Abstract: A variable mass flow airbag module includes a housing having gas discharge ports in direct communication with an airbag to be inflated for rapidly inflating the airbag and adapted to receive gas from a pyrotechnic inflator, stored gas or hybrid inflator, or other type of inflator. The housing has a vent opening which is controlled by a valve to vent a controlled variable amount of gas to achieve a desired mass flow of gas into the airbag to provide a desired level of energy absorption capability for optimizing occupant protection.

Abstract: A new and improved single side wall air bag inflator includes a housing containing an ignition device, a quantity of pyrotechnic gas generant material and a filter. The housing includes a cup-shaped base member having an annular bottom wall with a central opening for access to the ignition device and an integrally formed, upstanding ported side wall extends upwardly of the bottom wall. The side wall has a radially inwardly deformable, free upper end portion forming a retaining flange for securing a top wall in place spaced above the bottom wall and closing off an upper end portion of the housing. The top wall has a depressed outer peripheral edge portion facing and sealed with the downwardly and radially inwardly deformed upper end flange of the single side wall.

Abstract: An element fixedly mounted in a motor vehicle having a free end and an aperture spaced apart therefrom is provided for securing an inner end portion of a flexible tether to the vehicle for restraining an air bag cover during air bag deployment. An attachment connector having a hook at one end is adapted to be engaged in hooked relation over the free end of the fixed element with the inner end portion of the tether sandwiched between facing adjacent surfaces of the attachment connector and the fixed element. A unidirectional, self-locking, snap-in-type, fastener mounted on the attachment connector remote from the hook end has a shank that is passed through the tether and is thereafter positioned to extend through the aperture of the fixed element when the attachment connector is engaged with the fixed element and pivoted about the hook end with the tether in sandwiched relation between the fixed element and the attachment connector.

Abstract: An air bag inflator module adapted for quick action, snap-action, permanent attachment onto a support in a motor vehicle, such as a steering wheel. Installation of the module on the support requires the use of no tools. The module has a base facing and movable toward the support. A fastening system is provided including a plurality of quick action, snap-action type fasteners extending between the base and the support. Either the base or the support includes openings for receiving a first portion of the fasteners extended therethrough as the module is pushed into place on the support with a unidirectional thrust. Each fastener also includes a second portion permanently mounted on the other of the base or the support opposite the opening for supporting the first portion projecting outwardly thereof. A snapaction expandable holding device is provided on the first portion of each fastener for engaging an opposite surface on the base or support after insertion through the opening.

Abstract: The present invention comprises a new and improved method and apparatus for packing an inflatable air bag cushion into a housing of an air bag module assembly of an occupant restraint system for a motor vehicle. After securing an inlet chute of the air bag cushion in the open end of the housing and placing the air bag on a flat support with a larger portion of the back wall thereof overlaying a small portion of the back wall with the front wall in between in a folded condition, a central portion of the air bag is clamped by a large blade and subsequently a first edge portion is folded over the central portion and a second opposite edge portion is folded over the first edge portion so that opposite edge fold lines extend outwardly just inside opposite ends of the housing. A rolling clamp is attached transversely across the folded air bag and the air bag is rolled-up on an axis moved toward the housing.

Abstract: An airbag inflator including a stack of gas generant wafers, each having a central core opening and the stack contained in an elongated housing having an initiator at one end. The initiator is aligned with an elongated passage formed by aligned core openings of the stack of gas generant wafers contained in the housing. A thin disk extends across the elongated passage dividing the passage into smaller separate core chambers. A charge of granular pyrotechnic ignition material is contained in one of the core chambers formed between the disk and the initiator. Activation of the initiator causes ignition of the pyrotechnic material in the adjacent core chamber which in turn ignites the adjacent gas generant wafers. Ignition of the pyrotechnic ignition material and the gas generant wafers causes the thin disk to be consumed or rupture so that the gas generant wafers forming the other chamber are also ignited.

Abstract: A multi-stage air bag inflator includes a housing with at least two separated chambers, each containing gas generating material and an ignition system for activating the material to generate gas for rapidly filling an associated air bag. An internal wall is provided in the housing to form the separated chambers and the wall has a frangible section designed to rupture in response to a predetermined level of gas pressure in one of the chambers providing fluid communication between the chambers. The frangible section is supported against rupture in response to gas pressure in the other gas chamber so that different levels of air bag inflation with gas are possible in response to the severity of the impact.

