# Patent

## Title
Low flame smoke

## Abstract

A smoke producing method and device of the present disclosure produces a non-incendiary, organic-polymerization based, smoke-producing reaction. The method of generating smoke comprises initiating a frontal polymerization reaction by heating a composition comprising a monomer compound that exothermically polymerizes upon initiation with an initiator compound and an initiator compound that initiates polymerization of the monomer compound present at a mass concentration that is at least five percent of the mass concentration of the monomer compound. The polymerization of the monomer compound is exothermic, and in one embodiment the concentration of initiator compound is at least five percent of the concentration of monomer compound. The smoke mainly comprises thermal decomposition products of the initiator compound.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 61/643,565 titled “Low Flame Smoke,” filed on May 7, 2012, the entire contents of which are herein incorporated by reference.


GOVERNMENT LICENSE RIGHTS TO CONTRACTOR-OWNED INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
This invention was made with government support under Contract No. W911SR-11-C-0084 awarded by the United States Army. The government has certain rights in the invention.


BACKGROUND
Smoke generation devices generate smoke in military applications for signaling, for marking target or landing zones, and for screening of movements. Devices for producing obscurant smoke for the battlefield are typically either explosively-charged, meaning the devices use an explosive charge to disperse fine particles, or chemically-reactive, meaning a chemical reaction generates smoke. Some chemically-reactive smoke generation devices utilize inorganic materials that are activated in a self-sustaining chemical reaction to produces smoke as a byproduct of the heat generation. Examples of these smoke generation devices are thermite grenades and the HC (hexachloroethane), TA (terephthalic acid), and WP (white phosphorus, or red phosphorus) smoke grenades in the current military inventory. The reactions in these devices have large free energies of reaction, and are by necessity exothermic. As such, the reactions produce considerable heat and toxic, or hazardous, compounds. Typical smoke-producing reactions produce much more heat than is necessary to sustain the reaction. The adiabatic flame temperatures of these materials greatly exceed 1000° C., which is one of the factors that leads to their incendiary characteristics.
Heat generation is an issue with either explosively-charged or chemically-reactive smoke generation devices. Traditional smoke generation devices are incendiary and can set cloth, fuel, ammunition and other combustibles on fire, and cause serious burns or death. What is desired is a smoke producing mixture that is capable of producing smoke while minimizing the incendiary and chemical hazards of present devices.
SUMMARY
A smoke producing method and device of the present disclosure produces a non-incendiary, organic-polymerization based, smoke-producing reaction. In one embodiment, the method of generating smoke comprises initiating a frontal polymerization reaction by heating a composition comprising a monomer compound that exothermically polymerizes upon initiation with an initiator compound, and an initiator compound that initiates polymerization of the monomer compound present at a mass concentration that is at least five percent (5%) of the mass concentration of the monomer compound. In this embodiment, the smoke produced mainly comprises thermal decomposition products of the initiator compound. The initiator may also decompose exothermically. The by-product that results from smoke generation in this embodiment is a solid material that will slowly degrade over time if exposed to outside conditions.
In a typical polymer reaction, the initiator concentration controls the chain length of the produced polymer. Also, in a typical polymer reaction, the initiator is consumed, chemically bonded to the polymeric molecules. In this type of smoke producing reaction the objective, at a minimum, is to decompose and volatilize initiator as well as additives and/or portions of the monomer itself.
Frontal polymerization (FP) is a process in which the reaction propagates directionally through the reaction vessel because of the coupling of thermal transport and the Arrhenius-dependence of the kinetics of an exothermic reaction. Frontal polymerization is very much like a flame but propagating through condensed materials instead of a gas. In frontal polymerization reactions, the components are premixed, but stable until initiated by an external source. For example, consider a 2-part epoxy: as soon as the two components are mixed, an exothermic reaction is initiated). As another example, RTV type polymers will self-initiate once exposed to oxygen. The reactions developed here operate differently than either of these or similar types of examples.
Frontal Polymerization is a form of self-propagating high-temperature synthesis (SPHTS). Here the term “high-temperature” is used to indicate higher than ambient temperature, but certainly lower in temperature than pyrotechnic igniters used in current smoke grenades. In FP as in the case of SPHTS the system will not start reacting until sufficient energy is applied to the material to get a reaction front propagating through the system. This self-propagating wave moves rapidly through the system as long as sufficient heat is generated at the propagation front. Thus, these systems are inherently stable until a sufficient amount of energy is added to start the reaction. Materials with high heat capacity can be incorporated into the mixture. Thus, the system can be turned such that the heat released does not lead to excessive heating of the surrounding environment, thereby reducing incendiary hazards. In other words, the addition of filler materials has the effect of reducing the front temperature and thereby reducing the incendiary hazard since the “excess” heat generated can be “absorbed” in the material itself and not transmitted to the environment.
The reactants used in the smoke producing compounds disclosed herein have reaction temperatures in the range of 300-400° C., (However, as indicated above, the reaction temperature may be tuned to above ambient to 400 C). Thus, even with combustible, low heat capacity materials it is difficult for a device using these materials, particularly the exposed, exterior, material to get above the temperatures necessary to cause structural materials, such as wood, to combust. It is also unlikely that if there were an accidental activation of a device during storage that other devices in the same container would ignite or that other storage containers would be breached. In addition, the manufacture of devices with lower energetic materials is also much less hazardous that current pyrotechnic based devices.
In a typical polymerization compound to make a polymer, the initiator concentrations are on the order of 1% or less by mass. This concentration is expressed in polymer literature as 1 pph (parts per hundred of the monomer). As an example, a 10 gram sample with 20 pph initiator and 10 pph fumed silica contains 10 grams of monomer, 2.0 grams of initiator, and 1.0 grams of fumed silica. In experimental testing of the smoke producing compound of the present disclosure, it was found that increasing the amount of initiator in the compound increased the amount of smoke produced.
Smoke production is caused by a decomposition of the monomer-initiator pair in the smoke generation compound. The fact that smoke production comes from the monomer-initiator pairs has advantages. First, lower reaction temperatures can be used because higher temperatures are not required to volatize a third component in the mixture. Since the initiator is the source of the smoke in this embodiment, it is only necessary to have a sufficient reaction temperature to sustain the initiator decomposition reaction. Also, a higher efficiency of smoke production can be achieved. Since the smoke is due to the initiator and no longer to a third component the “extra” mass was no longer necessary. The monomer itself may decompose, leading to additional smoke production.



