Patent Publication Number: US-7900560-B1

Title: Stacked pellet flare assembly and methods of making and using the same

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation and claims the priority of U.S. patent application Ser. No. 10/763,789 filed on Jan. 23, 2004, which is hereby incorporated by reference. 
    
    
     STATEMENT REGARDING SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable. 
     REFERENCE TO A MICROFICHE APPENDIX 
     Not applicable. 
     FIELD OF THE INVENTION 
     The present invention relates to decoy flares and, more particularly to a new pellet design and arrangement for countermeasure flares and other pyrotechnic devices. 
     BACKGROUND OF THE INVENTION 
     Flare assemblies have been and continue to be utilized in various manners as defensive countermeasures. For instance, what may be characterized as “visual” flash flares have been utilized to at least generally distract, startle, and/or “throw off” a person responsible for guiding and/or aiming a missile, such as a laser guided missile, at an object, such as a tank or an airplane. A general premise behind these visual flash flares is that enough light in the visual wavelengths will be emitted via ignition of the associated payload that a person responsible for guiding and/or aiming a missile cannot help but be distracted by the magnitude of light produced. As one might expect from the magnitude of the desired output intensity, these visual flash flares typically exhibit a burn time of no more than about a couple seconds. 
     Conventional visual flash flares have typically included an ejectable payload made up of a loose or loosely packed, ignitable, granular composition. This granular payload composition has become undesirable for numerous reasons. For instance, low packing density exhibited by the granular compositions, inherent in some conventional visual flash flares, may result in to low energy density of the flare. As another detriment, transportation and storage of these types of flares may be expensive and has provided undesired detonation problems. These drawbacks, as well as others, seem to have made military units reluctant to employ these types of visual flash flare devices on board their aircraft. 
     Other prior art flare assemblies may be utilized to distract or “confuse” an infrared guided missile&#39;s guidance system into locking in on the infrared light from the flare assembly rather than the exhaust/plume of an aircraft. In this manner, flare assemblies have been utilized to decoy infrared guided missiles at least generally away from an aircraft.  FIGS. 1A-B  illustrate an example of a prior art flare pellet  20  utilized in infrared flare assemblies. These flare assemblies typically include one, and only one, flare pellet  20  that is generally press-formed to exhibit slightly smaller dimensions than the fully assembled flare. That is, the pellet  20  generally has a length  21 , width  22 , and depth (or thickness)  24  that is slightly smaller than the corresponding dimensions of the fully assembled flare. Eight longitudinal grooves  26  are defined in the outer surface  28  of the pellet  20  and run at least generally parallel to a longitudinal reference axis  23  of the pellet  20 . These grooves  26  are generally included to increase an initial surface area of the flare pellet  20  for ease of igniting and to generally control the energy output of the flare pellet  20  upon ignition. However, the design of this flare pellet  20  has not provided desired output energy versus burn time performance when used in conjunction with certain spectrally balanced infrared flare formulations. That is, the flare pellet  20  has provided burn times that are longer than desired and energy outputs that are less than desired. This due, at least in significant part, to the flare pellet exhibiting a greater web than desired. Herein, “web” generally refers to a distance between the outer surface  28  of the pellet  20  and a portion of the pellet  20  which is generally found to be the last portion to burn. For example, a web of the pellet  20  of  FIGS. 1A-B  may refer to a distance  25  between a trough of the groove  26   a  and a lateral reference axis  27 . To provide an idea of the web magnitude of the pellet  20 , this distance  25  has generally been about 0.25 inch. 
     Past attempts to modify the design of the flare pellet  20  to increase its initial surface area and/or to decrease the magnitude of the web, with the goal of increasing its peak output energy level and reducing its burn time, have resulted in flare pellets having insufficient structural integrity resulting in fragmenting and/or breaking of the pellet  20  during normal launch, flight movement/vibration. For instance, holes have been drilled in various flare pellets to increase their surface area and, thus, the peak energy output of the flare pellets. However, these designs have broken apart or collapsed upon having an appropriate ejection force imposed thereon and/or have jammed in the flare launcher. Accordingly, these past attempts have provided insufficient and inconsistent results. 
     Developments in infrared guided missile technology have enabled guidance systems of missiles to discriminate and reject spectral signatures of some conventional flare assemblies utilized in defensive countermeasures. Any detected spectral signal in which the band intensities and/or band ratios do not conform to a particular target aircraft&#39;s distinctive signature would be “ignored” by the missile&#39;s guidance system. Accordingly, it is beneficial to provide countermeasure flares capable of providing a spectral signature similar to that of aircraft desired to be defended. To date, certain energetic compositions of spectrally balanced flare assemblies do not burn fast enough to give the desired results. Conventional approaches have not successfully reformulated the compositions to be faster burning without sacrificing spectral balance, structural integrity, safe storage, and/or safe transport. 
     Another example of a conventional flare is what may be referred to as a standard illumination flare assembly that includes a single cast or pressed flare pellet that has and outside circumference and one end inhibited from burning. These flare pellets are generally ignited on one end and burn from end-to-end. These types of standard illumination flare assemblies typically have burn times that are an order of magnitude higher than decoy flares, typically ranging from tens of seconds to one or more minutes. However, in exchange for the length of the burn time, these flares typically do not exhibit sufficient magnitudes of visual light output to distract weapons operators. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention to provide a flare pellet geometry that will safely, with good physical integrity, yield faster (e.g., shorter) burn times and higher peak output levels with any given flare composition in any given form factor than any prior art pressed, extruded, or cast flare pellet. These attributes are achieved without the negative attributes (e.g., hazards) associated with the use of granular or powdered compositions, which are known to have been used in lieu of pressed, cast, or extruded flare pellets. These attributes are achievable with a variety of pyrotechnic flare compositions such as visual flare compositions, conventional magnesium/polytetrafluoroethylene infrared flare compositions, spectrally balanced infrared flare compositions, and others. 
     Herein, the term “flare pellet geometry” generally refers to a stacked arrangement of the pellets that make up the entire flare pellet as well as the individual pellets that make up the pellet stack assembly. Accordingly, “flare pellet geometry,” as applied to prior art flare pellets, includes the entire pressed, cast or extruded flare pellet including all of its surface features. “Flare pellet geometry” may refer to the dimensional features of the unit load pyrotechnic and especially those features that make up the initial combustible surfaces of the unit load pyrotechnic. 
