Abstract: A gas generant body having a plurality of alike, flat-surfaced projections equally spaced and radially equidistant about the periphery of one or both sides of the body. The spaced projections are defined by curved or arcuate walls emanating from the center of the generant body which flare outwardly to the body's perimeter, each having an angular arc length greater than the space therebetween. The outer edge of each projection is preferably contiguous with the perimeter of the body. When the projections are on both sides, as is preferred, the projections on one side are preferably in a staggered or offset relationship to those on the other side. A washer-shaped wafer disc is the most preferred overall generant body form. A stack or assembly of the multiprojection generant wafers may be formed into an array for use in a gas generator for an automobile gas bag inflator.

Abstract: A triboelectric coating process for applying powder to substrates are described. The coating powder is a mass of finely divided, heat fusible dielectric plastic material having an average particle size (Mv) of between about 30 and 45 microns and a particle size distribution (all percents defined in weight percent) of:0-5% larger than 88 microns,85-95% larger than 15.56 microns and94-100% larger than 11 microns.

Abstract: Slurry and spray dried azide-based gas generant intermediates are made having a hydrazoic acid content of less than about 3.times.10 EXP(-3) M/L, a pH of greater than 8.0 up to about 12.5, and impurity metal ions Ca, Mg, Pb, Fe, Mn and Cu, each below about 25 ppm. These intermediates are made by slurrying powdered ingredients of the azide and oxidizer/reactant in water, wet grinding the slurry and spray drying to form a particulate material which is molded into pellets or tablets which are useful as the gas generant in vehicle crash bags or inflators. The basicity of the water is adjusted to a pH of greater than 8.0 up to about 12.5, preferably about 10, by the addition of a base, such as NaOH, followed by the addition of such solid ingredients as S, MoS.sub.2 and NaN.sub.3, and preferably the NaN.sub.3 is added last, whereby hydrazoic acid production is minimized. The contaminant Ca and Mg ions are minimized by softening the water supplied.

Abstract: Gas generant pyrotechnic compositions especially suitable for inflating vehicle occupant restraint systems with nitrogen gas are described. The compositions are comprised (in wt. %) of about 65-74% of an azide, preferably sodium azide; about 17-29.5% of iron oxide, preferably ferric oxide; and about 1.0-6% metal nitrite or nitrate co-oxidizer, preferably sodium nitrate; to which base composition is added about 0.5-8% silica, alumina, titania or mixtures thereof; up to 6% bentonite and up to 4% molybdenum disulfide. Preferred driver and passenger side formulations are disclosed. The compositions burn from about 0.8 to 1.5 inches per second, have excellent slag and clinker properties, as well as excellent aging and mechanical strength characteristics when formed into cylindrical pellets or wafers. The formulation ingredients are amenable to water slurry mixing, spray drying and machine pressing into cylindrical pellets or wafers for insertion into a suitable gas generating device.

Abstract: An inflator, preferably for an automotive gas bag restraint system, containing a plurality of gas generant bodies which have a relatively inert burn inhibitor coating material thereon. The inhibitor material is preferably a plastic resin. The inhibitor material may also be alumina, titania, silica or a silicate compound,e.g. bentonite. The inhibitors are preferably applied to the generant bodies as a spray. The gas generant may be an azide or a non-azide, preferably an azide and most preferably sodium azide. The inhibited bodies may be any shape, preferably washer-shaped discs in side by side array.

Abstract: Multiple processes and apparatuses for improving the prior system of making gas generant pellets or tablets made of sodium azide, molybdenum disulfide and sulfur wherein powdered ingredients thereof are slurried in water, subjected to wet grinding, spray dried to a powdered material which is molded into pellets or tablets which find use in vehicle crash bags or inflators.The first improvement to the old process and apparatus involves adjusting the basicity of the water to a pH of greater than 8.0 up to about 12.5 via the addition of sodium hydroxide, followed by the addition of sulfur and molybdenum disulfide and finally the sodium azide whereby azide addition is made to a basic mixture of the other ingredients thereby keeping hydrazoic acid concentration levels below about 3.times.10EXP(-3) moles per liter.

