Radial flow disc inflator

• US 8,894,096 B2
• Filed: 03/15/2013
• Issued: 11/25/2014
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: Autoliv ASP Incorporated (Autoliv Incorporated)
• Original Assignee: Autoliv ASP Incorporated (Autoliv Incorporated)
• Inventors: Fischer, Christopher
• Primary Examiner(s): TO, TOAN C
• Application Number:
  US13/840,495
• Publication Number:
  US 20140265276A1
• Time in Patent Office: 620 Days
• Field of Search: 280/740, 280/741
• US Class Current: 280/741
• CPC Class Codes: B60R 2021/26011 using a filter through which the inflation gas passes
• CPC Class Codes: B60R 21/2644 using only solid reacting substances, e.g. pellets, powder
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

Air bag cushion inflators can include a body including a base member coupled to a diffuser member, the diffuser member including a sidewall with exit ports and a ceiling. A combustion chamber may be positioned within the body and includes a cap with an opening formed therein. A filter element may be positioned in fluid communication with the opening in the combustion chamber cap, and located between the combustion chamber cap and the diffuser member ceiling. The filter element includes at least one barrier and a plurality of apertures positioned to cause inflation gas from the combustion chamber to travel from the opening in the combustion chamber cap to the exit port along a tortuous path including at least one debris pocket and at least one impact region. Methods of forming a filter, and disposing the filter in an inflator body. Other aspects, embodiments, and features are also included.

Claims

1. An airbag cushion inflator, comprising:

a body comprising a base member coupled to a diffuser member, the diffuser member comprising a sidewall with an exit port formed therein and a ceiling;

a combustion chamber positioned within the body and comprising a cap with an opening formed therein;

a filter element in fluid communication with the opening in the combustion chamber cap and positioned between the combustion chamber cap and the diffuser member ceiling, the filter element including at least one barrier and a plurality of apertures positioned to cause inflation gas from the combustion chamber to travel from the opening in the combustion chamber cap to the exit port along a tortuous path including at least one debris pocket and at least one impact region.

2. The airbag cushion inflator of claim 1, wherein the filter element comprises a barrier extending between the combustion chamber cap and the ceiling of the diffuser member and encircling the opening in the combustion chamber cap, the barrier including at least one aperture.

3. The airbag cushion inflator of claim 1, wherein the filter element comprises a plurality of cylindrical barriers disposed in a coaxial relationship about the opening in the combustion chamber cap, each barrier of the plurality of barriers comprising at least one aperture forming a gas flow path therein.

4. The airbag cushion inflator of claim 3, wherein the filter element further comprises a trough positioned between at least two barriers of the plurality of barriers.

5. The airbag cushion inflator of claim 1, wherein the filter element comprises a plurality of axially offset barriers between the combustion chamber cap and the diffuser member ceiling.

6. The airbag cushion inflator of claim 5, wherein the filter element comprises:

a lower barrier with a plurality of first apertures formed at a radially outer portion thereof; and

an upper barrier with a plurality of first apertures formed in alignment with the plurality of first apertures of the lower barrier, and a second aperture formed at a radially inward portion thereof.

7. The airbag cushion inflator of claim 5, wherein the filter element comprises a lower barrier with a substantially wave-like configuration.

8. An inflatable airbag module, comprising:

an inflatable cushion; and

an inflator in fluid communication with the inflatable cushion, wherein the inflator comprises;

a base member and a diffuser member coupled together to form a body, wherein the diffuser member comprises a sidewall with an exit port formed therein and a ceiling;

a combustion chamber at least substantially enclosing a quantity of gas generant, the combustion chamber comprising a cap with an opening formed therein;

an initiator assembly coupled to the base member and disposed at least partially within the combustion chamber to be in sufficient communication with the quantity of gas generant to initiate a reaction for producing a supply of inflation gas during deployment; and

a filter element in fluid communication with the opening in the combustion chamber cap and positioned between the combustion chamber cap and the diffuser member ceiling, the filter element including at least one barrier and a plurality of apertures positioned to cause inflation gas from the combustion chamber to travel from the opening in the combustion chamber cap to the exit port along a tortuous path including at least one debris pocket and at least one impact region.

