Abstract: An improvement in an air bag system for a motor vehicle relating to a multiple level fluid fueled air bag inflator and method of operation thereof are provided. Such a multiple level inflator includes a stored gas chamber, a combustion chamber wherein, upon actuation, a fluid fuel and an oxidant are burned, an opener to open the stored gas chamber and an initiator device to initiate the burning of the fluid fuel and oxidant in the combustion chamber. Various performance levels can be obtained through the proper selected actuation and sequencing of actuation of the opener and the initiator device.

Abstract: Apparatus for inflating an inflatable device, methods for inflating an inflatable safety device and a method of manufacturing an apparatus for inflating an inflatable device are provided having a fuel containment assembly to contain a fuel in the form of a fluid. The fuel, upon proper initiation, is burned to produce gas used in the inflation of the inflatable device.

Abstract: A hybrid inflator for a vehicle airbag module produces an initial release of essentially unheated, stored, pressurized gas from the gas storage chamber of the inflator by way of a projectile, releasable from a nozzle opening in a combustion chamber housing upon combustion of a gas-generating combustible material housed within the combustion chamber housing, which ruptures and passes through a frangible burst element retaining the stored, pressurized gas in the gas storage chamber of the inflator, thereby permitting, initially, the unheated, stored, pressurized gas to discharge through the ruptured burst element and flow externally past the combustion chamber housing in an isolation housing and then to exit the inflator through gas exhaust ports in the inflator.

Abstract: A low pressure igniter system for a gas bag inflator using a head-end chamber or closure to house a pyrotechnic ignition compound that is ignited by an initiator (squib). The housing for the igniter includes a base having a skirt that extends from the periphery of the base with the base and the skirt being a single piece of material. When initiated the low pressure igniter has a large flame front producing hot gas and particles. The low pressure igniter provides a low cost alternative to current pyrotechnic igniters, and is further advantageous in that it makes practicable fabrication of inflator housings of sheet steel.

Abstract: A side impact airbag module assembly having a combination airbag inflator and module housing and an airbag cushion. The combination airbag inflator and module housing has an extruded unitary one-piece hollow elongated longitudinal body having an outer surface, an inner surface, a first open end, a second open end, and a plurality of gas exhaust ports extending from the inner surface to the outer surface. Two airbag receiving channels, each channel having a slot running along the channel, are respectively located on the outer surface of the longitudinal body, parallel with the body on opposite sides of the plurality of gas exhaust ports. A first endplug seals the first open end and a second endplug seals the second open end with the inner surface of the longitudinal body and the endplugs defining a gas generant chamber containing a gas generant.

Abstract: An apparatus and method for charging fluids to elongated pressure containers, such as inflators for airbag passive restraint systems is described. The disclosed method and apparatus enables the container to be filled from the side rather than from the end. The charging of more than one fluid to different chambers in the container is also facilitated, either by enabling two charges to be conducted simultaneously, or by allowing the two charges to be conducted through a single fill port.

Abstract: A unitary storage structures for the fluid components of a inflator of a vehicular airbag passive restraint system. The unitary storage structures facilitate the storage, testing, transportation and assembly of such components in the inflator. Advantageous methods of filling the storage chambers and of testing the filled structures for leaks prior to their transportation and assembly into the inflator housing are also disclosed.

Abstract: An airbag module and mounting. An inflator is received within the cushion, such that the cushion wraps around the back side of the inflator. The inflator includes an extending fastener, and possibly an extending tab. The inflator, or the tab, is partially retained by a receiving structure on the seat. The fastener extends through another section of the seat, such that securing the fastener secures the entire inflator. Additionally, since the cushion surrounds the inflator, the cushion is also secured. To maintain the cushion in the folded condition, a frangible wrap extends around the cushion and inflator. Upon inflation, the frangible wrap, and the seat covering, are torn by the expanding cushion to permit further expansion. This arrangement eliminates the need for a protective housing for the inflator and cushion. Other mounting arrangements are also provided.

Abstract: The storage of combustible mixed fluid fuel and oxidizer in a porous matrix provides for enhanced control of fluid fueled inflators such as are used in automotive passive restraint airbag systems. By storing such in mixtures in a porous matrix having pores smaller than the quenching distance of the stored mixture the flammability of the mixture is suppressed. Storage of the mixture in a porous matrix having larger pores provides a mechanism for controlling the rate of release of the mixture, as well as providing a heat sink which helps moderate the temperature of the mixture during the filling operation, during long term storage and during the combustion process. Several inflator embodiments, with particularly advantageous structures for storing and releasing the mixture, are disclosed.

Abstract: A plenum having a generally elliptical cross-section is provided around an end discharge cylindrical inflator to redistribute the inflation gases before they enter the airbag cushion, thereby avoiding a skewed initial deployment thereof.

Abstract: Igniters for use in airbag inflators are disclosed. The igniters are fabricated of consumable materials which produce essentially no solid by-products. The igniters, or parts thereof, can be formed by molding or extrusion processes. The invention also provides a consumable auto-ignition cap as part of one of the embodiments of the igniter assembly.

