Dual flow inflator for a vehicular airbag system
First Claim
1. An inflator for a vehicular airbag system, the inflator comprising:
- a gas chamber having a longitudinal axis, the gas chamber comprising a first exit orifice oriented to provide a first gas flow out of the gas chamber, substantially parallel to the longitudinal axis, and a second exit orifice oriented to provide a second gas flow out of the gas chamber in a direction substantially opposite the first gas flow, the first and second exit orifices each having an open configuration and a sealed configuration; and
an initiator oriented nonparallel to the longitudinal axis and disposed in communication with the gas chamber to induce the first gas flow through the first exit orifice and the second gas flow through the second exit orifice.
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Accused Products
Abstract
A dual flow inflator for airbags is disclosed, together with related manufacturing, installation, and deployment methods. The inflator may have a gas chamber with a first end with a first exit orifice and a second end with a second exit orifice. The exit orifices may be directed into inlet ports of an inflatable curtain so that inflation gases exit the inflator through the exit orifices and enter directly into the inflatable curtain. The exit orifices may provide axial gas flows in opposite directions so that each gas flow neutralizes the thrust of the other. The exit orifices may comprise frangible structures such as burst discs, scored surfaces, and compression closures. If desired, pistons may be utilized to ensure that the exit orifices are completely and simultaneously opened. Furthermore, the gas chamber may comprise a variety of configurations, including a unitary, one-piece structure, a multi-part structure with vessels attached to a tubular or spherical bulkhead, or a generally spherical shape.
55 Citations
59 Claims
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1. An inflator for a vehicular airbag system, the inflator comprising:
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a gas chamber having a longitudinal axis, the gas chamber comprising a first exit orifice oriented to provide a first gas flow out of the gas chamber, substantially parallel to the longitudinal axis, and a second exit orifice oriented to provide a second gas flow out of the gas chamber in a direction substantially opposite the first gas flow, the first and second exit orifices each having an open configuration and a sealed configuration; and
an initiator oriented nonparallel to the longitudinal axis and disposed in communication with the gas chamber to induce the first gas flow through the first exit orifice and the second gas flow through the second exit orifice. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23)
a first piston disposed generally between the initiator and the first exit orifice, the first piston moving toward the first exit orifice in response to a pressure increase initiated by the initiator to move the first exit orifice to the open configuration; and
a second piston disposed generally between the initiator and the second exit orifice, the second piston moving toward the second exit orifice in response to a pressure increase initiated by the initiator to move the second exit orifice to the open configuration.
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9. The inflator of claim 8, further comprising:
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a first puncture member disposed between the first piston and the first exit orifice such that the first piston actuates the first puncture member to impact the first exit orifice upon activation of the initiator; and
a second puncture member disposed between the second piston and the second exit orifice such that the second piston actuates the second puncture member to impact the second exit orifice upon activation of the initiator.
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10. The inflator of claim 1, further comprising a booster material positioned proximate the initiator to expedite the first and second gas flows.
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11. The inflator of claim 1, further comprising a gas-producing material that substantially provides the first and second gas flows through operation of the initiator, independent of any additional initiator.
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12. The inflator of claim 11, wherein the gas-producing material is selected to be insertable into the chamber as a cryogenic solid.
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13. The inflator of claim 11, wherein the gas-producing material comprises compressed gas.
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14. The inflator of claim 13, wherein the gas-producing material further comprises a liquid that vaporizes in response to decreasing pressure within the gas chamber to supplement the first and second gas flows.
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15. The inflator of claim 13, wherein the gas-producing material further comprises a pyrotechnic gas generant that combusts to supplement the first and second gas flows.
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16. The inflator of claim 11, wherein the gas producing material comprises a dissociating gas.
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17. The inflator of claim 11, wherein the gas-producing material comprises a pyrotechnic gas generant that combusts to provide the first and second gas flows, wherein the pyrotechnic gas generant is selected from the group consisting of gaseous generants, liquid generants, solid generants, and combinations of two or more solid, liquid, or gaseous generants.
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18. The inflator of claim 1, wherein the gas chamber is an integrally formed, unitary body.
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19. The inflator of claim 1, wherein the gas chamber comprises:
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a first vessel having an interior end with a first interior opening and an exterior end on which the first exit orifice is disposed;
a second vessel having an interior end with a second interior opening and an exterior on which the second exit orifice is disposed; and
a bulkhead with a first aperture shaped to communicate with the interior end of the first vessel and a second aperture sized to communicate with the interior end of the second vessel, the second aperture positioned opposite the first aperture.
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20. The inflator of claim 1, wherein the gas chamber comprises a first end on which the first outlet orifice is disposed and a second end on which the second outlet orifice is disposed, wherein the first end is shaped to be inserted into a first inlet port of an inflatable curtain of the vehicular airbag system, and wherein the second end is shaped to be inserted into a second inlet port of the inflatable curtain.
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21. The inflator of claim 1, wherein the first and second exit orifices are positioned to direct the first and second gas flows into an inflatable cushion of a type selected from the group consisting of a driver'"'"'s side airbag, a passenger'"'"'s side airbag, an overhead airbag, and a knee bolster.
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22. The inflator of claim 1, wherein the gas chamber comprises an elongated shape with a substantially circular cross section.
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23. The inflator of claim 1, wherein the gas chamber comprises a substantially spherical shape.
