Hybrid inflator with tortuous delivery passage

Abstract: A hybrid inflator (10) for a vehicle passenger restraint system comprises a centre tie (14) having upper and lower ends (16, 18), and a curved, continuous vessel wall (20) secured to the upper and lower ends of and surrounding the centre tie to define a pressure chamber (26) storing inert compressed gas. The centre tie defines a combustion chamber (30) extending from the lower end thereof, the combustion chamber receiving pyrotechnic gaseous heat source material (31) and a squib (32) for igniting it. The centre tie further defines a directional inlet port (40) extending from the combustion chamber into the pressure chamber and a rupturable diaphragm (44) seals the inlet port until ignition of the pyrotechnic generant. The centre tie also defines a directional outlet vent (50) extending from the pressure chamber adjacent the upper end of the centre tie, the directional outlet vent being oriented substantially opposed the inlet port. The outlet vent is part of an outlet passage (53) from the pressure chamber through the upper end of the centre tie, including an orifice cavity (52) and outlet orifice (54), oriented to provide further turns in the gas flow path. A rupturable diaphragm (58) seals the outlet passage until ignition of the gas generant. A diffuser (62) provides an additional change of direction of the outlet path.

Description: The invention herein relates to a hybrid inflator for vehicle passenger restraint systems and more particularly to a hybrid inflator with a tortuous gas delivery passage which minimises the possibility of hot products of combustion and related debris entering the airbag and enhances heat transfer to and expansion of compressed gas. Vehicle passenger restraint systems utilise an airbag which must be inflated quickly in the event of a vehicle crash to provide restraint and cushioning for the occupant. A hybrid inflator can be provided to fill the airbag, the hybrid inflator utilising a combination of compressed inert gas and the products of combustion of a pyrotechnic heat source. Hybrid inflators are desirable because they generally do not require the use of azides and are hence environmentally friendly, and the inflation gases delivered to the airbags are cooler than those from pyrotechnic gas generators, therefore permitting more latitude in the design of associated structures. However, the use of any pyrotechnic material in the production of inflation gasses creates the possibility of introducing hot products of combustion and associated hot debris from the inflator into the airbag. Although filters may be used to reduce this possibility, the filters add cost, weight, and bulk to the structure and can restrict gas delivery. WO-A-92/22441 discloses a hybrid inflator for a vehicle passenger restraint system, comprising: A) a centre tie having an upper and lower end; B) a curved continuous vessel wall secured to the upper and lower ends of and surrounding the centre tie to define a gas chamber receiving and storing a compressed gas; C) the centre tie defining a combustion chamber extending from the lower end thereof, the combustion chamber receiving and storing pyrotechnic gaseous heat source material and initiator means for igniting the pyrotechnic material; D) the centre tie further defining a directional inlet port extending only in a single direction from the combustion chamber into the gas chamber and means sealing the inlet port until at least ignition of the pyrotechnic material; The centre tie also defines, adjacent its upper end, a set of radial outlets, distributed around the circumference of the tie, leading inwards from the gas chamber to a central outlet passage which is sealed until after ignition of the pyrotechnic material. Ignition of the pyrotechnic gaseous heat source material causes subsequent release of both sealing means, permitting hot gas from the combustion chamber to enter the gas chamber through the directional inlet port, mix with the pressurised gas and exit with the pressurised gas through the passage to inflate an airbag. The present invention provides an inflator of this type wherein instead of a set of outlets extending in different radial directions the centre tie defines an outlet vent extending in only a single direction with a radial orientation opposite to that of the inlet port, whereby the hot gas from the inlet port is caused to flow through opposed generally C-shaped paths surrounding the centre tie to reach the outlet vent. This arrangement minimises delivery of hot products of combustion and debris from the inflator and achieves a controlled flow of inflation gasses to an airbag. The gas chamber is preferably in the form of a generally toroidal pressure chamber storing the inert gas, such as argon or nitrogen, at a pressure of 13.79 to 27.58 MPa (2,000 to 4,000 psi). According to additional aspects of the invention, the combustion chamber extends axially inwardly from the lower end of the centre tie, the pyrotechnic heat source material is boron potassium nitrate (BKNO 3 ), the initiator is mounted on a closure of the combustion chamber and includes an electrically operating squib for igniting the pyrotechnic heat source material, and the directional inlet port is sealed by a rupturable metal disk. Upon ignition, the pyrotechnic heat source material