Gas bag inflator with a two welded joint housing

Claim 2

A vehicle inflatable crash protection bag inflator comprising first and second structural components (14, 16), one (14) of said first and second structural components including a first cylinder (22) which is welded to a mating surface (24) on the other (16) of said structural components to define a first chamber (26), one of said first and second structural components including a second cylinder (28) which is welded to a mating surface (30) on the other of said structural components and which is concentric with and outwardly of said first cylinder (22) to define a second chamber (32) between said first and second cylinders, a solid gas generant composition (56) disposed in said first chamber and operable upon ignition to produce gas, means including a perforated tubular member (36) within said first chamber and igniter material (50) within said tubular member for igniting said solid gas generant composition which igniting means is free of attachment to one of said structural components, said first and second structural components being connected by only two welded joints (18, 20), aperture means (62) in said first cylinder for directing gas produced in said first chamber (26) into said second chamber (32), means (78, 80, 82, 84) in said second chamber for filtering the gas, and outlet port means (74) in said second cylinder for flow of the gas out of the inflator.

Claim 3

An inflator according to claim 1 wherein said first and second structural components (14, 16) are composed of aluminum.

Claim 4

An inflator according to claim 1 or claim 2 wherein said first and second structural components include generally parallel first and second plate members respectively, the inflator further comprising a charge of auto ignition material (98) disposed in said first chamber (26) adjacent one of said structural component plate members and adjacent said gas generant composition (56).

Claim 5

An inflator according to any preceding claim wherein said first and second structural components (14, 16) include generally parallel circular first and second plate members respectively, the inflator further comprises a plurality of strengthening ribs in the inner surface of one (14) of said structural component plate members and each of which rib means extends toward the center of said one of said structural component plate members between said first cylinder (22) and said tubular member (36) to define a plurality of pockets (96) in which additional solid gas generant composition may be disposed.

Claim 6

An inflator according to claim 4 wherein the inflator further comprises a charge of auto ignition material (98) disposed in one of said pockets and means (102) for holding said charge of auto ignition material in said one of said pockets.

Claim 7

An inflator according to any preceding claim wherein said tubular member (36) has a thickness which is less than 0.07 in (1.78 mm), and preferably less than 0.05 in (1.27 mm).

Claim 8

An inflator according to any preceding claim wherein said first structural component (14) includes said first cylinder (22) which is welded to a mating surface (24) on said second structural component (16) to define said first chamber (26), said second structural component (16) includes said second cylinder (28) which is welded to a mating surface (30) on said first structural component (14) to define said second chamber (32) between said first and second cylinders, and said igniting means (36, 50) is free of attachment to said second structural component (16) and is attached to said first structural component (14).

Claim 9

An inflator according to any preceding claim wherein the tubular member (36) is generally concentric with said first cylinder (22), and with one end engages one of said first and second structural components, its other end being spaced from the other of said structural components.

Claim 10

An inflator according to claim 8 further comprising means (38) for closing the end of the tubular member (36) which does not engage one fo the structural components.

Claim 11

An inflator according to any preceding claim further comprising a foil (52) for covering perforations (58) of the tubular member (36) until igniter material (50) therein is ignited.

Claim 12

An inflator according to any preceding claim, wherein said tubular member (36) is composed of steel and has a thickness which is equal to about 0.03 in (0.76 mm).

Claim 13

An inflator according to any preceding claim wherein said first and second structural components (14, 16) include first and second generally parallel plate members respectively, and one of said first and second structural component plate members further includes a generally cylindrical mounting post (34) extending inwardly thereof and onto which said one end of said tubular member (36) is press fit, its other end being closed by a cap member (38) press-fitted into it.

Claim 14

An inflator according to any preceding claim further comprising an initiator (44, 110) in direct contact with the igniter material (50) to ignite it.

Claim 15

An inflator according to claim 13 wherein said initiator (44, 110) includes a generally cylindrical housing (122) and a plurality of apertures (60, 112) spaced circumferentially in said housing for releasing hot gases for igniting said igniter material.

Claim 16

A vehicle inflatable crash protection bag inflator comprising first and second structural components including first and second generally parallel circular plate members respectively, one of said first and second structural components further including a first cylinder which is welded to a mating surface on the other of said structural components to define a first chamber, one of said first and second structural components further including a second cylinder which is welded to a mating surface on the other of said structural components and which is concentric with and outwardly of said first cylinder to define a second chamber between said first and second cylinders, means (36, 110) within said first cylinder for containing igniter material which means is free of attachment to said second structural component whereby said first and second structural components may be connected by only two welded joints, a solid gas generant composition disposed in said first chamber and operable upon ignition to produce gas, means including igniter material disposed in said igniter material containing means for ignition of said solid gas generant composition, means for igniting said igniter material, aperture means in said first cylinder for directing has produced in said first chamber into said second chamber, means in said second chamber for filtering the gas, outlet port means in said second cylinder for flow of the gas out of the inflator.

