Abstract:
A self igniting pyrotechnical sparkler. The sparkler includes a nonflammable support member or rod substantially covered with a pyrotechnic coating composition along one end and a pyrotechnical igniter coating covering over part of the pyrotechnic coating. The igniter coating including a mixture of potassium chlorate, antimony sulfate, powder aluminum, particulate magnesium, binder and/or glass beads.

Description:
CLAIM OF PRIORITY 
     This invention claims the benefit of U.S. Provisional Application No. 61/323,056, filed on Apr. 12, 2010. 
    
    
     BACKGROUND OF THE INVENTION 
     Sparklers are non-explosive, pyrotechnic devices which have been enjoyed for many years. They are basically comprised of a wire rod with a pyrotechnic coating composition which extends substantially the length of the rod. The uncoated portion of the rod serves as a handle. The composition is ignited by the use of a match or similar fire producing device which serves to initiate the pyrotechnic display of sparks emanating from the composition on the sparkler&#39;s rod. 
     It is well known that it is difficult to initiate sparklers because of the time it takes for the match or external flame to heat and ignite the pyrotechnic material. This can be dangerous to those igniting them, especially younger persons. Accordingly, it is an object of the present invention to provide a sparkler which can be ignited quickly, easily, and safely without the necessity of an external source of a flame. Furthermore, the invention provides a sparkler having an end with an additional pyrotechnic composition that permits the user to ignite it by striking the end on a safety striking surface such as that found on the packages of safety matches. The striking composition at the end of sparkler operates to initiate the sparkler pyrotechnic on the first or second striking. This striking is done safely away from the sparkling pyrotechnic which could otherwise burn the fingers of a user attempting to hold a lighted match under prior art sparklers. Other advantages of the present invention will become apparent from the detailed description of the present invention. 
     SUMMARY OF THE INVENTION 
     Various embodiments of the present invention are directed to a self igniting pyrotechnical sparkler for use with a safety strike surface having a rod which includes a pyrotechnic coating composition capable of producing sparks on ignition which covers a substantial length of the rod and the uncoated portion of the rod comprising a handle to hold such rod. A pyrotechnical igniter coating is positioned over the coating composition at the end opposite from the handle for striking a safety strike surface. The pyrotechnical igniter coating is preferably positioned directly over part of the pyrotechnic coating on the rod at the end opposite the handle. 
     Various embodiments of the invention are directed to a mixture of particulate potassium chloride, antimony sulfate, powder aluminum, particulate magnesium, cellulose nitrate and glass beads. These particulates are preferably in sizes between about 7 to 00 μm. The cellulose nitrate preferably includes 25 wt % of nitrocellulose lacquer. 
     Those and other details, objects and advantages of the present invention will become better understood or apparent from the following description and drawing showing an embodiment thereof. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Embodiments of the present invention are described herein by way of example in conjunction with the following figures: 
         FIG. 1  is a perspective view of a sparkler according to various embodiments of the invention. 
         FIG. 2  is a perspective view of a sparkler with an end cut way view according to various embodiments of the invention. 
     
    
    
