Gas generator for multi-stage air bag and air bag device

• US 6,722,694 B1
• Filed: 09/25/2000
• Issued: 04/20/2004
• Est. Priority Date: 02/16/1999
• Status: Expired due to Term

• Current Assignee: Daicel Chemical Industries Limited (Daicel Corporation)
• Original Assignee: Daicel Chemical Industries Limited (Daicel Corporation)
• Inventors: Ohji, Nobuyuki, Katsuda, Nobuyuki, Nakashima, Yoshihiro
• Primary Examiner(s): Morris, Lesley D.
• Assistant Examiner(s): LUM VANNUCCI, LEE SIN YEE
• Application Number:
  US09/601,238
• Time in Patent Office: 1,303 Days
• Field of Search: 280/731, 280/736, 280/741, 280/742, 439/677, 439/679, 439/680
• US Class Current: 280/736
• CPC Class Codes: B01D 2279/10 for air bags, e.g. inflators therefor
• CPC Class Codes: B01D 46/24 Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
• CPC Class Codes: B01D 46/2403 characterised by the physical shape or structure of the filtering element
• CPC Class Codes: B01D 46/4218 Influencing the heat transfer which act passively, e.g. isolations, heat sinks, cooling ribs
• CPC Class Codes: B60R 2021/01006 Mounting of electrical components in vehicles
• CPC Class Codes: B60R 2021/26029 Ignitors
• CPC Class Codes: B60R 2021/26064 characterised by auto-ignition means
• CPC Class Codes: B60R 2021/2633 with a plurality of inflation levels
• CPC Class Codes: B60R 2021/2648 comprising a plurality of combustion chambers or sub-chambers
• CPC Class Codes: B60R 21/2644 using only solid reacting substances, e.g. pellets, powder

Abstract

There is provided a multistage gas generator for an air bag in which the entire size of a container is suppressed, a volume ratio of each combustion chamber can arbitrarily be adjusted. Ignition means 311 are respectively disposed in the combustion chambers 305 and 306 provided in a housing 303. At least one of the combustion chambers is provided inside an inner shell 304 disposed eccentrically with respect to the center axis of the housing 3. The respective ignition means are disposed eccentrically with respect to the center axis of the housing 3. Further, a communication hole which allows mutual communication between the combustion chambers is provided. An automatic ignition material (AIM) which is to be ignited and burnt by a transmitted heat is provided in either one of the combustion chambers. One or both of axial end surfaces of a cylindrical filter means 350 are formed as inclining end surfaces 351 which get narrower in the axial extending direction. A supporting member 353 for supporting the inclining end surfaces 351 of the filter means 350 which is expanded radially by passage of an activation gas is provided in the housing.

Claims

1. A multistage gas generator for an air bag, comprising:

a housing including a diffuser shell having a plurality of gas discharge ports formed in a circumferential outer wall thereof, and a closure shell attached to the diffuser shell;

a first combustion chamber and a second combustion chamber provided inside the housing, each of the first combustion chamber and the second combustion chamber accommodating gas generating agents which generate combustion gas that inflates the air bag;

a first ignition unit attached to the housing for directly igniting only the gas generating agent accommodated in the first combustion chamber;

a second ignition unit attached to the housing for directly igniting only the gas generating agent accommodated in the second combustion chamber;

an inner cylinder for accommodating the first ignition unit therein and having at least an open end opposing the diffuser shell; and

a lid made of an element independent from said inner cylinder and provided between the open end and the diffuser shell such that a first surface of said lid opposes the diffuser shell and a second surface thereof covers the open end, said lid being substantially flat and having no opening at least in a portion thereof where the lid covers the open end,

wherein, said inner cylinder is provided eccentrically with respect to a center axis of said housing, and the first ignition unit and the second ignition unit are disposed in said housing eccentrically with respect to the center axis of said housing.

2. A multistage gas generator for an air bag according to claim 1, wherein the first ignition unit and the second ignition unit include a first igniter and a second igniter, respectively, that are actuated by an electric signal, the first igniter and the second igniter are provided inside said housing such that an axis of the first igniter and an axis of the second igniter are parallel to the center axis.

