GAS INFLATOR STRUCTURES, COOLING FILTERS THEREFOR AND METHODS OF MAKING SUCH FILTERS

Abstract: A cooling filter (30) for a chemical air bag inflator (44) is made by crimping smooth wire into a squiggle pattern, cut­ ting the crimped wire into a plurality of segments, placing the segments in a molding having the form desired for the filter, and pressing the wire segments together in the mold. The filter is characterised by its ability to determine and control the ope­ rating pressure of the inflator, and enables the structuring of an inflator for lower pressure operation with less weight and reduced cost.

Description: GAS INFLATOR STRUCTURES, COOLING FILTERS THEREFOR AND METHODSOF MAKING SUCH FILTERS BACKCl1\#O#jNI) 01 TIIJ-'. :1 NVl'N'i1TON Field of the Invention This invention relates to gas inflators or generators, and particularly to chemical or solid fuel gas generators that employ cooling filters and are useful for inflating safety cushions for automotive vehicle crash restraint systems. Description of the Prior Art Various forms of cooling filters for gas generators have been proposed in the prior art including filters made of wrapped screen wire or screen wire cut into a pattern and stacked. Typically, screen wire cooling filters, such as the filter disclosed in U. S. Patent 3,985,076 that was granted October 12, 1976, have a depth in the direction of flow of the effluent from thirteen cms. or less to several cms. While such cooling filters have worked satisfactorily, certain limiting conditions exist that are corrected or significantly improved by the present invention. - With reference to wranped screen cooling filters as described in patent 3,985,076, the effluent flow generally is parallel to the screen surface or between alternate layers of screen. The maintenance of a constant and uniform porosity is extremely important for the achievement of uniform and reproducible gas generator or inflator operation. Any step or loose section in the wrapped or stacked screens allows the effluent to pass through the filter uninterrupted with the result that the effluent going to the safety cushion or crash bag is neither cooled, nor filtered. Thus, wrapped screen filters require extreme care in fabrication, require careful inspection and have a high rejection rate in production. Cooling filters made with pattern cut and stacked screens generally overcome the problems associated with by-pass of the effluent resultina from flows within the filter. Such filters, however, are very expensive. Screen wire is relatively expensive and cutting the typical circular or doughnut pattern to make a stacked filter results in a significant waste of material. The present invention overcomes the aforementioned problems of the prior art cooling filters Iiil )lovi(l additionally, advantages of increased flexibility of inflator structural design, the use of lower cost materials, and ease of control of filter density and thereby control of inflator operating pressure. SU!A.#tAPY OF TIIE INVENTION Among the objects of the invention is to provide an improved method of making a cooling filter for a chemical or solid fuel gas inflator or generator, Another object of the invention is to provide a simplified structure for chemical or solid fuel gas inflators or generators. A further object of the invention is to provide an improved gas inflator or generator that can be structured for lower pressure operation with less weight and reduced cost. Still another object of the invention is to provide an improved cooling filter configuration for chemical or solid fuel gas inflators or generators that ensures intimate and uniform contact with the gas stream. Yet another object of the invention is to provide sur;.I# a cooling filter that can be made from wire of different materials with little or no waste of material. Another object of the invention is to provide such a cooling filter that, as applicable to chemical or solid fuel gas inflators or generators, is characterized by its ability, depending upon the manner in which it is made, to determine and control the operating pressure of the inflator. In accomplishing the foregoing objects and other objectives of the invention, there is provided a pressed wire filter made by crimping a length of wire in one or more planes, cutting the wire into short segments, and pressing the segments into a container or mold of the desired size, shape and form. The wires are crimped to provide interlocking whei pressed into tllc desil-eel Filt:oz- configuration, to cause random orientation of he wire seg- ments, and to cause multiple small and intricate gas paths through the filter. Inflators tested with the pressed wire filter according to the