Method and airbag inflation apparatus employing magnetic fluid

An airbag inflation apparatus includes a chamber for generating a gas to inflate an airbag. A valve, including a magnetic fluid and a source of magnetic field, preferably an electromagnet, is associated with the chamber for regulating the flow of the gas into the airbag. A sensor determines and feeds occupant information to the sensor.

BACKGROUND OF THE INVENTION

The present invention is directed to an inflatable passenger restraint system, and more particularly to an airbag inflation apparatus and method for regulating inflation in response to occupant parameters.

An inflatable passenger restraint system, such as an airbag, deploys when sensors in a vehicle detect conditions of an impending crash. The airbag is designed to protect vehicle occupants from impact with parts of the vehicle, such as the steering wheel, dashboard, and windshield. In some cases, side airbags protect vehicle occupants from impact with the sides of the interior of the vehicle.

However, airbags often injure rather than protect vehicle occupants. For instance, airbags may inflate too rapidly and forcefully resulting in bruises, broken bones, and even death, especially in smaller adults and children. In fact, automobile manufacturers recommend that young children ride in the backseat of a vehicle away from an airbag to avoid injury and possibly death from an airbag in the event of a crash. To prevent such injuries and deaths from airbags, manufacturers have sought to control airbag inflation using valves and other means.

Mechanically controlled, pyrotechnically controlled, electronically controlled, and pressure assist valves are currently utilized in controlled inflation airbag systems. However, mechanically and pyrotechnically controlled valves are costly and complex. Electronically controlled valves have a slow response time and often require mechanical springs that further increase response time and power required. Pressure assist valves minimize time required to completely open a valve, however, they restrict the ability to rapidly close or otherwise adjust the position of the valve after opening.

Other means of regulating airbag inflation include multiple inflation containers and multiple level inflators. However, multiple level inflators are expensive to manufacture due to the need to integrate two or more stored energy devices into one inflator. Also, the entire inflator must be replaced if one stored energy device is activated.

Numerous U.S. patents disclose airbag systems utilizing valves to regulate the flow of inflation fluid into the airbag. U.S. Pat. No. 5,161,776 discloses a solenoid valve assembly that is well suited for use in motor vehicle air bag assemblies. U.S. Pat. No. 5,582,425 teaches an airbag inflation system comprising a valve mechanism including two valves. One valve opens to initiate gas flow and a second valve controls gas flow by gradually increasing the flow passage area with the movement of a movable valve member. U.S. Pat. No. 5,927,753 teaches an airbag system with a valve that is actuable to regulate flow of inflation fluid through the valve so as to vary rates at which the inflation fluid pressure increases in the protection device. The valve may be a solenoid valve. U.S. Pat. No. 5,947,514 discloses an airbag system with controlled airbag inflation through the use of a throttling valve module including pintle valves, spool valves, and other electrically controlled valves. U.S. Pat. No. 6,076,852 teaches an airbag inflation apparatus which regulates the flow of inflation fluid using a solenoid valve to control outflow area.

U.S. Pat. No. 5,707,078 teaches an air bag module with adjustable cushion inflation provided by a valve member. The valve member is moved in one direction to simultaneously increase the size of the inflation outlet into the airbag while decreasing the size of the vent outlet and is moved in another direction to simultaneously decrease the size of the inflation outlet into the airbag while increasing the size of the vent outlet. The valve member is positioned by a control unit which receives input from various sensors within the vehicle regarding such factors as ambient temperature, occupant position, occupant weight, seat belt usage, etc to produce an optimum cushion inflation based upon these factors. An electromagnet, solenoid, or other device can be used to move the valve member, however, the valve member does not incorporate a magnetic fluid. This patent differs from the present invention as the valve described in the present invention does not contain a valve member that physically moves and controls the size of the inflation outlet into the airbag, rather only the particles within the magnetic fluid change position to control the gas inflation rate into the airbag.

