Slurry-loadable electrical initiator

Claim 1

A method for assembling an electrical initiator, comprising the steps of: loading a first slurry into a charge casing, said first slurry comprising first and second constituents in suspension in said first slurry, wherein a first pyrotechnic material comprises said first and second constituents, said charge casing having an open end and a closed end, said loading a first slurry step being through said open end; drying said first slurry after said loading a first slurry step; loading an ignition assembly into said charge casing to be substantially adjacent to said first pyrotechnic material, said loading an ignition assembly step being through said open end of said charge casing, said ignition assembly comprising a first electrical conductor and a second electrical conductor which is interconnected with said first electrical conductor and which interfaces with said first pyrotechnic material; and interconnecting said ignition assembly and said charge casing.

Claim 2

A method for assembling an electrical initiator, comprising the steps of: loading a first slurry into a charge casing, said first slurry comprising first and second constituents in suspension in said first slurry, wherein a first pyrotechnic material comprises said first and second constituents, said charge casing having an open end and a closed end, said loading a first slurry step being through said open end; drying said first slurry after said loading a first slurry step; loading an ignition assembly into said charge casing to be substantially adjacent to said first pyrotechnic material, said loading an ignition assembly step being through said open end of said charge casing, said ignition assembly comprising a first electrical conductor and a second electrical conductor which is interconnected with said first electrical conductor and which interfaces with said first pyrotechnic material; and interconnecting said ignition assembly and said charge casing.

Claim 15

A method for assembling an electrical initiator, comprising the steps of: providing a first slurry comprising a first constituent of a pyrotechnic material to a mixer; providing a second slurry comprising a second constituent of said pyrotechnic material to said mixer; mixing said first and second slurries together in said mixer, wherein said mixing step provides a pyrotechnic material slurry; injecting said pyrotechnic material slurry into a charge casing having an open end and a closed end, said injecting step being through said open end; drying said pyrotechnic material slurry after said injecting step to provide said pyrotechnic material: and closing said open end of said charge casing with an ignition assembly, said ignition assembly comprising a first electrical conductor and a second electrical conductor which is interconnected with said first electrical conductor and which interfaces with said pyrotechnic material.

Claim 16

A method for assembling an electrical initiator, comprising the steps of: providing a first slurry comprising a first constituent of a pyrotechnic material to a mixer; providing a second slurry comprising a second constituent of said pyrotechnic material to said mixer; mixing said first and second slurries together in said mixer, wherein said mixing step provides a pyrotechnic material slurry; injecting said pyrotechnic material slurry into a charge casing having an open end and a closed end, said injecting step being through said open end; drying said pyrotechnic material slurry after said injecting step to provide said pyrotechnic material: and closing said open end of said charge casing with an ignition assembly, said ignition assembly comprising a first electrical conductor and a second electrical conductor which is interconnected with said first electrical conductor and which interfaces with said pyrotechnic material.

Claim 29

A method for assembling an electrical initiator, comprising the steps of: loading a first slurry into a charge casing, said first slurry comprising first and second constituents in suspension in said first slurry, wherein a first pyrotechnic material comprises said first and second constituents, said charge casing having an open end and a closed end, said loading a first slurry step being through said open end, wherein prior to said loading a first slurry step said method comprises the steps of: providing a second slurry of at least said first constituent of said first pyrotechnic material, said first constituent being suspended in said second slurry; providing a third slurry of at least said second constituent of said first pyrotechnic material, said second constituent being suspended in said third slurry; and mixing said second and third slurries together into said first slurry before said loading a first slurry step, wherein said mixing step comprises providing each of said first and second slurries to a static mixer, and wherein said method further comprises the steps of: loading an ignition assembly into said charge casing to be substantially adjacent to said first pyrotechnic material, said loading an ignition assembly step being through said open end of said charge casing, said ignition assembly comprising at least one electrically conductive member and a bridge wire interconnected with said at least one electrically conductive member; and interconnecting said ignition assembly and said charge casing.

