properties in order to provide safer binders at higher energy levels and to increase the energy level or specific impulse in a propellant formulation. For the most part only nitrocellulose has found usefulness as an energetic polymer binder. However, nitrocellulose suffers from undesirable mechanical properties. Alternatively, it has been proposed to employ conventional non-energetic polymer binders in combination with energetic plasticizers such as for example, nitroglycerine, butanetriol trinitrate, and trimethylolethane trinitrate. It has also been suggested that the energetic polymer nitrocellulose be employed with either non-energetic or energetic plasticizers in an attempt to improve mechanical properties. However, none of these proposals has led to fully acceptable energetic binder formulations. Furthermore, there are occasions when the use of plasticizers is undesirable or its use is not possible, such as in space where the plasticizer volatilizes. Typical ammonium perchlorate-hydrocarbon space motor propellants optimize the specific impulse (Isp) obtained at about 80%-90% solids and have theoretical Isp's of approximately 320 to 330 lb.sec/lb at 1000 psi and 50:1 vacuum nozzle expansion.

Thus, there has been a continuing need for energetic polymers to be available for use in formulating solid high-energy compositions, such as propellants, explosives, gasifiers and the like. In this regard much recent work has centered on attempts to produce acceptable energetic polymers of glycidyl azide polymer and poly(oxytanes). A problem with elastomeric binders formed from poly(oxytanes) is their tendency to have mechanical characteristics less than that which would be desirable for a high-energy composition, particularly for a rocket motor propellant. It is especially difficult to provide poly(oxytane) binders having adequate stress capabilities. On the other hand glycidyl azide polymer is synthesized by first polymerizing epichlorohydrin to poly(epichlorohydrin) which is then converted to glycidyl azide polymer by reaction with sodium azide in dimethylsulfoxide. Beside the lack of a simple synthesis process, the production of glycidyl azide polymer requires relatively expensive reagents. Moreover, even after the polymer is synthesized it has been found that unplasticized glycidyl azide polymer-ammonium perchlorate solid propellants require about 78% solids to optimize Isp at about 254 sec. at 1000 psi and sea-level optimum expansion conditions.

Since the early 1950's poly(glycidyl nitrate), hereinafter referred to as PGN, has been known and recognized as a possible energetic prepolymer. The initial work on PGN was done by Thelan et al. at the Naval Ordnance Test Station (NOTS, now the Naval Weapons Center, NWC). They studied the polymerization of glycidyl nitrate by a variety of Lewis Acid catalysts with most of the work centering on the use of stannic chloride as a catalyst. No propellants were prepared by the NOTS workers and they noted that one drawback to their synthesis was the laborious purification procedure.

PGN AND PGN propellants were next examined at the Jet Propulsion Laboratory (JPL) by Ingnam and Nichols and at Aerojet General Corporation by Shookhoff and Klotz. The JPL workers found that PGN made using boron trifluoride etherate was low in both functionality (i.e. <2) and molecular weight (MW=1500) and therefore polyurethane propellants made from this PGN had poor mechanical properties. Similar observations were made by the Aerojet workers. In summary, it has long been recognized that PGN may be an excellent energetic polymer but until now a method of synthesis could not be found that would produce nearly difunctional material with acceptable hydroxyl equivalent weights. Nor has it been possible to formulate acceptable unplasticized "clean" space motor solid propellants having reduced levels of solids.

It is therefore desirable to provide a family of high energy, space motor, solid propellants and particularly such propellants which do not require the presence of plasticizer. A further object of this invention is to provide such high energy, space motor solid propellants containing ammonium perchlorate and beryllium or beryllium hydride. An even further object of this invention is to provide such high energy, space motor propellants requiring reduced solids loading to obtain optimized performance as measured by the specific impulse of the propellants.

Summary of the Invention

It has been discovered that high energy, space motor solid propellants not requiring the presence of a plasticizer, can be provided by utilizing a curable polyglycidyl nitrate (PGN) binder and a reduced amount of energetic solid particulate particles of ammonium perchlorate or hydroxy ammonium perchlorate oxidizer and beryllium or beryllium hydride fuel wherein the PGN employed is a PGN having a functionality of nearly 2.0 or more and a hydroxyl equivalent weight of about 1000-1700 or more. More preferably such high energy, space motor solid propellants are provided by utilizing an isocyanate curable PGN binder having a functionality of nearly 2.0 or more, a hydroxyl equivalent weight of about 1200 to 1600 and wherein the PGN employed has less than about 2 to 5% by weight cyclic oligomer present in the PGN.

