Inflator, method of manufacturing the same and module including said inflator

• US 10,589,709 B2
• Filed: 08/15/2017
• Issued: 03/17/2020
• Est. Priority Date: 09/30/2008
• Status: Active Grant

• Current Assignee: TRW Airbag Systems GmbH (Zeppelin - Stiftung der Stadt Friedrichshafen)
• Original Assignee: TRW Airbag Systems GmbH (Zeppelin - Stiftung der Stadt Friedrichshafen)
• Inventors: Bierwirth, Sebastian, Hofmann, Achim, Neumayer, Hans-Peter, Spitzenberger, Dieter, Fuerstenberger, Franz, Nuiding, Hannes, Leier, Dieter, Schoenhuber, Georg, Friedrich, Joerg
• Primary Examiner(s): Ilan, Ruth
• Application Number:
  US15/677,136
• Publication Number:
  US 20170341617A1
• Time in Patent Office: 945 Days
• Field of Search: 156500, 156245, 264261, 264263
• CPC Class Codes: B01D 2279/10 for air bags, e.g. inflators therefor
• CPC Class Codes: B01D 39/12 of wire gauze; of knitted wire; of expanded metal
• CPC Class Codes: B60R 2021/26029 Ignitors
• CPC Class Codes: B60R 2021/26076 characterised by casing
• CPC Class Codes: B60R 21/264 using instantaneous generation of gas, e.g. pyrotechnic B60R21/268 takes precedence
• CPC Class Codes: B60R 21/2644 using only solid reacting substances, e.g. pellets, powder
• CPC Class Codes: F42B 3/04 for producing gas under pressure generators of inflation fluid especially adapted for vehicle air bags B60R21/26

Abstract

An inflator as well as a method of manufacturing an inflator, a module including an inflator and an airbag module. In an inflator, especially for a protective device in a vehicle, comprising plural components a sealant is applied in the area of abutting components, especially a sealant which adheres to both abutting components.

Claims

1. An inflator comprising:

a first component (112), the first component being an inflator housing and a second component (114) connected to the first component (112) by an injected plastic base (116) by at least partially surrounding both components (112, 114) by injection molding, the second component being a pre-fabricated igniter,

wherein the first component (112) has an adhesive film (142) applied before injection molding in a contact area (140) with the plastic base (116), the adhesive film comprising a plastic film (144) and an adhesive layer (146),

wherein the first component (112) comprises an orifice (120) through which the second component (114) extends, the plastic base (116) extending through the orifice (120) and covering the first component (112) so that a circumferential edge (122) of the orifice (120) is embedded in the plastic base (116), wherein the adhesive film (142) is applied to the first component (112) on a contacting area (140) that extends circumferentially around the edge (122) of the orifice (120) on both an inner and outer surface of the first component,

wherein the materials of the plastic film (144) and the plastic base (116) are selected such that during injection-molding the plastic base (116), the plastic film (144) at least partially melts and combines with the plastic base (116), and

wherein the adhesive layer (146) is formed of a material that adheres the plastic film (144), and the plastic base (116) connected thereto, to the first component (112), the adhesive layer (146) being elastically or plastically deformable so as to form a bonding bridge that compensates for different thermal expansion coefficients between the materials of the first component (112) and the plastic base (116).

2. An inflator according to claim 1, wherein the first component (112) is made of metal, ceramic and/or plastic material.

3. An inflator according to claim 1, wherein the pre-fabricated igniter is closed to the outside.

4. An inflator according to claim 1, wherein the first component (112) has an orifice (120) for receiving and mounting the second component (114) the edge (122) of which is embedded in the plastic base (116) during injection molding.

5. An inflator according to claim 1, wherein the adhesive film (142) covers only part of the portion of the first component (112) surrounded by injection molding.

6. An inflator according to claim 1, wherein the adhesive film (142) covers the entire portion of the first component (112) surrounded by injection molding.

7. An inflator according to claim 1, wherein the adhesive film (142) projects from the portion of the first component (112) surrounded by injection molding.

8. An inflator according to claim 1, wherein the plastic film (144) is made of the same material as the plastic base (116).

9. An inflator according to claim 8, wherein the adhesive of the adhesive layer (146) can be activated by a predetermined contact pressure or thermal influence.

10. An inflator according to claim 1, wherein the plastic film (144) is made of a material which is suited for establishing a connection with the material of the plastic base (116).

11. An inflator according to claim 1, wherein the plastic film (144) includes a thermoplastic elastomer.

12. A method for manufacturing an inflator (10) for a vehicle occupant restraint system comprising the steps of:

providing a first component (112) containing metal and/or plastic material and/or ceramic material, the first component being an inflator housing,

providing a second component (114) to be connected to the first component (112) the second component being a pre-fabricated igniter,

applying an adhesive film (142) to the first component (112) in a connecting area, the adhesive film comprising a plastic film (144) and an adhesive layer (146),

positioning the second component (114) relative to the first component (112), and

jointly surrounding at least partially the first and second components (112, 114) by injection molding, thereby forming a plastic base (116) connecting the components (112, 114),

wherein the first component (112) comprises an orifice (120) through which the second component (114) extends, the plastic base (116) extending through the orifice (120) and covering the first component (112) so that a circumferential edge (122) of the orifice (120) is embedded in the plastic base (116), wherein the adhesive film (142) is applied to the first component (112) on a contacting area (140) that extends circumferentially around the edge (122) of the orifice (120) on both an inner and outer surface of the first component,

wherein the materials of the plastic film (144) and the plastic base (116) are selected such that during injection-molding the plastic base (116), the plastic film (144) at least partially melts and combines with the plastic base (116), and wherein the adhesive layer (146) is formed of a material that adheres the plastic film (144), and the plastic base (116) connected thereto, to the first component (112), the adhesive layer (146) being elastically or plastically deformable so as to form a bonding bridge that compensates for different thermal expansion coefficients between the materials of the first component (112) and the plastic base (116).

13. A method according to claim 12, wherein the plastic film (144) of the adhesive film (142) melts with the plastic base (116) during injection molding.

14. A method according to claim 12, wherein during or after applying the adhesive film (142) the adhesive of the adhesive film (142) is activated by pressing or heating.

15. A module comprising an inflator (10, 110), an airbag (96) inflatable by the inflator (10, 110) and a fastening means for attaching the module, wherein the inflator (10, 110) is formed according to claim 12.