Thiokol Corporation

Morton International, Inc.

Cordant Technologies Inc.

W Wayne Edwards

Robert B Wardle

Gary K Lund

Jerald C Hinshaw

Thomas K Highsmith

Graham C Shaw

Mikel R Stevens

Energetic polymers and methods for their synthesis are provided. The polymers are preferably produced from cyclic ether monomers having 4 or 5 member rings. The cyclic ether monomers preferably include energetic functional groups such that a polymer formed from the monomer is itself energetic. Polymerization is catalyzed by a combination of alkylating salt and alcohol. The preferred salts are triethoxonium salts with anions such as hexafluorophosphate, hexachloroantimonate, and tetrafluoroborate. It is found that by employing the combination of selected triethoxonium salts and selected alcohols that it is possible to produce an energetic polymer with predetermined functionality and molecular weight. The salt is found to scavenge water in the reaction mixture, thus increasing control over the functionality of the final product. The salt-alcohol combination also rapidly initiates polymerization and allows higher molecular weights to be achieved. This is particularly important in that one limitation previously experienced in polymerization of the types of monomers used in this invention was an inability to achieve rapid and complete polymerization.

Methods for controlled polymerization of energetic cyclic ethers using

A process for the hydrogenolysis of 2,4,6,8,10,12-hexabenzyl-2,4,6,8,10,12-hexaazatetracyclo�5.5.0.0.sup.5,9.0 .sup.3,11 !dodecane ('HBIW') is disclosed. In the process, a quantity of HBIW, a cosolvent, and a bromine source are placed into a reaction vessel. Acetic anhydride and a palladium hydrogenolysis catalyst are rapidly added to the reaction vessel. The hydrogenolysis catalyst should be substantially free of water. The reaction vessel is purged of an atmosphere capable of reacting with hydrogen, and hydrogen is quickly introduced into the reaction vessel to convert the HBIW to tetraacetyldibenzylhexaazaisowurtzitane ('TADB'). The acetic anhydride is added immediately prior to hydrogen introduction so that the acetic anhydride does not have time to react with the HBIW to form an acetylated derivative prior to commencement of the desired hydrogenation reaction. The process requires very little palladium catalyst, preferably less than 10% wt/wt based on the HBIW substrate. The TADB, precipitated on the palladium hydrogenolysis catalyst, is subjected to a second hydrogenation step using a formic acid solvent in the presence of hydrogen to form tetraacetyldiformylhexaazaisowurtzitane ('TADF').

Hydrogenolysis of

A method of preparing a thermoplastic elastomer having A blocks and at least one B block, wherein said A blocks are crystalline at temperatures below about 60.degree. C. and said B block is amorphous at temperatures above about -20.degree. C., said A blocks each being polyethers derived from monomers of oxetane and its derivatives and/or tetrahydrofuran and its derivatives, the method comprising: providing monofunctional hydroxyl terminated A blocks which are crystalline at temperatures below about 60.degree. C. and separately providing di-, tri- or tetrafunctional hydroxyl terminated B blocks which are amorphous at temperatures above about -20.degree. C., end-capping said A blocks by separately reacting said A blocks with a difunctional diisocyanate in which one isocyanate moiety is at least about five times as reactive with the terminal hydroxyl group of the A blocks as the other isocyanate moiety, whereby the more reactive isocyanate moiety tends to react with the terminal hydroxyl group of the A blocks, leaving the less reactive isocyanate moiety free and unreacted, and adding di-, tri- or tetrafunctional B block to the end-capped A blocks at approximately the stoichiometric ratios that they are intended to be present in the thermoplastic elastomer such that the free and unreacted isocyanate moiety on the end-capped A block reacts with a functional moiety of the B block to produce ABA or A.sub.n B thermoplastic elastomers.

Method of producing thermoplastic elastomers having alternate

4,10-dinitro-2,6,8,12-tetraoxa-4,10-diazatetracyclo[5.5.0.0.sup.5,9 0.sup.3,11 ]dodecane is synthesized by reacting a diacyl-2,3,5,6-tetraoxypiperazine or tetraoxadiazaisowurtzitane derivative, a strong acid, and a nitrate source, such that an exothermic reaction occurs which proceeds at a temperature above ambient temperature. The reaction product is precipitated by cooling. It may be purified by washing with methanol and/or sodium bicarbonate and by simmering in nitric acid.

Synthesis of

Gas generating compositions or propellants are provided which comprise a non-azide fuel which is a transition metal complex of an aminoarazole. Preferred transition metal complexes are zinc and copper complexes of 5-aminotetrazole and 3-amino-1,2,4-triazole, with the zinc complexes most preferred. The propellant compositions also include a conventional oxidizer, such as potassium nitrate or strontium nitrate. These compositions are useful for generating a nitrogen-containing gas for a variety of applications, especially for inflating air bags in automotive restraint systems, as well as other inflatable devices.

Non-azide gas generant formulation, method, and apparatus

Automotive airbag gas generant formulation providing alternative to commercially used formulations containing sodium azide. The composition comprises from about 25% to about 75% by weight of a heterocyclic compound having the following structure: ##STR1## wherein R is selected from hydrogen,

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Tremonton, UT, United States of America

W Wayne Edwards