Abstract: An improved ignition system for inflators such as those used in airbag passive restraint systems is disclosed. A breakable seal is provided in a storage chamber for a combustible fluid. Upon activation of an initiator the breakable seal is opened and the combustible fluid flows from the storage chamber into a combustion chamber where it is ignited to provide an enhanced volume of heated gas. The heated gas may be used either to directly inflate an associated inflatable apparatus or it may be used to first heat a further compressed gas and the combined gases used to inflate an inflatable apparatus. The breakable seal may be opened by a piston driven plunger. The design of the components of the ignition system provides control over the inflation characteristics.

Abstract: An airbag module featuring a reduced number of components is disclosed. The assembly of the module is simplified by the fewer number of components involved and by the use of a single fastener to hold the major components together as a module. The module comprises an inflator, an inflatable cushion, an optional cover and an optional insulator, all of which are held together by a single clamp.

Abstract: An improved inflator featuring a more reliable and more readily assembled reservoir is described. The reservoir features an interlocking channel lock connection with an adapter which is separately attached to the inflator housing. The reservoir is particularly intended for storing liquid fuels, but is applicable to a variety of fluids.

Abstract: An airbag module providing adaptive performance. The module includes a housing defining an interior. At least an inflator is received within the housing, and preferably the folded, uninflated cushion, also. Various arrangements are provided to selectively block, or create, a vent extending through the housing. This vent, when open, permits the inflation gas provided by the inflator to exit the housing without entering the cushion. The vent may be initially open, and blocked by a sliding cover block, may be initially closed and opened by movement of a slide plug, or may be initially closed and opened by deformation of a portion of the housing. The venting of the inflation gas will at least slow the rate of inflation of the cushion, and may reduce the final pressure within the cushion. As such, the housing will be vented for less severe collisions, and will not be vented for more severe collisions.

Abstract: The cost and ease of manufacture and assembly of airbag inflators is enhanced by welding sections of the inflator housing together in a recessed portion of the side wall of such housing. By providing a portion of the housing side wall which is recessed sufficiently that it contains all of the weld flashing produced during the welding operation it is possible to eliminate the machining operation for removing such flashing which, otherwise, could be required to provide external dimensions within specification.

Abstract: Apparatuses for inflating inflatable devices and associated methods of leak detection relying on the inclusion of a radioactive isotope leak trace material.

Abstract: A hybrid inflator having a quantity of stored gas in a pressure vessel, and a quantity of gas generant stored within a generant housing having at least one port in its longitudinal end. Within the generant housing the gas generant is retained within a porous sleeve. This sleeve is spaced inward from the non-porous generant housing, such that a free flow area is formed between the sleeve and the generant housing. The inflation gas created by the gas generant will thus flow radially outward through the sleeve, and then be turned to flow longitudinally toward the port(s) in the generant housing. Providing the free flow area reduces the pressure drop across the generant sleeve, resulting in less slag being forced through the sleeve to be entrained within the created gas flow. Additionally, the changes in direction forced upon the created gas flow to exit the generant housing cause additional amounts of slag to be removed from the created gas flow. This results in a hybrid inflator having reduced solid emissions.

Abstract: Featured for use as a part of an inflatable restraint system airbag module is an elongated cylindrical airbag inflator containing a load of a gas generant material. The inflator has a size (i.e., length) selected to correspond to the size of the load of the gas generant material stored within the inflator.

Abstract: An improvement in an airbag system for a motor vehicle relating to an adaptive output fluid fueled airbag inflator and method of operation thereof are provided. Such an inflator, in addition to a stored gas chamber, a combustion chamber wherein, upon actuation, a first fluid fuel and an oxidant are burned, and a first initiator device for initiating the combustion of the first fuel and the at least one oxidant, includes a combination of a fluid fuel container, which holds a supply of a second fluid fuel, and a second initiator device for initiating the combustion of the second fuel. Various selected performance levels can be obtained through the proper selection, actuation and sequencing of actuation of the initiator devices and burning of fuels contained within the inflator.

Abstract: A regenerative monopropellant inflator having improved initiation of the regenerative cycle and improve operating efficiency. The inflator may direct the flow of the monopropellant into a localized volume to create a "hot spot" to increase combustion. This serves to ensure that the regenerative cycle is initiated. Various arrangements are provided to increase the residence time of the combusting monopropellant within the inflator, to ensure complete combustion of the monopropellant, and thus increased efficiency. These arrangements include inducing a helical gas flow to increase the length of the path traveled by the gas. Various barriers may also be placed within the gas flow to force direction changes, which reduce the velocity of the gas.

