Method of making an air bag

• US 20020097139A1
• Filed: 02/20/2002
• Published: 07/25/2002
• Est. Priority Date: 01/19/2001
• Status: Active Grant

• Current Assignee: Anthony E. Troianello, George V. Gerber, Haim Goldberger
• Original Assignee: Anthony E. Troianello, George V. Gerber, Haim Goldberger
• Inventors: Goldberger, Haim, Gerber, George V., Troianello, Anthony E.
• Granted Patent: US 6,880,233 B2
• Time in Patent Office: Days
• US Class Current: 338/309
• CPC Class Codes: F42B 3/124 characterised by the configuration or material of the bridge F42B3/13 takes precedence
• CPC Class Codes: F42B 3/198 of electric initiator heads e.g., testing, machines
• CPC Class Codes: Y10T 29/49082 Resistor making
• CPC Class Codes: Y10T 29/49083 Heater type
• CPC Class Codes: Y10T 29/49098 Applying terminal
• CPC Class Codes: Y10T 29/49099 Coating resistive material on a base

Abstract

A fast heat rise resistor comprising a substrate, a foil bridge on the surface of the substrate, the foil bridge having an elevated portion and a contact portion, the elevated portion above the substrate, the contact portion in contact with the substrate, a conductive layer attached to the contact portion of said foil bridge. The activation energy and/or response time is reduced as the foil bridge is suspended over the substrate. Another aspect of the invention include a method of manufacturing the foil bridge and application to autoignition vehicle airbags.

Claims

1. A fast heat rise resistor comprising:

a substrate;

a foil bridge on the surface of the substrate, the foil bridge having an elevated portion and a contact portion, the elevated portion being adajcent the substrate, the contact portion being in contact with said substrate; and

a conductive layer attached to the contact portion of said foil bridge.

2. The resistor of claim 1 wherein the foil bridge is Ni/Cr.

3. The resistor of claim 1 wherein the substrate is polyimide.

4. The resistor of claim 1 wherein the conductive layer is copper plating.

5. The resistor of claim 1 further comprising a layer of film affixed between the substrate and the elevated portion of the foil bridge.

6. The resistor of claim 5 wherein the film is capton.

7. A method of manufacturing a fast heat rise resistor comprising,

affixing a layer of a film to a substrate;

applying a photoresist print and developing process to selectively remove portions of the film;

affixing a conductor plated foil to the film and the substrate; and

selectively etching away portions of the conductor plating and the foil to leave a foil trace of a certain width.

8. The method of claim 7 wherein the film is capton.

9. The method of claim 7 wherein the substrate is polyimide.

10. The method of claim 7 wherein the conductor plating is copper.

11. The method of claim 7 wherein the foil is Ni/Cr.

12. The method of claim 7 wherein the etching step further comprising:

selectively etching away portions of said conductor plating to leave a foil trace;

selectively etching away portions of said foil trace to leave a foil trace of a certain width.

14. The method of claim 13 wherein the step of positioning the explosive material adjacent to the foil resistor bridge includes positioning the explosive material between the substrate and the foil resistor bridge.

15. The method of claim 13 wherein the step of providing an explosive material further includes:

providing a first pyrotechnic material capable of creating a first explosion;

providing a second gas-generating pyrotechnic material suitable for inflating the air bag, the first explosion capable of igniting the second pyrotechnic material.

16. The method of claim 13 wherein the step of providing a foil resistor bridge includes removing a layer of film located between the substrate and the elevated portion of the foil resistor.

17. The method of claim 16 wherein the film is capton.

18. The method of claim 13 wherein the explosive material is liquid.

19. The method of claim 13 further compressing providing a layer of film between the elevated portion of the foil resistor bridge and the substrate.

20. The method of claim 19 wherein the explosive material is pressed powder.

13. A method of manufacturing vehicle air bags comprising:

providing a deflated vehicle air bag;

providing an explosive material suitable for inflating the air bag;

providing a foil resistor bridge affixed to a substrate, the bridge having an elevated portion and a contact portion, the elevated portion being located adjacent the substrate, the contact portion being in contact with the substrate;

positioning the explosive material adjacent to the foil resistor bridge;

providing a foil resistor bridge affixed to a substrate, the bridge having an elevated portion and a contact portion, said elevated portion above the substrate, said contact portion in contact with said substrate;

positioning the explosive material adjacent to the foil resistor bridge; and

providing an electrical connection to the foil resistor bridge capable of delivering electrical energy to the foil resistor bridge.