Inflator and airbag module

Abstract

An inflator for a protective device in a vehicle includes a diffuser (10) forming a substantially rotation-symmetric external housing of the inflator with a closing member (12), wherein the diffuser (10) includes a plurality of discharge orifices (78) arranged in a row, and which are of circular shape. The inflator also includes an igniter sleeve (38) which at least partially encloses an igniter (34) and an igniter chamber (42) filled with a booster charge and is adjacent to a first combustion chamber (44) filled with fuel, wherein the igniter sleeve (38), related to a central axis B of the igniter sleeve (38), has overflow orifices (98) unevenly distributed in circumferential direction.

Claims

1. An inflator for a protective device in a vehicle, comprising: a diffuser forming a substantially rotation-symmetric external housing of the inflator with a closing member, wherein the diffuser includes a plurality of discharge orifices arranged in a row and which are of circular shape; and an igniter sleeve which at least partially encloses an igniter and an igniter chamber filled with a booster charge and is adjacent to a first combustion chamber filled with fuel and; wherein the igniter sleeve includes a marker distant from a central axis (B) or extending non-symmetrically from the central axis (B) which indicates a predetermined orientation of the igniter sleeve; a combustion chamber sleeve that surrounds a second combustion chamber; wherein the igniter sleeve, related to the central axis (B) of the igniter sleeve, has overflow orifices unevenly distributed in a circumferential direction to define a maximum angular range () less than 180 such that all inflation fluid exits the igniter sleeve over an angular range less than 180, each of the overflow orifices being directed in a direction that does not intersect the combustion chamber sleeve.

2. The inflator according to claim 1, wherein the first combustion chamber is associated with a first activating stage of the inflator, and wherein the second combustion chamber is filled with fuel and associated with a second activating stage of the inflator, wherein both sleeves (60) are juxtaposed and are differently offset with respect to a central axis (A) of the inflator; wherein the distance between the central axis (B) of the igniter sleeve and a central axis (C) of the combustion chamber sleeve is between 22.5 and 27.5 mm, and wherein the ratio of the minimum inner diameter (c) of the combustion chamber sleeve to the minimum inner diameter (d) of the igniter sleeve is between 1.64 and 2.63, and wherein, related to a central axis (A) of the inflator, the first combustion chamber is radially confined at least partially by an at least partly circumferential filter, the ratio of the inner diameter (f) of the filter to the minimum inner diameter (d) of the igniter sleeve ranging between 3.19 and 4.76.

3. The inflator according to claim 1, wherein the first combustion chamber is associated with a first activating stage of the inflator, and wherein the second combustion chamber is filled with fuel and associated with a second activating stage of the inflator, wherein the combustion chamber sleeve is adjacent to the first combustion chamber which, related to a central axis (A) of the inflator, is radially confined at least partially by an at least partly circumferential filter, the ratio of the inner diameter (f) of the filter to the minimum inner diameter (c) of the combustion chamber sleeve ranging between 1.66 and 2.11; wherein the ratio of the outer diameter (a) of the inflator to the minimum inner diameter (d) of the igniter sleeve is between 4.09 and 5.98; and wherein the ratio of the outer diameter (a) of the inflator to the minimum inner diameter (c) of the combustion chamber sleeve is between 2.13 and 2.66.

4. The inflator according to claim 1, further comprising a radially projecting generator flange, related to a central axis (A) of the inflator, for mounting the inflator to a support, wherein the generator flange is substantially rectangular; wherein a ratio of a length (l) to a width (b) of the rectangle ranges between 1.12 and 1.31; wherein a ratio of the length (l) of the rectangle to an outer diameter (a) of the external housing ranges between 1.24 and 1.48; and wherein a ratio of the width (b) of the rectangle to the outer diameter (a) of the external housing is between 1.01 and 1.23.

5. The inflator according to claim 1, wherein at least in portions a wall thickness of the closing member is larger than that of the diffuser, wherein the closing member has a substantially planar bottom in which at least one opening for receiving an igniter carrier is formed and that at least the bottom has a larger wall thickness than the diffuser.

6. The inflator according to claim 1, wherein the diffuser includes a ceiling portion and the combustion chamber sleeve contacts the ceiling portion of the diffuser in a non-activated state of the inflator at least at one point, and wherein, related to a central axis (A) of the diffuser, the axial distance (g) between the combustion chamber sleeve and the ceiling portion is varying such that the maximum distance (g) between the combustion chamber sleeve and the ceiling portion of the diffuser is between 2.3 and 3.7 mm.

7. The inflator according to claim 1, wherein the igniter sleeve is offset with respect to a central axis (A) of the diffuser whose axial distance (i) from a ceiling portion of the diffuser is varying such that the maximum distance (i) between the igniter sleeve and the ceiling portion of the diffuser is between 2.1 and 3.5 mm.

8. An airbag module for a vehicle comprising an airbag having a volume of 40 to 60 liters, comprising an inflator according to claim 1.

9. An airbag module for a vehicle comprising an airbag having a volume of 60 to 135 liters, comprising inflator according to claim 1.

10. The inflator according to claim 1, wherein a connecting line extends between the central axis of the igniter sleeve and the portion of the filter maximally distant from the central axis, each overflow orifice allowing inflation fluid to exit the igniter sleeve being circumferentially positioned at an acute angle relative to the connecting line.

11. The inflator according to claim 1, wherein the igniter sleeve includes a nose or a recess as the marker and wherein the igniter sleeve has a configuration adapted to a configuration of a neighboring component of the inflator such that mounting of the igniter sleeve in the inflator is possible at the predetermined orientation only.

12. The inflator according to claim 1, wherein an axial cross-section of the igniter sleeve including the marker is different from an axial cross-section of the igniter sleeve spaced from the marker.

13. The inflator according to claim 1, wherein the maximum angular range () extends to both sides of a connecting line (x) between the central axis (B) of the igniter sleeve and the portion of the filter maximally distant from the central axis (B), wherein the angular range () is obtuse and ranges between 90 and 135.