     It is another object of the present invention to provide a flare pellet assembly that does not degrade desired spectral signatures. It is yet another object of the present invention to provide a flare pellet assembly that is capable of maintaining structural integrity throughout normal flight movement and/or vibrations as well as normal ejection forces. It is still another object of the present invention to provide a flare pellet assembly that is capable of being tailored to replicate an exhaust plume of any of a number of appropriate aircraft. These objectives, as well as others, may be met by the countermeasure system and related methods herein described. 
     In one aspect, the present invention is directed to a flare pellet assembly for use in a defensive countermeasure. This flare pellet assembly generally includes at a plurality of ignitable flare pellets that are arranged in a stack. This stacked arrangement of the flare pellets, along with one or more grooves that may be defined in and/or between adjacent flare pellets, at least generally enable the resultant flare pellet assembly to provide one or both infrared and visual output that reach desired countermeasure specifications. Moreover, this stacking of the individual flare pellets enables the resultant flare pellet assembly to structurally withstand normal in flight vibration as well as ejection forces such as those forces imposed on the flare pellet assembly when ejected from a flare launcher system. 
     These flare pellets of the invention may exhibit any appropriate geometric shape. For instance, one or more of the flare pellets may be substantially disk shaped. Further, the flare pellets may exhibit any appropriate design/configuration. As another example, one or more of the flare pellets may exhibit a frustum of a cone or pyramid as well as other appropriate configurations. Yet further, the flare pellets may have any appropriate dimensions. For instance, one or more of the flare pellets may include a thickness of about 0.225 inch, a length of about 1.88 inch, and/or a width of about 0.845 inch. In the case that at least one of the flare pellets is substantially disk shaped, the flare pellet(s) may have a thickness of about 0.30 inch and/or a diameter of about 1.98 inch. While numerous designs, shapes, and dimensions of the flare pellets of the flare pellet assembly may be appropriate, it is preferred that the individual flare pellets are substantially identical in size and general design. Moreover, while some embodiments of the flare pellet may be compatible with a number of appropriate form factors, preferred embodiments of the flare pellet assembly are compatible with at least one of a 1×1×8 inch form factor, a 1×2×8 inch form factor, a 2×2.5×8 inch form factor, a 55 mm diameter form factor, and a 36 mm form factor. Incidentally, a “form factor” is a term of art generally referring to a compatibility between flare pellet assemblies and flare casings or flare assemblies and dispensing systems. For example, a flare pellet assembly and a flare casing having the same form factor can be used together. 
     One family of embodiments of the flare pellet assembly may be characterized by having first and second flare pellets that are substantially immobilized relative to each other. For instance, in one embodiment, the first and second flare pellets may be at least generally affixed to each other using an appropriate adhesive and/or mechanical fastener(s). In another embodiment, the first and second flare pellets may be at least generally keyed to each other. In other words, the flare pellets may have at least generally complimentarily surfaces including lands and/or grooves configured to engage each other. This keyed design of the flare pellets at least generally fosters an immobilization of the flare pellets relative to each other in at least one direction. 
     The flare pellet assembly, at least in one family of embodiments, may be said to include a rod or beam that extends through a plurality of the flare pellets. In this family of embodiments, rotation of one or more of the flare pellets relative to the rod may be restricted, and preferably, substantially prevented. For instance, the flare pellet(s) of one embodiment may be affixed to the rod in any of a number of appropriate manners, such as by employing an appropriate adhesive. Another embodiment may have at least one protrusion associated with either the rod or the flare pellet(s) and a recess, complimentarily configured to accommodate the protrusion, associated with the other of the rod and the flare pellet(s). Incidentally, it should be noted that other embodiments may have a rod that includes both a protrusion and a recess, and the flare pellet(s) may also have a protrusion and a recess complimentarily configured to engage and/or be engaged by the protrusion and recess associated with the rod. 
     Some flare pellet assemblies including a rod may be equipped with a stop of sorts, such as a head, at one end and threading at the other end thereof. The flare pellet assembly may also include a threaded fastener engaged with the threading of the second end of the rod. In this arrangement, it may be said that a plurality of the flare pellets are at least generally disposed between the stop of the rod and the threaded fastener. This arrangement at least generally facilitates a maintenance of the stacked configuration of the flare pellets of the flare pellet assembly. 
     Another aspect of the present invention is directed to a flare pellet assembly that includes a flare pellet having a longitudinal reference axis and made of at least one ignitable material. Moreover, at least one tapered groove is defined in the flare pellet and at least generally tapers toward the longitudinal reference axis. 
     The tapered groove(s) of the flare pellet may include an interior angle of between about 5° and about 35°. So, for instance, the tapered groove(s) may have an interior angle of about 10° in one embodiment and about 20° in another embodiment. The tapered groove(s) may have any of a variety of appropriate arrangements. For example, the tapered groove(s) may be annularly disposed about the longitudinal reference axis. In at least one embodiment, the flare pellet may be said to include first and second flare pellets. In such an embodiment, the tapered groove may be defined between the first and second flare pellets. 
     In yet another aspect, the present invention is directed to a method of using a flare assembly, such as a visual flash flare assembly. In this method, a pellet assembly is ejected from a flare assembly. This pellet assembly generally is made up of an ignitable material that includes between about 40% and about 70% magnesium, between about 20% and about 50% sodium nitrate, and may optionally include plastic binder material such as Laminae™. In addition to ejection of the pellet assembly, the pellet assembly is ignited, and a visual light output reaching at least about 5.0 million candela is provided. 
     An infrared output of the pellet assembly may reach at least about 14,000 w/ster (watts per steradian) in the short infrared band (e.g., an infrared band between about 1.8μ and about 3.0μ), and/or at least about 22,000 w/ster in the mid infrared band (e.g., an infrared band between about 3.0μ and about 5.5μ). Incidentally, “reach” or the like herein generally means to meet or exceed a value or magnitude. In one embodiment, the pellet assembly may have a first infrared output that reaches at least about 10,000 w/ster in the short infrared band and a second infrared output in the mid infrared band. 
     Yet another aspect of the present invention is directed to a method of using a flare assembly, such as an infrared flash flare assembly. In this method, a pellet assembly made from an ignitable material that includes magnesium, polytetrafluoroethylene, and a fluoroelastomer, is ejected from a flare assembly and ignited. 
     In one embodiment, an infrared output is generally provided that is at least about 90,000 w/ster in the short infrared band. In another embodiment, an infrared output of at least about 130,000 w/ster in the mid infrared band is generally provided. Still another embodiment may include a step of providing a first infrared output in the short infrared band and a second infrared output in the mid infrared band as a result of igniting the pellet assembly. 
