PRIORITY CLAIM

[0001] This application claims priority to and the benefit of U.S. Provisional Application filed on May 12, 2016 with serial number 62/335,342 entitled "Housing for Explosive Device and Method of Assembly", which is herein incorporated by reference in its entirety.

FIELD OF THE INVENTION

[0002] The invention relates generally to a housing for an explosive device for entertainment purposes.

BACKGROUND

[0003] Conventional fireworks rely upon both the burst charge and the shell wall or casing to produce a sufficient dispersion of the fireworks effect. Conventionally, low explosive compounds are utilized such that the rate of decomposition is insufficient alone to produce the required dispersal of the fireworks effects. Examples of such low explosives are black powder based or flash or aluminum based charges. Accordingly, the casing of the fireworks serves to confine the initial deflagration of the explosive compound until sufficient pressure has developed within the shell to rupture it and thereafter the developed pressure serves to disperse the fireworks effects as desired.

[0004] One of the challenges is to develop a fireworks casing or housing that is easy to manufacture and assemble in a small form factor while at the same time increasing its burst strength and sound without necessarily increasing the amount of explosive compound in the casing. SUMMARY

[0005] In one example embodiment, there is provided an explosive casing, cartridge or housing for a small explosive or firecracker such that when fully assembled results in a tetrahedron or pyramidal, 3-D structure that provides an enhanced explosive sound and bursting strength. It would be advantageous to provide an inexpensive and simple method of assembling a casing for an explosive device or apparatus, as described herein.

[0006] In another example embodiment, a casing or housing for an explosive device is provided including a housing or casing formed from a substrate layer, wherein the substrate layer includes at least one layer of paper-based material, the substrate layer forming a tubular structure, the tubular structure having a first flap member formed at a first open end and a second flap member formed at a second open end with a tube body disposed in between the first and second open ends, the tube body being collinear with a longitudinal axis of the tubular structure and wherein each of the flap members are configured to be radially oriented about 90 degrees with respect to each other, each flap member having an inside surface, an outside surface and a distal end portion away from the tube body. The housing further includes a first seal forming a base for the housing, the first seal formed from a folded over first flap member that covers the first open end such that the inside surface of the flap member is in contact with and adhered to the tube body, wherein the outside surface is exposed and the distal end portion of the first flap member is substantially perpendicular to the longitudinal axis of the tubular structure. The housing further including a second seal forming a top for the housing, the second seal formed from a folded over second flap member that covers the second open end such that the inside surface and distal end portion of the second flap member is in contact with and adhered to the tube body, thereby forming a top for the casing or housing. In a related embodiment, the explosive device housing includes a substrate layer further comprised of a fiber reinforcement layer disposed on the paper-based material and in another related embodiment the substrate layer is further comprised of multiple layers of paper-based material and fiber reinforcement layers.

[0007] In another embodiment, an explosive device comprising the housing or casing described above includes a combustible or explosive compound disposed within the housing, wherein the explosive device provides an increase in burst strength as energy and gases from igniting the combustible material attempt to escape one of the end seals formed from the folded over flap member structure.

[0008] In yet another example embodiment, a casing or housing for an explosive device is provided including a housing or casing formed from a substrate layer, wherein the substrate layer includes at least one layer of paper-based material, the substrate layer forming a tubular structure, the tubular structure having a first flap member formed at a first open end and a second flap member formed at a second open end with a tube body disposed in between the first and second open ends, the tube body being collinear with a longitudinal axis of the tubular structure and wherein each of the flap members are configured to be radially oriented about 180 degrees with respect to each other, each flap member having an inside surface, an outside surface and a distal end portion away from the tube body. The housing further includes a first seal forming a base for the housing, the first seal formed from a folded over first flap member that covers the first open end such that the inside surface of the flap member is in contact with and adhered to the tube body, wherein the outside surface is exposed and the distal end portion of the first flap member is substantially perpendicular to the longitudinal axis of the tubular structure. The housing further including a second seal forming a top for the housing, the second seal formed from a folded over second flap member that covers the second open end such that the inside surface and distal end portion of the second flap member is in contact with and adhered to the tube body, thereby forming a top for the casing or housing. In a related embodiment, the explosive device housing includes a substrate layer further comprised of a fiber reinforcement layer disposed on the paper-based material and in another related embodiment the substrate layer is further comprised of multiple layers of paper-based material and fiber reinforcement layers, wherein the housing is configured into a tubular shape. In related embodiment, the tubular body is configured to be reduced in longitudinal length to facilitate forming an elliptical or spherical shape.