14. The inflator according to claim 13, wherein the angular range () includes areas in which a distance from the filter not blocked by components of the inflator is maximal and wherein the angular range () encloses the combustion chamber sleeve, the second combustion chamber being at least partially surrounded by the first combustion chamber.

15. The inflator according to claim 1, further comprising a fuel canister filled with fuel including a fuel canister bottom and a fuel canister opening opposed to the fuel canister bottom which is closed by means of a combustion chamber component.

16. The inflator according to claim 15, wherein the second combustion chamber is associated with a particular activating stage of the inflator, wherein the combustion chamber sleeve exhibits a combustion chamber sleeve opening or an open side and a combustion chamber sleeve bottom opposed thereto which covers the fuel canister opening, wherein a second fill member connected to the combustion chamber sleeve bottom is arranged at the combustion chamber sleeve bottom; and wherein at least part of a side wall of the fuel canister extending between the fuel canister opening and the fuel canister bottom is directly opposed to at least part of a side wall of the combustion chamber sleeve extending between the combustion chamber sleeve orifice or the open side of the combustion chamber sleeve and the combustion chamber sleeve bottom.

17. The inflator according to claim 1, further comprising an igniter unit, wherein the igniter unit has a marker, wherein the marker is a milled slot, and wherein the marker sets a predetermined orientation of connecting pins of the igniter unit.

18. The inflator according to claim 17, wherein the igniter unit is a pre-assembled unit having an igniter carrier and an igniter held therein which is adapted to be inserted in a bottom orifice of a closing member of the inflator.

19. An inflator for a protective device in a vehicle, comprising: a diffuser forming a substantially rotation-symmetric external housing of the inflator with a closing member, wherein the diffuser includes a plurality of discharge orifices arranged in a row and which are of circular shape; and an igniter sleeve which at least partially encloses an igniter and an igniter chamber filled with a booster charge and is adjacent to a first combustion chamber filled with fuel, wherein the igniter sleeve, related to a central axis (B) of the igniter sleeve, has overflow orifices unevenly distributed in a circumferential direction, wherein the igniter sleeve includes a marker distant from the central axis (B) or extending non-symmetrically from the central axis (B) which indicates a predetermined orientation of the igniter sleeve, and wherein the igniter sleeve includes a nose or a recess as the marker and wherein the igniter sleeve has a configuration which is adapted to a configuration of a neighboring component of the inflator such that mounting of the igniter sleeve in the inflator is possible at the predetermined orientation only; wherein the igniter sleeve is offset with respect to a central axis (A) of the diffuser and a bottom of the igniter sleeve is opposed to a ceiling portion of the diffuser, wherein the igniter sleeve bottom has a slant adapted to a curvature of the ceiling portion of the diffuser such that the igniter sleeve fits below the ceiling portion of the diffuser at the predetermined orientation only, and wherein the igniter sleeve is radially tapered in an axial direction toward the bottom of the igniter sleeve.

20. An inflator for a protective device in a vehicle, comprising: a diffuser forming a substantially rotation-symmetric external housing of the inflator with a closing member, wherein the diffuser includes a plurality of discharge orifices arranged in a row and which are of circular shape; and an igniter sleeve which at least partially encloses an igniter and an igniter chamber filled with a booster charge and is adjacent to a first combustion chamber filled with fuel, wherein the igniter sleeve, related to a central axis (B) of the igniter sleeve, has overflow orifices unevenly distributed in a circumferential direction, wherein the first combustion chamber is associated with a first activating stage of the inflator, as well as a combustion chamber sleeve which at least partially encloses a second combustion chamber filled with fuel and associated with a second activating stage of the inflator, wherein an axial distance of an open side of the igniter sleeve from a bottom of a closing member of the inflator is unequal to an axial distance of an open side of the combustion chamber sleeve from the bottom of the closing member, the distance of the igniter sleeve being larger, and wherein the igniter sleeve and the combustion chamber sleeve are attached to a first igniter carrier or to a second igniter carrier, wherein the axial height of the contact area between the igniter sleeve and the first igniter carrier is larger than the axial height of the contact area between the combustion chamber sleeve and the second igniter carrier; wherein both the igniter sleeve is raised a pressure developed during combustion of the booster charge and the combustion chamber sleeve is raised by a pressure developed during combustion of the fuel in a direction of a ceiling portion of a diffuser of the inflator, wherein by raising the combustion chamber sleeve a discharge orifice in the form of a discharge gap is released which leads out of the combustion chamber sleeve, whereas no discharge orifice is released by raising the igniter sleeve.

21. An inflator for a protective device in a vehicle, comprising: a diffuser forming a substantially rotation-symmetric external housing of the inflator with a closing member, wherein the diffuser includes a plurality of discharge orifices arranged in a row and which are of circular shape; and an igniter sleeve which at least partially encloses an igniter and an igniter chamber filled with a booster charge and is adjacent to a first combustion chamber filled with fuel, wherein the igniter sleeve, related to a central axis (B) of the igniter sleeve, has overflow orifices unevenly distributed in a circumferential direction, wherein the first combustion chamber is filled with the fuel which is associated with a first activating stage of the inflator and is closed on one side by a lid, wherein a first fill member is disposed between the fuel and the lid, wherein the first fill member has at least one circular recess into which an igniter sleeve associated with the first activating stage of the inflator or a combustion chamber sleeve associated with a second activating stage of the inflator projects; wherein the first fill member has two recesses of different size, wherein the igniter sleeve projects into a smaller recess and the combustion chamber sleeve projects into a larger recess; wherein a ratio of a diameter of the larger recess to a diameter of the smaller recess is between 1.52 and 2.25; and wherein the first fill member is designed in at least two parts, each of the two partial members has a shape of a double half moon.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Further features and advantages of the invention are resulting from the following description and from the attached drawings that are referred to, in which:

(2) FIG. 1 is a sectional side view of an inflator according to the invention of a first configuration.

(3) FIG. 2 is a sectional side view of an inflator according to the invention of a second configuration.

(4) FIG. 3 is a sectional top view of a diffuser of an inflator according to the invention.