     DESCRIPTION 
     Embodiments of the present invention are directed to a self-ignitable sparkler.  FIG. 1  depicts a self-igniting sparkler  10  according to various embodiments of the present invention. Sparkler  10  comprises a support member or rod  11 , such as a metal wire or other nonflammable material. Support member  11  provides a handle  12  at one end and a first pyrotechnic composition coating  13  extending the remaining length of member  11 . First pyrotechnic coating  13  is a conventional mixture of pyrotechnic materials. Coating  13  is preferably placed on member  11  by means of a multi-step slurry dipping process known in the prior art. The chemistries of the prior art processes can provide various additives to enhance the sparkling action or color renditions of the sparks and do not constitute a part of the invention. 
     At the end of rod  11  opposite from handle  12 , is initiator coating  15 . Igniter coating  15  is preferably a composition selected from those described hereinafter which is coated over composition coating  13  by a dipping process in, for example, an additional dipping station. Initiator coating  15  is bonded to the pyrotechnic composition coating  13 . The composition of igniter coating  15  is ignited upon striking igniter coating  15  on the ignition pad of a safety match box or envelope. In preferred embodiments of the invention, the results of testing indicate that the functionality of the composition mixture is highly dependent upon the particle size of the components as well as the amount of binder that is present in the solution. The formulations shown below in the presently preferred embodiments resulted in observed ignitions 95% of the time. 
     The details of preferred compositions are listed in the Tables below. The results and any observations made during each evaluation immediately follow a number of the tables. Particle analysis was not performed on the antimony sulfate due to the limited amount and high cost of this material. The antimony sulfate powder appeared to be very fine and mixed well with the potassium chlorate. Results from the tests indicate that the functionality of the mixture is highly dependent upon the particle size of the components as well as the amount of binder that is present in the solution. The formulation shown for example in Table 6 below resulted in 36 observed ignitions out of the 38 samples tested. Examples of preferred embodiments of the present invention are set forth below. 
     Various formulations were prepared by using the following general procedure. Potassium chlorate was first crushed into a fine powder. This was done to break up larger chunks that had formed in the powder due to the hygroscopic properties of potassium chlorate. The potassium chlorate was then weighed and transferred into a container. Next, antimony sulfate was weighed and transferred into the container of the potassium chlorate. The contents of that container were then slowly stirred into a uniform mixture. 
     The selected amounts of aluminum powder and magnesium were then weighed and transferred to an empty container. This mixture was then slowly stirred into a uniform mixture. The contents from the container containing the oxidizers were then slowly transferred to the container containing the metals and the mixture was stirred. 
     Thereafter, the desired amount of nitrocellulose was weighed and transferred to the mixture. The mass of this combined mixture was recorded. Next, acetone was added to the solution for viscosity of the mixture for dipping purposes and to see if it stayed on or stuck to the pyrotechnic coating  13 . The resulting mixture was stirred until it appeared to be uniform. Crushed glass was then added and the mixture was stirred until the solution became “soup-like” in appearance. 
     The tip ends of commercially available sparklers were then dipped into the resulting soup-like solution twice, allowing approximately 2 minutes of drying time between each application. Once all of the samples were dipped, they were allowed to air dry for approximately 1 hour in a fume hood. The samples were then transferred to a vacuum oven and allowed to dry for 12 hours at 60° C. Once dried, the samples were evaluated by striking the ends of the sparklers on a match book striking surface. Observations of ignition, sparks, or no-ignition were made and recorded. Up to 5 strikes were attempted on each sparkler. If the sparkler ignited, the number of strikes attempted before ignition was recorded. 
     Compositions Tested 
     A number of compositions prepared in accordance with the invention were tested. The results and any observations made during test evaluations of the present invention are set forth below. 
     
       
         
               
               
               
               
               
             
               
               
               
               
               
             
           
               
                   
               
               
                   
                 Particle 
                 Volume 
                 Mass 
                 Weight 
               
               
                 Component 
                 Size (μm) 
                 (mL) 
                 (g) 
                 Percent 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Potassium Chlorate 
                 32 
                 — 
                 4.22 
                 40.15% 
               
               
                 Antimony (III) Sulfate 
                 — 
                 — 
                 1.05 
                  9.99% 
               
               
                 Aluminum Powder 
                 37 
                 — 
                 1.05 
                  9.99% 
               
               
                 Magnesium 
                 201 
                 — 
                 0.23 
                  2.19% 
               
               
                 Collodion (4%-8%) 
                 — 
                 ~13.5* 
                 0.81 
                  7.71% 
               
               
                 Ground Glass (250 micron) 
                 79 
                 — 
                 2.1 
                 19.98% 
               
               
                 Ground Glass (500 micron)  
                 96 
                 — 
                 1.05 
                  9.99% 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
             
               
               
               
               
               
             
           
               
                   
               
               
                   
