Patent Description:
Rocket motor assemblies generally include at least one containment vessel (e.g., housing) having at least one propellant structure (e.g., a solid propellant grain) therein, and at least one thrust nozzle operatively associated with the containment vessel. Multi-stage rocket motor assemblies may, for example, include an outer housing holding a plurality of stages each including a containment vessel holding a propellant structure therein, and a thrust nozzle operatively associated with the containment vessel. The outer housing may be separable such that when a propellant structure of a given stage has been consumed, that stage may be separated from the other stages to remove excess weight and, hence, increase the range and/or the speed of the multi-stage rocket motor assembly. An adjoining stage may then be fired immediately, or at a desired later time during the flight of the multi-stage rocket motor assembly.

Rocket motor assemblies can also include flexible bearing assemblies operatively associated with the thrust nozzles thereof. Each stage of a multi-stage rocket motor assembly may, for example, include a different flexible bearing assembly operatively associated with the thrust nozzle thereof. A flexible bearing assembly may include a lamination of alternating flexible seals and rigid shims that are stacked and bonded together. The lamination may be laterally flexible, that is, in directions parallel to the flexible seals, but unyielding in the directions perpendicular to the flexible seals. Lateral movement of the flexible bearing assembly (e.g., by way of at least one actuator) may be used to modify the orientation of the thrust nozzle operatively associated therewith, so as to control the direction of the rocket motor assembly during use and operation (e.g., flight) of the rocket motor assembly.

Unfortunately, the material compositions and properties of conventional flexible seals for flexible bearing assemblies can impose undesirable limitations on production efficiency, and on at least one of the capabilities, performance, durability, and reliability of the flexible bearing assemblies (and, hence, on rocket motor assemblies including the flexible bearing assemblies). For example, conventional flexible seals formed from natural rubber (NR) based formulations or polyisoprene (PI) rubber-based formulations may have significant production costs associated with the large number of ingredients beyond NR and PI (e.g., additives, such as fillers, antioxidants, tackifiers, processing aids, plasticizers, activations, curatives, etc.) typically required to achieve desirable properties, and can also have low strength, be prone to significant cavitation and loading damage, exhibit poor low temperature capabilities, and exhibit poor aging characteristics. As another example, conventional flexible seals formed from silicone rubber formulations including a single, preselected grade of silicone rubber can only be used for a very limited number of rocket motor assembly types due to the unsuitability of various material properties (e.g., Shore A hardness, shear modulus, etc.) provided by the selected grade of silicone rubber relative to the various needs (e.g., various loading needs, various torquing needs, etc.) of other, different rocket motor assemblies.

Accordingly, there is a continuing need for flexible structures (e.g., flexible seals) having material compositions and properties capable of meeting the needs of a wide variety of rocket motor assemblies, as well as for methods of forming such flexible structures. It would also be desirable to have new assemblies (e.g., flexible assemblies, moveable thrust nozzle assemblies, rocket motor assemblies, etc.) including such flexible structures.

<CIT> discloses the production of homogeneous (rocket) propellant blocks with the specified inhibiting coatings of a silicone elastomer wherein the silicone elastomer contains, in chemically bound form, a polydiorganosiloxane with terminal hydroxyl (OH) groups and an alkyl silicate and/or polyalkyl silicate with <NUM>-<NUM> C alkyl groups, and also contains monomeric or polymeric aminoorganosiloxane(s) with an (alkyl)amino-, aminoalkylamino-, alkylpolyaminoalkylamino- or poly(aminoalkyl)-amino-alkyl group, by casting or spraying the different elastomer components around a homogeneous propellant block, placed concentrically in a mold, followed by cure, with addition of aminoorganosiloxane(s) to the mixture.

<CIT> discloses reinforced silicone resin films comprising at least two polymer layers, wherein at least one of the polymer layers comprises a cured product of a at least one silicone resin having an average of at least two silicon-bonded alkenyl groups or silicon-bonded hydrogen atoms per molecule, and at least one of the polymer layers comprises a carbon nanomaterial.

In accordance with one embodiment described herein, a method of forming a flexible structure according to the invention for a rocket motor assembly annular seal for a moveable thrust assembly of a rocket motor assembly according to claim <NUM> comprises forming a polysiloxane composition comprising at least two different silicone materials according to the features of the independent claims. A preliminary structure is formed from the polysiloxane composition. The preliminary structure is cured and the cured polysiloxane composition comprises crosslinked polysiloxane chains of the first silicone material and the second silicone material.

Preferred advantageous embodiments thereof are defined by the features of the dependent claims.

According to claim <NUM>, a flexible annular seal formed according to the method of the invention is provided.

According to claim <NUM> a flexible assembly for a rocket motor assembly comprises a first substrate, a second substrate overlying the first substrate, and a lamination comprising an alternating sequence of flexible structures and rigid structures extending between the first substrate and the second substrate. At least one of the flexible structures comprises the annular seal of the invention.

In yet further embodiments, According to claim <NUM> a moveable thrust nozzle assembly for a rocket motor assembly comprises a fixed housing and at least one flexible assembly coupled to and circumscribing a portion of the fixed housing. The at least one flexible assembly comprises an end-ring and a lamination comprising an alternating sequence of flexible structures and rigid structures extending between the fixed housing and the end-ring. At least one of the flexible structures comprises the annular seal of the invention.

According to claim <NUM>, a rocket motor assembly comprises at least one stage comprising a vessel containing a propellant structure and a moveable thrust nozzle assembly connected to an end of the vessel. The moveable thrust nozzle assembly comprises a fixed housing and a flexible assembly coupled to and circumscribing a portion of the fixed housing. The flexible assembly comprises an end-ring and a lamination comprising an alternating sequence of flexible structures and rigid structures extending between the fixed housing and the end-ring. At least one of the flexible structures the annular seal of the invention.

Methods of forming a flexible structure, such as a flexible structure for a rocket motor assembly, are described, as are related flexible structures, and flexible assemblies (e.g., flexible bearing assemblies, moveable thrust nozzle assemblies, rocket motor assemblies, etc.) including the flexible structures. The method according to claim <NUM> comprises forming a polysiloxane composition formed of and including at least two different silicone materials and, optionally, at least one additive (e.g., a crosslinking/curing agent). The polysiloxane composition is formed (e.g., molded, extruded, etc.) into a preliminary structure, and then the preliminary structure is cured to crosslink polysiloxane chains of the different silicone materials and form the flexible structure. The types and amounts of the different silicone materials and additive(s) (if any) of the polysiloxane composition may be selected relative to each other to at least provide the polysiloxane composition a different Shore A hardness than the Shore A hardness of each of the different silicone materials alone, as well as to at least provide the subsequently formed flexible structure a desired shear modulus. The flexible structures of the disclosure may exhibit material properties more favorable to the use of the flexible structures in a wide variety of assemblies (e.g., rocket motor assemblies) for aerospace applications than material properties of conventional flexible structures. Structures and assemblies formed in accordance with the methods of the disclosure may exhibit enhanced capabilities, performance, durability, and reliability as compared to corresponding conventional structures and assemblies formed through conventional methods.