burns and produces hot gasses which rupture the metal disk, permitting the hot gasses to enter the pressure chamber directionally through the inlet port and heat and expand the gasses therein. The path from the combustion chamber to the outlet passage begins and ends in substantially opposed directions, and this tortuous path decreases the amount of solid products of combustion and debris which exits through the outlet vent. According to other aspects of the invention, the outlet passage further comprises an orifice cavity defined by the centre tie for receiving gasses from the outlet vent, and a defined outlet orifice opening axially upwardly from the top of the centre tie. The outlet orifice controls the flow of gas from the inflator. According to additional aspects of the invention, a diffuser is provided atop the centre tie to receive and distribute inflation gas, the diffuser including a solid top plate juxtaposed the outlet orifice and a sidewall with radially directed exit openings. Thus, the outlet cavity and diffuser provide two additional 90 degree changes of direction in the tortuous path of inflation gasses delivered to an airbag. The airbag is mounted surrounding the diffuser, for inflation by the gases. The various features of novelty which characterise the invention are pointed out with particularity in the claims annexed to and forming a part of this specification. For a better understanding of the invention, its operating advantages, and specific objects attained by its use, reference is made to the accompanying drawings and description of the preferred embodiment, which follow. In the drawings: Fig. 1 is a vertical sectional view of a hybrid inflator according to the invention herein; Fig. 2 is a horizontal sectional view of the hybrid inflator of Fig. 1, taken along the lines 2-2 of Fig. 1; and Fig. 3 is a fragmented view of the upper end of the centre tie and the diffuser of the hybrid inflator of Fig. 1. The same reference numerals refer to the same elements throughout the various figures. A hybrid inflator 10 according to the invention herein is illustrated in Figs. 1 and 2, and is shown fragmentally in Fig. 3. With reference to Fig. 1, the hybrid inflator 10 has an airbag 12 mounted thereto for inflation. The airbag 12 is shown schematically, and in practice would be larger, folded compactly and packed closely adjacent the inflator 10 prior to use, as is well known in the art. The hybrid inflator 10 comprises a housing 11 having a generally cylindrical centre tie 14 having a radially extending circular flange 16 at its upper end and a radially extending circular flange 18 at its lower end. A curved continuous vessel wall 20 has a generally C-shaped cross section with an upper circular marginal edge portion 22 which is secured to the upper end flange 16 of the centre tie by weld 23, and a lower circular edge portion 24 which is secured to the lower end flange 18 of the centre tie by weld 25, whereby the vessel wall 20 and centre tie 14 together define a toroidal pressure chamber 26 surrounding the centre tie. The pressure chamber 26 is filled with an inert gas, such as argon or nitrogen, at pressure in the range of 13.79 to 27.58 MPa (2,000 to 4,000 psi)., and the gas is sealed in the chamber 26 by sealing means, described below, until operation of the hybrid inflator 10. The gas is introduced through a fill port 28, which is then welded shut at 29. The centre tie 14 defines a combustion chamber 30 which extends axially inwardly from the lower end of the centre tie. The combustion chamber 30 contains a pyrotechnic heat source material 31 generally comprised of boron potassium nitrate (BKNO 3 ) or other suitable pyrotechnic which produces hot gasses used to heat the stored gas. The combustion chamber 30 and pyrotechnic heat source material contained therein is further provided with an initiator squib 32 mounted in a cylindrical plug 34 which seals the combustion chamber 30 at the lower end of the centre tie. The plug 34 and the squib 32 are secured in position by a bevelled plate 36 which is welded to the centre tie 14. The centre tie 14 defines a directional inlet port 40, including circular inlet orifice 42 extending from the combustion chamber 30 into the gas chamber 26. The inlet port 40 is directional in that it extends radially along line 41 through the centre tie toward a limited arcuate portion of the gas chamber and vessel wall, generally indicated as Zone A in Fig. 2, and does not initially direct hot combustion gasses exiting from the combustion chamber 30 evenly throughout the gas chamber 26. The diameter of the inlet port 40 is less than one-sixth the circumference of the centre tie 14. Prior to operation of the hybrid inflator 10, the pressure chamber 26 is sealed from the pyrotechnic combustion chamber by a thin metal diaphragm 44 welded about its perimeter to a stepped portion 46 of the inlet port 40. The diaphragm 44 is backed by a solid plug 48 received in a chamfered seat adjacent the inlet orifice 42 of the inlet port 40, thereby providing support against the gas pressure for the thin diaphragm 44. The centre tie 14 further defines a directional outlet vent 50 at the upper end thereof, directional outlet vent 50 having an orientation along line 51 which is aligned with the line 41 of the directional inlet port 40. The opening to the outlet