(5) FIG. 4 is a sectional side view of the diffuser of FIG. 3.

(6) FIG. 5 is a sectional top view of a diffuser of an inflator according to the invention.

(7) FIG. 6 is a lateral sectional view of an igniter carrier of an inflator according to the invention.

(8) FIG. 7 illustrates the igniter carrier of FIG. 6 including an inserted packing ring.

(9) FIG. 8 illustrates the igniter carrier of FIG. 7 including an inserted igniter.

(10) FIG. 9 illustrates the igniter carrier and the igniter of FIG. 9 in the pre-assembled state.

(11) FIG. 10 is a lateral sectional view of a closing member of an inflator according to the invention.

(12) FIG. 11 illustrates the closing member of FIG. 10 including inserted igniter units.

(13) FIG. 12 is a partial top view of the closing member and the igniter units of FIG. 11.

(14) FIG. 13 is a perspective view of an igniter sleeve of an inflator according to the invention according to a first embodiment.

(15) FIG. 14 is a lateral sectional view of the igniter sleeve of FIG. 13.

(16) FIG. 15 is a sectional view along the line of cut A-A of FIG. 14.

(17) FIG. 16 is a lateral sectional view of an igniter sleeve according to a second embodiment.

(18) FIG. 17 is a lateral sectional view of an igniter sleeve according to a third embodiment.

(19) FIG. 18 is a sectional view along the line of cut A-A of FIG. 17.

(20) FIG. 19 is a perspective view of an igniter sleeve according to a fourth embodiment.

(21) FIG. 20 is a lateral sectional view of the igniter sleeve of FIG. 19.

(22) FIG. 21 is a sectional view along the line of cut A-A of FIG. 20.

(23) FIG. 22 is a sectional view along the line of cut C-C of FIG. 20.

(24) FIG. 23 is a perspective view of an igniter sleeve according to a fifth embodiment.

(25) FIG. 24 is a lateral sectional view of the igniter sleeve of FIG. 23.

(26) FIG. 25 is a sectional view along the line of cut A-A of FIG. 24.

(27) FIG. 26 is a sectional view along the line of cut C-C of FIG. 25.

(28) FIG. 27 is a top view of an inflator according to the invention partly cut in a lower area of the inflator.

(29) FIG. 28 is a partly cut perspective view of an inflator according to the invention without diffuser.

(30) FIG. 29 is a lateral sectional view of an inflator according to the invention according to the second configuration after activation of the second activating stage.

(31) FIG. 30 is a lateral sectional view of an inflator according to the invention without diffuser and fill member.

(32) FIG. 31 shows a cut-out from a lateral sectional view of an inflator according to the invention.

(33) FIG. 32 is a top view of a fill member part for the first combustion chamber of an inflator according to the invention in accordance with an embodiment.

(34) FIG. 33 is a perspective view of the fill member part of FIG. 32.

(35) FIG. 34 is a top view of an inflator according to the invention cut in an upper area of the inflator.

(36) FIG. 35 is a top view of a filter of an inflator according to the invention.

(37) FIG. 36 is a sectional view of the filter along the line A-A in FIG. 35 and

(38) FIG. 37 is a schematic lateral sectional view of an inflator according to the invention in accordance with the first configuration in an embodiment.

DESCRIPTION

(39) In the following detailed description of preferred embodiments and variants of the invention indications such as at the top, bottom etc. are used for a better comprehension. These indications relate to an orientation of the inflator as shown in the FIGS. 1 and 2.

(40) It is understood that individual features or groups of features described in connection with a configuration and/or an embodiment may also be the subject matter or element of any other configuration and/or embodiment, even if this is not expressly mentioned once again hereinafter. Each of the described sleeve variants or individual features of the same can be provided in any of the configurations, for instance. Also, the filter/diffuser designs, designs of discharge orifices and the other features can be combined at will.

(41) In FIG. 1 an inflator which is part of an airbag module having an inflatable airbag is shown according to a first configuration. The inflator comprises an external housing which is composed of a cup-shaped diffuser 10 and a closing member 12.

(42) The diffuser 10 includes a curved ceiling portion 14 and a substantially cylindrical circumferential wall 16 connected thereto. A generator flange 18 extends radially outwardly from the side of the circumferential wall 16 facing away from the ceiling portion 14. Hereinafter the generator flange 18 shall not be considered to be part of the external housing.

(43) The closing member 12 has a substantially plane bottom 20 and an outer circumferential pulled up edge 22 which is adjacent to the inside of the circumferential wall 16 of the diffuser 10. The wall thickness of the closing member 12 is larger at least in portions than that of the diffuser 10. Especially the bottom 20 of the closing member 12 is thicker than the circumferential wall 16 and the calling portion 14 of the diffuser 10.

(44) The external housing formed of the diffuser 10 (without generator flange 18) and the closing member 12 is substantially rotation-symmetric with respect to the central axis A of the inflator, as it is usual for so called disk-shape inflators which also include the subject matter of the invention. The central axis A of the inflator thus coincides with the central axis of the diffuser 10 and the closing member 12.

(45) The closing member 12 includes two bottom orifices 24 differently spaced apart from the central axis A of the inflator which serve for receiving pre-assembled igniter units 26, 28. Both igniter units 26, 28 comprise a respective igniter carrier 30 and 32 and a respective igniter 34 and 36 inserted in the former.

(46) The first igniter unit 26 (left in FIG. 1) is associated with a first activating stage of the inflator. An igniter sleeve 38 open at one side whose bottom 40 is opposed to the ceiling portion 14 of the diffuser 10 is attached to a receiving portion of the first igniter carrier 30. Between the igniter sleeve 38 and the first igniter carrier 30 a press fit is provided so that no further fastening measure (welding etc.) is necessary. The igniter sleeve 38 encloses an igniter chamber 42 into which the first igniter 34 projects. The igniter chamber 42 is filled with a booster charge (not shown), especially in the form of tablets.

