Method of filling containers with gases
A method of filling containers (50) with gases (12) provides each container, when filled, with a first predetermined amount of a first gas and a second predetermined amount of a second gas. The method comprises the step of forming a mixture comprising first and second amounts of the first and second gases, respectively. The first and second amounts are greater than and are in proportion to the first and second predetermined amounts, respectively. The method further comprises the steps of: determining a sum of the first and second predetermined amounts; and adding a third amount of the mixture to each of the containers. The third amount is equal to the sum of the first and second predetermined amounts.
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The present invention relates to a method of filling containers with gases. More particularly, the present invention relates to a method of filling containers with predetermined amounts of first and second gases.
BACKGROUND OF THE INVENTIONIt is known to provide an inflator for inflating an inflatable vehicle occupant protection device. One particular type of inflator is a heated gas inflator. In a heated gas inflator, a combustible mixture of gases is stored under pressure in a gas storage chamber. The heated gas inflator may include an outlet that is closed by a burst disk. An igniter assembly is associated with the gas storage chamber and is actuatable to ignite the combustible mixture of gases. When the combustible mixture of gases is ignited, the pressure of the gases within the gas storage chamber increases. The increased pressure ruptures the burst disk enabling the gases to exit the inflator through the outlet.
The combustible mixture of gases in a heated gas inflator generally includes hydrogen, an inert gas, and air. Actuation of the igniter assembly ignites the hydrogen to heat the inert gas and the air. Typically, the combustible mixture of gases has a precise amount of hydrogen. For example, the amount of hydrogen in the combustible mixture of gases may have a tolerance of approximately 0.001 grams. Additionally, since the molecular weight of hydrogen is low, the total mass of the hydrogen in the combustible mixture of gases may be less than one gram. When the total mass of the empty inflator is, for example, 1000 grams, adding less than one gram of hydrogen, with a tolerance of approximately 0.001 grams, tends to be difficult.
Currently, the process for adding the combustible mixture of gases to the inflator is time consuming and labor intensive. The process includes placing an empty inflator on a high precision scale and determining the mass of the empty inflator. The scale must be protected from air drafts, vibrations, and other variables that may alter the measured weight and thus, the determined mass, of the inflator. After the mass of the empty inflator is determined, hydrogen is introduced into the gas storage chamber of the inflator. After the hydrogen is added to the inflator and the scale has stabilized, the mass of the inflator and the stored hydrogen is determined. If the additional mass of the hydrogen is outside of the required tolerance, the amount of hydrogen in the gas storage chamber is adjusted and a subsequent determination of the mass of the inflator and the stored hydrogen is made.
When the amount of hydrogen added to the inflator is within its required tolerance, the inert gas is added to the gas storage chamber of the inflator. Generally, the combustible mixture of gases also has a precise amount of the inert gas. The inert gas is added to the gas storage chamber of the inflator using the same process as was used to add the hydrogen. After the precise amount of the inert gas has been added to the inflator, air is added to the gas storage chamber of the inflator to bring the pressure within the gas storage chamber to a predetermined level. When the pressure within the gas storage chamber reaches the predetermined level, the fill port for the gas storage chamber is sealed.
SUMMARY OF THE INVENTIONThe present invention relates to a method of filling containers with gases. Each container, when filled, includes a first predetermined amount of a first gas and a second predetermined amount of a second gas. The method comprises the steps of: forming a mixture comprising first and second amounts of the first and second gases, respectively. The first and second amounts are greater than and are in proportion to the first and second predetermined amounts, respectively. The method also comprises the steps of: determining a sum of the first and second predetermined amounts; and adding a third amount of the mixture to each of the containers. The third amount is equal to the sum of the first and second predetermined amounts.