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24. An inflator for a vehicular airbag system, the inflator comprising:
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a gas chamber having a longitudinal axis, the gas chamber comprising a first end with a first exit orifice and a second end with a second exit orifice displaced from the first orifice along the longitudinal axis, the first and second exit orifices each having an open configuration and a sealed configuration;
an initiator receptacle formed separately from and attached to the gas chamber; and
an initiator seated in the initiator receptacle, displaced from the longitudinal axis, to produce heat between the first and second ends to induce a first gas flow through the first exit orifice and a second gas flow through the second exit orifice. - View Dependent Claims (25, 26)
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27. An inflator for a vehicular airbag system, the inflator comprising:
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a first vessel having an interior end with a first interior opening and an exterior end with a first exit orifice that opens in response to activation of the inflator to permit pressurized gas to escape from the first vessel;
a second vessel having an interior end with a second interior opening and an exterior end with a second exit orifice that opens in response to activation of the inflator to permit pressurized gas to escape from the second vessel;
a bulkhead with a first aperture shaped to communicate with the interior end of the first vessel and a second aperture sized to communicate with the interior end of the second vessel, the second aperture positioned opposite the first aperture; and
an initiator oriented nonparallel to a longitudinal axis extending through the first and second orifices. - View Dependent Claims (28, 29, 30, 31, 32)
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33. An inflator for a vehicular airbag system, the inflator comprising:
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a first hemispherical portion with a first exit orifice having an open configuration and a sealed configuration;
a second hemispherical portion with a second exit orifice positioned opposite the first exit orifice, the second exit orifice having an open configuration and a sealed configuration; and
an initiator oriented nonparallel to a longitudinal axis extending through the first and second orifices and disposed in communication with a cavity formed by the first and second hemispherical portions to induce a first gas flow through the first exit orifice and a second gas flow through the second exit orifice. - View Dependent Claims (34, 35, 36, 37, 38, 39, 40, 41)
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42. A method for manufacturing an inflator for a vehicular airbag system, the method comprising:
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providing a gas chamber having a first end and a second end opposite the first end;
providing an initiator receptacle;
forming a first exit orifice in the first end, the first exit orifice having a sealed configuration and an open configuration;
forming a second exit orifice in the second end, the second exit orifice having a sealed configuration and an open configuration;
providing an initiator;
attaching the initiator receptacle to the gas chamber;
installing the initiator in the initiator receptacle such that the initiator is displaced from a longitudinal axis extending through the first and second orifices to position the initiator in communication with a portion of the gas chamber between the first and second ends;
inserting gas-producing material into the gas chamber; and
sealing the chamber with the first and second exit orifices in the sealed configuration to prevent escape of the gas-producing material until the initiator has been activated. - View Dependent Claims (43, 44, 45, 46, 47, 48, 49)
a first vessel having an interior end with a first interior opening and an exterior end on which the first exit orifice is disposed;
a second vessel having an interior end with a second interior opening and an exterior on which the second exit orifice is disposed; and
a bulkhead with a first aperture shaped to communicate with the interior end of the first vessel and a second aperture sized to communicate with the interior end of the second vessel, the second aperture positioned opposite the first aperture.
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45. The method of claim 42, wherein forming the first and second exit orifices comprises forming frangible structures selected from the group consisting of burst discs, scored surfaces, and compression closures.
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46. The method of claim 45, wherein the frangible structures are burst discs, the method further comprising:
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providing two burst disc retention members; and
disposing a burst disc retention member outside each of the burst discs to prevent ejection of the burst discs from the first and second exit orifices.
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47. The method of claim 45, wherein forming frangible structures comprises providing burst discs configured to unblock the first and second exit orifices in response to pressure shock.
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48. The method of claim 42, wherein inserting the gas-producing material into the gas chamber comprises disposing the gas-producing material to substantially provide first and second gas flows through the first and second exit orifices through operation of the initiator, independent of any additional initiator.
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49. The inflator of claim 48, wherein the gas-producing material is selected to be insertable into the chamber as a cryogenic solid.
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50. A method for inflating an inflatable curtain of a vehicular airbag system, the vehicular airbag system comprising an inflator having an initiator, a first end with a first exit orifice disposed proximate a first inlet port of the inflatable curtain, and a second end with a second exit orifice disposed proximate a second inlet port of the inflatable curtain, wherein each of the first and second exit orifices have an open configuration and a sealed configuration, the method comprising:
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activating the initiator, wherein the initiator is oriented nonparallel to a longitudinal axis extending through the first and second exit orifices;
moving the first exit orifice from the sealed configuration to the open configuration to permit a first gas flow to flow into the inflatable curtain from the inflator through the first exit orifice; and
moving the second exit orifice from the sealed configuration to the open configuration to permit a second gas flow to flow into the inflatable curtain from the inflator through the second exit orifice. - View Dependent Claims (51, 52, 53, 54, 55, 56)
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57. A method for manufacturing an inflator for a vehicular airbag system, the method comprising:
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providing a gas chamber having a first hemispherical portion and a second hemispherical portion;
forming a first exit orifice in the first hemispherical portion, the first exit orifice having a sealed configuration and an open configuration;
forming a second exit orifice in the second hemispherical portion, the second exit orifice positioned opposite the first exit orifice and having a sealed configuration and an open configuration; and
attaching an initiator to one of the hemispherical portions such that the initiator is oriented nonparallel to a longitudinal axis extending through the first and second orifices. - View Dependent Claims (58, 59)
attaching the first and second hemispherical portions together to provide a substantially spherical shape.
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59. The method of claim 57, further comprising forming a mounting flange that extends outward from an equatorial region between the first and second hemispherical portions.
Specification