Abstract: An elongated gas generator, or inflator, includes a pyrogen igniter mounted at one end thereof. The pyrogen igniter encloses a unitary grain of ignition material having a centrally located cavity. An initiator, or squib, is located to ignite the unitary grain at the surface of its centrally located cavity. The combustion products given off by the igniter are directed through a port and into a clear ignition channel provided in the center of the pyrotechnic gas generant material which extends the length of the gas generator, thereby causing the gas generant material to produce sufficient gas to inflate an associated airbag. The unitary grain of ignition material used in the pyrogen igniter facilitates and simplifies the assembly and manufacture of the igniter structure.

Abstract: An inflation system for automotive airbags which comprises a pyrogenic solid grain with igniter strips provided in grooves on its external surface. Upon ignition, the solid grain burns from its external surface inwardly while allowing the generated gas to pass freely from its external surface. Preferably both the pyrogenic solid grain and the igniter strips are extrusions, providing a simplified, less expensive manufacture.

Abstract: An airbag inflator assembly including an airbag inflator and an inflator attachment having a sleeve. The inflator includes an elongated sidewall and an end having a flange stop extending outwardly from the sidewall. The sleeve receives and supports the sidewall of the inflator with the flange stop butting against the sleeve. The sleeve has an inwardly extending resilient tab that faces away from the flange stop and engages a gas exhaust port defined by the sidewall to retain the inflator within the sleeve. At least one stud extends transversely to and outwardly from the sleeve for mounting the inflator attachment and inflator within an airbag module. The inflator attachment further includes at least two spaced-apart pairs of diametrically opposed ribs protruding inwardly from the sleeve and grippingly engaging the sidewall of the inflator. The sleeve also defines gas exhaust outlets, which on different versions of the sleeve may vary to accommodate different types of inflators.

Abstract: The reaction canister of an airbag module assembly is extruded to include a semicircular floor, first and second sidewalls, and first and second end plates closing the ends of the canister, with the floor extending uniformly between the sidewalls, and a bottom edge of each sidewall defining a channel along its length. A cylindrical inflator chamber is suspended beneath the floor of the canister by opposed parallel wings which are integral with the inflator chamber and are insertable into and slide in the channels to a position wherein the walls of the channel are staked to the wings. A plenum chamber is formed between the curved wall of the inflator chamber and the floor of the reaction canister. The plenum chamber separates gas exit vent holes of the inflator chamber from gas inlet passages or vent holes in the canister floor.

Abstract: Featured for use as a part of a reaction canister of an inflatable restraint system is a conventionally extruded one-piece canister structure body part having first and second opposite side walls and a bridging portion joining the first and second opposite side walls. In the body part, at least one of the bridging portion, first side wall and second side wall includes a tear seam adapted to tear under the influence of a build-up of pressure thereagainst to provide venting of such pressure. As a result of alleviating concerns such as of material fragmentation when exposed to extreme heat conditions, e.g., a fire, the invention allows the more widespread use of light weight, temperature sensitive materials in reaction canister constructions.

Abstract: A pressurized gas inflator suited for side impact airbags comprises an elongated cylindrical bottle having a closed end and an open end defining an outlet opening. A diaphragm is sealed across the open end of the bottle to form a chamber containing pressurized gas. A cup-shaped diffuser also has an open end secured to the open end of the bottle with the periphery of the diaphragm therebetween. A squib is mounted in the diffuser for rupturing the diaphragm. An enhanced squib with 300-400 milligrams of ZPP is used in one disclosed inflator and an augmented directional initiator is used in another disclosed inflator. The enhanced squib and augmented directional initiator provide heating to offset adiabatic cooling of the gas. The diffuser defines outlet ports for delivering the inflation gas. The cylindrical bottle has a mounting flange on its closed end, and the mounting flange may be an end cap with a radially extending flange.

Abstract: A side impact airbag module assembly adapted to mount on the exterior of the side of a seat back of an automobile seat back having an access opening and receiving means within a internal structural member. The side impact airbag module assembly includes an airbag module frame having a mounting flange adapted to extend through the access opening in the seat cover and having thereon self fasteners that secure the flange in the receiving means of the internal structural member of the seat. An airbag cushion and inflator assembly is secured to the frame, and an airbag module cover is also secured to the airbag module frame to conceal and protect the airbag cushion and inflator assembly and the airbag module frame. The airbag module is provided in one variation with depth limiters that prevent the mounting flange from being inserted too far into the receiving means, and clamp supports which further secure the mounting flange to the internal structural member.

Abstract: A method for producing composite materials by introducing additional phases into a porous body wherein a liquid precursor is infiltrated into the porous body, the liquid is decomposed to produce a desired phase, the body is fired for further densification, and the decomposed liquid is allowed to remain as an additional phase or reacts with the porous body to form an additional phase is disclosed. This allows for a novel method of introducing the additional phase, and by controlling the parameters such as infiltration time, firing schedule, porous body density, etc., the size, amount, extent and distribution of the added phases may be controlled.

Abstract: A diffuser device, an air bag/diffuser subassembly and an air bag module assembly for use in an inflatable air bag restraint system for use in a motor vehicle are provided. The diffuser device can function as a structural member, gas flow diffuser, heat shield and bag retainer and can serve to reduce the cost/weight of air bag module manufacture and assembly.