The following description provides specific details, such as material types, material thicknesses, and processing conditions in order to provide a thorough description of embodiments of the disclosure. However, a person of ordinary skill in the art will understand that the embodiments of the disclosure may be practiced without employing these specific details. Indeed, the embodiments of the disclosure may be practiced in conjunction with conventional fabrication techniques employed in the industry. In addition, the description provided below does not form a complete process flow for manufacturing a structure or assembly. The structures described below do not form a complete assembly. Additional acts to form the complete assembly from various structures may be performed by conventional fabrication techniques. Also note, any drawings accompanying the application are for illustrative purposes only, and are thus not drawn to scale. Additionally, elements common between figures may retain the same numerical designation.

As used herein, the term "may" with respect to a material, structure, feature or method act indicates that such is contemplated for use in implementation of an embodiment of the disclosure and such term is used in preference to the more restrictive term "is" so as to avoid any implication that other, compatible materials, structures, features and methods usable in combination therewith should or must be excluded.

As used herein, the term "configured" refers to a size, shape, material composition, and arrangement of one or more of at least one structure and at least one apparatus facilitating operation of one or more of the structure and the apparatus in a pre-determined way.

As used herein, the term "substantially," in reference to a given parameter, property, or condition, means to a degree that one of ordinary skill in the art would understand that the given parameter, property, or condition is met with a small degree of variance, such as within acceptable manufacturing tolerances.

For example, if materials in the figures are inverted, elements described as "below" or "beneath" or "under" or "on bottom of" other elements or features would then be oriented "above" or "on top of" the other elements or features. Thus, the term "below" can encompass both an orientation of above and below, depending on the context in which the term is used, which will be evident to one of ordinary skill in the art. The materials may be otherwise oriented (e.g., rotated <NUM> degrees, inverted, flipped, etc.) and the spatially relative descriptors used herein interpreted accordingly.

As used herein, the term "about" in reference to a given parameter is inclusive of the stated value and has the meaning dictated by the context (e.g., it includes the degree of error associated with measurement of the given parameter).

<FIG> is a simplified flow diagram illustrating a method <NUM> of forming a flexible structure, such as a flexible structure for use in an aerospace application (e.g., a flexible seal for a rocket motor assembly), in accordance with embodiments of the disclosure. The method <NUM> includes a mixing process <NUM> including forming a polysiloxane composition including at least two different silicone materials; a structure formation process <NUM> including forming the polysiloxane composition into a preliminary structure; and a curing process <NUM> including crosslinking polysiloxane chains of the preliminary structure. With the description as provided below, it will be readily apparent to one of ordinary skill in the art that the method described herein may be used in various applications. In other words, the method may be used whenever it is desired to form a flexible structure exhibiting desired material properties (e.g., mechanical properties, rheological properties, physical properties, chemical properties, etc.).

The mixing process <NUM> includes combining at least two different silicone materials, and, optionally, at least one additive to form a polysiloxane composition exhibiting desired material properties (e.g., rheological properties, such as Shore A hardness). As used herein the term, "silicone material" means and includes a material (e.g., resin, rubber, etc.) formed of and including a polysiloxane compound. The polysiloxane compound of each of the different silicone materials may independently exhibit the following chemical structure:
<CHM>
where, as described in further detail below, n is an integer from <NUM> to <NUM>,<NUM> (e.g., from <NUM> to <NUM>,<NUM>); each R is independently a pendant functional group; and each M is independently a reactive capping group.

Each R group may independently comprise hydrogen, an aliphatic group, a cyclic group, or a combination thereof. As used herein, the term "aliphatic group" means and includes a saturated or unsaturated, substituted or unsubstituted, linear or branched hydrocarbon group, such as an alkyl group, an alkenyl group, and an alkynyl group. A suitable alkyl group may be a saturated or unsaturated, substituted or unsubstituted, linear or branched hydrocarbon group having from <NUM> to <NUM> carbon atoms (e.g., methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, substituted derivatives thereof, etc.). A suitable alkenyl group may be a saturated or unsaturated, substituted or unsubstituted, linear or branched hydrocarbon group including from <NUM> to <NUM> carbon atoms and at least one carbon-carbon double bond. A suitable alkynyl group may be a saturated or unsaturated, substituted or unsubstituted, linear or branched hydrocarbon group including from <NUM> to <NUM> carbon atoms and at least one carbon-carbon triple bond. Optionally, the aliphatic group may include one or more heteroatoms (i.e., an element other than carbon and hydrogen, such as oxygen, nitrogen, sulfur, or silicon). In some embodiments, each R group is a methyl group. As used herein, the term "cyclic linkage" means and includes at least one saturated or unsaturated, substituted or unsubstituted, closed ring hydrocarbon group, such as an alicyclic group, an aryl group, or a combination thereof. A suitable alicyclic group may be a saturated or unsaturated, substituted or unsubstituted, closed ring hydrocarbon group including from <NUM> to <NUM> carbons (e.g., cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, substituted derivatives thereof, etc.). A suitable aryl group may include a saturated or unsaturated, substituted or unsubstituted, closed aromatic ring or a saturated or unsaturated, substituted or unsubstituted, closed aromatic ring system (e.g., phenyl, biphenyl, substituted derivatives thereof, etc.). Optionally, the cyclic group may include one or more heteroatoms. By way of non-limiting example, the cyclic group may be at least one of a heteroalicylic group and a heteroarylene group (e.g., furyl, thienyl, pyridyl, substituted derivatives thereof, etc). In embodiments wherein at least one R group is unsaturated, the R group may, optionally, include a moiety configured to react with another compound to form a chemical bond under conventional reaction conditions, such as those employed in hydrosilylation, condensation, addition, esterification, etherification, Michael reaction, imidation, amination, sulfonation, and the like. For example, each R group may independently include a vinyl moiety, a silanol moiety, an allyl moiety, a vinylcyclohexyl moiety, a styryl moiety, or a propargyl moiety.

Each M group may comprise a terminal functional group configured to react with another compound to form a chemical bond under conventional reaction conditions, such as those employed in hydrosilylation, condensation, addition, esterification, etherification, Michael reaction, imidation, amination, sulfonation, and the like. By way of non-limiting example, each M group may comprise a vinyl group, a silanol group, an allyl group, a vinylcyclohexyl group, a styryl group or a propargyl group. In some embodiments, each M group is a vinyl group. The M groups may facilitate crosslinking of each polysiloxane compound with at least one other polysiloxane compound to form the flexible structure, as described in further detail below.