     Yet another aspect of the present invention is directed to a method of using a flare assembly, such as what may be characterized as a spectrally-balanced flare assembly. In this method, a pellet assembly is ejected from a flare assembly and ignited. As a result of igniting the pellet assembly, first infrared output associated with the pellet assembly is at least about 6,000 w/ster in the mid infrared band for a duration of at least about 2.0 seconds. 
     The first infrared output may reach a peak infrared output of at least about 7,000 w/ster in one embodiment, at least about 7,500 w/ster in another embodiment, and at least about 8,000 w/ster in yet another embodiment. In one embodiment, a second infrared output of at least about 2,000 w/ster may be reached in the short infrared band during the above-mentioned duration of time. 
     Various refinements may exist of the features noted in relation to the above-disclosed aspects of the present invention. Further features may also be incorporated in these aspects of the present invention as well. These refinements and additional features may exist individually or in any combination. Moreover, each of the various features discussed herein in relation to one or more of the disclosed aspects of the present invention may generally be utilized by any other aspect(s) of the present invention as well, alone or in any combination. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  is an end view of a prior art MTV or spectrally balanced flare pellet. 
         FIG. 1B  is a side view of the flare pellet of  FIG. 1A . 
         FIG. 2  is a cut-away plan view of one embodiment of a flare pellet assembly of the invention. 
         FIG. 3  is a cut-away plan view of a flare pellet of the flare pellet assembly of  FIG. 2 . 
         FIG. 4  is a cut-away plan view of another embodiment of a flare pellet assembly of the invention. 
         FIG. 5A  is a plan view of a flare pellet of the flare pellet assembly of  FIG. 4 . 
         FIG. 5B  is another plan view of the flare pellet of  FIG. 5A . 
         FIG. 5C  is a cross-section view of first and second flare pellets that are keyed to each other. 
         FIG. 5D  is a cross-section view of a flare pellet and a rod that are keyed to each other. 
         FIG. 6  is a graph illustrating magnitudes of infrared output of a spectrally balanced infrared flare employing the flare pellet assembly of  FIG. 4 . 
         FIG. 7  is a spreadsheet illustrating various outputs of prior art infrared flares, visual flash flares of the invention, and infrared flash flares of the invention. 
         FIG. 8  is a cut-away plan view of a flare assembly including yet another embodiment of a flare pellet assembly of the invention. 
         FIG. 9A  is an end view of the flare assembly of  FIG. 8 . 
         FIG. 9B  is a magnified view of the circled area “A” of  FIG. 9A . 
         FIG. 10A  is top view of a flare pellet of the flare pellet assembly of  FIG. 8 . 
         FIGS. 10B-C  are side views of the flare pellet of  FIG. 10A . 
         FIG. 11  is a graph illustrating spectral output of a conventional prior art spectrally balanced flare pellet. 
         FIG. 12  is a graph illustrating spectral output of the flare pellet assembly of  FIG. 8 . 
         FIG. 13  is a cross-section view of a press and die for making flare pellets associated with the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS 
     The present invention will now be described in relation to the accompanying drawings, which at least assist in illustrating the various pertinent features thereof.  FIG. 2  illustrates a flare pellet assembly  30  for use in a pyrotechnic device such as a defensive countermeasure. This flare pellet assembly  30  is shown as including at a plurality of flare pellets  32  that are arranged in a stack at least generally along a longitudinal reference axis  34 . While the flare pellet assembly  30  is illustrated as including twenty-three flare pellets  32 , it should be noted that other numbers of flare pellets  32  may be incorporated in other embodiments of the flare pellet assembly  30 . Moreover, the flare pellet assembly  30  may exhibit any appropriate length  38  depending on such things as, for example, the desired overall length of the completed flare assembly the desired energy output of the assembly  30 , the dimensions of the individual flare pellets  32 , and the number of flare pellets  32  included in the assembly  30 . In any event, the flare pellet assembly  30  is shown as having an aperture  36  that extends through each of the pellets  32  and that is defined along the reference axis  34 . This aperture  36  may extend up to a substantial entirety of the length  38  of the assembly  30  or may only extend along a portion of the length  38  of the assembly  30 . The aperture  36  may be utilized, as shown in subsequent embodiments, to accommodate an appropriate mechanical fastener that at least generally assists in holding the flare pellets  32  of the flare pellet assembly  30  in the illustrated stacked arrangement. It should be noted, however, that other embodiments may exist which do not have an aperture  36 , while other embodiments may include a plurality of apertures disposed in any of a number of appropriate locations and/or orientations. 
     Each of these flare pellets  32  of the flare pellet assembly  30  is made of an appropriate ignitable material. For example, in one preferred embodiment, the flare pellets  32  are made of an ignitable material including between about 40% and about 70% magnesium, between about 20% and about 50% sodium nitrate, and about 10% Laminac™ or the like. To enhance the structural integrity of each of the flare pellets  32 , it is preferred that the same are manufactured by pressing, casting, molding, and/or extruding the ignitable material into the desired shape/design of the flare pellet  32 . For example,  FIG. 3  illustrates an exemplary flare pellet  32  that is what may be characterized as substantially disk shaped, biconvex, or at least pseudo-biconvex, and that includes a top  40 , a bottom  42 , and a side  44 . While the flare pellet  32  is shown as having a width, or in this case, a diameter,  46  measured substantially perpendicular to the reference axis  34 , and a length  48  measured substantially parallel to the reference axis  34  that generally coincides with a distance between the top  40  and the bottom  42  of the flare pellet  32 . This width  46  and length  48  of the flare pellet  32  may be any appropriate distances. For example, in one preferred embodiment, the width  46  of the flare pellet  32  may be about 1.277 inches, and the length  48  of the flare pellet  32  may be about 0.216 inch. Due to the design of the flare pellet  32 , a web of the same is generally equal to about half of the length  48  of the flare pellet  32 . 
