HYBRID INFLATOR AND VEHICLE SAFETY SYSTEM COMPRISING SAID HYBRID INFLATOR AS WELL AS METHOD OF FORMING A SHOCK WAVE

Abstract

The invention relates to a hybrid inflator (10) includes at least one combustion chamber (15) in which propellant charge is arranged and which has a discharge end (20), the propellant charge being formed of at least one propellant element (26), at least one igniting unit (12) by which the propellant charge can be ignited. The hybrid inflator (10) also includes at least one bursting element (14, 14, 14) which in the inactivated state of the hybrid inflator (10) delimits the combustion chamber (15) against a gas supply chamber (16) at the discharge end (20). The bursting element (14, 14, 14) and a restraint element (18, 18, 18) maintain the propellant charge in its position and/or the bursting element (14, 14, 14) and the propellant charge delimit a shock gas volume (SGV), wherein in the activated state of the hybrid inflator (10) the shock gas volume (SGV) acts on the bursting element (14, 14, 14) like a gas pressure spring.

Claims

1. A hybrid inflator (10) comprising: at least one combustion chamber (15) in which propellant charge is arranged and which includes a discharge end (20), wherein the propellant charge is formed of at least one propellant element (26), at least one igniting unit (12) by which the propellant charge can be ignited, and comprising at least one bursting element (14, 14, 14) which in the inactivated state of the hybrid inflator (10) delimits the combustion chamber (15) against a gas supply chamber (16) at the discharge end (20), wherein the bursting element (14, 14, 14) and a restraint element (18 18, 18) maintaining the propellant charge in its position and/or the bursting element (14, 14, 14) and the propellant charge delimit a shock gas volume (SGV) which in the activated state of the hybrid inflator (10) acts on the bursting element (14, 14, 14) like a gas pressure spring.

2. The hybrid inflator (10) according to claim 1, wherein the bursting element (14, 14, 14) includes an opening area (36) by which a shock wave can be generated, wherein between the opening area (36) and the igniting unit (12) the propellant charge is arranged so that a free space, especially a shock gas volume (SGV), is configured which is free from propellant charge and has an axial length (in parallel to the longitudinal hybrid inflator axis L) of at least 9 mm, preferably of at least 15 mm, especially preferably of at least 25 mm, and further especially preferably of at least 40 mm.

3. The hybrid inflator (10) according to claim 1, wherein the ratio of the shock gas volume (SGV) to the total empty volume of the combustion chamber (BKV) is at least 0.25, preferably 0.35, especially preferred 0.45, and/or wherein the hybrid inflator (10) includes an outer housing (11) having a constriction (17) formed between the combustion chamber (15) and the gas supply chamber (16), wherein the bursting element (14), especially in the form of a bursting sleeve, is inserted in the constriction (17), wherein especially the bursting element (14, 14) projects in the longitudinal hybrid inflator axis (L) from the combustion chamber (15) into the gas supply chamber (16), especially through the constriction (17).

4. The hybrid inflator (10) according to claim 1, wherein the combustion chamber screen (18) includes a peripheral wall (35) in which the combustion chamber (15) is arranged, wherein the peripheral wall (35) comprises a hollow-cylindrical portion and/or a hollow truncated portion and/or a hollow truncated pyramid portion, wherein preferably the restraint element (18) is configured as combustion chamber screen (18) comprising especially a universal ball joint-type portion (34) which is connected to the peripheral wall (35) especially on the combustion chamber side, wherein preferably the peripheral wall (35) has such longitudinal extension (L1) which corresponds at least to the longitudinal extension (L2) of a/the universal ball joint-type portion (34), preferably to 1.2 times, 2.5 times, especially to 1.5 times-2.0 times, the longitudinal extension (L2) of a/the universal ball joint-type portion (34).

5. The hybrid inflator (10) according to claim 1, wherein the restraint element is a hollow cylindrical or hollow conical screen, especially a spring (18), preferably a coil spring, wherein especially one end (25) of the spring (18) is arranged in the bursting element (14, 14, 14).

6. The hybrid inflator (10) according to claim 1, wherein at least one propellant element (26) is in the form of plural propellant rings (26), wherein the propellant rings (26) are arranged so that they form a passage (27) delimiting at least portions of the shock gas volume (SGV).

