Abstract: An inflator 10 of a vehicle occupant protection system contains an elongated housing 12 having a plurality of gas exit orifices 14 spaced along the length thereof. A first propellant body 31 and a second propellant body 33 are provided in lengths substantially equivalent to the length of the housing 12 wherein the first propellant body 31 is placed in physical contact with the second propellant body 33 for all or most of their respective lengths. Once the first propellant body 31 is ignited upon a crash event, resultant uniform ignition and combustion across the length of the second propellant body 33 results in uniform gas generation and uniform inflation of an airbag 26, wherein the airbag 26 is at least substantially coextensive with and in fluid communication with the housing 12. Preferred mixtures of first propellant body 31 contain silicone, a perchlorate oxidizer, and a nitrate salt.

Abstract: A thin film keypad includes a retainer sheet and a plurality of keycaps molded onto keycap attachment regions on the retainer sheet such that the keys are mechanically secured to the retainer sheet. The retainer sheet is made of a thin film material, such as polycarbonate or polyester, and each keycap attachment region includes at least a hole and/or at least one retainer anchor portion. The keycaps are molded from a plastic material, such as polycarbonate or polyester, ABS or a polycarbonate/ABS blend. The thin film material is placed in a molding tool and the plastic material is injected into a keycap mold cavity such that the plastic material flows through the holes and/or around the retainer anchor portions, thereby anchoring the keycaps to the retainer sheet.

Abstract: Assembly of a gas generator 10 includes the step of adding uncured silicone to a propellant cup 25. Granulated oxidizer is then added over the top of the silicone and allowed to disperse therein. Afterwards, the silicone is cured to provide flush communication with an inner wall 14 of the propellant cup 25. Other granulated gas generant constituents may be added as well. A gas generator 10 assembled in this manner provides more predictable burn rates of a gas generant composition 26 and therefore more predictable performance of the gas generator 10.

Abstract: A thin film keypad includes a retainer sheet and a plurality of keycaps molded onto keycap attachment regions on the retainer sheet such that the keys are mechanically secured to the retainer sheet. The retainer sheet is made of a thin film material, such as polycarbonate or polyester, and each keycap attachment region includes at least a hole and/or at least one retainer anchor portion. The keycaps are molded from a plastic material, such as polycarbonate or polyester, ABS or a polycarbonate/ABS blend. The thin film material is placed in a molding tool and the plastic material is injected into a keycap mold cavity such that the plastic material flows through the holes and/or around the retainer anchor portions, thereby anchoring the keycaps to the retainer sheet.

Abstract: An inflator 10 of a vehicle occupant protection system contains an elongated housing 12 having a plurality of gas exit orifices 14 spaced along the length thereof. A first propellant body 31 and a second propellant body 33 are provided in lengths substantially equivalent to the length of the housing 12 wherein the first propellant body 31 is placed in physical contact with the second propellant body 33 for all or most of their respective lengths. Once the first propellant body 31 is ignited upon a crash event, resultant uniform ignition and combustion across the length of the second propellant body 33 results in uniform gas generation and uniform inflation of an airbag 26, wherein the airbag 26 is at least substantially coextensive with and in fluid communication with the housing 12. Preferred mixtures of first propellant body 31 contain silicone, a perchlorate oxidizer, and a nitrate salt.

Abstract: A thin film keypad includes a retainer sheet and a plurality of keycaps molded onto keycap attachment regions on the retainer sheet such that the keys are mechanically secured to the retainer sheet. The retainer sheet is made of a thin film material, such as polycarbonate or polyester, and each keycap attachment region includes at least a hole and/or at least one retainer anchor portion. The keycaps are molded from a plastic material, such as polycarbonate or polyester, ABS or a polycarbonate/ABS blend. The thin film material is placed in a molding tool and the plastic material is injected into a keycap mold cavity such that the plastic material flows through the holes and/or around the retainer anchor portions, thereby anchoring the keycaps to the retainer sheet.

Abstract: Assembly of a gas generator 10 includes the step of adding uncured silicone to a propellant cup 25. Granulated oxidizer is then added over the top of the silicone and allowed to disperse therein. Afterwards, the silicone is cured to provide flush communication with an inner wall 14 of the propellant cup 25. Other granulated gas generant constituents may be added as well. A gas generator 10 assembled in this manner provides more predictable burn rates of a gas generant composition 26 and therefore more predictable performance of the gas generator 10.