The different silicone materials of the polysiloxane composition may comprise different grades of a single polysiloxane, and/or may comprise different polysiloxanes. Different grades of a single polysiloxane may, for example, exhibit substantially the same general chemical structure (e.g., the same R groups and M groups as one another), but different molecular weights (e.g., different polymer chain lengths than one another). In contrast, different polysiloxanes may, for example, exhibit different chemical structures (e.g., different R groups than one another, different M groups than one another, etc.), and may also exhibit substantially the same or different molecular weights. In some embodiments, each of the different silicone materials of the polysiloxane composition is formed of and includes a different grade of the same polysiloxane. In additional embodiments, at least one of the different silicone materials of the polysiloxane composition is formed of and includes a different polysiloxane than at least one other of the different silicone materials of the polysiloxane composition.

As a non-limiting example, one or more of the different silicone materials of the polysiloxane composition may independently be formed of and include a linear polysiloxane compound having a polymer backbone comprising repeating units of dimethylsiloxane, methylethylsiloxane, methylphenylsiloxane, diethylsiloxane, ethylphenylsiloxane, or diphenylsiloxane; and reactive capping groups comprising vinyl, silanol, allyl, vinylcyclohexyl, styryl, or propargyl. At least one of the different silicone materials may, for example, be formed of and include a vinyl-terminated polydimethylsiloxane, a vinyl-terminated polymethylethylsiloxane, a vinyl-terminated polymethylphenylsiloxane, a vinyl-terminated polydiethylsiloxane, a vinyl-terminated polyethylphenylsiloxane, a vinyl-terminated polydiphenylsiloxane, or combinations thereof. In some embodiments, the different silicone materials of the polysiloxane composition are formed of and include different vinyl-terminated polydimethylsiloxane compounds (e.g., vinyl-terminated polydimethylsiloxane compounds exhibiting different molecular weights than one another). Suitable silicone materials are commercially available from various sources, such as from Wacker Chemie AG (Adrian, MI) at least under the ELASTOSIL® (e.g., ELASTOSIL® R401/<NUM> resin, ELASTOSIL® R401/<NUM> resin, etc.) tradename. In some embodiments, a first of the different silicone materials is ELASTOSIL® R401/<NUM> resin, and a second of the different silicone materials is ELASTOSIL® R401/<NUM> resin.

If included, the additive may comprise at least one material that promotes the formation of a flexible structure from the polysiloxane composition, and/or enhances at least one material property (e.g., shear modulus) of the flexible structure to be formed from the polysiloxane composition. The polysiloxane composition comprises at least one crosslinking/curing agent that enhances at least one of close packing of polysiloxane chains of the different silicone materials and crosslinking of polysiloxane chains of the different silicone materials during and/or after the formation of a flexible structure from the polysiloxane composition. The type and amount of crosslinking/curing agent may at least partially depend on the different silicone materials utilized, and on the desired properties of the flexible structure to be formed, as described in further detail below. The crosslinking/curing agent comprises at least one of dicumyl peroxide and bis-(<NUM>, <NUM>-dischlorobenzoyl)-peroxide. In some embodiments, the crosslinking/curing agent comprises dicumyl peroxide. Suitable crosslinking/curing agents are commercially available from various sources, such as from Arkema, Inc. (King of Prussia, PA) at least under the DI-CUP® (e.g., DI-CUP® 40C, DI-CUP® 40KE, etc.) tradename. The crosslinking/curing agent may, for example, be present in the polysiloxane composition at from about <NUM> parts per hundred parts of resin (phr) to about <NUM> phr, such as from about <NUM> phr to about <NUM> phr, or about <NUM> phr. In some embodiments, the polysiloxane composition comprises at about <NUM> phr organic peroxide additive. In additional embodiments, the additive may comprise at least one of a cure accelerator, an adhesion promoter, a lubricant, a filler, and a pigment. In further embodiments, the polysiloxane composition may be substantially free of additives other than crosslinking/curing agents.

The quantity (e.g., amount, parts, etc.) and types of the different components of the polysiloxane composition may be selected to provide the polysiloxane composition, and a flexible structure subsequently formed from the polysiloxane composition, desired material properties (e.g., rheological properties, mechanical properties, physical properties, chemical properties, etc.). For example, the quantity and type of each of the different silicone materials and the additive(s) (if any) of the polysiloxane composition may be selected to provide the polysiloxane composition a desired Shore A hardness, and to provide a flexible structure formed from the polysiloxane composition a desired shear modulus. The desired Shore A hardness may be determined at least partially based on a chosen method of forming the flexible structure, and the desired shear modulus may be determined at least partially based on the desired end-use of the flexible structure. By way of non-limiting example, at least in embodiments wherein the flexible structure comprises a component (e.g., a flexible seal) of a rocket motor assembly, the quantity and type of the different silicone materials and the additive(s) (if any) may be selected relative to one another to tailor the Shore A hardness of the polysiloxane composition to a desired value less than about <NUM> at a temperature within a range of from about <NUM> to about <NUM>, and to tailor the shear modulus of the subsequently formed flexible structure to a desired value less than about <NUM> pounds per square inch (psi). The different silicone materials may be included in any ratio relative to another that facilitates the desired Shore A hardness of the polysiloxane composition and the desired shear modulus of the subsequently formed flexible structure. As a non-limiting example, a first silicone material having a Shore A hardness within a range of from about <NUM> to about <NUM> and a second silicone material having a Shore A hardness within a range of from about <NUM> to about <NUM> may each be selected and then combined in a pre-determined ratio, along with a selected crosslinking/curing agent (if any), to produce a polysiloxane composition having a desired Shore A hardness less than about <NUM> that may subsequently be cured to form a flexible structure exhibiting a shear modulus less than about <NUM> psi.

The polysiloxane composition is substantially homogeneous (e.g., the different silicone materials and any additives may be uniformly dispersed throughout the polysiloxane composition),.

The polysiloxane composition may be formed from the different silicone materials and any additive(s) using conventional processes (e.g., conventional material addition processes, conventional mixing processes, etc.) and conventional processing equipment, which are not described in detail herein. By way of non-limiting example, relatively less viscous silicone materials may be added to and mixed with relatively more viscous silicone materials in sequence to form a master batch, and then additive(s) (e.g., a cure package at least including a crosslinking/curing agent), if any, may be added to and mixed with the master batch. If included, the additive(s) may, for example, be added to and mixed with the master batch by way of a two roll mill.