7. The hybrid inflator (10) according to claim 6, wherein the propellant rings (26) are designed and arranged so that for an entirety of plural propellant rings (26) a rib-shaped structure, viewed in the axial cross-section, having preferably U-shaped or V-shaped clearances (37) is formed, with especially the thickness of the propellant rings (26) being reduced from the outer periphery thereof toward the center thereof so that preferably the propellant rings (26) can be ignited by the igniting unit (12) so that hot igniting gases and/or igniting particles can be supplied to the clearances (37).

8. The hybrid inflator (10) according to claim 1, wherein between the igniting unit (12) and a first propellant ring (28) of the propellant charge in the gas flow direction (G) of the combustion chamber (15) a preferably annular filling material (29), which of preference is made of closed-pore silicone foam, is arranged, and/or between the bursting element (14, 14, 14) and a last propellant ring (30) of the propellant charge in the gas flow direction (G) of the combustion chamber (15) a preferably annular spacer (31) is arranged.

9. The hybrid inflator (10) according to claim 1, wherein the ratio of the shock gas volume (SGV) to an area (n*(rGVK).sup.2) defined by the radius (rGVK) of the inner diameter of the gas supply chamber (16) is larger than 1 cm.

10. A vehicle safety system comprising a hybrid inflator (10) according to claim 1, an airbag unit and/or a crash sensor.

11. A method of forming a shock wave inside a hybrid inflator (10) according to claim 1, the method comprising the following steps of: activating an igniting unit (12), opening a bursting element (14, 14, 14) by pressing a shock gas volume (SGV) formed ahead of the bursting element (14, 14, 14) against the bursting element (14, 14, 14) and generating a shock wave in a gas supply chamber (16) downstream of the bursting element (14, 14, 14).

12. The method according to claim 11, wherein at least one of the following further steps of: guiding gas generated in a combustion chamber (15) in the direction of the bursting element (14, 14, 14), guiding the shock gas volume (SGV) into the gas supply chamber (16), igniting propellant charge present in the combustion chamber (15), while the gas is guided in the direction of the bursting element (14, 14, 14), supplying hot igniting gases and/or igniting particles to clearances (37) formed between propellant rings (26).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0043] Hereinafter the invention shall be illustrated in detail by way of embodiments with reference to the enclosed schematic Figures, in which

[0044] FIG. 1 shows a sectional view across a basic structure of a hybrid inflator according to the state of the art;

[0045] FIG. 2 shows a sectional view across a hybrid inflator according to a preferred embodiment, with the bursting element being in the form of a bursting sleeve;

[0046] FIG. 3 shows a sectional view across a hybrid inflator according to another embodiment, with the restraint element being a spring and the bursting element being a bursting sleeve;

[0047] FIG. 4 shows a sectional view across a hybrid inflator according to the invention in accordance with another preferred embodiment, with the propellant charge being formed of a plurality of propellant rings; and

[0048] FIG. 5 shows a sectional view across a hybrid inflator according to the invention in accordance with another preferred embodiment, with the bursting element being connected, especially welded, to the hybrid inflator housing in a pressure-tight manner.

DESCRIPTION

[0049] Hereinafter, for equal and equally acting parts the same reference numerals shall be used, wherein FIG. 1 represents the basic structure of a hybrid inflator 10. The latter includes an elongate cylindrical housing 11 forming the outer housing of the hybrid inflator 10. On the first axial end thereof an igniting unit 12 is formed, with a diffusor 13 being provided on the second axial end of the housing 11. The diffusor 13 is provided with discharge ports and is connected to the housing 11 in the axial direction and directs the discharging gas to a location of use, for example to an inflatable airbag (not shown).

[0050] A bursting element 14 divides the housing 11 into a combustion chamber 15 and a gas supply chamber 16. In the direction of the longitudinal inflator axis L the combustion chamber 15 is connected to the igniter 12 in the housing 11. In the combustion chamber 15 a predetermined quantity of propellant is present. Said propellant may be provided, for example, in the form of compressed molded bodies or propellant elements (26).

