Initiator assembly with integrated shorting element

Abstract

An initiator assembly for use with an assembly for use in a vehicular safety restraint installation such as in an airbag inflator or micro-gas generator is provided. The initiator assembly includes an integral, one-piece insert member that is injection molded with insulating material to an initiator. The insert member suitably engages a housing of the assembly for properly holding the initiator assembly in place relative to the housing both before and after the initiator is activated. The insulating material defines a receiving portion for receiving a shorting element. The shorting element creates a short circuit between a pair of initiator electrical terminals. The insulating material further defines an interface having a keyed mating portion for receiving a correspondingly shaped electrical connector in electrical contact with the electrical terminals.

Description

BACKGROUND OF THE INVENTION

[0001] This invention relates generally to vehicular safety restraint installations and, more particularly, to initiator assemblies and corresponding gas generator devices such as used in such applications.

[0002] Various safety restraint systems for the protection of vehicle occupants have come into widespread use. In such systems, a restraint device is typically actuated upon the occurrence of a condition during which a vehicle occupant is to be restrained. As will be appreciated, a vehicle collision is an example of a common occurrence for which restraint of a vehicle occupant is customarily desired.

[0003] One well-known type of actuatable restraint system seeks to protect a vehicle occupant using a cushion or bag, e.g., an “airbag cushion,” that is inflated or expanded with gas when the vehicle encounters a sudden deceleration, such as in the event of a collision. In such inflatable restraint systems, an airbag cushion is normally housed in an uninflated and folded condition to minimize space requirements. Such systems typically include one or more crash sensors mounted on or to the frame or body of the vehicle and which sensors serve to detect sudden decelerations of the vehicle and to electronically trigger activation of the system. Upon actuation of the system, the cushion begins to be inflated in a matter of no more than a few milliseconds with gas produced or supplied by a device commonly referred to as an “inflator.”

[0004] Many types of inflator devices have been disclosed in the art for use in the inflation of one or more inflatable restraint system airbag cushions. Inflator devices which form or produce inflation gas via the combustion of a gas generating material, i.e., a “gas generant,” are well known. It is also known that certain of such inflator devices may use such generated gas to supplement stored and pressurized gas by the addition of high temperature combustion products, including additional gas products, produced by the burning of the gas generating material to a supply of the stored, pressurized gas. In some cases, the combustion products produced by the burning of a gas generating material may be the sole or substantially the sole source for the inflation gas issuing forth from a particular inflator device.

[0005] It is common that inflator devices include an initiator, such as a squib, and an igniter. For example, common initiator devices or initiation elements used in such applications include: bridgewire, spark-discharge, heated or exploding wire or foil, through bulkhead (e.g., an initiator which discharges through a bulkhead such as in the form of a metal hermetic seal), and may, if desired, optionally contain a desired load of a suitable pyrotechnic charge. In practice, upon receipt of an appropriate triggering signal from a crash or other selected deceleration sensor, the initiator activates causing the rapid combustion of the igniter material, which, in turn, ignites the gas generant, such as in the form of tablets or wafers. In typical such inflator devices, it is common that a squib is used to ignite an igniter composition which is usually present in a separate compartment or canister. In this manner, the igniter material is generally physically separated from both the squib and the gas generant. In some cases, however, the igniter material may be present as a coating such as applied directly onto the gas generant tablets or wafers with an electrically actuated squib still being used to ignite the igniter material. In such case, though the igniter material is physically joined or in contact with the gas generant, both the igniter material and the gas generant are physically separated from the squib components. Very seldom, if ever, is a granular igniter composition physically mixed with gas generant tablets or wafers to effect ignition thereof.