9. The inflatable airbag module of claim 8, wherein the at least one barrier comprises a cylindrical barrier encircling the opening in the combustion chamber cap and extending between the combustion chamber cap and the ceiling of the diffuser member.

10. The inflatable airbag module of claim 8, wherein the at least one barrier comprises a plurality of cylindrical barriers disposed in a coaxial relationship about the opening in the combustion chamber cap, each barrier extending between the combustion chamber cap and the ceiling of the diffuser member.

11. The inflatable airbag module of claim 10, further comprising a trough between at least two barriers of the plurality of barriers.

12. The inflatable airbag module of claim 8, wherein the at least one barrier comprises a plurality of axially offset barriers to cause inflation gas to travel from the opening in the combustion chamber cap to the exit port along a tortuous path of back-and-forth oppositely-directed gas flow passageways formed by the plurality of barriers.

13. The inflatable airbag module of claim 12, wherein the plurality of axially offset barriers comprises a lower barrier and an upper barrier.

14. The inflatable airbag module of claim 12, comprising:

a plurality of first passageways formed between a lower barrier and the combustion chamber cap, each first passageway in fluid communication with the opening in the combustion chamber cap and facilitating a radially-outward flow of inflation gas toward a respective first aperture;

a second passageway formed between an upper barrier and the ceiling of the diffuser member, the second passageway in fluid communication with each of the respective first apertures and facilitating a radially-inward flow of inflation gas from the plurality of first apertures toward a second aperture; and

a plurality of third passageways formed between the lower barrier and the upper barrier, each third passageway in fluid communication with the second aperture and facilitating a radially-outward flow of inflation gas from the second aperture.

15. A method of forming an airbag cushion inflator, the method comprising:

forming a filter comprising at least one barrier and a plurality of apertures positioned and configured to direct a flow of inflation gas along a tortuous path including at least one debris pocket and at least one impact region;

disposing the filter in an inflator body in fluid communication with an opening in a combustion chamber cap, and between the combustion chamber cap and a diffuser member ceiling; and

wherein forming the filter comprising at least one barrier and a plurality of apertures positioned and configured to direct a flow of inflation gas along a tortuous path including at least one debris pocket and at least one impact region comprises;

forming the filter comprising a cylindrical barrier configured to encircle the opening in the combustion chamber cap, and sized to extend between the combustion chamber cap and the diffuser member ceiling.

16. The method of claim 15, wherein forming the filter comprising at least one barrier and a plurality of apertures positioned and configured to direct a flow of inflation gas along a tortuous path including at least one debris pocket and at least one impact region comprises:

forming the filter comprising a plurality of cylindrical barriers disposed in a coaxial relationship and configured to encircle the opening in the combustion chamber cap, wherein each barrier is sized to extend between the combustion chamber cap and the diffuser member ceiling.

17. The method of claim 16, further comprising:

forming a trough between at least two barriers of the plurality of barriers.

18. The method of claim 15, wherein forming the filter comprising at least one barrier and a plurality of apertures positioned and configured to direct a flow of inflation gas along a tortuous path including at least one debris pocket and at least one impact region comprises:

forming the filter comprising a lower barrier and an axially offset upper barrier, wherein the lower barrier and the upper barrier are configured to be positioned between the combustion chamber cap and the diffuser member ceiling.

19. The method of claim 18, wherein forming the filter comprising the lower barrier and the axially offset upper barrier comprises:

forming a plurality of first passageways configured to be positioned in fluid communication with the opening in the combustion chamber cap, and configured to facilitate a radially-outward flow of inflation gas toward a respective first aperture formed through the lower barrier and through the upper barrier;

forming a second passageway in fluid communication with each of the respective first apertures and configured to facilitate a radially-inward flow of inflation gas from the plurality of first apertures toward a second aperture formed in the upper barrier; and

forming a plurality of third passageways between the lower barrier and the upper barrier, each third passageway in fluid communication with the second aperture and configured to facilitate a radially-outward flow of inflation gas from the second aperture.