Abstract: An initiator suitable for use with airbag passive restraint systems and which does not use pyrotechnic materials is disclosed. The initiator provides an electrically actuated igniter which ignites an adjacently stored non-pyrotechnic fluid combustible material which may comprise a mixture of a fluid fuel and a fluid oxidizer, a fluid monopropellant or a fluid exothermically decomposable material. A sub-assembly of the non-pyrotechnic initiator with a fuel containment chamber and inflators which use the non-pyrotechnic initiator are also disclosed.

Abstract: An ignition enhanced gas generant grain and method of making an ignition enhanced gas generant involving the application of a dry blend igniter composition to a gas generant particle having a wet adhesive surface.

Abstract: An inflator for a vehicle inflatable safety system comprising a housing configured to contain a gas generating material, an igniting assembly, and an activating assembly. The igniting assembly includes an actuator plate that is configured to ignite the gas generating material contained in the housing and backer plate. The backer plate is attached to the housing such that a seal is formed therebetween that is capable of substantially stopping the flow of the gas generated by the gas generating material in any direction other than the predetermined directions. The igniting assembly also comprises a booster cup, an ignition charge, and a percussion primer. The booster cup with a conical-shaped end surface with the percussion primer disposed therein proximate to the actuator plate for igniting the gas generating material. The actuator plate and the end surface of the booster cup are in contact only along the peripheral edges thereof.

Abstract: Assemblies and methods are provided for cooling a hot gas utilizing a solid chemical coolant wherein the mass of coolant is maintained to avoid the creation of flow passageways, channels or the like therethrough which may otherwise serve to avoid or reduce either or both the amount and extent of contact between coolant and hot gas.

Abstract: An airbag inflator having a reduced area filter and cartridge-loaded generant. The inflator has a tubular housing with a plurality of exit ports in a limited angular extent. A filter having the general shape of a section of a tube is received within the housing within the extent of the exit ports. The filter has lateral edges which are compressed to reduce the thickness of the filter along these edges, increasing the inner diameter of the filter. A hollow cylindrical cartridge may be provided to house a quantity of pyrotechnic gas generant. The cylindrical cartridge is received within the housing, with the filter interposed between the cartridge and the exit ports. The increased inner diameter of the filter permits the use of a larger diameter cartridge compared to a filter which has not had its lateral edges compressed, which in turn permits a shorter inflator to hold the same volume of generant.

Abstract: A side impact airbag deployment system which consists of a vehicle seat having a seat bottom portion and a seat back portion, and a rigid seat frame member internally disposed within the seat back portion. An airbag module is secured to the rigid seat frame member and oriented for deployment of the airbag through the seat back portion, the module including an airbag and inflator assembly, and a cover member for containing the airbag and inflator assembly and for providing a defined pathway for deployment of said airbag when inflated. Further included is an opening on the seat back portion forming part of the defined pathway, as well as a mounting bracket, including an arrangement for mounting of the airbag and inflator assembly, and an arrangement for fastening the bracket to the rigid seat frame member. Another feature is that a portion of the cover member overlies the defined pathway and fits into the opening in the seat back portion so as to serve as a door and to provide an external decorative cover.

Abstract: Igniter compositions and methods of processing are provided which produce or result in relatively little particulate material, as compared to typical igniter compositions used in association with vehicle occupant restraint airbag cushions.

Abstract: Gas generant compositions and methods of processing are provided which produce or result in a relatively high burning rate and low burning rate pressure exponent, while also desirably providing a high gas output, as compared to normal or typical gas generant formulations such as used in association with vehicle occupant restraint airbag cushions.

Abstract: An initiator for an inflator of an automotive airbag restraint system includes a housing and a wall dividing the housing into two parts, one for housing a firing element of the initiator, and one for receiving at least one application specific integrated circuit which performs functions of a portion of an electronic control unit. A mounting element is located in the second part of the housing, and at least one application specific integrated circuit is carried by the mounting element. The mounting element and two or more application specific integrated circuits may be provided as a package, in which at least two application specific integrated circuits are mounted in a stacked condition to form an application specific integrated circuit stack. The application specific integrated circuits are configured such that predetermined electrical circuit locations of adjacent ones of the application specific integrated circuits to be interconnected are aligned.

Abstract: A positive lock for components of an air bag inflator assembly that includes a first member having a recess formed therein and comprising an ignition tube, a second member comprising a retainer disk, and a retaining means for locking the ignition tube to the retainer disk. The retainer disk has a hollow collar portion with a plurality of indented features formed in the distal end of the collar. At least a portion of the indented features are disposed in the recess in the ignition tube, thereby locking the retainer disk to the ignition tube. The indented features are configured such that upon a force parallel to the longitudinal axis of the ignition tube acting upon the retainer disk, the indented features deform so as to be at least partially disposed in the recess formed in the ignition tube.