present invention have shown better reproducibility than comparable tests with inflators provided with a wrapped screen filter. A primary reason for the better reproduc- ibility is believed to be better uniformity of the pressed wire filter pack with its more intricate gas paths which causes all of the effluent to make multiple contacts with the crimped wire segments or elements of the filter, thus ensuring intimate intimate uniform contact of the filter.with the effluent and providing cold surfaces for heat absorption and for the condensation of solids. As applicable to chemical inflators the pressed wire filter of the present invention is characterized by its ability to control the operating pressure of the inflator by the manner in which the crimped wire segments are pressed. Theinflator gas stream exit temperature, as is known in the art, is largely dependent upon the heat transfer surfaces that are available in the filter. These surfaces can be controlled by the weight and diameter of the wire used in the filter. Surprisingly, however, the density to which the crimped wire segments are pressed has no effect on the gas stream exit temperature as lonq as the distribution of the wire segments is uniform and sufficient porosity for flow is maintained. Tests conducted with filter bulk densities of from 25 to 50 percent of the theoretical solid metal density have produced a range of inflator operating pressure ranging from about 1200 psi with a low density filter to 2500 psi for a high density filter with no other changes to the inflator. With the ability to control inflator operatinq pressure, the pressed wire filter of the present invention makes possible desirable simplification in inflator construction be- cause the combustion chamber wall normals used for the controlling ballistic orifice can now be eliminated. Additionally, the ability to achieve satisfactory cool inc; and filtration in a reduced density filter enables a structural design for the inflator providing for lower pressure. operation with lower weight and at reduced cost. Description of the Drawings Figure 1 is a block diagram and Figures 2, 3, 9 and 10 are diagrammatic, cross-sectional illustrations of equipment that may be employed in practicing the method of the present invention; Figure 4 of the drawings illustrates a crimped wire segment of the improved filter according to the present invention; Figure 5 is a sectional view through the center of a circulator inflator according to the present invention; Figures 6 and 7 are curves illustrating for cooling filters of different weight combustion chamber and inflator outlet pressure variations during the inflator action time; and Figure 8 is a sectional view through the center of another form of circular inflator embodying the present invention. DESCPIPTlON OF T#iE PPFFEPPED EMBODIMENT The equipment 10 illustrated in Figures 1, 2 and 3 for making the pressed wire fiber filter according to the pre sent invention includes a machine 12 for crimping wire 14 as the wire 14 is drawn off a supply or roll of wire 16, a cutting machine 18 for cutting the crimped wire into short fibers or segments 20, a storage bin or container 22 for storing the crimped wire segments 20, a cylindrical container or mold 24 and a cooperating cylindrical ram 26, the size, shape and form of the mold 24 and the ram 26 being selected to provide the desired size , {-01'11l 0##t#and form ##l t-10C' I- i 1 lllj . The crimping machine 12 may be of any kllos:n tyl)e allel crimps the wire 14 into a wavy or squiggley pattern in one or more planes. The crimped wire 14, after being cut by cutting machine 18 into short fibers or segments 20, such as the segment illustrated in Figure 4, are loosely placed in random orientation in the mold 24, as indicated at 28 in Figure 2, where the segments 20 are pressed by the ram 26 into an annular pack 30 of the size, shape and form desired for the pressed wire fiber filter 30, the ram 26 exerting a pressing force of magnitude sufficient to move the ram and wire fibers 20 into the position shown in Figure 3. The mold 24 and ram 26 illustrated in Figures 2 and 3 are arranged to provide a pressed wire filter pack 30 of annular form having skewed opposed parallel faces. In order to provide for ready separation of the filter pack 30 from the mold 24 when formed, the mold 24 desirably is separable, as indicated, and comprises, a circular base member 32 and inner and out##-' cylindrical members 34 and 36, respectively, an upwardly ex tending cylindrical projection 38 on the base member 30 serving as a guide for the proper positioning of the cylindrical members 34 and 36. Oblique opposed surfaces on the projection 38 and on ram 26 form