Morton International, Inc.

Autoliv Asp, Incorporated

Kirk H Rasmussen

Bradley W Smith

Robert E Lewis

Larry D Rose

Matthew Alan Cox

Davin G Saderholm

Leland B Kort

Randall J Clark

Brian M Shaklik

Isaac Hoffman

Brian T Snyder

Gary V Adams

John E Allard

Dario G Brisighella, Jr

Matt Cox

James R Kaufmann

Kelly Ellis

An airbag assembly may include an airbag and an inflator in fluid communication with the airbag. The inflator may have a first chamber containing a first gas source and a second chamber containing a second gas source. A filter module may be positioned to filter and redirect gas flows from the first and second gas sources. The filter module may be constructed by securing a baffle within an interior cavity of a filter medium having a generally tubular shape, prior to installation of the filter module the inflator. The baffle may be supported directly by the material of the filter module, by a bracket, or by a support structure formed of wire thicker than that of the filter medium. The baffle may maintain isolation between the first and second chambers, or may help gas from the first gas source initiate gas provision from the second gas source.

Filter with integrated baffle

Inflatable airbag assemblies having a strap and clamp system to securely hold an inflator relative to a housing. The strap may be attached to an airbag cushion to restrict the movement of the strap or strap may not be attached to the airbag cushion and may move freely while positioned within openings in the housing.

Airbag assemblies with strap clamps

A closure structure for the relief aperture of an airbag cushion inflator includes a closure core having outer and inner surfaces that is disposable into the relief aperture from the exterior of the inflator to fill the relief aperture. A sealing flange continuously secured to the periphery of the outer surface of the closure core abuts the outer surface of the inflator. A temperature-sensitive venting window formed in the closure core precludes the passage of pressurized inflation gas during a predetermined first ambient temperature condition and opens to emit pressurized inflation gas during a second hotter ambient temperature condition. The venting window includes a venting passageway extending between the inner and the outer surfaces the closure core sealingly traversed by a relatively thin venting membrane made of a temperature-sensitive material exhibiting less structural robustness at the second ambient temperature condition than at the first ambient temperature condition.

Air bag inflation in high temperature conditions

A new type of airbag inflator that may be used in an airbag system is disclosed. The inflator will generally include a housing and two initiators. Accordingly, the inflator is a 'dual-stage' inflator. The two stages are disposed within the housing. The second initiator is disposed within a second stage generant cup. A cap is also used to engage the second stage cup. The cap maintains seated engagement with the second stage cup, even during deployment of the second stage. The second stage will also include one or more perforations, which constitute openings through which gas may flow. When the second initiator is in the unactuated state, these perforations will be isolated from the generant by the cap. Actuation of the second initiator unseals the one or more perforations but does not unseat the cap from the cup, due to constraints put in place to prevent such unseating.

Inflator second stage combustion control

The present invention provides an airbag inflator assembled, in part, using ultrasonic welding. The inflator includes a housing adapted to receive an initiator assembly and an adaptor socket to connect the inflator to the electronic systems of the vehicle. The initiator and the adaptor socket are welded together at a point of interface through the housing of the inflator using an ultrasound welding process. Joint seals are provided that allow the production of a gas-tight seal upon completion of assembly of the airbag inflator.

Ultrasonic welded initiator and connector socket

A driver side inflator base for a vehicle safety system which is stamped from a thin sheet of aluminum. The base includes a central axis, a plurality of stamped concentric rings extending upwardly from a bottom of the base and spaced from the central axis. An interface attachment flange is provided for mounting the inflator, and a squib pocket extending about the central axis of the base is capable of holding a squib of the gas inflator. The concentric rings, attachment flange and squib pocket are all formed during the stamping of the base; thus, excessive machining is not required. Only minor machining is necessary to complete the base. The base of the present invention is designed to reduce the overall inflator cost, while maintaining the processing capability and quality of current bases.

Method of making stamped driver inflator base

A driver side inflator housing for a vehicle safety system which includes a base which is stamped from a thin sheet of aluminum The base includes a central axis, a plurality of stamped concentric rings extending upwardly from a bottom of the base and spaced from the central axis. An interface attachment flange is provided for mounting the inflator, and a squib pocket extending about the central axis of the base is capable of holding the squib of the gas generating inflator. The concentric rings, attachment flange and squib pocket are all formed during the stamping of the base; thus excessive machining is not required. Only minor machining is necessary to complete the base. The base of the present invention is designed to reduce the overall inflator cost, while maintaining the processing capability and quality of current bases.

Stamped driver inflator base

An air bag cushion with a controlling doubler to provide occupant protection during both normal and out of position deployment has an enlarged gas permeable area for venting inflation gases. An obstruction to full deployment, such as a person against the steering wheel, causes venting through the enlarged area to be maintained thereby to prevent a full pressure build up which may cause injury to such person as he is pushed out of the way as the cushion deploys. Displacement of the face panel beyond a predetermined position releases a hinge mounted flap of gas impermeable material which seals off that portion of the gas permeable area that is in excess of the venting needed for a normal deployment. The flap is propelled to a closing position by the inflation gas during deployment.