Abstract: Gas generating compositions or propellants are provided which comprise a non-azide fuel which is a transition metal complex of an aminoarazole. Preferred transition metal complexes are zinc and copper complexes of 5-aminotetrazole and 3-amino-1,2,4-triazole, with the zinc complexes most preferred. The propellant compositions also include a conventional oxidizer, such as potassium nitrate or strontium nitrate. These compositions are useful for generating a nitrogen-containing gas for a variety of applications, especially for inflating air bags in automotive restraint systems, as well as other inflatable devices.

Abstract: Gas generating compositions or propellants are provided which comprise a fuel and a novel oxidizer therefor comprising an inorganic compound having a poly(nitrito) transition metal complex anion. The inorganic oxidant compounds are generically represented by the formula:M.sub.x.sup.1 M.sub.y.sup.2 (NO.sub.2).sub.zwherein (1) M.sup.1 is a metal selected from the (a) Group IA alkali metals, (b) Group IIA alkaline earth metals, preferably strontium, (c) Group IB metals, preferably copper, and (d) Group IIB metals, preferably zinc, of the Periodic Table, (2) M.sup.2 is a metal selected from the transition metals of Groups IVA-IIB of the Periodic Table, (3) x=1, 2, 3, or 4; y=1 or 2, and z=4 or 6 as determined by the required stoichiometry of the metals of the complex, and (4) the M.sup.1 and M.sup.2 metals selected are different metals. M.sup.1 is preferably the Group IA alkali metals, more preferably sodium and potassium, and most preferably potassium. M.sup.

Abstract: Gas generant pyrotechnic compositions especially suitable for inflating vehicle occupant restraint systems with nitrogen gas are described. The compositions are comprised (in wt. %) of about 65-74% of an azide, preferably sodium azide; about 17-25% of iron oxide, preferably ferric oxide; and about 3.5-6% metal nitrite or nitrate co-oxidizer, preferably sodium nitrate; to which base composition is added about 2.5-8% silica, alumina, titania or mixtures thereof, up to 6% bentonite and up to 4% molybdenum disulfide. Preferred driver and passenger side formulations are disclosed.The compositions burn from about 1.0 to 1.5 inches per second, have excellent slag and clinker properties, as well as excellent aging and mechanical strength characteristics when formed into cylindrical pellets or wafers.The formulation ingredients are amenable to water slurry mixing, spray drying and machine pressing into cylindrical pellets or wafers for insertion into a suitable gas generating device.

Abstract: An improved high yield process and apparatus for producing sodium hydrosulfite by reacting sodium borohydride, sulfur dioxide, sodium hydroxide, and sodium bisulfite is provided. The improved result of the invention is obtained by a feed system that requires the introduction of a first mixture comprising sodium borohydride, sodium hydroxide, and water into a flow stream prior to the introduction of a second mixture comprising water and sulfur dioxide. The improved result can be further enhanced by techniques of intimately mixing the first mixture and the flow stream as well as intimate mixing the second mixture and the flow stream.

Abstract: A process for preparing a free-flowing powder is disclosed, which powder is useful in primer compositions. The process comprises the steps of (a) dissolving a polar group-containing modified propylene polymer (MPP) at an elevated temperature in a solvent for the MPP, (b) cooling the solution to precipitate particles of the MPP, (c) collecting the precipitated particles by simultaneously centrifuging and spraying the particles with a liquid capable of removing the solvent from the particles and which is also a solvent for a film forming resin, such as an epoxy, which is present in the primer composition, (d) continuing step (c) until substantially all of the solvent for the MPP has been removed from the particles, and (e) collecting the resulting powder, which has an average particle size of less than about 5 microns.