Inflator system

• US 6,905,135 B2
• Filed: 01/11/2002
• Issued: 06/14/2005
• Est. Priority Date: 06/07/1995
• Status: Expired due to Fees

• Current Assignee: American Vehicular Sciences LLC (Acacia Research Corporation)
• Original Assignee: Automotive Technologies International Incorporated
• Inventors: Breed, David S.
• Primary Examiner(s): Ilan, Ruth
• Application Number:
  US10/043,557
• Publication Number:
  US 20020101067A1
• Time in Patent Office: 1,250 Days
• Field of Search: 280/741, 280/736, 102/470, 102/530, 102/531
• US Class Current: 280/741
• CPC Class Codes: B60N 2/02246 Electric motors therefor
• CPC Class Codes: B60N 2/0272 using sensors or detectors for detecting the position of seat parts
• CPC Class Codes: B60N 2/0276 reaction to emergency situations, e.g. crash
• CPC Class Codes: B60N 2/2863 backward facing
• CPC Class Codes: B60R 2021/0004 Frontal collision
• CPC Class Codes: B60R 2021/23107 the bag being integrated in a multi-bag system
• CPC Class Codes: B60R 2021/23153 specially adapted for rear seat passengers
• CPC Class Codes: B60R 2021/23161 specially adapted for protecting at least two passengers, e.g. preventing them from hitting each other
• CPC Class Codes: B60R 2021/23169 specially adapted for knee protection
• CPC Class Codes: B60R 2021/23519 Resin for coating fabric B60R2021/23514
• CPC Class Codes: B60R 2021/23523 Composite coated fabric B60R2021/23514
• CPC Class Codes: B60R 2021/23557 Molding
• CPC Class Codes: B60R 2021/2358 Bonding
• CPC Class Codes: B60R 2021/2359 Welding
• CPC Class Codes: B60R 21/20 Arrangements for storing inflatable members in their non-use or deflated condition; Arrangement or mounting of air bag modules or components
• CPC Class Codes: B60R 21/214 in roof panels
• CPC Class Codes: B60R 21/232 Curtain-type airbags deploying mainly in a vertical direction from their top edge
• CPC Class Codes: B60R 21/233 comprising a plurality of individual compartments; comprising two or more bag-like members, one within the other B60R21/232 takes precedence
• CPC Class Codes: B60R 21/235 characterised by their material
• CPC Class Codes: B60R 21/30 with means to draw ambient air into the flow line and mix such air with the inflation fluid
• CPC Class Codes: G07C 5/008 : communicating information to a remotely located station transmission systems for measured values G08C
• CPC Class Codes: G07C 5/0808 : Diagnosing performance data testing of vehicles G01M17/00; testing of electrical installation on vehicles G01R31/005

Abstract

Inflator module for inflating an airbag with gas including an elongate housing, an elongate block of propellant arranged in the housing and generating gas when burning and preferably, igniter material arranged on the propellant. The igniter material is substantially coextensive with the propellant in a longitudinal direction such that upon ignition of the igniter material, the propellant begins to burn across its entire length. This is beneficial as the pressure generated by the gas may be substantially uniform provided the propellant is uniformly distributed and homogeneous. The igniter material may be arranged on portions of the propellant not in contact with the housing such that the propellant is completely enclosed by the housing and igniter material, i.e., not exposed to the ambient atmosphere.

Claims

1. An inflator module for inflating an airbag with gas, comprising:

an elongate housing including a bottom wall, a top wall defining an opening through which gas flows to inflate the airbag and side walls connected to said bottom and top walls to thereby define a reaction chamber between said bottom wall, said top wall and said side walls; and

propellant extending longitudinally in said housing and generating gas when burning, said propellant being spaced apart from said top wall to define an unoccupied subchamber between said top wall and said propellant, said subchamber being a portion of said reaction chamber.

2. The inflator module of claim 1, wherein said propellant has a substantially uniform cross-sectional shape in a longitudinal direction of said propellant.

3. The inflator module of claim 1, wherein said propellant has a length in the longitudinal direction exceeding ten times a width or thickness of said propellant in a direction transverse to the longitudinal direction.

4. The inflator module of claim 1, further comprising a coating coated on said propellant and comprising igniter material, said subchamber being situated between said top wall and said coating.

5. The inflator module of claim 1, wherein said opening is elongate and oriented in the same direction as said propellant.

6. The inflator module of claim 4, further comprising an elongate screen arranged adjacent said opening and opposite said coating such that said screen faces said coating, said subchamber being situated between said screen and said coating.

7. The inflator module of claim 4, wherein said coating is substantially coextensive with said propellant in a longitudinal direction such that upon ignition of said igniter material, said propellant begins to burn across its entire length.

