Abstract: A flexible inflator for an inflation assembly and related gas generating propellant compositions are provided. The flexible inflator includes at least one elongated strand of a propellant co-extruded with a moisture barrier. The propellant compositions are adapted for co-extrusion with a plastic sheath which forms the moisture barrier surrounding the propellant and include a binder fuel component effective to render the composition flexible and to impart sufficient adhesive properties such that the propellant composition and the plastic sheath adhere together, and an oxidizer.

Abstract: An airbag inflator is provided including a housing defining a storage chamber containing contents including a supply of a gas source material in a fluid form and a propagation member contained at least in part within the storage chamber and defining a propagation chamber having a volume containing a supply of a reactive material that reacts to at least produce heat. The propagation member having a first end and a second end and including a plurality of gas exit holes. A first initiator at the first end of the propagation member is in discharge communication with the supply of reactive material and effective to initiate the reactive material and a second initiator at the second end of the propagation member is in discharge communication with the supply of reactive material and effective to initiate the reactive material. At least one of the first and second initiators is actuated to produce a supply of inflation gas for inflating an airbag.

Abstract: An inflatable bolster system is provided for supporting a body portion of a vehicle occupant such as the knees and lower body or pelvis during a collision. The inflatable bolster includes a decorative substantially rigid front panel and an expandable metal rear panel attached to the non-metal decorative front panel. The inflatable bolster has an inflation orifice, and may have at least one vertical expansion fold and at least one horizontal expansion fold on the rear panel.

Abstract: A glove compartment assembly incorporates a compact airbag module with a cushion constructed at least partially of a rigid material. The cushion may be sandwiched between front and rear door covers so that inflation of the cushion moves the front door cover toward the knees of a vehicle user to provide antisubmarining protection. The cushion may incorporate the front door cover as a portion of its inflation gas-containing membrane. The glove compartment assembly may utilize a uniquely designed latching system, such as an electric latching assembly, a latching assembly disposed generally off the door, or a break-away latching assembly disposed generally on the front door cover, to permit motion of the front door cover away from the instrument panel without interfering with the airbag module.

Abstract: Enhanced airbag modules and associated methods are provided. An airbag module according to the invention may have a cushion with a venting portion. During normal vehicle operation, the venting portion may be closed so that inflation gas is not permitted to flow through the venting portion. A pyrotechnic may be ignited to open the venting portion when venting is desired. The pyrotechnic may be directly attached to the venting portion to burn through or mechanically rupture the venting portion, thereby forming an exit port. Alternatively, the venting portion may have a flap that can be detached from the housing by ignition of a pyrotechnic to permit venting through an exit port of the housing. The pyrotechnic may then be disposed within a fastener designed to fracture upon ignition of the pyrotechnic to release the flap from attachment to the housing. The pyrotechnic may, for example, be an initiator or rapid deflagration cord (RDC).

Abstract: A toroidal-shaped adaptive output inflator is provided wherein the inflator includes an outer housing and an inner housing together defining an outer chamber and an inner chamber. A supply of gas-generating pyrotechnic material having a burn rate that is pressure dependent is contained within the outer chamber and at least a portion of the supply of gas-generating pyrotechnic material is reactable to generate a product gas. The inflator also includes a first plurality of apertures and a second plurality of apertures each formed in the inner housing, and each providing independent fluidic communication between the outer chamber and the inner chamber wherethrough at least a portion of the product gas can exit the outer chamber into the inner chamber.

Abstract: The tethered airbag system includes an inflatable cushion and an extensible tether. The extensible tether includes an extensible region and is attached to both the inflatable cushion and to a point within a vehicle. For instance, the tether may be attached to the roof of the vehicle. When in use, the inflatable cushion deploys to a location immediately in front of an occupant of the vehicle. Following deployment of the cushion, when a sufficient force is applied to the inflatable cushion, the extensible region is released so that the extensible tether may extend to its full length and the inflatable cushion may extend further away from the point where the tether is attached to the vehicle.

Abstract: The invention provides apparatus for inflating an inflatable safety restraint cushion and associated methods for producing an inflation gas for inflating an inflatable safety restraint cushion which rely, at least in part, on Joule-Thomson heating.

Abstract: An airbag housing having elastically deflectable mounting tabs is disclosed. The mounting tabs allow for positionable attachment of an airbag module to a vehicle structural member. The mounting tabs may be defined by U-shaped slots in the airbag housing. The semi-flexible mounting tabs deflect during attachment of the airbag module to the steering wheel to provide good fit and finish between an associated decorative airbag cover and the steering wheel. The mounting tabs may also include attachment members to provide attachment location for coupling the airbag housing to the vehicle structural member.

Abstract: A flexible inflator for an inflation assembly and related gas generating propellant compositions are provided. The flexible inflator includes at least one elongated strand of a propellant co-extruded with a moisture barrier. The propellant compositions are adapted for co-extrusion with a plastic sheath which forms the moisture barrier surrounding the propellant and include a binder fuel component effective to render the composition flexible and to impart sufficient adhesive properties such that the propellant composition and the plastic sheath adhere together, and an oxidizer.

