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A flameless heater apparatus and method whose heating capacity and performance can be selected and tuned at the time of manufacture, and which is easily used and has a long shelf life. The apparatus and method may be used in flameless ration heaters, such as may be used in military or emergency situ

A flameless heater apparatus and method whose heating capacity and performance can be selected and tuned at the time of manufacture, and which is easily used and has a long shelf life. The apparatus and method may be used in flameless ration heaters, such as may be used in military or emergency situations. There is provided a flameless heating method and apparatus in which the solid reactive ingredients (not including liquid reactant, typically water) are not all blended or mixed together at the time of apparatus fabrication. Rather, at least one key ingredient (typically a super-corroding alloy of magnesium and iron) in a dry powder form is kept physically segregated from all the other ingredients, such as catalysts (normally acids such as acetic or tartaric acid or acidic mixtures) and surfactants. The exothermic chemical reaction is initiated only after at least one (typically a dry powder catalyst) goes into aqueous solution after the application of water (saline or non-saline). The catalytic solution flows out, through, and about and among water-permeable pockets in the pouch-like apparatus which contain one or more other ingredients, including the active ingredient (e.g., the Mg—Fe alloy). Thus, the catalyst and the active ingredient do not come into effective contact until a flowing aqueous saline solution carries a reactive catalytic-saline solution to the active ingredient alloy, and then mixes the inter-reactive ingredients to generate the desired heat.

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1. A method for flamelessly heating an item comprising the steps of: providing a pouch;defining at least two water-permeable pockets in the pouch;disposing in at least one water-permeable pocket a dry powder active ingredient;disposing in at least one different water-permeable pocket, physically seg

1. A method for flamelessly heating an item comprising the steps of: providing a pouch;defining at least two water-permeable pockets in the pouch;disposing in at least one water-permeable pocket a dry powder active ingredient;disposing in at least one different water-permeable pocket, physically segregated from the active ingredient, a dry powder catalyst;supplying the pouch with a salt activator;at time of use, wetting the pouch with water sufficient to penetrate the water-permeable pockets, causing a substantial portion of the salt activator and the catalyst to dissolve into solution; andpermitting the resulting solution to move amongst the water-permeable pockets and come into contact with the active ingredient to initiate an exothermic reaction in the pouch. 2. The method of claim 1 wherein the step of supplying the pouch with a salt activator comprises disposing dry powder salt in a water-permeable pocket defined in the pouch. 3. The method of claim 1 wherein the step of supplying the pouch with a salt activator comprises placing dry powder salt upon the pouch immediately prior to use. 4. The method of claim 1 wherein the steps of supplying the pouch with a salt activator and wetting the pouch with water comprise the combined step of applying saline solution to the pouch. 5. The method of claim 1 further comprising the step of disposing in at least one water-permeable pocket at least one other ingredient selected from the group consisting of a dry powder surfactant, a dry powder hydrogen getter, and an inert material. 6. The method of claim 1 further comprising the step of incorporating in a separate solution at least one ingredient selected from the group consisting of a surfactant, a catalyst, and a salt activator and wherein the step of wetting the pouch comprises wetting the pouch with the separate solution. 7. The method of claim 1 further comprising the step of selectively tuning the rate of the exothermic reaction by: selectively measuring the disposition of a powder active ingredient in at least one pocket; andselectively measuring the disposition in the other pockets of at least one other ingredient selected from the group consisting of dry powder salt and dry powder catalyst;wherein the measuring steps occur prior to a step of sealing closed the pockets. 8. The method of claim 1 wherein the step of disposing the dry powder active ingredient comprises disposing a magnesium-iron alloy containing up to 12 weight percent of iron. 9. The method of claim 8 wherein the step of disposing a magnesium-iron alloy containing up to 12 weight percent of iron comprises disposing a magnesium-iron alloy containing approximately 5 weight percent of iron. 10. The method of claim 8 further comprising the step of incorporating a hydrogen getter into the magnesium-iron alloy. 11. The method of claim 8 further comprising the step of incorporating an inert material into the magnesium-iron alloy. 12. The method of claim 1 wherein the step of defining at least two water-permeable pockets in the pouch comprises defining at least three pockets, and further comprising the steps of: disposing the powder active ingredient in at least one pocket; anddisposing in at least one of the other pockets in the pouch, besides the pockets in which active ingredient is disposed, at least one other ingredient selected from the group consisting of the catalyst, a powder salt activator, and a powder surfactant. 