Claim 30

A method for assembling an electrical initiator, comprising the steps of: loading a first slurry into a charge casing, said first slurry comprising first and second constituents in suspension in said first slurry, wherein a first pyrotechnic material comprises said first and second constituents, said charge casing having an open end and a closed end, said loading a first slurry step being through said open end, wherein prior to said loading a first slurry step said method comprises the steps of: providing a second slurry of at least said first constituent of said first pyrotechnic material, said first constituent being suspended in said second slurry; providing a third slurry of at least said second constituent of said first pyrotechnic material, said second constituent being suspended in said third slurry; and mixing said second and third slurries together into said first slurry before said loading a first slurry step, wherein said mixing step comprises providing each of said first and second slurries to a static mixer, and wherein said method further comprises the steps of: loading an ignition assembly into said charge casing to be substantially adjacent to said first pyrotechnic material, said loading an ignition assembly step being through said open end of said charge casing, said ignition assembly comprising at least one electrically conductive member and a bridge wire interconnected with said at least one electrically conductive member; and interconnecting said ignition assembly and said charge casing.

Claim 31

A method for assembling an electrical initiator, comprising the steps of: loading a first slurry into a charge casing, said first slurry comprising first and second constituents in suspension in said first slurry, wherein a first pyrotechnic material comprises said first and second constituents, said charge casing having an open end and a closed end, said loading a first slurry step being through said open end, wherein prior to said loading a first slurry step said method comprises the steps of: providing a second slurry of at least said first constituent of said first pyrotechnic material, said first constituent being suspended in said second slurry; providing a third slurry of at least said second constituent of said first pyrotechnic material, said second constituent being suspended in said third slurry; and mixing said second and third slurries together into said first slurry before said loading a first slurry step, wherein said loading a first slurry step comprises using a positive displacement pump, and wherein said method further comprises the step of: loading an ignition assembly into said charge casing to be substantially adjacent to said first pyrotechnic material, said loading an ignition assembly step being through said open end of said charge casing, said ignition assembly comprising at least one electrically conductive member and a bridge wire interconnected with said at least one electrically conductive member; and interconnecting said ignition assembly and said charge casing.

Claim 32

A method for assembling an electrical initiator, comprising the steps of: loading a first slurry into a charge casing, said first slurry comprising first and second constituents in suspension in said first slurry, wherein a first pyrotechnic material comprises said first and second constituents, said charge casing having an open end and a closed end, said loading a first slurry step being through said open end, wherein prior to said loading a first slurry step said method comprises the steps of: providing a second slurry of at least said first constituent of said first pyrotechnic material, said first constituent being suspended in said second slurry; providing a third slurry of at least said second constituent of said first pyrotechnic material, said second constituent being suspended in said third slurry; and mixing said second and third slurries together into said first slurry before said loading a first slurry step, wherein said loading a first slurry step comprises using a positive displacement pump, and wherein said method further comprises the step of: loading an ignition assembly into said charge casing to be substantially adjacent to said first pyrotechnic material, said loading an ignition assembly step being through said open end of said charge casing, said ignition assembly comprising at least one electrically conductive member and a bridge wire interconnected with said at least one electrically conductive member; and interconnecting said ignition assembly and said charge casing.

Claim 33

A method for assembling an electrical initiator, comprising the steps of: loading a first slurry into a charge casing, said first slurry comprising first and second constituents in suspension in said first slurry, wherein a first pyrotechnic material comprises said first and second constituents, said charge casing having an open end and a closed end, said loading a first slurry step being through said open end, wherein prior to said loading a first slurry step said method comprises the steps of: providing a second slurry of at least said first constituent of said first pyrotechnic material, said first constituent being suspended in said second slurry; providing a third slurry of at least said second constituent of said first pyrotechnic material, said second constituent being suspended in said third slurry; and mixing said second and third slurries together into said first slurry before said loading a first slurry step, wherein said first constituent comprises zirconium and said second constituent comprises potassium perchlorate, and wherein said method further comprises the steps of: loading an ignition assembly into said charge casing to be substantially adjacent to said first pyrotechnic material, said loading an ignition assembly step being through said open end of said charge casing, said ignition assembly comprising at least one electrically conductive member and a bridge wire interconnected with said at least one electrically conductive member; and interconnecting said ignition assembly and said charge casing.