vent 50 is diametrically opposed the outlet of the directional inlet port 40, i.e., it faces a limited arcuate portion of the pressure chamber diametrically opposite the inlet port 40, as generally indicated as Zone B in Fig. 2. The directional outlet vent 50 comprises a portion of an outlet passage 53, further including an orifice cavity 52 and an outlet orifice 54. The outlet orifice 54 is defined by a bevelled plate 56 which is welded to a mating recess in the upper end of the centre tie 14, partially defining the orifice cavity 52, and the outlet orifice 54 is covered by a rupturable metal diaphragm 58 which has its periphery welded to the underside of the bevelled plate 56 surrounding the outlet orifice 54. As shown in Fig. 1, the metal diaphragm 58 tends to bow upwardly under the pressure of the stored compressed gas. The outlet vent 50 is preferably rectangular or slot-like, having parallel walls and being of constant cross section along its length. The cross sectional area of the outlet vent 50 is larger than the cross sectional area of the outlet orifice 54, wherein the outlet orifice 54 controls the rate of supply of inflation gas to the airbag 12. The hybrid inflator 10 further comprises a diffuser 60 which has an inverted cup shape including a top wall 62 and cylindrical sidewall 64. The top wall 62 is juxtaposed the outlet orifice 54, such that gas flowing from the outlet orifice is directed toward the top wall. The lower marginal edge of the sidewall is received and secured in a mating recess in the upper end of the centre tie 14, as best seen in Fig. 1. The sidewall 64 of the diffuser 60 is provided with a plurality of evenly spaced apart diffuser exit openings 68. The hybrid inflator 10 is utilised to inflate the airbag 12, and the mouth of the airbag is shown secured to the hybrid inflator 10 at a peripheral flange 70 mounted to the vessel wall 20. Thus, inflation gasses exiting the hybrid inflator 10 at the diffuser openings 68 enter the interior of the airbag 12 for inflating it. The hybrid inflator 10 functions in the following manner. In response to a signal indicative of a vehicle crash, a control signal is communicated to the initiator squib 32, which is activated. Upon activation, the initiator squib 32 fires, igniting the pyrotechnic heat source 31. As pressure in the pyrotechnic combustion chamber 30 rises and exceeds the gas storage pressure, the plug 48 is unseated. Subsequently, the thin metal diaphragm 44 ruptures when the combustion pressure exceeds the gas storage pressure and the strength of the diaphragm. Hot gas and hot particles from the burning pyrotechnic heat source and initiator squib flow through the directional inlet port 40, generally along line 41, into a limited arcuate portion of the pressure chamber 26. The hot gas and hot particles from the burning pyrotechnic heat the stored gas, causing a rapid pressure rise in the chamber 26. When the pressure in chamber 26 exceeds the structural capability of the metal diaphragm 58 covering the outlet orifice 54, the metal diaphragm ruptures, allowing the gas to exit through the diffuser orifices 68 into the airbag 12. The major volume of stored gas is in the toroidal chamber 26, and it is augmented by the gas from the burning pyrotechnic heat source material 31. Thus, after the initial volume of gas in the orifice cavity 52 is delivered, the flow of inflation gas is through the outlet vent 50, orifice cavity 52 and outlet orifice 54. As noted above, the outlet orifice 54 throttles the flow of gas from the inflator and provides a desired fill rate into the airbag, which can be adjusted as desired for particular airbag structures by varying the diameter of the orifice. The flow path from combustion chamber 30 to the diffuser outlet openings 68 is tortuous and thereby prevents or substantially minimises hot particles entering the airbag 12. In particular, hot particles and debris from the combustion chamber 30 are first directed along the exit line 41 of the inlet port 40 to the pressure chamber 26. The flow of heated gas is then around the pressure chamber 26, flanking the centre tie as indicated by arrows 72 in Fig. 2. The outlet path next turns radially inwardly as shown by arrows 74 in Fig. 2 to enter the outlet vent 50. This path between diametrically opposed openings also promotes heat exchange from the hot pyrotechnic gasses to the stored gas, thereby heating and expanding the stored gas. The direction of flow changes direction by 90 degrees within the orifice cavity 52, with the outlet flow being generally axially with respect to the centre tie 14, as best seen in Fig. 3. The outlet flow then impinges on the top wall 62 of the diffuser 60 and next turns another 90 degrees to exit the diffuser openings 68. Because the gasses weigh less than particles and debris which develop from operation of the squib, burning the pyrotechnic heat source material and rupturing the diaphragm 44, the particles and debris substantially do not achieve all of the directional changes in the path from the combustion chamber to the outlets of the diffuser openings 68, preventing or greatly minimising expulsion of hot particles to the interior of the airbag 12. A filter screen may be provided within the diffuser, if desired and as known in the art; however, only a lightweight diffuser screen is required, if at all.