BRIEF DESCRIPTION OF THE DRAWINGS
The disclosure can be better understood with reference to the following drawings. The elements of the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the disclosure. Furthermore, like reference numerals designate corresponding parts throughout the several views.
FIG. 1 is a functional schematic of an exemplary test performed to measure the characteristics of a smoke producing sample.
FIGS. 2a-2f show a series of photographic measurements showing the smoke density increase as increasing amounts of sample smoke producing material are activated.
FIG. 3 is plot of the optical density versus time for a variety of smoke producing compositions under test.
FIG. 4a is a schematic of a hypothetical mechanism of the decomposition pathway of the Luperox® 231.
FIG. 4b is a schematic of a hypothetical mechanism of the decomposition pathway of the mono- and di-function monomer impurities in the commercial grade TMPTA.
FIG. 5 illustrates the results of an additional series of tests run with concentrations approaching 50 pph.
FIGS. 6a-6c illustrate the tests performed to analyze initiation of a smoke producing reaction to measure the amount of smoke produced when the reaction was initiated from the front of a smoke producing sample contained in a glass vial.
FIGS. 7a-7c illustrate the tests performed to analyze initiation of a smoke producing reaction.
FIG. 8 illustrates a plurality of cylindrical shapes tested in a series of trails of the smoke producing composition.
FIG. 9 is a photograph of a test setup from a series of tests of the smoke producing composition spread out on a section of lumber.
FIG. 10 illustrates the visible absorption spectrum of the smoke produced from the TMPTA-Luperox 231 reaction from the start of the reaction to about 20 minutes after is shown.
FIG. 11 illustrates the infrared absorption spectrum of the smoke produced from the TMPTA-Luperox 231 reaction from the start of the reaction to about 9 minutes after the reaction.
FIG. 12 depicts a stacked disked embodiment of a smoke generating device.
FIG. 13 depicts embodiment of a smoke producing device comprising a substrate formed from a single sheet of material, rolled into a spiral shape.
FIG. 14 depicts a “stacked spiral” arrangement in which a plurality of spiral substrates are stacked atop one another.
FIGS. 15a, 15b and 15c depict an embodiment of a smoke producing device in which a plurality of cylindrical petals are arranged “concentrically” inside a cylindrical container that is hinged on one side.