3. A multistage gas generator for an air bag according to claim 2, wherein the first igniter and the second igniter include a first lead wire and a second lead wire, respectively for transmitting the electric signal to the first igniter and the second igniter, and the first lead wire and the second lead wire extends in the same direction.

4. A gas multistage generator for an air bag according to claim 2, wherein the first igniter and the second igniter include a first connecting portion and a second connecting portion for connecting a first connector and a second connector disposed on a tip end of a first lead wire and a second lead wire, respectively, and the first connecting portion and the second connecting portion are provided with a defining unit for selectively receiving the first connector and the second connector, respectively.

5. A multistage gas generator for an air bag according to claim 4, wherein the first connector and the first igniter, and the second connector and the second igniter respectively include conductive portions for selectively contacting the first connector to the first igniter, and the second connector to the second igniter, and the defining unit is at least one of a shape, a number, and a position of the conductive portions which are formed differently from each other.

6. A multistage gas generator for an air bag according to claim 4, wherein the defining unit is the first connector and the first connecting portion is formed into such a shape that the first connector fits with the first connecting portion.

7. A multistage gas generator for an air bag according to claim 4, wherein the defining unit is one of a groove, and a projection formed in the first connecting portion and the second connecting portion such that at least one of a position and a shape of the defining unit provided in the first connecting portion and the second connecting portion are different from each other.

8. A multistage gas generator for an air bag according to claim 2, wherein the closure shell includes a collar portion for accommodating the first igniter and the second igniter, and the first igniter and the second igniter are attached to the collar portion.

9. A multistage gas generator for an air bag according to claim 2, wherein the first igniter and the second igniter are attached to the same collar portion.

10. A multistage gas generator for an air bag according to claim 1, wherein said second combustion chamber is cylindrical in shape and is provided with an opening adapted to open by combustion of the gas generating agent provided therein.

11. A multistage gas generator for an air bag according to claim 10, wherein an outer surface of an inner shell is substantially in direct contact with the gas generating agent provided inside the first combustion chamber.

12. A multistage gas generator for an air bag according to claim 10, wherein the opening includes a plurality of holes which are covered by a breaking member prior to combustion of the gas generating agent provided in said second combustion chamber, and the holes are opened selectively by combustion of the gas generating agent in said second combustion chamber.

13. A multistage gas generator for an air bag according to claim 10, wherein said second combustion chamber is provided inside said first combustion chamber, and said first ignition unit and said second ignition unit are provided within said first combustion chamber and said second combustion chamber, respectively.

14. A multistage gas generator for an air bag according to claim 13, wherein said second combustion chamber is provided inside said first combustion chamber eccentrically with respect to the center axis of said housing.

15. A multistage gas generator for an air bag according to claim 13, wherein said second combustion chamber is joined to the closure shell by friction welding.

16. A multistage gas generator for an air bag according to claim 1, wherein said second combustion chamber is provided with an automatic ignition material (AIM) for igniting and burning the gas generating agent accommodated in the second combustion chamber by heat generated by combustion of the gas generating agent disposed in said first combustion chamber.

17. A multistage gas generator for an air bag according to claim 1, wherein an automatic ignition material (AIM) ignited and burnt by a transmitted heat is disposed in either one of said first combustion chamber and said second combustion chamber.

18. A multistage gas generator for an air bag according to claim 17, wherein gas generating agent provided within said second combustion chamber are burnt later than the gas generating agent provided within said first combustion chamber by the heat.

19. A multistage gas generator for an air bag according to claim 18, wherein the automatic ignition material burns the gas generating agent provided inside the second combustion chamber 100 milliseconds or later after said first ignition unit is actuated.

20. A multistage gas generator for an air bag according to claim 18, wherein the automatic ignition material is disposed in combination with said second ignition unit.

21. A multistage gas generator for an air bag according to any one of claims 17 to 20, wherein two combustion chambers for accommodating the gas generating agent are provided in the housing, the gas generating agent which are burnt first is accommodated in the combustion chamber as first gas generating agent, and the gas generating agent which are burnt at a delayed timing are accommodated in the combustion chamber as second gas generating agent.

