Igniter pellet and related composition for decoy countermeasure assembly

A method of forming an igniter pellet for use with a countermeasure assembly having an impulse cartridge with a pellet receptacle therein, the method comprising:

• Forming a moisture-insensitive first ignition composition for a first layer of the igniter pellet by:
• dissolving a first rubber-based binder in a polar solvent to form a binder solution;
• mixing the binder solution with a first fuel material that includes Boron, and a first oxidizer material that includes Bismuth Oxide and/or Potassium Perchlorate to form a first mixture;
• adding a low boiling point non-polar solvent to the mixture and precipitating the binder from the mixture to form a coagulation composition;
• converting the coagulation composition to a first moldable granular composition;
• Providing a second ignition composition that comprises a mixture of Magnesium, Polytetrafluoroethylene and a fluoropolymer elastomer binder;
• Positioning the first and second ignition compositions into the pellet receptacle of the impulse cartridge wherein the first composition forms a first layer, and the second composition forms a second layer that is covered and isolated from ambient moisture by the first layer.

A deployable infrared countermeasure assembly, comprising:

• An outer case suitable for installation into countermeasure dispensing systems and containing;
• A port for installation of an impulse cartridge to eject the countermeasure payload;
• An Igniter Assembly to transfer the ignition train from the impulse cartridge to the countermeasure flare payload, the igniter assembly having an igniter pellet therein;
• A deployable, ignitable payload to provide the Infrared Signature;
• An impulse cartridge coupled to the base portion or port of the outer flare case, wherein the impulse cartridge comprises an electrical activator adjacent to an ignition and output charge, wherein the output charge expels the payload including the igniter assembly containing the hybrid ignition pellet
• Wherein the ignition pellet comprises:
• a first layer formed by a first composition comprising a mixture of a first fuel material that includes Boron, a first oxidizer material that includes Bismuth Oxide and/or Potassium Perchlorate, a granular matrix binder holding the fuel material and the oxidizer material together, wherein the first composition is insensitive to ambient moisture;
• a second layer formed by a second composition different than the first composition, the second composition comprising a second fuel material that includes Magnesium, a second oxidizer that includes Polytetrafluoroethylene, and a binder material that includes a fluoropolymer elastomer;
• wherein the second layer is configured to be fully contained in the igniter assembly and covered by the first layer so that the first layer is adjacent to the output of the impulse cartridge and the second layer is isolated and protected from ambient moisture by the moisture insensitive first layer.

A method of forming an igniter pellet for use with a countermeasure assembly having an igniter assembly with a pellet receptacle therein, the method comprising:

• Forming a moisture-insensitive ignition composition by:
• dissolving a first rubber-based binder in a polar solvent to form a binder solution;
• mixing the binder solution with a first fuel material that includes Boron, a first oxidizer material that includes Bismuth Oxide and/or Potassium Perchlorate, and a second oxidizer material and burn rate enhancer that includes finely divided Potassium Perchlorate powder to form a mixture;
• adding a low boiling point non-polar solvent to the mixture and precipitating the binder from the mixture to form a coagulation composition;
• converting the coagulation composition to a first moldable granular composition;
• Positioning the moisture insensitive ignition composition into the pellet receptacle of the igniter assembly to form an igniter pellet adjacent to the output of the impulse cartridge.