Gas generation system

• US 7,188,567 B1
• Filed: 11/10/2000
• Issued: 03/13/2007
• Est. Priority Date: 11/12/1999
• Status: Expired due to Fees

• Current Assignee: Zodiac Automotive US, Inc.
• Original Assignee: Zodiac Automotive US, Inc.
• Inventors: Holland, Gary F., Wilson, Michael A., Gregg, Gary S., Italiane, John R., Nguyen, Andrew C., Styner, James M.
• Primary Examiner(s): CLEMENT, MICHELLE RENEE
• Application Number:
  US10/130,191
• Time in Patent Office: 2,314 Days
• Field of Search: 102/530, 102/367, 280/736, 280/741, 149/47
• US Class Current: 102/530
• CPC Class Codes: B60R 2021/2633 with a plurality of inflation levels
• CPC Class Codes: B60R 21/264 using instantaneous generation of gas, e.g. pyrotechnic B60R21/268 takes precedence
• CPC Class Codes: C06D 5/06 by reaction of two or more solids

Abstract

A gas generator (24; 140) may be used in an inflatable member system (20) which includes an inflatable member (22) expandable from a stowed condition to a deployed condition. The generator may include a flexible container (30; 150) within the inflatable member, a gas generant (28; 148), initially located within the flexible container, and an initiator (34). A propagating member (60; 142) may be located within the container to permit the initiator to initiate the generant upon triggering of the initiator to inflate the inflatable member from stowed to deployed conditions. A sustainer (44; 152; 156) may be provided to sustain the gas generation and may be positioned within a generator housing upstream of the propagating member or at or adjacent the downstream end of the propagating member.

Claims

1. An inflatable member system, comprising:

an inflatable member expandable from a stowed condition to a deployed condition;

a gas generant, initially located within the inflatable member; and

an initiator;

a housing having upstream and downstream ends and an interior space and wherein the initiator is mounted in the upstream housing end; and

a sustainer gas generant initially positioned within the housing;

wherein;

the initiator is positioned to, upon triggering, cause ignition of the gas generant so that the gas generant combusts over a first time interval so as to generate inflation gas in a sufficient amount to substantially fully inflate the inflatable member from the stowed condition to the deployed condition in which the inflatable member contains a first volume of inflation gas; and

the initiator is positioned to, upon triggering, cause ignition of the sustainer gas generant so that the sustainer gas generant combusts over a second time interval, ending after an end of the first time interval, so as to generate sustainer gas in a sufficient amount to substantially maintain the inflatable member in the deployed condition containing approximately the first volume of inflation gas.

2. The inflatable member system of claim 1 wherein:

the first interval has a length of less than 0.030 seconds;

the second interval has a length of at least 0.150 seconds.

3. The inflatable member system of claim 1 further comprising:

a flexible container within the inflatable member, wherein the gas generant is initially located within the flexible container; and

a conduit at least partially within the flexible container, the conduit having a sidewall extending from a proximal end proximate the initiator to a distal end and separating a conduit interior from a conduit exterior, the sidewall having a plurality of apertures and the gas generant located substantially external to the conduit;

wherein;

the initiator is positioned to, upon triggering, cause a flame front to migrate from the proximal end toward the distal end;

the plurality of apertures are positioned and have sufficient size to permit the flame front to communicate through each aperture from the conduit interior to the conduit exterior so as to ignite a portion of the gas generant proximate such aperture and cause a distributed ignition of said gas generant to generate the gas.

4. The inflatable member system of claim 1 further comprising an ignition cord extending from a proximal end coupled to the housing downstream end to a distal end and containing a charge and wherein the initiator is positioned to, upon triggering, cause ignition of the ignition cord which in turn causes combustion of the gas generant which in turn causes the inflatable member to inflate from the stowed condition to the deployed condition.

5. The inflatable member system of claim 1 wherein said gas generant includes comparatively large particles of a coolant compound intermixed with a finely divided powdered fuel/oxidizer solid propellant composite in order to effect lower bulk average gas temperatures.

6. The inflatable member system of claim 5 wherein said coolant effectively absorbs heat by a process selected from the group consisting of endothermic phase transition and decomposition.

7. The inflatable member system of claim 6 wherein said coolant is selected from the group consisting of magnesium carbonate, magnesite, aluminum hydroxide, magnesium hydroxide, hydroxides of lanthanide elements, boric acid, carbonates of the alkali metal elements and carbonates of the alkaline earth elements.

8. The inflatable member system of claim 7 wherein said coolant is magnesium carbonate.

9. The inflatable member system of claim 7 wherein the mass of said coolant is from 5% to 200%, by weight, of the mass of the propellant composite.