U.S. Pat. No. 6,036,226 discloses a “smart” airbag inflator with a piston for regeneratively pumping liquid propellant from a reservoir into a combustion chamber for ignition and combustion to generate airbag inflation gases. A magneto-rheological fluid fills a damping chamber in the piston and an electromagnet varies a magnetic field exerted on the magneto-rheological fluid. Thus, the damping force of the piston may be regulated and the damping force controls the rate of liquid propellant combustion and inflation rate of the airbag. While this patent is directed to controlling the rate of liquid propellant combustion to control the inflation rate of the airbag, the present invention controls the rate and amount of combustion gas passing between the reaction chamber and the airbag. Also, in the present invention, the rate of liquid propellant combustion always remains the same.

U.S. Pat. No. 6,039,347 discloses another airbag inflator with a pair of telescoping pistons in which liquid propellant is regneratively pumped from a reservoir into a combustion chamber for ignition and combustion to generate airbag inflation gases. Pressurization of the combustion chamber causes one piston to pressurize a hydraulic fluid chamber which causes the second piston to pressurize the liquid propellant reservoir. Again, a damping fluid such as a magneto-rheological fluid in a damping chamber of the second piston controls the rate of airbag inflation gas generation. While this patent is directed to controlling the rate of airbag inflation gas generation, the present invention controls the rate and amount of combustion gas passing between the reaction chamber and the airbag. In the present invention, the rate of airbag inflation gas generation always remains the same.

Valves employing magnetorheological (MR) fluids to control gas flow are well known in the art. Magnetorheological fluids are magnetic field responsive fluids containing magnetizable particles coated with a surfactant and dispersed in a carrier liquid. These fluids typically have been used in devices, such as dampers, shock absorbers, seals, valves and the like to provide varying stress levels controlled by an external magnetic field. The variable stress is created by magnetic coupling of the particles in the form of chains or bent wall-like structures upon interaction with an external magnetic field. As to the composition, these fluids are typically made of micron-sized particles dispersed in an engineering medium, such as hydraulic oil, mineral oil, or water, or the like.

U.S. Pat. No. 6,044,866 teaches a gas flow valve comprising at least one gas inlet, at least one gas outlet, a magnetic fluid arranged in the gas flow path such that the gas must pass trough the magnetic fluid, and a means for application of a magnetic field such as a permanent magnet or an electromagnet. The gas flow valve utilizes the change in viscosity of the magnetic fluid due to the application of a magnetic field to control the gas flow through the valve. The valve is capable of permitting partial gas flow in addition to no gas flow and full gas flow so that the gas volume flowing through the valve in accordance with the invention can be continuously adjusted. However, the patent does not suggest any applications of the valve and it is not used in a controlled airbag inflation system. Further, the patent only generally discloses that any type of magnetic fluid may be used in the valve, while in the present invention it is necessary to carefully design and produce the magnetic fluid used in the valve located between the reaction chamber and the airbag. The properties of the magnetic fluid such as viscosity and yield stress must be extremely controllable upon the application of varying degrees of a magnetic field in order to protect the passengers in the vehicle. The response time of the magnetic fluid must also be extremely fast in order to inflate the airbag during a collision.

U.S. Pat. No. 6,186,176 discloses a method and system for controlling the flow of a gaseous medium through a fluid using an electrorheologic fluid, a means of guiding the gaseous medium through the electrorheologic fluid, and a means for applying an electric field at least partially in the area of the electrorheologic fluid. The viscosity of the electrorheologic fluid is controlled by the application of the electric field thereby controlling the flow of the gaseous medium through the electrorheological fluid. The means of guiding the gaseous medium through the fluid can be a shaped container. Preferably, the gaseous medium is air. The patent also suggests that the system may be used as a control valve or an overpressure valve.