[0006] Another type of vehicular actuatable occupant restraint system has or includes a seat belt which is extendable across a vehicle occupant and includes an actuatable device, such as a pretensioner, provided to move at least a portion of the seat belt relative to the occupant. For example, one modern seat belt is known as a 3-point restraint because it is secured to the vehicle at three points arranged about the vehicle occupant to provide a diagonal torso section and a horizontal lap portion to secure or otherwise hold the vehicle occupant in the seat. The seat belt is customarily attached to the vehicle by a spring-loaded retractor tending to tighten in the belt, and by a buckle for quick release of the belt. Seat belt pretensioners are typically sited at the retractor or at the buckle end of the restraining seat belt. Seat belt pretensioners are commonly designed to store energy which, when released, effects the pretensioning operation. This energy may be mechanical energy such as in the form of a stressed spring, but more modern pretensioners are commonly pyrotechnically operated. Pyrotechnically operated pretensioners typically comprise a sealed tube containing a gas generant composition which reacts rapidly to generate gas which expands rapidly to provide the energy to effect the pretensioning operation. For example, such generated gas may be used to drive a piston or the like, such as included or used in a pretensioner, in association with a seat belt or other restraint device. In view of the relatively small amount of gas generated or produced from or in such devices as compared to gas generating inflators typically used in the inflation of inflatable restraint system airbag cushions, such devices are commonly referred to as “micro-gas generators.”

[0007] Micro-gas generators have in the past typically been composed of a single housing which contains an initiation element such as in the form of squib, an intermediate igniter composition and a high output, gas generating material. Squibs used in such devices typically include a heated bridgewire to which has been applied a thermally sensitive very hot burning initiator composition however, other known initiation elements can, if desired be used. Thus, micro-gas generators are typically very small devices which generally contain the components of an airbag inflator, including an initiation element, igniter composition and a high output, gas generating material without the degree of physical separation typically present in airbag inflators. Further, due to the very small operating time requirements associated with micro-gas generator applications (such as operating times of only about 6 milliseconds or less), such devices generally contain a much larger ratio of igniter material to gas generating material, as compared to typical airbag inflator devices. For example, inflators used in association for inflation of frontal impact airbag cushions employed for driver protection typically contain or include igniter material in a range of about 3-10% by weight of the total gas producing material (e.g., igniter material and gas generating output charge) present in the inflator device. In contrast, in micro-gas generators, the igniter material may generally be present within the device in a relative amount of at least about 20% by weight of the total gas producing material present therewithin and typically in a range of about 20-50% by weight of the total gas producing material present in the device.

[0008] As identified above, gas generator devices such as in the form of inflator assemblies typically include an initiator device for activating a gas generant material to produce or form a gas such as to inflate one or more inflatable restraint system airbag cushions. Initiator assemblies typically include an initiator with an associated means for attaching the initiator to a housing containing the gas generant material. Initiator assemblies also typically include at least one electrical terminal for electrical contact to an electrical connector in combination with a vehicle. When an initiator includes more than one electrical terminal, a shorting clip may desirably be employed to create a short circuit between the electrical terminals when the terminals are not in electrical contact with an associated electrical connector. As will be appreciated, such inclusion and use of a shorting clip can prevent accidental actuation of the initiator prior to connection with the electrical connector.

[0009] In the past, the inclusion of shorting clips in initiator assemblies typically has undesirably impacted either or both the manufacture and costs associated with gas generators including such assemblies. For example, the inclusion and use of a separate, molded plastic shorting clip ring adds to the cost of the assembly. In addition, the incorporation and use of such a separate shorting clip ring may raise quality concerns as, for example, such a separate shorting clip ring can accidentally or unintentionally fall out of proper placement or position within an assembly.

[0010] In view of the above, there is a need and a demand for an initiator assembly that can be connected to serviceable electrical connectors without the use of a separate shorting clip assembly. Further, there is a need and a demand for a less costly initiator assembly that can include an optional shorting clip, without the use of a separate shorting clip assembly.

SUMMARY OF THE INVENTION

[0011] A general object of the invention is to provide an improved assembly for use in a vehicular safety restraint installation. More particularly, a general objective of the invention is to provide an improved assembly such as to facilitate the making of a suitable connection between an initiator and an associated housing and such as may facilitate the inclusion or incorporation of a shorting clip.

[0012] A more specific objective of the invention is to overcome one or more of the problems described above.

