VARIABLE STAND-OFF ASSEMBLY

Abstract

A variable stand-off distance explosive cord assembly for a casing is disclosed. In various embodiments, the assembly includes an explosive cord configured for positioning at a stand-off distance from the casing and a thermally responsive material configured to vary the stand-off distance from a first distance to a second distance.

Claims

1. A variable stand-off distance explosive cord assembly for a casing, comprising: an explosive cord configured for positioning at a stand-off distance from the casing; and a thermally responsive material configured to vary the stand-off distance from a first distance to a second distance.

2. The variable stand-off distance explosive cord assembly of claim 1, wherein the thermally responsive material is positioned between the casing and the explosive cord.

3. The variable stand-off distance explosive cord assembly of claim 2, wherein the explosive cord defines a length along the casing and wherein the thermally responsive material extends along at least a portion of the length of the explosive cord.

4. The variable stand-off distance explosive cord assembly of claim 3, wherein the thermally responsive material comprises a plurality of blocks spaced along the length.

5. The variable stand-off distance explosive cord assembly of claim 3, wherein the thermally responsive material extends along the length of the explosive cord.

6. The variable stand-off distance explosive cord assembly of claim 3, wherein, following ignition of the explosive cord, the first distance is configured to result in a scoring of the casing.

7. The variable stand-off distance explosive cord assembly of claim 6, wherein, following ignition of the explosive cord, the second distance is configured to result in a cutting through of the casing.

8. The variable stand-off distance explosive cord assembly of claim 7, wherein the explosive cord is a linear shaped charge.

9. The variable stand-off distance explosive cord assembly of claim 1, wherein the explosive cord is positioned between the thermally responsive material and the casing.

10. The variable stand-off distance explosive cord assembly of claim 9, wherein, following ignition of the explosive cord, the first distance is configured to result in a scoring of the casing.

11. The variable stand-off distance explosive cord assembly of claim 10, wherein, following ignition of the explosive cord, the second distance is configured to result in a cutting through of the casing.

12. The variable stand-off distance explosive cord assembly of claim 11, wherein the explosive cord is a linear shaped charge.

13. A rocket motor, comprising: a casing; an explosive cord configured for positioning at a stand-off distance from the casing; and a thermally responsive material configured to vary the stand-off distance from a first distance to a second distance.

14. The rocket motor of claim 13, wherein the thermally responsive material is positioned between the casing and the explosive cord.

15. The rocket motor of claim 14, wherein the explosive cord defines a length along the casing and wherein the thermally responsive material extends along at least a portion of the length of the explosive cord.

16. The rocket motor of claim 15, wherein the thermally responsive material extends along the length of the explosive cord.

17. The rocket motor of claim 15, wherein, following ignition of the explosive cord, the first distance is configured to result in a scoring of the casing.

18. The rocket motor of claim 17, wherein, following ignition of the explosive cord, the second distance is configured to result in a cutting through of the casing.

19. A propellant containing device, comprising: a casing enclosing an explosive charge; an explosive cord configured for positioning at a stand-off distance from the casing; and a thermally responsive material configured to vary the stand-off distance from a first distance to a second distance.

20. The propellant containing device of claim 19, wherein, following ignition of the explosive cord, the first distance is configured to result in a scoring of the casing, and, following ignition of the explosive cord, the second distance is configured to result in a cutting through of the casing.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The subject matter of the present disclosure is particularly pointed out and distinctly claimed in the concluding portion of the specification. A more complete understanding of the present disclosure, however, may best be obtained by referring to the following detailed description and claims in connection with the following drawings. While the drawings illustrate various embodiments employing the principles described herein, the drawings do not limit the scope of the claims.

[0011] FIGS. 1A and 1B are side and axial views, respectively, of a casing configured for carrying an energetic material interior to the casing, in accordance with various embodiments;

[0012] FIGS. 2A and 2B are side and axial views, respectively, of a variable stand-off mechanism, in accordance with various embodiments;

[0013] FIG. 3 is a graph generally depicting penetration depth as a function of standoff distance for a linear shaped charge, in accordance with various embodiments;

[0014] FIGS. 4A and 4B are axial views of a variable stand-off mechanism having an under-mount configuration, in accordance with various embodiments; and

[0015] FIGS. 5A and 5B are axial views of a variable stand-off mechanism having an over-mount configuration, in accordance with various embodiments.

