Morton International, Inc.

Leland B Kort

Randall J Clark

Bradley W Smith

Walter A Moore

Kelly B Johnson

Brett Hussey

Kirk H Rasmussen

L John Pierotti

Karl K Rink

George C Marjanski

Michael H Wong

William A Chandler, Jr

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

A hybrid inflator for an inflatable restraint system has a center frame and two tubular end caps forming an elongated housing defining a chamber storing pressurized inert gas. Unit means for heating and delivering the stored gas are mounted in the center frame and positioned to deliver inflation gasses centrally with respect to the elongated housing. In a two unit embodiment, one unit includes a squib and a pyrotechnic gas generant, and the other unit defines an outlet orifice and baffle plate. In another two unit embodiment, the second unit includes an essentially non gas-producing heating composition which, when activated, heats and expands the pressurized gas. In a third embodiment, a unit includes heating material and ignition means and defines the outlet orifice. The center manifold is extruded metal stock with two opposing flat surfaces adapted to mount one or more units.

Hybrid inflator with elongated housing and center discharge

A heat-enhanced boosted inflator for a vehicle airbag includes a housing defining a storage chamber having compressed inflation gas therein and a heating cup mounted to the housing and defining a portion of a gas delivery path to the airbag. The heating cup contains a heat-producing material and the gas flows through the heat-producing material to heat-expand it. One heat-producing material is thermite (Al+FeO.sub.3) and ignitor means initiate its reaction. A cylindrical heating cup provides an annular heating chamber containing the heat-producing material and further defines an outlet plenum containing inflation gas which is released initially for a 'soft' onset of inflation.

Flow-through heat-enhanced hybrid inflator

Stamped metal toroidal hybrid gas generator with sliding piston

A process for converting sheet stock into a seamless outer shell for a toroidal shaped hybrid inflator for air bag inflation systems. In the process a seamless toroidal shaped shell is fabricated from sheet stock by a sequence of process steps comprising first drawing the sheet into a cup shaped blank, with curved transitions between the bottom wall and the sidewall, and then shaping the open end of the cup to the desired toroidal shape while simultaneously thickening the areas adjacent to the perimeter of the open end of the cup and finally removing the central portion of the bottom of the cup--thereby producing the desired shell.

Process to make a toroid outer shell from sheet stock

An elongated tubular hybrid gas generator for the inflation of air bags in which the ratio of length to diameter is at least ten. The device may be substituted for a structural element in a motor vehicle, e.g. a steering column or a beam in a door panel with consequent savings in weight and size.

Large L/D ratio tubular hybrid gas generator for the inflation of air

A hybrid gas generator includes a chamber for storing inert gas under high pressure, a chamber for storing pyrotechnic material used to heat the stored gas, a diffuser which contains gas orifices for dispensing gas uniformly into an air bag assembly, a thin metal diaphragm to provide a pressure seal between the storage chamber and the diffuser, and a metal disk that is scored with a circular groove to seal the pyrotechnic material from the stored gas. Upon receiving an electrical signal an initiator fires and ignites the pyrotechnic charge. As pressure in the combustion chamber rises and exceeds the pressure in the storage chamber the metal disk that is scored with a circular groove ruptures and allows hot gas and burning pyrotechnic material to heat the gas and cause a rapid pressure rise in the gas storage chamber. When the pressure in the gas storage chamber exceeds the rupture pressure of the thin metal diaphragm between the storage chamber and the diffuser, it ruptures and allows the heated gas to vent through the diffuser orifices into the air bag assembly. Other features include the use of metal stampings for many of the parts instead of machined or forged parts, an end plug made in one piece with the storage chamber which reduces the number of bulkhead welds, a dimpled or pronged orifice plate which prevents the exiting orifice from being plugged, and a perforated diffuser with small holes which prevent fragments from escaping the inflator without the use of screens or meshes.

Hybrid (augmented) gas generator

The invention is a low cost inflator having a thin-walled hermetic liner, filled with either a stored gas or a flammable fluid mixture, and having a minimal number of joints required for sealing. Structural support is provided by parts that are not required to be hermetic. To activate the inflator, a small amount of pyrotechnic is used to move a piston, crushing the thin-walled liner and compressing the stored inert gas, or alternatively compressing and igniting the stored flammable fluid mixture, causing the gas to escape into the air bag. Optionally, the stored inert gas or flammable fluid mixture can be augmented by hot gases produced by the pyrotechnic. The piston-driving material may be composed of a wide variety of pyrotechnic materials, combustible mixtures of fluid fuels and oxidants, or compatible combinations of both. The inflator design incorporating a stored combustible fluid mixture will, upon ignition of the mixture, produce a heated gas able to more quickly inflate the air bag, as compared to a cold gas or blow down system of the same size and pressure. The combustible fluid mixture is selected so that while production of undesirable incomplete products of combustion and particulate matter are minimized, the fluid mixture must be compressed to ignite, thereby eliminating storage and handling issues problematic to some inflators featuring combustible fluid mixtures.

Piston-actuated air bag inflator with hermetic liner

A hybrid inflator for a vehicle passenger restraint system comprises a center tie having upper and lower ends, and a curved, continuous vessel wall secured to the upper and lower ends of and surrounding the center tie to define a pressure chamber storing inert compressed gas. The center tie defines a combustion chamber extending from the lower end thereof, the combustion chamber receiving pyrotechnic gaseous heat source material and a squib for igniting it. The center tie further defines a directional inlet port extending from the combustion chamber into the pressure chamber and a rupturable diaphragm seals the inlet port until ignition of the pyrotechnic generant. The center tie also defines a directional outlet vent extending from the pressure chamber adjacent the upper end of the center tie, the directional outlet vent being oriented substantially opposed the inlet port. The outlet vent is part of an outlet passage from the pressure chamber through the upper end of the center tie, including an orifice cavity and outlet orifice, oriented to provide further turns in the gas flow path. A rupturable diaphragm seals the outlet passage until ignition of the gas generant. A diffuser provides an additional change of direction of the outlet path.

Hybrid inflator with tortuous delivery passage

In an air bag inflation system, the present invention reduces the pressure at which gas flow is initiated from a stored gas inflator into an air bag to be inflated. In many air bag inflation systems gas flow normally begins following rupture of a diaphragm due to a pressure differential. In the present system this differential is reduced.

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Lakewood, CO, United States of America

Leland B Kort