[0013] The general object of the invention can be attained, at least in part, through a specified assembly for use in a vehicular safety restraint installation. In accordance with one preferred embodiment of the invention, such an assembly includes an initiator and an associated collar assembly joined to the initiator. The initiator includes a pair of electrical terminals for electrical contact with an electrical connector. The electrical terminals can receive an electrical signal from the electrical connector. The collar assembly desirably includes a collar member, an insert member and a shorting element. The collar member is desirably formed of an injection-molded insulating material and surrounds at least portions of the initiator. The collar member defines an interface that contains at least portions of each of the pair of electrical terminals. The collar member interface includes a keyed mating portion that accepts an electrical connector in a keyed mated connection and a receiving portion that accepts the shorting element in a secured connection. The insert member is joined by injection molding to the collar member insulating material. The shorting element is secured, at least in part, to the receiving portion of the collar member interface. The shorting element serves to establish a short circuit between the pair of electrical terminals when the electrical connector is not in electrical contact with the pair of electrical terminals.

[0014] The prior art generally fails to provide initiator assemblies which desirably incorporate various desired features, such as shorting assemblies, in an as simply, effective and efficient a manner as may be desired.

[0015] The invention further comprehends an initiator assembly for use in a vehicle. In accordance with one preferred embodiment of the invention, such an initiator assembly includes an initiator and an associated collar assembly joined thereto. More particularly, the initiator includes a pair of electrical conductive pins for electrical contact with an electrical connector to receive an electrical signal from the electrical connector. The collar assembly desirably includes a collar member, an insert member and a shorting element. The collar member is desirably formed of an injection-molded insulating material and surrounds at least portions of the initiator. The collar member defines an interface that contains at least portions of each of the pair of electrical conductive pins. The collar member interface includes a keyed mating portion that accepts the electrical connector in a keyed mated connection and a receiving portion that accepts a shorting element in a secured connection, e.g., a keyed mated connection. The insert member is joined by injection molding with the collar member insulating material. The insert member includes a body portion and a shoulder portion integral therewith. The body portion has an interior section with an inward length extending inwardly within the collar member insulating material. The shoulder portion includes an outward length extending outwardly from the collar member insulating material. The shorting element is desirably secured by a snap-fit to the receiving portion of the collar member interface. The shorting element establishes a short circuit between the pair of electrical conductive pins when the electrical connector is not in electrical contact with the pair of electrical conductive pins.

[0016] Other objects and advantages will be apparent to those skilled in the art from the following detailed description taken in conjunction with the appended claims and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] FIG. 1 is a simplified fragmentary cross sectional view of a vehicular safety restraint installation incorporating an initiator assembly in accordance with one preferred embodiment of the invention.

[0018] FIG. 2 is a partial cross-sectional view of an initiator assembly in accordance with another preferred embodiment of the invention.

[0019] FIG. 3 is a partially exploded perspective view of the initiator assembly shown in FIG. 2 with the shorting element shown as detached.

[0020] FIG. 4 is a perspective view of the initiator assembly shown in FIG. 3 but now showing the shorting element attached.

[0021] FIGS. 5A-5F each illustrates a top view of an initiator assembly in accordance with the invention and incorporating alternative collar member key configurations in accordance with alternative embodiments of the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0022] The present invention provides assemblies for use in various vehicular safety restraint installations and may be embodied in a variety of different structures, including vehicular safety restraint installation assemblies such as airbag inflators and micro-gas generators, for example.

[0023] As representative, FIG. 1 illustrates the present invention as embodied in a vehicular safety restraint installation assembly, generally designated with the reference numeral 20, in accordance with one preferred embodiment of the invention. As identified above, the vehicular safety restraint installation assembly 20 can, for example, desirably be in the form of an airbag inflator or a micro-gas generator. The vehicular safety restraint installation assembly 20 includes a generally cylindrical tube 22 with an open end 23 and whereat a housing 24 is joined. In a normal or an at-rest state or condition, the housing 24 holds or contains a supply of a gas generant material 26. As will be appreciated, various gas generant materials can be used in the practice of the invention and it is to be understood that the broader practice of the invention is not necessarily limited to use with or in conjunction with specific or particular gas generant materials.

[0024] As shown in FIG. 1, the housing 24 can have a generally tubular cross section and include generally opposed open first and second ends, 27 and 28, respectively. The first housing end 27 is closed via an end closure assembly 29. As will be appreciated, various end closure assemblies can desirably be used in the practice of the invention and the specific form or type of such end closure does not generally form a limitation on the broader practice of the invention.

