Peroxide linear inflator

• US 20050104349A1
• Filed: 11/17/2004
• Published: 05/19/2005
• Est. Priority Date: 11/18/2003
• Status: Active Grant

• Current Assignee: Automotive Systems Laboratory, Incorporated (Ningbo Junsheng Investment Group Co., Ltd.)
• Original Assignee: Automotive Systems Laboratory, Incorporated (Ningbo Junsheng Investment Group Co., Ltd.)
• Inventors: Williams, Graylon K., Stevens, Bruce A.
• Granted Patent: US 7,243,946 B2
• Time in Patent Office: Days
• US Class Current: 280/741
• CPC Class Codes: B60R 2021/2725 using a fluid fuel gas generator
• CPC Class Codes: B60R 21/272 with means for increasing the pressure of the gas just before or during liberation, e.g. hybrid inflators

Abstract

An inflator (10) comprising a housing (12) having an interior and a plurality of gas exit orifices (14) formed therealong. A gas source material (20) is positioned in the housing interior and is enclosed in a pliable, rupturable substantially gas-and-moisture-impermeable container (24). The gas source (20) is a material (for example, hydrogen peroxide) adapted to undergo decomposition to form at least one gaseous decomposition product comprising an inflation gas. A reactant material (22) is also positioned in the interior of the housing (12). The reactant (22) is a material (such as a catalyst) adapted to react with the gas source material to produce decomposition of the gas source material (20). An enclosure (28) is positioned within the housing (12) to form a cavity (30) between an outer wall of the housing (12) and the enclosure (28). The reactant material (22) is positioned in the cavity (30). A plurality of orifices (34) formed along the enclosure (28) enables fluid communication between the interior of the enclosure (28) and the cavity (30). The container (24) is positioned in the enclosure (28). A resilient, expandable bladder (42) is also positioned in the enclosure (28). A propellant (44) is provided within the bladder (42) for generation of combustion gases upon ignition of the propellant (44), to produce expansion of the bladder (42). Upon ignition of the propellant (44), combustion gases expand the bladder (42), forcing a portion of the container (24) into the enclosure orifices (34), thereby stressing and rupturing the portions of the container (24) in the orifices (34) and releasing the hydrogen peroxide (20) to flow through the orifices (34) into the cavity (30), where it reacts with the catalyst (22) to produce inflation gas.

Claims

1. An inflator comprising:

a housing having an interior and a plurality of orifices formed therealong to enable fluid communication between the interior of the housing and an exterior of the housing;

an amount of a gas source material positioned in the interior of the housing, the gas source material being formulated to undergo decomposition to form decomposition products including at least one gaseous decomposition product comprising an inflation gas;

an amount of a reactant material positioned in the interior of the housing in fluid isolation from the gas source material, the reactant material being selected to react with the gas source material to produce decomposition of the gas source material, the gas source material contained in a rupturable substantially container, the reactant material communicating with the gas source material upon rupture of the rupturable container; and

a mechanism for producing rupture of the container to enable fluid communication between the gas source material and the reactant material.

2. The inflator of claim 1 wherein the gas source material comprises liquid hydrogen peroxide.

3. The inflator of claim 2 wherein the reactant material comprises a catalyst selected from the group consisting of manganate and cupric oxide;

silver;

manganate;

potassium permanganate;

potassium permanganate and alumina beads; and

mixtures thereof.

4. The inflator of claim 1 wherein a filter is positioned intermediate the interior of the housing and the plurality of housing orifices for filtering the inflation gas.

5. The inflator of claim 1 further comprising an enclosure positioned within the housing to form a cavity between an outer wall of the housing and the enclosure, the enclosure having an interior and a plurality of orifices formed therealong to enable fluid communication between the interior of the enclosure and the interior of the housing, and wherein the container is positioned in the interior of the enclosure.

6. The inflator of claim 5 wherein the enclosure is formed from a porous material.

7. The inflator of claim 5 wherein the enclosure is substantially coextensive with the housing.

8. The inflator of claim 5 wherein the mechanism for producing rupture of the container forces a portion of the container into at least one orifice of the plurality of enclosure orifices, thereby stressing and rupturing the portion of the container in the at least one orifice and releasing contents of the container to flow through the orifice into the cavity.

9. The inflator of claim 8 wherein the mechanism for producing rupture of the container includes a resilient, expandable bladder positioned in the interior of the enclosure in communication with the container such that, upon expansion, the bladder contacts the container to force a portion of the container into the at least one orifice of the plurality of enclosure orifices, thereby stressing and rupturing the portion of the container in the at least one orifice.

10. The inflator of claim 9 wherein the mechanism for producing rupture of the container further comprises a propellant provided within the bladder for generation of combustion gases upon ignition of the propellant, to produce expansion of the bladder, and an ignition source for igniting the propellant.

