Patent ID: 7854811

Claim:
A solvent-free process to make mouldable plastic explosives or mouldable plastic explosive simulant products, comprising the steps of: (a) mixing at room temperature the following ingredients to form a substantially homogeneous mixture: (1) a powdered explosive or inert simulant thereof in the range of 15-92% (wt/wt); (2) a viscous liquid binder in the range of 5-60% (wt/wt); (3) optionally, a plasticizer sufficient to increase the plasticity and malleability of the product without substantially negatively affecting surface adhesion of the product, in the range of 0.1-10% (wt/wt); (4) optionally, a rheology modifier sufficient to increase thixotropy, increase resistance to sagging, and minimize separation of the liquid binder from the powdered explosive or simulant, in the range of 1-30% (wt/wt) of the binder; (5) optionally, a coloring agent sufficient to impart visually detectable, permanent, indelible color to the product; (6) a volatile chemical taggant sufficient to be detectable in the product by ion mobility spectrometer or by detector canine in the range of 0.01-1% (wt/wt), and survive the process to retain detectability in the product; with the proviso that no solvent is used in the process; (b) manipulating the mixture to a predetermined shape and size by extruding and cutting, or pressing the mixture into moulds, and optionally; (c) packaging the resultant shaped and sized product for shipping.