Air bag cushion protection during both normal and out of position

A hybrid inflator comprises a housing formed of welded-together metal stampings defining a toroidal gas chamber surrounding a center tie and storing pressurized gas therein. The center tie has a generally cylindrical sidewall and an outlet wall at an upper end thereof defines a rupturably sealed outlet orifice. An inverted stamped metal cup is matingly received in the center tie. The lip of the cup is welded to the lower end of the center tie, and the cup sidewall is circumferentially grooved for separating a sliding piston portion under pressure. A squib support wall and squib closes the lower end of the center tie and inverted cup to define a combustion chamber containing a pyrotechnic gas generant which, upon ignition, causes the inverted cup to separate at the groove and drive the sliding piston upwardly to an open position uncovering inlet openings from the combustion chamber to the gas storage chamber. Hot gasses from the combustion chamber flow into the gas storage chamber and the outlet orifice rupturably opens permitting stored gas and combustion products to exit the inflator. The sliding piston and center tie are tapered to control movement of the piston by friction and deformation, together with lanced limit stop tabs. The cup has a convex bottom, deformation portions and may carry a lance to open the orifice. A baffle provides a surface on which incomplete products of combustion are collected and captures debris. A deformable outlet diffuser provides compact packaging.

Stamped metal toroidal hybrid gas generator

Stamped metal toroidal hybrid gas generator with sliding piston

The invention is an airbag having two modes of deployment. In the normal mode, with a driver in the normal seated position, the airbag is fully deployed and inflated to attain its full normal reach and provide a cushion for protection of the driver in a collision. In the other mode, when a driver is too close to the airbag at the moment of collision, the airbag will deploy only to a shorter reach and thus protect the too-close driver from being forcibly pushed backwards by the airbag inflating to its full normal reach. In the mode for normal deployment an inner flap covers gas exhausting structure on the rear panel of the airbag to prevent escape of inflation gas from the airbag during inflation. But when a driver is too close to the airbag at the moment of collision the inner flap is held away from the gas exhausting structure, keeping such structure uncovered for escape of inflation gas which would otherwise fully inflate the airbag.

Airbag with alternate deployment modes

This invention relates to a clamping structure for assembling an automotive air bag to an automotive air bag inflator. The clamping structure includes an annular retainer ring and module housing. Integral 'L' shaped tabs or studs descending from the annular retainer are designed to pass through radial slots in the air bag and module housing. The tab or stud is formed to have an 'L' shape with the short leg of the 'L' having a slight angle. Then as the retainer is rotated into place, the short leg of the 'L' shaped tab or stud will be forced into contact with the housing and clamp the assembly together.

Rivetless cushion retaining ring with tabs which lock the ring in place

An air bag module uses a tubular inflator that is mounted off center in the module with the diffuser lying in the plane of the bottom of the module housing. The housing and inflator retaining bracket combine to make a pocket which changes the direction of some of the gas produced by the inflator and allows all of the gas to flow up into the inflatable cushion. A different housing, retaining ring, cushion and inflator retaining bracket are used in the assemblage of the module than are employed in air bag modules of current production. The appearance and function of the module, however, is not changed to a purchaser of the automotive vehicle in which the module is installed, only the internal components of the module are changed.

Air bag module with an off-center mounted tubular inflator

An air bag module uses a toroidal inflator which is clamped in the center of the module. The toroidal inflator used in the module does not have a flange for the attachment thereof to the module housing. The inflator is clamped in the module between the housing and a retaining bracket so that an inflator flange is not needed. The appearance and function of the module are not changed. Only the internal components of the module are changed.

Air bag module with a centrally mounted toroidal inflator using a

An air bag module using a tubular inflator uses a different housing, retaining ring, cushion and inflator bracket than are currently used, with the appearance and function of the module not being changed but only the internal components. The inflator is placed in a slotted section of the module housing with the diffuser thereof protruding from the center through a hole in a raised portion of the module housing slotted section, which hole is sized closely to the size of the diffuser. The diffuser extends directly into the module at a 90.degree. angle to the plane surface of the housing. The retaining ring has raised portions in the center thereof to match the raised portion of the module housing, has holes in the raised portions, and has tabs which extend through holes in the cushion and the module housing. The module housing has tabs on the raised portion thereof which extend through holes in the cushion and retaining ring. The cushion uses a rectangular mounting so that the cushion can match the radius of the module housing in the raised portion which goes over the tubular inflator. The retaining bracket extends around the back side of the inflator to hold it in place and includes cover retaining brackets incorporated therein. Studs which hold the module together extend from the retaining ring through holes in the cushion, module housing, and retaining bracket.

Growing community of inventors

West Point, UT, United States of America

Kirk H Rasmussen