| abstract |
Methods of forming channels within a substrate include molding a sacrificial component directly into the substrate and igniting the sacrificial component to deflate the sacrificial component and form a channel in the substrate. The sacrificial component can contain oxidizing agents such as chlorates, perchlorates, nitrates, dichromates, nitramides and / or sulfates, which are embedded in a polymeric matrix, and the oxidizing agents can be 30% to 80% by weight of the sacrificial component. The sacrificial component can also contain one or more of the following components: unoxidized metal powder fuels, polymer bubbles filled with combustible gas, one or more metallocenes and / or one or more metal oxide particles, one or more polymers with nitroester, nitro, azido and / or Nitramine functional groups, one or more erosion suppressors such as oxamide, ammonium sulfate, calcium carbonate, calcium phosphate and ammonium chloride, and non-flammable hollow bubbles and / or inert particles. The polymeric matrix can have a limiting oxygen index of less than about 30. |