     Still referring to  FIG. 3 , in addition to the top  40 , bottom  42 , and side  44 , the flare pellet  32  also includes first and second outer surfaces  50 ,  52  (respectively). The first outer surface  50  at least generally spans between the top  40  of the flare pellet  32  and the side  44  of the flare pellet  32 . Likewise, the second outer surface  52  of the flare pellet  32  at least generally spans between the bottom  42  of the flare pellet  32  and the side  44  of the flare pellet  32 . These first and second outer surfaces  50 ,  52  are oriented such that it may be said that the flare pellet  32  at least generally tapers from its width  46  (measured at opposing portions of the side  44  and intersecting the reference axis  34 ) toward a central width  54  associated with each of the top  40  and bottom  42  of the flare pellet  32 . Moreover, these first and second outer surfaces  50 ,  52  are oriented such that it may be said that the flare pellet  32  at least generally tapers from its length  48  (measured from the top  40  to the bottom  42  and parallel to the reference axis  34 ) toward a peripheral length  56  associated with side  44  of the flare pellet  32 . Incidentally, a surface length  58  of each of the first and second outer surfaces  50 ,  52  may be any appropriate length. For example, one preferred embodiment may have first and second outer surfaces  50 ,  52  both having a surface length  58  of about 0.411 inch. Incidentally, while the first and second outer surfaces  50 ,  52  have been described as having the same surface length  58 , other embodiments may exhibit first and second outer surfaces  50 ,  52  having differing outer surface lengths  58 . 
       FIG. 4  illustrates another embodiment of a flare pellet assembly of the invention, and as such, a “single prime” designation is used to distinguish the flare pellet assembly  30 ′, as well as various features thereof, shown in  FIG. 4  from the flare pellet assembly  30  shown in  FIG. 2 . Like the flare pellet assembly  30  of  FIG. 2 , the flare pellet assembly  30 ′ of  FIG. 4  is shown as including at a plurality of flare pellets  32 ′ that are arranged in a stack at least generally aligned with the longitudinal reference axis  34 . While the flare pellet assembly  30 ′ is illustrated as including at least twelve flare pellets  32 ′, it should be noted that other quantities of flare pellets  32 ′ may be incorporated in other embodiments of the flare pellet assembly  30 ′. 
       FIG. 4  illustrates that the flare pellet assembly  30 ′ has an aperture  36  that extends through each of the pellets  32 ′ and that is defined along the reference axis  34 . Disposed at least generally within this aperture  36  is a rod  62  having a stop  64 , such as a head or other appropriate stop feature, at a first end  65  thereof and threading (not shown) disposed at a second opposing end  67  thereof. The threading associated with the second end  67  of the rod  62  is preferably threadingly engaged with a threaded nut  68 . In this arrangement, it may be said that the stack of flare pellets  32 ′ are positioned at least generally between the stop  64  of the rod  62  and the nut  68 . A length  38 ′ of this flare pellet assembly  30 ′ generally refers to a distance between the first end  65  of the rod  62  and most remote portion of one of the second end  67  of the rod  62  and the nut  68 . As with the flare pellet assembly  30  illustrated in  FIG. 2 , this flare pellet assembly  30 ′ may exhibit any appropriate length  38 ′ depending on such things as, for example, the desired energy output of the assembly  30 ′, the dimensions of the individual flare pellets  32 ′, and the number of flare pellets  32 ′ included in the assembly  30 ′. One beneficial feature of this embodiment, is that the rod  62  is preferably designed so that the desired quantity of flare pellets  32 ′ associated with the assembly  30 ′ are substantially prevented from any significant movement in a direction parallel to the reference axis  34 . In other words, employment of this rod  62  and the nut  68  may be said to at least generally assist in longitudinally immobilizing the flare pellets  32 ′ relative to the rod  62 . Moreover, this rod  62  tends to provide structural support for the flare pellet assembly  30 ′, and accordingly, at least generally reduces a tendency for structural damage during ejection of the flare pellet assembly  30 ′ from a flare launcher. 
     Still referring to  FIG. 4 , in some embodiments of the flare pellet assembly  30 ′, an appropriate base  66  may be disposed at least generally between the stop  64  of the rod  62  and the flare pellet  32 ′ nearest the stop  64 . This base may be made of any appropriate material such as aluminum or filled plastic, and may be utilized for any appropriate purpose. For example, the base  66  may be made of an appropriate shock absorbing material and may be employed to dampen at least some of the vibration associated with aircraft flight to at least generally hinder and/or prevent structural damage to the flare pellets  32 ′. Moreover, an appropriate washer  72  may also be disposed about the rod  62  toward the second end  67  of the rod  62 . Particularly, this washer  72  may be positioned at least generally between the nut  68  and the flare pellet  32 ′ nearest the nut  68 . 
       FIG. 4  also illustrates that an appropriate adhesive or potting compound  70  such as, for example, epoxy or RTV (room-temperature-vulcanizing) adhesives/sealants may be employed in the flare pellet assembly  30 ′ to at least generally assist in immobilizing various parts of the assembly  30 ′. More particularly, this adhesive  70  is shown as being disposed between each flare pellet  32 ′ and the rod  62 . This at least generally hinders movement of the flare pellets  32 ′ relative to the rod  62 . In addition, the adhesive  70  is disposed between the base  66  and the rod  64 . Further, the adhesive  70  may also be disposed between adjacent flare pellets  32 ′ ( FIG. 5C ) to at least generally hinder movement of the flare pellets  32 ′ relative to each other. It should be noted that any number of adhesives may be employed in this flare pellet assembly  30 ′. For instance, a first adhesive may be disposed between the rod  62  and the flare pellets  32 ′, a second adhesive may be disposed between the rod  62  and the base  66 , and a third adhesive may be utilized between adjacent flare pellets  32 ′. 
     The flare pellet assembly  30 ′ of  FIG. 4  also includes a wrap  72  that is disposed about the stack of flare pellets  32 ′. This wrap  72  may be any appropriate wrap such as, but not limited to, an aluminum foil or other appropriate foil affixed to the flare pellets  32 ′ using an appropriate adhesive or the like, such as an acrylic adhesive. Moreover, in some embodiments, this wrap  72  may also include a layer of nylon, for example, nylon tape, or other appropriate material. As one benefit of this arrangement, employment of the wrap  72  may be said to at least generally contribute to immobilizing the flare pellets  32 ′ relative to each other. Another benefit of utilizing this wrap  72  may be to assist in the ignition of the flare pellet at high altitudes and also at high q conditions. 
     Each of these flare pellets  32 ′ of the flare pellet assembly  30 ′ of  FIG. 4  is made of an appropriate ignitable material including, but not limited to, any of the ignitable materials disclosed herein. For example, in one preferred embodiment, the flare pellets  32 ′ are made of an ignitable material including between about 50% and about 70% magnesium, between about 14% and about 34% polytetrafluoroethylene (PTFE), and about 16% Viton® or other appropriate flouroelastomer. In another preferred embodiment, the flare pellets  32 ′ are made of an ignitable material including between about 50% and about 70% magnesium, between about 25% and about 45% PTFE, and about 5% to 10% acrylic rubber binder or other appropriate binder. 