(47) The igniter sleeve 38 is completely surrounded by a first combustion chamber 44 which is filled with a fuel (not shown), especially in the form of tablets. As can be recognized from FIG. 1, the diameter of the igniter sleeve 38 is tapered step by step towards its bottom 40. The tapering leaves more space for fuel in the first combustion chamber 44 compared to an igniter sleeve having a constant diameter.

(48) The first combustion chamber 44 is axially confined by the ceiling portion 14 of the diffuser 10 and the bottom 20 of the closing member 12. Radially the first combustion chamber 44 is confined by a completely circumferential annular filter 46 which extends along the inner side of the pulled up edge 22 of the closing member 12 or along the inner side of the circumferential wall 16 of the diffuser 10, with an annular gap 48 being formed between the filter 46 and the circumferential wall 16.

(49) Below the filter 46 the first combustion chamber 44 is confined in radial direction by a supporting element 50 on which the filter 46 is axially supported. In the case of a not completely circumferential supporting element 50, the first combustion chamber 44 is confined in the areas lying there between by the edge 22 of the closing member 12. The fact that the filter 46 does not extend to the bottom 20 of the closing member 12 allows saving costs for additional filter material and weight.

(50) Between the fuel of the first combustion chamber 44 and the ceiling portion 14 of the diffuser 10 a first fill member 52 is arranged. According to the first embodiment illustrated in FIG. 1, the first fill member 52 is made of expanded metal (knitted mesh) and includes elastic finger-type portions 54 supported toward the ceiling portion 14 of the diffuser 10.

(51) The second igniter 36 (on the right in FIG. 1) protrudes into a second combustion chamber 56 which is surrounded at least partially by the first combustion chamber 44. The second combustion chamber 56 is substantially confined by a fuel canister 58 made of aluminum, copper, plastic material or steel and a combustion chamber sleeve 60 made of steel surrounding the fuel canister 58.

(52) The fuel canister 58 has a substantially cylindrical side wall 62. On an axial end face facing the ceiling portion 14 of the diffuser 10 the fuel canister 58 includes a fuel canister opening 64; in the shown embodiment said end face is completely open. At the opposite end face the fuel canister 58 includes a fuel canister bottom 66 having a central fuel canister bottom opening 68. The fuel canister bottom opening 68 is formed by a bent inner edge portion 70 extending from the fuel canister bottom 66 into the interior of the fuel canister 58. The fuel canister bottom 66 having the bent inner edge portion 70 is supported on an upper receiving portion of the second igniter carrier 32. A press fit is provided between the fuel canister 58 and the second igniter carrier 32 so that no further fastening measure (welding etc.) is required.

(53) The fuel chamber sleeve 60 is pushed onto the fuel canister 58 in opposite orientation so that a fuel chamber sleeve bottom 72 opposed to the ceiling portion 14 of the diffuser 10 completely closes the open side of the fuel canister 58. The free edge 74 at the open side of the combustion chamber sleeve 60 is attached to a lower receiving portion of the second igniter carrier 32. A press fit is provided between the combustion chamber sleeve 60 and the second igniter carrier 32 so that no further fastening measure (welding etc) is required.

(54) At the combustion chamber sleeve bottom 72 a second fill member 76 tightly connected to the same is arranged that protrudes into the fuel canister 58. Otherwise the second combustion chamber 56 is filled with fuel (not shown), especially in the form of tablets.

(55) Hereinafter the basic functioning of the inflator is described. Special features of the functioning shall further below be explained in detail.

(56) As mentioned already, the inflator is designed in two stages. Upon activation of the first stage the first igniter 34 ignites the booster charge in the igniter chamber 42. During combustion of the booster charge igniting jets (hot gas) escape from overflow orifices of the igniter sleeve 33 (not visible in FIG. 1), which will be discussed in detail later, into the first combustion chamber 44 and ignite the fuel provided there. The gas formed during combustion flows through the filter 46 cooling the gas and freeing it from particles and subsequently through discharge orifices 73 of the diffuser 10 which will equally be discussed in detail later into the airbag.

(57) Upon activation of the second stage which, in response to the recognized situation of accident and the activation control, can basically take place after, before or independently of the first stage, the second igniter 36 ignites the fuel in the second combustion chamber 56. The gas formed during combustion of the fuel can escape from the second combustion chamber 56 into the first combustion chamber 44 by a special mechanism which will be described in detail later. From there the gas flows through the filter 46 and the discharge orifices 78 into the airbag.

(58) The structure of the inflator shown in FIG. 1 (first high configuration) permits inflating an airbag having a volume of 60 to 135 liters and thus is suited especially for passenger airbag modules.

(59) The construction height of the inflator, especially the axial height h1 of the external housing, in the first configuration ranges between 50 and 70 mm and in the shown embodiment according to FIG. 1 is approx. 60 mm.

(60) In the first configuration of the inflator the ratio of the volume of the first combustion chamber 44 to the volume of the second combustion chamber 56 ranges between 2.34 and 3.27, preferably between 2.54 and 3.00. In the shown embodiment according to FIG. 1 this ratio is approx, 2.76.

(61) In the first configuration of the inflator the ratio of the volume of the first combustion chamber 44 to the volume of the igniter sleeve 38 ranges between 13.5 and 31.0, preferably between 16.0 and 24.0. In the shown embodiment according to FIG. 1 this ratio is approx. 19.3.

(62) In the first configuration of the inflator the ratio of the outer diameter a of the external housing of the inflator (without generator flange 18, cf. FIG. 5) to the height h1 of the external housing is between 0.94 and 1.16 and in the shown embodiment according to FIG. 1 amounts to approx. 1.06.

(63) FIG. 2 illustrates a second configuration of the inflator having a definitely lower constructional height compared to the first configuration and accordingly is also referred to as flat configuration. The structure of the inflator in both configurations is substantially identical with several exceptions. Hereinafter the most important differences will be discussed.

(64) Compared to the first configuration, in the second configuration the axial extensions of the closing member 12, the igniter sleeve 38, the fuel canister 58, the combustion chamber sleeve 66, the igniter chamber 42 and the two combustion chambers 44, 56 reduced.