[0009] In another example embodiment, a method is provided for forming a robust casing or housing adapted to receive and contain therein an explosive or combustible material, the method including the steps of forming a substrate from a sheet of paper-based material and a sheet of fiber reinforcement material disposed on the paper-based material sheet and forming a tubular structure from the substrate having a first open end and a second open end and a tube body therebetween, the tube body being collinear with a longitudinal axis of the tube. This embodiment uses tubes which are prepared by winding the substrate layers around an inner mandrel form in a convolute fashion. In another embodiment the tubes could be formed using a spiral winding process which produces a continuous tube. The method includes removing material from the first and second end of the tube so as to form a first flap member at the first end and a second flap member at the second end of the tube, each of the flap members adapted to be radially oriented about 90 degrees with respect to each other, each flap member having an inside surface, an outside surface and a distal end away from the tube body. The method next includes the step of folding over the first flap member to cover the first open end such that the inside surface of the flap member is in contact with and adhered to the tube body, wherein the outside surface is exposed and the distal end of the flap member is substantially perpendicular to the longitudinal axis of the tube, thereby forming a base for the casing. The next step includes folding over a second flap member to cover the second open end such that the inside surface and distal end of the second flap member is in contact with and adhered to the tube body, thereby forming a tip for the casing.

[0010] The invention now will be described more fully hereinafter with reference to the accompanying drawings, which are intended to be read in conjunction with both this summary, the detailed description and any preferred and/or particular embodiments specifically discussed or otherwise disclosed. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided by way of illustration only and so that this disclosure will be thorough, complete and will fully convey the full scope of the invention to those skilled in the art.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Fig. 1 illustrates a first step of assembling a housing for an example embodiment of an explosive casing device according to the teachings of the invention;

[0012] Fig. 2 illustrates another step of assembling the housing of the casing device according to the teachings of the invention;

[0013] Fig. 3 illustrates an example embodiment of part of a housing formed for the casing device as taught herein;

[0014] Fig. 4 illustrates an example embodiment of a partially formed housing for the casing device with a bottom end closed and with a top end open with a flap disposed near the top end opening;

[0015] Fig. 5 illustrates a front view of an example embodiment of a fully assembled casing housing in the shape of a tetrahedron or 3-D pyramid; [0016] Fig. 6 illustrates a perspective view of an example embodiment of a fully assembled casing housing in the shape of a tetrahedron or 3-D pyramid according to the teachings herein; and

[0017] Fig. 7 illustrates a front view of an example embodiment of a casing housing with a wick or fuse member protruding therefrom according to the teachings herein.

DETAILED DESCRIPTION OF THE INVENTION

[0018] Following are more detailed descriptions of various related concepts related to, and embodiments of, methods and apparatus according to the present disclosure. It should be appreciated that various aspects of the subject matter introduced above and discussed in greater detail below may be implemented in any of numerous ways, as the subject matter is not limited to any particular manner of implementation. Examples of specific

implementations and applications are provided primarily for illustrative purposes.

[0019] The various embodiments of the invention are directed to an explosive device, such as a firecracker, and to robust casings and housings that need to house certain materials and then disintegrate over a certain period of time, thereby releasing the contents.

[0020] Referring to the figures, Figs. 1-6 illustrates an example embodiment of an explosive device 30 and a method of assembling an enhanced casing or housing for the explosive device 30 (see Figs. 5 and 6) according to the teachings of the invention. Referring now to Fig. l, the explosive device casing or housing is first formed from a substrate layer 5 is formed from a sheet (paper-based) material 10 having a layer of fiber reinforcement 12 disposed thereon. Sheet material 10 includes and is not limited to paper-based materials, thick paper, cardboard, cloth, plastic sheeting, leather, burlap material, vinyl and other malleable and perforable materials. In one example embodiment, the housing or casing is formed from substrate layer 5 having at least one layer of paper-based material. In another example embodiment, substrate layer 5 is formed from multiple layers of material 24 or alternating layers of paper-based material and fiber reinforcement layers. In one example embodiment, the substrate layer includes 8 layers of material 24, which can be alternating layers of a paper-based material and the fiber reinforced material or about 3 to about 8 layers of the paper-based materials or alternating paper-based and fiber reinforced materials (see Fig. 4 for instance).

[0021] Substrate layer 5 is then formed into a tubular structure 20 (Figs. 2 and 3) with a tube body 21 seam 22 and outer sheet 10, tubular structure 20 having a first flap member 25 formed at a first open end 20A and a second flap member 27 formed at a second open end 20B with the tube body disposed in between the first and second open ends, the tube body being collinear with a longitudinal axis 20C of tubular structure 20 and wherein each of the flap members are configured to be radially oriented about 90 degrees with respect to each other. First flap 25 member has an inside surface 26A, an outside surface 26B and a distal end portion 32 located away from the tube body, while second flap 27 member has an inside surface 28A, an outside surface 28B and a distal end portion 34 located away from the tube body.

[0022] Referring now to Fig. 4, device housing 30 includes a first seal 32 forming a base for the housing, first seal 33 formed from a folded over first flap member 25 that covers the first open end 20A such that the inside surface 26A of flap member 25 is in contact with and adhered to the tube body. In this embodiment, outside surface 26B is exposed and distal end portion 32 of first flap member 25 is substantially perpendicular to the longitudinal axis 20C of tubular structure 20. In this example embodiment, multiple layers 22 of first seal 32 are shown and are adhered to the body of housing 30 for added strength. Second flap member 27 is illustrated as being open such that an internal container 36 is formed in housing 30 for disposing an explosive compound or combustible material therein (along with a wick or fuse member). In a related embodiment, non-combustible material is disposed within container 36 wherein the user may be interested in a robust casing that may be able to disintegrate later to dispense the contents.