                 Particle 
                 Volume 
                 Mass 
                 Weight 
               
               
                 Component 
                 Size (μm) 
                 (mL) 
                 (g) 
                 Percent 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Potassium Chlorate 
                 32 
                 — 
                 4.2172 
                 40.74% 
               
               
                 Antimony (III) Sulfate 
                 — 
                 — 
                 1.0500 
                 10.14% 
               
               
                 Aluminum Powder 
                 8 
                 — 
                 1.0486 
                 10.13% 
               
               
                 Magnesium 
                 61 
                 — 
                 0.2084 
                  2.01% 
               
               
                 Nitrocellulose Lacquer 
                 — 
                 ~2.7* 
                 0.6700 
                  6.47% 
               
               
                 (25%) 
                   
                   
                   
                   
               
               
                 Glass (−60 mesh)  
                 216 
                 — 
                 2.1114 
                 20.40% 
               
               
                 Glass (−100 mesh)  
                 78 
                 — 
                 1.0459 
                 10.10% 
               
               
                 Acetone 
                 — 
                  7  
                 — 
                 — 
               
               
                   
               
             
          
         
       
     
     In this example, 2 out of the 5 sparklers ignited. 
     The remaining 3 that did not ignite sparked during the striking procedure. In addition to the sparklers, five wooden sticks were dipped and tested and all five ignited. During the striking attempts, the samples that did not ignite produced burning particles that flew off of the sample. This prevents flame propagation to occur on the sparkler and creates a potential burn hazard. The particle size of the aluminum was increased for this composition in attempt to slow down the burn rate of samples and prevent particles from igniting so rapidly that they become detached from the sparkler 
     
       
         
               
               
               
               
               
             
           
               
                   
               
               
                   
                 Particle 
                 Volume 
                 Mass 
                 Weight 
               
               
                 Component 
                 Size (μm) 
                 (mL) 
                 (g) 
                 Percent 
               
               
                   
               
             
             
               
                 Potassium Chlorate 
                 32 
                 — 
                 4.2255 
                 39.33% 
               
               
                 Antimony (III) Sulfate 
                 — 
                 — 
                 1.0510 
                  9.78% 
               
               
                 Aluminum Powder 
                  7 
                 — 
                 1.0547 
                  9.82% 
               
               
                 Magnesium 
                 61 
                 — 
                 0.2153 
                  2.00% 
               
               
                 Nitrocellulose Lacquer 
                 — 
                 ~4.6* 
                 1.0305 
                  9.59% 
               
               
                 (25%) 
                   
                   
                   
                   
               
               
                 Glass (−60 mesh) 
                 216  
                 — 
                 2.1171 
                 19.70% 
               
               
                 Glass (−100 mesh) 
                 78 
                 — 
                 1.0506 
                  9.78% 
               
               
                 Acetone 
                 — 
                  5  
                 — 
                 — 
               
               
                   
               
             
          
         
       
     
     The nitrocellulose binder component was increased in this mixture to better hold the composition together during the striking procedure. In this example, 3 out of the 6 sparklers ignited after 2 or 3 strikes. 
     
       
         
               
               
               
               
               
             
           
               
                   
               
               
                   
                 Particle 
                 Volume 
                 Mass 
                 Weight 
               
               
                 Component 
                 Size (μm) 
                 (mL) 
                 (g) 
                 Percent 
               
               
                   
               
             
             
               
                 Potassium Chlorate 
                 32 
                 — 
                 4.2209 
                 37.53% 
               
               
                 Antimony (III) Sulfate 
                 — 
                 — 
                 1.0464 
                  9.30% 
               
               
                 Aluminum Powder 
                  7 
                 — 
                 1.0564 
                  9.39% 
               
               
                 Magnesium 
                 61 
                 — 
                 0.2078 
                  1.85% 
               
               
                 Nitrocellulose Lacquer 
                 — 
                 ~6.5* 
                 1.5499 
                 13.78% 
               
               
                 (25%) 
                   
                   
                   
                   
               
               
                 Glass (−60 mesh) 
                 216  
                 — 
                 2.1137 
                 18.80% 
               
               
                 Glass (−100 mesh) 
                 78 
                 — 
                 1.0508 
                  9.34% 
               
               
                 Acetone 
                 — 
                  5  
                 — 
                 — 
               
               
                   
               
             
          
         
       
     
     The nitrocellulose binder component was doubled for this composition. 12 out of 12 sparklers ignited after 1 to 2 strikes. 
     
