Fabrication of molded block of dilute high explosive foamed polyurethane

A process for forming a molded foamed polyurethane explosive block with pentaerythritol tetranitrate in a manner in which the generation of excessive exothermic heat is inhibited during the reaction to form the foamed polyurethane which comprises controlling said exothermic heat generation by adding to a mixture comprising:

• a) reactants used to form said foamed polyurethane;
• and
• b) said pentaerythritol tetranitrate;
• one or more non-reactive filler materials selected from the group consisting of particulate talc, wood flour, aluminum, zinc, and monoammonium phosphate in an amount sufficient to limit the maximum temperature generated to not more than about 125.degree. C. and within a range of from about 1.0 wt. % to about 50 wt. %, based on the total weight of said mixture.

A process for forming a molded foamed polyurethane explosive block with pentaerythritol tetranitrate which comprises:

• a) introducing into a mixing chamber by remote control, wherein a mold forms a bottom wall of said mixing chamber, and the remainder of said mixing chamber is portable and removable from said mold;
• i) reactants used to form said foamable polyurethane, including one or more non-reactive filler materials used to control the exothermic heat generated during the reaction to form said polyurethane;
• and
• ii) pentaerythritol tetranitrate;
• b) blending together said reactants used to form said foamable polyurethane, said one or more non-reactive filler materials, and said pentaerythritol tetranitrate in said portable mixing chamber;
• and
• c) removing said portable mixing chamber from said mold.

A process for forming a molded foamed polyurethane explosive block with pentaerythritol tetranitrate in a manner in which the generation of excessive exothermic heat is inhibited during the reaction to form the foamed polyurethane which comprises controlling said exothermic heat generation by adding to a mixture comprising:

• a) reactants used to form said foamed polyurethane;
• and
• b) said pentaerythritol tetranitrate;
• one or more non-reactive filler materials in an amount sufficient to limit the maximum temperature generated to not more than about 125.degree. C. and within a range of from about 1.0 wt. % to about 50 wt. %, based on the total weight of said mixture.

A process for forming a molded foamed polyurethane explosive block with pentaerythritol tetranitrate in a manner in which the generation of excessive exothermic heat is inhibited during the reaction to form the foamed polyurethane which comprises forming a mixture of:

• a) reactants used to form said foamed polyurethane;
• b) said pentaerythritol tetranitrate;
• and
• c) a sufficient amount of said one or more non-reactive filler materials, including monoammonium phosphate, to limit the maximum exothermic temperature generated during said reaction to form said foamed polyurethane to less than 125.degree. C., and to further impart fire retardant properties to said molded foamed polyurethane explosive block with pentaerythritol tetranitrate.

A process for forming a molded foamed polyurethane explosive block with pentaerythritol tetranitrate in a manner in which the generation of excessive exothermic heat is controlled during the reaction to form the foamed polyurethane which comprises:

• a) forming a mixture comprising:
• i) reactants used to form said foamed polyurethane;
• and
• ii) said pentaerythritol tetranitrate;
• and
• b) adding to said mixture from about 1.0 wt. % to about 50 wt. %, based on the weight of said mixture, of one or more non-reactive filler materials, having a particle size ranging from about 325 mesh (Tyler) to about 16 mesh (Tyler), to control said exothermic heat generation, including monoammonium phosphate to further impart fire retardant properties to said molded foamed polyurethane explosive block with pentaerythritol tetranitrate;
• whereby said one or more non-reactive filler materials will inhibit said exothermic heat generation during said formation of said molded foamed polyurethane explosive block with pentaerythritol tetranitrate.