the desired skewed opposed surfaces of filter pack 30. The wires are crimped to provide interlocking when pressed into a filter, to cause random orientation of the wire segments, and to provide multiple small and intricate gas paths through the filter. One material that may be used for the wire 14 is bright carbon steel in diameters from 0.12 to 0.63 iniminetres in diameter. It will l)L# understood, however, that depending upon the a#plication, other materials may be used for the wire 14 such as aluminum, copper or stainless steel. The wire 14 may be crimped in various patterns, one such pattern being shown in Figure 4. Typically, the width of the crimped wire segment may vary from 3 to 100 wire diameters. The leJ#qth oF tho wire fibers. or segments have no significant effect upon the end fui#ctioi# of tlle filter. The fibers or segments must be reasonably short, however, to facilitate their handling and their distribution in the container or mold 24. If the wire segments are too long, they tend to hand together tenaciously and cannot be easily handled. In general, the wire fibers or segments may range in length from approximately 0. 3 centimetres to 2.5 centimetres. Since the individual wire fibers or segments are loose during the filter assembly, and may also come loose after the filter pack has been pressed, it is desirable to place a layer of woven screen over the pressed wire filter on both the gas inlet and exit sides. Such layers of woven screen are indicated in Figure 2 by reference numerals 40 and 42, respectively, the screen 40 typically comprising one layer of 12 mesh screen and the screen 42 two layers of 80 mesh screen. If desired, the layers of woven screen 40 and 42 may be associated with the filter pack 30 after pressing of the latter into the desired configuration has been effected. Typical applications of the pressed wire filter pack, 30 constructed according to the foregoing method are illustrated in Figures 5 and 8. Specifically, Figure 5 shows such a pressed wire filter pack 30 substituted for the spirally wrapped wire screen cooling device 30 of the yen- era tor disclosed in the aforementioned U. S. Patent 3,985,076, the disclosure of which patent, by reference, is incorporated herein. Figure 8 shows a licllltcr weiq ] #t, lower cost structural arrangement for a gas generator or inflator that is designed for lower pressure operation. The gas generator 44 of Figure 5 includes a centrally located electric squib 46 that is surrounded by granular pyrotechnic material 48 in a perforated cylinder 50 having an end cap 52. The squib 46 is supported in a mounting adapter 54 through which electrical wires 55 external Uor energizing the squib 46. A rupturable il#r 56 is disposed in surrounding relation to the cylinder 50. Diaphragm 5G, in turn, is surrounded by elletize gas generant material 58 which is surrounded by an annular filter 60. The diaphragm 56 serves the dual purpose of retaining the granular pyrotechnic material 48 in the perforated cylinder 50 and of ensuring that the gases produced by the pyrotechnic material 48 have sufficient pressure to permeate the gas generant material 58 thoroughly for efficient ignition before they are released by rupture of the diaphragm 56. The assemblage embraced by the annular filter 60 is enclosed within a hermetically sealed rupturable container 62. The container 62 is preferably made of aluminum and comprises a drawn, cup-shaped member 64 sealed to an end disc 66 with a double-crimn seal 68, typical of metal containers used for preserving food and beverages. The annular filter 60 is preferably made in two parts, an inner part comprising a plurality of layers of fine screen 70 (about 30 to 60 mesh) surrounded by a plurality of layers of coarse screen 72 (about 8 to 16 mesh) . The fine screen 70 filters solid particles out of the gases, and the coarse screen 72 creates a plenum chamber between the fine screen 70 and the wall of rupturable container 62 for build-up of gas pressure to rupture container 62 and to provide for a free-flow of gases therefrom. Container 62 is enclosed in an inner housing formed by a cylinder 74 having a plurality of periplleral orifices 7G near one end, an end cap 78 that fits over the other end, and a concave half shell 80 of the outer housing. The concave half shell 80 has an annular mounting flange 82 and internal screw threads 84 for engagement with the convex half shell 86. Convex half shell 86 has external threads 88 and a plurality of peripheral orifices 90. An annular space 92 between the inner housing cylinder 74 ancl the outer housing half shells 80 and 8G contains a coclill(l filter pack 30 and optionally an adjusting material or substance 94 for