Filter assembly for non-welded inflator device

Claim 2

A self sealing annular filter component for operation within a housing portion of a pyrotechnic inflator device, said filter comprising: (a) first and second ring-shaped members configured to form annular frame means of said filter component, at least one of said ring-shaped members having at least one tab member formed integrally thereupon and extending outwardly therefrom toward said other ring-shaped member to maintain a set spacing between said ring-shaped members; and (b) a plurality of filtration means supported upon said filter frame means, each said filtration means positioned so as to at least partially overlap a preceding underlying one of said filtration means around an entire outer annular surface of said filter frame means, an entire upper and lower circumferential edge of said first and said second ring-shaped members, respectively, further being adapted for obtaining circular line contact with an inner portion of said inflator housing, thus causing said filter component to be self-sealing against said inner portion as a result of outwardly directed hoop stresses produced upon said filter component by activation of said pyrotechnic inflator, such that a gaseous combustion product produced thereby is prevented from bypassing said filter component and is therefore directed through said filtration means in a serpentine path so as to cool and filter said gas.

Claim 3

The filter of claim 1 wherein said housing portion comprises: (a) a domed diffuser member, having a first open end and a second closed end; and (b) a closure plate member sealing the open end of said diffuser member, said closure plate member and said domed diffuser member being sealed together without welding either of said members to form an inflator housing capable of withstanding elevated pressures produced during activation of said inflator device.

Claim 4

The filter of claim 2 wherein a peripheral lip portion on said open end of said diffuser member is sealed over an outer circumferential edge of said closure plate member by mechanical means so as to form a hermetic seal therebetween.

Claim 5

The filter of claim 3 wherein said mechanical sealing means is magnaforming.

Claim 6

The filter of claim 3 wherein said first and said second ring shaped members each comprise a metal stamping having a substantially straight wall portion with a first end and a second end and an angled flange portion, integrally formed with said first end, extending outwardly from said wall portion at an acute angle therefrom, said ring shaped members adapted for an interengaging fit therebetween to form said annular frame means.

Claim 7

The filter of claim 5 wherein said angled flange portion of each said ring shaped member extends away from its corresponding straight wall portion at an angle of about 11/2° greater than an internal contact angle between said filter and, respectively, said diffuser member and said closure plate member, such that said filter is substantially wedged against said inner portion of the housing to provide a gas-tight seal therebetween upon activation of the inflator device.

Claim 8

The filter of claim 6 wherein said inflator device is operatively associated with an automobile air bag passive safety device.

Claim 9

The filter of claim 7 wherein said domed diffuser member futher comprises a plurality of diffuser ports spaced equidistantly around a circumferential peripheral portion thereof, said ports providing fluid communication between a combustion cavity defined within said inflator housing by said annular filter component and an inner portion of said automobile air bag passive safety device, to permit the deployment thereof upon activation of said inflator.

Claim 10

A self-sealing annular filter component for operation within a housing portion of a pyrotechnic inflator device, said filter comprising: (a) first and second ring-shaped members, each said member comprising a metal stamping having a substantially straight wall portion with a first end and a second end and an angled flange portion, integral with said first end, extending outwardly from said wall portion at an acute angle therefrom, at least one said ring-shaped member having at least one tab member formed integrally thereupon and extending outwardly therefrom toward said other ring-shaped member to maintain a set spacing between said ring-shaped members, said ring-shaped members adapted for an interengaging fit therebetween to form an annular filter frame; (b) a plurality of filter layers supported upon said filter frame, each said layer positioned so as to at least partially overlap a preceding underlying one of said layers around an entire annular surface of said filter frame, said annular filter component adapted for operation within a housing portion of a pyrotechnic inflator device, said housing portion comprising (a) a domed diffuser member having a first open end and a second closed end, said diffuser member defining a plurality of diffuser ports spaced equidistantly around a circumferential peripheral portion thereof, said ports providing fluid communication between a combustion cavity defined within said diffuser by said annular filter component and an inner portion of an automobile air bag operatively associated with said inflator so as to permit the deployment of said air bag upon activation of said inflator; (b) a closure plate member sealing the open end of said diffuser member, thus forming said inflator housing; both said diffuser member and said closure plate member formed of a relatively lightweight, corrosion-resistant, high tensile strength material, and further, said open end of said diffuser member being mechanically formed over an outer peripheral lip portion of said closure plate member to form a hermetic seal therebetween, and wherein the angled flange portion of each said ring-shaped member extends away from the corresponding straight wall portion of said member at an angle of about 11/2° greater than an internal contact angle between said filter and, respectively, said diffuser member and said closure plate member in order that said filter component is substantially wedged against an inner portion of said inflator housing to provide a gas-tight seal therebetween upon activation of the inflator device.

