HYBRID INFLATOR, METHOD OF OPERATING A HYBRID INFLATOR, AIRBAG MODULE AND VEHICLE SAFETY SYSTEM

Abstract

The invention relates to a hybrid inflator (10) comprising a combustion chamber (20) and a pressure gas tank (30), wherein in the idle state of the hybrid inflator (10) an outlet opening (31) of the pressure gas tank (30) is closed by a bursting element (32) which in the case of function of the hybrid inflator (10) can be destroyed by means of a penetration element (40), wherein a mixing chamber (70) is formed between the pressure gas tank (30) and the combustion chamber (20). In accordance with the invention, between the combustion chamber (20) and the mixing chamber (70) at least in portions a partition wall (80) having a combustion chamber side (81) and a mixing chamber side (82) is formed, wherein the partition wall (80) includes at least one combustion chamber opening (85) which in the idle state of the hybrid inflator (10) is closed by a cover (88) formed on the mixing chamber side (82) of the partition wall (80).

Claims

1. A hybrid inflator (10) comprising a combustion chamber (20) and a pressure gas tank (30), wherein in the idle state of the hybrid inflator (10) an outlet opening (31) of the pressure gas tank (30) is closed by a bursting element (32) which in the case of function of the hybrid inflator (10) can be destroyed by means of a penetration element (40), with a mixing chamber (70) being formed between the pressure gas tank (30) and the combustion chamber (20), wherein between the combustion chamber (20) and the mixing chamber (70) at least in portions a partition wall (80) having a combustion chamber side (81) and a mixing chamber side (82) is formed, wherein the partition wall (80) includes at least one combustion chamber opening (85) which in the idle state of the hybrid inflator (10) is closed by a cover (88) formed on the mixing chamber side (82) of the partition wall (80).

2. The hybrid inflator (10) according to claim 1, wherein the cover (88) is a membrane and/or film, especially a tamping, which is especially made from metal, preferably from steel or copper or aluminum, wherein especially the mixing chamber (70) has at least one generator opening (75) for fluid-communicating the hybrid inflator (10) with an element to be inflated, especially an airbag.

3. A hybrid inflator (10) comprising a combustion chamber (20) and a pressure gas tank (30), wherein in the idle state of the hybrid inflator (10) an outlet opening (31) of the pressure gas tank (30) is closed by a bursting element (32) which in the case of function of the hybrid inflator (10) can be destroyed by means of a penetration element (40) in wherein the case of function of the hybrid inflator (10) the gas pressure generated or adapted to be generated within the combustion chamber (20) is lower than the pressure prevailing in the pressure gas tank (30) in the idle state of the hybrid inflator (10).

4. The hybrid inflator (10) according to claim 3, wherein the combustion chamber (20) an ignition tube (60) is formed, wherein the penetration element (40) is longitudinally movable at least in portions inside the ignition tube (60), wherein the ignition tube (60) is filled with a pyrotechnical igniting mixture and/or a pyrotechnical booster charge, the ignition tube (60) including at least one opening (64) for fluid communicating an inner area of the ignition tube (60) with the combustion chamber (20), wherein between the combustion chamber (20) and the pressure gas tank (30) a mixing chamber (70) is formed.

5. The hybrid inflator (10) according to claim 4, wherein between the combustion chamber (20) and the mixing chamber (70) at least in portions a partition wall (80) having a combustion chamber side (81) and a mixing chamber side (82) is formed, wherein the partition wall (80) includes at least one combustion chamber opening (85) which in the idle state of the hybrid inflator (10) is closed by a cover (88) formed on the mixing chamber side (82) of the partition wall (80).

6. The hybrid inflator (10) according to claim 4, wherein the ignition tube (60) at its end (63) facing the pressure gas tank (30) includes a collar portion (65) forming the partition wall (80) between the combustion chamber (20) and the mixing chamber (70), wherein in the longitudinal extension (L) of the hybrid inflator (10) the ignition tube (60) is completely surrounded by a combustion chamber (20) of circular ring shape in cross-section, and wherein the bursting element of the pressure gas tank (30) can be destroyed by the penetration element (40) in a projectile-like manner.