Abstract: A new and improved single side wall air bag inflator includes a housing containing an ignition device, a quantity of pyrotechnic gas generant material and a filter. The housing includes a cup-shaped base member having an annular bottom wall with a central opening for access to the ignition device and an integrally formed, upstanding ported side wall extends upwardly of the bottom wall. The side wall has a radially inwardly deformable, free upper end portion forming a retaining flange for securing a top wall in place spaced above the bottom wall and closing off an upper end portion of the housing. The top wall has a depressed outer peripheral edge portion facing and sealed with the downwardly and radially inwardly deformed upper end flange of the single side wall.

Abstract: A pyrotechnic air bag inflator utilizing non-azide gas generating material such as mixtures of copper oxide and amino tetrazol includes a unitary, rigid, drop-in type, filter for cooling and filtering high temperature, high pressure corrosive gas generated when the air bag inflator is activated to inflate an associated air bag. The filter comprises a reticulated structure formed of strong, porous, metal, metal alloy or ceramic material having a high thermal diffusivity and surface area for absorbing heat from the gas and defining a plurality of tortuous passages for entrapping contaminants from the gas passing through the filter.

Abstract: A tethered cover of an airbag inflator system designed to fit in an opening in the instrument panel of a motor vehicle is described. The cover has one or more metal attachment rods which extend along opposite edges of the panel opening. Parts of the rods are sandwiched between an outer substrate and a metal inner substrate provided in the cover. Other parts of the rods are exposed opposite the edge of the panel opening to permit engagement with fasteners on the panel which secure the cover in a closed position. The cover also has a metal tether attachment rod, a portion of which is sandwiched between the inner and outer substrates while a further outer portion is exposed for attachment to a loop at one end of a flexible tether. The cover is strong and is easy to assemble despite possible variations in the tolerances of cover attachment fasteners.

Abstract: An inflatable air bag for cushioning restraint of an occupant in a motor vehicle is fabricated from a single pattern piece cut from a thin, strong, lightweight, flat segment of flexible sheet material by sewing or seaming along cut edges of the pattern in a designated sequence to provide an air bag having a shape when fully inflated, providing a maximum effective cushioning surface for engaging the vehicle occupant. The single pattern piece is symmetrical with respect to bisecting longitudinal and transverse central axes and includes central portion forming a large, occupant engaging surface area, pairs of side edge portions at opposite ends of the central portion forming opposite side walls of the inflated air bag and pairs of throat portions at opposite ends of the longitudinal central axis for forming an inlet throat of the air bag for receiving inflation gas.

Abstract: An air bag retention system for securing a gas filling or inlet end of an inflatable air bag during deployment along a delivery chute extended toward a panel opening in a motor vehicle, includes an air bag having at least one pocket on an outside surface opening toward the panel. The delivery chute includes at least one retaining tab having a free end extending into the air bag pocket toward the inlet end for preventing the inlet end of the air bag from moving out of the chute during the rapid inflation thereof in response to generated gas flowing rapidly into the air bag.

Abstract: A new and improved multi-cell, partitioned, air bag for cushioning engagement with an occupant in a motor vehicle when the air bag is rapidly inflated with gas. The air bag is formed of thin, flexible, pervious sheet material having an inlet for receiving gas at a forward end and a rearwardly facing cushioning surface formed for engaging the vehicle occupant when the air bag is inflated. A flexible, internal wall or partition extends between the inlet and the cushioning surface for dividing the air bag into an upper or head cushioning cell or chamber adapted for engaging the occupant's head and a lower, or torso cushioning cell or chamber adapted for cushioning the occupant's torso. Vents are provided for reducing the inflation pressure in the upper chamber relative to the lower or torso chamber to reduce or prevent head injury and abrasion yet provide a desired level of energy absorption for cushioning the occupant's torso.