With continued reference to <FIG>, the structure formation process <NUM> includes forming the polysiloxane composition into a preliminary structure having an annular shape. For example, a volume of the polysiloxane composition may be subjected to a conventional molding process (e.g., an injection molding process, a compression molding process, a transfer molding process, etc.) to form the preliminary structure to comprise a bulk structure of a desired shape and size. As another example, a volume of the polysiloxane composition may be subjected to a conventional extrusion process to form the preliminary structure to comprise a bulk structure of a desired shape and size.

Following formation, the preliminary structure may be subjected to the curing process <NUM> to form the flexible annular seal. The curing process <NUM> may enhance at least one of close packing of polysiloxane chains and crosslinking of polysiloxane chains of the preliminary structure such that the flexible structure formed therefrom exhibits one or more different, desired material properties (e.g., shear modulus, elastic modulus, bulk modulus, thermal resistance, tensile strength, hardness, abrasion resistance, chemical resistance, extrusion resistance, elongation, etc.) relative to the preliminary structure. As used herein, the terms "crosslink" and "crosslinking" refer to a process in which more than one polymer chain, or more than one portion of a long polymer chain, are joined together by at least one chemical bond (e.g., a covalent bond). The crosslinking may, for example, be facilitated through chemical reactions between a crosslinking/curing agent of the polysiloxane composition and the reacting capping groups of the polysiloxane compounds of the different silicone materials of the polysiloxane composition. The curing process <NUM> includes subjecting the preliminary structure to at least an elevated temperature and and may include elevated pressure(s) (e.g., using a conventional curing apparatus, such as an autoclave, a compression mold, a heat gun, a lamination press, etc.) for a sufficient period of time to at least partially crosslink the polysiloxane chains of the preliminary structure. The preliminary structure is subjected to (e.g., heated at) a temperature within a range of from about <NUM> to about <NUM>, such as from about <NUM> to about <NUM>, or from about <NUM> to about <NUM> for a period of time within a range of from about <NUM> minutes to about <NUM> hours (from about <NUM> minutes to about <NUM> hours, such as from about <NUM> minutes to about <NUM> hours, or from about <NUM> minutes to about <NUM> hour) to cure the preliminary structure and form the flexible annular seal. In some embodiments, the curing process <NUM> facilitates the formation of a flexible structure having a shear modulus less than about <NUM> psi.

<FIG> is a perspective view of a flexible annular seal. formed according to the methods previously described herein with reference to <FIG>. The flexible seal is configured to be incorporated into and used into a component (e.g., a flexible bearing assembly, a thermal protection assembly) of a rocket motor assembly, as described in further detail below.

<FIG> is a cross-sectional view of a flexible assembly <NUM>, in accordance with an embodiment of the disclosure. The flexible assembly <NUM> may include a first substrate <NUM>, a second substrate <NUM>, and a lamination <NUM> comprising an alternating sequence of flexible structures <NUM> and rigid structures <NUM> extending between the first substrate <NUM> and the second substrate <NUM>. One or more of the flexible structures <NUM> are similar to the flexible structure <NUM> previously described herein with reference to <FIG>. The flexible assembly <NUM> may, for example, comprise a flexible bearing assembly or a thermal protection assembly for a moveable thrust nozzle assembly of a rocket motor assembly, as described in further detail below.

The first substrate <NUM> and the second substrate <NUM> may each independently be formed of and include at least one rigid material, such as a rigid material suitable for use in an aerospace environment. By way of non-limiting example, the first substrate <NUM> and the second substrate <NUM> may each independently be formed of and include at least one thermally stable material, such as a composite material (e.g., a carbon cloth phenolic composite material, a glass cloth phenolic composite material, a ceramic-metal composite material, etc.), a metal (e.g., tungsten, titanium, molybdenum, niobium, vanadium, hafnium, tantalum, chromium, zirconium, iron, nickel, copper, aluminum, silicon, etc.), a metal alloy (e.g., a cobalt-based alloy, an iron-based alloy, a nickel-based alloy, an iron- and nickel-based alloy, a cobalt- and nickel-based alloy, an iron- and cobalt-based alloy, an aluminum-based alloy, a copper-based alloy, a magnesium-based alloy, a titanium-based alloy, a steel, a low-carbon steel, a stainless steel, etc.), and a ceramic (e.g., carbides, nitrides, oxides, and/or borides, such as carbides and borides of at least one of tungsten, titanium, molybdenum, niobium, vanadium, hafnium, tantalum, chromium, zirconium, aluminum, and silicon). In some embodiments, the first substrate <NUM> and the second substrate <NUM> each independently comprise at least one of a composite material, a metal, and a metal alloy. In addition, the first substrate <NUM> and the second substrate <NUM> may each independently exhibit a desired geometric configuration (e.g., shape and size). In some embodiments, the first substrate <NUM> and the second substrate <NUM> comprise opposing annular structures (e.g., opposing end-rings). The first substrate <NUM> and the second substrate <NUM> may exhibit substantially the same material composition and geometric configuration as one another, or the first substrate <NUM> may exhibit at least one of a different material composition and a different geometric configuration than the second substrate <NUM>. The first substrate <NUM> and the second substrate <NUM> may each be formed using conventional processes and conventional processing equipment, which are not described in detail herein.

Each of the rigid structures <NUM> (e.g., rigid shims) also may be independently formed of and include at least one rigid material, such as a rigid material suitable for use in an aerospace environment. By way of non-limiting example, each of the rigid structures <NUM> may independently be formed of and include at least one thermally stable material, such as composite material (e.g., a carbon cloth phenolic composite material, a glass cloth phenolic composite material, a ceramic-metal composite material, etc.), a metal (e.g., tungsten, titanium, molybdenum, niobium, vanadium, hafnium, tantalum, chromium, zirconium, iron, nickel, copper, aluminum, silicon, etc.), a metal alloy (e.g., a cobalt-based alloy, an iron-based alloy, a nickel-based alloy, an iron- and nickel-based alloy, a cobalt- and nickel-based alloy, an iron- and cobalt-based alloy, an aluminum-based alloy, a copper-based alloy, a magnesium-based alloy, a titanium-based alloy, a steel, a low-carbon steel, a stainless steel, etc.), and a ceramic (e.g., carbides, nitrides, oxides, and/or borides, such as carbides and borides of at least one of tungsten, titanium, molybdenum, niobium, vanadium, hafnium, tantalum, chromium, zirconium, aluminum, and silicon). In some embodiments, the rigid structures <NUM> each independently comprise at least one of a composite material, a metal, and a metal alloy. The rigid structures <NUM> may each exhibit substantially the same material composition, or at least one of the rigid structures <NUM> may exhibit a different material composition than at least one other of the rigid structures <NUM>. In addition, each of the rigid structures <NUM> may independently exhibit a desired geometric configuration (e.g., shape and size). The rigid structures <NUM> may each exhibit substantially the same geometric configuration (e.g., substantially the same shape, and substantially the same size) as one another, or at least one of the rigid structures <NUM> may exhibit a different geometric configuration (e.g., a different shape, and/or a different size) than at least one other of the rigid structures <NUM>. In some embodiments, the rigid structures <NUM> comprise annular structures having a common center but different diameters. The diameters of the rigid structures <NUM> may, for example, sequentially increase in a direction extending from one of the first substrate <NUM> and the second substrate <NUM> to the other of the first substrate <NUM> and the second substrate <NUM>. The rigid structures <NUM> may each be formed using conventional processes and conventional processing equipment, which are not described in detail herein.