       FIGS. 5A-B  illustrate a flare pellet  32 ′ that is shaped to resemble a disk or plate and that at least generally includes some similar features of the flare pellet  32  of  FIG. 3 . Accordingly, unless otherwise noted, the description of the flare pellet  32  of  FIG. 3  applies to this flare pellet  32 ′. For example, while the flare pellet  32 ′ may exhibit any appropriate width  46  and/or length  48 , in one preferred embodiment, the width  46  of the flare pellet  32 ′ may be about 1.98 inches, and the length  48  of the flare pellet  32 ′ may be about 0.30 inch. 
     Still referring to  FIGS. 5A-B , the flare pellet  32 ′ includes a first side  40 ′, a second side  42 ′, a circumferential side  44 ′, and first and second outer surfaces  50 ′,  52 ′ (respectively). The first outer surface  50 ′ at least generally extends between the first side  40 ′ and the circumferential side  44 ′ of the flare pellet  32 ′. Likewise, the second outer surface  52 ′ at least generally extends between the second side  42 ′ and the circumferential side  44 ′ of the flare pellet  32 ′. These first and second outer surfaces  50 ′,  52 ′ are configured such that it may be said that the flare pellet  32 ′ at least generally tapers from a first central portion  51  of the flare pellet  32 ′ toward the circumferential side  44 ′ of the flare pellet  32 ′. Indeed, it may be said that flare pellet  32 ′ narrows by a distance  55  from the second side  42 ′ to the circumferential side  44 ′ and by the same distance  55  from the first side  40 ′ to the circumferential side  44 ′. Another way of stating this is that the first and second surfaces  50 ′,  52 ′ are oriented at an angle “α” greater than 0° and less than 90° relative to a plane parallel with one or both the first and second sides  40 ′,  42 ′. While this angle “α” may be any appropriate angle, in one preferred embodiment, the angle “α” is about 5°. 
     Still referring to the flare pellet  32 ′ of  FIGS. 5A-B , the first and second outer surfaces  50 ′,  52 ′ are configured such that it may be said that the flare pellet  32 ′ at least generally tapers from a second central portion  53  toward each of the first and second sides  40 ′,  42 ′ of the flare pellet  32 ′. While, a surface length  58  of each of the first and second outer surfaces  50 ′,  52 ′ may be any appropriate length, the surface length  58  in one preferred embodiment is about 0.7228 inch. Incidentally, while the first and second outer surfaces  50 ′,  52 ′ may exhibit the same surface length  58 , other embodiments may include first and second outer surfaces  50 ′,  52 ′ having differing outer surface lengths  58 . 
       FIGS. 5C  shows first and second flare pellets  32   a ,  32   b  (respectively) having adhesive  70  disposed therebetween to facilitate immobilization of the first flare pellet  32   a  relative to the second flare pellet  32   b . This adhesive  70  may be said to promote a structural integrity of the corresponding flare pellet assembly during the imposition of ejection forces and/or in flight vibration. In addition, the flare pellets  32   a ,  32   b  are keyed to each other. That is, the first flare pellet  32   a  includes a protrusion  74  and the second flare pellet  32   b  includes a recess  76  complimentarily configured to accommodate the protrusion  74  of the first flare pellet  32   a . Appropriate engagement of the protrusion  74  of the first flare pellet  32   a  with the recess  76  of the second flare pellet  32   b  may also contribute to immobilizing of the first flare pellet  32   a  relative to the second flare pellet  32   b . It should be noted that any appropriate quantity of protrusions  74  and recesses  76  may be employed. Moreover, any of a number of appropriate shapes, sizes, locations, and designs of the protrusion(s)  74  and the recess(es)  76  may be utilized. And while this keying feature has been shown in combination with the use of adhesive  70 , some embodiments may employ this keying feature without also utilizing the adhesive  70  between the first and second flare pellets  32   a ,  32   b.    
       FIG. 5D  shows first, second, and third flare pellets  32   a ′,  32   b ′,  32   c ′ (respectively) disposed about a rod  62 ′. More particularly, the second flare pellet  32   b ′ and the rod  62 ′ are keyed to each other. In other words, the rod  62 ′ is equipped with a protrusion  78 , and the second flare pellet  32   b ′ includes a recess  80  complimentarily configured to accommodate the protrusion  78  of the rod  62 ′. Appropriate engagement of the protrusion  78  of the rod  62 ′ with the recess  80  of the second flare pellet  32   b ′ may contribute to immobilizing of the second flare pellet  32   b ′ relative to the rod  62 ′. It should be noted that any appropriate quantity of protrusions  78  and recesses  80  may be employed. Further, other embodiments may have the second flare pellet  32   b ′ including at least one protrusion  78  and the rod  62 ′ including at least one recess  80 . Yet further, any of a number of appropriate shapes, sizes, locations, and designs of the protrusion(s)  78  and the recess(es)  80  may be utilized. Still further, this keying feature may or may not be utilized in combination with the keying feature disclosed in regard to  FIG. 5C . 
       FIG. 6  shows a graph  82  demonstrating first and second outputs  84 ,  86  (respectively) achieved using the flare pellet assembly  30 ′ of  FIG. 4 . The first output  84  is indicative of energy output within the mid infrared band (e.g., a band between about 3.0μ, and about 5.5μ), and the second output  86  is indicative of energy output within the short infrared band (e.g., a band between about 1.8μ, and about 3.0μ. As shown, ignition of the flare pellet assembly  30 ′ achieved a magnitude of at least about 6000 w/ster throughout a range of time spanning from about 0.7 second after ignition to about 3.6 seconds after ignition indicated by the first output  84 . Moreover, ignition of the flare pellet assembly  30 ′ achieved a magnitude of about 2000 w/ster or more throughout that same time period indicated by the second output  86 . In addition, ignition of the flare pellet assembly  30 ′ also provided a peak magnitude of about 8000 w/ster for the first output and a peak magnitude of about 2700 w/ster for the second output. 