Abstract: A new and improved airbag inflator including a varying permeability filter. The inflator includes a housing for holding gas generating materials and has an outer diffuser wall with a plurality of discharge or diffuser ports arranged to direct the gas into an airbag for rapid inflation. The housing includes a ring of diffuser ports spaced apart around the periphery of the outer diffuser side wall and these ports are generally closer to one of the top or bottom end walls of the container than they are to the opposite end wall. A new and improved gas filter of varying permeability is mounted in the housing inside the periphery of the outer diffuser wall adjacent to the ring of ports. The annular filter has a gas permeability characteristic that varies between a maximum permeability rating in a first region farthest away from the ring of ports to a minimum permeability rating adjacent a second region closer to the ports.

Abstract: A pyrotechnic inflator for an air bag includes a housing for containing gas generating material for inflating an air bag. The housing has a wall formed of rigid, porous material and serves both as a filter for entrapping contaminants from the gas that is generated within as the gas passes outward through the wall into the air bag and cools the gas by absorbing heat therefrom. Gas generating material and an ignition train is hermetically sealed in a bag or packet inside the porous housing which serves triple duty as a solid pyrotechnic container, a gas filter and a gas cooler.

Abstract: An air bag inflator including a housing formed of sheet metal includes an annular base having a central opening and a cover for containing gas generating pyrotechnic material including an annular top wall spaced from the base having a central opening in coaxial alignment with the central opening of the base and a cylindrical, ported, outer side wall integrally formed around a periphery of the top wall extending downwardly thereof and having a lower edge secured to a portion of the base outwardly of the central opening. The housing includes a hollow, igniter-containing, rivet having an upper end wall closing over the central opening of the top wall and having a tubular, ported, side wall integrally formed with the upper end wall thereof extending downwardly through the central openings of the base and the top wall.

Abstract: A break-away fastening system for securing an air bag deployment door in position closing a panel opening used for air bag deployment includes a fastener extending from the door toward a facing edge flange of the panel around the panel opening. The fastener includes a head at an end portion directed toward the edge flange and adapted to be inserted through an aperture provided therein as the door is moved into place covering the panel opening. After full insertion, fingers of the head snap outwardly away from each other on an opposite side of the edge flange to lock the head and thus secure the door firmly in place. The fastener has at least one frangible section of reduced cross-section between the door and the edge flange which section is fractured or broken upon deployment of the air bag against the door as it moves through the panel opening.

Abstract: Apparatus for x-ray viewing of the firing cycle of an air bag inflator includes a pressure tank for containing an inflator during a firing cycle thereof having an access opening in a wall for receiving the inflator. A mounting ring is secured in place in the access opening having a stop flange at an inner open end for engaging the base of the inflator when inserted into the open end of the housing and limiting the amount of insertion of the inflator into the tank. A pressure plug is removably securable in the mounting ring to engage the base of the inflator for rigidly securing the same in a fixed position in the tank and sealing off the tank during a firing cycle. An x-ray apparatus and film pack or recorder are disposed on opposite sides of the tank to view the progress of the ignition process during a firing cycle of the inflator.

Abstract: An air bag inflator for inflating an air bag includes a housing for generating gas having only two walled chambers, including a centrally disposed ignition chamber and an outer chamber in coaxial relation therewith. The outer chamber provides a dual function of containing a quantity of gas generating material in an inner portion thereof and holding a filter for cooling and collecting contaminants from the generated gas in an outer portion thereof. The filter is mounted with an inlet face of substantial area in direct contact with and surrounding a body of gas generating material and no wall is provided between the filter and the generating material.

Abstract: A tethered cover airbag system is provided for motor vehicles and the like having a panel formed with an opening in the vicinity of an occupant's seat and including an inflatable airbag mounted in a housing or canister for containing the bag in a deflated condition. The housing has an open end aligned with a panel opening to permit the airbag to pass outwardly when deployed for cushioning support for an occupant in the adjacent seat. A cover is provided for normally closing the panel opening to protect the airbag and is bodily movable to uncover the opening during airbag deployment. A flexible tether is interconnected between the cover and the panel edge or the housing for limiting the movement of the cover away from the panel during deployment. A suitable attachment system is provided for spreading the load exerted by the tether over a large area of the cover for reducing stress exerted on the cover during airbag deployment.