[0023] Referring to Figs. 4-6, a second seal 35 is formed which forms a top 38 for housing 30, the second seal being formed from a folded over second flap member 27 that covers the second open end 20B such that inside surface 28A and distal end portion 34 of the second flap member is in contact with and adhered to tube body 21, thereby forming top or tip 38 for the casing or housing. In summary, Fig. 5 illustrates a front view of an example embodiment of a fully assembled casing housing in the shape of a tetrahedron or 3-D pyramid while Fig. 6 illustrates a perspective view of an example embodiment of a fully assembled casing housing in the shape of a tetrahedron or 3-D pyramid according to the teachings herein. In other embodiments, the casing or housing is formed in a tubular, spherical, elliptical, square and rectangular shape and is not just necessarily limited to a pyramidal shape or configuration.

[0024] In a related embodiment, and in reference to Figs. 6 and 7, an explosive device is formed from the housing or casing described above when a combustible material or explosive compound is disposed within the housing (in container 36 - opening). One of the advantages of the described casing design for use as an explosive device is that it provides an increase in burst strength as built up energy, gases and pressure from igniting the combustible material attempt to escape one of the end seals formed from the folded over flap member structure. To this end, in a related embodiment, a small aperture 39 is formed near top 38 or a hole 40 is made in one of the faces (Fig. 7) of the casing to accommodate a fuse member 42 if this is used for an explosive device or firecracker. In another related embodiment, burst strength and pressure is increased from igniting the combustible material when the body and end seals are formed from the multiple layer substrate. [0025] Referring to Figures 1-7, there is described a method of forming a robust casing or housing adapted to receive and contain therein an explosive or combustible material. The method includes the steps of forming a substrate layer 5 from a sheet of paper-based material 10 and a sheet of fiber reinforcement material 12 disposed on the paper-based material sheet and then forming a tubular body 20 from the substrate layer having a first open end 20A and a second open end 20B and a tube body 21 therebetween, the tube body being collinear with a longitudinal axis 20C of the tube. Next material is removed from the first and second end of the tube so as to form a first flap member at the first end and a second flap member at the second end of the tube, each of the flap members configured to be radially oriented about 90 degrees with respect to each other, each flap member having an inside surface, an outside surface and a distal end away from the tube body. Next, the first flap member is folded over to cover the first open end such that the inside surface of the flap member is in contact with and adhered to the tube body, wherein the outside surface is exposed and the distal end of the flap member is substantially perpendicular to the longitudinal axis of the tube, thereby forming a base for the casing. Finally, the second flap member is folded over so as to cover the second open end such that the inside surface and distal end of the second flap member is in contact with and adhered to the tube body, thereby forming a top or cover for the housing or casing. In a related embodiment, a method of forming an explosive device from the housing formed above further includes the step of disposing an explosive or combustible material within the housing before folding over the second flap member. The simplicity of the housing or casing and the method of construction of the explosive device described herein allows for the manufacturing of the housing and resulting explosive device using mechanized and robotic machinery.

[0026] In a related embodiment for making the housing, the folded over flaps adhere to casing body (of whatever shape desired) and with some materials this will require the application of a small amount of glue or adhesive prior to folding over the flap. Some materials may not require any additional glue to adhere adequately to the casing body. In yet another related embodiment, the method of forming an explosive device further includes the step of disposing an explosive or combustible material by injecting the material into the housing as a fuse member is inserted into the housing.

[0027] In related embodiments, the explosive device and casing disclosed herein is constructed in a variety of sizes to fulfill a variety of applications in the fireworks industry. Further, the housing or casing could be made small enough to be a replacement for the standard firecracker or made large enough to replace the large explosive charges in aerial fireworks. In addition, the housing of and the explosive device can be constructed from a variety of materials and several quality levels of materials. The higher quality of stock material used will result in better casing strength and therefore a louder explosion. The housing and resulting explosive device constructed based on the described design is also a very efficient use of paper fiber stock input, with little to now waste of materials used as compared to traditional methods of constructing small firecrackers.

[0028] The following patents are incorporated by reference in their entireties: U.S. Pat. Nos. 3,090,175; 3,217,647; 4,714,506; 6,899,033; and 7,546,721.

[0029] While the invention has been described above in terms of specific embodiments, it is to be understood that the invention is not limited to these disclosed embodiments. Upon reading the teachings of this disclosure many modifications and other embodiments of the invention will come to mind of those skilled in the art to which this invention pertains, and which are intended to be and are covered by both this disclosure and the appended claims. It is indeed intended that the scope of the invention should be determined by proper interpretation and construction of the appended claims and their legal equivalents, as understood by those of skill in the art relying upon the disclosure in this specification and the attached drawings.