There is thus a need for an inflatable passenger restraint system with controlled airbag inflation. In the present invention, a valve employing a magnetorheological fluid to control gas flow is applied to an inflatable passenger restraint system. More specifically, the present invention provides an alternative valve means utilizing the properties of a magnetic fluid to control the inflation rate of an airbag.

BRIEF SUMMARY OF THE INVENTION

The principal object of the present invention is to provide an airbag inflation apparatus which overcomes the drawbacks associated with conventional airbag inflation apparatus.

An object of the present invention is to provide an airbag inflation apparatus which employs a magnetorheological fluid to control the flow of gas(es) between the reaction chamber and the airbag.

Another object of the present invention is to provide an airbag inflation apparatus which is simple in construction, inexpensive to manufacture, and has a faster response time to inflate the airbag during a collision.

Yet another object of the present invention is to provide an airbag inflation apparatus in which the rate of propellant combustion or inflation gas(es) generation remains the same.

Still yet another object of the present invention is to provide an airbag inflation apparatus which is reusable upon activation.

In summary, the main object of the present invention is to provide an airbag inflation apparatus which is simple in construction, inexpensive to manufacture and has a faster response time than the conventional devices. The apparatus of the invention employs a magnetorheological fluid to control or regulate the flow of inflation gas(es) between the reaction chamber and the airbag.

In accordance with the present invention, an airbag inflation apparatus includes a chamber for generating a gas to inflate an airbag. A valve, including a magnetic fluid and a source of magnetic field, preferably an electromagnet, is associated with the chamber for regulating the flow of the gas into the airbag. A sensor determines and feeds occupant information to the sensor.

DETAILED DESCRIPTION OF THE INVENTION

In accordance with the present invention and as illustrated inFIG. 1, an airbag inflation apparatus includes crash sensor(s)10, occupant weight and position sensor(s) (not shown), an igniter12, a combustible material capable of generating airbag inflation gas(es)14, a reaction chamber16, a valve18(FIG. 2) including a magnetic fluid20and a source of magnetic field, preferably an electromagnet22, and an airbag24. The valve18is located between the reaction chamber16and the airbag24. The valve18is a shaped container, such as a rectangular or cylindrical container containing the magnetic fluid20and surrounded by the electromagnet22, and connects the outlet of the reaction chamber16to the inlet of the airbag24. The valve is preferably made of metal or plastic, or a similar suitable material.

When crash sensor(s)10detects a probable collision, the igniter12ignites the combustible material in the reaction chamber16to generate airbag inflation gas(es)14. The combustible material may be liquid propellant, ignitable gas generating material, pressurized inflation fluid, or a combination of pressurized inflation fluid and ignitable material for heating the inflation fluid. Common ignitable gas generating materials include a mixture of NaN3, KNO3, and SiO2or nitrocellulose based double-base powder. A pressurized inflation fluid may be air, and the ignitable material for heating the inflation fluid may be hydrogen, methane, or a mixture of hydrogen and methane. The igniter can produce an electrical impulse.

In addition, when the crash sensor(s)10detects a probable collision, the weight and position sensor(s) record the size and position of vehicle occupant(s). The valve18uses the crash data from the crash sensor(s)10and the occupant weight and position data from the occupant weight and position sensor(s) to control the rate at which the airbag inflation gas(es)14flows out of the reaction chamber16and into the airbag24. In particular, based on the crash data from the crash sensor(s)10and the occupant weight and position data from the occupant weight and position sensor(s), the strength of the magnetic field produced by the electromagnet22adjusts the viscosity of the magnetic fluid20and the conformation of the particles24within the magnetic fluid20to control the flow rate of inflation or combustion gas(es)14from the reaction chamber16to the airbag24.

As illustrated inFIG. 2, if the crash data and occupant weight and position data indicate that the highest inflation gas flow rate is desirable, the electromagnet22produces no magnetic field and the particles26remain suspended in the magnetic fluid20allowing the inflation gas(es)14to flow freely between the reaction chamber16and the airbag24.