Abstract: An airbag system for motor vehicles wherein the airbag mechanism is concealed behind a cover provided on the instrument panel. A tether is provided to restrain the cover from uncontrolled movement during deployment of the airbag. One end of the tether is fixed to either the airbag housing or to a fixed portion of the instrument panel, while the other end of the tether is detachably mounted to the cover. The detachable feature of the attachment means permits the cover to be easily removed for repair, inspection or replacement without the need to disturb the airbag or its housing.

Abstract: A gas generant wafer design having a channel region integrally formed into one or both of its sides or faces. Characteristic of the wafer is that the geometric design of the wafer is improved by increasing its cross-section in the same manner that an "I-Beam" increases the structural characteristic of a linear structural member.

Abstract: Chemical coolant formulations for treating the hot gas formed by an airbag inflator and corresponding methods of inflating an airbag cushion are provided. The chemical coolant formulations include a first ingredient which, when contacted by the hot gas, endothermically decomposes to form a cooling gas and a solid slag component and a second ingredient which, when contacted by the hot gas, forms a liquid slag component. The solid and liquid slag components cooperate to form a unified slag mass.

Abstract: A driver side inflator base for a vehicle safety system which is stamped from a thin sheet of aluminum. The base includes a central axis, a plurality of stamped concentric rings extending upwardly from a bottom of the base and spaced from the central axis. An interface attachment flange is provided for mounting the inflator, and a squib pocket extending about the central axis of the base is capable of holding a squib of the gas inflator. The concentric rings, attachment flange and squib pocket are all formed during the stamping of the base; thus, excessive machining is not required. Only minor machining is necessary to complete the base. The base of the present invention is designed to reduce the overall inflator cost, while maintaining the processing capability and quality of current bases.

Abstract: This invention relates to a horn switch which is encapsulated in an airbag module cover by use of a reinforcing fabric attached to the horn switch. The encapsulation results in a firm retention of the horn switch when the airbag inflates, enhances actuation and feel when the horn switch is pressed by the driver, and simplifies manufacturing of the airbag module cover and horn switch assembly.

Abstract: An airbag inflator which can supply airbag inflation gas in an adaptive output is provided. The subject inflator includes two discrete isolated chambers of gas generant materials and permits several distinct inflation performance scenarios while desirably employing a single set of inflation gas treatment components such as filters for the treatment of products of both chambers.

Abstract: A gas charged high pressure accumulator includes a hollow housing and a composite flexible diaphragm dividing the interior volume into two leak tight chambers, one of these chambers being adapted to receive hydraulic fluid under pressure and the other chamber containing compressed nitrogen gas. The composite diaphragm is made of only two layers including a first elastic rubber layer facing the fluid chamber and a thin metal layer vapor deposited on the side of the rubber layer facing the gas chamber. The metal deposited film forms a gas impermeable barrier to prevent leakage of the charged gas through the diaphragm into the hydraulic fluid chamber. The surface of the metal film is formed with adjacent scales or plates to enhance the flexibility of the diaphragm, while a continuous metal film is attached underneath to the rubber substrate.

Abstract: A method and apparatus for igniting a pyrotechnic gas generator, or inflator, such as those used in automotive airbag systems is disclosed. The ignition system uses a flammable gas to ignite the pyrotechnic gas generant. The flammable gas can be stored either throughout interior free space in the inflator or it can be maintained in a separate sealed container either separately or jointly with the pyrotechnic gas generant. The method and apparatus offer both cost savings and a reduction in delay time over conventional pyrotechnic ignition systems.

Abstract: A simplified airbag inflator providing a convoluted pathway for passage of inflation gases from the combustion chamber of the inflator to exhaust ports leading to an inflatable airbag is provided. The inflator has a U-shaped filter element and U-shaped diffuser attached to an inflator housing defining the combustion chamber. The combustion chamber is closed off with an end plate having generally axially aligned exit holes therein. Inflation gases would flow axially from the combustion chamber through the exit holes in the end plate, radially then axially through the filter element, and then radially out exhaust ports in the diffuser.

Abstract: An inflatable cushion for a vehicle occupant restraint system includes a bag formed of flexible material and defining an internal cavity, and inflatable to a predetermined three-dimensional configuration. The bag is constructed of a plurality of panels of a durable, flexible material which are joined together to define a predetermined three-dimensional configuration such that at least a part of the bag will overlie an A pillar of a vehicle when the bag is in an inflated condition.