DETAILED DESCRIPTION

[0016] The following detailed description of various embodiments herein makes reference to the accompanying drawings, which show various embodiments by way of illustration. While these various embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, it should be understood that other embodiments may be realized and that changes may be made without departing from the scope of the disclosure. Thus, the detailed description herein is presented for purposes of illustration only and not of limitation. Furthermore, any reference to singular includes plural embodiments, and any reference to more than one component or step may include a singular embodiment or step. Also, any reference to attached, fixed, connected, or the like may include permanent, removable, temporary, partial, full or any other possible attachment option. Additionally, any reference to without contact (or similar phrases) may also include reduced contact or minimal contact. It should also be understood that unless specifically stated otherwise, references to a, an or the may include one or more than one and that reference to an item in the singular may also include the item in the plural. Further, all ranges may include upper and lower values and all ranges and ratio limits disclosed herein may be combined.

[0017] Referring now to the drawings, FIGS. 1A and 1B schematically illustrate a rocket motor 100 which, in various embodiments, may be a component of a rocket or some other device configured to contain a propellant or other energetic material. As described herein, the rocket motor 100 may include a first end 102 and a second end 104 spaced from the first end 102 along a central or longitudinal axis, C. In various embodiments, a cone 106 may be configured for positioning at the first end 102 and a nozzle 108 may be configured for positioning at the second end 104. Typically, the rocket motor 100 includes a casing 110 that houses a propellant 112 which, when ignited, exhausts through the nozzle 108, providing the rocket motor 100 with thrust. In various embodiments, the casing 110 is provided with an explosive thermal cord 114, configured to score or cut through the surface of the casing 110 when certain thermal events arise. By way of non-limiting example, in various embodiments, the explosive thermal cord 114 may comprise a linear shaped charge 116 positioned on and oriented longitudinally along the casing 110. The linear shaped charge 116, in various embodiments, is positioned adjacent a charge support member 120 and housed within a protective outer sheath 122.

[0018] As described further below, in various embodiments, the explosive thermal cord 114 or linear shaped charge 116 is configured to either score an outer surface 124 of the casing 110 or cut completely through the casing 110 depending on whether the rocket motor 100 is exposed to a fast cook-off event (e.g., rapid heating, on the order of seconds or minutes, resulting from direct contact with a flame) or a slow cook-off (e.g., slow heating, on the order of hours or days, resulting from indirect contact with a heat source) event, respectively. During a fast cook-off event, for example, longitudinal scoring of the outer surface 124 of the casing 110 provides a longitudinally stressed portion that allows the casing 110 to rupture longitudinally in the event propellant grains adjacent an inner surface 126 of the casing 110 ignite, thereby venting the resulting combustion products (typically at high pressure) through the ruptured portions of the casing 110, rather than through the nozzle 108. Venting the combustion products through the side of the casing 110 prevents the rocket motor 100 from uncontrolled flight following ignition of the propellant 112 proximate the inner surface 126 due to heating of the casing 110 from direct exposure to fire (e.g., a fast cook-off event), which may occur during storage or transport or even while the rocket motor 100 is secured, for example, under the wing or fuselage of an aircraft prior to flight. During a slow cook-off event, longitudinal cuts through the casing, from the outer surface 124 to the inner surface 126, reduce the likelihood of a detonation of the propellant 112, in its entirety, following simultaneous autoignition of most, if not all, of the propellant within the casing 110.

[0019] Referring now to FIGS. 2A and 2B, schematic side and axial views of a section of a casing 210 having a linear shaped charge 216 positioned thereon, respectively, are provided in accordance with various embodiments. A first variable stand-off mechanism 230 is provide at a first location and a second variable stand-off mechanism 232 is provided at a second location, spaced longitudinally along a central or longitudinal axis, C, from the first location. In various embodiments, the linear shaped charge 216 is positioned at a stand-off distance 234 from an outer surface 224 of the casing 210. The stand-off distance 234 may be defined, in various embodiments, as the distance running normal from the outer surface 224 of the casing 210 to an inner apex 236 of the linear shaped charge 216. Referring briefly to FIG. 3, a graph 300 depicts a typical relationship between penetration depth (y-axis) and stand-off distance (x-axis) for a linear shaped charge, such as the linear shaped charge 216 illustrated in FIGS. 2A and 2B. As depicted, an optimal stand-off distance is typical for any combination of characteristics of the linear shaped charge, which characteristics may include, for example, the type of explosive and ignition source and the materials or liner types used, if any, to surround the linear shaped charge. As will be described further below, in various embodiments, variable stand-off mechanisms, such as the first variable stand-off mechanism 230 and the second variable stand-off mechanism 232 described above, as well as the various embodiments described below, may be employed to control the penetration distance into a casing based on the environment surrounding the casing. More specifically, in various embodiments, variable stand-off mechanisms may be employed to control the degree of penetration into a casing based on whether the casing is subjected to thermal environments leading to slow cook-off or fast cook-off events.