[0051] In the direction of the longitudinal inflator axis L the gas supply chamber 16 is adjacent to the combustion chamber 15. The gas supply chamber 16 is filled with gas, especially cold gas such as e.g. argon, helium or any other suitable gas mixture. The bursting element 14 does not close the gas supply chamber 16 against the combustion chamber 15 in a pressure-tight manner so that a fluid communication exists between the two chambers 15 and 16. Due to this fact, during manufacture of the hybrid inflator 10 upon filling the gas supply chamber 16 with gas, especially cold gas, said gas also flows into the combustion chamber via through holes of the bursting element 15 until pressure compensation is reached between the two chambers 15 and 16. Preferably, the pressure compensation is brought about within about 5 seconds. Hence, prior to activation of the hybrid inflator 10 compressed gas is present both in the gas supply chamber 16 and in the combustion chamber 15 in mutual fluid communication.

[0052] In the variant of a hybrid inflator 10 shown hero the bursting element 14 is press-fitted or clamped into the housing 11. The bursting element 14 may also be adhesively connected to the housing 11, however.

[0053] The housing 11 includes an annularly peripheral constriction 17 in the area in which the bursting element 14 is fastened in the housing 11. The outer surface of the bursting element 14 is adjacent to the inside of the constriction 17 so that the bursting element 14 is supported in the area of the constriction 17 and the bursting element 14 is thus additionally secured. In the case that the bursting element 14 is adhesively connected to the housing 11, the annularly peripheral constriction 17 may be dispensed with, wherein the housing 11 may include an equally continuous cylindrical shape in this area.

[0054] In order to withhold burn-up particles, for example, ahead of the bursting element 14 a restraint element 18 is configured as a combustion chamber screen in the combustion chamber 15. The curvatures of the bursting element 14 and of the restraint element 18 are configured in opposite directions.

[0055] When the hybrid inflator 10 is activated, the igniting unit 12 receives an electric signal to activate the hybrid inflator 10 and, resp., to ignite the propellant charge present in the combustion chamber 15. The ignition of the propellant charge present in the combustion chamber 15, especially of the solid propellant charge, results in sudden increase in pressure inside the combustion chamber 15 so that the bursting element 14 can be destroyed and opened, respectively. In the bursting element 14 a large opening is formed. Said abrupt opening generates a shock wave which enters the gas supply chamber 16 and passes through the same up to a bursting disk 19 arranged on the end side of the gas supply chamber. The bursting disk 19 may be replaced with a different bursting membrane or with a bursting sleeve.

[0056] In the shown embodiment of a hybrid inflator 10 the igniting unit 12, the restraint unit 18 and the bursting element 14 are located on the longitudinal hybrid inflator axis L. In this way, optimum ignition of the propellant charge provided in the combustion chamber 15 is achieved so that efficient formation and propagation of the shock wave is obtained.

[0057] The hybrid inflator 10 shown here can be used, for example, for inflating an airbag and/or can be used in a belt tensioner system.

[0058] Furthermore, it is possible that in the hybrid inflator 10 additional propellant (not shown) is received within the gas supply chamber 16 for resupplying hot gas.

[0059] FIG. 2 represents a first possible embodiment of a hybrid inflator 10 further developed according to the invention. In the combustion chamber 15 a propellant charge comprising a plurality of propellant elements 26 is arranged, wherein the propellant elements 26 may be present in the form of tablets, rings or cylindrical molded bodies having one or more passages or else in the form of granules. The combustion chamber 15 is filled with gas and includes a discharge end 20. At the discharge end 20 is formed the bursting element 14 which delimits the combustion chamber 15 at the discharge end 20 in the inactivated state of the hybrid inflator 10 against the gas supply chamber 16.

[0060] The bursting element 14 is a bursting sleeve. The peripheral wall 21 of the bursting sleeve 14 is adjacent at least in portions to the inner surface of the constriction 17. The bursting sleeve 14 is inserted into the constriction 17 and projects into the gas supply chamber 16. The bursting element 14 of FIG. 1 does not project into the gas supply chamber 16, however. Projecting into the gas supply chamber 16 of the bursting element 14 is to be understood so that the extension of the bursting element 14 protrudes from the constriction 17. The restraint element 18 maintaining the propellant charge in its position is a combustion chamber screen in the embodiment according to FIG. 2.

[0061] The bursting element 14 in the form of a bursting sleeve substantially has a flat lid 23, a cylindrical peripheral wall 21 and a fastening portion 24. The lid 23 includes an opening area 36 which is substantially arranged in the center of the lid. The fastening portion 24 is partly truncated and abuts on the inner wall of the housing 11.