[0025] The housing second end 28 is generally closed by an initiator assembly, generally designated by the reference numeral 30 and such as in accordance with one embodiment of the invention. As detailed below, the initiator assembly 30 includes an initiator 32 with a collar assembly 34 joined thereto. The collar assembly 34 comprises a collar member 36, such as desirably formed of a molded insulating material, as further described below, and an insert member 38. As detailed below, the collar member 36 desirably surrounds at least portions of the initiator 32.

[0026] Various initiation elements, such as known in the art and such as identified above, may be used in the practice of the invention. Thus, it is to be appreciated that the broader practice of the invention is not necessarily limited to or by the particular form or type of initiator used or employed therein. Typically, suitable such initiators include at least one electrical terminal for electrical contact with an associated electrical connector (not shown) and such as designed to properly receive an electrical signal therefrom. In the initiator assembly 30, the initiator 32 includes a pair of electrical terminals, shown as electrical conductive pins 40 and 42, respectively. The electrical conductive pins 40 and 42 are adapted to receive an electrical signal from an associated electrical connector and in turn activate a charge within the initiator 32. The activated charge in turn initiates reaction of the gas generant material 26, e.g., ignites the gas generant material 26 within the housing 24. The gas generant material 26 reacts to produce or form a gas such as may be discharged from the initiator assembly 30, such as through one or more openings 43 formed or created in the end closure assembly 29.

[0027] As will be appreciated, the product gas can be variously used or applied as may be desired in accordance with particular applications. For example, in the case of an airbag inflator the product gas can be applied for the inflation of an associated inflatable airbag cushion. In the case of a micro-gas generator, the product gas can be applied to effect pretensioning operation of a seat belt, for example. Those skilled in the art and guided by the teachings herein provided will appreciate that various applications applying generated gas can desirably employ practice of the invention and thus the broader practice of the invention is not necessarily limited by or to particular such applications.

[0028] As described more fully below relative to other illustrated embodiments, the collar member 36 defines an assembly or collar interface 50 which includes a receiving portion 56 for accepting a shorting element 64.

[0029] The shorting element 64 establishes a short circuit between the pair of electrical conductive pins 40 and 42 when an associated electrical connector is not in electrical contact with the electrical conductive pins 40 and 42. As will be appreciated by those skilled in the art and guided by the teachings herein provided, the shorting element 64 can desirably be made of one or more appropriately selected electrically conductive materials. Suitable such electrically conductive materials may include copper-based spring materials such as phosphor bronze or beryllium copper, as well as spring steel or stainless steel with gold plating for conductivity purposes, for example. Through such an inclusion of a shorting element in the initiator assemblies of the invention, accidental actuation of the initiator, such as by static electricity, for example, prior to proper desired engagement with an associated electrical connector can desirably be avoided or prevented.

[0030] As will also be appreciated by those skilled in the art and guided by the teaching herein provided, insert members of various configurations can be used in particular embodiments of the invention. In this regards, U.S. Pat. No. 6,073,963, issued to Hamilton et al., discloses initiator assemblies having various insert member configurations useful in this invention, and is herein incorporated by reference herein in its entirety.

[0031] In the embodiment illustrated in FIG. 1, the insert member 38 is an integral, one-piece unit that includes a body portion 80 and a shoulder portion 84. The body portion 80 has an interior section 82 with an inward length extending inwardly into the collar member insulating material. The shoulder portion 84 has an outward length extending outwardly from the collar member insulating material and can securely connect the initiator assembly 30 with or to the housing 24. The length of the shoulder 84 extending outwardly from the collar member insulating material is, in accordance with one preferred embodiment of the invention, preferably less than the length of the interior section 82. In accordance with certain preferred embodiments, the outward length of the shoulder 84 is less than 2 times the inward length of the interior section 82. The outward length of the shoulder portion 84 is desirably a length that is sufficient for contact with engagement portions of the associated housing 24. The insert member 38 can, as shown, also include an intermediate or transition section 88 that is disposed between the interior section 82 of the body portion 80 and the shoulder portion 84. The intermediate section 88 is integral (i.e., in a one-piece construction) with the body portion 80 and the shoulder portion 84. The interior section 82 can also be defined as having a height in a direction parallel to the substantial portions of the conductive pins 40 and 42. The intermediate section 88 has an exterior height located outwardly of the collar member insulating material.