As illustrated inFIG. 3, if the crash data and the occupant weight and position data indicate that a zero inflation gas flow rate is desirable, the electromagnet22produces a magnetic field causing the magnetic coupling of the particles26to form chains or bent wall-like structures28that completely block the gas flow between the reaction chamber16and the airbag24. The inflation gas(es) is instead vented to the atmosphere through a relief valve (not shown) in the reaction chamber16.

As illustrated inFIG. 4, if the crash data and the occupant weight and position data indicate that the airbag24should inflate at some intermediate inflation gas flow rate, the electromagnet22produces a magnetic field of intermediate strength causing the magnetic coupling of some of the particles26to form short chains or bent wall-like structures30to partially block the gas flow between the reaction chamber16and the airbag24, while the other particles26remain freely suspended in the magnetic fluid20. Excess inflation gas(es) not permitted to enter the airbag24is vented to the atmosphere through a relief valve (not shown) in the reaction chamber. Many intermediate inflation gas flow rates are possible.

The particles in the magnetic fluid may be synthesized by various techniques, such as chemical synthesis, sol-gel, chemical co-precipitation, and microwave plasma technique. The microwave plasma technique, described in U.S. Pat. No. 6,409,851 by Sethuram (incorporated herein in its entirety by reference) is the preferred technique as it is unique in that it gives better control over particle size, shape, and purity, and can be readily extended to produce different compositions of powders. The particles include core particles coated with a surfactant and/or coating. If the particles are coated with both a surfactant and a coating, the particles would have three layers. Preferably, the coating layer is the outermost layer that covers the surfactant layer, while the surfactant layer covers the innermost layer, the particles. The particles are preferably made of a magnetic material, such as iron, iron oxide, cobalt, cobalt oxide, nickel, nickel oxide, an alloy such as steel, or a combination thereof. Preferably, the particles are made of iron, iron oxide, or a combination thereof. The composition of the particles is important as the composition controls the magnetic properties of the magnetic fluid, and therefore determines the different possible airbag inflation gas rates and amounts.

The average diameter or size of the particles is from about 1 nm to 10 μm. The preferred size of the particles is from about 1 nm to 5 μm, while the most preferred size of the particles is from about 10 nm to 1 μm. The size of the particles is important as the size controls the magnetic properties of the magnetic fluid and, therefore, determines the different possible airbag inflation gas rates and amounts.

Colloidal particles have an inherent tendency to aggregate and form clusters or agglomerate due to attractive van der Waals (vdW) forces. To stabilize the particles against these attractive forces, it is necessary to introduce a repulsive interparticle force, either by an electrostatic or by a steric means. Electrostatic stabilization utilizes the surface charge typically present on the particles, which is effective in a medium having a high dielectric constant, such as water, while in steric stabilization, a sufficiently thick layer of a polymeric or surfactant molecules is introduced around the particles. The surface layer functions as a steric barrier to prevent particle agglomeration, and thereby ensures stability of the fluid. The surface layer also prevents dissolution of the magnetic materials. This technique is preferred for the present invention. The particles are preferably coated with a surfactant and/or coating by adsorption of surfactant and/or coating molecules onto the particles in the presence of ultrasonic irradiation in a high shear field. The types of surfactants that may be utilized in the present invention include, but are not limited to, lecithin, polyethylene glycol, oleic acid, Surfynol® surfactants (available from Air Products), and a combination thereof. The types of coatings that may be utilized in the present invention include, but are not limited to, silica, gold, silver, platinum, steel, cobalt, carbon, a polymer, and a combination thereof. The polymer can be polyethylene glycol, polystyrene, dextran, or a combination thereof. Preferably, the particles are only coated with lecithin or Surfynol® surfactants.

