Abstract: A multi-level gas inflator for an air bag or other safety device, comprising an elongated pressure vessel having a primary gas generant portion with a first open end and a secondary portion with a second open end. The primary gas generant portion has a primary ignition device and primary gas generating energetics disposed therein. The primary ignition device is mounted on and closes the pressure vessel at the first open end thereof. The secondary portion may have a secondary ignition device and secondary gas generating energetics disposed therein. The secondary ignition device may be mounted on the pressure vessel at the second open end thereof. A suitable gas under a predetermined pressure is present in the primary and secondary portions. One or more separate dividers or divider walls are disposed within the midportion of the pressure vessel to separate the primary and secondary portions.

Abstract: A gas generator comprising a pressure vessel containing a gas under a first predetermined pressure. An initiator housing closes one end of the pressure vessel and has an opening at the inner end thereof that is closed by an initiator rupture disk constructed to rupture at a second predetermined pressure in the initiator housing greater than the first predetermined pressure. A micro-gas generator or initiator is disposed within the initiator housing. A manifold closes the other end of the pressure vessel and has an opening at the inner end thereof closed by a manifold rupture disk constructed to rupture at a third predetermined pressure greater than the first predetermined pressure.

Abstract: A multi-level gas inflator for an air bag or other safety device, comprising an elongated pressure vessel having a primary gas generant portion with a first open end and a secondary gas generant portion with a second open end. The primary gas generant portion has a primary ignition device and primary gas generating energetics disposed therein. The primary ignition device is mounted on and closes the pressure vessel at the first open end thereof. The secondary gas generant portion has a secondary ignition device and secondary gas generating energetics disposed therein. The secondary ignition device is mounted on and closes the pressure vessel at the second open end thereof. A suitable gas under a predetermined pressure is present in the primary and secondary gas generant portions. One or more dividers or divider walls are disposed within the midportion of the pressure vessel to separate the primary and secondary gas generant portions.

Abstract: A multi-level output inflator for inflating an airbag in the event of a vehicle crash, comprising a housing, a wall section disposed in the housing to define separate primary and secondary combustion chambers therein. A primary initiator and primary propellant are disposed within the primary combustion chamber, and a secondary initiator and secondary propellant are disposed with the secondary combustion chamber. The housing comprises a primary nozzle in communication with the primary combustion chamber, and a secondary nozzle in communication with the secondary combustion chamber. The primary and secondary initiators may be fired separately, simultaneously, or in a timed sequence to inflate the air bag at different rates and levels depending on the nature of the vehicle crash. A method of assembling the components of the inflator is also described and covered.