Detailed Description of the Invention

In U.S. Pat. No. 5,120,827 there is described a process for the production of PGN that produces nearly difunctional material with acceptable hydroxyl equivalent weights, particularly PGN having a functionality of nearly 2.0 or more, or essentially equivalent to the hydroxy functionality of the polyol initiator employed in the process, and a hydroxyl equivalent weight of about 1000-1700 or more, preferably about 1200 to 1600. Moreover, that Application provides a process for producing PGN that has present greatly reduced amounts of cylic oligomer, that is about 2-5% by weight or less of said oligomer.

In said concurrently filed Application, the improved process for the production of PGN, in which cylic oligomer formation is suppressed and PGN having a functionality substantially equal to the functionality of the polyol initiator and an acceptable hydroxyl equivalent weight is obtained, is provided by a process wherein a catalyst-initiator complex is formed and reacted with glycidyl nitrate (GN) and wherein the ratio of mols catalyst/mol hydroxyls in the initiator is <1:1, the glycidyl nitrate is added to the catalyst-initiator complex reaction mixture at a rate substantially equivalent to the rate at which it reacts with the complex such that no effective net amount of glycidyl nitrate monomer is built up, i.e. monomer is used up essentially as fast as it is added to the reaction mixture, and the reaction temperature is maintained within the range of from about 10.degree.-25.degree. C. Additionally, the process provides for the removal of any potential alkoxide groups, such as ethoxide groups, from the catalyst-initiator complex mixture when the catalyst employed in the process leads to the formation of such groups.

According to the process described in said concurrently filed Application glycidyl nitrate, ##STR1## is polymerized to PGN, ##STR2## initiator, wherein n is an integer essentially equivalent to the hydroxy functionality of the initiator and x is an integer representing the repeating units, by forming a catalyst-initiator complex and reacting the complex with glycidyl nitrate and wherein the ratio of mols catalysts/mols hydroxyls in the initiator is <1:1, the glycidyl nitrate monomer is added to the catalyst-initiator complex reaction mixture at a rate in which the monomer is used up (reacted) essentially as fast as it is added, and the reaction temperature is maintained at a temperature within the range of from about 10.degree. to 25.degree. C.

The polymerization reaction is a cationic polymerization process conducted using a polyol initiator and an acid catalyst. The acid catalyst may be chosen from among those known in the art, including BF.sub.3, HBF.sub.4 and triethyloxonium hexafluorophosphate (TEOP). The Lewis acid catalyst forms a preinitiator complex with the polyol, for example, butanediol is known to form a complex with boron trifluoride (BF.sub.3).

The polyol initiator employed generally has the hydroxyl groups of the polyol unhindered. The polyol is preferably a diol. As examples of suitable diols there may be mentioned ethylene glycol, propylene glycol, 1,3-propanediol and 1,4-butanediol. Suitable triols include, but are not limited to glycerol, trimethylolpropane and 1,2,4-butanetriol. A suitable tetrol is, but is not limited to 2,2'-dihydroxymethyl-1,3-propanediol. The molecular weight of the polyol is relatively low, preferably less than 500, more preferably below 300 and most preferably below about 150.

The acid catalyst is used at a much lower level relative to hydroxyl groups of the polyol than is taught in the prior art. It was discovered that a much more controlled reaction occurs if the catalyst, such as a Lewis Acid, is used at a molar ratio relative to hydroxyl groups of the polyol of less than 1:1, preferably from about 0.4:1 to about 0.8:1. If a proton acid is used as the catalyst, the ratio of hydrogen ions released by the acid catalyst to the hydroxyl groups of the alcohol is also less than 1:1, preferably 0.4:1 to about 0.8:1. By using a substantially lower level of acid catalyst, incorporation of a greater percentage of the polyol molecules internally within polymer molecules is achieved, cylic oligomer formation is suppressed to a level of about 2 to 5% or less, and lower polydispersity is achieved.

The cationic polymerization reaction may be carried out in a suitable organic solvent conducive to the cationic polymerization. If a solvent is employed, such suitable solvent is a non-protic, non-ether, inert solvent. Such solvents include, but are not limited to methylene chloride, chloroform, and 1,2-dichloroethane.

The polymerization reaction is conducted in a manner whereby the glycidyl nitrate monomer is added to the reaction mixture at a rate essentially equivalent to its rate of reaction, so that no effective net concentration of monomer is built up in the reaction mixture and the reaction temperature is maintained at a temperature within the range of from about 10.degree. to 25.degree. C., preferably from about 11.degree. to 17.degree. C. and most preferably about 130.degree. to 15.degree. C. It will be appreciated that the faster heat is taken away from the reactive mixture the faster glycidyl nitrate monomer can be added to the reaction mixture.