[0020] Returning now to FIGS. 2A and 2B, in various embodiments, a first material 238 may be positioned below the linear shaped charge 216 or between the outer surface 224 of the casing 210 and an inner surface 240 of the linear shaped charge 216. Similarly, in various embodiments, a second material 242 may be positioned above the linear shaped charge 216 or adjacent an outer surface 244 of the linear shaped charge 216. In various embodiments, a protective outer sheath 222 may enclose the linear shaped charge 216, the first material 238 and the second material 242. In various embodiments, the first material 238 and the second material 242 may be selected such that their respective coefficients of thermal expansion result in the linear shaped charge 216 being urged either toward or away from the penetration surface, such as the outer surface 224 of the casing 210, depending on changes in the surrounding ambient temperature. Thus, for example, assuming a first coefficient of thermal expansion (e.g., linear expansion), .sub.1, of the first material 238 is greater in value than a second coefficient of thermal expansion, .sub.2, of the second material 242, then an increase in temperature will result in the first material 238 urging the linear shaped charge 216 farther away from the outer surface 224 of the casing 210. Similarly, assuming the first coefficient of thermal expansion, .sub.1, of the first material 238 is lesser in value than the second coefficient of thermal expansion, .sub.2, of the second material 242, then an increase in temperature will result in the second material 242 urging the linear shaped charge 216 closer to the outer surface 224 of the casing 210. As described further below, this feature of the variable stand-off mechanisms disclosed herein may be employed to adjust the expected penetration distance into a casing as a function of temperature.

[0021] Still referring to FIGS. 2A and 2B, in various embodiments, the first material 238 and the second material 242 are confined substantially to an axial dimension of a variable stand-off mechanism, such as, for example, a first axial dimension 246 of the first variable stand-off mechanism 230 and a second axial dimension 248 of the second variable stand-off mechanism 232. Thus, in various embodiments, a series of variable stand-off mechanisms, N in number, may be positioned along the length or a portion thereof of the linear shaped charge 216. In various embodiments, however, the first material 238 and the second material 242 may extend along the length of the linear shaped charge 216, providing, in essence, a continuous variable stand-off mechanism extending the length of the linear shaped charge 216.

[0022] Referring now to FIGS. 4A and 4B, axial views of a variable stand-off mechanism 430 having an under-mount configuration are provided, in accordance with various embodiments. As illustrated, a section of a casing 410 has a linear shaped charge 416 positioned above a thermally responsive material 438; or, with regard to a general orientation, the thermally responsive material 438 is positioned between the casing 410 and the linear shaped charge 416. In various embodiments, the thermally responsive material 538 is characterized by a coefficient of thermal expansion (e.g., linear expansion), a. Referring to FIG. 4A, the linear shaped charge 416 is spaced an initial stand-off distance 433 from an outer surface 424 of the casing 410. The initial stand-off distance 433 will remain constant or nearly constant at an initial ambient temperature, T.sub.0. In various embodiments, the initial stand-off distance 433 is sub-optimal in the sense of maximizing the penetration depth into the casing 410 following ignition of the linear shaped charge 416. With brief reference to FIG. 3, the initial stand-off distance 433 may be characterized as an initial stand-off distance 333 positioned to the left of (i.e., lesser in value than) an optimal stand-off distance 335.

[0023] Referring now to FIG. 4B, when exposed to an ambient temperature, T.sub.A, greater than the initial ambient temperature, T.sub.0, the thermally responsive material 438 will increase in length by a value proportional to the coefficient of thermal expansion, . Stated generally, the increase in length may be estimated by the relation L/La T, where L may be considered an initial length 439 of the thermally responsive material 438 (which is also the initial stand-off distance 433) and T=T.sub.AT.sub.0. Thus, as indicated in FIG. 4B, a second stand-off distance 435, greater in value than the initial stand-off distance 433, will result following the thermally responsive material being exposed to a temperature T.sub.A>T.sub.0. In various embodiments, the second stand-off distance 435 is optimal in the sense of maximizing the penetration depth into the casing 410 following ignition of the linear shaped charge 416. With brief reference to FIG. 3, the second stand-off distance 435 may be characterized as the optimal or near optimal stand-off distance 335.