In accordance with another aspect, the present invention relates to a method of filling inflators with gases. Each inflator, when filled, includes a first predetermined amount of a first gas and a second predetermined amount of a second gas and is actuatable for inflating an inflatable safety device of a vehicle safety system. The method comprises the steps of: forming, in a mixing vessel, a mixture comprising first and second amounts of the first and second gases, respectively, wherein a ratio of the first amount to the second amount equals a ratio of the first predetermined amount of the first gas to the second predetermined amount of the second gas; determining a sum of the first and second predetermined amounts; and adding a third amount of the mixture to each of the inflators. The third amount is equal to the sum of the first and second predetermined amounts.
The foregoing and other features of the present invention will become apparent to those skilled in the art to which the present invention relates upon reading the following description with reference to the accompanying drawings, in which:
The inflatable curtain 20 of
A conduit 44 connects the inflator 10 to the inflatable curtain 20. Upon actuation of the inflator 10, inflation fluid flows through the conduit 44 and into the inflatable curtain 20. In response to receiving the inflation fluid, the inflatable curtain 20 deploys from the deflated condition to an inflated condition to cover portions of the side structure of the vehicle 26, such as side windows 34 and 36.
As shown in
A diffuser end cap 84 closes the second end 60 of the tubular body portion 52. The diffuser end cap 84 includes a tubular end portion 86 having inner and outer surfaces 88 and 90, respectively. A circular gas fill port 92 extends through the tubular end portion 86 of the diffuser end cap 84. The diffuser end cap 84 also includes an end portion 96 that includes an annular end wall portion 100 and a tubular discharge portion 102. The tubular discharge portion 102 of the end portion 96 extends axially away from the annular end wall portion 100 in a direction parallel to an axis A. The tubular discharge portion 102 includes a passage 106 that provides an exit path for inflation fluid to flow out of the container 50.
Prior to actuation of the igniter 74, a rupturable burst disk 110 closes the passage 106 of the tubular discharge portion 102 of the diffuser end cap 84. The burst disk 110 is designed to rupture when subjected to a predetermined pressure differential.
The tubular body portion 52, the igniter end cap 66, and the diffuser end cap 84 collectively define the gas storage chamber 14. The gas storage chamber 14 extends along axis A between the igniter end cap 66 and the diffuser end cap 84. The inner surface 54 of the tubular body portion 52 and the inner surface 88 of the tubular end portion 86 of the diffuser end cap 84 define a radial outer boundary of the gas storage chamber 14.
When the igniter 74 of the inflator 10 receives an actuation signal from electronic circuitry 114 (
The apparatus 120 also includes a mixing vessel 130. The mixing vessel 130 has a volume that is significantly greater than the volume of the gas storage chamber 14 of the inflator 10. In a preferred embodiment of the invention, the volume of the mixing vessel 130 is over one thousand times greater than the volume of the gas storage chamber 14 of the inflator 10.
A conduit 134 connects vessel 122 to the mixing vessel 130. A valve 136 attaches the conduit 134 to the mixing vessel 130. When the valve 136 is open, hydrogen flows into the mixing vessel 130. A conduit 140 connects vessel 124 to the mixing vessel 130. A valve 142 attaches the conduit 140 to mixing vessel 130. When the valve 142 is open, argon flows into the mixing vessel 130.
To ensure a proper mixture of the hydrogen and argon in the mixing vessel 130, the scale 146 is used to determine the mass of the empty mixing vessel 130. The valve 136 is then opened and a quantity of hydrogen flows into the mixing vessel 130. The valve 136 is closed and the scale 146 is used to determine mass of the hydrogen that was added to the mixing vessel 130. Since the amount of hydrogen added to the mixing vessel 130 is preferably enough to fill over one thousand inflators, the added hydrogen will have a sufficient mass so as to be easily monitored using the scale.
After the amount of hydrogen that was added to the mixing vessel 130 is determined, the amount of argon to be added to the mixing vessel 130 is calculated. The amount of argon to be added to the mixing vessel 130 is determined from the ratio of the predetermined amount of hydrogen to the predetermined amount of argon in the combustible mixture of gases 12 and from the determined amount of hydrogen so that mass ratio of hydrogen to argon in the mixing vessel 130 is equal to the mass ratio of hydrogen to argon to be added to the inflator, e.g., a mass ratio of 1/33.
