Abstract: Two sensor modules that each contain two Hall effect sensors are positioned with respect to each other and with respect to a circuit board in a gear tooth sensor assembly. The sensor modules are arranged rotated in the plane of a positioning surface 120° with respect to each other, and tilted toward each other 15°. Sensor leads are bent at an angle of 98.64° such that the leads on both sensors pass perpendicularly through holes in a single circuit board tilted at an angle of 4.30° away from a plane tangent to the gear at a point halfway between the sensors. The sensor package is formed by a plastic mounting bracket arranged to position the sensor modules with respect to each other and the circuit board. The first two angles are selected, and the second two angles are determined so that the sensors are inserted perpendicular to the circuit board.

Abstract: An airbag deployment rate sensor employs a tape or string that is wound on a spool and connected to the fabric of an airbag cushion so that as the airbag deploys, tape or string is pulled from the spool causing it to rotate. A brake is applied to the spool to prevent the buildup of momentum and so the tape and the spool will come to a rapid stop when the tape is no longer being withdrawn from the spool because the portion of the airbag to which the tape is connected has collided with an object. A sensor is positioned to detect rotation of the spool and so to monitor the rate at which tape or string is being withdrawn.

Abstract: An initiator has a circuit board with two spaced copper traces and a bridge resistor of Nichrome® or tantalum nitride at one end, and wire leads or pins joining the wire traces at the other end. A zener diode is placed between the wire leads and a bridge resistor. Immediately before the wire leads reach the circuit board they pass through a ferrite core. The wire leads, the ferrite core, and the circuit board except for the end of the board to which the bridge resistor is mounted, is insert molded into a body of glass filled nylon 6,6. The nylon body mounts an aluminum can that covers the bridge resistor and is bonded to a circumferential groove in the nylon body. The bridge resistor is covered with primary explosives such as zirconium potassium perchlorate and the can is filled with gas generating granules such as 5-aminotetrazole.

Abstract: An upper housing is ultrasonically welded to a lower housing forming a hermetic seal about two opposed ferromagnetic leads extending from a reed switch. A shock sensing magnet has a cylindrical bore and is spring biased within the housing to slide along the glass capsule of the reed switch in response to acceleration. The magnet functions as a shock sensing mass, and is shaped to increase the reed switch dwell time. The reed switch leads are bent to extend downwardly along the sides of the housing and are bent horizontally to be parallel to the housing sides and a circuit board. A strip of mu-metal wraps three sides of the housing and has tabs extending partly beneath the housing for soldering to the circuit board. The magnet and the housing are constructed from plastics which can withstand momentary high temperature associated with a re-flow solder process.

Abstract: A flow sensor has a paddle assembly that is mounted to a housing by opposed pivot posts which extend from the paddle assembly between the paddle and the magnet. The housing has two pivot post clips that resiliently capture the pivot posts which are received in mounting holes in resilient clips A shroud surrounds the housing and positions a biasing magnet which repels the magnet on the paddle assembly. The shroud slides over the housing and provides a transverse passageway that is aligned with a passageway in the housing. An activation sensor positioned within a sleeve is positioned within the transverse passageway of the housing and passes through a transverse passageway in the shroud pinning the two subassemblies together.

Abstract: A smart igniter bus system has a repeater connected by a bus to a controller, and one or more smart igniters connected by the bus to the repeater so that the repeater is between the smart igniters and the controller. The repeater receives data transmitted on the bus by the controller and processes the signal sent by the controller with onboard logic. Utilizing the onboard logic, the repeaters are preprogrammed to rebroadcast control signals sent by the controller or to only rebroadcast selected signals, or to generate and transmit new command signals.

Abstract: A turbine type flow meter has a four-vaned plastic torpedo-shaped turbine mounted by portions of the plastic turbine within a housing between first and second bearings. The turbine supports a pair of magnets of the Neodymium-Iron-Boron type which rotate with the turbine. An upstream portion of the housing incorporates a sensor cavity, which is sealed from a flow cavity containing the turbine. A connector and an attached printed circuit board with a Hall effect sensor is mounted within the sensor cavity closely spaced from the rotating magnets. The sensor housing is constructed from two parts. Each part of the housing incorporates mating structures that are designed for joining by spin welding.

Abstract: An ignitor has an outer metal can containing a quantity of reactive material for initiating a pyrotechnic material. A circuit board has a first side that is in contact with the reactive material and a second side that is isolated from the reactive material. A metal structure adjacent the circuit board is well grounded. At least two electrical pins are electrically connected to first electrical traces formed on the second side of the circuit board. Electrical discharge gaps are formed by second electrical traces extending from the first electrical traces to form sharp points which extend to within less than about 0.127 mm of a conductive path to ground.

Abstract: A shock sensor has a sensing mass mounted on a metallic reed or spring which, under the influence of a crash-induced acceleration, drives the spring against a contact to close an electrical circuit. The contact end of the spring is twisted to be oriented with respect to the fixed contact at an angle of 60 degrees out of the plane containing the spring. The sensor is oriented such that the acceleration force is approximately normal to the plane containing the spring. The angled contact increases reliability, reduces closure signal noise, and increases contact dwell time. Dwell time can be further enhanced for high shock loads by providing a two stage mass spring system. A second mass/spring combination is arranged so the motion of the second mass, after the first reed has made electrical contact, holds the contact closed.

Abstract: A crash sensor comprising a magnetic field sensor with means for concentrating magnetic flux from the magnet, wherein the magnetic field sensor detects a change in magnetic field strength as the sensing mass moves causing a corresponding change in output voltage or current from the magnetic field sensor. The magnetic field sensor is used for determining crash severity for timely deployment of an occupant restraint system.

Abstract: A smart ignitor control system has communications output electronic circuitry and communications input electronic circuitry. The communications output electronic circuitry generates output serial clock, data, and handshaking signals for communication with a master ASIC that is adapted to communicate with a smart ignitor. The communications input electronic circuitry inputs data and handshaking signals from a master ASIC. Smart ignitors are in circuit communication with the master ASIC via an ignitor bus. Optionally, additional circuitry digitizes analog voltages and waveforms from the ignitor bus and transmits the digitized data to an electronic information processor.

Abstract: A bidirectional shock sensor has a housing mounted directly to a printed circuit board. The housing contains a switch or sensor embedded in the housing and is connected by leads to the circuit board. A pendulum sensing mass is suspended from two flexible pendulum arms. The arms come together where they are attached to the housing and constrain the mass to swing along an arc that lies in a plane. A magnet either forms the sensing mass or is mounted to the sensing mass. A reed switch or Giant Magneto-Restrictive (GMR) type sensor is encapsulated within the base of the housing. When a shock causes motion of the sensing mass and the magnet the motion is detected by the sensor or switch.