Abstract: A consumable igniter tube for a solid fuel passenger side airbag inflator is provided. The igniter tube is composed of a thin metallic material, such as aluminum foil, that has it walls being at least partially, and preferably essentially fully devoured, almost instantaneously upon ignition of the primary igniter charge that is initially confined within the tube. The entire combustion products produced from the burning igniter charge, including hot gases as well as hot burning particulates, are thereby released through the openings created in the consumed igniter tube walls and vented into the adjacent combustion chamber that contains the solid fuel gas generant. All of the burning igniter products are thus used to ignite the solid fuel gas generant, which, upon ignition, generates inflation gases that eventually exit the inflator into a folded airbag in order to inflate and deploy the airbag into the passenger compartment of the vehicle.

Abstract: In a gas generant composition containing a source of ammonia, such as an ammonium salt or an ammonia-transitional metal complex that emits ammonia as a degradation product, a zeolite, particularly chabazite, is added as an ammonia-absorbing material. In gas generant formulations containing a copper compound and a nitrate source, the zeolite acts to reduce or prevent formation of copper tetrammine dinitrate.

Abstract: An airbag inflator with venturi effect cooling and gas supplement. The inflator includes a housing having a quantity of gas-producing fuel therein, and possibly a stored gas also, along with appropriate igniters. These materials are stored within a gas production chamber of the housing. The gas leaving this chamber travels through the housing to an exit port on the housing. Intermediate the gas production chamber and the housing exit port is a venturi section of the housing. This section reduces the pressure of the gas, and thus the pressure at the interior end of draw vents opening onto the venturi section. The vents therefore draw outside air into the housing to mix with the gas. This cools the gas to the desired temperature, and also supplements the gas exiting the housing. As such, the need for a heat sink to cool the gas is reduced or eliminated. Furthermore, since the cushion is inflated with a mixture of gas and air, the amount of gas typically needed is reduced by the amount of added air.

Abstract: An improved inflator wherein a flowing combustible fluid is combusted in a combustion zone defined by diverging walls is disclosed. The improved inflator provides enhanced consistency of operation thereby permitting the use of lighter components while avoiding deployments which produce excessive "bag slap".

Abstract: A variable volume airbag cushion. The cushion includes a front wall having a central region for contacting the passenger, and a periphery. This periphery is connected to a periphery of a rear wall. The rear wall includes a central inlet operatively connected to a gas generator. The generator provides gas to initially inflate the volume defined between the front wall and rear walls. The rear wall includes at least one pleat therein, with the pleat held by a frangible connection such as a tear seam. It is preferred that the pleat be folded over to lie against the remainder of the rear wall, and secured thereto, again by a frangible connection. The pleats reduce the size of the rear wall, and therefore the volume between the front and rear walls. The frangible connections will rupture above a predetermined gas pressure in the cushion. This permits the rear wall to expand to its full size, increasing the volume between the front and rear walls.

Abstract: An airbag cushion and method of folding thereof are provided which utilize a series of pleated folds which unfold in sequence one after another when an inflating fluid flows into the airbag cushion. In the so folded airbag cushion, a series of folds is made wherein a successive fold is made generally perpendicular to the preceding fold.

Abstract: An assembly and method are provided for the attachment of a protective cover to an airbag module assembly wherein the possibility of a portion of the folded airbag cushion extending over either of the sides of the reaction canister body and thus subject to being snagged or caught between the reaction canister body and the end plate upon attachment of the end plate(s) to the reaction canister body is avoided.

Abstract: The use of unitary liquid fuel storage chambers provides advantages in the manufacturing and assembly of inflators for use in airbag passive restraint systems. A unique process of injecting liquid fuel through a conduit which is controlled to discharge the liquid fuel beneath the rising surface of the liquid fuel in the container and then sealing the storage chamber with a unique stopper provides consistently accurately filled unitary fuel containing storage chambers. The filled and sealed unitary storage chambers can then be either stored or assembled into an inflator. The assembly of the inflator can be at a location separate from that at which the storage container is loaded with fuel, whereby the relatively hazardous loading and handling of liquid fuels can be separated from the inflator assembly area.