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 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 variable volume airbag cushion. The cushion includes a front wall having a central region for contacting the passenger, and a periphery. This periphery is connected to a periphery of a rear wall. The rear wall includes a central inlet operatively connected to a gas generator. The generator provides gas to initially inflate the volume defined between the front wall and rear walls. The rear wall includes at least one pleat therein, with the pleat held by a frangible connection such as a tear seam. It is preferred that the pleat be folded over to lie against the remainder of the rear wall, and secured thereto, again by a frangible connection. The pleats reduce the size of the rear wall, and therefore the volume between the front and rear walls. The frangible connections will rupture above a predetermined gas pressure in the cushion. This permits the rear wall to expand to its full size, increasing the volume between the front and rear walls.

Abstract: A generant cartridge for incorporation into an airbag inflation module, is produced by shrink wrapping a plastic envelope around gas generant pellets or wafers thereby completely encapsulating the gas generant in a hermetically sealed envelope. The gas generant cartridge may be prepared at one location and brought to an assembly line located at another location. As a result, the assembly of the generant into the module inflator is simplified. The gas generant may be shrink wrapped with an entire filter assembly or with only a portion of the filter assembly and then inserted into an inflator. A booster charge for rapid ignition of the gas generant may also be inserted in the cartridge.

Abstract: A side impact airbag module assembly having a combination airbag inflator and module housing and an airbag cushion. The combination airbag inflator and module housing has an extruded unitary one-piece hollow elongated longitudinal body having an outer surface, an inner surface, a first open end, a second open end, and a plurality of gas exhaust ports extending from the inner surface to the outer surface. Two airbag receiving channels, each channel having a slot running along the channel, are respectively located on the outer surface of the longitudinal body, parallel with the body on opposite sides of the plurality of gas exhaust ports. A first endplug seals the first open end and a second endplug seals the second open end with the inner surface of the longitudinal body and the endplugs defining a gas generant chamber containing a gas generant.

Abstract: A gas generator for vehicle occupant restraint systems comprises an elongated housing having gas outlet openings, a sealed, rupturable gas generant cartridge positioned within the housing, and pyrotechnic gas generant contained in the cartridge in the form of a plurality of wafers having openings defining a central passage. An igniter capsule mounted at one end of the housing has an exit opening juxtaposed the sealed gas generant cartridge and the central passage of the gas generant therein. The igniter capsule contains ignitor material, and an initiator and initiator charge. The initiator ignites the ignitor material which expels a fireball of hot combustion products from the capsules exit opening, rupturing the sealed cartridge and igniting the gas generant charge to produce gas for inflating an air bag. A rupturable seal is provided over the exit opening of the ignitor capsule and a nozzle directs hot combustion products to the gas generant cartridge.

Abstract: A gas generator for vehicle occupant restraint systems comprises an elongated housing having gas outlet openings, a sealed, rupturable gas generant cartridge positioned within the housing, and pyrotechnic gas generant contained in the cartridge. An igniter capsule mounted at one end of the housing has an exit opening juxtaposed the sealed gas generant cartridge. The igniter capsule contains ignitor material, and an initiator and initiator charge. The initiator ignites the ignitor material which expels a fireball of hot combustion products from the opening, capsules exit rupturing the sealed cartridge and igniting the gas generant charge to produce gas for inflating an air bag. A rupturable seal is provided over the exit opening of the ignitor capsule and a nozzle directs hot combustion products to the gas generant cartridge. The initiator charge is auto ignitor material for operating the gas generator if it is exposed to fire.

Abstract: A universal squib connector for automobile driver and passenger air bag collision protection systems includes a ferrite bead having two holes in spaced relation with an electric terminal positioned in each hole for making electrical contact with an associated one of the protruding pins of a pin type electric squib. The arrangement enables the use of a single configuration of gas generator and a single configuration of electric initiator or squib for the igniter system of the gas generator while providing EMI/RFI protection and the advantages realizable from both pin type and pig tail type connection of the collision sensor to the input conductors or lead wires to the squib and also the electrical system of the vehicle according to the preferences of individual automobile manufacturers.

Abstract: A universal squib connector for automobile driver and passenger air bag collision protection systems includes a ferrite bead having two holes in spaced relation with an electric terminal positioned in each hole for making electrical contact with an associated one of the protruding pins of a pin type electric squib. The arrangement enables the use of a single configuration of gas generator and a single configuration of electric initiator or squib for the igniter system of the gas generator while providing EMI/RFI protection and the advantages realizable from both pin type and pig tail type connection of the collision sensor to the input conductors or lead wires to the squib and also the electrical system of the vehicle according to the preferences of individual automobile manufacturers.

