US Government As Represented by the Secretary of the Army

USA As Represented by Secretary of the Navy

Neha Mehta

Daniel Stec, Iii

Gartung Cheng

Brian Edward Fuchs

Kathy Yang

Jerry S Salan

Karl Oyler

Emily A Cordaro

John William Fronabarger

Paritosh R Dave

Jon G Bragg

Gerard I Gillen

Amy Wilson

Andrew G Pearsall

Paula Cook

Neelam Mehta

Carl Hu

Matthew L Jorgensen

Michael D Williams

Raja G Duddu

Jesse J Sabatini

Christopher Csernica

Jason B Pattison

Steven H Marino

Lily F W Walsh

Andrew Perich

John Marin

Daniel W Ward

Pamela Tran

R Hunter Muir

Shannon Lenahan

Gartumg Cheng

Kin Yee

Robert Lateer

Gregory Papatrefon

Akash Shah

The present invention is directed to a process for continuous production of copper (I) nitrotetrazolate (DBX-1) by reacting aqueous copper salt with aqueous 5-nitrotetrazolate salt in the presence of a reducing agent. All the reactants are introduced into a continuous flow reactor system, which is composed of a temperature controlled tubular reactor and a mixer that allows for radial mixing. An optional stirred tank reactor may also be incorporated into the process to complete the reaction and allow for crystal growth.

Continuous manufacture of DBX-1

The present invention is directed to a method for preparing 5-nitrotetrazolate using a strongly acidic ionic cation exchange resin that has improve yields over prior art methods. The methods disclosed herein can be used either in a batch process or continuous flow reactor. In one exemplary process, starting material sodium 5-aminotetrazolate in solution is added into a reaction vessel containing a strongly acidic ionic cation exchange resin to facilitate production of 5-nitrotetrazolate. Multiple reactors containing resins may be connected in series to improve 5-nitrotetrazolate yields and purity levels.

Method for preparing sodium nitrotetrazolate using cation exchange resin

Lead free microdet electric detonators comprising a bridgewire having milled DBX-1 as a spot charge and unmilled DBX-1 as the intermediate material. Such improved microdet electric detonator is free of lead azide and lead styphnate, but with comparable stability, power and sensitivity to current lead-based M100 electric detonators.

Electric detonator with milled and unmilled DBX-1

A method of manufacture of the primary explosive material copper(I) 5-nitrotetazolate (DBX-1) by a synthesis starting with 5-aminotetrazolate (5-AT); wherein, the synthesis provides intermediates acid copper salt of 5-NT and sodium 5-nitrotetrazolate (NaNT) sodium 5-nitrotetrazolate (NaNT)&#x2014;that are both, free of any 5-aminotetrazolate (5-AT) starting material&#x2014;such that the subsequent production of the DBX-1 is not inhibited. Further, this method utilizes an internal filter within the reactor&#x2014;to minimize handling of explosively dangerous intermediates.

Synthesis of copper(I) 5-nitrotetrazolate

A non-toxic primer mix in which DBX-1 (copper(I) 5-nitrotetrazole) acts as the primary explosive portion of the primer. Furthermore, in this mix, boron carbide (BC) replaces the traditional frictionator/fuel, toxic antimony trisulfide. In addition, potassium nitrate replaces the toxic barium nitrate (BaNO)) as the oxidizer, providing an ignition flame from the primer in a pyrotechnic reaction. The non-toxic primer therefore embodies a lead-free, barium-free, antimony-free explosive material that can include added fuels, sensitizers, explosives and/or binders.

Non-toxic primer mix

Secondary crystalline high explosives are disclosed which are suitable for filling very small volume loading holes in micro-electric initiators for micro-electro-mechanical mechanisms (MEMS), used as safe and arm (S&A) devices. The explosives are prepared by adding the such a high explosive to an aqueous first volatile mobile phase, adding such a high explosive to a non-aqueous second volatile mobile phase, mixing the first and second volatile mobile phases and then loading the combined phases into the MEMS device and allowing the aqueous and non-aqueous solvents to evaporate depositing the high explosive. Enhanced adhesion between the deposited high explosive and enhanced rheological properties can be obtained by adding a polymeric binder to both mobile phases.

High explosive fills for MEMS devices

A method for preparing an insensitive bis(2,2-dinitropropyl)nitramine (BDNPN) as a fine powder which exhibits desirable insensitive munitions (IM) characteristics for use alone or compounded with other energetic materials such as RDX.

Preparation of insensitive bis(2,2,-dinitropropyl) nitramine (BDNPN)

A lead-free primer energetic composition including Cyanuric Triazide (60%), Tetracene (5%), Barium Nitrate (20%) and Antimony Trisulfide (15%) is produced. The lead-free primer energetic composition is used to construct a primary detonator including a transfer charge of Cyanuric Triazide, which produces a further initiation train that may subsequently detonate a secondary explosive, i.e., HDX, RDX, or a pyrotechnic device.

Lead free detonator and composition

High explosives suitable for filling very small volume loading holes in micro-electric initiators for micro-electro-mechanical mechanisms, used as safe and arm devices, are prepared from slurries of crystalline energetic materials including organic liquid and applied using various methods. These methods include swipe loading, pressure loading and syringe loading. The organic liquid serves as a volatile mobile phase in the slurry so as to partially dissolve the energetic material so that, upon evaporation of the mobile phase, the energetic material precipitates and adheres to the loading hole.

High explosive fills for very small volume applications

Methods for making and using high explosive fills for MEMS devices

High explosive coatings and inks suitable for use in micro-electronic initiators for micro-electro-mechanical mechanisms used as safe and arm devices, are prepared from coating compositions of crystalline energetic materials and applied using various methods. These methods include wiping and spraying, as well as, pressure applications using a syringe or the like, and application of thick film ink to write specified patterns on a selected surface. A volatile mobile phase may be added to the coating composition to partially dissolve the energetic material so that, upon evaporation of the mobile phase, the energetic material precipitates and adheres to the selected surface.

Method for producing and using high explosive material

A detonator for a hand grenade fuze comprises a detonator case; a slider that is transversely reciprocable in the detonator case from an unarmed position to an armed position, the slider including a longitudinal through-hole filled with a primary explosive; a spring that biases the slider to the unarmed position; an arming mechanism attached to the slider, the arming mechanism comprising a shape memory alloy; an explosive lead disposed below the slider; and a booster charge disposed below the explosive lead.

Hand grenade fuze

The present invention discloses a process for the on-demand production of small quantities of lead azide. First, a metered quantity of sodium azide solution and a metered quantity of a solution of a lead salt sufficient to react with the sodium azide are introduced into a T-mixer or Y-mixer. Then, the sodium azide and lead salt solutions are conveyed into a static mixer and the azide and lead compounds are permitted to react together, forming insoluble crystals of lead azide as a slurry in an aqueous medium. The lead azide crystals are then separated from the aqueous medium. The process is carried out within an explosion-proof chamber.

On-demand lead azide production

High explosives suitable for filling very small volume loading holes in micro-electric initiators for micro-electro-mechanical mechanisms, used as safe and arm devices, are prepared from slurries of crystalline energetic materials and applied using various methods. These methods include swipe loading, pressure loading and syringe loading. A volatile mobile phase may be added to the slurry so as to partially dissolve the energetic material so that, upon evaporation of the mobile phase, the energetic material precipitates and adheres to the loading hole.

Methods for making and using high explosive fills for very small volume applications

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Succasunna, NJ, United States of America

Neha Mehta