With reference again to
A conduit 166 connects the mixing vessel 130 to the first valve 160. When the first valve 160 is open, a mixture of hydrogen and argon flows into the first input line 152 of the member 150 and is directed into the gas storage chamber 14 of the inflator 10. As a result, when the first valve 160 is open, hydrogen and argon are added simultaneously to the gas storage chamber 14 of the inflator 10.
A conduit 168 connects the vessel 126 to the second valve 162. When the second valve 162 is open, air flows into the second input line 154 of the member 150 and is directed into the gas storage chamber 14 of the inflator 10.
To fill the inflator 10 with the combustible mixture of gases 12, the member 150 is secured to the inflator 10 so that the output line 156 of the member directs a flow of gas through the fill port 92 (
Next, the sum of the predetermined amounts of hydrogen and argon is determined. For purposes of example, assume that the inflator 10 is a 180 cm3 inflator that holds approximately 75 grams of the combustible mixture of gases 12. Also, for purposes of example, assume that the combustible mixture of gases 12 includes 12% by volume hydrogen, 20% by volume argon, and 68% by volume air. When filled with the combustible mixture of gases 12, the inflator 10 will hold approximately 0.65 grams of hydrogen, 21.47 grams of argon, and 52.88 grams of air at a pressure of 6000 p.s.i. to 7000 p.s.i.
As set forth in the Background of the Invention, adding such a small mass of hydrogen to the inflator, with a tolerance of approximately 0.001 grams, tends to be difficult. Instead of adding the approximately 0.65 grams of hydrogen to the inflator 10 and then later adding the approximately 21.47 grams of argon, the hydrogen and argon are simultaneously added to the inflator 10 according the method of the present invention.
In our example, the determined sum of the predetermined amounts of hydrogen and argon equals approximately 22.12 grams (the sum of 0.65 grams and 21.47 grams). After the sum of the predetermined amounts is determined, an amount of the mixture of hydrogen and argon equal to the sum of the predetermined amounts, e.g., 22.12 grams, is added to the gas storage chamber 14 of the inflator 10. A scale 174 is used for determining the amount (mass) of the mixture of hydrogen and argon that has been added to the inflator 10.
Since both the hydrogen and the argon have associated tolerances, assuming the proportion of the hydrogen and argon in the mixture is proper (e.g., a ratio of 1/33) and assuming that the mixture of hydrogen and argon flowing into the inflator 10 is homogenous, the tolerance for the mixture of hydrogen and argon will be larger than the individual tolerances for the hydrogen and the argon. For example, if the tolerance for the hydrogen is 0.001 grams and the tolerance for the argon is 0.005 grams, the tolerance for the mixture of hydrogen and argon may be greater than 0.005 grams while still maintaining the proper amounts of hydrogen and argon in the inflator 10. This results from the fact that the hydrogen only accounts for approximately 1/34 (0.65 grams H2/22.12 grams mixture) of the total added mass of the mixture and the argon only accounts for 33/34 (21.47 grams Ar/22.12 grams mixture) of the total added mass. Thus, when the amount of the mixture of hydrogen and argon added to the inflator 10 is within a 0.005 gram tolerance, the amount of hydrogen added is within its 0.001 gram tolerance (0.005 grams times 1/34 equals 0.000147 grams) and the amount of argon added is also within its 0.005 gram tolerance (0.005 grams times 33/34 equals 0.000485 grams).
After the mixture of hydrogen and argon is added to the gas storage chamber 14 of the inflator 10, the second valve 162 is opened and air is added to the gas storage chamber 14 of the inflator 10. the scale 174 is used to determine the weight of the air added to the storage chamber 14 of the inflator 10. After the air is added to the inflator, the fill port 92 of the inflator 10 is closed and the inflator is removed from the apparatus 10.