Claim 34

A method for assembling an electrical initiator, comprising the steps of: loading a first slurry into a charge casing, said first slurry comprising first and second constituents in suspension in said first slurry, wherein a first pyrotechnic material comprises said first and second constituents, said charge casing having an open end and a closed end, said loading a first slurry step being through said open end, wherein prior to said loading a first slurry step said method comprises the steps of: providing a second slurry of at least said first constituent of said first pyrotechnic material, said first constituent being suspended in said second slurry; providing a third slurry of at least said second constituent of said first pyrotechnic material, said second constituent being suspended in said third slurry; and mixing said second and third slurries together into said first slurry before said loading a first slurry step, wherein said first constituent comprises zirconium and said second constituent comprises potassium perchlorate, and wherein said method further comprises the steps of: loading an ignition assembly into said charge casing to be substantially adjacent to said first pyrotechnic material, said loading an ignition assembly step being through said open end of said charge casing, said ignition assembly comprising at least one electrically conductive member and a bridge wire interconnected with said at least one electrically conductive member; and interconnecting said ignition assembly and said charge casing.

Claim 35

A method for assembling an electrical initiator, comprising the steps of: loading a first slurry into a charge casing, said first slurry comprising first and second constituents in suspension in said first slurry, wherein a first pyrotechnic material comprises said first and second constituents, said charge casing having an open end and a closed end, said loading a first slurry step being through said open end, wherein prior to said loading a first slurry step said method comprises the steps of: providing a second slurry of at least said first constituent of said first pyrotechnic material, said first constituent being suspended in said second slurry; maintaining a viscosity of said second slurry between about 500,000 centipoise and about 2,000,000 centipoise during said providing a second slurry step; providing a third slurry of at least said second constituent of said first pyrotechnic material, said second constituent being suspended in said third slurry; maintaining a viscosity of said third slurry between about 500,000 centipoise and about 2,000,000 centipoise during said providing a third slurry step; and mixing said second and third slurries together into said first slurry before said loading a first slurry step, wherein said method further comprises the steps of: loading an ignition assembly into said charge casing to be substantially adjacent to said first pyrotechnic material, said loading an ignition assembly step being through said open end of said charge casing, said ignition assembly comprising at least one electrically conductive member and a bridge wire interconnected with said at least one electrically conductive member; and interconnecting said ignition assembly and said charge casing.

Claim 36

A method for assembling an electrical initiator, comprising the steps of: loading a first slurry into a charge casing, said first slurry comprising first and second constituents in suspension in said first slurry, wherein a first pyrotechnic material comprises said first and second constituents, said charge casing having an open end and a closed end, said loading a first slurry step being through said open end, wherein prior to said loading a first slurry step said method comprises the steps of: providing a second slurry of at least said first constituent of said first pyrotechnic material, said first constituent being suspended in said second slurry; maintaining a viscosity of said second slurry between about 500,000 centipoise and about 2,000,000 centipoise during said providing a second slurry step; providing a third slurry of at least said second constituent of said first pyrotechnic material, said second constituent being suspended in said third slurry; maintaining a viscosity of said third slurry between about 500,000 centipoise and about 2,000,000 centipoise during said providing a third slurry step; and mixing said second and third slurries together into said first slurry before said loading a first slurry step, wherein said method further comprises the steps of: loading an ignition assembly into said charge casing to be substantially adjacent to said first pyrotechnic material, said loading an ignition assembly step being through said open end of said charge casing, said ignition assembly comprising at least one electrically conductive member and a bridge wire interconnected with said at least one electrically conductive member; and interconnecting said ignition assembly and said charge casing.