[0024] Referring still to FIGS. 4A and 4B, in various embodiments, the linear shaped charge 416 and the thermally responsive material 438 may be configured such that the initial stand-off distance 433 results in a scoring of the outer surface 424 of the casing 410 following ignition of the linear shaped charge 416. In various embodiments, the scoring of the outer surface 424 is sufficiently deep within the casing 410 to provide a longitudinally stressed portion that allows the casing 410 to rupture longitudinally during a fast cook-off evente.g., where the casing 410 surrounds a propellant 412 within a rocket motor, such as the rocket motor 100 described above with reference to FIG. 1, that is directly exposed to a fire. In various embodiments, a fast cook-off ignition source 450 may be secured directly to or proximate the linear shaped charge 416 and be configured to ignite the linear shaped charge 416 when exposed to a temperature characteristic of a direct flamee.g., a fast cook-off ignition temperature, T.sub.f3000 F.

[0025] Similarly, the linear shaped charge 416 and the thermally responsive material 438 may be configured such that the second stand-off distance 435 results in a complete or substantially complete cutting through of the casing 410 following ignition of the linear shaped charge 416. In various embodiments, the cutting through of the casing 410, from the outer surface 424 to an inner surface 426 of the casing 410, is sufficient to prevent detonation of propellant within the casing during a slow cook-off evente.g., where the casing 410 surrounds the propellant 412 within a rocket motor, such as the rocket motor 100 described above with reference to FIG. 1, that is indirectly exposed to an ambient temperature T.sub.A>T.sub.0, but substantially less than T.sub.f. In various embodiments, a slow cook-off ignition source 452 may be secured directly to or proximate the linear shaped charge 416 and be configured to ignite the linear shaped charge 416 when the temperature of the propellant 412 reaches or exceeds a temperature characteristic of indirect heatinge.g., a slow cook-off ignition temperature, T.sub.s300 F.that occurs over a substantial period of time. As described above, the slow cook-off event may develop over a period of days, whereas a fast cook-off event may develop over a period of seconds or minutes.

[0026] Referring now to FIGS. 5A and 5B, axial views of a variable stand-off mechanism 530 having an over-mount configuration are provided, in accordance with various embodiments. As illustrated, a section of a casing 510 has a linear shaped charge 516 positioned below a thermally responsive material 538; or, with regard to a general orientation, the thermally responsive material 538 is positioned such that the linear shaped charge 516 is between the casing 510 and the thermally responsive material 538. In various embodiments, the thermally responsive material 538 may be secured to a protective outer sheath 522 or similar structure and used to position the linear shaped charge 516 at a stand-off distance from an outer surface 524 of the casing 510. In various embodiments, the thermally responsive material 538 is characterized by a coefficient of thermal expansion (e.g., linear expansion), . As described below, materials contemplated as thermally responsive include those producing a change in length that is on the order of at least about 10%2% of an initial length. Referring to FIG. 5A, the linear shaped charge 516 is spaced an initial stand-off distance 537 from the outer surface 524 of the casing 510. The initial stand-off distance 537 will remain essentially constant at an initial ambient temperature, T.sub.0. In various embodiments, the initial stand-off distance 537 is sub-optimal in the sense of maximizing the penetration depth into the casing 510 following ignition of the linear shaped charge 516. With brief reference to FIG. 3, the initial stand-off distance 537 may be characterized as an initial stand-off distance 337 positioned to the right of (i.e., greater in value than) the optimal stand-off distance 335 described above.

[0027] Referring now to FIG. 5B, when exposed to an ambient temperature, T.sub.A, greater than the initial ambient temperature, T.sub.0, the thermally responsive material 538 will increase in length by a value proportional to the coefficient of thermal expansion, a. Similar to that described above, the increase in length may be estimated by the relation L/L T, where L may be considered an initial length 539 of the thermally responsive material 538 and T=T.sub.AT.sub.0. Thus, as indicated in FIG. 5B, a second stand-off distance 535, lesser in value than the initial stand-off distance 537, will result following the thermally responsive material being exposed to a temperature T.sub.A>T.sub.0. In various embodiments, the second stand-off distance 535 is optimal in the sense of maximizing the penetration depth into the casing 510 following ignition of the linear shaped charge 516. With brief reference to FIG. 3, the second stand-off distance 535 may be characterized as the optimal stand-off distance 335.