As shown in
At step 408, the amount of the second gas, e.g., argon, to be added to the mixing vessel 130 is calculated. The mass ratio of the first and second gases in the mixing vessel 130 should be equal to the mass ratio of the predetermined amounts of the first and second gases in the inflator. In our example, the mass ratio of hydrogen to argon is 1/33. Thus, the amount of argon to be added to the mixing vessel 130 at step 408 equals thirty-three times the amount of hydrogen added at step 406. In our example, 700 grams of hydrogen was added to the mixing vessel 130 at step 406. Therefore, at step 408, the calculated amount of the argon is 23.1 kilograms.
At step 410, the calculated amount of the second gas is added to the mixing vessel 130. At step 412, the amount of the second gas added to the mixing vessel 130 is determined. To determine the amount of the second gas added to the mixing vessel 130, the mass of the mixing vessel 130 after the addition of the second gas is determined. The previously determined mass of the mixing vessel 130 after the addition of the first gas and prior to the addition of the second gas is subtracted from the determined mass of the mixing vessel 130 after the addition of the second gas. The difference between the two determined masses represents the mass of the second gas added to the mixing vessel 130.
At step 414, a determination is made as to whether the correct amount of the second gas has been added to the mixing vessel 130. The determination at step 414 is made by comparing the determined amount of the second gas added to the mixing vessel 130 from step 412 to the calculated amount of the second gas from step 408. When the determined amount of the second gas added is within a predetermined tolerance of the calculated amount of the second gas, the determination at step 414 is affirmative.
In response to a negative determination at step 414, the process 400 proceeds to step 416 and the amount of the second gas in the mixing vessel 130 is increased if the amount of the second gas is too low. The amount of the second gas can not become too high, because the systems (in a manner not shown), is constantly being monitored by continually weighing the second gas in the mixing vessel and closing off the flow of the second gas when the correct weight is in the mixing vessel 130. From step 416, the process 400 returns to step 414. In response to an affirmative determination at step 414, the process proceeds to step 418.
At step 418, the sum of the predetermined amounts of the first and second gas to be added to an inflator is determined. In our example, the predetermined amount of the first gas, hydrogen, is 0.65 grams and the predetermined amount of the second gas, argon, is 21.47 grams. Therefore, the sum of the predetermined amounts that is determined at step 418 is 22.12 grams grams.
As shown with reference to
At step 424, the mixture of the first and second gases is added to the inflator. The amount of the mixture added to the inflator is the amount determined at step 418. At step 426, the amount of the mixture of the first and second gases added to the inflator is determined. To determine the amount of the mixture added to the inflator, the mass of the inflator after the addition of the mixture of gases is determined. The previously determined mass of the empty inflator is subtracted from the determined mass of the inflator after the addition of the mixture of gases. The difference between the two determined masses represents the mass of the mixture of gases added to the inflator.
At step 428, a determination is made as to whether the correct amount of the mixture of gases has been added to the inflator. The determination at step 428 is made by comparing the determined amount of the mixture of gases added to the inflator from step 426 to the determined sum from step 418. When the determined amount of the mixture of gases added is within a predetermined tolerance of the determined sum, the determination at step 428 is affirmative.
In response to a negative determination at step 428, the process 400 proceeds to step 430, and the amount of the mixture of gases in the inflator is adjusted by either adding or removing an amount of the mixture. From step 430, the process 400 returns to step 428. In response to an affirmative determination at step 428, the process 400 proceeds to step 432. At step 432, a predetermined amount of air is added to the inflator. As noted above the air added to the inflator is weighted. The air increases the pressure of the gases in the gas storage chamber of the inflator to a predetermined pressure. At step 434, the fill port of the inflator is closed and sealed and, at step 436, the inflator is removed from the apparatus.
From step 436, the process 400 proceeds to step 438. At step 438, the amount of the mixture of the first and second gases remaining in the mixing vessel 130 is determined. The amount of the mixture remaining may be determined by monitoring the total mass of the mixing vessel 130 and the mixture of gases. At step 440, a determination is made as to whether the remaining amount of the mixture of gases is greater than the sum of the predetermined amounts from step 418. When the determination at step 440 is affirmative, and the amount of the mixture of gases remaining in the mixing vessel 130 is greater than the sum of the predetermined amounts from step 418, the process 400 proceeds to step 442 and another empty inflator is inserted into the apparatus 120 to be filled. From step 442, the process 400 returns to step 422. When the determination at step 440 is negative, the process 400 proceeds to step 444 and ends.