       FIG. 7  is a spreadsheet comparing output of prior art infrared flares utilizing the pellet geometry illustrated in  FIGS. 1A-B  (tests  1 - 4 ) with output achieved utilizing the flare pellet assembly  30 ′ (tests  5 - 9 ). Incidentally, the form factors refer to the particular sizes of the flare assemblies and are known to those of ordinary skill in the art. Referring to tests  5 - 7 , the design of the flare pellet assemblies of the invention has enabled these visual flares to achieve peak light outputs of more than 8.7 million candela and still be compatible with a 1×2×8 inch form factor. Moreover, tests  5 - 7  indicate that those visual flash flares of the invention are also capable of providing peak infrared outputs of at least 14,615 w/ster in the short infrared band and at least 22,874 w/ster in the mid infrared band. 
     Tests  8 - 9  of  FIG. 7  show data indicative of the output that was produced from a 1×2×8 inch form factor-compatible, infrared flash flare of the invention. This data of tests  8 - 9  may be compared to the data of test  3 , which is indicative of the output that was produced from a 1×2×8 inch form factor-compatible, infrared flash flare having a prior art flare geometry like that shown in  FIGS. 1A-B . Tests  8 - 9  indicate that the infrared flash flares of the invention provided peak infrared outputs of at least about 106,004 w/ster in the short infrared band, as compared to only 27,192 w/ster provided by the prior art flare of test  3 . Moreover, tests  8 - 9  indicate that the infrared flash flares of the invention provided peak infrared outputs of at least about 145,281 w/ster in the mid infrared band, in comparison to only 40,896 w/ster provided by the prior art flare of test  3 . In addition to providing these peak infrared outputs, the infrared flash flares of tests  8 - 9  also produced peak light outputs of at least about 1,668,127 candela, in comparison to only 641,587 candela from the prior art flare of test  3 . The differences in output and burn time are due, significantly in part, to the flare pellet assemblies of the invention having surface areas that are much greater than the surface areas of the prior art pellets ( FIG. 1 ) for corresponding form factors. For example, for a 1×2×8 form factor, the surface area of a flare pellet assembly of the invention may be about 3.0 to about 4.5 times greater than the surface area of flare pellet  20  of  FIG. 1 . 
     Still referring to  FIG. 7 , it should be noted that the flare pellet geometry of test  4 , like that of test  3 , is like that shown in  FIGS. 1A-B . However, the flare pellet utilized generate the output shown in test  4  is compatible with a 2×2.5×8 inch form factor, and therefore includes a significant amount more ignitable flare material than the 1×2×8 form factor pellets utilized to produce the output indicated in tests  8 - 9 . Even though the conventional infrared flare of test  4  is substantially larger in size than the infrared flash flares of tests  8 - 9 , which utilize the design of the present invention, the prior art infrared flare of test  4  failed to provide the peak outputs attained utilizing the flare pellet assembly design of the present invention. 
       FIG. 8  illustrates a flare assembly  100  that includes yet another embodiment of a flare pellet assembly of the invention, and accordingly, a “double prime” designation is utilized to distinguish the flare pellet assembly  30 ″ shown in  FIG. 8  from the flare pellet assemblies  30  and  30 ′. This flare assembly  100  has a first end  102 , an opposing second end  104  from which the flare pellet assembly  30 ″ is ejected, a reference axis  34 , and a length  106  defined between the first and second ends  102 ,  104  measured parallel with the reference axis  34 . In addition, an outer casing  108  of the flare assembly  100  is disposed about the pellet assembly  30 ″ and along the substantial entirety of the length  106  of the flare assembly  100 . This outer casing  108  may be made of any appropriate material such as, for example, aluminum. Referring to  FIGS. 8-9B , toward the second end  104  of the flare assembly  100  is a cap  110 . The location of this cap  110  is such that it may be said that the flare pellet assembly  30 ″ is disposed between the cap  110  and the second end  102  of the flare assembly  100 . The cap  110  may be at least temporarily held in place in any of a number of appropriate manners. For example, the cap  110  may be adhesively interconnected with the outer casing  108  of the flare assembly  100  using an appropriate adhesive  112 . In addition or alternatively, the cap  110  may be at least temporarily prevented from dissociating from the second end  104  by providing one or more retention stakes  114  in the outer casing  108 . This cap  110  may be made of any appropriate material such as, for example, aluminum, plastic, and the like. 
     Referring specifically to  FIG. 8 , disposed toward the first end  102  of the flare assembly  100  is a number of components utilized to at least generally assist in launching/ejecting the flare pellet assembly  30 ″ from a remainder of the flare assembly  100 . Defined in the case  108  is an impulse cartridge port  113  having a shipping plug  109  disposed therein. Further, a piston  107  is disposed adjacent the impulse cartridge port  113 . Also found between the first end  102  of the flare assembly  100  and the flare pellet assembly  30 ″ is a sequencing igniter  111 . 
     In operation, the flare assembly  100  of  FIG. 8  may be said to function in the following manner. Prior to use, the flare assembly  100  may be inserted into a magazine (not shown) of a flare dispenser (not shown). The shipping plug  109  may be removed from the impulse cartridge port  113  of the case  108 , and an appropriate impulse cartridge (not shown), such as an electro-explosive device, is inserted into the impulse cartridge port  113  of the case  108 . This procedure may be repeated until a desired number of flare assemblies  100  is installed in the magazine. The magazine, with any other appropriate ancillary components (not shown), may then be engaged or associated with a flare dispenser (not shown). 
     To utilize the flare assembly  100 , an electrical firing current is applied to electrical contacts of the impulse cartridge (not shown) which generally causes a resistance element internal to the impulse cartridge to heat and ignite its pyrotechnic compositions. A propellant charge in the impulse cartridge burns, and the resulting hot gasses and hot particles rupture a closure of the impulse cartridge pressurizing the free volume between the first end  102  of the flare case  108  and the piston  107 . The hot gasses and hot particles from the impulse cartridge simultaneously flow through a spit hole  115  in the piston  107  and ignite a pyrotechnic pellet (not shown) that is internal to the pyrotechnic sequencing igniter  111 . The pressure of the hot gasses in the free volume between the first end  102  of the case  100  and the piston  107  biases the piston toward the pyrotechnic sequencing igniter  115 , which, in turn, is biased toward the flare pellet assembly  30 ″, which then pushes against the closure  110  of the flare assembly  100 . The forces exerted against the closure  110  are preferably great enough to override or overcome the retention of the closure  110  within the case  108 . The pressure of the hot gasses behind the piston  107  continues to push against the above-mentioned components of the flare assembly  100 , thus causing the flare pellet assembly  30 ″ to be ejected from the case  108  of the flare assembly  100 . Once clear of the case  108 , bore rider portions of the pyrotechnic sequencing igniter  111  move outward (e.g., away from the reference axis  34 ) allowing a flame from the pyrotechnic pellet portion of the igniter  111  to impinge on an ignition material that the pellets  32 ″ are coated with, thus igniting the stack of pellets  32 ″ of the flare pellet assembly  30 ″. In addition, pressure from the burning flare pellets  32 ″ ruptures the protective wrap  72  of the flare pellet assembly  30 ″ completing ignition/activation of the assembly  30 ″. While  FIG. 8  illustrates one appropriate design of a flare assembly  100  in which flare pellet assemblies of the invention (e.g.,  30 ,  30 ′,  30 ″) may be utilized, it should be noted that the flare pellet assemblies herein described may be employed in any appropriate flare launcher and/or flare assembly. 