Claim 11

A self-sealing annular filter component for operation within a housing portion of a pyrotechnic inflator device, said filter comprising: (a) first and second ring-shaped members, each said member comprising a metal stamping having a substantially straight wall portion with a first end and a second end and an angled flange portion, integral with said first end, extending outwardly from said wall portion at an acute angle therefrom, at least one said ring-shaped member having at least one tab member formed integrally thereupon and extending outwardly therefrom toward said other ring-shaped member to maintain a set spacing between said ring-shaped members, said ring-shaped members adapted for an interengaging fit therebetween to form an annular filter frame; (b) a plurality of filter layers supported upon said filter frame, each said layer positioned so as to at least partially overlap a preceding underlying one of said layers around an entire annular surface of said filter frame, said annular filter component adapted for operation within a housing portion of a pyrotechnic inflator device, said housing portion comprising (a) a domed diffuser member having a first open end and a second closed end, said diffuser member defining a plurality of diffuser ports spaced equidistantly around a circumferential peripheral portion thereof, said ports providing fluid communication between a combustion cavity defined within said diffuser by said annular filter component and an inner portion of an automobile air bag operatively associated with said inflator so as to permit the deployment of said air bag upon activation of said inflator; (b) a closure plate member sealing the open end of said diffuser member, thus forming said inflator housing; both said diffuser member and said closure plate member formed of a relatively lightweight, corrosion-resistant, high tensile strength material, and further, said open end of said diffuser member being mechanically formed over an outer peripheral lip portion of said closure plate member to form a hermetic seal therebetween, and wherein the angled flange portion of each said ring-shaped member extends away from the corresponding straight wall portion of said member at an angle of about 11/2° greater than an internal contact angle between said filter and, respectively, said diffuser member and said closure plate member in order that said filter component is substantially wedged against an inner portion of said inflator housing to provide a gas-tight seal therebetween upon activation of the inflator device.

Claim 12

The filter of claim 9 wherein said filter layers comprise at least two layers of a metal screen material having mesh size measurements different from one another and at least one layer of an inert fibrous material.

Claim 13

The filter of claim 10 wherein said inert fibrous material comprises a ceramic fiber pad, said pad interposed between at least two layers of said metal screen.

Claim 14

The filter of claim 11 wherein said ceramic fiber pad comprises a mixture of aluminum oxide and silicon oxide fibers.

Claim 15

The filter of claim 10 wherein the mesh size measurements of said at least two layers of metal screen correspondingly decrease from an inner edge adacent said combustion cavity to an outer edge abutting an inner wall portion of said inflator housing, to ensure filtration of substantially all particulate material produced upon activation of the inflator device.

Claim 16

The filter of claim 13 wherein said layer of metal screen material adjacent said outer edge thereof is secured to a corresponding adjacent edge surface of each of said ring-shaped frame members by mechanical means or adhesive means to maintain said filter layers in proper arrangement.

Claim 17

The filter of claim 14 wherein said mechanical means is a weld between said outer layer of metal screen material and said ring-shaped filter frame members.

Claim 18

The filter of claim 9 wherein said filter layers comprise, in order, from an inner edge of said filter adjacent said combustion cavity to an outer edge of said filter, abutting an inner wall portion of said inflator housing: (a) a first layer of coarse slag screen; (b) a second layer of coarse slag screen; (c) a third layer of a 100 micron screen; (d) a fourth layer of an inert ceramic pad; (e) a fifth layer of 100 mesh screen; and (f) a sixth layer of 28 mesh screen, each said layer substantially overlaying each preceding layer and wherein said sixth layer of said 28 mesh screen is secured to said ring-shaped filter frame member along a peripheral edge thereof to hold said filter together.

Claim 19

A method for constructing a lightweight non-welded inflator apparatus for installation in an automobile passive safety device, said method comprising: (a) Forging a diffuser member of a material which is relatively lightweight, corrosive resistant and having a high tensile strength, said diffuser member having a first domed end and a second open end; (b) lowering the annular filter component of claim 9 through said open end of said diffuser member and into position therein; (c) placing a discreetly packaged propellant assembly into a combustion cavity defined by said filter component within said diffuser member; (d) forging a substantially flat closure plate member for sealing the open end of said diffuser member; (e) mating the closure plate member to the open end of the diffuser member; and (f) magnaforming said diffuser member over a peripheral edge of said closure plate member to form a structural seal therebetween without welding either of said members, said seal capable of withstanding elevated pressures produced by the combustion of said propellant.