7. A method of operating a hybrid inflator (10), especially according to claim 1, comprises the method steps of: a) activating an igniter of the hybrid inflator (10); b) activating a penetration element (40) and moving the penetration element (40) in the direction of a bursting element (32) closing an outlet opening (31) of a pressure gas tank (30); c) opening the bursting element (32) by means of the penetration element (40); d) discharge of a first gas provided in the pressure gas tank (30) through the discharge opening (31) of the pressure gas tank (30) into a mixing chamber (70); e) building up back pressure in the mixing chamber (70) and discharge of the first gas from the mixing chamber (70) through at least one generator opening (75) of the mixing chamber (70) into an element to be inflated; f) opening at least one cover (88) closing a combustion chamber opening (85); g) discharge of a second gas generated in the combustion chamber (20) through the combustion chamber opening (85) into the mixing chamber (70).

8. The method according to claim 7, further comprising: h) mixing the second gas with the first gas in the mixing chamber (70) and forming a filling gas; i) discharge of the filling gas from the mixing chamber (70) through the at least one generator opening (75) into the element to be inflated.

9. The method according to claim 7, wherein in the material and/or the thickness of the at least one cover (88) of the at least one combustion chamber opening (75) is designed so that in step e) the cover (88) is pressed onto the combustion chamber opening (75) such that the pressure inside the combustion chamber (20) increases or may increase for opening the cover (88).

10. The method according to claim 7, wherein in the idle state of the hybrid inflator (10) the cover (88) is connected to the mixing chamber side (82) of a partition wall (80) formed between the combustion chamber (20) and the mixing chamber (70).

11. The method according to claim 7, wherein in step b) a pyrotechnical igniting mixture and/or a pyrotechnical booster charge is/are ignited in an ignition tube (60) formed in the combustion chamber (20).

12. An airbag module comprising a hybrid inflator (10) according to claim 1.

13. An airbag module comprising a hybrid inflator (10) according to claim 1.

14. An airbag module comprising a hybrid inflator (10) according to claim 3.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0088] Hereinafter the invention shall be illustrated in detail by way of embodiments with reference to the enclosed schematic figures, wherein

[0089] FIG. 1 shows a hybrid inflator according to the invention in the idle state;

[0090] FIG. 2 shows a hybrid inflator according to the invention in the functioning state and, resp., in the case of function;

[0091] FIGS. 3a, 3b and 3c show different views regarding a first embodiment of a penetration element; and

[0092] FIG. 4 shows a second embodiment of a penetration element.

DESCRIPTION

[0093] Hereinafter like reference numerals will be used for equal and equally acting parts.

[0094] In FIG. 1 a hybrid inflator 10 according to the invention is shown. It comprises a combustion chamber 20 and a pressure gas tank 30. FIG. 1 shows the hybrid inflator 10 according to the invention in an idle state. In the idle state an outlet opening 31 of the pressure gas tank 30 is closed by a bursting element 32. The bursting element 32 is arranged and, resp., fastened inside the pressure gas tank 30 by means of a bursting element holder 33.

[0095] The hybrid inflator 10 further comprises an igniter 15 comprising an igniter cap 16 and an ignition tube 60. In the ignition tube 60 an ignition channel 61 is formed. Especially the igniter cap 16 protrudes into the ignition tube 60, especially into the first end 62 of the ignition tube 60 and, resp., of the ignition channel 61. In the ignition tube 60 a pyrotechnical igniting mixture and/or a pyrotechnical booster charge comprising a plurality of booster elements (90) is/are provided.

[0096] The ignition tube 60 is formed inside the combustion chamber 20. The ignition tube 60 in the present case includes a circular cross-section. The combustion chamber 20, too, has a housing portion 21 which forms a combustion chamber 20 being ring-shaped in cross-section. The combustion chamber 20 thus surrounds the ignition tube 60 and the ignition channel 61, respectively. In the area of the igniter 15 a solid ring 18, for example made from compressible foam or silicone material, is formed. Said solid ring on the one hand serves for fixing and fastening the ignition tube 60, especially the first end 62 of the ignition tube 60. Moreover, by the solid ring 18 also the propellant bed located in the combustion chamber 20 and comprising a plurality of propellant compacts 89 may be fixed in position. In the ignition tube 60 openings 64 are formed. The openings 64 serve for establishing fluid communication between an inner area of the ignition tube 60 and, resp., the ignition channel 61 and the combustion chamber 20. The booster elements 90 and the propellant compacts 89 may comprise different known pyrotechnical compacts or molded compacts known to those skilled in the art from the field of gas generators and inflators, especially for vehicle safety systems. These may be compressed pellets, extrudates, granules or else a respective monolith of different geometry, wherein passages may also penetrate said bodies, i.e. the latter may take a hollow-cylindrical shape, for example. Accordingly, also different common dimensions and sizes are imaginable, wherein preferably the booster elements 90 have a smaller dimension than the propellant compacts 89 so as to cause a more rapid gas production upon activation and burn-off of the same. Of preference, the booster elements 90 are dimensioned so that they cannot pass through the openings 64 from the ignition channel 61 into the combustion chamber 20.