13. The method of claim 12 further comprising the step of disposing in any pocket either a hydrogen getter or an inert material. 14. The method of claim 12 wherein at least one of the other pockets holds a powder salt activator, and the step of wetting the pouch comprises applying non-saline water to the pouch. 15. The method of claim 12 wherein none of the pockets holds a powder salt activator and wherein the step of supplying the pouch with a salt activator comprises placing dry powder salt upon the pouch immediately prior to use. 16. The method of claim 12 wherein none of the pockets holds a powder salt activator and the steps of supplying the pouch with a salt activator and of wetting the pouch comprise the combined step of applying a saline solution to the pouch. 17. The method of claim 12 wherein the step of disposing in the other pockets in the pouch at least one other ingredient comprises disposing a powder mixture of at least two of the other ingredients. 18. The method of claim 12 further comprising the step of incorporating in a separate solution at least one ingredient selected from the group consisting of a surfactant, a catalyst, and a salt activator and wherein the step of wetting the pouch comprises wetting the pouch with the separate solution. 19. The method of claim 12 further comprising the step of selectively tuning the rate of the exothermic reaction by: selectively measuring the disposition of the powder active ingredient in at least one pocket; andselectively measuring the disposition in the other pockets of at least one other ingredient selected from the group consisting of dry powder salt and dry powder catalyst;wherein the measuring steps occur prior to a step of sealing closed the pockets. 20. The method of claim 1 wherein: the step of providing a pouch comprises providing two or more pouches connected together; andthe step of defining at least two water-permeable pockets comprises defining at least one water-permeable pocket in each pouch. 21. The method of claim 20 further comprising the steps of: disposing an active ingredient in at least one pocket;disposing in selected other pockets, besides the pockets in which active ingredient is disposed, one or more ingredients selected from the group consisting of a catalyst, a salt activator, and a surfactant. 22. The method of claim 21 further comprising the step of disposing in any pocket a hydrogen getter or an inert ingredient. 23. The method of claim 21 wherein at least one of the pockets holds a powder salt activator, and the step of wetting the pouch comprises applying non-saline water to the pouch. 24. The method of claim 21 wherein none of the pockets holds a powder salt activator and wherein the step of supplying the pouch with a salt activator comprises placing dry powder salt activator upon the pouch immediately prior to use. 25. The method of claim 21 wherein none of the pockets holds a powder salt activator and the steps of supplying the pouch with a salt activator and of wetting the pouch comprise the combined step of applying a saline solution to the pouch. 26. The method of claim 21 wherein the step of disposing in the other pockets in the pouch at least one other ingredient comprises disposing a powder mixture of at least two of the other ingredients. 27. The method of claim 21 further comprising the step of incorporating in a separate solution at least one ingredient selected from the group consisting of a surfactant, a catalyst, and a salt activator and wherein the step of wetting the pouch comprises wetting the pouch with the separate solution. 28. The method of claim 21 further comprising the step of selectively tuning the rate of the exothermic reaction by: selectively measuring the disposition of the active ingredient in at least one pocket; andselectively measuring the disposition in the other pockets of mixtures of one or more of the other ingredients selected from the group consisting of dry powder salt and dry powder catalyst;wherein the measuring steps occur prior to a step of sealing closed the pockets. 29. The method of claim 1 wherein the step of defining at least two water-permeable pockets in the pouch comprises creating non-frangible seams in the pouch. 30. A method for flamelessly heating an item comprising the steps of: providing a pouch;defining with non-frangible seams a plurality of water-permeable pockets in the pouch;disposing in at least one water-permeable pocket a dry powder active ingredient;disposing in at least one water-permeable pocket, physically segregated from the active ingredient, a dry powder catalyst;supplying the pouch with a salt activator;at time of use, wetting the pouch with water sufficient to penetrate the water-permeable pockets, causing a substantial portion of the salt activator and the catalyst to dissolve into solution; andpermitting the resulting solution to move amongst the water-permeable pockets and come into contact with the active ingredient to initiate an exothermic reaction in the pouch. 31. The method of claim 30 wherein the step of supplying the pouch with a salt activator comprises disposing dry salt activator powder in a water-permeable pocket defined in the pouch. 