Claim 17

A vehicle inflatable crash protection bag inflator comprising first and second structural components including first and second generally parallel circular plate members respectively, one of said first and second structural components further including a first cylinder which is welded to a mating surface on the other of said structural components to define a first chamber, one of said first and second structural components further including a second cylinder which is welded to a mating surface on the other of said structural components and which is concentric with and outwardly of said first cylinder to define a second chamber between said first and second cylinders, means (36, 110) within said first cylinder for containing igniter material which means is free of attachment to said second structural component whereby said first and second structural components may be connected by only two welded joints, a solid gas generant composition disposed in said first chamber and operable upon ignition to produce gas, means including igniter material disposed in said igniter material containing means for ignition of said solid gas generant composition, means for igniting said igniter material, aperture means in said first cylinder for directing has produced in said first chamber into said second chamber, means in said second chamber for filtering the gas, outlet port means in said second cylinder for flow of the gas out of the inflator.

Claim 18

An inflator according to any preceding claim further comprising a plurality of strengthening ribs (90) in the outer surface of said second structural member (16) intermediate the edged and center thereof and each of which extends toward the center of the second structural member to define a plurality of slots (88) between said ribs respectively providing means (92) for attachment of a tool for holding said second structural member for welding of said first and second cylinders to said respective structural components.

Claim 19

A vehicle inflatable crash protection bag inflator comprising first and second structural components, said first structural component including a first cylinder which is welded to a mating surface on said second structural component to define a first chamber, said second structural component including a second cylinder which is welded to a mating surface on said first structural component and which is concentric with and outwardly of said first cylinder to define a second chamber between said first and second cylinders, means within said first cylinder for containing igniter material which means is free of attachment to said second structural component, said first and second structural components connected by only two welded joints, a solid gas generant composition disposed in said first chamber and operable upon ignition to produce gas, means including igniter material disposed in said igniter material containing means for ignition of said solid gas generant composition, means for igniting said igniter material, aperture means in said first cylinder for directing gas produced in said first chamber into said second chamber, means in said second chamber for filtering the gas, and outlet port means in said second cylinder for flow of the gas out of the inflator.

Claim 20

A vehicle inflatable crash protection bag inflator comprising first and second structural components, said first structural component including a first cylinder which is welded to a mating surface on said second structural component to define a first chamber, said second structural component including a second cylinder which is welded to a mating surface on said first structural component and which is concentric with and outwardly of said first cylinder to define a second chamber between said first and second cylinders, means within said first cylinder for containing igniter material which means is free of attachment to said second structural component, said first and second structural components connected by only two welded joints, a solid gas generant composition disposed in said first chamber and operable upon ignition to produce gas, means including igniter material disposed in said igniter material containing means for ignition of said solid gas generant composition, means for igniting said igniter material, aperture means in said first cylinder for directing gas produced in said first chamber into said second chamber, means in said second chamber for filtering the gas, and outlet port means in said second cylinder for flow of the gas out of the inflator.

Claim 21

A vehicle inflatable crash protection bag inflator comprising first and second structural components, said first structural component including a first cylinder which is welded to a mating surface on said second structural component to define a first chamber, said second structural component including a second cylinder which is welded to a mating surface on said first structural component and which is concentric with and outwardly of said first cylinder to define a second chamber between said first and second cylinders, a generally tubular member having a thickness less than about 0.07 in (1.78 mm) which is within said first chamber and generally concentric with said first cylinder and one end of which engages said first structural component and the other end of which is spaced from said second structural component whereby said first and second structural components may be connected by only two welded joints, means for closing said tubular member other end, a solid gas generant composition disposed in said first chamber and operable upon ignition to produce gas, igniter material disposed in said tubular member, means for igniting said igniter material to produce gas for igniting said solid gas generant composition, a plurality of perforation means in said tubular member for directing the gas produced therein out of said tubular member for igniting said solid gas generant composition, foil means for covering said perforation means until said igniter material is ignited, means in direct contact with said igniter material for igniting said igniter material, aperture means in said first cylinder for directing gas produced in said first chamber into said second chamber; means in said second chamber for filtering the gas, and outlet port means in said second cylinder for flow of the gas out of the inflator.