       
         
               
               
               
               
               
             
           
               
                   
               
               
                   
                 Particle  
                 Volume 
                 Mass 
                 Weight 
               
               
                 Component 
                 Size (μm) 
                 (mL) 
                 (g) 
                 Percent 
               
               
                   
               
             
             
               
                 Potassium Chlorate 
                 32 
                 — 
                 4.2232 
                 37.59% 
               
               
                 Antimony (III) Sulfate 
                 — 
                 — 
                 1.0531 
                  9.37% 
               
               
                 Aluminum Powder 
                  7 
                 — 
                 1.0546 
                  9.39% 
               
               
                 Magnesium 
                 61 
                 — 
                 0.2106 
                  1.87% 
               
               
                 Nitrocellulose Lacquer 
                 — 
                 ~6.5* 
                 1.5306 
                 13.62% 
               
               
                 (25%) 
                   
                   
                   
                   
               
               
                 Glass (−60 mesh) 
                 216  
                 — 
                 2.1144 
                 18.82% 
               
               
                 Glass (−100 mesh) 
                 78 
                 — 
                 1.0486 
                  9.33% 
               
               
                   
               
             
          
         
       
     
     The composition in Example 4 was replicated. The dipping procedure began using a slightly more dilute solution and a thinner application was noted on some of the samples. In this example, 24 out of 26 sparklers ignited. 
     
       
         
               
             
               
               
               
               
             
           
               
                   
               
               
                 Presently Preferred Embodiment 
               
             
          
           
               
                   
                   
                 Particle  
                 Weight 
               
               
                   
                 Component 
                 Size 
                 Percent 
               
               
                   
                   
               
               
                   
                 Potassium Chlorate 
                  32 μm 
                 37.3% 
               
               
                   
                 Antimony Trisulfide 
                 — 
                  9.3% 
               
               
                   
                 Aluminum Powder (3 μm) 
                   7 μm 
                  9.3% 
               
               
                   
                 Magnesium (74 μm-44 μm) 
                  61 μm 
                  1.8% 
               
               
                   
                 Cellulose Nitrate (25 wt. % 
                 — 
                 14.4% 
               
               
                   
                 Nitrocellulose Lacquer) 
                   
                   
               
               
                   
                 Glass (−60 Mesh) 
                 216 μm 
                 18.7% 
               
               
                   
                 Glass (−100 Mesh) 
                  78 μm 
                  9.2% 
               
               
                   
                   
               
             
          
         
       
     
     Three additional compositions were formulated using the same procedure set forth above in Example 6. The details of each composition are listed below. Please note that particle analysis was not performed on the antimony sulfate due to the limited amount and high cost of this material. However, this powder appeared to be very fine and mixed well with the potassium chlorate. 
     
       
         
               
               
               
               
               
             
           
               
                   
               
               
                   
                 Particle 
                 Volume 
                 Mass  
                 Weight 
               
               
                 Component 
                 Size (μm) 
                 (mL) 
                 (g) 
                 Percent 
               
               
                   
               
             
             
               
                 Potassium Chlorate 
                 32 
                 — 
                 4.2285 
                 33.94% 
               
               
                 Antimony (III) Sulfate 
                 — 
                 — 
                 1.0523 
                  8.45% 
               
               
                 Aluminum Powder 
                  7 
                 — 
                 1.0498 
                  8.43% 
               
               
                 Magnesium 
                 61 
                 — 
                 0.2111 
                  1.69% 
               