32. The method of claim 30 wherein the step of supplying the pouch with a salt activator comprises placing dry powder salt upon the pouch immediately prior to use. 33. The method of claim 30 wherein the steps of supplying the pouch with a salt activator and wetting the pouch with water comprise the combined step of applying saline solution to the pouch. 34. The method of claim 30 further comprising the step of disposing in at least one water-permeable pocket at least one other ingredient selected from the group consisting of a dry powder surfactant, a dry powder hydrogen getter, and an inert material. 35. The method of claim 30 further comprising the step of incorporating in a separate solution at least one ingredient selected from the group consisting of a surfactant, a catalyst, and a salt activator and wherein the step of wetting the pouch comprises wetting the pouch with the separate solution. 36. The method of claim 30 further comprising the step of selectively tuning the rate of the exothermic reaction by: selectively measuring the disposition of the powder active ingredient in at least one pocket; andselectively measuring the disposition in other pockets of at least one other ingredient selected from the group consisting of dry powder salt and dry powder catalyst;wherein the measuring steps occur prior to a step of sealing closed the pockets. 37. The method of claim 30 wherein the step of disposing the dry powder active ingredient comprises disposing a magnesium-iron alloy containing up to 12 weight percent of iron. 38. The method of claim 37 wherein the step of disposing a magnesium-iron alloy containing up to 12 weight percent of iron comprises disposing a magnesium-iron alloy containing approximately 5 weight percent of iron. 39. The method of claim 37 further comprising the step of incorporating a hydrogen getter into the magnesium-iron alloy. 40. The method of claim 37 further comprising the step of incorporating an inert material into the magnesium-iron alloy. 41. The method of claim 30 wherein: the step of providing a pouch comprises providing two or more pouches connected together; andthe step of defining at least two water-permeable pockets comprises defining at least one water-permeable pocket in each pouch. 42. The method of claim 41 further comprising the steps of: disposing active ingredient in at least one pocket;disposing in selected pockets, besides the pockets in which active ingredient is disposed, one or more other ingredients selected from the group consisting of a catalyst, a salt activator, and a surfactant. 43. The method of claim 42 further comprising the step of disposing in any pocket a hydrogen getter or an inert ingredient. 44. The method of claim 42 wherein at least one of the pockets holds a powder salt activator, and the step of wetting the pouch comprises applying non-saline water to the pouch. 45. The method of claim 42 wherein none of the pockets holds a powder salt activator and wherein the step of supplying the pouch with a salt activator comprises placing dry powder salt activator upon the pouch immediately prior to use. 46. The method of claim 42 wherein none of the pockets holds a powder salt activator and the steps of supplying the pouch with a salt activator and of wetting the pouch comprise the combined step of applying a saline solution to the pouch. 47. The method of claim 42 wherein the step of disposing in the other pockets in the pouch at least one other ingredient comprises disposing a powder mixture of at least two of the other ingredients. 48. The method of claim 42 further comprising the step of incorporating in a separate solution at least one ingredient selected from the group consisting of a surfactant, a catalyst, and a salt activator and wherein the step of wetting the pouch comprises wetting the pouch with the separate solution. 49. The method of claim 42 further comprising the step of selectively tuning the rate of the exothermic reaction by: selectively measuring the disposition of the powder active ingredient in at least one pocket; andselectively measuring the disposition in the other pockets of at least one of the other ingredient selected from the group consisting of dry powder salt and dry powder catalyst;wherein the measuring steps occur prior to a step of sealing closed the pockets. 50. An apparatus for flamelessly heating an item, the apparatus comprising: one pouch;at least two water-permeable pockets in the pouch;a dry powder active ingredient disposed in at least one water-permeable pocket;a dry powder catalyst disposed in at least one different water-permeable pocket, physically segregated from the active ingredient;a salt activator;wherein the pouch is wetted at the time of use with water sufficient to penetrate the water-permeable pockets, causing a substantial portion of the salt activator and the catalyst to dissolve into solution; andwherein the resulting solution is allowed to move amongst the water-permeable pockets and come into contact with the active ingredient to initiate an exothermic reaction in the pouch. 51. An apparatus according to claim 50 wherein the salt activator comprises dry powder salt activator disposed in at least one water-permeable pocket defined in the pouch. 52. An apparatus according to claim 50 wherein the salt activator comprises a dry powder salt disposed upon the pouch exterior immediately prior to use. 53. An apparatus according to claim 50 wherein the salt activator comprises a saline solution applied to the pouch exterior immediately prior to use. 54. An apparatus according to claim 50 further comprising at least one other ingredient, selected from the group consisting of a dry powder surfactant, a dry powder hydrogen getter, and an inert material, disposed in at least one other water-permeable pocket. 