[0097] Between the combustion chamber 20 and a mixing chamber 70 a partition wall 80 comprising a combustion chamber side 81 and a mixing chamber side 82 is formed. The combustion chamber side 81 thus faces the combustion chamber 20. The mixing chamber side 82 faces the mixing chamber 70. The partition wall 80 includes combustion chamber openings 85 which in the shown idle state of the hybrid inflator 10 are closed by covers 88 formed on the mixing chamber side 82 of the partition wall 80. The covers 88 may also be referred to as tamping. Preferably the covers 88 are made from metal, especially from steel or copper or aluminum. The covers 88 may be glued or welded to the partition wall 80.

[0098] The mixing chamber 70 includes generator openings 75 for fluid-communicating the hybrid inflator 10 and, resp., the interior of the hybrid inflator 10 with an element to be inflated, preferably an airbag (not shown).

[0099] The ignition tube 60 includes, at its second end 63, viz. at its end 63 facing the pressure gas tank 30, a collar portion 65 which at least in portions forms the partition wall 80 between the combustion chamber 20 and the mixing chamber 70.

[0100] Inside the ignition tube 60 the penetration element 40 (exemplified in detail in FIGS. 3a-4) is arranged and, resp., supported to be longitudinally movable at least in portions. A notch 66 in the form of a shoulder prevents the penetration element 40 from being displaced completely in the direction of the first end 62 of the ignition tube 60.

[0101] FIG. 2 shows the hybrid inflator 10 in a functioning state. For reaching the functioning state and for inflating the element to be inflated such as the airbag, according to the invention the following method steps which can be reproduced by way of FIG. 2 are successively carried out.

[0102] First of all, the igniter 15 of the hybrid inflator 10 is activated. In this way, the booster elements (90) located inside the ignition tube 60, i.e. the so called igniting mixture or booster charge, are ignited. The energy thus generated inside the ignition tube 60 and, resp., the pressure produced inside the ignition tube 60 and, resp., ignition gas acts on the penetration element 40 which is moved in the direction of the pressure gas tank 30.

[0103] Hence the penetration element 40 is moved in the direction of the outlet opening 31 and in the direction of the bursting element 32 closing the outlet opening 31. The penetration element 40 thus destroys and, resp., opens the bursting element 32 so that the pressure gas tank 30 is opened.

[0104] After that, a first gas provided in the pressure gas tank 30, especially cold gas, may flow out through the outlet opening 31 of the pressure tank 30 and flow into the mixing chamber 70. Inside the mixing chamber 70 thus back pressure is built up, wherein simultaneously the first gas, especially cold gas, flows from the mixing chamber 70 through the generator openings 75 into the element to be inflated (not shown). Due to the back pressure built up in the mixing chamber 70, the covers 88 are pressed into and, resp., onto the combustion chamber openings 85.

[0105] Only after a certain portion of the first gas, viz. cold gas, has flown into the element to be inflated, does the back pressure in the mixing chamber 70 decrease. Meanwhile the igniting gas may flow from the ignition tube 60 through the openings 64 into the combustion chamber 20. There the propellant bed and, resp., the individual propellant compacts 89 are ignited so that an opening pressure is built up in the combustion chamber 20. After a certain period of time, the pressure in the combustion chamber 20 is so high that the covers 88 can be opened. Subsequently the second gas, viz. hot gas, generated by the burn-off of the propellant compacts 89 in the combustion chamber 20 flows through the combustion chamber openings 85 into the mixing chamber 70.

[0106] In the mixing chamber 70 the hot gas is mixed with the cold gas and a filling gas is formed. Said filling gas may flow out of the mixing chamber 70 through the generator openings 75 into the element to be inflated.

[0107] The material and/or the thickness of the covers 88 of the combustion chamber openings 85 is/are designed so that the back pressure formed because of the cold gas is pressed onto the combustion chamber opening 85 so that the pressure in the combustion chamber 20 may increase for opening the covers 88, preferably to a particular predefined value.