8. The inflator module of claim 7, wherein said coating is arranged on portions of said propellant not in contact with said housing such that said propellant is completely enclosed by said housing and said coating.

9. The inflator module of claim 7, wherein said bottom wall is elongate, said propellant being affixed to said bottom wall and said coating being arranged between said propellant and said top wall such that upon ignition of said igniter material, said propellant bums in a direction toward said bottom wall.

10. The inflator module of claim 4, wherein said coating is arranged on portions of said propellant not in contact with said housing such that said propellant is completely enclosed by said housing and said coating.

11. The inflator module of claim 10, wherein said propellant extends in a longitudinal direction of said housing, said coating being substantially coextensive with said propellant such that upon ignition of said igniter material, said propellant begins to burn across its entire length.

12. The inflator module of claim 10, wherein said propellant and said coating have a length in the longitudinal direction exceeding ten times a width or thickness of said propellant and said coating in a direction transverse to the longitudinal direction.

13. The inflator module of claim 10, further comprising an elongate screen arranged adjacent said opening and opposite said coating such that said screen faces said coating, said subchamber being situated between said screen and said coating.

14. The inflator module of claim 13, wherein said propellant is affixed to said bottom wall and said coating is arranged between said propellant and said top wall such that upon ignition of said igniter material,said propellant burns in a direction toward said bottom wall.

15. An inflator system arranged in a vehicle for inflating an airbag, comprising:

an elongate housing including a bottom wall, a top wall defining an opening through which gas flows to inflate the airbag and side walls connected to said bottom and top walls to thereby define a reaction chamber between said bottom wall, said top wall and said side walls;

an elongate mass of propellant; and

a layer of igniter material coated on said propellant and being substantially coextensive with said propellant in a longitudinal direction such that upon ignition of said igniter material, said propellant begins to burn across its entire length, said igniter material layer being spaced apart from said top wall to define an unoccupied subchamber between said top wall and said igniter material layer, said subchamber being a portion of said reaction chamber.

16. In a vehicle having a passenger compartment, an airbag module to protect an occupant in the passenger compartment in the event of a crash of the vehicle, the module comprising:

an airbag housing;

at least one airbag situated in said airbag housing;

an inflator module arranged in said airbag housing for inflating said at least one airbag, said inflator module comprising an elongate inflator housing including a bottom wall, a top wall defining an opening through which gas flows to inflate said at least one airbag and side walls connected to said bottom and top walls to thereby define a reaction chamber between said bottom wall, said top wall and said side walls and propellant extending longitudinally in said inflator housing and generating gas when burning, said propellant being spaced apart from said top wall to define an unoccupied subchamber between said top wall and said propellant, said subchamber being a portion of said reaction chamber;

an initiator for initiating said inflator module to produce gas in response to the crash of the vehicle; and

a cover for releasably retaining said at least one airbag in said airbag housing.

17. The module of claim 16, wherein said propellant has a substantially uniform cross-sectional shape in a longitudinal direction of said propellant.

18. The module of claim 16, further comprising a coating coated on said propellant and comprising igniter material, said subchamber being arranged between said top wall and said coating.

19. The module of claim 16, wherein said opening is elongate and oriented in the same direction as said propellant.

20. The module of claim 18, further comprising an elongate screen arranged adjacent said opening and opposite said coating such that said screen faces said coating, said subchamber being situated between said screen and said coating.

21. The module of claim 18, wherein said coating is substantially coextensive with said propellant in a longitudinal direction such that upon ignition of said igniter material, said propellant begins to burn across its entire length.

22. The module of claim 21, wherein said coating is arranged on portions of said propellant not in contact with said inflator housing such that said propellant is completely enclosed by said inflator housing and said coating.

23. The module of claim 21, wherein said propellant is affixed to said bottom wall and said coating is arranged between said propellant and said top wall such that upon ignition of said igniter material, said propellant bums in a direction toward said bottom wall.

24. The module of claim 18, wherein said coating is arranged on portions of said propellant not in contact with said inflator housing such that said propellant is completely enclosed by said inflator housing and said coating.

25. The module of claim 24, wherein said propellant extends in a longitudinal direction of said inflator housing, said coating being substantially coextensive with said propellant such that upon ignition of said igniter material, said propellant begins to bum across its entire length.

26. The module of claim 24, further comprising an elongate screen arranged adjacent said opening and opposite said coating such that said screen faces said coating, said subchamber being situated between said screen and said coating.

27. The module of claim 26, wherein said propellant is affixed to said wall and said coating is arranged between said propellant and said top wall such that upon ignition of said igniter material, said propellant burns in a direction toward said bottom wall.

