Abstract: A gas generant formulation for a side impact airbag that includes a primary fuel, a primary oxidizer, a secondary fuel, and a secondary oxidizer. The secondary fuel includes at least melamine nitrate in an amount that is in a range of about 1.00% by weight to about 10.00% by weight. The secondary oxidizer includes at least potassium perchlorate that is in an amount that is in a range of about 1.00% by weight to about 10.00% by weight. The formulation provides a burn rate that is at least 50 mm/sec at 40 MPa and a burn rate slope that is equal to or less than 0.40.

Abstract: Pyrotechnic compositions are provided herein. The pyrotechnic composition includes potassium nitrate (KNO3), potassium perchlorate (KClO4), an inorganic fuel including boron, an organic fuel including one or more of carbon, hydrogen, and oxygen, and one or more binders. The pyrotechnic composition may have one or more of: a heat of explosion (HEX) of greater than or equal to about 5.000 J/g, a maximum flame temperature at combustion (Tc) of greater than or equal to about 2,500 K (2,227° C.), and a gas yield of greater than or equal to about 15 moles/kg. Methods of preparing the pyrotechnic composition are also provided including wet granulation methods.

Abstract: Cool burning hydrate fuels are provided for gas generant compositions for automotive inflatable restraint systems. The cool burning hydrate fuel is a compound comprising carbon, hydrogen, oxygen, a transition metal, and optionally nitrogen. The cool burning hydrate fuel is a transition metal salt of an organic compound or transition metal complex salt having (i) at least one functional group selected from the group consisting of: amide, imide, hydroxyl, carboxylic acid, and combinations thereof, (ii) an oxygen-to-carbon mole ratio of greater than or equal to about 0.5, (iii) at least one-half a water molecule of hydration, and (iv) an exothermic heat of formation of at least about ?400 KJ/mole. The fuel may have a water release temperature of ?about 140° C. The cool burning hydrate fuel may be one or more of copper cyanurate dihydrate, a copper melamine oxalate dihydrate, and a copper malonate hydrate.

Abstract: A gas generant composition for an automotive inflatable restraint system is provided with a fuel having a thermally stable crystalline hydrate compound with a water release temperature of greater than or equal to about 140° C. The thermally stable crystalline hydrate compound serves as a ballistic modifier, which can serve to increase burn rate, reduce pressure sensitivity, reduce temperature sensitivity, and the like. The thermally stable crystalline hydrate compound may be selected from the group consisting of: a copper phthalate hydrate, copper pyromellitate dihydrate, copper fumarate dihydrate, copper (3-nitrophthalate) dihydrate, and combinations thereof.

Abstract: Cool burning gas generant compositions for an automotive inflatable restraint system are provided that include a bismuth-containing compound selected from the group consisting of: bismuth citrate, bismuth subsalicylate, bismuth hydroxide, copper bismuth hydroxy nitrate, bismuth subcarbonate, bismuth suboxalate, and combinations thereof. The gas generant comprises at least one copper-containing component. The gas generant includes at least one oxidizer, fuel, and optional coolant. The maximum flame temperature at combustion (Tc) of less than or equal to about 1700K (1,427° C.). The cool burning gas generant composition generates liquid phase combustion products making it suitable for use in a filterless inflatable restraint system. Copper and bismuth present in the cool burning gas generant composition react to form an alloy having a melting point at or near the maximum flame temperature at combustion (Tc).

Abstract: Cool burning gas generant compositions for an automotive inflatable restraint system are provided that include a bismuth-containing compound selected from the group consisting of: bismuth citrate, bismuth subsalicylate, bismuth hydroxide, copper bismuth hydroxy nitrate, bismuth subcarbonate, bismuth suboxalate, and combinations thereof. The gas generant comprises at least one copper-containing component. The gas generant includes at least one oxidizer, fuel, and optional coolant. The maximum flame temperature at combustion (Tc) of less than or equal to about 1700K (1,427° C.). The cool burning gas generant composition generates liquid phase combustion products making it suitable for use in a filterless inflatable restraint system. Copper and bismuth present in the cool burning gas generant composition react to form an alloy having a melting point at or near the maximum flame temperature at combustion (Tc).