DETAILED DESCRIPTION
The disclosure provides compositions for producing smoke. Various embodiments of the compositions disclosed herein have advantages over previously known smoke-producing compositions; for example: low or no flame front (safe to use indoors, outdoors, and in training environments with flame hazards); low toxicity of the smoke and any non-smoke residues; environmentally friendly (little to no residue or hazardous byproducts); high packing density; high smoke yield/low agglomeration of smoke particles; easily aerosolized, rapid smoke generation (short time constant); good obscuration properties in the visible portion of the electromagnetic spectrum; long smoke durations with appropriate buoyancy; and good shelf life (i.e., after mixing components, the mixture does not self-initiate polymerization).
In general, there are a minimum of two components—a monomer and an initiator—required to achieve polymerization. In the present embodiment, the monomer provides the carbon compounds that will form the polymer chains and the initiator provides a mechanism to join the carbon compounds together. The baseline monomer used in the composition of the present disclosure is TMPTA (trimethylolpropane triacrylate). Other monomers are possible and it is possible to combine other materials with the monomer for various effects. For example, by combining TMPTA with dibutyl phthalate, a large amount of smoke can be generated, but the smoke is not as buoyant as with TMPTA only. It may be possible to develop a smoke with tailorable buoyancy—which is useful if it is desired to reduce the duration of the smoke. Currently, in an enclosed environment, the smoke producing compound of the present disclosure can result in smoke durations in excess of 20 min. Note that the monomer may also be a material with a backbone other than carbon; for example, the Silicon backbone in Silicone caulk or RTV sealant. In addition, the production of a polymer is not a necessity. The primary role of the monomer is that it provides the heat source so that the reaction proceeds in a timely manner. In Frontal Polymerization, as opposed to other polymerization mechanisms, the mixed monomer and initiator are stable until an external excitation source is added.
For example, by combining TMPTA with methyl benzoate, benzyl benzoate, and pentyl acetate, considerable amounts of smoke are produced but they have slightly less buoyancy than TMPTA only. This may result in the ability to tailor the buoyancy. These materials are esters used as food additives/aromatics. An additional reason for employing TMPTA monomer in the smoke mixture is that it is a good, high quality (purity), inexpensive monomer.
The baseline initiator for the smoke producing compound of the present disclosure is Luperox®-231 (1,1-Bis(tert-butylperoxy)-3,3,5-trimethylcyclohexane). Other initiators are possible but may have, or are shown to have, undesirable effects. For example, t-butyl peroxybenzoate may be used with good smoke generation results. However, the benzoic acid byproducts are considerably more hazardous than the trimethyl cyclohexanes (TMCH) generated with the baseline initiator. The trimethyl cyclohexane smoke product or byproduct is not an acid or acid forming material. According to the toxicity analysis the inhalation and LD50 thresholds of TMCH are much higher than for the currently used materials (HC and RP).
One embodiment of the smoke producing compound of the present disclosure requires two other components: an ignition mechanism and a filler. The ignition (or initiation) mechanism used in the testing disclosed herein was a heat source. The heat source does not have to, but can, be pyrogenic. To date, Estes model rocket igniters, simple nichrome wire loops attached to voltage sources, hot air from a heat gun, soldering iron tips, open flame, focused intense light, have all been used to initiate the FP reaction. This ignition mechanism list is not exhaustive. Other ignition mechanisms considered are: piezo devices that might be used to ignite something more pyrogenic such as cannon fuse, battery powered voltage sources for nichrome wire, etc. A mixture including monomer and initiator will not self-initiate without an ignition source—this contributes to the long shelf life and inertness of the material.
Ignition tests have been conducted with a 1′′ conduction loop of 30 gauge nickel chromium (NiCr, or nichrome) wire with a resistance/unit length of approximately 0.5 Ohm/in. The wire was buried slightly under the surface of the smoke producing composition (which is typically in gel form) and a current draw of approximately 1 Amp was sufficient to initiate the FP reaction. Using Power, P=I2R, where I is the current in Amps and R is the resistance in Ohms, this yields an input Power of P=(1 Amp)2(0.5 Ohm)=0.5 W.
In the current embodiment (for an application such as smoke grenade usage), the filler provides a mechanism, or a matrix, for the smoke mixture to have a shape other than that provided by its container (e.g., a liquid or gas assumes the shape of its container, but a solid or a gel may not). Fumed silica, kaolin (clay) powder, and powdered sugar have all been used as fillers. Fumed silica has provided the best performance the mass required is low, it has a high area-mass ratio which provides significant thickening with a low thermal mass. This prevents it from robbing the reaction of the heat required for the reaction to propagate. Increasing the amounts of kaolin powder and powdered sugar have been shown to rob the reaction of its necessary heat and reduce the amount of smoke.
There are other envisioned applications where the smoke mixture is left as a liquid—so the filler/thickening agent might not be required or might be detrimental to the application. An example of a situation in which the thickening agent is not required: A liquid smoke mixture is carried on a military robot. If an individual approached too close to the robot, the liquid would be sprayed onto a hot surface (i.e., hot plate or wire) located somewhere on the robot. This would generate a signaling/deterrent smoke. In addition, this might not require large temperatures to initiate the reaction so that the smoke generation mechanism is not an incendiary hazard to the robot or to the local environment.
The primary mixture components of the smoke producing composition also have enough thermal conductivity that, if a point ignition source is applied, the bulk mixture reactants may quickly convect the required reaction energy away from the reaction site and cause the reaction to quench itself. The very low thermal conductivity of fumed silica “insulates” the reaction region, preventing the heat of reaction or of initiation from convecting away too rapidly. When no filler is present a large area heat source, such as a heat gun, may be required to inject significant heat into the mixture to overwhelm the convective heat losses. Present experimentation has shown cases where, for all other mixture components held constant, increases in filler (fumed silica) have resulted in a higher absorption smoke. The filler may provide more nucleation sites for polymerization to initiate.
In one embodiment of the smoke producing compound, if X g of TMPTA monomer is used, then greater than 0.1 X g of Luperox® 231 initiator, and greater than or equal to 0.1 X g of fumed silica filler are to be used. This mixture would be considered a “greater than 10 pph” mixture (greater than 10 parts initiator to 100 parts monomer). Note that the initiator concentration may be allowed to approach infinity (i.e., no monomer) and still generate smoke. The initiator may also decompose exothermically. In comparison, ratios for standard reactions wherein the polymerization product, not the smoke product, is desired, are characterized by initiator concentrations utilizing much less than 10 pph—typically 0.01 pph-0.1 pph, but less than 1 pph.