11. The inflator of claim 10 wherein the propellant comprises a compound of silicone and potassium perchlorate.

12. The inflator of claim 11 wherein the propellant comprises silicone as a fuel in a concentration of about 10-25% by weight;

a perchlorate oxidizer such as ammonium, lithium, or potassium perchlorate; and

a strontium salt such as strontium nitrate or strontium carbonate as a coolant.

13. The inflator of claim 9 wherein the ignition source comprises an electric match.

14. The inflator of claim 9 wherein the bladder is substantially coextensive with the housing

15. The inflator of claim 9 wherein the bladder is formed from a rubber compound.

16. The inflator of claim 9 wherein the mechanism for producing rupture of the container further comprises a compressed fluid source for providing an expandable fluid to the bladder to expand the bladder upon activation of the inflator.

17. The inflator of claim 9 wherein an interior wall of the bladder is coated with propellant.

18. The inflator of claim 1 wherein the container comprises a bag formed from a polyester film.

19. The inflator of claim 18, wherein the polyester film is a Mylar®

compound.

20. The inflator of claim 1 wherein the gas source material is enclosed in the container.

21. The inflator of claim 1 wherein the reactant material is enclosed in the container.

22. The inflator of claim 1 wherein the container is substantially coextensive with the housing.

23. The inflator of claim 1 wherein the container comprises a first layer and a second layer joined to the first layer along at least one seam to provide at least one hermetically sealed compartment between the layers.

24. The inflator of claim 23 wherein the second layer is joined to the first layer along a plurality of intersecting seams to provide a plurality of hermetically sealed compartments between the layers.

25. The inflator of claim 24 wherein each compartment of the plurality of compartments has a substantially equal amount of gas source material container therein.

26. The inflator of claim 23 wherein a first ultimate load is required to produce rupture of the first layer and a second ultimate load is required to produce rupture of the second layer, and wherein the second ultimate load is greater than the first ultimate load.

27. The inflator of claim 23 wherein the first layer has a first thickness and the second layer has a second thickness, and wherein the second thickness is greater than the first thickness.

28. The inflator of claim 23 wherein the first layer and the second layer are formed from different materials.

29. The inflator of claim 1 wherein the housing is formed from a porous material.

30. An airbag system comprising:

at least one airbag; and

an inflator including;

a housing having an interior and a plurality of orifices formed therealong to enable fluid communication between an interior of the housing and an exterior of the housing;

an amount of a gas source material positioned in the interior of the housing, the gas source material being adapted to undergo decomposition to form decomposition products including at least one gaseous decomposition product comprising an inflation gas;

an amount of a reactant material positioned in the interior of the housing in fluid isolation from the gas source material the reactant material being adapted to react with the gas source material to produce decomposition of the gas source material, the gas source material enclosed in a rupturable container, the reactant material positioned to communicate with the gas source material upon rupture of the rupturable container; and

a mechanism for producing rupture of the container to enable fluid communication between the gas source material and the reactant material.

31. The inflator of claim 30 further comprising an enclosure positioned within the housing to form a cavity between an outer wall of the housing and the enclosure, the enclosure having an interior and a plurality of orifices formed therealong to enable fluid communication between the interior of the enclosure and the interior of the housing, and wherein the container is positioned in the interior of the enclosure.

32. The inflator of claim 30 wherein the mechanism for producing rupture of the container forces a portion of the container into at least one orifice of the plurality of enclosure orifices, thereby stressing and rupturing the portion of the container in the at least one orifice and releasing contents of the container to flow through the orifice into the interior of the housing.

33. The inflator of claim 32 wherein the mechanism for producing rupture of the container includes a resilient, expandable bladder positioned in the interior of the enclosure in communication with the container such that, upon expansion, the bladder contacts the container to force a portion of the container into the at least one orifice of the plurality of enclosure orifices, thereby stressing and rupturing the portion of the container in the at least one orifice.

34. The inflator of claim 33 wherein the mechanism for producing rupture of the container further comprises a propellant provided within the bladder for generation of combustion gases upon ignition of the propellant, to produce expansion of the bladder, and an ignition source for igniting the propellant.

35. The inflator of claim 34 wherein the ignition source comprises an electric match.

36. A vehicle occupant restraint system comprising:

a safety belt assembly including a housing and a safety belt extending from the housing, and an airbag system comprising at least one airbag and an airbag inflator including;

a housing having an interior and a plurality of orifices formed therealong to enable fluid communication between an interior of the housing and an exterior of the housing;

an amount of a gas source material positioned in the interior of the housing, the gas source material being adapted to undergo decomposition to form decomposition products including at least one gaseous decomposition product comprising an inflation gas;

an amount of a reactant material positioned in the interior of the housing in fluid isolation from the gas source material the reactant material being adapted to react with the gas source material to produce decomposition of the gas source material, one of the gas source material and the reactant material being enclosed in a pliable, rupturable substantially gas-and-moisture-impermeable container, the other one of the gas source material and the reactant material being in communication with the rupturable container; and

a mechanism for producing rupture of the container to enable fluid communication between the gas source material and the reactant material.