[0028] Referring still to FIGS. 5A and 5B, in various embodiments, the linear shaped charge 516 and the thermally responsive material 538 may be configured such that the initial stand-off distance 537 results in a scoring of the outer surface 524 of the casing 510 following ignition of the linear shaped charge 516. In various embodiments, the scoring of the outer surface 524 is sufficiently deep within the casing 510 to provide a longitudinally stressed portion that allows the casing 510 to rupture longitudinally during a fast cook-off evente.g., where the casing 510 surrounds a propellant 512 within a rocket motor, such as the rocket motor 100 described above with reference to FIG. 1, that is directly exposed to a fire. In various embodiments, a fast cook-off ignition source 550 may be secured directly to or proximate the linear shaped charge 516 and be configured to ignite the linear shaped charge 516 when exposed to a temperature characteristic of a direct flamee.g., a fast cook-off ignition temperature, T.sub.f3000 F.

[0029] Similarly, the linear shaped charge 516 and the thermally responsive material 538 may be configured such that the second stand-off distance 535 results in a complete or substantially complete cutting through of the casing 510 following ignition of the linear shaped charge 516. In various embodiments, the cutting through of the casing 510, from the outer surface 524 to an inner surface 526 of the casing 510, is sufficient to prevent detonation of propellant within the casing during a slow cook-off evente.g., where the casing 510 surrounds the propellant 512 within a rocket motor, such as the rocket motor 100 described above with reference to FIG. 1, that is indirectly exposed to an ambient temperature T.sub.A>T.sub.0, but substantially less than T.sub.f. In various embodiments, a slow cook-off ignition source 552 may be secured directly to or proximate the linear shaped charge 516 and be configured to ignite the linear shaped charge 516 when the temperature of the propellant 512 reaches or exceeds a temperature characteristic of indirect heatinge.g., a slow cook-off ignition temperature, T.sub.s300 F.that occurs over a substantial period of time, similar to that described above.

[0030] In various embodiments, the thermally responsive materials described above and employed to translate the explosive thermal cord from an initial stand-off distance to a second stand-off distance comprise materials capable of expansion in a linear direction on the order of at least about 10% (e.g., 102%) under a temperature difference of about 200 F. Suitable classes of such materials include thermoplastic materials, such as, for example, polyether ether ketone (PEEK), acrylonitrile butadiene styrene (ABS) and nylon. These materials exhibit coefficients of thermal expansion, a, on the order of 50E-06/ F. or greater, which results in L/L on the order of 10% at a temperature difference, T, on the order of 200 F. Advantageously, the materials also have melting temperatures sufficiently greater than about 300 F., such that if the ambient temperature does not become high enough to ignite the explosive cord during a slow cook-off event, the thermally responsive material will return to its initial length when the systeme.g., the rocket motor 100 described above with reference to FIG. 1returns to its initial temperature.

[0031] Finally, it should be understood that any of the above described concepts can be used alone or in combination with any or all of the other above described concepts. Although various embodiments have been disclosed and described, one of ordinary skill in this art would recognize that certain modifications would come within the scope of this disclosure. Accordingly, the description is not intended to be exhaustive or to limit the principles described or illustrated herein to any precise form. Many modifications and variations are possible in light of the above teaching. Further, throughout the present disclosure, like reference numbers denote like elements. Accordingly, elements with element numbering may be shown in the figures, but may not necessarily be repeated herein for the sake of clarity.

[0032] Benefits, other advantages, and solutions to problems have been described herein with regard to specific embodiments. Furthermore, the connecting lines shown in the various figures contained herein are intended to represent exemplary functional relationships and/or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical system. However, the benefits, advantages, solutions to problems, and any elements that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements of the disclosure. The scope of the disclosure is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean one and only one unless explicitly so stated, but rather one or more. Moreover, where a phrase similar to at least one of A, B, or C is used in the claims, it is intended that the phrase be interpreted to mean that A alone may be present in an embodiment, B alone may be present in an embodiment, C alone may be present in an embodiment, or that any combination of the elements A, B and C may be present in a single embodiment; for example, A and B, A and C, B and C, or A and B and C. Different cross-hatching is used throughout the figures to denote different parts but not necessarily to denote the same or different materials.

[0033] Systems, methods and apparatus are provided herein. In the detailed description herein, references to one embodiment, an embodiment, various embodiments, etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiments.

[0034] Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. 112(f) unless the element is expressly recited using the phrase means for. As used herein, the terms comprises, comprising, or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.