28. In a vehicle having a passenger compartment, an airbag module to protect an occupant in the passenger compartment in the event of a crash of the vehicle, the module comprising:

an airbag housing;

at least one airbag situated in said airbag housing;

an inflator system arranged in said airbag housing for inflating said at least one airbag, said inflator system comprising an elongate housing including a bottom wall, a top wall defining an opening through which gas flows to inflate said at least one airbag and side walls connected to said bottom and top walls to thereby define a reaction chamber between said bottom wall, said top wall and said side walls;

an elongate mass of propellant; and

a layer of igniter material coated on said propellant and being substantially coextensive with said propellant in a longitudinal direction such that upon ignition of said igniter material, said propellant begins to burn across its entire length, said igniter material layer being spaced apart from said top wall to define an unoccupied subchamber between said top wall and said igniter material layer, said subchamber being a portion of said reaction chamber;

an initiator for initiating said inflator system to produce gas in response to the crash of the vehicle; and

a cover for releasably retaining said at least one airbag in said airbag housing.

29. A vehicle including a front, a rear and left and right sides and having a longitudinal direction parallel to the left and right sides, comprising:

an airbag module arranged along one of the left and right sides of the vehicle and including

an airbag housing oriented in the longitudinal direction of the vehicle;

at least one airbag situated in said airbag housing and arranged to inflate along one of the left and right sides of the vehicle;

an inflator module arranged in said airbag housing for inflating said at least one airbag, said inflator module comprising an elongate inflator housing including a bottom wall, a top wall defining an opening through which gas flows to inflate said at least one airbag and side walls connected to said bottom and top walls to thereby define a reaction chamber between said bottom wall, said top wall and said side walls, and propellant arranged in said inflator housing and generating gas when burning, said propellant being oriented in the longitudinal direction of the vehicle, said propellant being spaced apart from said top wall to define an unoccupied subchamber between said top wall and said propellant, said subchamber being a portion of said reaction chamber;

an initiator for initiating said inflator module to produce gas in response to the crash of the vehicle, and

a cover for releasably retaining said at least one airbag in said airbag housing.

30. The vehicle of claim 29, wherein said at least one airbag is a single airbag arranged to extend from a location in front of a B-pillar of the vehicle to a location behind the B-pillar such that said airbag is restrained by the B-pillar upon inflation.

31. The vehicle of claim 29, wherein said airbag module is mounted to a ceiling of the vehicle.

32. The vehicle of claim 29, wherein said airbag module is mounted adjacent to and slightly away from the left or right side of the vehicle.

33. The vehicle of claim 29, wherein said inflator module further comprises a coating comprising igniter material coated on said propellant and substantially coextensive with said propellant in the longitudinal direction such that upon ignition of said igniter material, said propellant begins to burn across its entire length, said subchamber being situated between said coating and said top wall.

34. The vehicle of claim 29, wherein said inflator module further comprises a coating comprising igniter material coated on portions of said propellant not in contact with said inflator housing such that said propellant is completely enclosed by said inflator housing and said coating, said subchamber being situated between said coating and said top wall.

35. A vehicle including a front, a rear and left and right sides and having a longitudinal direction parallel to the left and right sides, comprising:

an airbag module arranged along one of the left and right sides of the vehicle and including

an airbag housing oriented in the longitudinal direction of the vehicle;

at least one airbag situated in said airbag housing and arranged to inflate along one of the left and right sides of the vehicle;

an inflator system arranged in said airbag housing for inflating said at least one airbag, said inflator system comprising an elongate inflator housing including a bottom wall, a top wall defining an opening through which gas flows to inflate said at least one airbag and side walls connected to said bottom and top walls to thereby define a reaction chamber between said bottom wall, said top wall and said side walls and propellant oriented in the longitudinal direction of the vehicle, said propellant being spaced apart from said top wall to define an unoccupied subchamber between said top wall and said propellant, said subchamber being a portion of said reaction chamber;

an initiator for initiating said inflator system to produce gas in response to the crash of the vehicle; and

a cover for releasably retaining said at least one airbag in said airbag housing.

36. The vehicle of claim 35, wherein said at least one airbag is a single airbag arranged to extend from a location in front of a B-pillar of the vehicle to a location behind the B-pillar such that said airbag is restrained by the B-pillar upon inflation.

37. The vehicle of claim 35, wherein said airbag module is mounted to a ceiling of the vehicle.

38. The vehicle of claim 35, wherein said airbag module is mounted adjacent to and slightly away from the left or right side of the vehicle.