From the above description of the invention, those skilled in the art will perceive improvements, changes and modifications. For example, nitrogen may be used in the process as a substitute for argon. Such improvements, changes and modifications within the skill of the art are intended to be covered by the appended claims.
Claims
1. A method of filling containers with gases, each container, when filled, including a first predetermined amount of a first gas and a second predetermined amount of a second gas, the method comprising the steps of:
- forming a mixture comprising first and second amounts of the first and second gases, respectively, the first and second amounts being greater than and in proportion to the first and second predetermined amounts, respectively;
- determining a sum of the first and second predetermined amounts; and
- adding a third amount of the mixture to each of the containers, the third amount being equal to the sum of the first and second predetermined amounts.
2. The method of claim 1 wherein the step of forming a mixture further includes the steps of:
- determining a ratio of the first predetermined amount to the second predetermined amount;
- adding the first amount of the first gas to a mixing vessel;
- determining the second amount of the second gas to be added to the mixing vessel so that the ratio of the first amount to the second amount equals the determined ratio of the first predetermined amount to the second predetermined amount; and
- adding the determined second amount of the second gas to the mixing vessel.
3. The method of claim 1 wherein the step of adding a third amount of the mixture to each of the containers further includes the steps of:
- adding mixture to a first container;
- determining the amount of mixture added to the first container;
- comparing the determined amount of mixture added to the third amount; and
- adjusting the amount of mixture added when the determined amount of mixture added is outside of a predetermined tolerance relative to the third amount.
4. The method of claim 3 wherein the step of determining the amount of mixture added to the first container includes the steps of:
- determining a mass of the first container when empty;
- determining a mass of the first container after the mixture has been added; and
- subtracting the determined mass of the first container when empty from the determined mass of the first container after the mixture has been added.
5. The method of claim 3 further including the steps of:
- replacing the first container with a second container when the determined amount of mixture added to the first container is within the predetermined tolerance;
- adding mixture to the second container;
- determining the amount of mixture added to the second container;
- comparing the determined amount of mixture added to the second container to the third amount; and
- adjusting the amount of mixture added to the second container when the determined amount of mixture added is outside of the predetermined tolerance relative to the third amount.
6. The method of claim 5 further including the step of determining, prior to replacing the first container with the second container, whether an amount of mixture remaining is greater than the sum of the first and second predetermined amounts.
7. The method of claim 1 further including the step of adding a third gas to each of the containers after the third amount of the mixture has been added.
8. The method of claim 7 wherein the step of adding a third gas to each of the containers includes the step of increasing a pressure of the gases in gas storage chambers of each of the containers to a predetermined pressure.
9. The method of claim 7 further including the step of closing a fill port of each of the containers after the third gas has been added.
10. A method of filling inflators with gases, each inflator, when filled, including a first predetermined amount of a first gas and a second predetermined amount of a second gas and being actuatable for inflating an inflatable safety device of a vehicle safety system, the method comprising the steps of:
- forming, in a mixing vessel, a mixture comprising first and second amounts of the first and second gases, respectively, wherein a ratio of the first amount to the second amount equals a ratio of the first predetermined amount of the first gas to the second predetermined amount of the second gas;
- determining a sum of the first and second predetermined amounts; and
- adding a third amount of the mixture to each of the inflators, the third amount being equal to the sum of the first and second predetermined amounts.
Type: Application
Filed: Jun 13, 2006
Publication Date: Dec 20, 2007
Applicant:
Inventors: Fred J. Cook (Gilbert, AZ), William B. Butler (Mesa, AZ), George W. Goetz (Fountain Hills, AZ), Darrin L. Johnson (Fountain Hills, AZ), Christopher J. Ruf (Mesa, AZ), Barry F. Shaffer (Gilbert, AZ)
Application Number: 11/452,023