Abstract: An apparatus for inflating a vehicle occupant restraint includes an inflator housing which holds gas generating material. The inflator housing includes a combustion cup which is formed from one piece of sheet metal. A diffuser cup, which is also formed from one piece of sheet metal, encloses the combustion cup. A chamber in the combustion cup holds the gas generating material and is closed by a cover. Flanges on the combustion cup, diffuser cup and cover are disposed in overlapping engagement with each other. During formation of the combustion and diffuser cups, the sheet metal is strained hardened to increase the yield strength and ultimate tensile strength of portions of the inflator housing.

Abstract: An ignition material packet assembly which comprises: (1) a first cup-shaped member having an open top, formed of an engineering thermoplastic for electrically insulating a pyrotechnic material stored within the assembly, (2) a second cup-shaped member inserted at least partially within the outer plastic member and retained therein by a friction fit created therebetween such that a compression gap is formed between a corresponding base portion of the first and second cup-shaped members, wherein the second cup-shaped member has an open top and is formed of a lightweight metal; (3) a pyrotechnic material comprising a mixture of an ignition enhancing material and an autoignition material sealed within the metal cup member and (4) a metal lid member closing the open top of the inner cup member to hermetically seal the pyrotechnic material therein.