22. A multistage gas generator for an air bag according to claim 1, wherein said first ignition unit includes a first igniter and a first transfer charge independently ignited and burnt by the first igniter, and the gas generating agent provided within said first combustion chamber are ignited and burnt only by flames generated by combustion of the first transfer charge.

23. A multistage gas generator for an air bag according to claim 1, wherein, said second ignition unit includes an automatic ignition material (AIM) ignited and burnt by a heat generated by combustion of the gas generating agent in the first combustion chamber.

24. A multistage gas generator for an air bag according to claim 1, wherein said housing is formed by joining the diffuser shell and the closure shell by friction welding.

25. A multistage gas generator for an air bag according to claim 1, wherein said housing includes a flange portion for mounting the gas generator to a module case, and the flange portion is formed on the closure shell.

26. A multistage gas generator for an air bag according to claim 25, wherein the flange portion includes a positioning portion for specifying at least one of a direction and a position of the gas generator for attaching to a module.

27. A multistage gas generator for an air bag according to claim 26, wherein the positioning portion is a notch portion provided in at least a portion of the flange portion.

28. A multistage gas generator for an air bag according to claim 25, wherein the flange portion includes a positioning portion for specifying at least one of a direction and a position of the closure shell to be fixed at a time of joining the diffuser shell and the closure shell by welding.

29. A multistage gas generator for an air bag according to claim 25, wherein the flange portion includes a plurality of projecting portions projected in a radial direction of said housing for attaching the gas generator to the module case, and at least one of the plurality of projecting portions is formed into an asymmetric shape with respect to a rest of the plurality of projecting portions.

30. A multistage gas generator for an air bag according to claim 1, wherein said first ignition unit includes an injecting-direction restrictor for restricting an injecting direction of flame which is generated by actuation thereof.

31. A multistage gas generator for an air bag according to claim 30, wherein the injecting-direction restrictor is a hollow container that surrounds at least a portion of the first ignition unit, and has two or more flame-transferring holes for restricting the injecting direction of the flame into a predetermined direction.

32. A multistage gas generator for an air bag according to claim 31, wherein the injecting direction of the flame is a direction along an inner surface of said housing.

33. A multistage gas generator for an air bag according to claim 1, wherein said first ignition unit and said second ignition unit have different outputs from each other.

34. A multistage gas generator for an air bag according to claim 1, wherein the ignition unit disposed in each of the respective combustion chambers include an igniter which is activated by an electric signal, a cable for transmitting the electric signal is connected to each of the igniters through a connector, and the connector includes positioning means capable of connecting the connector to only one of the igniters.

35. A multistage gas generator for an airbag according to claim 34, wherein the positioning means has a shape of the connectors which are different from one another foe each of the igniters to be connected.

36. A multistage gas generator for an air bag according to claim 34, wherein the positioning means is at least one of a groove and a projection formed on the connector such that at least one of positions and shapes thereof are different for each of the igniters to be connected.

37. A multistage gas generator for an air bag according to claim 1, further comprising:

a cylindrical filter unit for at least one of purifying and cooling an activation gas and including an inclining end surface formed at an end portion thereof to be narrower in an axial extending direction such that an interior angle with respect to an inner peripheral surface is an acute angle, and said housing is provided with a supporting member that opposes and contacts the inclining end surface.

38. A multistage gas generator for an air bag according to claim 37, wherein the supporting member is an inner peripheral surface of the housing opposed to the inclining end surface.

39. A multistage gas generator for an air bag according to claim 37, wherein

said supporting member is a filter unit supporting member disposed in the housing and said inclining end surface engages said filter unit supporting member.

40. A multistage gas generator for an air bag according to claim 37, wherein at least one end portion of the filter unit is formed with an inclining end surface, and the supporting member is provided in the axial direction of the filter unit and on a side where the inclining end surface is formed.

41. A multistage gas generator for an air bag according to claim 40, wherein

said lid is part of a retainer having an annular portion and an outer peripheral wall disposed in the housing on an axially opposite side of the inclining end surface of the filter unit, and an inner surface of the outer peripheral wall of the retainer is opposed to an outer peripheral surface of the filter unit.

42. A multistage gas generator for an air bag according to claim 37, wherein said cylindrical filter unit has a self-contracting structure that prevents the filter unit from expanding in a radial direction thereof when the filter unit is pushed against an inner surface of the housing by pressure generated by combustion of the gas generating agents to prevent the combustion gas from passing between the supporting member and the inclining end surface.