[0108] After opening the pressure gas tank 30, at first only cold gas flows into the mixing chamber 70 and initially merely the cold gas flows through the generator openings 75 to the outside. In this initial phase of activating the hybrid inflator 10, less load is imparted to the airbag and thus the entire airbag module, wherein subsequently the principal filling of the airbag by means of the filling gas may take place by the hot gas inflow from the combustion chamber 20. A desired low onset, also referred to as S-slope, is achieved.

[0109] The penetration element 40 is exemplified in detail in FIGS. 3a-4. The penetration element 40 does not have a complete gas-permeable passage in its axial direction between its two axial ends. Concretely speaking, from a first end 41 of the penetration element 40 a first hollow 43 is formed in the direction of a second end 42 of the penetration element 40, with the first hollow 43 being delimited by a first approach surface 93 of a radially extending approach element 92. The approach element 92 is an integrative component of the penetration element 40 and is a flat element having a particular thickness.

[0110] The approach element 92 substantially has the task to enable movement or displacement of the penetration element 40 in the case of function of the hybrid inflator 10 in that gas produced by the igniter 15, especially combustion gas by burn-off of the booster elements 90, is enabled to act with thrust on the first approach surface 93 of the approach element 92.

[0111] As is clearly visible from FIG. 1, the first approach surface 93 faces the igniter 15 and, resp., the igniter cap 16. The approach element 92 includes on its side opposed to the first approach surface 93, facing away from the igniter 15, a second approach surface 94 which faces toward the bursting element 32. Starting from the second approach surface 94 toward the second end 42 of the penetration element 40 a second hollow 95 is formed.

[0112] The area of the penetration element 40 extending from the second approach surface 94 to the second end 42 of the penetration element 40 is configured as a portion 91 of the penetration element 40 through which gas may flow or can be understood to be such portion, respectively. The portion 91 through which gas may flow extends from a stop face 52 of the penetration element 40 to the second end 42 of the penetration element 40 via an extension area E91, as shown in FIG. 3a. The stop face 52 will be described in more detail further below.

[0113] At the second end 42 of the penetration element 40 a penetration edge 44 is formed. Since the penetration element 40 includes a circular cross-section, also the penetration edge 44 is arranged substantially in circular shape.

[0114] In the mounting situation shown in FIGS. 1 and 2 the longitudinal extension LE of the penetration element 40 corresponds to the longitudinal axis L of the hybrid inflator 10. Starting from the penetration edge 44, the penetration element 40 includes two recesses 45 extending in the longitudinal extension LE of the penetration element 40. The recesses 45 thus constitute interruptions 46 in the penetration edge 44.

[0115] The penetration edge 44 is formed of two penetration edge portions 47.

[0116] The recesses 45 take a slot shape and at the same time form the interruptions 46 in the penetration edge 44. Due to the design of recesses 45 two penetration legs 48 are formed. The penetration legs 48 act as blades or tines. In the area of the penetration edge 44 and, resp., in the area of the penetration edge portions 47 tapers 49 are formed. This allows for easier destruction of a bursting element 32.

[0117] The penetration element 40 moreover includes a stop face 50 formed over the complete periphery. The stop face 50 is constituted by a shoulder portion 51 spaced apart from the penetration edge 44. The shoulder portion 51 causes an extension of the cross-section of the outer wall of the penetration element 40. In the functioning state of the hybrid inflator 10 the stop face 50 causes the penetration element 40 to contact the bursting element holder 33, especially the end face 34 thereof. The penetration element 40 thus cannot be moved further into the pressure gas tank 30. The cross-section of the shoulder portion 51 is larger than the inner cross-section of the outlet opening 31 of the pressure gas tank 30.

[0118] Due to the shoulder portion 51 a further, viz. second, stop face 52 is formed. The second stop face 52 faces the first end 41 of the penetration element 40. In the idle state of the hybrid inflator 10 (cf. FIG. 1) the second stop face 52 rests on the notch 66 of the ignition tube 60. With the aid of the second stop face 52 the penetration element 40 is thus prevented from being moved in the direction of the first end 62 of the ignition tube 60.

[0119] In a radially circumferential wall 53 of the penetration element 40 in the shown example four gas outlet openings 54 are formed. With the aid of the gas outlet openings 54, in the case of function of the hybrid inflator cold gas flowing out of the pressure gas tank 30 may flow into the mixing chamber 70. In the case of function of the hybrid inflator 10, the penetration element 40 thus cannot cover the outlet opening 31 of the pressure gas tank 30 in a gas-tight manner. Accordingly, especially the cold gas from the pressure gas tank 30 may flow through the portion 91 through which gas may flow, namely coming from the pressure gas tank 30, initially via the second hollow 95 and further via at least one of the four gas outlet openings 54.