     Still referring to the flare pellet assembly  30 ″ of the flare assembly  100  of  FIG. 8 , a plurality of flare pellets  32 ″ are arranged in a stack at least generally along a longitudinal reference axis  34 , and the flare pellet assembly  30 ″ includes an aperture  36 , a rod  62 , and a nut  68  like those described above. Each of these flare pellets  32 ″ may be made of an appropriate ignitable material described herein as well as those ignitable materials described in U.S. Pat. No. 5,472,533 to Herbage et al, the entire disclosure of which is herein incorporated in its entirety. 
       FIGS. 10A-C  illustrate an exemplary flare pellet  32 ″ of the flare pellet assembly  30 ″. Unlike the flare pellets  32 ,  32 ′, this flare pellet  32 ″ has an at least generally rectangular cross-sectional shape when taken perpendicular to the reference axis  34 . In addition, this flare pellet  32 ″ includes a top  40 ″, a bottom  42 ″, and first, second, third, and fourth sides  44   a ,  44   b ,  44   c , and  44   d  (respectively). A first width  46   a  of the flare pellet  32 ″ extends between the first and third sides  44   a ,  44   c  of the flare pellet  32 ″ and is generally measured substantially perpendicular to the reference axis  34 . Similarly, a second width  46   b  of the flare pellet  32 ″ extends between the second and fourth sides  44   b ,  44   d  of the flare pellet  32 ″ and is generally measured substantially perpendicular to the reference axis  34 . These first and second widths  46   a ,  46   b  may be any appropriate widths. For example, in one preferred embodiment, the first width  46  is about 0.845 inch and the second width is about 1.880 inches. In addition to these widths  46   a ,  46   b , the flare pellet  32 ″ also has a length  48  measured substantially parallel to the reference axis  34  that generally coincides with a distance between the top  40 ″ and the bottom  42 ″ of the flare pellet  32 ″. This length  48  may be any appropriate length and, in one preferred embodiment, is about 0.225 inch. 
     Still referring to  FIGS. 10A-C , in addition to the top  40 , bottom  42 , and sides  44   a - d , the flare pellet  32 ″ also includes first, second, third, and fourth upper outer surfaces  50   a ,  50   b ,  50   c , and  50   d  (respectively), and first, second, third, and fourth lower outer surfaces  52   a ,  52   b ,  52   c , and  52   d  (respectively). The first upper outer surface  50   a  at least generally extends between the top  40 ″ and the first side  44   a  of the flare pellet  32 ″. Likewise, the second upper outer surface  50   b  at least generally extends between the top  40 ″ and the second side  44   b  of the flare pellet  32 ″, the third upper outer surface  50   c  at least generally extends between the top  40 ″ and the third side  44   c , and the fourth upper outer surface  50   d  at least generally extends between the top  40 ″ and the fourth side  44   d . Moreover, the first lower outer surface  52   a  at least generally extends between the bottom  42 ″ and the first side  44   a  of the flare pellet  32 ″, the second lower outer surface  52   b  at least generally extends between the bottom  42 ″ and the second side  44   b , the third lower outer surface  52   c  at least generally extends between the bottom  42 ″ and the third side  44   c , and the fourth lower outer surface  52   d  at least generally extends between the bottom  42 ″ and the fourth side  44   d.    
     The above-described upper and lower outer surfaces  50   a - d ,  52   a - d  of  FIGS. 10A-C  are configured such that it may be said that the flare pellet  32 ″ at least generally tapers from a first central portion  51  of the flare pellet  32 ″ toward the sides  44   a - d  of the flare pellet  32 ″. Incidentally a width  46   c  of this central portion  51 , which also coincides with a width of the top  40 ″ and bottom  42 ″, may be any of a number of appropriate distances, and, in one preferred embodiment, is about 0.400 inch. It may be said that flare pellet  32 ″ at least generally narrows from it length  48 , found at the central portion  51 , to a side length  57  measured at any of the sides  44   a - d  of the flare pellet  32 ″. As another way of stating this, and as a more particular statement, the upper and lower surfaces  50   a - d ,  52   a - d  are oriented at angles greater than 0° and less than 90° relative to a plane parallel with one or both the top  40 ″ and bottom  42 ″. For instance, the first and third upper and lower surfaces  50   a ,  50   c ,  52   a ,  52   c  may be oriented at an angle “β” of about 5°. As another example, the second and fourth lower surfaces  50   b ,  50   d ,  52   b ,  52   d  may be oriented at an angle “γ” of about 16.3°. In some embodiments, one or more of the upper and lower outer surfaces  50   a - d ,  52   a - d  may be oriented at differing angles compared to the others. So, for instance, in one embodiment, all of the upper and lower outer surfaces  50   a - d ,  52   a - d  may exhibit differing angles relative to a plane parallel with one or both the top  40 ″and bottom  42 ″ of the flare pellet  32 ″. 
       FIG. 11  is a graph showing first and second outputs  120 ,  122  (respectively) of a spectrally balanced prior art flare having a geometry like that shown in  FIGS. 1A-B  and having a 1×2×8 form factor. By comparison,  FIG. 12  is a graph showing third and fourth outputs  124 ,  126  (respectively) of an embodiment of the flare pellet assembly  30 ″ having a 1×2×8 form factor and including the same ignitable composition as the flare pellet that was utilized to generate the output of  FIG. 11 . The output shown in  FIG. 11  illustrates that the corresponding flare&#39;s burn lasted for about 8 10 seconds, as opposed to the about 5 second burn time shown in  FIG. 12 . This is due to the increased surface area of the  FIG. 12  flare pellet (e.g.,  32 ″ of  FIG. 9 ) relative to the  FIG. 11  flare pellet (e.g.,  20  of  FIG. 1 ). Another way of stating this is that the shorter burn time illustrated in  FIG. 12  is due to a smaller flare pellet web than the flare pellet web affecting the burn time shown in  FIG. 11 . Since the burn time of  FIG. 12  is shorter than that of  FIG. 11 , the third output  124  is significantly greater than the first output  120  in the mid infrared band between about 0.8 seconds after ignition and about 2.8 seconds after ignition. Moreover, the fourth output  126  is, in most cases, generally equal to or greater than the second output  122  in the short infrared band and roughly in about the same time frame. Since infrared guided missiles may be appropriately decoyed away with a burn of only about 2-3 seconds, this greater output of  FIG. 12  may more closely resemble an exhaust plume of an aircraft and may be more effective than the flare of  FIG. 11 . This shorter burn time and greater output has previously been unattainable as prior attempts at providing a flare pellet with such output have resulted in flare pellets with degraded spectral ratios (e.g., attempting to formulate faster burning compositions) and/or structural instability (e.g., could not withstand flight vibration without chipping, cracking, and/or breaking). 