The shape of the particles is important for two reasons. First, the magnetic effect is dependent upon the particle volume fraction, which in turn is a function of the particle shape. For instance, needle shaped particles exhibit similar magnetic effect at concentrations ten times smaller than spherical particles because of larger surface area per volume. Second, the flow characteristics of the particles in a liquid medium are dependent upon their shape. The shapes utilized in this invention include, but are not limited to, spherical, needle-like, cubic, irregular, cylindrical, diamond, oval, and a combination thereof (FIG. 6). The shapes of the particles are important as the shapes control the magnetic properties of the magnetic fluid and therefore determine the different possible airbag inflation gas rates and amounts.

The particulate volume or weight fraction is also important as the magnetic character and zero field viscosity are dependent upon the particulate volume or weight fraction. Zero field viscosity refers to the viscosity of the magnetic fluid when it is not acted upon by a magnetic field and if it is too large the airbag inflation gases may not be able to diffuse through the magnetic fluid and into the airbag at a significant rate. A magnetic fluid with a larger particulate volume or weight fraction exhibits greater magnetic character and zero field viscosity than a magnetic fluid with a smaller particulate volume or weight fraction. Preferably, the particulate weight fraction is about 1% and 95%.

The particles coated with a surfactant are dispersed in a carrier liquid by high shear mixing followed by ultrasonification to form a homogenous fluid. The carrier liquid helps to retain the fluidity of the magnetic fluid when the magnetic fluid is not acted upon by a magnetic field. Carrier liquids include water based and oil based liquids, such as glycerol/water and/or mineral oil mixtures. Preferably, the carrier liquid is hydraulic oil, mineral oil, silicone oil, biodegradable oils, or a combination thereof.

EXAMPLE

Ultrafine powders of iron oxide with an average particle size of about 45–50 nm were produced using the proprietary microwave plasma chemical synthesis process described in U.S. Pat. No. 6,409,851 by Sethuram et al. Vapors of iron pentacarbonyl were fed into the plasmatron with argon/oxygen as the plasma gas. The plasma gas flow rate was about 0.003–0.0034 m3/min and that of the carrier gas was about 0.0003–0.0004 m3/min. The plasma temperature was about 900–950° C., the powder feed rate was about 50–60 gm/hr, and the quenching water flow rate was about 2.0–2.5 liter/min at 20° C. The reactor column diameter was about 48 mm and its length was about 10″. The microwave forward power was about 4 kW, the reflected power was about 0.7 kW, and the operating frequency was about 2450 MHZ.

Standard magnetic characterization of temperature dependent susceptibility and M-H hysteresis loops were performed using a variable temperature range of about 5 K to 350 K and magnetic fields of about 0 T–5 T. The magnetic characterization tests were performed using Magnetic Property Measurement Systems from Quantum Design that uses SQUID magnetometry. The coercivity of the iron oxide nanopowders was about 176 Oe and the magnetic saturation was about 40 emu/g.

Lecithin (2 wt %-optimized) was mixed in Mobil DTE 20 series hydraulic oil using a high speed emulsifier at speeds close to 11,000 rpm. The iron oxide nanopowders were added to the oil and the mixing continued. The mixing speed was kept constant at about 11,000 rpm for a mixing time of about 30 minutes. The solids loading was about 60 wt %.

Force versus displacement hysteresis cycles at 0–2 A were generated using an unpressureized Rheonetics truck seat damper (available from Lord Corporation, Cary, N.C.). The force versus displacement hysteresis cycles are shown inFIG. 5. As the field increases, the area within the force vs. displacement hysteresis (or energy dissipation or damping) also increases. This indicates that there is a substantial magnetorheological effect in the fluid, which is responsible for the closing and opening of the valve in the airbag inflation apparatus of the invention.

While this invention has been described as having preferred sequences, ranges, steps, materials, or designs, it is understood that it includes further modifications, variations, uses and/or adaptations thereof following in general the principle of the invention, and including such departures from the present disclosure as those come within the known or customary practice in the art to which the invention pertains, and as may be applied to the central features hereinbeforesetforth, and fall within the scope of the invention and of the limits of the appended claims.