43. A multistage gas generator for an air bag according to claim 37, wherein

said lid is a portion of a retainer provided inside said housing and in contact with said cylindrical filter unit.

44. A multistage gas generator for an air bag according to claim 1, wherein the gas generating agent provided inside the first combustion chamber and said second combustion chamber are different from each other in at least one of burning rate, composition, composition ratio, shape, and amount.

45. A multistage gas generator for an air bag according to claim 1, further comprising:

a single filter unit provided inside said housing for at least one of purifying and cooling combustion gas generated by combustion of the gas generating agent disposed in said first combustion chamber and said second combustion chamber, and combustion gases generated in said first combustion chamber and said second combustion chamber pass through the single filter unit.

46. An air bag apparatus, comprising:

a gas generator for an air bag,

an impact sensor for sensing an impact to actuate the gas generator,

an air bag which is expanded by introducing thereinto gas generated by the gas generator, and

a module case for accommodating the air bag, wherein

the gas generator for the air bag is the air bag gas generator for the multistage type air bag described in claim 1 or 23.

47. A multistage air bag apparatus, comprising:

an air bag gas generator, including,

a housing including a diffuser shell having a plurality of gas discharge ports formed in a circumferential outer wall thereof, and a closure shell attached to the diffuser shell;

a first combustion chamber and a second combustion chamber provided inside said housing, each of the first combustion chamber and the second combustion chamber accommodating gas generating agents which generate combustion gas that inflates the air bag,

a first ignition unit for directly igniting only the gas generating agent accommodated in the first combustion chamber;

a second ignition unit for directly igniting only the gas generating agent accommodated in the second combustion chamber;

an inner cylinder for accommodating the first ignition unit therein and having at least an open end opposing the diffuser shell;

a lid made of an element independent from said inner cylinder and provided between the open end and the diffuser shell such that a first surface of said lid opposes the diffuser shell and a second surface thereof covers the open end, said lid being substantially flat and having no opening at least in a portion thereof where the lid covers the open end; and

a control unit including a first outputting portion and a second outputting portion for outputting activation signals to said first ignition unit and said second ignition unit through a first lead wire and a second lead wire, respectively, the first lead wire and the second lead wire including, at one end thereof, a first connector and a second connector provided with a first defining unit for selectively and electrically communicating the first outputting portion with the first connector, and the second outputting portion with the second connector,

wherein said inner cylinder is provided eccentrically with respect to a center axis of said housing, and said first ignition unit and said second ignition unit are disposed in said housing eccentrically with respect to the center axis of said housing.

48. A multistage air bag apparatus according to claim 47, wherein the first lead wire and the second lead wire include, at another end thereof, a third connector and a fourth connector, respectively, provided with a second defining unit.

49. A multistage air bag apparatus according to claim 48, wherein said first ignition unit and said second ignition unit include a first connecting portion and a second connecting portion provided with the second defining unit for selectively connecting said first ignition unit with the third connector and said second ignition unit with the fourth connector.

50. A multistage air bag apparatus according to claim 48, wherein conductive portions are provided in each of said first ignition unit, said second ignition unit, the first outputting portion, the second outputting portion, the first connector, the second connector, the third connector, and the fourth connector for conducting ignition signals outputted from the control unit to said first ignition unit and said second ignition unit.

51. A multistage air bag apparatus according to claim 50, wherein the first defining unit and the second defining unit are realized by forming differently in at least one of a shape, a number and a position of the conductive portion.

52. A multistage air bag apparatus according to claim 51, wherein the conductive portion of the connector is convex in shape or concave in shape, and is connected to the conductive portion of the connecting portion formed into one of a concave shape and convex shape.

53. A multistage air bag apparatus according to claim 48, wherein the third connector and the fourth connector are formed integrally.

54. A multistage air bag apparatus according to claim 47 or 48, wherein the first defining unit is formed on a way-connector which is provided at least one position on the lead wire which connects the igniter and the outputting portion.

55. A multistage air bag apparatus according to claim 47, wherein as many lead wires as electrical ignition type igniters are provided.