The TMPTA (Trimethylolpropane triacrylate) is a trifunctional monomer. This means that there are three double-bond carbon ends associated with each monomer molecule. Typical monomer-polymer system include compounds that have a single carbon double-bond along the monomer chain; ethylene, styrene, vinyl chloride. A single initiator molecule causes the breaking of the double bond and a monomer free radial to be formed. This monomer free radical then reacts with other monomers and a polymer molecule begins to grow. Termination of the process occurs when two free radicals combine; either a second polymer free radical or the other half of the initiator molecule. Polymer molecules of 1000 to 100,000 monomers are commonly produced. One of the controlling parameters of the final chain length is the number of initiator molecules added. Thus, typical initiator concentrations are a few hundredths to millionths of percent; high initiator concentrations yield low molecular weight polymer molecules. The heat generated from the polymerization process is due to the breaking of the carbon double bond and the formation of a carbon single bond. This process releases 60 kJ of energy per mole of double bonds. The process temperature of the reaction depends on the heat capacity of the monomer molecules. Molecules such as poly(ethylene) C2H4 have a much lower heat capacity than molecules such as styrene C8H10 and have much higher reaction temperature since they both have a single double-bonded carbon that participates in the reaction.
Experimental Testing
The addition of “excess” initiator, in this case Luperox® 231 Di-(tert-butylperoxy)-3,3,5-trimethylcyclohexane)), to a trifunctional monomer is against all polymerization practice because it increases the amount of smoke and decreases the quality of the resultant polymer. In fact, the more initiator is added, the poorer the strength of the resultant polymer, because there are more voids, more fractures, etc. During the course of this work it was not clear, until experimental tests were performed, that the polymerization reaction would even occur as increasing amount of initiator were added to the monomer. Increasing the initiator amount beyond the minimum necessary to sustain the polymerization reaction, likely causes an excessive number of polymerization reactions to occur simultaneously in a confined space. The distinct polymers formed by these multiple polymerization reactions will not necessarily bond with other polymers to form longer polymers. The result is that shorter than normally desired polymer chains are formed, resulting in a far weaker polymer product. As the initiator concentration is increased excessively, the polymer product has much shorter chains and is far weaker.
A series of preliminary experiments were conducted with initiator concentrations from 1 to 15 pph (parts per hundred of monomer). These preliminary tests qualitatively indicated that higher initiator concentrations resulted in increasing smoke yields. More importantly, these tests indicated that high initiator concentrations did not adversely affect the rate of the polymerization process and that sufficient heat was generated for the initiator to decompose into a visible smoke.
FIG. 1 is a functional schematic of an exemplary test performed to measure the characteristics of a smoke producing sample 101 in a chamber 100. The chamber 100 was substantially one (1) cubic foot in volume (11′′×12′′ by 10′′). Specifically, a Fisher Scientific® Dry Box was used as an air tight chamber 100 in this test. An FP reaction of the sample 101 was remotely initiated via a wire 108 extending through the chamber wall and to a power source (not shown). A fan 106 inside the chamber 100 circulated the smoke (not shown) produced by the reaction. Visible spectra measurements were taken with an Ocean Optics HR2000 UV-Vis spectrometer 102. The optical cell (not shown) was a Starna 34-SOG-100 10 cm cell. Infrared spectra were determined with a Nexus470 FTIR 103 using a 4′′ pathlength cell (not shown) with KBr windows (not shown).
The chamber 101 comprised a transparent window 107 to allow visual access to the sample under test for viewing the smoke and measuring smoke parameters. A vent hood 104 collected fumes from the test and a vent 105 vented fumes outside of the building.
In a similar test of the smoke producing sample, a 50 ft3 PVC and plastic wrapped chamber (not shown) was constructed. Two clear plastic windows 204 (FIG. 2a) on the chamber 200 (FIG. 2a) provided for optical measurements and visualization of the smoke production.
A series of experiments were completed in both the 1 ft3 and 50 ft3 chambers to test the limits of smoke production with increasing initiator concentration. Measurements of smoke production versus initiator concentration from 5 to 50 pph have been made in the 1 ft3 chamber and from 5 to 25 pph in the 50 ft3 chamber. For tests in both the 1 ft3 and 50 ft3 chambers optical transmission measurements (I/I0) were made versus time using a 633 nm laser and Newport laser power meter. From these tests it was determined that increasing the initiator concentration to at least 25-30 pph gave a good smoke production reaction and that increasing to 50 pph would continue to produce more smoke. Tests were run to quantify the amount of material necessary to produced a dense enough smoke for obscuration. A series of tests using different sample weights with 25 pph starting material versus optical density were run in the 50 ft3 chamber. The amount of material was increased from 5 to 25 grams of monomer (all with 25 pph of initiator); this corresponds to 0.1 to 0.5 grams of monomer per ft3 of chamber volume.
FIGS. 2a-2f show a series of photographic measurements showing the smoke density increase as increasing amounts of sample smoke producing material are activated. A laser power meter 201 measured optical transmission of smoke in the chamber 200. Tape 203 defined a rectangular transparent window 204. Two tape strips 202 were mounted horizontally on the opposite inside side wall of the chamber. As can be seen in FIG. 2a, which illustrates the chamber 200 before a smoke producing reaction is initiated, the tape strips 202 are clearly visible through the window 204. However, as smoke concentration increases, as shown in FIG. 2b, in which the smoke density is 0.10 grams monomer per cubic foot, the tape strips 202 become less visible. The beam 207 from the laser power meter 201 is clearly visible in FIG. 2b. 
In FIG. 2c, which illustrates a smoke density of 0.15 grams monomer per cubic foot, the tape strips 202 are invisible. In FIG. 2d, the smoke density is 0.20 grams monomer per cubic foot. In FIG. 2e, the smoke density is 0.25 grams monomer per cubic foot. In FIG. 2f, the smoke density is 0.30 grams monomer per cubic foot.
It is notable that the testing illustrated in FIGS. 2a-2f was performed indoors in plastic containment chambers. This highlights the non-incendiary characteristic of the reaction. The smoke does have an odor to it so the chamber needs to be vented outside. However, an unpleasant odor could be advantageous in some situations where a “stink bomb” might be desired.
FIG. 3 is a plot of the optical density versus time for the same mass of materials from testing performed in 50 ft3 chamber. This figure shows that after about 0.15 grams of starting monomer per cubic foot (gm/ft3), the optical density drops below 0.1. Comparing the results of FIG. 2c with FIG. 3 at 0.15 gm/ft3 the smoke density is almost sufficient to totally obscure the reference tapes 202 (FIG. 2c) on the opposite wall. As the sample mass increases up to 0.3 gcf the smoke density and its obscurant ability clearly increase.
The photographic series FIGS. 2a-2f illustrates a quirk of the laser beam visibility: with increasing smoke density, the laser beam 207 actually seems brighter and more visible. This result is also shown in the data of FIG. 3. The measured optical density for starting sample mass of greater than 0.15 gcf is actually greater than for 0.15 gcf itself, while it is clear from the photographs in FIG. 2c-2f that the smoke is denser. This higher measured optical density is likely due to a multiple scattering phenomena competing with the initial beam absorption/scattering. Note also from FIG. 3 that the duration of the smoke (at least in this controlled environment, i.e., in the absence of driving winds) is considerable.
Decomposition Products
The starting monomer and initiator in the exemplary testing was TMPTA and Luperox® 231. The expected decomposition products have been analyzed both through a literature review and via Gas Chromotograph-Mass Spectrometer (GC-MS) analysis of the smoke products. The literature review lists as the decomposition products:

    
    
        a. 3,3,5-trimethylcyclohexane,
        b. 2,4,4-trimethylcyclohexane,
        c. Trimethylcyclopentane
        d. t-butyl alcohol,
        e. acetone,
        f. ethane, and
        g. carbon dioxide.
    
    


Experimental GC-MS analysis essentially confirmed the literature results but showed only three components in the smoke:

    
    
        a. 3,3,5-trimethylcyclohexane,
        b. 2,4,4-trimethylcyclohexane, and
        c. t-butyl alcohol.
    
    


Neither acetone nor trimethylcyclopentane were detected. The molecular weights and melting and boiling points of some of the decomposition components are listed in Table 1 below. Acetone and Tert-butyl alcohol are gases room temperatures and the trimethylcyclohexane is liquid droplets at room temperature.







TABLE 1







Molecular weights and melting and boiling points of


Luperox ® 231 decomposition products













Molecular
Melting
Boiling



Decomposition Product
Weight
Point
Point



Vapor Species
[g/mole]
[° C.]
[° C.]
















1,3,5-trimethylcyclohexane
126.24
−49.7
138.5



Acetone
58.08
−95
56.2



Tert-butyl alcohol
74.12
25.2
82.2










FIG. 4a is a schematic of the decomposition pathway of the Luperox® 231 and FIG. 4b is a schematic of the decomposition pathway of the mono- and di-function monomer impurities in the commercial grade TMPTA. In this schematic, dotted lines are cleavage.
From the GC-MS analysis of the smoke produced, the reaction products are trimethylcyclohexane and t-butyl alcohol. The reaction products of the monomer decomposition are not seen in the smoke but may affect its infrared absorption properties.
Total Sample Mass Loss During Smoke Production
A series of tests were performed to measure the mass loss of the sample smoke generation compound versus the amount of initiator used in the compound. These tests were performed to confirm that the majority of the initiator was decomposing, and this expectation was confirmed. For the higher initiator concentrations and for thin (<1⁄8′′) sample thickness, there was more mass loss than just the initiator itself. The significance of sample thickness is discussed further below.
A series of tests was also performed to determine the mass loss over a wider initiator concentration range, and the initiator concentration was varied from 1 pph to 30 pph. The fumed silica (thickening agent) content was held constant at 10 pph. The starting TMPTA monomer was 2 grams and the mass of the initiator was varied from 0.02 to 0.60 grams. Two to three samples were run for each mixture composition. The results of these tests are presented in Table 2 below.







TABLE 2







Percent mass loss of monomer-initiator-filler mixtures versus


the initial initiator concentration.