37. The inflator of claim 36 further comprising an enclosure positioned within the housing to form a cavity between an outer wall of the housing and the enclosure, the enclosure having an interior and a plurality of orifices formed therealong to enable fluid communication between the interior of the enclosure and the interior of the housing, and wherein the container is positioned in the interior of the enclosure.

38. The inflator of claim 37 wherein the mechanism for producing rupture of the container forces a portion of the container into at least one orifice of the plurality of enclosure orifices, thereby stressing and rupturing the portion of the container in the at least one orifice and releasing contents of the container to flow through the orifice into the interior of the housing.

39. The inflator of claim 38 wherein the mechanism for producing rupture of the container includes a resilient, expandable bladder positioned in the interior of the enclosure in communication with the container such that, upon expansion, the bladder contacts the container to force a portion of the container into the at least one orifice of the plurality of enclosure orifices, thereby stressing and rupturing the portion of the container in the at least one orifice.

40. The inflator of claim 39 wherein the mechanism for producing rupture of the container further comprises a propellant provided within the bladder for generation of combustion gases upon ignition of the propellant, to produce expansion of the bladder, and an ignition source for igniting the propellant.

41. The inflator of claim 40 wherein the ignition source comprises an electric match.

42. A method for generating inflation gas for a vehicle occupant restraint system, comprising the steps of:

providing a housing having an interior and a plurality of orifices formed therealong to enable fluid communication between an interior of the housing and an exterior of the housing;

positioning an amount of a gas source material in the interior of the housing, the gas source material being adapted to undergo decomposition to form decomposition products including at least one gaseous decomposition product comprising an inflation gas;

positioning an amount of a reactant material in the interior of the housing in fluid isolation from the gas source material the reactant material being adapted to react with the gas source material to produce decomposition of the gas source material, one of the gas source material and the reactant material being enclosed in a pliable, rupturable substantially gas-and-moisture-impermeable container, the other one of the gas source material and the reactant material being in communication with the rupturable container;

providing a mechanism for rupturing the container to enable fluid communication between the gas source material in the container and the reactant material; and

rupturing the container to provide fluid communication between the gas source material and the reactant material, thereby producing decomposition of the gas source material and formation of an inflation gas.

43. The method of claim 42 wherein the step of providing an amount of a gas source material comprises providing an amount of gas source material sufficient to generate the inflation gas at a rate sufficient to inflate, at a predetermined inflation rate, an inflatable element of a vehicle occupant restraint system having a predetermined volume, upon reaction with the reactant composition.

44. The method of claim 42 wherein the step of providing an amount of a gas source material comprises gas source material comprises providing an amount of liquid hydrogen peroxide

45. The method of claim 42 wherein the step of providing an amount of a reactant material comprises providing a catalyst selected from the group consisting of manganate and cupric oxide;

silver;

manganate;

potassium permanganate;

potassium permanganate and alumina beads; and

mixtures thereof

46. The method of claim 42 further comprising the step of providing a filter positioned intermediate the interior of the housing and the plurality of housing orifices for filtering the inflation gas.

47. The method of claim 42 further comprising the steps of:

providing an enclosure positioned within the housing to form a cavity between an outer wall of the housing and the enclosure, the enclosure having an interior and a plurality of orifices formed therealong to enable fluid communication between the interior of the enclosure and the cavity; and

positioning the container in the interior of the enclosure.

48. The method of claim 47 wherein the step of providing a mechanism for rupturing the container comprises providing a mechanism for forcing a portion of the container into at least one orifice of the plurality of enclosure orifices, thereby stressing and rupturing the portion of the container in the at least one orifice and releasing contents of the container to flow through the orifice into the interior of the housing.

49. The method of claim 48 wherein the step of providing a mechanism for forcing a portion of the container into at least one orifice of the plurality of enclosure orifices comprises providing a resilient, expandable bladder positioned in the interior of the enclosure in communication with the container, and wherein the step of rupturing the container comprises the step of expanding the bladder so as to press against the container and force a portion of the container into the at least one orifice of the plurality of enclosure orifices, thereby stressing and rupturing the portion of the container in the at least one orifice.

50. The method of claim 49 wherein the step of providing a mechanism for forcing a portion of the container into at least one orifice of the plurality of enclosure orifices further comprises the steps of:

providing a propellant within the bladder for generation of combustion gases upon ignition of the propellant, to produce expansion of the bladder, and

providing an ignition source for igniting the propellant,

wherein the step of rupturing the container comprises the step of igniting the propellant to generate expending combustion gases, thereby producing expansion of the bladder.

51. The method of claim 49 wherein the step of providing a mechanism for forcing a portion of the container into at least one orifice of the plurality of enclosure orifices further comprises the step of providing a source of compressed fluid operatively coupled to the bladder for providing an expandable fluid to the bladder to expand the bladder upon activation of the inflator, and wherein the step of rupturing the container comprises enabling fluid communication between the source of compressed fluid and the bladder to expand the bladder.