Abstract: A material for a pyrotechnic composition and related pyrotechnic compositions are provided in which the material includes a substituted basic metal nitrate including a reaction product of an acidic organic compound and a basic metal nitrate. A method for enhancing a burn rate of a gas generant composition and a burn rate enhanced gas generant composition including a reaction product of basic metal nitrate and tetrazoles, tetrazole derivatives, and combinations thereof, and a nitrogen-containing co-fuel such as guanidine nitrate are also disclosed. The burn rate enhance gas generant composition may optionally include an additional oxidizer such as basic copper nitrate.

Abstract: A method of joining tubular structures using friction welding is disclosed. The invention provides a method of joining a first tubular structure having a conical contact surface to a second tubular member with an elliptical contact orifice by placing the conical surface within the contact orifice, rotating one of the structures, and pressing them together to form a weld. The invention further discloses airbag inflators constructed using the method of the invention.

Abstract: A module configured to be mounted in a vehicle instrument panel is disclosed. In one embodiment, the module has a reaction plate and a plurality of snap locking fasteners that extend from the reaction plate and are engagable to a vehicle mounting member. The module may be used to attach an airbag to an instrument panel. The module provides for a module cover without fastener openings or holes. The invention also includes a module having a mounting bracket that is pivotally attachable to a vehicle mounting member. The pivotal attachment may include tongue and groove members.

Abstract: A sun visor attachment for mounting a sun visor is disclosed. The sun visor attachment enables a sun visor assembly to be attached out of a trajectory of an overhead airbag. A sun visor assembly can be rigidly attached either on the overhead airbag module housing containing mounting brackets rearward of the deployment door, or it can be rigidly attached to a resilient substrate affixed between a headliner and the overhead airbag module behind the airbag outlet.

Abstract: An inflatable curtain having an inflatable portion and a non-inflatable portion is disclosed. First and second stiffening elements are positioned along the upper edge of the inflatable curtain. The inflatable curtain is adapted to be stored within an interior portion of a vehicle prior to inflation. The vehicle has a roof at its highest point, and a housing within the vehicle and close to the roof defines an internal recess that accommodates the inflatable curtain. A side impact of a magnitude greater than a predetermined threshold value is sensed by a sensor mechanism within the vehicle, which then provides an electrical signal to an inflator which is in fluid communication with the inflatable portion of the inflatable curtain. The electrical signal causes the inflator to be actuated in a known manner. The inflator discharges fluid under pressure into the inflatable portion of the inflatable curtain.

Abstract: An airbag inflator housing for mounting an airbag inflator to a vehicle. The airbag inflator housing includes a press-fit inflator mount for engaging an outer surface of an airbag inflator and a bracket member attached to the inflator mount that is configured to be attached to a vehicle. The inflator housing may hold the inflator in a press-fit manner by having an inside diameter that is smaller than an outside diameter of the airbag inflator. Alternatively, the inflator housing may hold the inflator in a clearance-fit or slip-fit manner, in which the inside diameter is equivalent to or larger than an outside diameter of the airbag inflator. In these inflator housings, the inflator must be additionally secured by a weld, a set screw, crimping, adhesive, or another suitable method.

Abstract: A linear actuator with an internal dampening mechanism is disclosed. The actuator has a housing has a first end and a second end and forms an internal chamber. A constricted opening is also added to the actuator at the first end. A piston is disposed within the housing and is capable of sliding along the chamber. The piston has a head portion and a shaft portion. The shaft portion is slidable through the constricted opening whereas the head portion is not slidable through the constricted opening. A fluid is also added to the actuator. The fluid is disposed within the housing. In one embodiment, the actuator is constructed such that the sliding of the shaft portion forces a fluid through the constricted opening such that the movement of the piston is dampened. In an alternative embodiment, the actuator includes one or more second pistons and an orifice.

Abstract: A single increment initiator charge for use in an inflatable restraint system and a method of preparing the single increment initiator charge are provided. The single increment initiator charge includes a homogeneous blend of zirconium, an oxidizer such as potassium perchlorate, and a combustion enhancer such as titanium hydride in an amount effective to result in the single increment initiator charge being effective to ignite an associated pyrotechnic charge. The single increment initiator charge may be formed by preparing a homogeneous blend such as by dry-blending the constituents or by mixing the constituents with a solvent such as an alcohol to form a slurry, loading the homogeneous blend into a charge holder and compressing the homogeneous blend.

Abstract: Inflation apparatuses and methods are provided wherein a hydrocarbon-containing inflation gas-producing mixture is formed via the fluid extraction of the hydrocarbon from a substrate material.

Abstract: A pyrotechnic inflator for an airbag module is disclosed. The pyrotechnic inflator may have a generally tubular housing that contains an initiator, a baffle, and a quantity of inflation gas generant. The generant is disposed in a compartment defined by the baffle. The baffle has a passageway with a first end and a second end. Direct fluid communication between the first and second ends is restricted by a blockage within the passageway. Upon receipt of an activation signal, the initiator directs initiation gas into the first end. The initiation gas may exit the first end through a plurality of first end holes to reach and ignite the generant with or without requiring any intermediate igniter material. The generant combusts to produce inflation gas, which enters the second end of the passageway through a plurality of second end holes. The inflation gas exits the inflator to inflate a cushion.