[0032] Turning now to FIGS. 2-4, there is illustrated an initiator assembly 230, in accordance with one preferred embodiment of the invention. The initiator assembly 230 includes an initiator 232 (shown in FIG. 2) with a collar assembly 234 joined thereto. The collar assembly 234 comprises a collar member 236, such as desirably formed of an insulating material, such as described below, and includes an insert member 238. The initiator 232, the collar member 236, and the insert member 238 can be combined by, in or through an injection molding process in which a liquid or flowable insulating material, such as used to form or make the collar member 236, is disposed about portions of the initiator 232 and portions of the insert member 238. When the collar member insulating material solidifies, the insert member 238 is fixedly held to the collar member insulating material and the collar member insulating material is fixedly held to the initiator 232. As shown, the collar member 236 can desirably surround at least portions of the initiator 232. As will be appreciated, the insert member 238 can desirably engage with at least a portion of an associated assembly housing, such as the housing 24 described above relative to FIG. 1, in fixed relative position to provide the initiator 232 in reaction initiating discharge communication with at least a portion of a supply of associated gas generant material (not shown).

[0033] Those skilled in the art and guided by the teachings herein provided will appreciate that the collar member insulating material can be selected from a variety of materials including various plastic or similar compositions such as known in the art and such as are conducive to processing via injection molding and such as are well-suited for providing electrical insulation. In general, properties or conditions important in the selection of an appropriate material for use in such an application include: tensile and impact strength, electrical insulating properties or characteristics, as well as having a melt temperature lower than the autoignition temperature of the associated pyrotechnic material. Glass-reinforced nylon is a preferred insulating material for use in such applications. Examples of other useful or suitable insulating materials for use in such applications include glass-reinforced polyester and glass-reinforced polyetherimide. Moreover, those skilled in the art and guided by the teachings herein provided will appreciate that other materials, e.g., other thermoplastic materials, may also be suitable and used in the practice of the invention in various embodiments.

[0034] The initiator 232 includes a pair of electrical terminals such as in the form of a pair of electrical conductive pins 240 and 242, respectively. In operation, the electrical conductive pins 240 and 242 receive an electrical signal from an associated electrical connector (not shown), which in turn activates a charge within the initiator 232. As further shown in FIG. 2, the conductive pin 240 includes or has a respective terminal tip 244 and the conductive pin 242 includes or has a respective terminal tip 246

[0035] The collar member 236 defines an assembly or collar interface 250. The collar interface 250 includes an inner wall 252 and defines a cavity 253. Portions of the first and second electrical conductive pins 240 and 242 extend into the cavity 253 and are spaced from each other as well as from the inner wall 252. The collar interface 250 can terminate adjacent to the terminal tips 244 and 246. As will be appreciated, the collar member 236 desirably serves to insulate the conductive pins 240 and 242 from each other.

[0036] The collar interface 250 includes a keyed mating portion 254, such as described in greater detail below and such as suited for accepting an associated electrical connector in a keyed mated connection.

[0037] The keyed mating portion 254 includes a receiving portion 256. The receiving portion 256, as shown in FIG. 2, can desirably be formed of the collar member insulating material. The receiving portion 256, as shown in FIG. 3, includes a center support element 258 positioned between two associated side support elements 260 and 262, respectively. The receiving portion 256 generally extends parallel to or with the electrical conductive pins 240 and 242. The receiving portion 256, as detailed below, is generally designed to receive a shorting element 264 in a secured connection.

[0038] As shown in FIG. 3, the shorting element 264 includes two shorting element legs 266 and 268, respectively. When the shorting element 264 is secured to the receiving portion 256, as shown in FIG. 4, the first shorting element leg 266 acts in combination with the first conductive pin 240 and the second shorting element leg 268 acts in combination with the second conductive pin 242 to establish a short circuit between the first and second electrical conductive pins 240 and 242. In accordance with one preferred embodiment of the invention, the shorting element legs 266 and 268 are preferably independently biased into contact with the electrical conductive pins 240 and 242, respectively. Consequently, when an electrical connector is pushed into the collar interface 250, and thus into electrical contact with the electrical conductive pins 240 and 242, the electrical connector removes the shorting element 264 from contact with the electrical conductive pins 240 and 242 and thus avoids a short circuit between the first and second electrical conductive pins 240 and 242.