(65) In the second configuration the filter 46 extends from the ceiling portion 14 of the diffuser 10 to the bottom area of the closing member 12. At its lower end the filter 46 is axially supported on an inclined transition area 80 of the closing member 12, therefore in this case a separate supporting element for the filter 46 as in the first configuration is not provided.

(66) Instead of the first fill member 52 of expanded metal including the elastic finger-type portions 64, according to a second embodiment a flat first fill member 82 of resilient silicone is provided. The embodiment of the first fill member 82 shown in FIG. 2 can also be employed in the first configuration. The second embodiment of the first fill member 82 will be discussed in detail further below.

(67) The structure of the inflator shown in FIG. 2 (second flat configuration) permits inflating an airbag having a volume of 40 to 60 liters and is thus especially suited for driver airbag modules.

(68) The construction height of the inflator, especially the axial height h2 of the external housing, in the second configuration ranges between 30 and 50 mm and in the shown embodiment according to FIG. 2 is approx. 40 mm.

(69) In the second configuration of the inflator the ratio of the volume of the first combustion chamber 44 to the volume of the second combustion chamber 56 ranges between 2.07 and 3.78, preferably between 2.41 and 3.21. In the shown embodiment according to FIG. 2 this ratio amounts to approx. 2.82.

(70) In the second configuration of the inflator the ratio of the volume of the first combustion chamber 44 to the volume of the igniter sleeve 38 is between 9.0 and 35.0, preferably between 11.6 and 22.0. In the shown embodiment according to FIG. 2 this ratio is approx. 15.5.

(71) In the second configuration of the inflator the ratio of the outer diameter a of the external housing of the inflator to the height h2 of the external housing is between 1.38 and 1.78 and in the shown embodiment according to FIG. 2 is approx. 1.57.

(72) Hereinafter different peculiarities of the inflator illustrated in FIGS. 1 and 2 are described.

(73) The FIGS. 3 and 4 show the diffuser 10 of the inflator which is formed to be substantially rotation-symmetric except for the generator flange 18. In the circumferential wall 16 extending substantially in parallel to the central axis A a plurality of discharge orifices 78 are provided. The discharge orifices 78 are throughout disposed in a row extending at a constant height in circumferential direction. More precisely, all centers of the discharge orifices 78 have the same axial distance from the radially extending generator flange 18.

(74) In the row more than twelve, preferably more than fourteen discharge orifices 78 are provided. In the shown embodiment it is an odd number: exactly twenty-three discharge orifices 78 are arranged in a row. In general, the ratio of the outer circumference of the diffuser 10 in millimeters to the number n of the discharge orifices in the row is less than 16.5, preferably less than 14.1, further preferably less than 9.85. Further preferably the ratio ranges between 7.57 and 9.85, further preferably between 8.20 and 8.96. In the shown embodiment this ratio is approx. 8.56.

(75) As indicated in FIG. 4, at the inside of the diffuser 10 the discharge orifices 78 are covered by a tamping in the form of a circumferential tamping strip 84. The dimensions of the tamping strip 84 are selected such that it fits in the annular gap 48 between the circumferential wall 16 of the diffuser 10 and the circumferential filter 46 (cf. FIGS. 1 and 2).

(76) The row of the discharge orifices 78 is not completely circumferential. Viewed clockwise, the discharge orifice denoted with 78a marks the beginning and the discharge orifice denoted with 78b denotes the end of the row. Within the row the distances between neighboring discharge orifices 78 (related to the centers thereof) are equal. The distance between the first discharge orifice 78a and the last discharge orifice 78b, on the other hand is twice as large. Since the number n of the discharge orifices 78 in the row is odd, thus the arrangement of the discharge orifices 78 is such thatrelated to the central axis Aeach discharge orifice 78 is opposed to another discharge orifice, with one exception: The discharge orifice denoted with 78c is opposed to the area between the first discharge orifice 78a and the last discharge orifice 78b and thus to no discharge orifice. In this area of the diffuser inside a joint of the tamping strip 84 is disposed. Here a discharge orifice would impair the tightness to the outer area of the inflator.

(77) In general, the angular distance between neighboring discharge orifices 78 in such a constellation (Irrespective of whether the number n of the discharge orifices is even or odd) amounts to 360/(n+1).

(78) The preferably circular discharge orifices 78 have at least two different flow cross-sections; in the shown embodiment there are a total of three different flow cross-sections. The discharge orifices 78 are therefore provided with the addition (1), (2) or (3) in FIG. 3 so as to mark the relevant flow cross-section. The different flow cross-sections (1), (2) and (3) are defined by different diameters of the discharge orifices 78.

(79) The flow cross-sections (1), (2) and (3) of the discharge orifices 78 are selected such that opposite discharge orifices 78 have equal flow cross-sections. On the other hand, neighboring discharge orifices 78 within the row have different flow cross-sections. In the shown embodiment the following sequence of the flow cross-sections is repeated in the row: small flow cross-section (1).fwdarw.medium flow cross-section (2).fwdarw.small flow cross-section (1).fwdarw.large flow cross-section (3).

(80) The ratio of the outer circumference of the diffuser 10 (without generator flange 18) in mm to the number of the discharge orifices 78 having a small flow cross-section (1) is less than 19.7 and preferably is between 15.1 and 19.7. In the shown embodiment this ratio is approx. 17.9.

(81) The ratio of the outer circumference of the diffuser 10 in mm to the number of the discharge orifices 78 having a medium flow cross-section (2) as well as to the number of the discharge orifices 78 having a large cross-section (3) is less than 39.4 and preferably is between 28.2 and 39.4. In the shown embodiment this ratio amounts to approx. 32.3.

(82) The ratio of the total flow cross-section of all discharge orifices 78 in the row in mm.sup.2 to the outer circumference of the diffuser 10 in mm is more than 110 and preferably ranges between 110 and 139. In the shown embodiment this ratio is approx. 124.