10. The inflatable member system of claim 9 wherein said gas generant contains, by weight, about 50% of granular magnesium carbonate and 50% of said propellant composite.

11. The inflatable member system of claim 10 wherein said propellant composite burns rapidly at ambient pressure conditions.

12. A method for deploying an inflatable member (22) from a stowed condition to a deployed condition, comprising:

providing a gas generant (148), initially located within a flexible container within the inflatable member; and

providing an initiator (34);

providing a conduit (142) at least partially within the flexible container, the conduit having a sidewall extending from a proximal end proximate the initiator to a distal end and separating a conduit interior from a conduit exterior, the sidewall having a plurality of apertures (146) and the gas generant substantially external to the conduit;

triggering the initiator to cause a flame front to migrate from the proximal end toward the distal end;

permitting the flame front to communicate through each aperture from the conduit interior to the conduit exterior so as to ignite a portion of the gas generant proximate such aperture and cause a distributed ignition of said gas generant to generate gas;

permitting the generated gas to substantially inflate the inflatable member from the stowed condition the deployed condition.

13. The method of claim 12 wherein the gas generant substantially combusts over a first time interval and the method further comprises:

providing a sustainer gas generant (152;

156), initially positioned within the conduit or upstream thereof, the sustainer gas generant having a burn rate effective to combust during a second time interval upon ignition, the second time interval being longer than the first time interval and extending beyond the first time interval so that combustion of the sustainer gas generant maintains the inflatable member in the deployed condition after the end of the first interval.

14. A gas generator comprising:

an initiator;

a housing having upstream and downstream ends and an interior space and wherein the initiator is mounted in the upstream housing end;

a gas generant, a major portion of which is located external to the housing; and

a sustainer gas generant initially positioned within the housing;

wherein;

the initiator is positioned to, upon triggering, cause ignition of the gas generant so that the gas generant combusts over a first time interval so as to generate a first gas; and

the initiator is positioned to, upon triggering, cause ignition of the sustainer gas generant so that the sustainer gas generant combusts over a second time interval, ending after an end of the first time interval, so as to generate sustainer gas in a sufficient amount to substantially maintain the inflatable member in the deployed condition.

15. The gas generator of claim 14 wherein:

the first interval has a length of less than 0.030 seconds; and

the second interval has a length of at least 0.150 seconds.

16. The gas generator of claim 14 wherein the sustainer gas generant is formed as at least one annulus positioned coaxially with the initiator.

17. The gas generator of claim 16 wherein the sustainer gas generant comprises a single extruded sustainer tube.

18. The gas generator of claim 14 further comprising an ignition propagating member extending from an upstream end within the housing to a downstream end external to the housing and wherein the sustainer gas generant is formed as at least one annulus having a common centerline with the ignition propagating member.

19. The gas generator of claim 18 wherein the propagating member is a rapid deflagrating cord having a sheath and a pyrotechnic charge contained within the sheath.

20. The gas generator of claim 19 further comprising a tube containing the gas generant and having a proximal end secured to the housing.

21. An inflatable member systems, comprising:

an inflatable member expandable from a stowed condition to a deployed condition;

a flexible container within the inflatable member;

a gas generant, initially located within the flexible container; and

an initiator;

characterized in that;

an elongate ignition propagating member, at least partially within the flexible container, extends from a proximal end to a distal end of the flexible container;

the gas generant is located external to the ignition propagating member;

the initiator is positioned to, upon triggering, cause a flame front to migrate from the proximal end toward the distal end; and

the inflation gas generated by combustion of the gas generant is of sufficient amount to substantially inflate the inflatable member from the stowed condition to the deployed condition.

22. The inflatable member system of claim 21 wherein:

the ignition propagating member (142) comprises a conduit having a sidewall extending from the proximal end proximate the initiator to the distal end and separating a conduit interior from a conduit exterior, the sidewall having a plurality of apertures (146); and

the plurality of apertures are positioned and have sufficient size to permit the flame front to communicate through each aperture from the conduit interior to the conduit exterior so as to ignite a portion of the gas generant proximate such aperture and cause a distributed ignition of said gas generant to generate inflation gas.

23. The inflatable member system of claim 22 wherein said conduit is at least one of flexible and formable.

24. The inflatable member system of claim 22 wherein said flexible container comprises at least one layer of polymer film.