Abstract: Because of the length of the airbag gas generator that is used on the passenger side of an automotive vehicle, it has been extremely difficult and expensive to provide an ignition system that would ignite solid gas generant pellets and wafers uniformly throughout the entire length thereof. In order to effect ignition of all pellets throughout the length of the gas generator combustion chamber substantially simultaneously, there is positioned in concentric relation therein an elongated BKNO.sub.3 dipped igniter tube having similarly dipped disks positioned thereon in spaced relation, transversely thereof, BKNO.sub.3 powder initiated by a squib directs fire down the igniter tube to produce a rapid flash of fire that ignites the BKNO.sub.3 dipped igniter tube and disks and surrounding gas generant pellets. The hot gas from the gas generant pellets is cooled and filtered by a screen pack assembly prior to exiting through holes in the cylindrical wall of the gas generator and directed to an airbag for inflation.

Abstract: An impact extruded perforated aluminum housing contains a two-stage gas generator having a perforated bulkhead positioned between the stages. Each stage includes a combustion chamber having an igniter and pyrotechnic charge therein with cooling and filter screens surrounding the combustion chamber. The igniter of the first stage is fired by a squib responsively to an external electrical signal. A rupturable barrier and a ball valve associated with the bulkhead control the flow of gas through the bulkhead and provide mechanical timing for ignition delay in the firing of the second stage after the first stage has been fired, and also provide pressure control after ignition of both stages to prevent repressurizing the first stage. A rupturable foil barrier surrounding the combustion chamber in the first stage promotes a rapid rise in pressure therein and thus breakout sooner therefrom of gas to an airbag to be inflated.

Abstract: A vehicle inflatable crash protection bag inflator. The inflator housing comprises two structural components which are welded together by only two welded joints to define an inner or combustion chamber containing gas generant material and an outer or diffuser chamber. An igniter tube is disposed in the combustion chamber free of attachment to one of the structural components and is press fit or otherwise suitably attached to a mounting post on the other structural component. The igniter tube is perforated and wrapped with a foil whereby the igniter material is disposed in direct contact with a squib to better ensure ignition thereof. Alternatively, the igniter tube and igniter material may be eliminated and the gas generant material disposed in direct closely surrounding relation to the squib. The housing is composed of aluminum, and the inflator has a minimum weight and size.

Abstract: A lightweight and inexpensive inflator for a vehicle passenger side restraint bag. The inflator includes a thin igniter housing member and also includes a thin arcuate barrier member which defines a combustion chamber for holding gas generant material for combustion thereof. The inflator housing has generated gas outlet apertures only on one side and the barrier member faces that side so that generated gas is directed toward the other side of the housing and is then redirected through a filter pack to the apertures. The filter pack includes a plenum providing screen which is blocked to the entrance of redirected gas by the pressing of other layers of the filter pack against the housing wall whereby the redirected gas is directed through a fibrous filter member before being directed into the plenum and out through the housing apertures.

Abstract: A gas generator or inflator particularly for the inflation of inflatable protective bags that are used in vehicle safety systems includes first and second aluminum structural components. The first component, a diffuser shell having outlet ports, includes integrally formed concentric cylinders which define chambers containing ignition materials, a solid gas generant composition and filters and provide ports for the passage of generated gases from chamber to chamber and then through the outlet ports. The second component, a base shell, has an attachment flange, includes an initiator, and is provided with three concentric surfaces that mate with the ends of the concentric cylinders of the first component. The three concentric cylinders of the first component are simultaneously joined with the concentric mating surfaces of the second component by a single inertia welding operation.

Abstract: A safety igniter for flares is attachable to the flare parachute by a lanyard that operates the igniter when the parachute opens. The igniter is packaged in a housing that is mounted into the flare casing adjacent the ignition surface of the flare candle. The housing has two contiguous bores of different diameters, the larger bore containing a primer-charge holder and a firing-pin holder, both of which are movable in the bore. The primer-charge holder is retained adjacent the shoulder at the juncture of the bores, so that its motion is rotational only; while that of the firing-pin holder is primarily a forceful axial motion produced by the parachute lanyard, to which it is operatively attached. The primer charge is normally out of angular alignment with the firing pin and the chamber in the housing containing a pyrotechnic charge, but is aligned with a dead-air chamber.