(83) It is evident from the top view of the diffuser 10 of the inflator illustrated in FIG. 5 that the generator flange 18 radially outwardly extending from the circumferential wall 16 of the diffuser 10 has a substantially rectangular shape. The central axis A of the rotation-symmetric external housing having circular cross-section extends across the center M of the generator flange 18.

(84) The ratio of the length l to the width b of the rectangle describing the generator flange 18 ranges between 1.12 and 1.31, preferably between 1.16 and 1.27. In the shown embodiment this ratio is approx. 1.21.

(85) The ratio of the length l of the rectangle to the outer diameter a of the external housing (without generator flange 18) is between 1.24 and 1.48, preferably between 1.30 and 1.42. In the shown embodiment this ratio is approx. 1.36.

(86) The ratio of the width b of the rectangle to the outer diameter a of the external housing is between 1.01 and 1.23, preferably between 1.06 and 1.17. In the shown embodiment this ratio is approx. 1.12.

(87) In the FIGS. 6 to 9 different steps of assembling one of the igniter units 26, 28 are illustrated, before the latter is inserted as a pre-assembled unit into one of the bottom orifices 24 of the closing member 12. First, in the igniter carrier 30 or 32 shown in FIG. 6 a packing ring 86 is inserted in an igniter seat (cf. FIG. 7), before the igniter 34 or 36 is inserted in the igniter seat of the igniter carrier 30 or 32 (cf. FIG. 8). After that, the projecting circumferential edge 88 of the igniter seat is beaded such that the igniter 34 or 36 is safely held in the igniter carrier 30 or 32 (cf. FIG. 9).

(88) At a particular position the igniter carrier 30 or 32 has a milled slot as marker 90. The marker 90 provides an orientation of the igniter unit 26 or 28. A mounting tool used for assembling the inflator is designed so that it can receive the igniter unit 26 or 26 in a predetermined orientation only. When mounting the igniter unit 26 or 28, it is mounted in the desired orientation by means of the appropriate tool (cf. FIGS. 10 to 12).

(89) FIGS. 13 to 26 show different embodiments of the igniter sleeve 38 which is arranged on the first igniter carrier 30 at a predetermined orientation. To this end, the igniter sleeve 38 has a marker 92 distant from its central axis B or extending non-symmetrically from the central axis B. By means of the marker 92 it is possible to ensure the correct orientation of the igniter sleeve 38 during attachment onto the first igniter unit 26.

(90) In the embodiment of the igniter sleeve 33 shown in FIGS. 13 to 15 the marker 92 is in the form of a nose extending radially outwardly from a tapered portion 94 of the side wall 96 of the igniter sleeve 38. Similarly to the igniter unit 26 and 28 provided with the marker 90, a mounting tool used for assembling the inflator includes a recess corresponding to the nose so that the igniter sleeve 38 can be accommodated in the mounting tool at a predetermined orientation only. The mounting tool is adjusted such that when mounted the igniter sleeve 38 is attached to the first igniter carrier 30 at the orientation shown in FIG. 27.

(91) In FIG. 16 another embodiment of the igniter sleeve 38 is shown. The bottom 40 of the igniter sleeve 38 is inclined at a predetermined angle vis--vis a plane perpendicular to the central axis B of the igniter sleeve 38. The slant of the igniter sleeve bottom 40 is adapted to the axial curvature of the ceiling portion 14 of the diffuser 10 so that the igniter sleeve 38 fits below the ceiling portion 14 of the diffuser 10 at the predetermined orientation only.

(92) Further alternative embodiments of the igniter sleeve 38 having special markers 92 are illustrated in the FIGS. 17 and 18, 19 to 22 and 23 to 26.

(93) When activating the first state of the inflator, the igniter sleeve 38 is moved upwards, i.e. in the direction of the ceiling portion 14 of the diffuser 10, by the pressure developed during combustion of the booster charge. The maximum movement of the igniter sleeve 38 is confined by the ceiling portion 14 of the diffuser 10 which in turn is deformed (bulging). In contrast to the combustion chamber sleeve 60 (as will be explained further below) the igniter sleeve 38 does not detach from the receiving portion of the first igniter carrier 30, i.e. by raising the igniter sleeve 38 no additional discharge orifice leading out of the igniter chamber 42 is formed.

(94) All embodiments of the igniter sleeve 38 have in common thatrelated to the central axis B of the igniter sleeve 33they have overflow orifices 98 unevenly spaced in circumferential direction. More precisely, the overflow orifices 98 are restricted to a particular area of the side wall 96 of the igniter sleeve 38. When the igniter sleeve 38 is attached to the first igniter carrier 30 at the predetermined orientation, the overflow orifices 98 are not directed directly to the filter 46. The central axes of the outer overflow orifices 98 in the particular area of the side wall 96 define in circumferential direction a limited angular range for the discharge of the hot gas (igniting jets) when burning the booster charge in the igniter chamber 42 (cf. FIG. 15).

(95) As indicated in FIG. 27, the angular range extends to both sides of a connecting line between the central axis B of the igniter sleeve 38 and the portion of the filter 46 maximally distant from the central axis B. Especially the angular range includes those areas of the first combustion chamber 44 filled with feel which have a maximum distance from the filter 46 not blocked by components of the inflator. The angular range is obtuse and is between 90 and 135, preferably between 100 and 120. In the shown embodiment according to FIG. 27 the angular range is approx. 110.

(96) As is equally visible from FIG. 27, the angular range also includes the combustion chamber sleeve 60. The overflow orifices 98 are disposed such that the emitting igniting jets are not directed directly to the combustion chamber sleeve 60, however, but mostly to areas in which as much fuel as possible is covered over an as large length as possible.

(97) From FIG. 28 the particular structure of the second combustion chamber 56 is evident. The bottom 66 of the fuel canister 58 is supported on a substantially horizontal surface of the second igniter carrier 32, and the bent edge portion 70 of the feel canister bottom 66 is supported on a circumferential outer surface of the second igniter carrier 32. The fuel canister 58 thus stands stably and can conveniently be filled with fuel.