56. A multistage air bag apparatus according to claim 47, wherein the outputting portion includes a connecting portion for connecting to the connector, and the first defining unit is formed on the connecting portion of the outputting portions and the connector which connects the lead wire extending from the gas generator to the outputting portion.

57. A multistage air bag apparatus according to claim 47, wherein the way-connector includes a plug portion and a jack portion having connecting portions, the first defining unit is formed on the connecting portions of the plug portion and the jack portion of the way-connector which connects the lead wire extending from the gas generator and the lead wire extending from the outputting portion.

58. A multistage air bag apparatus according to claim 47, wherein the first connector and the second connector are formed integrally.

59. A connector for a multistage type air bag apparatus according to claim 47, wherein the first connector and the second connector are provided with the defining unit such that the defining unit permits the first outputting portion to connect only to the first igniter and permits the second outputting portion to connect only to the second igniter.

60. A multistage gas generator for an air bag, comprising:

a housing including a diffuser shell having a plurality of gas discharge ports formed in a circumferential outer wall thereof, and a closure shell attached to the diffuser shell;

a first combustion chamber and a second combustion chamber provided inside the housing, each of the first combustion chamber and the second combustion chamber accommodating gas generating agents which generate combustion gas that inflates the air bag;

a first ignition unit attached to the housing for directly igniting only a gas generating agent accommodated in the first combustion chamber;

a second ignition unit attached to the housing for directly igniting only a gas generating agent accommodated in the second combustion chamber;

an inner cylinder for accommodating the first ignition unit therein and having at least an open end opposing the diffuser shell;

a single retainer provided with a bent portion bent in an axial direction of said housing, and disposed inside the first combustion chamber such that the bent portion is in engagement with an outer circumferential surface of said inner cylinder; and

a cylindrical filter unit for at least one of purifying and cooling an activation gas and including an inclining end surface formed at an end portion thereof to be narrower in an axial extending direction such that an interior angle with respect to an inner peripheral surface is an acute angle, and said housing is provided with a supporting member that opposes and contacts the inclining end surface,

wherein said inner cylinder is provided eccentrically with respect to a center axis of said housing, and the first ignition unit and the second ignition unit are disposed in said housing eccentrically with respect to the center axis of said housing, and

wherein said cylindrical filter unit is provided with an inclining end surface at both ends thereof.

61. A multistage gas generator for an air bag, according to claim 60, wherein the bent portion of the single retainer engages with an outer circumferential surface of said inner cylinder.

62. A method of manufacturing a multistage gas generator for an air bag, comprising:

providing a cylindrical housing including a diffuser shell provided with a plurality of gas discharge ports formed in a circumferential outer wall thereof, and a closure shell;

providing, within the housing, a first combustion chamber and a second combustion chamber, each of the first combustion chamber and the second combustion chamber accommodating gas generating agents which generate combustion gas that inflates the air bag;

providing, within the housing, a coolant for at least one of cooling and filtering combustion gas generated upon combustion of the gas generating agents;

providing first ignition means for directly igniting and burning only the gas generating agent accommodated in the first combustion chamber;

providing second ignition means for directly igniting and burning only the gas generating agent accommodated in the second combustion chamber;

providing, within the housing, a cylindrical member for accommodating the first ignition means therein, and having at least an open end opposing the diffuser shell;

providing, within the housing, a single retainer having a bent portion bent in an axial direction of said housing, and disposed inside the first combustion chamber such that the bent portion is in engagement with an outer circumferential surface of said cylindrical member;

providing a lid, made of an element independent from said inner cylinder, between the open end and the diffuser shell such that a first surface of said lid opposes the diffuser shell and a second surface thereof covers the open end, said lid being substantially flat and having no opening at least in a portion thereof where the lid covers the open end; and

attaching the closure shell to the diffuser shell by friction welding.

63. The method of claim 62, further comprising:

providing a coolant inside the first combustion chamber; and

providing, inside the housing, a retainer between the diffuser shell and the open end of the inner shell, the retainer being adapted to contact the coolant to retain the coolant at a predetermined position.

64. A multistage gas generator for an air bag, according to claim 62, wherein the bent portion of the single retainer engages with an outer circumferential surface of said inner cylinder.