When the reaction of catalyst and initiator results in the formation of alkoxide groups in the catalyst-initiator complex, such as for example, the presence of alkoxide group compounds in the reaction mixture formed by the reaction of boron trifluoride etherate and 1,4-butanediol, the resulting PGN products are low in functionality. Pre-reacting the polyol 1,4-butanediol and boron trifluoride etherate and then removing diethylether under vacuum produces a PGN product essentially free of alkoxide groups. If, however, the catalyst and initiator would not form products containing such alkoxide groups, such as when boron trifluoride gas is employed instead of boron trifluoride etherate, then prereaction of the catalyst and initiator and removal of potential alkoxide compounds is not necessary.

The hydroxyl equivalent weight of the PGN polymer produced according to this process will generally be from about 1000 to 1700 or more, preferably from about 1200 to about 1600 and the amount of cyclic oligomer produced will generally be about 2-5% by weight or less.

It has been discovered that the improved PGN produced according to the process of said concurrently filed Application permits the production of high energy, space motor solid propellants not requiring the presence of a plasticizer. The high energy, space motor solid propellants of this invention require greatly reduced amounts of solid particulate materials in order to obtain optimized performance as measured by the specific impulse of the propellant. The solids content may be as low as about 40-60% by weight, and is generally from about 40-75% by weight. However, if desired, propellant formulations with higher solids contents of up to about 85% by weight can be formulated. The lower solids levels permit better processability of the solid propellent formulations.

It is surprising that the high energy, space motor, PGN solid propellants of this invention provide optimized performance at reduced solid levels and without the presence of a plasticizer thus permitting their use in space based applications. With the plasticizer-free, reduced solids content solid propellants of this invention, it is possible to obtain propellants with a specific impulse of about 390 to 410 or more pounds force-sec per pound mass at 500 and 1000 psi pressure and vacuum expansion ratios of 50:1 to 70:1.

Although a plasticizer is not required, and for high energy space motor solid propellants is undesirable, it will be recognized that it is possible to add a small amount of suitable plasticizers to the solid propellants of this invention for applications wherein the presence of a plasticizer is not prohibited or is not undesirable. In such cases any suitable plasticizer may be employed and generally in a small amount, generally about 5% by weight or less of plasticizer, and most preferably less than about 2% by weight. As examples of suitable plasticizers which may be present in the high energy solid propellants there may be mentioned high-energy plasticizers such as nitroglycerine (NG), butanetriol trinitrate (BTTN), trimethylolethane trinitrate (TMETN) and triethylene glycol dinitrate (TEGDN).

The high energy, space motor solid propellants will generally comprise from about 40 to about 85 wt. %, preferably 40-75 wt. %, and most preferably about 40-60 wt. % particulate solids, including fuel material particulates and oxidizer particulates. The particulate solids level in the propellants could, if desired, comprise also up to about 85% by weight or more. The fuel particulates employed in the solid propellant formulation of this invention are beryllium or beryllium hydride or mixtures thereof. Particulate oxidizer material employed is ammonium perchlorate (AP) or hydroxy ammonium perchlorate (HAP) but can also include mixtures with cyclotetramethylene tetranitramine (HMX), cyclotrimethylene trinitramine (RDX) and other high energy nitramines such as CL-20 and mixtures thereof. The high energy solid propellants may optionally include minor amounts of additional components known in the art, such as bonding agents and burn rate modifiers such as diaminofurazan (DAF) or diaminoglyoxime (DAG) and the like.

Cured PGN elastomers are formed by curing with isocyanates having a functionality of at least two or more, such as for example, hexamethylene diisocyanate (HMDI), toluene diisocyanate (TDI), and polyfunctional isocyanates, such as for example, Desmodur N-100 available from the Mobay Chemical Co., a division of Farbenfabriken Bayer AG, and mixtures thereof.