(98) After filling the combustion chamber sleeve 60 is slipped with the second fill member 76 onto the fuel canister 58 at an opposite orientation (compared to the fuel canister 53). According to the shown embodiment, the fuel chamber sleeve 60 having a slightly larger axial height than the fuel canister 68 is slipped on until the free edge 74 of the open side of the combustion chamber sleeve 60 is held by the lower receiving portion of the second igniter carrier 32 and the fuel canister opening 64 (here: the open side) is completely covered by the combustion chamber sleeve bottom 72. Then the substantially cylindrical side walls 62, 102 of the fuel canister 58 and of the combustion chamber sleeve 60 are immediately opposed to each other, more precisely the inner shell of the side wall 102 of the combustion chamber sleeve covers the outer shell of the side wall 62 of the fuel canister substantially over the entire axial length of the two sleeves 58, 60.

(99) In the vicinity of the fuel canister opening 64, approximately at the height of the second fill member 76 protruding into the fuel canister 58, in the side wall 62 of the fuel canister 58 a preferably completely circumferential bead 104 is embossed. The bead 104 serves for reinforcing the fuel canister 58, especially in the upper area close to the fuel canister opening 64.

(100) In the fuel canister bottom 66 plural fuel canister bottom holes 106 are formed. The side wall 62 of the fuel canister 58, on the other hand, includes no openings or holes. The combustion chamber sleeve 60 slipped onto the fuel canister 58 is completely free of holes, apart from its open side.

(101) Prior to activating the second stage of the inflator, the second combustion chamber 56 is completely closed. In the case of activation of the second stage, the fuel burns off in the second combustion chamber 56 and the burning gas formed generates excessive pressure in the second combustion chamber 56. The combustion chamber sleeve 60 is forced toward the ceiling portion 14 of the diffuser 10 by the excessive pressure.

(102) A marginal area 108 of the combustion chamber sleeve bottom 72 distant from the central axis A of the inflator contacts the ceiling portion 14 of the diffuser 10 either already in the non-activated state of the inflator or after a slight upward displacement of the combustion chamber sleeve 60. In each case the ceiling portion 14 which itself bulges due to the formation of gas restricts the axial movement of the combustion chamber sleeve 60.

(103) Since the combustion chamber sleeve 60 is supported at the marginal area of the ceiling portion 14, due to the continuously provided pressure in the second combustion chamber 56 the combustion chamber sleeve 60 tilts about the contact point 110, as shown in FIG. 29. It is also possible that the combustion chamber sleeve 60 deforms unevenly in addition or alternatively to the tilting. In any case, a portion of the side wall 102 of the combustion chamber sleeve 60 facing away from the outer edge of the inflator is raised from the second igniter carrier 32 and releases a discharge gap 112 which is visible especially in the detailed magnification X of FIG. 29.

(104) The gas formed during combustion of the fuel in the second combustion chamber 56 flows through the holes 106 in the fuel canister bottom 66 to the discharge gap 112 and through the same from the second combustion chamber 56 into the first combustion chamber 44. According to another embodiment of the fuel canister 58, initially the latter exhibits no fuel canister bottom holes 106; the holes are formed as late as by the pressure developed during combustion of the fuel and tearing of the fuel canister bottom 66 caused thereby.

(105) The distance between the central axis B of the igniter sleeve 38 and the central axis C of the combustion chamber sleeve 60 represented in FIG. 30 in the mounted state ranges between 22.5 and 27.5 mm, preferably between 23.5 and 26.5 mm. In the shown embodiment this distance is approx. 25 mm.

(106) The ratio of the minimum inner diameter c of the combustion chamber sleeve 60 to the minimum inner diameter d of the igniter sleeve 33 is between 1.64 and 2.63, preferably between 1.33 and 2.32. In the shown embodiment this ratio is approx. 2.06.

(107) The first combustion chamber 44 of the inflator is radially confined, as mentioned already, at least partially by the circumferential filter 46. The ratio of the inner diameter f of the filter 46 to the minimum inner diameter d of the igniter sleeve 38 is between 3.19 and 4.76, preferably between 3.50 and 4.27. In the shown embodiment this ratio is approx. 3.85.

(108) The ratio of the inner diameter f of the filter 46 to the minimum inner diameter c of the combustion chamber sleeve 60 is between 1.66 and 2.11, preferably between 1.76 and 1.99. In the illustrated embodiment this ratio is approx. 1.87.

(109) The ratio of the outer diameter a of the inflator, more precisely the external housing (without taking the generator flange 18 into account), to the minimum inner diameter d of the igniter sleeve 38 is between 4.09 and 5.98, preferably between 4.46 and 5.39. In the shown embodiment this ratio preferably is approx. 4.89.

(110) The ratio of the outer diameter a of the inflator to the minimum inner diameter c of the combustion chamber sleeve 60 is between 2.13 and 2.66, preferably between 2.24 and 2.5. In the shown embodiment this ratio amounts to approx. 2.38.

(111) As can also be inferred from FIG. 30, the axial height of the contact area between the igniter sleeve 38 and the first igniter carrier 30 is larger than the axial height of the contact area between the combustion chamber sleeve and the second igniter carrier 32.

(112) In FIG. 31 the arrangement of the igniter sleeve 38 and the combustion chamber sleeve 60 relative to the ceiling portion 14 of the diffuser 10 is shown. Related to the central axis A of the diffuser 10, both the axial distance g between the combustion chamber sleeve 60 and the ceiling portion 14 and the axial distance i between the igniter sleeve 38 and the ceiling portion 14 are varying. In the shown embodiment the combustion chamber sleeve 60 contacts the ceiling portion 14 of the diffuser 10 already in the non-activated state of the inflator at the contact point 110 in the outer marginal area of the inflator.

(113) The axial distance g between the combustion chamber sleeve 60 and the ceiling portion 14 of the diffuser 10 is largest at the central axis A of the diffuser 10 and continuously decreases with an increasing radial distance from the central axis A. The maximum distance g is between 2.3 and 3.7 mm, preferably between 2.7 and 3.3 mm. In the illustrated embodiment this maximum distance g is approx, 3.0 mm.

