Abstract: An inflator having a base containing a diffuser and a canister having a chamber for receiving and holding gas under pressure are inserted in aligned, separated position in a pressure chamber. The pressure chamber is closed, sealed and filled with gas, thereby filling the canister. When the gas fill reaches the desired pressure, an integral top press is activated, thereby joining the base with the filled inflator canister. The base is then welded or crimped to the inflator chamber, thereby assembling a complete airbag inflating device.

Abstract: Apparatus for inflating an inflatable device, methods for inflating an inflatable safety device and a method of manufacturing an apparatus for inflating an inflatable device are provided having a fuel containment assembly to contain a fuel in the form of a fluid. The fuel, upon proper initiation, is burned to produce gas used in the inflation of the inflatable device.

Abstract: An integral label/gasket for use in crimped sealing engagement with an airbag inflator. The integral label/gasket combines a flat, generally annular label, an annular, deformable outer gasket seal and an annular, deformable inner gasket seal into one component. The outer gasket seal is secured to and extends downwardly from a bottom surface of the label adjacent an outer edge of the label, and the inner gasket seal is secured to and extends downwardly from the bottom surface of the label adjacent an inner edge of the label. The label, for printing handling and operational warnings and other information thereon, has adhesive on a top surface thereof for securing the label to a baseplate of an airbag inflator.

Abstract: A flexible sensor, such as a membrane switch, is molded into a plastic automotive panel by a low temperature, low pressure, method which avoids damage to the switch while insuring its placement at a desired depth below the surface of the panel. This is achieved by a process which includes a first step of spraying a mold with a rapid gelling liquid plastic to a preselected thickness. After the plastic has firmed, the sensor is placed thereon and is encapsulated by spraying with a second layer of the plastic. The resulting shell with the embedded sensor may then be provided with a backing, such as a plastic foam.

Abstract: An apparatus and method for charging fluids to elongated pressure containers, such as inflators for airbag passive restraint systems is described. The disclosed method and apparatus enables the container to be filled from the side rather than from the end. The charging of more than one fluid to different chambers in the container is also facilitated, either by enabling two charges to be conducted simultaneously, or by allowing the two charges to be conducted through a single fill port.

Abstract: Featured in an air bag inflator in respect of which, during assembly, there is a requirement for the ignition train to be installed last, along with a need to hermetically seal both the gas generant material and the ignition train from the environment, is the use of two independent pressure vessels, one of which contains the gas generant material, filtering and cooling elements and a separate pressure vessel having an open end into which is inserted a squib capable of being activated by an appropriate signal and which contains all of the primary and secondary ignition pyrotechnics, the open end of the pressure vessel being closed by the presence of the squib, the pressure vessel having a necked region in its length which forms a plenum chamber when mated to the second pressure vessel containing the gas generant material, etc.

Abstract: An airbag module incorporates an inflatable airbag cushion having an inflatable body and a collar defining an open mouth for receiving inflation gas, with a stiffening collar ring secured to the collar. The airbag module also includes an inflator and a module housing, the inflator having a peripheral bracket extending radially outwardly and the module housing having an opening. The collar of the airbag cushion extends through the opening and the inflator fits within the open mouth of the airbag cushion with the collar ring and collar seated between the module housing and the peripheral bracket. Clamping structure secures the airbag cushion to the airbag module. The clamping structure is an inwardly facing c-shaped ring having a top leg secured to or integral with the module housing and a bottom leg, with the peripheral bracket, the collar ring and the collar clamped between the legs.

Abstract: An inflator mount for attachment to an inflator having a cylindrical sidewall and a peripheral inflator flange radially extending from the sidewall, and for mounting the inflator within an airbag module. The inflator mount includes a generally flat annular bracket having an inside edge defining an opening that accommodates passage of the radially extending peripheral inflator flange. An inflator flange grip extends downwardly and inwardly from the inside edge of the annular bracket. The inflator flange grip slidingly receives and grippingly engages the inflator flange and embraces the underside thereof to thereby secure the inflator mount to the inflator and adapt the inflator and inflator mount for mounting in an airbag module by means of the annular bracket.

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: An airbag module cover having downwardly extending sidewalls is mounted in the base of an airbag housing. The base has downwardly extending peripheral legs thereon having inner and outer walls forming a generally U- or V-shaped integral groove at the lower extremity thereof. The legs have locking tabs positioned above the grooves which tabs are adapted to protrude into or through the sidewalls of the cover. When the sidewalls of the cover are locked in the grooves of the legs, the inner and outer walls of the legs provide lateral support for the sidewalls for preventing separation of the cover sidewalls from the housing during airbag deployment.

Abstract: A molded cover for an automotive airbag module is provided with one or more windows therethrough to transmit light from a light source within said module. The light source is typically used to indicate the location or identify function switches under the molded cover.

Abstract: A method of attaching a mounting bracket to an inflator having a cylindrical sidewall and a peripheral inflator flange radially extending from the sidewall that includes: providing a unitary mounting bracket having a annular support, a flange seat adjacent the annular support for receiving the peripheral inflator flange and a cylindrical sleeve extending from the flange seat and having a distal portion; sliding the cylindrical sleeve of the mounting bracket onto the inflator until the inflator flange butts against the flange seat; and applying a suitable amount of axial force to the distal portion of the sleeve so that the distal portion deforms radially inwardly into a clamping band underlying at least a portion of the inflator flange. The inflator flange is clamped between the clamping band and the flange seat to secure the mounting bracket to the inflator. Preferably, a crimping die is used to crimp the distal portion of the sleeve into a clamping band while the inflator is supported in an inflator nest.

Abstract: An air bag inflator including a housing formed of sheet metal includes an annular base having a central opening and a cover for containing gas generating pyrotechnic material including an annular top wall spaced from the base having a central opening in coaxial alignment with the central opening of the base and a cylindrical, ported, outer side wall integrally formed around a periphery of the top wall extending downwardly thereof and having a lower edge secured to a portion of the base outwardly of the central opening. The housing includes a hollow, igniter-containing, rivet having an upper end wall closing over the central opening of the top wall and having a tubular, ported, side wall integrally formed with the upper end wall thereof extending downwardly through the central openings of the base and the top wall.

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: A membrane horn switch has a flexible thin front plate and a rigid thick back plate. The plates are coated with a conductive layer which are separated by dielectric material applied to either or both plates. The plates are attached together around their perimeters using a pressure sensitive adhesive. The switch is attached directly to an airbag cover, eliminating the need for external backing other than that which is provided by the rigid back plate of the switch.