[0039] As shown, the shorting element 264 is desirably designed to fit over the receiving portion 256 in a secured connection. More particularly, as shown in FIGS. 3 and 4, each of the shorting element legs 266 and 268 have an inverted “u”—shape and fits securely over a corresponding one of the two receiving portion side support elements 260 and 262, respectively. In accordance with one particularly preferred embodiment, the shorting element can be desirably secured to an associated receiving portion via a snap fit.

[0040] If desired and as shown, the shorting element 264 can also include a projection, such as an extension 270, that when in combination with a recess in the collar member 236, such as in the form of a groove 272, can secure the shorting element 264 via a snap fit to or with the receiving portion 256. Those skilled in the art and guided by the teachings herein provided will appreciate that shorting elements and receiving portions of various shapes or forms can be used in the practice of the invention and that the broader practice of the invention is not necessarily limited to the incorporation and use of particular or specific shapes or forms for either or both the shorting element and the receiving portion.

[0041] Perhaps as best viewed by reference to FIGS. 3 and 4, the keyed mating portion 254 includes a particular shape or form that corresponds to the shape or form of the associated electrical connector. In particular, the keyed mating portion 254 is shown in a shape including two rectangular portions, designated by the reference numeral 274 and 275, respectively, and two rounded extensions, designated by the reference numeral 276 and 277, respectively, and presented at the respective sides of the rectangular portions 274 and 275. The key configuration of the keyed mating portion 254 can desirably ensure correct or proper electrical contact to or with an electrical connector having a corresponding key configuration. The configuration of the keyed mating portion 254 is desirably coordinated with the configuration of the associated electrical connector to desirably provide or result in a keyed mated connection, such as to better ensure correct or proper electrical contact by or between an associated initiator and connector. As will be appreciated, the keyed mating portion 254 allows the initiator assembly 230 to be fit to serviceable electrical connectors without requiring the inclusion or presence of additional parts or components, such as a shorting element assembly.

[0042] The collar member 236 may also desirably define at least one mating window or slot 290 such as to further secure the electrical connection of the initiator assembly 230 with an associated electrical connector (not shown). For example, when an electrical connector is desirably joined with the initiator assembly 230, such as by mating insertion with the assembly interface 250, one or more coordinating tabs of the electrical connector can desirably fit into the slot 290 to thereby further secure the electrical connection of the initiator assembly 230 with the electrical connector. It is to be understood and appreciated that in such an embodiment, the mating window or slot 290 is desirably relatively small or narrow and thus results in a collar assembly having increased or improved strength as compared to assemblies with wider or larger such windows or slots.

[0043] FIGS. 5A-5F illustrate initiator assemblies with alternative key configurations in accordance with alternative embodiments of the invention. These initiator assemblies are individually specifically designated by the reference numeral 330 followed by the corresponding lower case letter of the alphabet (e.g., 330a, 330b, 330c, 330d, 330e and 330f, respectively). Similarly, corresponding components or elements in the various embodiments are designated by the same reference numeral with the corresponding associated lower case letter. Thus, each of the assemblies 330a-f includes a corresponding collar assembly 334a-f, a collar member 336a-f such as formed by or of a selected insulating material, an insert member 338a-f, first and second electrical conductive pins 340a-f and 342a-f, respectively, an assembly or collar interface 350a-f, a keyed mating portion 354a-f, and a shorting element 364a-f, respectively. As will be appreciated by one skilled in the art and guided by the teachings herein provided, interfaces and keyed mating portions of various selected shapes, sizes and forms can be utilized in the practice of the invention as may be desired in particular applications.

[0044] In view of the above, the invention provides an improved initiator assembly such as may facilitate suitable connection between an initiator and an associated vehicular safety restraint installation housing. Further, a shorting clip can desirably be incorporated in the initiator assembly of the invention without requiring the inclusion of a shorting clip assembly. Still further, initiator assemblies in accordance with the invention may allow keyed mated connection with serviceable electrical connectors without the need for a separably produced shorting element assembly. As will be appreciated, by eliminating the need for a separate shorting element assembly, manufacture and production can be simplified and the costs associated therewith reduced.