Initiator Concentration [parts per hundred]













1
5
10
20
30
















Percent mass loss
0.5-1
4.0-5.2
9.8-13.4
22-32
33-49


(number of samples)
(2)
(3)
(3)
(3)
(2)









As can be seen from Table 2, from about 1 to 5 pph of initiator, the mass loss was approximately proportional to the amount of initiator added. At higher initiator concentrations (greater than 10 pph) the total mass loss was greater than the initiator mass. The additional mass loss—resulting in more smoke—is considered to be due to a decomposition of mono-functional, and di-functional “impurities” that are present in the commercial grade TMPTA. The additional mass loss could be due to a decomposition of the tri-functional TMPTA itself, but this is considered to be unlikely.
FIG. 5 illustrates the results of an additional series of tests run with concentrations approaching 50 pph. Note that it is unclear whether that the mass loss rate is decreasing at the 50 pph (50%) point. This indicates that it is desirable to perform additional tests with initiator concentrations greater than 50 pph.
The internal temperature of 5 gram samples of the mixed compound was measured in order to better understand the safety, and non-incendiary, characteristics of the frontal polymerization reaction. In initiator concentrations of less than 5 pph, the internal sample temperature was 100-200° C. At initiator concentrations from about 15 to 30 pph, the internal temperature increased to 300-350° C. This temperature is likely sufficient to lead to some decomposition of the monomer itself, which may be helped by the appreciable excess of initiator.
Effect of Sample Layer Thickness and Geometry on Smoke Production
A series of tests was performed to determine the effect of aspect ratio (width v. length at fixed heights) of the sample versus the amount of smoke produced. These tests were conducted under three testing/operating scenarios, 1) front and rear initiation of the reaction, 2) cylindrical samples of varying aspect ratio, initiated from the top “free” surface, and 3) rectangular samples of varying aspect ratios. Test geometries 1) and 2) were conducted in the one ft3 test chamber and the third series of tests were conducted in the 50 ft3 chamber. The sample smoke producing compound was 10 pph Luperox® 231 and 10 pph filmed silica filler.
Tests of Front Versus Rear Reaction
FIGS. 6a-6c illustrate the tests performed to analyze initiation of a smoke producing reaction to measure the amount of smoke produced when the reaction was initiated from the front, expanding portion, of the sample contained in a glass vial. In FIG. 6a, the sample 600 is disposed near an open front end 601 of a glass vial 602. In FIG. 6b, the sample 600 has just been ignited. FIG. 6c is a wider view of the sample 600 after the smoke has expanded. The smoke was close to neutrally buoyant and filled the test chamber in an amount that would be expected, given the size of the sample.
FIGS. 7a-7c illustrate the tests performed to analyze initiation of a smoke producing reaction to measure the amount of smoke produced when the reaction is initiated from a sample disposed in the rear, constrained, portion of a glass vial. In FIG. 7a, the sample 700 is disposed near the rear end 701 of a glass vial 702. In this series of tests, as shown in FIGS. 7b and 7c, any hot smoke vapors have to travel through the unreacted portion of the sample before reaching the open end 703 of the vial 702. The resultant smoke was denser than the surrounding air and tended to sink to the bottom of the test chamber. In both of the tests illustrated in FIGS. 6 and 7, the frontal polymerization reaction proceeded to completion.
Tests of Cylindrical Samples of Varying Aspect Ratios
The second series of trials tested a constant volume of material in three cylinder shapes with bores of different aspect ratios, 2:1, 1:1, 1:3, and 1:5, as illustrated in FIG. 8. The cylinder bores were generated by drilling holes in a Delrin puck. A syringe was used to place the samples in the bore holes. These tests showed that the 2:1 aspect ratio sample had the most smoke production; the 1:3 and 1:5 aspect ratio tests produced a minor amount of smoke. The 2:1 aspect ratio test produced a typical amount of smoke. The test results are reported in Table 3 below. In each of these tests, the reaction was initiated at the top of the sample with enclosed sides and bottom. The conclusion from these tests is that a low aspect ratio of height to diameter is desirable.







TABLE 3







Optical transmittance of smoke produced for various aspect


ratio cylindrical samples









Sample Aspect Ratio
Sample Diameter
Optical Transmittance


[diameter to height]
[inches]
[I/I0]





2:1
1
0.20


1:1
5⁄8
0.8 


1:3
1⁄2
0.97


1:5
1⁄4
1.0-no signal loss









Tests of Rectangular Samples of Varying Aspect Ratios

FIG. 9 is a photograph of a test setup from the final series of tests, which were conducted with 10 gram samples (20 pph initiator, 10 pph silica), spread out on a section of lumber 900. Selected thickness lumber guide rails 901 were spaced about one inch apart, the guide rails were varied from 3/16 inches in height, to 1⁄4′′ in height to 1⁄2′′ in height, and the sample 902 (shown after the reaction) was spread out to roughly 1.5 to 4 inches long between the guide rails. Note that the in FIG. 9 lumber shows no signs of combustion and in spite of the fact that it has been used for several dozen tests. The measured optical density values are given in Table 4 below. These results confirm that the layer thickness play a critical role in the efficiency of smoke produced.







TABLE 4







Optical transmittance measurements versus aspect ratio and


sample thickness for fixed mass samples.












Sample
Sample
Sample
Optical



Aspect Ratio
Thickness
Length
Transmittance



[height to length]
[inches]
[inches]
[I/I0]
















1:20
 3/16
~4
0.10



1:12
1⁄4
~3
0.25



1:3 
1⁄2
~1.5
.98-no signal loss










Test with Monomers and Initiators Other than TMPTA and Luperox® 231

A series of tests were conducted with TMPTA and initiators other than Luperox® 231 and tests of monomers other than TMPTA to confirm that the smoke production was due to the decomposition of the Luperox® 231 and to confirm the effectiveness of TMPTA as the monomer. These tests were only run for qualitative, rather than quantitative smoke production assessment. The mixture composition was 10 pph initiator and 10 pph fumed silica. Table 5 shows the results of these tests.