Claims: A hybrid inflator (10) for a vehicle passenger restraint system, comprising: A) a centre tie (14) having an upper and lower end; B) a curved continuous vessel wall (20) secured to the upper and lower ends of and surrounding the centre tie to define a gas chamber (26) receiving and storing a compressed gas; C) the centre tie defining a combustion chamber (30) extending from the lower end thereof, the combustion chamber receiving and storing pyrotechnic gaseous heat source material (31) and initiator means (32) for igniting the pyrotechnic material; D) the centre tie further defining a directional inlet port (40) extending only in a single direction from the combustion chamber (30) into the gas chamber (26) and means (44, 48) sealing the inlet port until at least ignition of the pyrotechnic material; E) the centre tie further defining an outlet vent (50) from the gas chamber adjacent the upper end of the centre tie, forming at least a portion of an outlet passage (53) from the gas chamber through the upper end of the centre tie and means (58) sealing the outlet passage until after ignition of the pyrotechnic material; wherein ignition of the pyrotechnic gaseous heat source material (31) causes subsequent release of both sealing means (44, 48, 58), permitting hot gas from the combustion chamber (30) to enter the gas chamber (26) through the directional inlet port (40), mix with the pressurised gas and exit with the pressurised gas through the outlet vent (50), characterised in that the outlet vent (50) extends in only a single direction and has a radial orientation opposite to that of the inlet port (40), whereby the hot gas from the inlet port is caused to flow through opposed generally C-shaped paths (72) surrounding the centre tie to reach the outlet vent. A hybrid inflator according to claim 1 wherein the centre tie (14) is generally cylindrical and the inlet port (40) delivers hot gas from the combustion chamber through a limited arcuate portion (A) of the centre tie. A hybrid inflator according to claim 2 wherein the inlet port (40) includes an inlet orifice (42) which delivers hot gas through the limited arcuate portion (A) of the centre tie. A hybrid inflator according to any preceding claim wherein the means sealing the inlet port (40) is a rupturable metal diaphragm (44). A hybrid inflator according to any preceding claim wherein the outlet vent (50) receives gas from the gas chamber (26) through a limited arcuate portion (B) of the centre tie (14) diametrically opposed to the inlet port (40). A hybrid inflator according to any preceding claim wherein the outlet passage (53) further comprises an orifice cavity (52) defined in the upper end of the centre tie (14) and connected to the gas chamber by the outlet vent (53), and an outlet orifice (54) from the orifice cavity. A hybrid inflator according to claim 6 wherein the portion of the outlet passage (53) from the outlet vent (50) to the outlet orifice (54) turns substantially 90 degrees in the orifice cavity (52). A hybrid inflator according to claim 6 or claim 7 wherein the outlet orifice (54) has a smaller cross sectional area than the outlet vent (50) and thereby controls the flow of inflation gases from, the hybrid inflator. A hybrid inflator according to any preceding claim wherein the means sealing the outlet passage (53) comprises a rupturable metal diaphragm (58) covering over an outlet orifice (54) communicating with the outlet passage. A hybrid inflator according to any preceding claim and further comprising a diffuser (60) positioned over an outlet orifice (54) communicating with the outlet passage (53), the diffuser including a top wall (62) positioned juxtaposed the outlet orifice for turning the path of the outlet gases substantially 90 degrees, and a peripheral sidewall (64) including a plurality of spaced-apart orifices (68) for delivering the inflation gases to an airbag (12). A hybrid inflator according to any preceding claim wherein the gas generant (31) is boron potassium nitrate (BKNO 3 ). A hybrid inflator according to any preceding claim wherein the gas chamber (26) contains an inert gas pressurised in the range of 13.79 - 27.58 MPa (2,000-4,000 lb/in 2 ). A hybrid inflator according to any preceding claim wherein the centre tie (14) is generally cylindrical, extends only in a single direction and has a radially extending circular top flange (16) and a radially extending circular bottom flange (18), wherein the vessel wall (20) is annular with a C-shaped cross-section with upper and lower circular edges, the upper edge (22) being secured to the circular top flange (16) of the centre tie and the lower edge (24) being secured to the circular bottom flange (18) of the centre tie, the vessel wall and centre tie together defining a toroidal pressure chamber (26) and extending only in a single direction. A hybrid inflator according to any preceding claim further comprising a plug (34) closing the combustion chamber, the plug mounting an initiator squib (32) for igniting the pyrotechnic heat source material. A hybrid inflator according to any preceding claim wherein the inlet port (40) is substantially circular having a diameter no greater than one-sixth of the circumference of the centre tie. A hybrid inflator according to any preceding claim wherein the outlet passage (53) connects the gas chamber with an airbag (12) mounted to the vessel wall (20).

Inventors: CLARK RANDALL J, KORT LELAND B, SMITH BRADLEY W, CLARK, RANDALL J., KORT, LELAND B., SMITH, BRADLEY W.
Applicants: AUTOLIV ASP INC, AUTOLIV ASP, INC.
Application year: 1995
Main classification: B60R21
IPC codes: B60R21