[0062] The bursting element 14 and the restraint element 18 delimit a shock gas volume SGV which in the activated state of the hybrid inflator 10 acts on the bursting element 14 like a gas pressure spring. The space SGV formed by the bursting element 14 and the restraint element 18 is substantially free from burn-up particles and propellant elements so that a shock gas volume SGV is formed in this enlarged space. When the hybrid inflator 10 is activated, at first an igniter-side bursting element 22 is destroyed so that hot ignition gas and/or hot igniting particles may penetrate the combustion chamber 15. The propellant charge in the combustion chamber 15 is ignited and burnt up in this way, thus causing the pressure in the combustion chamber 15 to be increased. The gas pressure formed in this way thus presses onto the shock gas volume SGV so that the bursting element 14 is destroyed and, resp., opened. Accordingly, first the opening area 36 of the lid 23 of the bursting element 14 is opened. After that, the shock gas volume SGV flows into the gas supply chamber 16 very quickly, namely in the way of a gas pressure spring. Since the lid 23 of the bursting element 14 protrudes into the gas supply chamber 16, the shock wave is initiated at this point so that the shock wave propagates extremely quickly toward the bursting disk 19 of the hybrid inflator 10 and, resp., moves there through the gas supply chamber 16 so as to open the bursting disk 19.

[0063] In FIG. 3 another embodiment regarding a hybrid inflator 10 according to the invention is shown. The bursting element 14 is equally designed as bursting sleeve. In this context, the same explanations as given already in connection with the embodiment according to FIG. 2 are applicable. The restraint element 18 maintaining the propellant charge and, resp., the propellant elements 26 in its position is a spring, namely a coil spring. The right-hand end 25 as shown in FIG. 4 of the spring is inserted in the bursting element 14. The restraint element 18 keeps a gas volume passage free inside the propellant charge. Along with the bursting element 14 the restraint element 18 delimits a shock gas volume SGV. The shock gas volume SGV is pressed against the lid 23 of the bursting element 14 upon activation of the hybrid inflator 10. The shock gas volume in the form of a shock wave package initiates an extremely intense shock wave in the gas supply chamber 16.

[0064] FIG. 4 represents another embodiment of a hybrid inflator 10 according to the invention. In the combustion chamber 15 a propellant charge is disposed, wherein the individual propellant elements 26 are in the form of propellant rings each having a central through passage. The propellant rings 26 are juxtaposed in the longitudinal hybrid inflator axis L so that in total a passage 27 is formed. Said passage 27 is regarded as part of the shock gas volume SGV to be formed. The arrangement of the propellant rings 26 and of the bursting element 14, which is a simple bursting membrane, delimit a shock gas volume SGV acting on the bursting element 14 like a gas pressure spring in the activated state of the hybrid inflator 10.

[0065] The propellant rings 26 are configured and arranged so that for an entirety of plural propellant rings 26 a rib-shaped structure viewed in the axial cross-section having preferably U-shaped or V-shaped clearances 37 is formed. Accordingly, the thickness of the propellant rings 26 decreases from the outer periphery thereof toward the center thereof. Upon activation of the hybrid inflator 10 the propellant rings 26 can be ignited by the igniting unit 12 so that hot igniting gases and/or igniting particles are supplied to the clearances 37.

[0066] As an alternative to the individual propellant elements 26, one single propellant ring (not shown) may be provided in the form of a monolith having a central through passage which may be designed to have a corresponding longitudinal extension, so-to-speak in exchange for a sequence of the individual propellant rings 26.

[0067] Between the igniting unit 12 and a first propellant ring 28 in the gas flow direction G of the combustion chamber 15 an annularly designed filling material 29 is disposed. Said filling material 29 preferably is made of closed-pore silicone foam. The filling material 29 causes the shock gas volume SGV available in total in the combustion chamber 15 to be displaced away from the igniting unit 12 and to be displaced in the direction of the bursting element 14. It would be a drawback in terms of energy when the igniting unit 12 initially would have to heat a gas volume in its direct environment, viz. in the area of the filling material 29. Instead, the energy of the igniting unit 12 may be guided directly to the shock gas volume SGV ahead of the bursting element 14.

