Abstract: A hybrid inflator that includes a solid propellant and a pressurized medium comprising oxygen and at least one inert gas is provided. The solid propellant can be fuel-rich in that without excess oxygen it generates significant amounts of CO and H2. The at least one inert gas is contained in an inflator housing and the amount thereof is greater, on a molar basis, than the oxygen. The propellant has acceptable long-term stability in that such propellant does not ignite when exposed to a temperature of 107° C. for a period of 400 hours.

Abstract: Hybrid inflators for an inflatable safety system are disclosed. In one embodiment, the hybrid inflator uses a dual function initiator in that the combustion products from the initiator both ignite the propellant by direct contact therewith and propel a projectile through a outlet closure disk to release the stored pressurized medium. In another embodiment, the hardware configuration of the hybrid inflator allows the propellant to be loaded into the inflator after all hardware connections proximate the propellant, which require a weld, have in fact been welded. In another embodiment, the main inflator outlet closure disk is disposed at substantially a mid portion of the inflator. In another embodiment, the propellant gases are required to flow from the combustion chamber and into the stored gas housing prior to exiting the inflator, such by using a projectile to rupture the main inflator outlet closure disk and to thereafter seal the gas generator.