neutralizing the acidity or the alkalinity of the gases. The cooling filter pack 30 is made as described by reEcr- ence to Figures 1, 2 and 3 and is retained in position bo- tween the orifices 76 of the inner housing cylinder 74 and the orifices 90 of the outer housing convex half shell 86 by a flange 96 on the end cap 78 and an annular retaining member 98 The flange 96 and the annular retaining member 98 have perforations indicated at 100 and 102, respectively, to permit the flow of the generated gases through the filter pack 30. An annular supporting member 104 retains the pIS adjusting material 94 in a position adjacent the orifices 76 in the inner housing cylinder 74. The mounting adapter 54 for squib 46 is retained in the concave shell 80 by a snap ring 106 that fits in a groove 108 of the adapter 54 and into a recess 110 of the half shell SO. The wall of-the concave half shell 80 is confined between the snap Ting 106 and a shoulder 112 on the adapter 54 is also sealed reltaive to the half shell 80 by an elastomeric composition 114. An annular, elastomeric, O-ring seal 116 is provided at the juncture of the two half shells 80 and 86 and adjacent the retaining member 98 to prevent the escape of gases therethrough. Similarly, a bead 118 of a room temperature vulcanizing silicone rubber is provided at the juncture of the annular retaining member 98 and the inner housing cylinder 74 to prevent the escape of gases there through, that is, to minimize channeling of qases between the annular retaining member 98 and the inner housing cylinder 74. The invention is illustrated but not limited by the following examples of operation of inflator 44 in which the gas generant 58 employed, in each case, consisted of 70% sodium azide (NaN2), 28t molybdenum disulfide and 20 sulfur. The com##us tion chamber filter 60 comprised three layers ##(' 70 of 40 mesh wire screen and two layers 72 of 12 mesh wire screen. The pressure in the inner cylinder 74, that is, the combustion chamber pressure, and the pressure of the effluent gases exiting the peripheral orifices 90 of the generator 44 into an evacated tank were measured, as was also the p11 of the gas in the tank. EXAMPLE 1 75 grams and 25 grams of pellets allG.35mm in diameter and 1.52 mm and 3.04 mm thick, respectively, were used for the gas generant 58. The ignition system included a type CIL-S154 squib and 3 grams of composition UIX-172 for the pyrotechnic material 48. UIX-172 is an ignition powder consisting of 15% by weight boron and 85 % pot##.#2uni nitr#t.-e. The cooling filter 30 comprised 175 grams of ul crimped wi#e segments with 2-60 mesh wire screen layers 42 on -top and 1-30 mesh wire screen layer 40 underneath. The material used for the neutralizer 94 comprised iron sulfate, FeSO4. The results are plotted in Figure 6 wherein it is seen that the pressure in the combustion chamber increased to a maximum pressure of 133.4 kg/cm2 ininan interval of 8 milliseconds (msec) after an ignition delay of 2 msec, the generator action time being 40 msec Action time is defined as the intervening time between 10% of the maximum on the rising portion of the pressure curve to 10% of the maximum on the falling portion of the pressure curve. The maximum tank pressure, occurring 55 msec after ignition, is seen to be 2 3.6 Worn. The pH of the gas in the tank, as measured, was 9. EXAMPLE 2 93 grams of pellets 1.52 mm thick and 6.35mm in diameter were used for the gas generant 58. The ignition system included a DuPont squib, Part No. S-109 and 3 grams of composition UIX-172 for the pyrotechnic material 48. The cooling filter comprised 185 grams of crimped wire segments with 2 80 mesh wire wi l-cscreen mayers layers 42 42 on top and 1-12 mesh wire screen layer 40 underneath. iloc material used for tile neutralizer 94 comprised 12 grams of cadmium chloride. The -results are plotted in Figure 7 wherein it is seen that the pressure in the combuation chamber increased to a maximum in excess of 189.6 kg/cm2 in an interval of about 6 msec after an ignition delay of 2-3 msec, the generator action time being 45 msec. The maximum tank pressure is seen to be 2.8kg/an2 which pressure occurred 60 msec after ignition. The pil of the gas in the tank, as measured, was 10. The lighter weight lower cost inflator structure illustrated in Figure 8 includes a circular housing 120 having a cover member 122 of inverted cup-shaped form that is attached to a cup-shaped base member 124, internal threads 126 on the latter engaging external threads 128 on cover member 122. A mounting flange 130 is provided on base member 124. An electric squib 132 that is contnjnctll witjjj a bulge 134 is mounted within base member l2'i , being sui#l)oute'1 by an