51. The vehicle of claim 35, further comprising a layer of igniter material arranged on said propellant and being substantially coextensive with said propellant in the longitudinal direction such that upon ignition of said igniter material, said propellant begins to burn across its entire length, said subchamber being situated between said top wall and said igniter material layer.

39. An inflator module for inflating an airbag with gas, comprising:

an elongate housing including an elongate bottom wall, a top wall having an opening through which gas flows to inflate the airbag, a pair of opposed longitudinally extending walls connected to said bottom and top walls and opposed lateral end walls connected to said bottom and top walls to thereby define a reaction chamber between said bottom wall, said top wall, said longitudinally extending walls and said lateral walls; and

propellant arranged in said reaction chamber and generating gas when burning, said propellant being arranged along substantially the entire length of said longitudinally extending walls, said propellant being spaced apart from said top wail to define an unoccupied subchamber between said top wall and said propellant, said subchamber being a portion of said reaction chamber.

40. The inflator module of claim 39, wherein said propellant has a substantially uniform cross-sectional shape in a longitudinal direction of said propellant.

41. The inflator module of claim 39, wherein said propellant has a length in the longitudinal direction exceeding ten times a width or thickness of said propellant in a direction transverse to the longitudinal direction.

42. The inflator module of claim 39, further comprising a coating coated on an upper surface of said propellant and comprising igniter material, said subchamber being situated between said top wall and said coating.

43. The inflator module of claim 39, wherein said opening is elongate and oriented in the same direction as said propellant.

44. The inflator module of claim 39, further comprising an elongate screen arranged adjacent said opening and opposite said propellant, said subchamber being situated between said screen and said propellant.

45. The inflator module of claim 42, wherein said coating is substantially coextensive with said propellant in a longitudinal direction such that upon ignition of said igniter material, said propellant begins to burn across its entire length.

46. The inflator module of claim 42, wherein said coating is arranged on portions of said propellant not in contact with said bottom wall, said longitudinally extending walls and said lateral walls such that said propellant is completely enclosed by said housing and said coating.

47. The inflator module of claim 45, wherein said propellant is affixed to said bottom wall and said coating is arranged between said propellant and said top wall such that upon ignition of said igniter material, said propellant burns in a direction toward said bottom wall.

48. An inflator module for inflating an airbag with gas, comprising:

an elongate housing; and

propellant extending longitudinally in said housing and generating gas when burning;

said housing including a top wall having an opening through which gas flows to inflate the airbag and a bottom wall opposite said top wall, said propellant being affixed to said bottom wall and being arranged to burn in a direction toward said bottom wall, said propellant being spaced apart from said top wall to define an unoccupied chamber between said top wall and said propellant.

49. An inflator module for inflating an airbag with gas, comprising:

an elongate housing;

propellant extending longitudinally in said housing and generating gas when burning; and

igniter material arranged on portions of said propellant not in contact with said housing such that said propellant is completely enclosed by said housing and said igniter material,

said housing including a top wall having an opening through which gas flows to inflate the airbag and a bottom wall opposite said top wall, said propellant being affixed to said bottom wall and said igniter material being arranged between said propellant and said top wall such that upon ignition of said igniter material, said propellant burns in a direction toward said bottom wall, said igniter material being spaced apart from said top wall to define an unoccupied chamber between said top wall and said igniter material.

50. An inflator module for inflating an airbag with gas, comprising:

an elongate housing including a bottom wall, a top wall having an opening through which gas flows to inflate the airbag, a pair of opposed longitudinally extending walls connected to said bottom wall and opposed lateral end walls connected to said bottom wall to thereby define a reaction chamber between said bottom wall, said top wall, said longitudinally extending walls and said lateral walls; and

propellant arranged in said reaction chamber and generating gas when burning, said propellant being arranged along substantially the entire length of said longitudinally extending walls;

said propellant being spaced apart from said top wall to define an unoccupied chamber between said top wall and said propellant,

said propellant being affixed to said bottom wall and being arranged to burn in a direction toward said bottom wall.

52. An inflator module for inflating an airbag with gas, comprising:

an elongate housing including an elongate bottom wall, a pair of opposed longitudinally extending walls connected to said bottom wall and opposed lateral end walls connected to said bottom wall to thereby define a reaction chamber between said bottom wall, said longitudinally extending walls and said lateral walls, said housing including an opening opposite said bottom wall through which gas flows to inflate the airbag;

propellant arranged in said reaction chamber and generating gas when burning, said propellant being arranged along substantially the entire length of said longitudinally extending walls; and

an elongate screen arranged adjacent said opening and opposite said propellant such that a chamber is defined in said housing between said screen and said propellant.