Each of the flexible structures <NUM> may be configured at least partially based on the configurations of each other component of flexible assembly <NUM> to provide the flexible assembly <NUM> with desired properties. For example, each of the flexible structures <NUM> may be cooperatively configured relative to each other of the flexible structures <NUM>, the rigid structures <NUM>, the first substrate <NUM>, and the second substrate <NUM> to facilitate desired movements (e.g., lateral movements) of one or more portions of the flexible assembly <NUM> during use and operation of the flexible assembly <NUM>. The desired movements may, for example, be tailored to a desired flight path (e.g., trajectory) of a rocket motor assembly including the flexible assembly <NUM>. By way of non-limiting example, each of the flexible structures <NUM> may independently exhibit a configuration permitting a component, such as a thrust nozzle, of a rocket motor assembly including the flexible assembly <NUM> (e.g., as a flexible bearing assembly) to change direction in a pre-determined way during use and operation (e.g., in order to reach a target destination) at least partially based on a change in the position of the flexible assembly <NUM>.

Each of the flexible structures <NUM> may exhibit substantially the same material properties, or at least one of the flexible structures <NUM> may exhibit a different material property than at least one other of the flexible structures <NUM>. The material composition of the each of the flexible structures <NUM> may be tailored to provide each of the flexible structures <NUM> substantially the same material properties, or to provide at least one of the flexible structures <NUM> a different material property than at least one other of the flexible structures <NUM>. In some embodiments, each of the flexible structures <NUM> exhibits substantially the same material properties as each other of the flexible structures <NUM>. Flexible structures <NUM> exhibiting substantially the same material properties may each be formed of and include substantially the same material composition (e.g., substantially the same cured polysiloxane composition, including substantially the same crosslinked polysiloxane chemical structures, substantially the same crosslinked polysiloxane molecular weight, and substantially the same quantity of crosslinked polysiloxanes), or at least one of the flexible structures <NUM> may be formed of and include a different material composition (e.g., a different cured polysiloxane composition, including a different crosslinked polysiloxane chemical structure, a different crosslinked polysiloxane molecular weight, and/or a different quantity of crosslinked polysiloxanes) than at least one other of the flexible structures <NUM>. In some embodiments, at least one of the flexible structures <NUM> exhibits a different material property than at least one other of the flexible structures <NUM>. Flexible structures <NUM> exhibiting at least one different material property than one another may exhibit different material compositions (e.g., different cured polysiloxane compositions, including different crosslinked polysiloxane chemical structures, different crosslinked polysiloxane molecular weights, and/or different quantities of crosslinked polysiloxanes) than one another. The material composition (and, hence, material properties) of each of the flexible structures <NUM> may be controlled at least partially by selecting the quantities and types of the different silicone materials and additive(s) (if any) present within the polysiloxane composition(s) utilized to form each of the flexible structures <NUM>, in accordance with the methods previously described herein in relation to <FIG>. In some embodiments, each of the flexible structures <NUM> have substantially the same shear modulus of less than about <NUM> psi. In additional embodiments, each of the flexible structures <NUM> has a shear modulus less than about <NUM> psi, but at least one of the flexible structures <NUM> has a different shear modulus than at least one other of the flexible structures <NUM>.

Each of the flexible structures <NUM> may exhibit substantially the same geometric configuration (e.g., substantially the same shape, and substantially the same size), or at least one of the flexible structures <NUM> may exhibit a different geometric configuration (e.g., a different shape, and/or a different size) than at least one other of the flexible structures <NUM>. In some embodiments, each of the flexible structures <NUM> exhibits substantially the same shape, but at least one of the flexible structures <NUM> exhibits a different size (e.g., a different length, a different width, and/or a different height) than at least one of the flexible structures <NUM>. For example, the flexible structures <NUM> may comprise annular structures (e.g., similar to the flexible structure <NUM> previously described in relation to <FIG>) having a common center but different diameters. The diameters of the flexible structures <NUM> may, for example, sequentially increase in a direction extending from one of the first substrate <NUM> and the second substrate <NUM> to the other of the first substrate <NUM> and the second substrate <NUM>. The geometric configurations selected for the flexible structures <NUM> may at least partially depend on the geometric configurations of the other components (e.g., the first substrate <NUM>, the second substrate <NUM>, the rigid structures <NUM>, etc.) of the flexible assembly <NUM>. Each of the flexible structures <NUM> may independently be formed according to the methods previously described herein with reference to <FIG>.

The flexible assembly <NUM> may be formed of and include any quantity and sequence (e.g., pattern) of the flexible structures <NUM> and the rigid structures <NUM> facilitating movement of the flexible assembly <NUM> in a pre-determined way. By way of non-limiting example, as shown in <FIG>, the lamination <NUM> may be formed of and include a nested, alternating sequence of a desired number of the flexible structures <NUM> and the rigid structures <NUM>, beginning with one of the flexible structures <NUM> at a location proximate (e.g., adjacent) the first substrate <NUM> and ending with another of the flexible structures <NUM> at another location proximate (e.g., adjacent) the second substrate <NUM>. While <FIG> depicts the flexible assembly <NUM> as being formed of and including an alternating sequence of four (<NUM>) flexible structures <NUM> and three (<NUM>) the rigid structures <NUM>, the flexible assembly <NUM> may include a different number of flexible structures <NUM> and rigid structures <NUM>. For example, the flexible assembly <NUM> may include from one (<NUM>) to one hundred (<NUM>) of the flexible structures <NUM>, and from zero (<NUM>) to one hundred (<NUM>) of the rigid structures <NUM>. The quantity and the sequence of the flexible structures <NUM> and the rigid structures <NUM> may at least partially depend on the configurations (e.g., material compositions, shapes, sizes, etc.) of the flexible structures <NUM> and the rigid structures <NUM> of the flexible assembly <NUM>. The quantity and the sequence of the flexible structures <NUM> and the rigid structures <NUM> may also at least partially depend on the configurations of additional structures and/or assemblies (e.g., thrust nozzle assemblies, rocket motor assemblies, etc.) with which the flexible assembly <NUM> is to be operatively associated (e.g., included in), as described in further detail below.