[0045] The invention illustratively disclosed herein suitably may be practiced in the absence of any element, part, step, component, or ingredient which is not specifically disclosed herein.

[0046] While in the foregoing detailed description this invention has been described in relation to certain preferred embodiments thereof, and many details have been set forth for purposes of illustration, it will be apparent to those skilled in the art that the invention is susceptible to additional embodiments and that certain of the details described herein can be varied considerably without departing from the basic principles of the invention.

Claims

1. An assembly for use in a vehicular safety restraint installation, comprising:

an initiator including a pair of electrical terminals for electrical contact with an electrical connector to receive an electrical signal from the electrical connector; and

a collar assembly joined to the initiator and including:

a collar member formed of an injection-molded insulating material and surrounding at least portions of the initiator, the collar member defining an interface that contains at least portions of each of the pair of electrical terminals, the interface including a keyed mating portion for accepting the electrical connector in a keyed mated connection and defining a receiving portion for accepting a shorting element in a secured connection;

an insert member joined by injection molding with the collar member insulating material; and

a shorting element secured at least in part to the receiving portion of the collar member interface, the shorting element establishing a short circuit between the pair of electrical terminals when the electrical connector is not in electrical contact with the pair of electrical terminals.

2. The assembly of claim 1 wherein the pair of electrical terminals comprises a pair of conductive pins.

3. The assembly of claim 1 wherein the shorting element is secured to the receiving portion via a snap fit.

4. The assembly of claim 1 wherein the injection-molded insulating material is glass-reinforced.

5. The assembly of claim 4 wherein the injection-molded insulating material comprises glass-reinforced nylon.

6. The assembly of claim 4 wherein the injection-molded insulating material comprises glass-reinforced polyester.

7. The assembly of claim 4 wherein the injection-molded insulating material comprises glass-reinforced polyetherimide.

8. The assembly of claim 1 wherein the insert member includes a body member and a shoulder integral therewith, the body member having an interior section with an inward length extending inwardly within the collar member insulating material and the shoulder having an outward length extending outwardly from the collar member insulating material.

9. The assembly of claim 1 wherein the collar member further defines at least one mating slot.

10. The assembly of claim 1 additionally comprising:

a body including a housing containing a supply of gas generant material and

wherein the insert member engages with at least a portion of the body in fixed relative position and wherein, upon actuation, the initiator being in reaction initiating discharge communication with at least a portion of the supply of gas generant material.

11. The assembly of claim 10 being an airbag inflator.

12. The assembly of claim 10 being a micro-gas generator.

13. An initiator assembly for use in a vehicle, comprising:

an initiator including a pair of electrical conductive pins for electrical contact with an electrical connector to receive an electrical signal from the electrical connector; and

a collar assembly joined to the initiator and including:

a collar member formed of an injection-molded insulating material and surrounding at least portions of the initiator, the collar member defining an interface that contains at least portions of each of the pair of electrical conductive pins, the interface including a keyed mating portion for accepting the electrical connector in a keyed mated connection and a receiving portion for accepting a shorting element in a secured connection;

an insert member joined by injection molding with the collar member insulating material, the insert member including a body portion and a shoulder portion integral therewith, the body portion having an interior section with an inward length extending inwardly within the collar member insulating material and the shoulder portion having an outward length extending outwardly from the collar member insulating material; and

a shorting element snap-fit secured to the receiving portion of the collar member interface, the shorting element establishing a short circuit between the pair of electrical conductive pins when the electrical connector is not in electrical contact with the pair of electrical conductive pins.

14. The initiator assembly of claim 13 wherein the collar member further defines at least one mating slot.

15. The initiator assembly of claim 13 wherein the injection-molded insulating material is glass-reinforced.

16. The initiator assembly of claim 15 wherein the injection-molded insulating material comprises glass-reinforced nylon.

17. The initiator assembly of claim 15 wherein the injection-molded insulating material comprises glass-reinforced polyester.

18. The initiator assembly of claim 15 wherein the injection-molded insulating material comprises glass-reinforced polyetherimide.

19. An airbag inflator comprising the initiator assembly of claim 13.

20. A micro-gas generator comprising the initiator assembly of claim 13.