adapter 136 through which electrical wires 138 for energizing the squib 132 extend from the bottom of base member 124. A perforated cylinder 140 arranged in extending relation to tube 13-4 contains granular pyrotechnic material 143. Cylinder 140 is provided with an end cap 141 and is surrounded by a rupturable diaphragm 142. The remaining space provided in base member 124, when cover member 122 is in proper threaded engagement therewitl1, is filled with a gas generant material in pelletized form as indicated at 144. Cover member 122, as shown, includes a plurality of peripheral orifices 146. Mounted within cover member 122 is a cylindrical member 148, a pressed wire filter 150, a perforated metal plate 152, and a wire screen filter 154. Pressed wire filter 150 is of circular convex form and is provided with an inverted, generally cup-shaped, retaining member 156 having an upper offset portion 158 which bears agains-tthe upper inner wall of cover 122. The upper surface of retaining member 156, except for the offset portion 158, includes a plurality of perforations indicated at 169. The lower circular edge 162 of retaining member 156 is bent inwardly for providing lower peripheral edge support for the pressed wire filter 150. Additionally, for retaining the integrity of the filter 150, there is desirably provided layers of wire screen 164 and 166 on the top and bottom surfaces, respectively, of the filter. Filter 150 is further supported in cover 122 of inflator 120 by an inwardly tapering upper portion 149 of cylindrical member 140, the upper peripheral edge of the filter retaining member 156 bearing against the inwardly tapering portion 149 of retaining member 148. A plurality of peripheral orifices (not shown) are provided in portion 149 of member '148, preferably angularly spaced from the orifices 146 in member 122. The pressed wire filter 150 is macle oF crimped xi re segments tllat may be identical to or Similar to tilco wire segment 20 illustrated in Figure 4. Figures 9 and 10 are semi-schematic cross sectional illustrations of typical equipment for making 'the filter 150. As there shown, the equipmcllt includes a separable container or mold 168 and a cooperating ram 170, the mold 168 and ram 170 being of the proper size, shape and form to provide a packed filter 150 of desired configuration. Mold 168, as shown, is comprised of a base member 172 having an upstanding circular projection 174 the upper surface 176 of which is concave in shape matching the convex form desired for the filter 150, and further includes a cylindrical member 178 that is positioned on the base member 172 in snug engagement with the upstanding projection 174. The lower surface of ram 170 is of convex shape and matches the concave form desired for the filter 150, as seen in Figure 8. Crimped wire fibers or segments indicated at 180, after being cut by a cutting machine such as the cutting machine 18 of Figure 1, are loosely positioned in random orientation in the mold.168, as indicated in Figure 9, where they are pressed by the ram 170 into a pack of the convex shape and form required of the pressed wire fiber filter 150, layers 164 and 166 being provided, as indicated to retain the segments. Ram 170 exerts a pressing force of magnitude sufficient to move the ram and the wire fibers or segments into the position shown in Figure 10. Plold 168, as indicated, is readily separable whereby easy access to the formed and packed filter 150 is provided. It will be understood that, if desired, the retaining wire screen members 164 and 166, as seen in Figure 9, may be brought into association with the associated filter pack 150 after the pressing of the filter into the desired size, shape and form has been effected. Thus, in accordance with the invention there has been provided an improved filter configuration for the removal of heat and solid particulates from the effluent of chemical air bag inflators, a filter that ensures intimate and uniform contact with the gas being generated and expelled from the inflator, that can be made of different materials with little or no waste of material, and that is characterized by its ability to determine the operating pressure of the inflator or generator. Variables in the construction of the improved cooling filter include the material and diameter of the selected wire, the manner and degree of crimp, and the density to which the wire segments are pressed. There has been provided, additionally, a method of making such a cooling filter. There has further been provided an improved and simplified structure for gas inflators, specifically' an inflator that can be structured for lower pressure operation with less weight and at reduced cost.