The flexible assembly <NUM> may be formed by adhering (e.g., bonding, attaching, coupling, etc.) a first of the flexible structures <NUM> to the first substrate <NUM>, adhering a first of the rigid structures <NUM> to the first of the flexible structures <NUM>, adhering a second of the flexible structures <NUM> to the first of the rigid structures <NUM>, adhering a second of the rigid structures <NUM> to the second of the flexible structures <NUM>, and so on for a desired quantity of the flexible structures <NUM> and the rigid structures <NUM>. The second substrate <NUM> may be adhered to a last of the flexible structures <NUM> (e.g., a flexible structure <NUM> adhered to a last of the rigid structures <NUM>). At least one adhesive material may be used to adhere different components (e.g., the first substrate <NUM>, the flexible structures <NUM>, the rigid structures <NUM>, and the second substrate <NUM>) of the flexible assembly <NUM> to one another. By way of non-limiting example, for each of the flexible structures <NUM>, an adhesive system formed of and including at least two adhesive materials (e.g., at least two adhesive layers) may be used to attach the flexible structure <NUM> to adjacent components (e.g., the first substrate <NUM>, at least one of the rigid structures <NUM>, and/or the second substrate <NUM>) of the flexible assembly <NUM>. The adhesive system may, for example, include a first adhesive material attached to the flexible structure <NUM> and a second adhesive material attached to the first adhesive material and to the other, adjacent component of the flexible assembly <NUM>. The adhesive material (e.g., adhesive system) may be selected at least partially based on the material compositions of the flexible structures <NUM> and the other components of the flexible assembly <NUM> adjacent thereto. In some embodiments, substantially the same adhesive material (e.g., substantially the same adhesive system) is used to adhere each of the flexible structures <NUM> to other components of the flexible assembly <NUM> adjacent thereto. In additional embodiments, a different adhesive material (e.g., a different adhesive system) is used to adhere at least one of the flexible structures <NUM> to adjacent components of the flexible assembly <NUM> than is used to adhere at least one other of the flexible structures <NUM> to other components of the flexible assembly <NUM> adjacent thereto.

The material composition(s) of the flexible structures <NUM> may facilitate increased interfacial adhesion strength (e.g., stronger bond lines) between the flexible structures <NUM> and other, adjacent components of the flexible assembly <NUM> as compared to conventional flexible structures (e.g., conventional silicone-based flexible structures, such as flexible structures formed of and including a single silicone material rather than a combination of at least two different silicone materials). The increased interfacial adhesion strength may permit the use of relatively fewer materials and/or structures within the flexible assembly <NUM> as compared to conventional flexible assemblies (e.g., conventional flexible bearing assemblies for rocket motor assemblies), while at least maintaining or even improving the structural integrity of the flexible assembly <NUM> during use and operation as compared to such conventional flexible assemblies. For example, the material composition(s) of the flexible structures <NUM> may facilitate the omission of one or more carbon structures (e.g., carbon tapes) between the flexible structures <NUM> and one or more other, adjacent components of the flexible assembly <NUM>, while maintaining or even decreasing the risk of delamination as compared to conventional flexible assemblies including one or more carbon structures between conventional flexible structures and one or more other, adjacent components of the conventional flexible assemblies.

<FIG> is a cut-away perspective view a moveable thrust nozzle assembly <NUM>, in accordance with an embodiment of the disclosure. The moveable thrust nozzle assembly <NUM> may include a fixed housing <NUM>, a flexible bearing assembly <NUM> coupled to (e.g., directly coupled to and/or indirectly coupled to) and circumscribing a portion of the fixed housing <NUM>, and a thermal protection assembly <NUM> coupled to (e.g., directly coupled to and/or indirectly coupled to) and circumscribing another portion of the fixed housing <NUM>. The flexible bearing assembly <NUM> may include an end-ring <NUM> and a lamination <NUM> comprising an alternating sequence of flexible structures <NUM> (e.g., flexible seals) and rigid structures <NUM> (e.g., rigid shims) in a nested relationship and extending between the fixed housing <NUM> and the end-ring <NUM>. The thermal protection assembly <NUM> may be positioned adjacent (e.g., over and in contact with) the flexible bearing assembly <NUM>, and may include a first (aft) end-ring <NUM>, a second end-ring <NUM>, and a lamination <NUM> comprising an alternating sequence of flexible structures <NUM> (e.g., flexible seals) and rigid structures <NUM> (e.g., rigid shims) in a nested relationship and extending between the first end-ring <NUM> and the second end-ring <NUM>.

At least one of the flexible bearing assembly <NUM> and the thermal protection assembly <NUM> is similar to the flexible assembly <NUM> previously described herein with reference to <FIG>. The components and component arrangement of at least one of the flexible bearing assembly <NUM> and the thermal protection assembly <NUM> may, for example, be substantially similar to components and component arrangement of the flexible assembly <NUM> (<FIG>). In some embodiments, the flexible structures <NUM> of the flexible bearing assembly <NUM> at least have material compositions similar to those previously discussed in relation to the flexible structures <NUM> (<FIG>) of the flexible assembly <NUM> (<FIG>). Each of the flexible structures <NUM> of the flexible bearing assembly <NUM> may be independently formed of and include crosslinked polysiloxane chains formed from at least two different silicone materials according to the methods previously described herein with reference to <FIG>. In addition, the flexible structures <NUM> of the flexible bearing assembly <NUM> may be adhered to other, adjacent components of the flexible bearing assembly <NUM> in substantially the same manner as that previously described in relation to the flexible structures <NUM> of flexible assembly <NUM>. In additional embodiments, the flexible structures <NUM> of the thermal protection assembly <NUM> at least have material compositions similar to those previously discussed in relation to the flexible structures <NUM> of flexible assembly <NUM>. Each of the flexible structures <NUM> of the thermal protection assembly <NUM> may be independently formed of and include crosslinked polysiloxane chains formed from at least two different silicone materials according to the methods previously described herein with reference to <FIG>. In addition, the flexible structures <NUM> of the thermal protection assembly <NUM> may be adhered to other, adjacent components of the thermal protection assembly <NUM> in substantially the same manner as that previously described in relation to the flexible structures <NUM> of flexible assembly <NUM>. The material composition (and, hence, material properties) of each of the flexible structures <NUM> of the flexible bearing assembly <NUM> may be substantially similar to the material composition of each of the flexible structures <NUM> of the thermal protection assembly <NUM>, or the material composition of at least one of the flexible structures <NUM> of the flexible bearing assembly <NUM> may be different than the material composition of at least one of the flexible structures <NUM> of the thermal protection assembly <NUM>.