Claim 37

A method for assembling an electrical initiator, comprising the steps of: mixing a first slurry comprising first and second constituents in suspension in said first slurry, wherein a first pyrotechnic material comprises said first and second constituents, wherein said mixing step produces no more than about 20 grams of said first slurry at any one time in a continuous process; loading said first slurry into a charge casing, said charge casing having an open end and a closed end, said loading a first slurry step being through said open end; loading an ignition assembly into said charge casing to be substantially adjacent to said first pyrotechnic material, said loading an ignition assembly step being through said open end of said charge casing, said ignition assembly comprising at least one electrically conductive member and a bridge wire interconnected with said at least one electrically conductive member; and interconnecting said ignition assembly and said charge casing.

Claim 38

A method for assembling an electrical initiator, comprising the steps of: mixing a first slurry comprising first and second constituents in suspension in said first slurry, wherein a first pyrotechnic material comprises said first and second constituents, wherein said mixing step produces no more than about 20 grams of said first slurry at any one time in a continuous process; loading said first slurry into a charge casing, said charge casing having an open end and a closed end, said loading a first slurry step being through said open end; loading an ignition assembly into said charge casing to be substantially adjacent to said first pyrotechnic material, said loading an ignition assembly step being through said open end of said charge casing, said ignition assembly comprising at least one electrically conductive member and a bridge wire interconnected with said at least one electrically conductive member; and interconnecting said ignition assembly and said charge casing.

Claim 39

A method for assembling an electrical initiator, comprising the steps of: loading a first slurry into a charge casing, said first slurry comprising first and second constituents in suspension in said first slurry, wherein a first pyrotechnic material comprises said first and second constituents, said charge casing having an open end and a closed end, said loading a first slurry step being through said open end; loading an ignition assembly into said charge casing to be substantially adjacent to said first pyrotechnic material, said loading an ignition assembly step being through said open end of said charge casing, said ignition assembly comprising at least one electrically conductive member and a bridge wire interconnected with said at least one electrically conductive member; drying said first slurry in said charge casing before said loading an ignition assembly step, wherein said loading an ignition assembly step comprises compressing said first pyrotechnic material after said drying step using at least part of said ignition assembly; and interconnecting said ignition assembly and said charge casing.

Claim 40

A method for assembling an electrical initiator, comprising the steps of: loading a first slurry into a charge casing, said first slurry comprising first and second constituents in suspension in said first slurry, wherein a first pyrotechnic material comprises said first and second constituents, said charge casing having an open end and a closed end, said loading a first slurry step being through said open end; loading an ignition assembly into said charge casing to be substantially adjacent to said first pyrotechnic material, said loading an ignition assembly step being through said open end of said charge casing, said ignition assembly comprising at least one electrically conductive member and a bridge wire interconnected with said at least one electrically conductive member; drying said first slurry in said charge casing before said loading an ignition assembly step, wherein said loading an ignition assembly step comprises compressing said first pyrotechnic material after said drying step using at least part of said ignition assembly; and interconnecting said ignition assembly and said charge casing.

Claim 41

A method for assembling an electrical initiator, comprising the steps of: loading a first slurry into a charge casing, said first slurry comprising first and second constituents in suspension in said first slurry, wherein a first pyrotechnic material comprises said first and second constituents, said charge casing having an open end and a closed end, said loading a first slurry step being through said open end; maintaining a viscosity of said first slurry between about 500,000 centipoise and about 2,000,000 centipoise during said loading a first slurry step; loading an ignition assembly into said charge casing to be substantially adjacent to said first pyrotechnic material, said loading an ignition assembly step being through said open end of said charge casing, said ignition assembly comprising at least one conductive member and a bridge wire interconnected with said at least one electrically conductive member; and interconnecting said ignition assembly and said charge casing.