[0120] The radially circumferential wall 53 also delimits the second hollow 95 in portions in the radial direction.

[0121] As two recesses 45 are introduced into the penetration element 40 and, resp., two interruptions 46 are introduced into the penetration edge 44, the bursting element 32 cannot be evenly damaged. The possibility of tearing and/or punching out a large circular area of the bursting element 32 is strongly reduced due to this formation of a penetration element 40. Should nevertheless a portion of the bursting element 32 be punched or torn out, the cold gas provided in the pressure gas tank 30 may pass through the recesses 45 into the first hollow 43 and continue flowing through the gas outlet openings 54 into the mixing chamber 70.

[0122] FIG. 4 illustrates an alternative embodiment of a penetration element 40. This, too, includes a first end 41 as well as a second end 42, wherein, analogously to FIG. 3a and FIG. 3c, equally a first hollow 43, an approach element 92 having a first approach surface 93 and a second approach surface 94 and a second hollow 95 are formed therebetween. Also, a penetration edge 44 is divided into individual penetration portions 47 again because of interruptions 46 and, resp., recesses 45. The recesses 45 again constitute two penetration legs 48. In the area of the penetration edge portions 47 moreover tapers 49 are formed so that destruction of the bursting element 32 is facilitated. There are equally shown the first stop face 50 and the second stop face 52 both of which are formed by reason of the shoulder portion 51. The two gas outlet openings 54 are formed because of extended recesses 45 in the embodiment according to FIG. 4, however. In other words, the gas outlet openings 54 are formed by the partial portions and, resp., end portions 55 of the recesses 45.

[0123] The round gas outlet openings 54 illustrated in FIGS. 3a-3c are formed by an extension of the recesses 45 in the embodiment according to FIG. 4. Hence in this case it is not necessary to incorporate holes into the shoulder portion 51 in a further manufacturing step.

[0124] The penetration element 40 according to the embodiment of FIG. 4 moreover includes a clearance 56. For example, a sealing element may be introduced into said clearance. The clearance 56 is configured to be a fully peripheral groove.

[0125] It is referred to the fact that the hybrid inflator 10 shown in FIGS. 1 and 2 may also be configured with an alternative penetration element. It is especially possible that the penetration element does not correspond to the embodiments according to FIGS. 3a-4.

[0126] In addition, it is referred to the fact that the penetration elements 40 shown in FIGS. 3a to 4 may also be configured in alternative inflators, especially hybrid inflators which do not correspond to the embodiments according to FIGS. 1 and 2.

LIST OF REFERENCE NUMERALS

[0127] 10 hybrid inflator [0128] 15 igniter [0129] 16 igniter cap [0130] 18 solid ring [0131] 20 combustion chamber [0132] 21 housing portion [0133] 30 pressure gas tank [0134] 31 outlet opening [0135] 32 bursting element [0136] 33 bursting element holder [0137] 34 end face [0138] 40 penetration element [0139] 41 first end of penetration element [0140] 42 second end of penetration element [0141] 43 first hollow [0142] 44 penetration edge [0143] 45 recess [0144] 46 interruption [0145] 47 penetration edge portion [0146] 48 penetration leg [0147] 49 taper [0148] 50 stop face [0149] 51 shoulder portion [0150] 52 stop face [0151] 53 wall [0152] 54 gas outlet opening [0153] 55 end portion of recess [0154] 56 clearance [0155] 60 ignition tube [0156] 61 ignition channel [0157] 62 first end of ignition tube [0158] 63 second end of ignition tube [0159] 64 opening [0160] 65 collar portion [0161] 66 notch [0162] 70 mixing chamber [0163] 75 generator opening [0164] 80 partition wall [0165] 81 combustion chamber side [0166] 82 mixing chamber side [0167] 85 combustion chamber opening [0168] 88 cover [0169] 89 propellant body [0170] 90 booster element [0171] 91 portion through which gas may flow [0172] 92 approach element [0173] 93 first approach area [0174] 94 second approach area [0175] 95 second hollow [0176] L longitudinal axis of hybrid inflator [0177] LE longitudinal extension of penetration element [0178] E91 extension area of the portion through which gas may flow