Claims: CLAIMS 1. A method of making a pressed wire segment filter (30, 150) characterised by the steps of crimping smooth wire (14) into a squiggley pattern, cutting the crimped wire into a plurality of segments (20), placing the crimped wire segments in a container (24, 168) having the shape and form desired for the filter, and pressing said wire segments together in the container. 2. A method as claimed in claim 1, wherein the smooth wire (14) is crimped in more than one plane to ensure random distribution, orientation, and interlocking of the segments (20) when pressed in the container (24, 168) thereby to provide uniformity in packing and to provide multiple intricate gas paths through the filter (30, 150) whereby gas flow through the filter is caused to make multiple contacts with the segments of the filter. 3. A method as claimed in claim 1 or 2, including the steps of placing layers of woven screen (40, 42 or 164, 166) over the pressed wire filters (20, 150) on both the effluent inlet and exit sides. 4. A method as claimed in claim 1, 2 or 3, wherein the material of the smooth wire (14) from which the crimped wire segments (20) are made is bright carbon steel. 5. A filter (30, 150) for a chemical air bag inflator (44, 120) characterised by compressed together crimped wire segments (20). 6. A gas inflator (44, 120) for an inflatable occupant restraint, characterised by a housing, a gas generating charge (58, 144) in said housing, means (46, 132) for igniting said charge in response to a predetermined signal, an outlet (90, 146) in said housing for the expulsion of gases formed upon igniting and burning of said charge, and a filter pack (30, 150) in said housing between said charge and said outlet, said filter pack being made of pressed crimped wire segments (20). 7. A filter or gas inflator as claimed in claim 5 or 6, wherein the crimped wire segments (20) are crimped in more than one plane. 8. A filter or gas inflator as claimed in claim 5, 6 or 7, wherein the material from which the crimped wire segments (20) are made is bright carbone steel. 9. A filter or gas inflator as claimed in claim 5, 6, 7 or 8, wherein the width of each of the crimped wire segments (20) is in a range of three to one hundred wire diameters, and the length of each of the segments is in a range from one-eighth inch to one inch. 10. A filter or gas inflator as claimed in claim 5, 6, 7, 8 or 9, including layers of woven screen (40, 42 or 164, 166) on opposite sides of the filter ¯ filter pack. 11. 1 gas inflator as claimed in claim 6, 7, 8, 9 or 10, wherein the housing includes an inner housing (74, 78) containing the charge (58) and igniting means (46) and having peripheral orifices (76) for the expulsion of gases, and an outer housing (80, 86) which surrounds the inner housing and defines an annular chamber (92) therewith, the outlet from the housing comprising peripheral orifices (90) in said outer housing, and wherein said filter pack (30) is annular in shape and is positioned in said annular chamber between the orifices (76, 90) of said inner and outer housings. 12. A gas inflator as claimed in claim 6, 7, 8, 9 or 10 including a circular perforated plate (152) in the housing (122, 124) said plate being positioned to separate the filter pack (150) from the charge (144) and the igniting means (132). 13. A gas inflator as claimed in claim 12, wherein the filter pack (150) is generally cylindrical with one of its opposite surfaces being convex and the other concave, the peripheral edge adjacent the concave surface of said filter pack being in engagement with said plate adjacent the peripheral edge of said plate, and wherein the outlet in said housing comprises orifices (146) in the peripheral wall of said housing adjacent the convex surface of said filter pack. 14. A gas inflator as claimed in claim 13, including a perforated retaining member (156) covering at least the convex surface of the filter pack (150), said retaining member including an offset portion (158) projecting from the central convex surface portion of the filter pack, said offset portion of the retaining member cooperating with an inner surface of the housing to provide support for said filter pack.

Inventors: SCHNEITER, FRED E.
Applicants: THIOKOL CORPORATION
Application year: 1979
Main classification: B01D39
IPC codes: B01D39, F42B3, B60R21