25. The inflatable member system of claim 22 wherein:

said gas generant has a burn rate effective to combust during a first time interval upon ignition;

the migration of the flame front defines a downstream direction;

a sustainer gas generant (152;

156) is initially positioned within the conduit or upstream thereof, the sustainer gas generant having a burn rate effective to combust during a second time interval upon ignition, the second time interval being longer than the first time interval and extending beyond the first time interval so that combustion of the sustainer gas generant maintains the inflatable member in the deployed condition after the end of the first interval.

26. The inflatable member system of claim 25 further comprising:

a housing (144) having upstream and downstream ends and an interior space and wherein the initiator (34) is mounted in the upstream housing end and the conduit proximal end is mounted in the downstream housing end and wherein the sustainer gas generant (152) is initially positioned within the housing.

27. The inflatable member system of claim 26 wherein the sustainer gas generant (152) is initially positioned on a lateral interior surface of the housing (144) surrounding a space between the initiator and the conduit.

28. The inflatable member system of claim 25 wherein the sustainer gas generant (156) is located in a distal end portion of the conduit.

29. The inflatable member system of claim 25 wherein the sustainer gas generant generates an amount of gas one to ten times the molar amount of inflation gas.

30. The inflatable member system of claim 21 wherein the ignition propagating member comprises an ignition cord having a charge within a sheathe.

31. The inflatable member system of claim 30 further characterized by a sustainer gas generant initially positioned within the distal end portion of the flexible container or upstream thereof, the sustainer gas generant having a burn rate effective to combust during a second time interval upon ignition, the second time interval being longer than the first time interval and extending beyond the first time interval so that combustion of the sustainer gas generant maintains the inflatable member in the deployed condition after the end of the first interval.

32. A gas generating system, comprising:

a flexible container (150);

a gas generant (148), initially located within the flexible container; and

an initiator (34);

characterized in that;

a conduit (142) is at least partially within the flexible container, the conduit having a sidewall extending from a proximal end (142A) proximate the initiator to a distal end (142B) and separating a conduit interior from a conduit exterior, the sidewall has a plurality of apertures (146) and the gas generant is located substantially external to the conduit;

the initiator is positioned to, upon triggering, cause a flame front to migrate from the proximal end toward the distal end; and

the plurality of apertures are positioned and having sufficient size to permit the flame front to communicate through each aperture from the conduit interior to the conduit exterior so as to ignite a portion of the gas generant proximate such aperture and cause a distributed ignition of said gas generant to generate gas.

33. An inflatable member system comprising:

a. an inflatable member expandable by gas to a substantially fully-inflated volume V;

b. means, comprising a primary gas generant initially located within the inflatable member, for rapidly inflating the inflatable member to volume V;

c. means, comprising a sustainer gas generant, for sustaining inflation of the inflatable member at substantially volume V for a period of time longer than is sustainable through use of the primary gas generant alone; and

d. means for igniting the primary gas generant and the sustainer gas generant.

34. An inflatable member system comprising:

a. an inflatable member expandable by gas to a substantially fully-inflated volume V;

b. a primary gas generant initially located within the inflatable member, for rapidly inflating the inflatable member to volume V;

c. an elongated flexible member (i) containing the primary gas generant and (ii) having (A) an upstream end and (B) a closed downstream end;

d. an elongated housing having (i) an upstream end, (ii) a downstream end coupled to the upstream end of the elongated flexible member, and (iii) a shoulder proximate the downstream end;

e. a sustainer gas generant contained within the elongated housing, for sustaining inflation of the inflatable member at substantially volume V for a period of time longer than is sustainable through use of the primary gas generant alone;

f. means, comprising an initiator, for igniting (i) the primary gas generant so that it combusts over a first time interval so as to generate inflation gas in a sufficient amount to inflate the inflatable member to volume V and (ii) the sustainer gas generant so that it combusts over a second time interval, ending after the first time interval, so as to generate sustainer gas in a sufficient amount to maintain inflation of the inflatable member at approximately volume V;

g. an end plug (i) positioned within the elongated housing adjacent the upstream end and (ii) carrying the initiator;

h. means, comprising (i) a first annular elastomeric foam ring positioned intermediate the end plug and the sustainer gas generant and (ii) a second annular elastomeric foam ring positioned intermediate the sustainer gas generant and the shoulder, for supporting the sustainer gas generant under slight longitudinal compression;

i. a ferrule having (i) a radially-extending flange positioned between the second annular elastomeric foam ring and the shoulder and (ii) a central aperture; and

j. an elongated ignition propagating member (i) comprising a sheath and an explosive contained therein and (ii) having (A) an upstream end received by the central aperture and (B) a downstream end positioned within the elongated flexible member.