Claim 42

A method for assembling an electrical initiator, comprising the steps of: loading a first slurry into a charge casing, said first slurry comprising first and second constituents in suspension in said first slurry, wherein a first pyrotechnic material comprises said first and second constituents, said charge casing having an open end and a closed end, said loading a first slurry step being through said open end; maintaining a viscosity of said first slurry between about 500,000 centipoise and about 2,000,000 centipoise during said loading a first slurry step; loading an ignition assembly into said charge casing to be substantially adjacent to said first pyrotechnic material, said loading an ignition assembly step being through said open end of said charge casing, said ignition assembly comprising at least one conductive member and a bridge wire interconnected with said at least one electrically conductive member; and interconnecting said ignition assembly and said charge casing.

Claim 43

A method for assembling an electrical initiator, comprising the steps of: loading a first slurry into a charge casing, said first slurry comprising first and second constituents in suspension in said first slurry, wherein a first pyrotechnic material comprises said first and second constituents, said charge casing having an open end and a closed end, said loading a first slurry step being through said open end; maintaining a variance of less than about 1 millimeter on an upper surface of said first pyrotechnic material when in said charge casing after said loading a first slurry step; loading an ignition assembly into said charge casing to be substantially adjacent to said first pyrotechnic material, said loading an ignition assembly step being through said open end of said charge casing, said ignition assembly comprising at least one electrically conductive member and a bridge wire interconnected with said at least one electrically conductive member; and interconnecting said ignition assembly and said charge casing.

Claim 44

A method for assembling an electrical initiator, comprising the steps of: loading a first slurry into a charge casing, said first slurry comprising first and second constituents in suspension in said first slurry, wherein a first pyrotechnic material comprises said first and second constituents, said charge casing having an open end and a closed end, said loading a first slurry step being through said open end; maintaining a variance of less than about 1 millimeter on an upper surface of said first pyrotechnic material when in said charge casing after said loading a first slurry step; loading an ignition assembly into said charge casing to be substantially adjacent to said first pyrotechnic material, said loading an ignition assembly step being through said open end of said charge casing, said ignition assembly comprising at least one electrically conductive member and a bridge wire interconnected with said at least one electrically conductive member; and interconnecting said ignition assembly and said charge casing.

Claim 45

A method for assembling an electrical initiator, comprising the steps of: providing a first slurry comprising a first constituent of a pyrotechnic material to a mixer; maintaining a viscosity of said first slurry between about 500,000 centipoise and about 2,000,000 centipoise during said providing a first slurry step; providing a second slurry comprising a second constituent of a pyrotechnic material to said mixer; maintaining a viscosity of said second slurry between about 500,000 centipoise and about 2,000,000 centipoise during said providing a second slurry step; mixing said first and second slurries together in said mixer, wherein said mixing step provides a pyrotechnic material slurry; injecting said pyrotechnic material slurry into a charge casing having an open end and a closed end, said injecting step being through said open end; and closing said open end of said charge casing with an ignition assembly, said ignition assembly comprising at least one electrically conductive member and a bridge wire interconnected with said at least one member.

Claim 46

A method for assembling an electrical initiator, comprising the steps of: providing a first slurry comprising a first constituent of a pyrotechnic material to a mixer; maintaining a viscosity of said first slurry between about 500,000 centipoise and about 2,000,000 centipoise during said providing a first slurry step; providing a second slurry comprising a second constituent of a pyrotechnic material to said mixer; maintaining a viscosity of said second slurry between about 500,000 centipoise and about 2,000,000 centipoise during said providing a second slurry step; mixing said first and second slurries together in said mixer, wherein said mixing step provides a pyrotechnic material slurry; injecting said pyrotechnic material slurry into a charge casing having an open end and a closed end, said injecting step being through said open end; and closing said open end of said charge casing with an ignition assembly, said ignition assembly comprising at least one electrically conductive member and a bridge wire interconnected with said at least one member.