               
                 Nitrocellulose Lacquer 
                 — 
                 ~3.3* 
                 2.7539 
                 22.10% 
               
               
                 (25%) 
                   
                   
                   
                   
               
               
                 Glass (−60 mesh) 
                 216  
                 — 
                 2.1149 
                 16.97% 
               
               
                 Glass (−100 mesh) 
                 78 
                 — 
                 1.0491 
                  8.42% 
               
               
                 Acetone 
                 — 
                  5  
                 — 
                 — 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
             
           
               
                   
               
               
                   
                 Particle  
                 Volume 
                 Mass 
                 Weight 
               
               
                 Component 
                 Size (μm) 
                 (mL) 
                 (g) 
                 Percent 
               
               
                   
               
             
             
               
                 Potassium Chlorate 
                 32 
                 — 
                 4.2271 
                 36.97% 
               
               
                 Antimony (III) Sulfate 
                 — 
                 — 
                 1.0492 
                  9.18% 
               
               
                 Aluminum Powder 
                  7 
                 — 
                 1.0501 
                  9.18% 
               
               
                 Magnesium 
                 61 
                 — 
                 0.211  
                  1.85% 
               
               
                 Nitrocellulose Lacquer 
                   
                 ~2.8* 
                 1.7403 
                 15.22% 
               
               
                 (25%) 
                   
                   
                   
                   
               
               
                 Glass (−60 mesh) 
                 216  
                 — 
                 2.1109 
                 18.46% 
               
               
                 Glass (−100 mesh) 
                 78 
                 — 
                 1.0449 
                  9.14% 
               
               
                 Acetone 
                 5 
                 — 
                 — 
                 — 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
             
           
               
                   
               
               
                   
                 Particle 
                 Volume 
                 Mass  
                 Weight 
               
               
                 Component 
                 Size (μm) 
                 (mL) 
                 (g) 
                 Percent 
               
               
                   
               
             
             
               
                 Potassium Chlorate 
                 32 
                 — 
                 4.216   
                 37.26% 
               
               
                 Antimony Trisulfide 
                 — 
                 — 
                 1.0492  
                  9.27% 
               
               
                 Aluminum Powder 
                  7 
                 — 
                 1.0483  
                  9.27% 
               
               
                 Magnesium 
                 61 
                 — 
                 0.2091  
                  1.85% 
               
               
                 Nitrocellulose Lacquer 
                 — 
                 ~2.8* 
                 1.63013 
                 14.41% 
               
               
                 (25%) 
                   
                   
                   
                   
               
               
                 Glass (−60 mesh) 
                 216  
                 — 
                 2.1144  
                 18.69% 
               
               
                 Glass (−100 mesh) 
                 78 
                 — 
                 1.0471  
                  9.25% 
               
               
                 Acetone 
                 — 
                  5  
                 — 
                 — 
               
               
                   
               
             
          
         
       
     
     In Example 9, Antimony trisulfide was substituted for antimony (III) sulfate and 20 out of 20 sparklers ignited after 1 to 2 strikes. It should be noted that these tests were conducted using a very worn striking surface. When a fresh standard matchbook surface was used, 10 out of 10 ignited on the first strike. Application of this composition to the sparklers resulted in a sparkler that was very easy to ignite and produced an initial burn that was very similar to that of a sparkler that was not dipped in the composition. 
     Observations made during the evaluations of these compositions show that the binder (nitrocellulose) needs to account for approximately 14.4 wt % of the solution. Compositions with lower binder levels are not preferred nor are binder levels higher than 22.1 wt %. Sparklers were ignited when the binder accounted for 22.1 wt %; however, several attempts (3 strikes or greater) were necessary for ignition to occur. 
     While several embodiments of the invention have been described, it should be apparent that various modifications, alterations and adaptations to those embodiments may occur to persons skilled in the art with the attainment of some or all of the advantages of the present invention. It is therefore intended to cover all such modifications, alterations and adaptations without departing from the scope and spirit of the present invention.