TABLE 5







Monomer-Initiator combinations tested for their qualitative


smoke production ability.









Initiators











t-butyl


Monomers
Luperoxe ® 231
peroxybenzoate





TMPTA (Trimethylolpropane
Good smoke-Control
Similar to Control


triacrylate)
sample


TMPTA + dibutyl phthalate
Good or better smoke-
No Test



smoke sinks


PETA (Petaerythritol
Poor smoke
Poor smoke


triacrylate)


DTMPTA
Poor or no smoke
No smoke


(Di(trimethylolpropane)


triacrylate)









The results in this table highlight the fact that the Luperox® 231/TMPTA initiator/monomer combination is rather unique in its ability to produce large volumes of smoke. The t-butyl peroxybenzoate initiator did produce good quality of smoke. However, one of its reaction products would be benzoic acid. Thus, a smoke from this initiator would have a much higher toxicity than the methylcyclohexanes from Luperox® 231. The TMPTA+dibutyl phthalate mixture did produce a good quality, albeit sinking, smoke.
Visible Optical Signatures
FIG. 10 illustrates the visible absorption spectrum of the smoke produced from the TMPTA-Luperox 231 reaction from the start of the reaction to about 20 minutes after is shown. The data was taken using the one ft3 chamber that was connected to the Ocean Optics spectrometer through flow-ports installed in the back of the chamber. This figure shows that the smoke produced has a uniform absorption across the (entire) visible spectrum from 300-1000 inn. Thus, it evenly scatters all the visible wavelengths. It can also be seen in the figure that the smoke has a persistence of at least 5 minutes. From this data and from other tests this indicates that the particle sizes are in a range where there is not rapid sedimentation of the particles or droplets.
Infrared Optical Signatures
FIG. 11 illustrates the infrared absorption spectrum of the smoke produced from the TMPTA-Luperox 231 reaction from the start of the reaction to about 9 minutes after the reaction. The data was taken using the 1 ft3 chamber that was connected to the Nexus 470 FTIR system through flow-ports installed in the back of the chamber. The infrared cell has KBr windows. The infrared spectrum has unique peaks associated with the trimethylcyclohexane, t-butyl alcohol, and acetone produced in the reaction. The infrared peak from a human body is centered around 10 μm; indicating that the current version of this smoke is not an infrared obscurant for humans. The absorption peaks at approximately 6, 7 and 8 μm indicate that the smoke has obscurant properties for 225, 150, and 100° C. bodies. No efforts were made during the Phase I research to modify the reaction products to make the smoke obscure humans.
Toxicity of Decomposition Products
The toxicity of the decomposition products has been analyzed from the MSDS data that is available for the initiator decomposition products: trimethylcyclohexane, tert-butyl alcohol, and acetone. Values for the known decomposition products of our formulation and current inventory grenades are given in Table 6 below. While excessive exposure to acetone and tert-butyl alcohol should be avoided, these compounds are the primary component of many household products such as nail polish remover. Table 6 below shows that the decomposition products of the smoke producing formulation disclosed herein are substantially less toxic or reactive than presently used compounds. (Hexachloroethane and phosphoric acid are included as reference materials.)







TABLE 6







Toxicity and workplace exposure data for


Luperox ® 231 decomposition products.











LD50
Exposure limit




[mg/kg]
[(mg/kg)/time-hrs]
notes














trimethylcyclohexanes
No data
No data
Chronic effect on humans-




TWA 2000 mg/m3
toxic to lungs


methylcyclohexane
2,250-oral
  7613 vapor-4 hours
Chronic effect on humans-





toxic to lungs


tert-butyl alcohol
2,743-oral
10,000 vapor-4 hours
may cause reproductive





system damage


acetone
 3000-oral
44,000 vapor-4 hours
may cause CNS damage


hexachloroethane
4,900-oral
No data but known
Confirmed animal


(M8 HC)

respiratory irritant
carcinogen, very toxic to




TWA-10 mg/m3
aquatic life-long lasting


Terephthalic acid
3200
TWA-10 mg/m3
Chronic toxicity to


(M83 TA)