(114) The axial distance i of the igniter sleeve 33 disposed next to the central axis A of the diffuser 10 is not constant, either, but continuously decreases with an increasing radial distance from the central axis A of the diffuser 10. The maximum distance i between the igniter sleeve 38 and the ceiling portion 14 of the diffuser 10 is between 2.1 and 3.5 mm, preferably between 2.5 and 3.1 mm. In the illustrated embodiment this maximum distance i is approx. 2.8 mm.

(115) In the FIGS. 32 and 33 one respective part 114 of the first two-part fill member 82 of the second embodiment is shown which is arranged in the first combustion chamber 44 between the fuel and the ceiling portion 14 of the diffuser 10 and can be used both with the high first configuration (cf. FIG. 1) and with the flat second configuration (cf. FIG. 2). The first fill member 82 made of silicone can also be in one piece. In the two-part design of the first fill member 82 the two parts 114 preferably exhibit the double half-moon shape shown in FIGS. 32 and 33.

(116) In the inserted state, the first fill member 82 has two recesses 116, 118 into which the igniter sleeve 38 and the combustion chamber sleeve 60 protrude. The smaller first recess 116 is circular and is adapted to the upper outer diameter of the igniter sleeve 38. The larger second recess 118 is equally circular and is adapted to the upper outer diameter of the combustion chamber sleeve 60.

(117) The ratio of the diameter of the larger second recess 118 to the diameter of the smaller first recess 116 is between 1.52 and 2.25, preferably between 1.67 and 2.03. In the shown embodiment this ratio is approx. 1.84.

(118) FIG. 34 is a section across the inflator according to the first configuration (cf. FIG. 1) showing the filter 46 in an upper area of the inflator. The filter 46 which is separately illustrated in FIGS. 35 and 36 includes a critical filter portion 120 which comes closer to the combustion chamber sleeve 60 than the other areas of the filter 46.

(119) Said critical filter portion 120 has a reduced thickness compared to the adjacent areas of the filter 46. In this way a gap 122 is formed between the combustion chamber sleeve 60 and the critical filter portion 120. The critical filter portion 120 is compressed in radial direction, i.e. the filter material is more compressed in the critical filter portion 120 than in the adjacent areas.

(120) The combustion chamber sleeve 60, on the other hand, exhibits an increased material thickness in the area opposed to the critical filter portion 120 (cf. also FIGS. 1 and 5). In the shown embodiment the upper part of the combustion chamber sleeve 60 is thickened ever its complete circumference.

(121) The ratio of the minimum radial thickness j of the critical filter portion 120 to the thickness k of the adjacent areas of the filter 46 is between 0.43 and 0.93, preferably between 0.53 and 0.78. In the shown embodiment this ratio is approx. 0.65.

(122) The ratio of the minimum radial thickness j of the critical filter portion 120 to the maximum width m of the gap 122 between the combustion chamber sleeve 60 and the critical filter portion 120 is between 1.17 and 2.85, preferably between 1.50 and 2.23, in the shown embodiment this ratio is approx. 1.83.

(123) As is evident from the FIGS. 1 and 2 as well as from FIG. 37, the filter 46 generally extends in axial direction beyond the circumferential wall 16 of the diffuser 10 extending in axial direction into the area of the closing member.

(124) In the embodiment of the high first configuration of the inflator illustrated in FIG. 37 no separate support element 50 is provided for the filter 46. Rather, the pulled up edge 22 of the closing member 12 includes at least one supporting portion 124 constituting an axial support for the filter 46. The supporting portion 124 can be formed by a completely circumferential embossed bead or by plural beads spaced apart in circumferential direction. The filter 46 is supported on the supporting portion or portions 124 only by a radially outer area.

LIST OF REFERENCE NUMERALS

(125) 10 diffuser 12 closing member 14 ceiling portion 16 circumferential wall 18 generator flange 20 bottom 22 edge 24 bottom orifices 26 first igniter unit 28 second igniter unit 30 first igniter carrier 32 second igniter carrier 34 first igniter 36 second igniter 38 igniter sleeve 40 igniter sleeve bottom 42 igniter chamber 44 first combustion chamber 46 filter 48 annular gap 50 supporting element 52 first fill member (first embodiment) 54 finger-type portions 56 second combustion chamber 58 fuel canister 60 combustion chamber sleeve 62 fuel canister side well 64 fuel canister opening 66 fuel canister bottom 68 fuel canister bottom opening 70 marginal portion 72 combustion chamber sleeve bottom 74 free combustion chamber sleeve edge 76 second fill member 78 discharge orifices 78a first discharge orifice (beginning of row) 78b last discharge orifice (end of row) 78c discharge orifice without opposite discharge orifice 78(1) discharge orifice having small flow cross-section 78(2) discharge orifice having medium flow cross-section 78(3) discharge orifice having large flow cross-section 80 transition area 82 first fill member (second embodiment) 84 tamping strip 86 packing ring 88 igniter carrier edge 90 marker of the igniter carrier 92 marker of the igniter sleeve 94 tapered portion 96 igniter sleeve side wall 98 overflow orifices 102 side wall of combustion chamber sleeve 104 bead 106 fuel canister bottom holes 108 marginal area of fuel chamber sleeve bottom 110 contact point 112 discharge gap 114 fill member part 116 first recess of first fill member 118 second recess of first fill member 120 critical filter portion 122 gap 124 supporting portion A central axis of inflator, diffuser and closing member a outer diameter of inflator (without generator flange) h1 axial height of external housing (first configuration) h2 axial height of external housing (second configuration) n number of discharge orifices in the row M center of generator flange l length of rectangular flange b width of rectangular flange B central axis of rectangular flange angular range x connecting line C central axis of combustion chamber sleeve and fuel canister c minimum inner diameter of combustion chamber sleeve d minimum inner diameter of igniter sleeve f inner diameter of filter g axial distance between combustion chamber sleeve and ceiling portion i axial distance between igniter sleeve and ceiling portion j minimum thickness of critical filter portion k thickness of the remaining filter m maximum width of gap