65. The method of manufacturing a multistage gas generator for an air bag according to claim 62, further comprising:

welding the inner shell to the closure shell by friction welding while the inner shell is provided eccentrically with respect to a center axis of the housing.

66. The method of manufacturing a multistage gas generator for an air bag according to claim 62, further comprising:

providing the closure shell having a flange portion provided with a positioning portion for mounting the gas generator to a module case,

wherein the step of welding the diffuser shell further includes the step of,

welding the diffuser shell to the closure shell while the closure shell is fixed at a predetermined position by positioning the closure shell with the positioning portion.

67. A multistage gas generator for an air bag, comprising:

a cylindrical housing including a diffuser shell provided with a plurality of gas discharge ports and a closure shell, said cylindrical housing containing a first combustion chamber therein;

an inner shell defining a second combustion chamber therein, said inner shell being provided inside the housing such that a center axis of said inner shell is eccentric with respect to a center axis of said housing;

a first gas generating agent provided inside the first combustion chamber and in direct contact with said inner shell;

a second gas generating agent, provided inside the second combustion chamber, for generating combustion gas that inflates the air bag;

a single coolant that cools combustion gas generated by combustion of at least one of said first gas generating agent and said second gas generating agent, said single coolant being provided within said housing such that an inner circumferential surface defines a first combustion chamber;

a first ignition unit for directly igniting and burning only the first gas generating agent; and

a second ignition unit for directly igniting and burning only the second gas generating agent.

68. A multistage gas generator for an air bag, comprising:

a cylindrical housing including a diffuser shell, provided with a plurality of gas discharge ports, and a closure shell, said cylindrical housing defining a first combustion chamber therein;

an inner shell defining a second combustion chamber therein, said inner shell being provided inside said housing such that a center axis of said inner shell is eccentric with respect to a center axis of said housing;

a first gas generating agent provided inside the first combustion chamber;

a second gas generating agent, provided inside the second combustion chamber, for generating combustion gas that inflates the air bag;

a first igniter provided inside the first combustion chamber;

a second igniter provided inside the second combustion chamber;

a transfer charge provided inside the first combustion chamber to be ignited by said first igniter and for igniting said first gas generating agent, said transfer charge generating a combustion product;

an inner cylinder provided within the first combustion chamber for accommodating said transfer charge therein, a center axis of said inner cylinder being eccentric with respect to the center axis of said housing and having a plurality of flame transferring holes provided in equal intervals for evenly distributing the combustion product, generated in said inner cylinder, into the first combustion chamber except in directions along an imaginary line that intersects with a center axis of the inner cylinder and the center axis of said housing for evenly igniting the first gas generating agent.

70. A multistage gas generator for an air bag according to claim 68, wherein said injecting-direction restricting means is a plurality of ports formed in the inner cylinder for discharging the combustion product towards the center axis of the housing.

71. A multistage gas generator for an air bag according to claim 68, wherein said injecting-direction restricting means is a deflector plate for deflecting combustion product towards the center axis of the housing.

72. A multistage gas generator according to claim 68, wherein the plurality of flame transferring holes distribute the combustion product into the first combustion chamber except in directions along an imaginary line that intersects with a center axis of the inner cylinder and the center axis of said housing.

69. A multistage gas generator for an air bag, comprising:

a housing including a diffuser shell having a plurality of gas discharge ports formed in a circumferential outer wall thereof, and a closure shell attached to the diffuser shell;

a first combustion chamber and a second combustion chamber provided inside the housing, each of the first combustion chamber and the second combustion chamber accommodating gas generating agents which generate combustion gas that inflates the air bag;

first ignition means attached to the housing for directly igniting only the gas generating agent accommodated in the first combustion chamber;

second ignition means attached to the housing for directly igniting only the gas generating agent accommodated in the second combustion chamber;

an inner cylinder including a circumferential wall and accommodating the second ignition means therein, the circumferential wall having an opening portion; and

a shielding plate disposed outside the inner cylinder and opposing and spaced apart from the opening portion, the shielding plate preventing a combustion flame, generated in the combustion chamber provided outside the inner cylinder, from coming into direct contact with the opening portion.