The following is a typical example of a method for the preparation of poly(glycidyl nitrate) according to the aforementioned concurrently filed application, suitable for use in the high energy space motor solid propellants of this invention. A clean, dry, three neck r.b. flask is equipped with a vacuum adapter, rubber septum, magnetic stirring bar and a thermometer. The flask is charged with 29.7 g (0.33 mole) of dry 1,4-butanediol, cooled to 20.degree. C. and 46.8 g (0.33 mole) of BF.sub.3 etherate is slowly added via a syringe while maintaining the temperature below 25.degree. C. This mixture is stirred for 1 hr. at 25.degree. C. then the ether is removed by pulling a partial vacuum for 1 hr. and a full vacuum for 16 hrs. Dry methylene chloride (175 ml) is added to the flask and the contents are transferred using a cannula to a clean dry 5 liter jacketed resin flask previously filled with 400 ml dry methylene chloride and cooled to 10.degree. C. equipped with a mechanical stirrer, thermometer, N.sub.2 purge, and a peristaltic addition pump. An additional 25 ml of dry methylene chloride is used to insure quantitative transfer of the catalyst initiator complex. The temperature in the reactor is adjusted to 13.degree..+-.2.degree. C. and a solution of 1190 g (10 moles) of monomer grade glycidyl nitrate in 800 ml of dry methylene chloride is added at such a rate as to maintain a temperature of 13.degree..+-.2.degree. C. This typically takes 4.5 hours. The reaction is stirred for 0.5 hr. then quenched by the addition of 400 ml of a saturated sodium chloride solution. The brine solution is separated and the methylene chloride solution of PGN is washed three times with 500 ml of saturated sodium bicarbonate solution. The methylene chloride solution is dried over magnesium sulfate and the methylene chloride removed on a rotoevaporator at a pressure of <1 mm and a temperature of 40.degree. C. (1 hr.) and 55.degree. C. (2 hrs.) to give essentially a quantitative yield of poly(glycidyl nitrate) as a viscous light yellow liquid.

The invention is now illustrated in greater detail by way of the following illustrative examples. In all the following examples the PGN prepolymer employed in the binder of the solid propellants is one prepared according to the preceding illustrative preparation and having a molecular weight of about 2500 and a hydroxyl equivalent weight of about 1250. The binder contains about 0.47% at mononitroaniline (MNA) as a nitrate ester stabilizer and about 0.03% at triphenylbismuth (TPB) as a urethane cure catalyst. Theoretical specific impulse values are calculated according to the program described in Gordon, S. and McBride, B., "Computer Program for Calculation of Complex Chemical Equilibrium Composition, Rocket Performance, Incident and Reflected Shock and Chapman--Jouquet Detonations", NASA, SP-273 (1976).

Table I sets forth the theoretical specific impulses for various high-energy unplasticized space motor PGN/AP or HAP/BeH.sub.2 solid propellants at 500 and 1000 psi at 50:1 and 70:1 expansion ratios for various solid loadings of the propellant. The binder comprises the PGN prepolymer and HMDI curative isocyanate present in a 12/1 wt. ratio. For comparison purposes performance characteristics are also set forth on Table I for two standard commercial high energy space motor solid propellants, namely TP-H-3340 and TP-H-1202. The two standard high energy space motor solid propellants each contain isophorone diisocyanate (IPDI) cured hydroxyl terminated polybutadiene (HTPB) binder and the formulations, by weight percent, were as follows:

TP-H-3340: HTPB/IPDI-11%, AP-71%, Al-18%

TP-H-1202: HTPB/IPDI-18%, AP-50%, Al-20%, HMX-12%

As shown by the data in Table I, at every solids loading level from 60 to 85%, superior performance is achieved by both the AP and HAP containing solid propellant formulations of this invention. Moreover, at the 70:1 expansion ratio theoretical Isp's for the solid propellant formulations containing 80 and 85% total solids level can exceed 400 lb-sec/lb.

Table II sets forth the theoretical specific impulses for a series of high energy space motor solid propellant beryllium hydride-containing formulations at various levels of solids loading at 1000 psi pressure ratio at expansion ratios of 50:1 and 100:1. Similarly, Table III sets forth theoretical specific impulses for a series of high energy space motor solid propellant beryllium-containing formulations at various levels of solids loading at 1000 psi pressure at expansion ratios of 50:1 and 100:1.

The data in Table II and III further confirm the superior performance achievable by the solid propellant compositions of this invention at solids loading of 50 to 85% total solids. It is noted, however, that unlike the BeH.sub.2 formulation in Table II, the performance of the Be formulations of Table III did not increase with increasing solids levels. It is believed that this may be attributable to the strong increase in flame temperature driving unfavorable reactions. The data in Examples 70 to 77 at 60% solids levels indicates that both HMX and DAG are favorable additives to decrease the flame temperature and to increase the energy level.

Examples of high energy space motor solid propellants that can be produced according to this invention are set forth in Examples 78 and 79, containing 60% and 50% total solids, respectively.

Example 78

The 450 gram batch of solid propellant was prepared in the following manner. Into a suitable mixing vessel, under vacuum, the PGN, MNA and Be ingredients were added and mixed for about 15 minutes. To the mixture 50% by weight of each of the course and fine AP were added and mixed for a further 15 minutes after which the remaining 50% of each of the course and fine AP were added and mixed for an additional 15 minute period. Then TPB in toluene was added and mixed for a further period of about 15 minutes followed by addition thereto of the N-100/HMDI mix which was subjected to a further mixing for a period of about 15 minutes. The propellant was allowed to cure for 3 days at 135.degree. F.