55. An apparatus according to claim 50 further comprising a separate container which contains a separate solution with at least one ingredient selected from the group consisting of a surfactant, a catalyst, and a salt activator; wherein the separate solution in the separate container wets the pouch at time of use. 56. An apparatus according to claim 50 comprising: a selectively measured quantity of powder active ingredient sealed in at least one pocket; anda selectively measured quantity of at least one other ingredient selected from the group consisting of dry powder salt and dry powder catalyst; and sealed into another pocket;whereby the rate of the exothermic reaction is selectively fine tuned. 57. An apparatus according to claim 50 wherein the active ingredient comprises a magnesium-iron alloy containing up to 12 weight percent of iron. 58. An apparatus according to claim 57 wherein the magnesium-iron alloy contains approximately 5 weight percent of iron. 59. An apparatus according to claim 57 further comprising a hydrogen getter incorporated into the magnesium-iron alloy. 60. An apparatus according to claim 57 further comprising an inert material incorporated into the magnesium-iron alloy. 61. An apparatus according to claim 50 wherein the at least two water-permeable pockets in the pouch comprise at least three pockets, and further comprising: the powder active ingredient disposed in at least one pocket; andat least one other ingredient selected from the group consisting of a catalyst, a powder salt activator, and a powder surfactant disposed in at least one other pocket in the pouch, besides the pocket in which the active ingredient is disposed. 62. An apparatus according to claim 61 further comprising a hydrogen getter or an inert material disposed in any pocket. 63. An apparatus according to claim 61 wherein the salt activator comprises dry salt activator powder disposed in at least one water-permeable pocket defined in the pouch. 64. An apparatus according to claim 61 wherein none of the pockets holds a powder salt activator and the salt activator comprises dry powder salt placed upon the pouch immediately prior to use. 65. An apparatus according to claim 61 wherein none of the pockets holds a powder salt activator and the salt activator comprises a saline solution applied to the pouch immediately prior to use. 66. An apparatus according to claim 61 wherein the at least one other ingredient comprises a powder mixture of at least two of the other ingredients. 67. An apparatus according to claim 61 further comprising a separate container which contains a separate solution with at least one ingredient selected from the group consisting of a surfactant, a catalyst, and a salt activator; wherein the separate solution in the separate container wets the pouch at time of use. 68. An apparatus according to claim 61 further comprising: a selectively measured quantity of powder active ingredient sealed in at least one pocket; anda selectively measured quantity of at least one other ingredient selected from the group consisting of dry powder salt and dry powder catalyst; and sealed into another pocket;whereby the rate of the exothermic reaction is selectively fine tuned. 69. An apparatus according to claim 50 comprising: at least two pouches connected together; andat least one water-permeable pocket in each pouch. 70. An apparatus according to claim 69 further comprising: an active ingredient disposed in at least one pocket; andone or more ingredients from the group consisting of a catalyst, a salt activator, and a surfactant disposed in at least one other pocket, besides the pocket with the active ingredient. 71. An apparatus according to claim 70 further comprising a pocket containing at least one ingredient selected from the group consisting of an inert material and a hydrogen getter. 72. An apparatus according to claim 70 wherein the salt activator comprises dry salt activator powder disposed in at least one water-permeable pocket defined in the pouch. 73. An apparatus according to claim 70 wherein the salt activator comprises a dry powder salt disposed upon the pouch exterior immediately prior to use. 74. An apparatus according to claim 70 wherein the salt activator comprises a saline solution applied to the pouch exterior immediately prior to use. 75. An apparatus according to claim 70 further comprising at least one other ingredient selected from the group consisting of a dry powder surfactant, a dry powder hydrogen getter, and an inert material, disposed in at least one other water-permeable pocket. 76. An apparatus according to claim 70 further comprising a separate container which contains a separate solution with at least one ingredient selected from the group consisting of a surfactant, a catalyst, and a salt activator; wherein the separate solution in the separate container wets the pouch at time of use. 77. An apparatus according to claim 70 wherein the rate of the exothermic reaction is selectively fine tuned by: incorporating a measured quantity of powder active ingredient sealed in at least one pocket; andincorporating a measured quantity of at least one other ingredient sealed into another pocket. 78. An apparatus according to claim 50 wherein the at least two water-permeable pockets in the pouch are defined by non-frangible seams in the pouch.