In some embodiments, except for the material composition(s) (and, hence, material properties) of the flexible structures <NUM> of the flexible bearing assembly <NUM> and/or the material composition(s) (and, hence, material properties) of flexible structures <NUM> of the thermal protection assembly <NUM>, at least one of the moveable thrust nozzle assembly <NUM>, the flexible bearing assembly <NUM>, and the thermal protection assembly <NUM> may exhibit one or more components and/or component arrangements substantially similar to those described in <CIT>, issued October <NUM>, <NUM>, and assigned to the assignee of the present disclosure.

<FIG> is a cross-sectional view of a rocket motor assembly <NUM>, in accordance with an embodiment of the disclosure. The rocket motor assembly <NUM> may include an outer housing <NUM> having a closed forward end <NUM> and an open aft end <NUM>. The outer housing <NUM> may comprise a single, substantially monolithic structure, or may comprise a plurality of connected (e.g., attached, coupled, bonded, etc.) structures. As used herein, the term "monolithic structure" means and includes a structure formed as, and comprising a single, unitary structure of a material. The rocket motor assembly <NUM> may also include plurality of stages <NUM> provided in an end-to-end relationship with one another within the outer housing <NUM>. For example, as shown in <FIG>, the rocket motor assembly <NUM> may include a first stage <NUM>, a second stage <NUM>, and a third stage <NUM> each contained within the outer housing <NUM>. In additional embodiments, the rocket motor assembly <NUM> may include a different number of stages <NUM>, such as from one (<NUM>) stage to ten (<NUM>) stages. The stages <NUM> may include vessels <NUM> (e.g., a first vessel <NUM>, a second vessel <NUM>, and a third vessel <NUM>) each containing at least one propellant <NUM>, and moveable thrust nozzle assemblies <NUM> (e.g., a first moveable thrust nozzle assembly <NUM>, a second moveable thrust nozzle assembly <NUM>, and a third moveable thrust nozzle assembly <NUM>) physically connected to aft ends of the vessels <NUM>. In addition, the outer housing <NUM> may be configured to be severable at locations <NUM>, as indicated by dashed lines, associated with the stages <NUM> during use and operation of the rocket motor assembly <NUM> (e.g., following combustion of the propellant <NUM> within a given one of the stages <NUM>). Each of the outer housing <NUM>, the vessels <NUM>, and the propellant(s) <NUM> may independently exhibit a desired configuration (e.g., material composition, size, shape, etc.), and may be formed using conventional processes and equipment, which are not described in detail herein.

At least one of the different moveable thrust nozzle assemblies <NUM> (e.g., the first moveable thrust nozzle assembly <NUM>, the second moveable thrust nozzle assembly <NUM>, and/or the third moveable thrust nozzle assembly <NUM>) of the different stages <NUM> of the rocket motor assembly <NUM> is similar to the moveable thrust nozzle assembly <NUM> previously described herein with reference to <FIG>. The components and component arrangement of at least one of the moveable thrust nozzle assemblies <NUM> is similar to components and component arrangement of the moveable thrust nozzle assembly <NUM> (<FIG>). The moveable thrust nozzle assemblies <NUM> may include flexible bearing assemblies <NUM> (e.g., a first flexible bearing assembly <NUM>, a second flexible bearing assembly <NUM>, and a third flexible bearing assembly <NUM>), and at least one of the flexible bearing assemblies <NUM> may be substantially similar to the flexible bearing assembly <NUM> (e.g., including the flexible structures <NUM> and the rigid structures <NUM>) (<FIG>) of the moveable thrust nozzle assembly <NUM> (<FIG>). One or more of the flexible bearing assemblies <NUM> may, for example, include flexible structures (e.g., flexible seals) each independently including crosslinked polysiloxane chains formed from at least two different silicone materials according to the methods previously described herein with reference to <FIG>. The flexible structures may also be adhered to other, adjacent components of the at least one of the flexible bearing assemblies <NUM> in substantially the same manner as that previously described in relation to adhering the flexible structures <NUM> (<FIG>) of the flexible assembly <NUM> (<FIG>) to other, adjacent components of the flexible assembly <NUM>.

In some embodiments, the material composition(s) of at least the flexible structures of each of the flexible bearing assemblies <NUM> (e.g., the first flexible bearing assembly <NUM>, the second flexible bearing assembly <NUM>, and the third flexible bearing assembly <NUM>) of the different stages <NUM> (e.g., the first stage <NUM>, the second stage <NUM>, and the third stage <NUM>) of the rocket motor assembly <NUM> are substantially similar to the material composition(s) of at least the flexible structures of each other of the flexible bearing assemblies <NUM> of the different stages <NUM> of the rocket motor assembly <NUM>. The flexible structures of each of the flexible bearing assemblies <NUM> may include substantially the same material composition (e.g., cured polysiloxane composition) formed from at least two different silicone materials according to the methods previously described herein with reference to <FIG>. For example, the flexible structures of each of the flexible bearing assemblies <NUM> may include substantially the same cured polysiloxane composition facilitating a shear modulus less than about <NUM> psi.

In additional embodiments, the material composition(s) of at least one of the flexible structures of at least one of the flexible bearing assemblies <NUM> (e.g., the first flexible bearing assembly <NUM>, the second flexible bearing assembly <NUM>, and/or the third flexible bearing assembly <NUM>) of the different stages <NUM> of the rocket motor assembly <NUM> may be different than the material composition(s) of at least one other of the flexible structures of at least one other of the flexible bearing assemblies <NUM> of the different stages <NUM> of the rocket motor assembly <NUM>. For example, the flexible structures of each of the flexible bearing assemblies <NUM> may each independently comprise crosslinking polymer chains formed from at least two different silicone materials according to the methods previously described herein with reference to <FIG>, but at least one of the flexible structures of at least one of the flexible bearing assemblies <NUM> may include a different material composition than at least one other of the flexible structures of at least one other of the flexible bearing assemblies <NUM>. In some embodiments, the flexible structures of each of the flexible bearing assemblies <NUM> have different material compositions (e.g., different cured polysiloxane compositions) than the flexible structures of each other of the flexible bearing assemblies <NUM>. If at least one of the flexible structures of at least one of the flexible bearing assemblies <NUM> has a different material composition than at least one other of the flexible structures of at least one other of the flexible bearing assemblies <NUM>, the at least one of the flexible structures may exhibit substantially similar material properties (e.g., substantially the same shear modulus) to the at least one other of the flexible structures, or may exhibit different material properties (e.g., a different shear modulus) than the at least one other of the flexible structures. For example, flexible structures of different flexible bearing assemblies <NUM> having different material compositions than one another may each have substantially the same shear modulus less than about <NUM> psi, or at least one of the flexible structures from the different flexible bearing assemblies <NUM> may have a different shear modulus less than about <NUM> psi than at least one other of the flexible structures from the different flexible bearing assemblies <NUM>.

