Vesta Research, Ltd.

Declan Farrell

Santosh Limaye

Shanthi Subramanian

A shaped, flexible fuel and energetic system is presented. The shaped, flexible fuel comprises at least one polymeric binding material and porous silicon particles dispersed throughout the polymeric binding material. The porous silicon particles are prepared from a metallurgical grade silicon powder. The shaped, flexible fuel preferably includes shapes such as: an article, a film, a wire and a tape. The energetic system comprises the shaped, flexible fuel portion used alone or in combination with at least one oxidizer.

Shaped, flexible fuel and energetic system therefrom

Silicon nanosponge particles prepared from a metallurgical grade silicon powder having an initial particle size ranging from about 1 micron to about 4 microns is presented. Each silicon nanosponge particle has a structure comprising a plurality of nanocrystals with pores disposed between the nanocrystals and throughout the entire nanosponge particle.

Silicon nanosponge particles

Porous silicon particles are prepared from a metallurgical grade silicon powder having an initial particle size greater than about 1 micron is presented. Each porous silicon particle comprises a solid core surrounded by a porous silicon layer having a thickness greater than about 0.5 microns.

Porous silicon particles

A process for producing a silicon nitride compound is presented. A starting solution comprising fluorosilicic acid is provided. The starting solution is derived from a silicon, etching process wherein silicon is etched with a solution comprising hydrofluoric acid and where silicon powder has been removed. The starting solution is heated to yield a vapor solution comprising silicon tetrafluoride, hydrogen fluoride, and water. The hydrogen fluoride is separated from the vapor solution wherein a pure stream of silicon tetrafluoride and water vapor remain. The silicon tetrafluoride and water vapor are hydrolyzed to yield a concentrated fluorosilicic acid solution. The fluorosilicic acid is reacted with a base to yield a fluorosilicic salt. The fluorosilicic salt is heated to yield anhydrous silicon tetrafluoride. The anhydrous silicon tetrafluoride is reacted with a metal hydride to yield a monosilane. The monosilane is reacted to form a silicon compound and a silicon nitride compound. The silicon and the silicon nitride compounds are recovered. In an alternate embodiment, the hydrogen fluoride is recovered from the reaction process and reintroduced into the porous silicon etching process.

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Dun Laoghaire, Ireland

Declan Farrell