multiple organ systems


phosphoric acid
 1550-oral
  850 vapor-1 hour
TLV-1 mg/m3





LD50 = Median Lethal Dose


TWA = Time Weighted Average


TLV = Threshold Limit Value






Questions have been raised as to whether adding oxiders to the mix would it speed up the reaction and make smoke faster. The composition is not incendiary, and adding (inorganic) oxidizers to the mix may cause it to start a fire, which would be undesirable. Therefore, the composition avoids inorganic oxidizers. The smoke in the composition is produced from the decomposition of the initiator in the composition, which can be thought of as an/the oxidizer. The composition differs from currently known formulations in that it is this “oxidizer” that makes the smoke. Adding an inorganic oxidizer would likely cause the smoke production to decrease.
The desired smoke production requires approximately 0.020 grams of material per cubic foot of obscured volume when viewed through a 10 m thick smoke screen. For a 5 m thick smoke screen 0.04 grams/cu. ft. of material are required. The Obscurant factor is constant across the visible spectrum, and has infrared absorption in specific wavelength ranges. Assuming ideal and complete reaction efficiency, for a 300 m3 (3 m×10 m×10 m or 10,600 ft3) obscured volume, approximately 200 cm3 of material is projected to be required, representing a device approximately 4 inch in height and 2 inches diameter; without casing, fuse or ignition source. Analysis of the mechanism of smoke production indicates a strong potential that a smoke could be produced with 0.010-0.015 grams of material per cubic foot of required coverage. The casing and fusing requirements will result in a final device size of generally 5 inches in height and about 3 inches diameter; which represents devices currently in the inventory.
It is unlikely that the local oxygen concentration has any effect on the amount of smoke produced. Based upon the decomposition mechanism of the Luperox® 231, oxygen is not required. It is currently unknown whether extra mass loss from the mono- or di-functional monomers requires oxygen or not.
FIG. 12 depicts an embodiment of a smoke generating device 1100 using the compound disclosed herein. In this “stacked disk arrangement,” the smoke generating compound (not shown) is applied to disks 1101, 1102, 1103, 1104 and 1105 stacked atop one another. Although five (5) disks 1101-1105 are shown in FIG. 11, this number of disks is illustrated for explanatory purposes; a smoke generating device 1100 may comprise 10-30 stacked disks, or more or fewer, as desired.
In this embodiment, each disk 1101-1105 is formed from non-woven fiber, such as a plastic fiber similar to Scotch Brite® pads or a plastic Brillo® pad, or fiberglass. The disks 1101-1105 may also be formed from other materials with a high surface area for maximizing the composition's exposure to oxygen during the smoke-producing reaction.
An ignition wire 1106 extends through openings 1107 in the disks 1101-1105 for initiating the reaction. In other embodiments, the ignition wire 1106 may be “woven” into the fiber comprising the disk.
Wires 1108, 1109, 1110, and 1111 extend between adjacent disks. In this regard, wire 1108 extends between disk 1101 and disk 1102; wire 1109 extends between disk 1102 and disk 1103; wire 1110 extends between disk 1103 and disk 1104; wire 1111 extends between disk 1104 and disk 1105.
In some embodiments, insulators (not shown) are disposed between adjacent disks to isolate each disk from the remaining disks, to prevent the disks from sticking together.
FIG. 13 depicts an embodiment of a smoke producing device comprising a substrate 1300 formed from a single sheet of material, rolled into a spiral shape as shown. The substrate 1300 may be formed from the materials discussed above with respect to FIG. 12. An ignition line 1301 extends through the substrate 1300.
FIG. 14 depicts a “stacked spiral” arrangement in which a plurality of spiral substrates 1400 like those discussed above with respect to FIG. 13 are stacked atop one another. Each substrate comprises an ignition line 1401.
FIGS. 15a, 15b and 15c depict an embodiment of a smoke producing device in which a plurality of cylindrical petals 150, 151 and 152 nested inside a cylindrical container 153 that is hinged on one side via a hinge 154. FIGS. 15a and 15b depict the container 153 before the smoke producing ignition is initiated, and FIG. 15c depicts the container 153 after the ignition has begun. Although three petals 150, 151, and 152 are depicted in the illustrated embodiment, more or fewer petals are employed in other embodiments.
The ignition sequence causes the container 153 to be split so that it opens up along a hinge line 155 of the container 153. The concentrically arranged petals 150, 151 and 152 are ignited and split along one side so that they “open up” like a blooming flower. Each of the petals 150, 151 and 152 may be formed from the materials discussed with respect to FIG. 12 above.

## Claims

1. A low-temperature method of generating smoke, the method comprising initiating a frontal polymerization reaction by heating a composition comprising a monomer compound that exothermically polymerizes upon initiation with an initiator compound and an initiator compound that initiates polymerization of the monomer compound present at a mass concentration that is 5% or more of the mass concentration of the monomer compound, wherein the polymerization of the monomer compound is exothermic, wherein the concentration of initiator compound is 5% or more of the concentration of monomer compound, and wherein the smoke mainly comprises thermal decomposition products of the initiator compound; wherein the initiator compound is t-butyl peroxybenzoate.

2. The method of claim 1, wherein the monomer compound is TMPTA.

3. The method of claim 1, wherein the monomer-initiator combination will not self-initiate or self-polymerize.

4. The method of claim 1, wherein the reaction is self-sustaining once the reaction has been initiated.

5. The method of claim 1 comprising heating the composition by running an electric current through a conductive wire in contact with the composition.

6. The method of claim 1, comprising heating the composition by running an electric current through a nickel-chromium wire in contact with the composition.

7. The method of claim 1, wherein the mass/mass ratio of initiator compound to monomer compound is about 1:1-20:1.

8. The method of claim 1, wherein the composition comprises a filler agent.

9. The method of claim 1, wherein the composition comprises an infrared-opaque agent.

10. The method of claim 1, wherein the composition is in a non-fluid form having a first dimension and a second dimension, and the ratio of the first dimension to the second dimension is less than 1.

11. The method of claim 1, wherein the composition does not contain a significant amount of an inorganic oxidizer.

12. The method of claim 1, wherein the composition further comprises dibutyl phthalate.

13. The method of claim 1, wherein the composition further comprises fumed silica.