The methods of the disclosure facilitate the formation of flexible flexible annular seals and assemblies (e.g., flexible bearing assemblies, thermal protection assemblies, moveable thrust nozzle assemblies, rocket motor assemblies, etc.) exhibiting properties enabling the structures and assemblies to be used in a wider array of applications (e.g., aerospace applications) than many structures and assemblies conventionally utilized. Embodiments of the disclosure may be used to provide virtually infinite flexibility to tailor properties of a flexible structure, such as the shear modulus of the flexible structure, to particular end-use requirements of a structure or assembly including the flexible structure. The methods, structures, and assemblies according to embodiments of the disclosure provide a simplied means of controlling the movement of one of more components of a rocket motor assembly during use and operation of the rocket motor assembly as compared to conventional methods, structures, and assemblies. The flexible structures (e.g., the flexible structure <NUM> (<FIG>)) formed according to embodiments of the disclosure may exhibit material properties suitable for a relatively wider variety of assemblies (e.g., flexible bearing assemblies, moveable thrust nozzle assemblies, rocket motor assemblies, etc.) and end-uses than corresponding flexible structures formed through conventional methods. Accordingly, the flexible structures and methods of the disclosure may facilitate or improve the standardization of components for such assemblies, and/or may enhance the fast and simple customization of components for such assemblies. The methods, structures, and assemblies of the disclosure may facilitate improved production efficiency (e.g., reduced production time, reduced material costs, etc.), and enhanced capabilities, performance, durability, and reliability as compared to conventional methods, structures, and assemblies.

The following examples serve to explain embodiments of the disclosure in more detail. The examples are not to be construed as being exhaustive or exclusive as to the scope of this disclosure.

Different flexible structures were prepared, and then the maximum torque (MH) of each of the different flexible structures was determined. The MH values were determined through conventional techniques using either a Moving Die Rheometer (MDR-<NUM>) of Alpha Technologies (USA) or a Rubber Processing Analyzer (RPA-<NUM>) of Alpha Technologies (USA). The different flexible structures were formed from different ratios of ELASTOSIL® R401/<NUM> resin and ELASTOSIL® R401/<NUM> resin, and about <NUM> phr of DI-CUP® 40KE dicumyl peroxide. ELASTOSIL® R401/<NUM> resin was combined with ELASTOSIL® R401/<NUM> resin on a two-roll mill, and then the DI-CUP® 40KE dicumyl peroxide was added to the resulting mixture. The two-roll mill was set at a differential speed setting of <NUM>/<NUM> and a nip of <NUM>". Milling was done up to about <NUM> minutes to obtain uniform mass. <FIG> is a graph comparing the MH values for each of the different compositions, as analyzed by MDR-<NUM> after curing for about <NUM> minutes at <NUM>°F. The linear correlation depicted in <FIG> indicates that ELASTOSIL® R401/<NUM> resin and ELASTOSIL® R401/<NUM> resin can be combined (e.g., blended) in various amounts to obtain desired material properties (e.g., rheological properties, mechanical properties, etc.) in the flexible structures formed therefrom.

The effects of crosslinking/curing agent concentration on the MH values of different formulations formed from DI-CUP® 40KE dicumyl peroxide and ELASTOSIL® R401/<NUM> resin or ELASTOSIL® R401/<NUM> resin were analyzed. The MH values were determined through conventional techniques using a Moving Die Rheometer (MDR) of Alpha Technologies (USA). The different formulations included different concentrations of DI-CUP® 40KE within a range of from about <NUM> phr to about <NUM> phr. <FIG> is a graph comparing the MH values for each of the different formulations analyzed. The linear correlation depicted in <FIG> indicates that various amounts of DI-CUP® 40KE dicumyl peroxide can be combined with ELASTOSIL® R401/<NUM> resin and ELASTOSIL® R401/<NUM> resin to obtain desired material properties (e.g., rheological properties, mechanical properties, etc.) in flexible structures formed therefrom.

The effects of crosslinking/curing agent concentration on the stability of different formulations formed from DI-CUP® 40KE dicumyl peroxide and ELASTOSIL® R401/<NUM> resin or ELASTOSIL® R401/<NUM> resin was analyzed using conventional techniques. Product stability was analyzed for different concentrations of DI-CUP® 40KE dicumyl peroxide within a range of from about <NUM> phr to about <NUM> phr as a function of elastic shear modulus (G') at different cure times using a Rubber Processing Analyzer (RPA-<NUM>) of Alpha Technologies (USA). <FIG> is a graph comparing the G' of ELASTOSIL® R401/<NUM> resin with different concentrations of DI-CUP® 40KE dicumyl peroxide as a function of cure time at <NUM>°F. <FIG> is a graph comparing the G' of ELASTOSIL® R401/<NUM> resin with different concentrations of DI-CUP® 40KE dicumyl peroxide as a function of cure time at <NUM>°F. As shown in <FIG> and <FIG>, no cure reversion behavior was witnessed, indicating that flexible structures formed from various concentrations of organic peroxide, ELASTOSIL® R401/<NUM> resin, and ELASTOSIL® R401/<NUM> resin will be stable as cured.

Claim 1:
A method of forming a flexible annular seal for a moveable thrust assembly of a rocket motor assembly comprising:
selecting a first silicone material;
selecting a second silicone material;
combining the first silicone material and the second silicone material with at least one curing/crosslinking agent to form a polysiloxane composition including the first silicone material, the second silicone material, and the at least one curing/crosslinking agent, the at least one curing/crosslinking agent being selected from dicumyl peroxide and bis (<NUM>,<NUM>-dischlorobenzoyl)-peroxide;
forming a preliminary structure having an annular shape from the polysiloxane composition; and
curing the preliminary structure to form a cured structure comprising a cured polysiloxane composition, wherein the curing comprises subjecting the preliminary structure to a temperature within a range of from about <NUM> to <NUM> for a period of time within a range of from <NUM> minutes to <NUM> hours;
the method characterized by;
forming the polysiloxane composition to be homogeneous, including a uniform dispersion of the first silicone material, the second silicone material, and the at least one curing/crosslinking agent; and
forming the cured structure, the cured polysiloxane composition comprising crosslinked polysiloxane chains of the first silicone material and the second silicone material.