Abstract: A gas generating inflator assembly for a vehicle safety restraint system including an inflator housing having two walls, an inner wall and an outer wall. The inner and outer walls form a combustion chamber therebetween. A filter pack is disposed within the combustion chamber along an inner diameter of the outer wall. Gas generant is also disposed within the combustion chamber. An internal structure is disposed within the combustion chamber for diffusing the ignitor blast and retaining slag produced by the ignited gas generant. The internal structure is spaced from the filter pack and the inner wall such that a portion of the gas generant is located between the internal structure and the inner wall and another portion of the gas generant is located between the internal structure and the filtration pack.

Abstract: Components of a vehicle airbag gas generator, or inflator, are coated with reactivity resistant materials to protect them from deterioration caused by contact with the high temperature, reactive gases generated by recently developed non-azide high reactive temperature gas generating materials. Suitable coatings include those produced from ceramics and reactivity resistant metals. These coatings also provide long term protection of the components from deterioration caused by the environment/atmosphere within the inflator.

Abstract: Unitary filters for airbags. The filters may be formed from various combinations of ceramic grit, ceramic fiber, metal grit, metal fiber, and non-metal fibers. Combinations of disparate particle sizes may be used to increase filter diffusion and reduce the size of particles filtered. The disparate size particles may be uniformly mixed, or may be in relatively discrete layers. Fibers may be used to increase the strength of the filter. The fibers may be mixed with an initial slurry, or the slurry may be pressed into a mat of the fibers.

Abstract: Material, such as catalysts, absorbents, and adsorbents, are disposed within an automotive airbag so as to contact airbag inflation gases passing therethrough and remove undesirable gases therefrom.

Abstract: A gas generant charge comprises a heterogeneous mixture of between about 80 and about 95 wt % of a first gas generant composition 1) and between about 5 and about 20 wt % of a second gas generant composition 2), based on the total weight of 1) plus 2). The first gas generant composition 1) comprises between about 20 and about 40 wt % fuel A) and between about 20 and about 60 wt % oxidizer B). Between about 50 and about 85 wt % of the fuel A) is a triazole or tetrazole compound A.sup.1), and between about 15 and about 50 wt % of the fuel is, a water-soluble fuel A.sup.2). At least about 20 wt % of the oxidizer B), up to 100%, a transition metal oxide B.sup.1); balance of the oxidizer is selected from the group B.sup.2) consisting of alkali and/or alkaline earth metal nitrates, chlorates or perchlorates.

Abstract: A method of forming a filter for an inflatable vehicle occupant restraint inflator includes a tubular filter element having a generally cylindrical interior surface and a generally cylindrical outer surface having a predetermined diameter and a predetermined axial length and spaced radially outwardly from the inner surface. A tubular support member surrounds the outer surface. The support member is of an axial length equal to at least a major portion of the axial length of the outer surface and has an inner diameter substantially similar to the diameter of the outer surface for close surrounding engagement therewith. The support member has a plurality of through openings.

Abstract: A filter for an inflatable vehicle occupant restraint inflator includes a tubular filter element having a generally cylindrical interior surface and a generally cylindrical outer surface having a predetermined diameter and a predetermined axial length and spaced radially outwardly from the inner surface. A tubular support member surrounds the outer surface. The support member is of an axial length equal to at least a major portion of the axial length of the outer surface and has an inner diameter substantially similar to the diameter of the outer surface for close surrounding engagement therewith. The support member has a plurality of through openings.

Abstract: The present invention is directed to the use of protective layers on or adjacent to interior surfaces of the metal housings of gas generators, or inflators, used in automotive airbag systems. The protective layers are provided to protect such housings from deterioration which might otherwise be caused by impingement of the high temperature and chemically reactive generated gases and other associated reaction products on the interior surfaces of the housing. The protective layers can be in the form of coatings or platings on the housing surface or they can be provided as separate structures which shield specific portions of the housing's interior surfaces. The invention is particularly useful in protecting aluminum housings when they are used with the newer high reaction temperature non-azide gas generant materials.

Abstract: A filter, seal and port arrangement for a pyrotechnic air bag inflator. The seal consists of a ring or annulus of sheet metal which has a foot section abutting against the filter, and a leg section of the seal angled to form an interference fit against an interior wall of the generator housing. For annular filters used in axial flow inflators, a ring is used at the radially inner and outer edges of the annular filter. For tubular filters used in radial flow inflators, a single seal at a longitudinal end may be sufficient. With such tubular filters, the seal may include a stand-off to form an annular void between the radially outer face of the filter and the wall of the housing. This void will act as a plenum to ensure that a greater volume of the filter is used. The tubular filter itself may also be formed with raised lands such that the interposed grooves form such a plenum. In a similar manner the disk filters may also have plenum producing lands on their outer faces, or the housing may include such lands.