       FIG. 13  illustrates one example of a device  150  that may be utilized in making the individual flare pellets (e.g.,  32 ,  32 ′,  32 ″). This device  150  may be characterized as having a punch  152  and anvil  164 . The punch  152  of the device  150  is generally a solid structure, except for a core rod receptacle  156  defined therein. The anvil  164  of the device  150  includes a sleeve  158  to at least generally assist in keeping a pellet precursor material  160  from leaking out from sides of the device  150 . 
     To make a flare pellet assembly, such as any of the flare pellet assemblies described herein, the removable sleeve  158  is associated with the device  150 . Then, a pre-measured charge of one or more ignitable materials, or flare pellet precursor material  160 , is loaded at least generally into the sleeve  158 . At or before this point, it is desirable to have the anvil  164  and core rod  166  preassembled together with the sleeve  158 . The punch  152  is assembled to the tooling with the core rod  166  nesting up into the receptacle  156  defined in the punch  152 . The charged tooling is then placed on a press  162  (usually a hydraulic press). The press  162  is energized, and the press biases at least one of the punch  152  and the anvil  164  toward the other at least generally in one of the directions indicated by arrow  168 , thus forming the flare pellet precursor material  160  into a pellet. The press  162  is then retracted, and the tooling removed. The punch  152  and the anvil/core rod  166  are then removed from the tooling leaving the flare composition pellet in the sleeve  158 . The sleeve  158  is then again placed on a push out sleeve  154  of the device  150 , and the punch  152  is again directed into the sleeve  158 . The tooling is then placed back into the press  162 , and the action of the press  162  is used to push the flare pellet out of the sleeve  158 . 
     While  FIG. 13  illustrates one device for making flare pellets, other appropriate manners including, but not limited to, extrusion, molding, and/or casting of flare pellets may also be utilized to form a plurality of flare pellets. In any event, once these individual flare pellets are fabricated, the same are stacked to form a pellet assembly (e.g.,  30 ), and an appropriate casing (e.g.,  72 ) is disposed about at least a portion of the pellet assembly. 
     Various manners of forming usable pellets may depend on the pyrotechnic or even potentially pyrophoric compositions being utilized. For instance, some compositions can be formed into pellets by pressing and typically not by extruding or casting. Other compositions may be formed into pellets by casting only, while others may be suitable for extruding, and still others by pressing and extruding. As a more particular example, the spectrally balanced flare compositions and the visible light flare compositions described herein may be pressed to form a pellet, while the MTV composition used for infrared flash flares may be pressed or extruded. It should be noted, however, that any appropriate manner of forming any appropriate composition(s) into flare pellets is included within the scope of this disclosure. 
     Again, one of the objects of the invention is to provide a flare pellet geometry that provides a thinner web (e.g., distance between peripheral surfaces of the flare pellet and a geometric center of the same) than can be obtained using conventional fabrication methods. The thin web design of the flare pellets, with their attendant high initial surface areas, at least generally promote a rapid, high-intensity burn that may be tailored or controlled to mimic a spectral signature of an aircraft exhaust plume. Accordingly, the web thickness may be no more than about 0.20 inch in one embodiment, no more than about 0.17 inch in another embodiment, no more than about 0.15 inch in still another embodiment, and no more than about 0.12 inch in yet another embodiment. 
     The flare pellets (e.g.,  32 ,  32 ′,  32 ″) of the invention are typically thinner at the outer edges than in the center. When assembled in a stack as a flare pellet assembly (e.g., 30, 30′, 30″), this difference in thickness from the central portion to the outer edges defines grooves between adjacent flare pellets to which ignition materials may be applied and, upon ignition of the flare pellet assembly, allows relief for rapid escape of hot gasses. In other words, the stacked pellet configuration provides a significantly larger surface area available for combustion than conventional designs. For example, the prior art flare pellet  20  shown in  FIG. 1  has a surface area per gram of flare composition of only about 0.283 sq in./g. By contrast, the flare pellet assemblies of the invention exhibit surface areas per gram of flare composition of about 0.76 sq in./g in one embodiment and about 0.85 sq in./g in another embodiment. This larger than normal surface area promotes the rapid burning of the flare pellet assembly yielding increased mass flow and resultant higher than normal energy output for a shorter overall period of time. A shape of the time versus intensity energy output curve can be modified to suit the intended application by varying, among other things, any of the geometric features, some of which are: 
     1) the thickness of one or more of the pellets in the stack; 
     2) the number of pellets in a given form factor; 
     3) the radii of the bi-convex pellet surfaces; 
     4) the angle(s) of the various surfaces (e.g.,  50 ,  50 ′,  50   a - d ,  52 ,  52 ′,  52   a - d ); and 
     5) the dimensions of the central portions of one or more pellets. 
     When assembled, the stack of pellets provide a rapid burning substitute for a conventional flare pellet. The assembly can then be prepared and assembled into any standard form factor flare case, along with any appropriate ancillary flare hardware, to yield a completed flare that can be fired using any appropriate flare launcher system. 
     Those skilled in the art will now see that certain modifications can be made to the assembly and related methods herein disclosed with respect to the illustrated embodiments, without departing from the spirit of the instant invention. And while the invention has been described above with respect to the preferred embodiments, it will be understood that the invention is adapted to numerous rearrangements, modifications, and alterations, and all such arrangements, modifications, and alterations are intended to be within the scope of the appended claims. For instance, while the invention has been disclosed in regard to aircraft defensive countermeasures, the invention may have application in pyrotechnic devices at least generally associated with naval and/or land vehicles.