Abstract: An improved method for fabricating a filter for use in automotive air bag inflators which comprises forming a hollow cylindrical inner core or combustion screen of filter material and outer filter layers wound outward from the surface of the core so as to be maintained in cylindrical relation thereabout. This invention is specifically directed to an improved filter which does not include a perforated support tube and relies on only the interior combustion screen for support in the final wrapping of the remaining filter structure.

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: An improved method for fabricating a filter for use in automotive air bag inflators which comprises forming a hollow cylindrical inner core or combustion screen of filter material and outer filter layers wound outward from the surface of the core so as to be maintained in cylindrical relation thereabout. This invention is specifically directed to an improved filter which does not include a perforated support tube and relies on only the interior combustion screen for support in the final wrapping of the remaining filter structure.

Abstract: Gas generant compositions utilize cupric nitrate complexes of nitrogen-containing compounds as fuels in conjunction with an oxidizer.

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 unitary rigid filter for use in a high temperature, high pressure application in a pyrotechnic airbag inflator includes a matrix structure formed of porous carbonaceous foam material coated with silicon material and having a high thermal conductivity coefficient for absorbing heat from the gases generated on ignition of a pyrotechnic material. The porous, carbonaceous foam has a porosity or permeability of approximately 40 ppi to 80 ppi and a thin, sheet-like liner of porous, ceramic paper is mounted on the body of the foam matrix structure for improving operational characteristics.

Abstract: A gas generant body having a plurality of alike, flat-surfaced projections equally spaced and radially equidistant about the periphery of one or both sides of the body. The spaced projections are defined by curved or arcuate walls emanating from the center of the generant body which flare outwardly to the body's perimeter, each having an angular arc length greater than the space therebetween. The outer edge of each projection is preferably contiguous with the perimeter of the body. When the projections are on both sides, as is preferred, the projections on one side are preferably in a staggered or offset relationship to those on the other side. A washer-shaped wafer disc is the most preferred overall generant body form. A stack or assembly of the multiprojection generant wafers may be formed into an array for use in a gas generator for an automobile gas bag inflator.

Abstract: A pyrotechnic air bag inflator utilizing non-azide gas generating material such as mixtures of copper oxide and amino tetrazol includes a unitary, rigid, drop-in type, filter for cooling and filtering high temperature, high pressure corrosive gas generated when the air bag inflator is activated to inflate an associated air bag. The filter comprises a reticulated structure formed of strong, porous, metal, metal alloy or ceramic material having a high thermal diffusivity and surface area for absorbing heat from the gas and defining a plurality of tortuous passages for entrapping contaminants from the gas passing through the filter.

Abstract: A tethered knee bolster panel which is deployed rearward in the passenger compartment of an automotive vehicle during a crash to provide lower torso restraint. The knee bolster is an air bag system which propels the knee bolster panel rearward during deployment. The activated knee bolster allows automobile designers the flexibility to provide increased leg room in the vehicle while maintaining the same level of safety during a crash.

Abstract: A pyrotechnic inflator for an air bag includes a housing for containing gas generating material for inflating an air bag. The housing has a wall formed of rigid, porous material and serves both as a filter for entrapping contaminants from the gas that is generated within as the gas passes outward through the wall into the air bag and cools the gas by absorbing heat therefrom. Gas generating material and an ignition train is hermetically sealed in a bag or packet inside the porous housing which serves triple duty as a solid pyrotechnic container, a gas filter and a gas cooler.

Abstract: A compartmentalized airbag knee bolster device is mounted to the instrument panel of a vehicle for restraining forward movement of the knees of the front seat occupants. The device contains a plenum chamber attached to an inflator for pressurizing the plenum chamber. A plurality of airbag compartments are in communication with the plenum chamber by a plurality of one way valves. A knee bolster panel is positioned in front of the plenum chamber with the compartments of the airbag situated therebetween. On inflation of the compartmentalized airbag, the knee bolster panel contacts the front of the knees of a vehicle occupant to restrain forward knee movement. The pressure in the compartments behind the area of the knee bolster panel engaged by the occupant's knees increases in the contacted compartments, and accordingly the rigidity of the airbag in the proximate area of contact with the knees.

Abstract: An air bag inflator for generating gas to rapidly inflate an air bag includes a housing having spaced-apart opposite end walls with aligned outer peripheral edges, an outer side wall extending between the end walls around the peripheral edges defining an outer chamber for containing gas-generating material and a filter element. The housing also includes an inner side wall extending between the end walls in concentric, centered relation for containing an ignition squib and ignition-enhancing material and provided with ignition ports in communication with the other combustion chamber. The outer side wall is provided with a plurality of ports directing hot products of combustion outwardly to inflate an associated air bag. At least one pair of concentric crimp-formed joints are provided to interconnect the side walls and at least one of the end walls, top or bottom.

Abstract: A gas generant composition contains as a fuel a mixture of a major portion of a triazole or tetrazole and a minor portion of a water soluble fuel; and an oxidizer component, at least 20 wt % of said oxidizer component being a transition metal oxide, such as CuO. Generant compositions in accordance with the invention autoignite in a range around 170.degree. C., providing autoignition of the generant without the need for separate autoignition devices. Also, the generant compositions are useful as autoignition pyrotechnic in autoignition devices.

Abstract: A device is provided for increasing the surface area of the gas generant used in an automotive safety air bag module. Depending on crash conditions, the surface area of the gas generant is increased by shattering the gas generant wafers. One embodiment utilizes a squib having a high brisance zone which upon activation shatters the gas generant wafers. Alternatively, a dual function squib is used which can produce mechanical forces which force a breaking object to impact on the gas generating wafers thereby shattering them and increasing the surface area of the gas generant.