Abstract: A gas generant composition for an automotive inflatable restraint system includes one or more: fuels, such as guanidine nitrate; oxidizers, such as basic copper nitrate; and an alkaline earth zirconium oxide. The gas generant composition is substantially free of potassium perchlorate. The alkaline earth zirconium oxide may be barium zirconate (BaZrO3), calcium zirconate (CaZrO3), and/or strontium zirconate (SrZrO3). The alkaline earth zirconium oxide may be present at ?about 0.1% by mass to ?about 6% by mass of the gas generant composition. Such gas generants may be cool burning (e.g., a maximum flame temperature at combustion (Tc) of ?about 1700K (1,427° C.)), have a linear burn rate of ?about 20 mm per second at a pressure of about 21 MPa and a linear burn rate pressure exponent (n) of ?about 0.35. Method of making such gas generants are also provided.

Abstract: An igniter composition has (i) a source of copper selected from basic copper nitrate, copper oxide, copper hydroxide, and/or copper complex of guanylurea nitrate, (ii) one or more oxidizers, (iii) a binder selected from guanidine nitrate and/or guanylurea nitrate, and (iv) an inorganic fuel comprising an elemental metal or metal hydride selected from the group consisting of: titanium, silicon, aluminum, magnesium, iron, and combinations thereof. The igniter composition may be substantially free of boron or contain minimal amounts of boron. A minimum flame temperature at combustion (Tc) of ?about 2300K (2,027° C.). Such a mixture may be spray dried to form a powder that is compacted to form a solid igniter composition, such as a pellet or grain. The mixture that is spray dried may have a heat of explosion (HEX) of ?about 1,000 calories per gram (cal/g). Inorganic fuel can then be added to the spray-dried powder.

Abstract: A gas generant composition for passive inflatable restraint systems (e.g., airbags) for automobiles is provided that comprises a melamine oxalate compound. The gas generant may be a cool burning gas generant composition that comprises a melamine oxalate compound, a co-fuel, such as guanidine nitrate, and an oxidizer, such as basic copper nitrate. The gas generant composition has advantageous combustion properties, including a maximum flame temperature at combustion (Tc) of ?about 1700 K (1,427° C.), a linear burn rate of ?about 18 mm per second at a pressure of about 10 megapascals (MPa), a gas yield of the gas generant composition of ?about 5.7 moles/100 cm3, and a linear burn rate pressure exponent of ?about 0.35.

Abstract: A gas generant composition for an automotive inflatable restraint system is provided with a fuel having a thermally stable crystalline hydrate compound with a water release temperature of greater than or equal to about 140° C. The thermally stable crystalline hydrate compound serves as a ballistic modifier, which can serve to increase burn rate, reduce pressure sensitivity, reduce temperature sensitivity, and the like. The thermally stable crystalline hydrate compound may be selected from the group consisting of: a copper phthalate hydrate, copper pyromellitate dihydrate, copper fumarate dihydrate, copper (3-nitrophthalate) dihydrate, and combinations thereof.

Abstract: Cool burning hydrate fuels are provided for gas generant compositions for automotive inflatable restraint systems. The cool burning hydrate fuel is a compound comprising carbon, hydrogen, oxygen, a transition metal, and optionally nitrogen. The cool burning hydrate fuel is a transition metal salt of an organic compound or transition metal complex salt having (i) at least one functional group selected from the group consisting of: amide, imide, hydroxyl, carboxylic acid, and combinations thereof, (ii) an oxygen-to-carbon mole ratio of greater than or equal to about 0.5, (iii) at least one-half a water molecule of hydration, and (iv) an exothermic heat of formation of at least about ?400 KJ/mole. The fuel may have a water release temperature of ?about 140° C. The cool burning hydrate fuel may be one or more of copper cyanurate dihydrate, a copper melamine oxalate dihydrate, and a copper malonate hydrate.

Abstract: Gas generants comprising copper are provided that have improved slagging ability. In certain aspects, the gas generants include a fuel, an oxidizer comprising basic copper nitrate, and a large particle size endothermic slag-forming component, such as aluminum hydroxide (Al(OH)3). The gas generants may be cool burning, e.g., having a maximum flame temperature at combustion (Tc)?about 1,900K (1,627° C.). The disclosure also provides methods of enhancing slag formation for a gas generant composition that comprises copper. Such methods enhance slag formation during combustion of the gas generant composition by at least 50%.

Abstract: Cool burning gas generating compositions having minimal performance variation at temperature and pressure extremes are provided. The gas generants include a primary fuel comprising a metal salt of a dicarboxylic acid (e.g., copper adipate), a secondary fuel (e.g., guanidine nitrate), at least one oxidizer (e.g., basic copper nitrate), and a burn rate modifier (e.g., zinc oxide). Such a cool burning gas generant composition has a maximum flame temperature at combustion (Tc) of ?1700K and a linear burn rate pressure exponent of ?0.3, along with superior combustion stability and desirably high gas output. Moreover, such a cool burning gas generant enables improved, lighter and more efficient inflator assemblies requiring fewer inflator components.