Claim 47

A method for assembling an electrical initiator, comprising the steps of: providing a first slurry comprising a first constituent of a pyrotechnic material to a mixer; maintaining a viscosity of said first slurry at least at about 500,000 centipoise during said providing a first slurry step; providing a second slurry comprising a second constituent of a pyrotechnic material to said mixer; maintaining a viscosity of said second slurry at least at about 500,000 centipoise during said providing a second slurry step; mixing said first and second slurries together in said mixer, wherein said mixing step provides a pyrotechnic material slurry; injecting said pyrotechnic material slurry into a charge casing having an open end and a closed end, said injecting step being through said open end; and closing said open end of said charge casing with an ignition assembly, said ignition assembly comprising at least one electrically conductive member and a bridge wire interconnected with said at least one member.

Claim 48

A method for assembling an electrical initiator, comprising the steps of: providing a first slurry comprising a first constituent of a pyrotechnic material to a mixer; maintaining a viscosity of said first slurry at least at about 500,000 centipoise during said providing a first slurry step; providing a second slurry comprising a second constituent of a pyrotechnic material to said mixer; maintaining a viscosity of said second slurry at least at about 500,000 centipoise during said providing a second slurry step; mixing said first and second slurries together in said mixer, wherein said mixing step provides a pyrotechnic material slurry; injecting said pyrotechnic material slurry into a charge casing having an open end and a closed end, said injecting step being through said open end; and closing said open end of said charge casing with an ignition assembly, said ignition assembly comprising at least one electrically conductive member and a bridge wire interconnected with said at least one member.

Claim 49

A method for assembling an electrical initiator, comprising the steps of: providing a first slurry comprising a first constituent of a pyrotechnic material to a mixer; providing a second slurry comprising a second constituent of a pyrotechnic material to said mixer; mixing said first and second slurries together in said mixer, wherein said mixing step provides a pyrotechnic material slurry, and wherein said mixing step produces no more than about 20 grams of said pyrotechnic material slurry at any one time; injecting said pyrotechnic material slurry into a charge casing having an open end and a closed end, said injecting step being through said open end; and closing said open end of said charge casing with an ignition assembly, said ignition assembly comprising at least one electrically conductive member and a bridge wire interconnected with said at least one member.

Claim 50

A method for assembling an electrical initiator, comprising the steps of: providing a first slurry comprising a first constituent of a pyrotechnic material to a mixer; providing a second slurry comprising a second constituent of a pyrotechnic material to said mixer; mixing said first and second slurries together in said mixer, wherein said mixing step provides a pyrotechnic material slurry, and wherein said mixing step produces no more than about 20 grams of said pyrotechnic material slurry at any one time; injecting said pyrotechnic material slurry into a charge casing having an open end and a closed end, said injecting step being through said open end; and closing said open end of said charge casing with an ignition assembly, said ignition assembly comprising at least one electrically conductive member and a bridge wire interconnected with said at least one member.

Claim 51

A method for assembling an electrical initiator, comprising the steps of: providing a first slurry comprising a first constituent of a pyrotechnic material to a mixer; providing a second slurry comprising a second constituent of a pyrotechnic material to said mixer; mixing said first and second slurries together in said mixer, wherein said mixing step provides a pyrotechnic material slurry; injecting said pyrotechnic material slurry into a charge casing having an open end and a closed end, said injecting step being through said open end; maintaining a viscosity of said pyrotechnic material slurry at least at about 500,000 centipoise during said injecting step; and closing said open end of said charge casing with an ignition assembly, said ignition assembly comprising at least one electrically conductive member and a bridge wire interconnected with said at least one member.