Example 79

The 450 gram batch was prepared in a manner similar to Example 78 except that no vacuum was applied until addition of the TPB in toluene to the mixture.

Each of the formulations of Examples 78 and 79 cured to good elastomeric high energy space motor solid propellants.

Properties of the two propellants are set forth in Table IV.

With the foregoing description of the invention, those skilled in the art will appreciate that modifications may be made to the invention without departing from the spirit thereof. Therefore, it is not intended that the scope of the invention be limited to the specific embodiments illustrated and described.

Claims

We claim:

1. A high energy, space motor, solid propellant having a theoretical specific impulse, at 1,000 psi and expansion ratio of 50:1, of at least about 350 lb-sec/lb and comprising an isocyanate cured polyglycidyl nitrate binder and from about 40 to about 75% by weight high energy particulate solids comprising oxidizer particulates selected from the ammonium perchlorate and hydroxy ammonium perchlorate and fuel particulates selected from beryllium and beryllium hydride and wherein the polyglycidyl nitrate is an isocyanate curable polyglycidyl nitrate polymer having a functionality of nearly 2.0 or more and a hydroxyl equivalent weight of from about 1000 to about 1700 and has less than about 2 to 5% by weight cyclic oligomer present in the polyglycidyl nitrate.

2. A high energy, solid propellant of claim 1 wherein the particulate solids comprise from about 40 to 60% by weight.

3. A high energy, space motor, plasticizer-free, solid propellant comprising an isocyanate cured polyglycidyl nitrate binder and from about 40 to about 75% by weight high energy particulate solids comprising oxidizer particulates selected from ammonium perchlorate and hydroxy ammonium perchlorate and fuel particulates selected from beryllium and beryllium hydride, wherein the polyglycidyl nitrate is an isocyanate curable polyglycidyl nitrate polymer having a functionality of nearly 2.0 or more and a hydroxyl equivalent weight of from about 1000 to about 7000 and has less than about 2 to 5% by weight cyclic oligomer present in the polyglycidyl nitrate.

4. A high energy, space motor, plasticizer-free, solid propellant of claim 3 wherein the particulate solids comprise from about 40 to 60% by weight.

5. A high energy, space motor, plasticizer-free, solid propellant of claim 3 wherein the oxidizer particulates comprise ammonium perchlorate.

6. A high energy, space motor, plasticizer-free, solid propellant of claim 5 wherein the fuel particulates also comprise beryllium.

7. A high energy, space motor, plasticizer-free, solid propellant of claim 3 wherein the oxidizer particulates comprise ammonium perchlorate and the fuel particulates comprise beryllium.

8. A high energy, space motor, plasticizer-free, solid propellant of claim 3 wherein the oxidizer particulates comprise ammonium perchlorate and the fuel particulates comprise beryllium hydride.

9. A high energy, space motor, plasticizer-free, solid propellant of claim 7 wherein the particulates additionally comprise cyclotetramethylene tetranitramine, diaminoglyoxime and mixtures thereof.

10. A high energy, space motor, plasticizer-free, solid propellant of claim 8 wherein the particulate solids additionally comprise cyclotetramethylene tetranitramine, diaminoglyoxime and mixtures thereof.

11. A high energy, space motor, plasticizer-free, solid propellant of claim 3 wherein the propellant includes additional components selected from bonding agent, burn rate modifier, nitrate ester stabilizer and urethane cure catalyst.

12. A high energy, space motor, solid propellant having a theoretical specific impulse at 1,000 psi and expansion ratio of 50:1 of at least about 380 lb-sec/lb and comprising about 15 to about 60% by weight of an isocyanate cured polyglycidyl nitrate binder and from about 40 to about 85% by weight of particulate solids and wherein the particulate solids comprise oxidizer particulates selected from ammonium perchlorate or hydroxy ammonium perchlorate and fuel particulates selected from beryllium and beryllium hydride and wherein the polyglycidyl nitrate is an isocyanate curable polyglycidyl nitrate polymer having a functionality of nearly 2.0 or more and a hydroxyl equivalent weight of from about 1000 to about 1700 and has less than about 2 to 5% by weight cyclic oligomer present in the polyglycidyl nitrate.

13. The propellant of claim 12, wherein the binder is present in an amount of about 25 to 60% by weight and said particulate solids are present in an amount of about 40 to 75% by weight.

14. The propellant of claim 1, wherein said specific impulse is above 380.

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Abstract

Description