[0068] A spacer 31 is formed between the bursting element 14 and a last propellant ring 30 in the gas How direction G of the combustion chamber 15. With the aid of the spacer 31, especially with the aid of the passage 32, a larger shock gas volume SGV is formed. In the area of the spacer 31 the gas does not have to ignite any propellant charge.

[0069] In FIG. 5 a hybrid inflator 10 according to the invention is shown, with the propellant charge or the propellant elements 26 in the combustion chamber 15 being under atmospheric pressure, i.e. not being surrounded by the compressed gas of the biased gas supply chamber 16. The bursting element 14 is a bursting disk which is welded in a pressure-tight manner to the housing 11 of the hybrid inflator 10 with the aid of a bursting element support 33. The restraint element 18 is configured as a combustion chamber screen having a universal ball joint-type portion 34 as well as a peripheral wall 35. The peripheral wall 35 is arranged to point toward the bursting element 14 and includes a hollow truncated portion. In the shown example, the peripheral wall 35 has a longitudinal extension L1 corresponding to 1.5 times the longitudinal extension L2 of the universal ball joint-type portion 34. Due to the large longitudinal extension L1 of the peripheral wall 35, the bursting element 14 and the restraint element 18 delimit an appropriately large shock gas volume SGV which in the activated state of the hybrid inflator 10 acts on the bursting element 14 like a gas pressure spring.

[0070] In the shown example according to FIG. 5, the shock gas volume SGV may act on the bursting element 14 so that the bursting element 14 can be opened by such great force that the shock wave may propagate into the gas supply chamber 16 and a bursting disk 19 (not shown here) may be opened in a robust way.

[0071] It is also imaginable that the combustion chamber 15 is completely free from any propellant charge. In this case the entire free combustion chamber volume can be regarded as shock gas volume (SGV) which acts on the bursting element 14, 14, 14 like a gas pressure spring upon activation of the hybrid inflator 10.

[0072] It is applicable to all shown embodiments according to FIGS. 2 to 5 that the ratio of the shock gas volume SGV to the entire empty volume of the combustion chamber BKV is at least 0.25, preferably 0.35, especially preferred 0.45. Empty volume of the combustion chamber BKV is to be understood as the empty volume of the combustion chamber which is formed without any combustion chamber fittings and without any propellant charge. The empty volume of the combustion chamber BKV thus reaches from the igniter-side end of the combustion chamber (without igniter unit) to the constriction 17 and, resp., to the transition to the gas supply chamber 16.

[0073] Moreover, it is possible with respect to all embodiments according to FIGS. 2 to 5, that the ratio of the shock gas volume SGV to an area defined by the radius (rGVK) of the inner diameter of the gas supply chamber 16 is larger than 1 cm, wherein: SGV/(n*(rGKV).sup.2)>1 cm. Merely by way of example, this connection has to be understood to the effect that with a particular shock gas volume SGV related to an area determined by the radius rGVK of the gas supply chamber 16, viz. the area n*(rGVK).sup.2, with n being the circle number pi, a certain thickness as regards a shock wave package is required to initiate a robust shock wave.

LIST OF REFERENCE NUMERALS

[0074] 10 hybrid inflator [0075] 11 housing [0076] 12 igniting unit [0077] 13 diffusor [0078] 14, 14, 14 bursting element [0079] 15 combustion chamber [0080] 16 gas supply chamber [0081] 17 constrict ion [0082] 18, 18, 18 restraint element [0083] 19 bursting disk [0084] 20 discharge end [0085] 21 peripheral wall [0086] 22 igniter-side bursting element [0087] 23 lid [0088] 24 fastening portion [0089] 25 end of spring [0090] 26 propellant ring/propellant element [0091] 27 passage [0092] 28 first propellant ring [0093] 29 filling material [0094] 30 last propellant ring [0095] 31 spacer [0096] 32 passage [0097] 33 bursting element support [0098] 34 universal ball joint-type portion [0099] 35 peripheral wall [0100] 36 opening area [0101] 37 clearance [0102] G gas flow direction [0103] L longitudinal hybrid inflator axis [0104] L1 longitudinal extension of peripheral wall [0105] L2 longitudinal extension of universal ball joint-type portion [0106] SGV shock gas volume [0107] BKV empty volume of combustion chamber [0108] rGVK radius of gas supply chamber [0109] Lfrei length of free space