Claim 22

A vehicle inflatable crash protection bag inflator comprising first and second structural components, said first structural component including a first cylinder which is welded to a mating surface on said second structural component to define a first chamber, said second structural component including a second cylinder which is welded to a mating surface on said first structural component and which is concentric with and outwardly of said first cylinder to define a second chamber between said first and second cylinders, a generally tubular member having a thickness less than about 0.07 in (1.78 mm) which is within said first chamber and generally concentric with said first cylinder and one end of which engages said first structural component and the other end of which is spaced from said second structural component whereby said first and second structural components may be connected by only two welded joints, means for closing said tubular member other end, a solid gas generant composition disposed in said first chamber and operable upon ignition to produce gas, igniter material disposed in said tubular member, means for igniting said igniter material to produce gas for igniting said solid gas generant composition, a plurality of perforation means in said tubular member for directing the gas produced therein out of said tubular member for igniting said solid gas generant composition, foil means for covering said perforation means until said igniter material is ignited, means in direct contact with said igniter material for igniting said igniter material, aperture means in said first cylinder for directing gas produced in said first chamber into said second chamber; means in said second chamber for filtering the gas, and outlet port means in said second cylinder for flow of the gas out of the inflator.

Claim 23

A vehicle inflatable crash protection bag inflator comprising first and second structural components, one of said first and second structural components including a first cylinder which is welded to a mating surface on the other of said structural components to define a first chamber, one of said first and second structural components including a second cylinder which is welded to a mating surface on the other of said structural components and which is concentric with and outwardly of said first cylinder to define a second chamber between said first and second cylinders, a squib disposed at least partially in said first chamber and mounted to one of said first and second structural components and spaced from the other of said structural components, gas generant material disposed in said first chamber in direct closely surrounding relation to said squib whereby the squib may fire directly into the gas generant material and the first and second structural components may be connected by only two welded joints, aperture means in said first cylinder for directing gas produced in said first chamber into said second chamber, means in said second chamber for filtering the gas, and outlet port means in said second cylinder for flow of the gas out of the inflator.

Claim 24

A vehicle inflatable crash protection bag inflator comprising first and second structural components, one of said first and second structural components including a first cylinder which is welded to a mating surface on the other of said structural components to define a first chamber, one of said first and second structural components including a second cylinder which is welded to a mating surface on the other of said structural components and which is concentric with and outwardly of said first cylinder to define a second chamber between said first and second cylinders, a squib disposed at least partially in said first chamber and mounted to one of said first and second structural components and spaced from the other of said structural components, gas generant material disposed in said first chamber in direct closely surrounding relation to said squib whereby the squib may fire directly into the gas generant material and the first and second structural components may be connected by only two welded joints, aperture means in said first cylinder for directing gas produced in said first chamber into said second chamber, means in said second chamber for filtering the gas, and outlet port means in said second cylinder for flow of the gas out of the inflator.

Claim 25

A vehicle inflatable crash protection bag inflator comprising first and second structural components, said first structural component including a first cylinder which is welded to a mating surface on said second structural component to define a first chamber, said second structural component including a second cylinder which is welded to a mating surface on said first structural component and which is concentric with and outwardly of said first cylinder to define a second chamber between said first and second cylinders, a squib disposed at least partially in said first chamber and mounted to said first structural component and spaced from the second structural component, gas generant material disposed in said first chamber in direct closely surrounding relation to said squib whereby the squib may fire directly into the gas generant material and the first and second structural components may be connected by only two welded joints, aperture means in said first cylinder for directing gas produced in said first chamber into said second chamber, means in said second chamber for filtering the gas, and outlet port means in said second cylinder for flow of the gas out of the inflator.

Claim 26

A vehicle inflatable crash protection bag inflator comprising first and second structural components, said first structural component including a first cylinder which is welded to a mating surface on said second structural component to define a first chamber, said second structural component including a second cylinder which is welded to a mating surface on said first structural component and which is concentric with and outwardly of said first cylinder to define a second chamber between said first and second cylinders, a squib disposed at least partially in said first chamber and mounted to said first structural component and spaced from the second structural component, gas generant material disposed in said first chamber in direct closely surrounding relation to said squib whereby the squib may fire directly into the gas generant material and the first and second structural components may be connected by only two welded joints, aperture means in said first cylinder for directing gas produced in said first chamber into said second chamber, means in said second chamber for filtering the gas, and outlet port means in said second cylinder for flow of the gas out of the inflator.

Claim 27

An inflator according to any preceding claim wherein said first and second structural components (14, 16) include generally parallel circular first and second plate members respectively, the inflator further comprise a plurality of strengthening rib means in the inner surface of said first structural component plate member (14) and each of which rib means extends toward the center of said first structural component plate member between said first cylinder and said igniting means to define a plurality of pockets (96) in which additional gas generant composition may be disposed.