Claim 52

A method for assembling an electrical initiator, comprising the steps of: providing a first slurry comprising a first constituent of a pyrotechnic material to a mixer; providing a second slurry comprising a second constituent of a pyrotechnic material to said mixer; mixing said first and second slurries together in said mixer, wherein said mixing step provides a pyrotechnic material slurry; injecting said pyrotechnic material slurry into a charge casing having an open end and a closed end, said injecting step being through said open end; maintaining a viscosity of said pyrotechnic material slurry at least at about 500,000 centipoise during said injecting step; and closing said open end of said charge casing with an ignition assembly, said ignition assembly comprising at least one electrically conductive member and a bridge wire interconnected with said at least one member.

Claim 53

A method for assembling an electrical initiator, comprising the steps of: providing a first slurry comprising a first constituent of a pyrotechnic material to a mixer; providing a second slurry comprising a second constituent of a pyrotechnic material to said mixer; mixing said first and second slurries together in said mixer, wherein said mixing step provides a a pyrotechnic material slurry; injecting said pyrotechnic material slurry into a charge casing having an open end and a closed end, said injecting step being through said open end; closing said open end of said charge casing with an ignition assembly, said ignition assembly comprising at least one electrically conductive member and a bridge wire interconnected with said at least one member; drying said pyrotechnic material slurry in said charge casing before said closing step, said drying step providing a solid pyrotechnic material; and maintaining a variance on an upper surface of said pyrotechnic material of less than about 1 millimeter.

Claim 54

A method for assembling an electrical initiator, comprising the steps of: providing a first slurry comprising a first constituent of a pyrotechnic material to a mixer; providing a second slurry comprising a second constituent of a pyrotechnic material to said mixer; mixing said first and second slurries together in said mixer, wherein said mixing step provides a a pyrotechnic material slurry; injecting said pyrotechnic material slurry into a charge casing having an open end and a closed end, said injecting step being through said open end; closing said open end of said charge casing with an ignition assembly, said ignition assembly comprising at least one electrically conductive member and a bridge wire interconnected with said at least one member; drying said pyrotechnic material slurry in said charge casing before said closing step, said drying step providing a solid pyrotechnic material; and maintaining a variance on an upper surface of said pyrotechnic material of less than about 1 millimeter.

Claim 55

A method for assembling an electrical initiator, comprising the steps of: providing a first slurry comprising a first constituent of a pyrotechnic material to a mixer; providing a second slurry comprising a second constituent of a pyrotechnic material to said mixer; mixing said first and second slurries together in said mixer, wherein said mixing step provides a pyrotechnic material slurry; injecting said pyrotechnic material slurry into a charge casing having an open end and a closed end, said injecting step being through said open end; closing said open end of said charge casing with an ignition assembly, said ignition assembly comprising at least one electrically conductive member and a bridge wire interconnected with said at least one member; and drying said pyrotechnic material slurry in said charge casing before said closing step, said drying step providing a solid pyrotechnic material, wherein said closing step comprises compressing said solid pyrotechnic material after said drying step using at least part of said ignition assembly and interconnecting said ignition assembly with said charge casing during said compressing step.

Claim 56

A method for assembling an electrical initiator, comprising the steps of: providing a first slurry comprising a first constituent of a pyrotechnic material to a mixer; providing a second slurry comprising a second constituent of a pyrotechnic material to said mixer; mixing said first and second slurries together in said mixer, wherein said mixing step provides a pyrotechnic material slurry; injecting said pyrotechnic material slurry into a charge casing having an open end and a closed end, said injecting step being through said open end; closing said open end of said charge casing with an ignition assembly, said ignition assembly comprising at least one electrically conductive member and a bridge wire interconnected with said at least one member; and drying said pyrotechnic material slurry in said charge casing before said closing step, said drying step providing a solid pyrotechnic material, wherein said closing step comprises compressing said solid pyrotechnic material after said drying step using at least part of said ignition assembly and interconnecting said ignition assembly with said charge casing during said compressing step.