Abstract: Gas generants comprising copper are provided that have improved slagging ability. In certain aspects, the gas generants include a fuel, an oxidizer comprising basic copper nitrate, and a large particle size endothermic slag-forming component, such as aluminum hydroxide (Al(OH)3). The gas generants may be cool burning, e.g., having a maximum flame temperature at combustion (Tc)?about 1,900K (1,627° C.). The disclosure also provides methods of enhancing slag formation for a gas generant composition that comprises copper. Such methods enhance slag formation during combustion of the gas generant composition by at least 50%.

Abstract: Compositions and methods relate to gas generants used in inflatable restraint systems. The gas generant grains include a fuel mixture having at least one fuel and at least one oxidizer, which have a burn rate that is susceptible to pressure sensitivity during combustion. The gas generant composition further includes a plurality of pressure sensitivity modifying glass fiber particles distributed therein to lessen the pressure sensitivity and/or to increase combustion stability of the gas generant. Such gas generants can be formed via spray drying techniques.

Abstract: Alkali metal perchlorate-containing gas generant compositions which, upon combustion, produce or result in an improved effluent and related methods for generating an inflation gas for use in an inflatable restraint system are provided. Such alkali metal perchlorate-containing gas generant compositions include at least one alkali metal perchlorate present with a mean particle size in excess of 100 microns. Such alkali metal perchlorate-containing gas generant compositions also include or contain a suitable non-azide, organic, nitrogen-containing fuel and at least one copper-containing compound selected from the group consisting of basic copper nitrate, cupric oxide, copper diammine dinitrate-ammonium nitrate mixture wherein ammonium nitrate is present in the mixture in a range of about 3 to about 90 weight percent, copper diammine bitetrazole, a copper-nitrate complex resulting from reaction of 5-aminotetrazole with basic copper nitrate and combinations thereof.

Abstract: An inflator assembly having an inflator body that forms a chamber wherein a quantity of a gas generating solid reacts to form gas. A quantity of gas treatment material is included to treat the formed gas to form a treated gas. At least one assembly exit opening permits the treated gas to exit the inflator assembly. The required gas generating solid has a flame temperature of no more than 1670 K with the inflator assembly having significant weight and volume reductions as compared to an otherwise identical performing inflator assembly that utilizes gas generating composition having higher flame temperatures.

Abstract: Methods of making and resultant compositions thereof, which include a gas generant having a coating including an inorganic combustion inhibitor. Such coated gas generants are useful in pyrotechnic compositions and ignition materials, and may be employed, for example, in inflatable restraint systems. The ratio of coated and uncoated gas generant bodies within an airbag inflator may be tailored to provide S-curve inflation performance. Spray application of aqueous mixture including the combustion inhibitor onto the gas generant body provides a rapid way to achieve a thin but robust coating.

Abstract: Alkali metal perchlorate-containing gas generant compositions which, upon combustion, produce or result in an improved effluent and related methods for generating an inflation gas for use in an inflatable restraint system are provided. Such alkali metal perchlorate-containing gas generant compositions include at least one alkali metal perchlorate present with a mean particle size in excess of 100 microns. Such alkali metal perchlorate-containing gas generant compositions also include or contain a suitable non-azide, organic, nitrogen-containing fuel and at least one copper-containing compound selected from the group consisting of basic copper nitrate, cupric oxide, copper diammine dinitrate-ammonium nitrate mixture wherein ammonium nitrate is present in the mixture in a range of about 3 to about 90 weight percent, copper diammine bitetrazole, a copper-nitrate complex resulting from reaction of 5-aminotetrazole with basic copper nitrate and combinations thereof.

Abstract: Alkali metal perchlorate-containing gas generant compositions which, upon combustion, produce or result in an improved effluent and related methods for generating an inflation gas for use in an inflatable restraint system are provided. Such alkali metal perchlorate-containing gas generant compositions include at least one alkali metal perchlorate present with a mean particle size in excess of 100 microns. Such alkali metal perchlorate-containing gas generant compositions also include or contain a suitable non-azide, organic, nitrogen-containing fuel and at least one copper-containing compound selected from the group consisting of basic copper nitrate, cupric oxide, copper diammine dinitrate-ammonium nitrate mixture wherein ammonium nitrate is present in the mixture in a range of about 3 to about 90 weight percent, copper diammine bitetrazole, a copper-nitrate complex resulting from reaction of 5-aminotetrazole with basic copper nitrate and combinations thereof.