[특허]System and method for inflation gas filtration through a tortuous flow pathway

Autoliv ASP, Inc.

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특허 상세정보

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System and method for inflation gas filtration through a tortuous flow pathway

특허상세정보
국가/구분	United States(US) Patent 등록
국제특허분류(IPC7판)	B60R-021/26 B01D-039/10 B01D-046/24
출원번호	US-0153496 (2014-01-13)
등록번호	US-9193327 (2015-11-24)
발명자 / 주소	Clark, Marcus T.
출원인 / 주소	Autoliv ASP, Inc.
대리인 / 주소	Madson IP, P.C.
인용정보	피인용 횟수 : 0 인용 특허 : 12

초록
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An airbag assembly may include an airbag and an inflator that provides inflation gas to inflate the airbag. A filter module may be positioned such that inflation gas exiting the inflator must first pass through the filter module. The filter module may be formed of a sheet of metal that is wrapped into a generally tubular shape. The filter module may have a first layer and a second layer that generally encircles the first layer. The first layer may have a pattern of holes and dimples that are separate from and/or displaced from each other. The dimples may protrude toward the second layer to maintain spacing to enable relatively unrestricted gas flow from the holes of the first layer through unaligned holes of the second layer. The resulting tortuous gas flow path may help to slow, cool, and/or purify the gas before it exits the inflator.

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1. An inflator for an airbag assembly for protecting a vehicle occupant from injury, the inflator comprising: an exterior wall comprising a first aperture;a gas source contained within a chamber defined within the exterior wall, wherein, in response to receipt by the inflator of a first activation signal, the gas source provides a gas; anda filter module made from a sheet wrapped in a spiral configuration comprising a first layer and a second layer, wherein: the first layer is a first segment of the sheet and comprises a first plurality of holes, wherein the first layer is positioned such that the gas passes through the first plurality of holes to reach the second layer;the second layer is a second segment of the sheet and comprises a second plurality of holes, each hole of the second plurality of holes is not aligned radially with each hole of the first plurality of holes, wherein the second layer is positioned such that the gas passes through the second plurality of holes to reach the first aperture; andone of the first layer and the second layer comprises a first plurality of dimples, wherein each dimple of the first plurality of dimples protrudes toward the other of the first layer and the second layer to maintain an open spacing between the first layer and the second layer for the gas to flow along a tortuous pathway through the open spacing from the first plurality of holes to the second plurality of holes, wherein each dimple of the plurality of dimples is separate from each hole of the corresponding plurality of holes. 2. The inflator of claim 1, wherein the dimples of the first plurality of dimples are arranged such that each dimple of the first plurality of dimples is substantially between and substantially equidistant from two adjacent holes of the corresponding first plurality of holes. 3. The inflator of claim 1, wherein the first layer comprises the first plurality of dimples, wherein the first plurality of dimples protrude toward the second layer, wherein the second layer further comprises a second plurality of dimples that protrude toward the exterior wall to maintain spacing between the second layer and one selection from the group consisting of the exterior wall, and a third layer of the filter module. 4. The inflator of claim 3, wherein each dimple of the first plurality of dimples is offset from each adjacent hole of the first plurality of holes by an offset of at least 0.5 mm. 5. The inflator of claim 1, wherein the first layer and the second layer cooperate to define a generally tubular shape in which the first layer is generally encircled by the second layer, wherein the gas passes from the gas source to a cavity generally encircled by the first layer. 6. The inflator of claim 5, wherein the first plurality of holes is offset along an axis of the generally tubular shape from the second plurality of holes. 7. The inflator of claim 5, wherein the filter module further comprises a third layer that cooperates with the first layer and the second layer to define the generally tubular shape, wherein the second layer is generally encircled by the third layer, the third layer comprising a third plurality of holes, each of which is not aligned with each hole of the second plurality of holes. 8. The inflator of claim 5, wherein the exterior wall comprises a plurality of apertures, one of which is the first aperture, wherein the plurality of apertures is offset along an axis of the generally tubular shape from at least one selection from the group consisting of the second plurality of holes, and a third plurality of holes of a third layer that generally encircles the second layer. 9. The inflator of claim 5, wherein the first and second layers are segments of a single metal sheet that is wrapped in a spiral configuration. 10. A method of manufacturing an inflator, the method comprising: providing an exterior wall comprising a first aperture;providing a gas source;positioning the gas source within a chamber defined within the exterior wall such that, in response to receipt by the inflator of a first activation signal, the gas source provides a gas;providing a filter module by: providing a metal sheet comprising a first segment and a second segment adjacent to the first segment, wherein the first segment comprises a first plurality of holes and the second segment comprises a second plurality of holes;forming a first plurality of dimples on one of the first segment and the second segment; andwrapping the metal sheet into a generally tubular shape such that the first segment defines a first layer that generally encircles a cavity into which the gas flows from the gas source and the second segment defines a second layer that generally encircles the first layer, with the metal sheet in the generally tubular shape, the first plurality of dimples protrudes toward the other of the first segment and the second segment to maintain an open spacing between the first layer and the second layer;wherein, in the generally tubular shape, each hole of the second plurality of holes is displaced along an axis of the generally tubular shape from each hole of the first plurality of holes; andinserting the filter module into the exterior wall such that, during inflation, the gas flows along a tortuous pathway through the filter module to reach the first aperture. 11. The method of claim 10, wherein forming the first plurality of dimples comprises arranging the first plurality of dimples such that each dimple of the first plurality of dimples is substantially between and substantially equidistant from two adjacent holes of the corresponding plurality of holes. 12. The method of claim 10, wherein forming the first plurality of dimples comprises forming the first plurality of dimples on the first segment such that, with the metal sheet in the generally tubular shape, the first plurality of dimples protrudes toward the second segment, wherein providing the metal sheet further comprises forming a second plurality of dimples on the second segment such that, with the metal sheet in the generally tubular shape, the second plurality of dimples protrudes toward the exterior wall to maintain spacing between the second layer and one selection from the group consisting of the exterior wall, and a third layer of the filter module. 13. The method of claim 10, wherein the metal sheet further comprises a third segment adjacent to the second segment, wherein the third segment comprises a third plurality of holes, wherein, in the generally tubular shape, the third segment defines a third layer that substantially encircles the second layer, wherein, in the generally tubular shape, each hole of the third plurality of holes is displaced along the axis of the generally tubular shape from each hole of the second plurality of holes. 14. The method of claim 10, wherein the exterior wall comprises a plurality of apertures, one of which is the first aperture, wherein inserting the filter module into the exterior wall comprises offsetting the plurality of apertures along the axis of the generally tubular shape from at least one selection from the group consisting of the second plurality of holes, and a third plurality of holes of a third layer that generally encircles the second layer. 15. An airbag assembly for protecting a vehicle occupant from injury, the airbag assembly comprising: an airbag; andan inflator connected to the airbag to expel gas into the airbag to inflate the airbag, the inflator comprising: an exterior wall comprising a first aperture;a gas source contained within a chamber defined within the exterior wall, wherein, in response to receipt by the inflator of a first activation signal, the gas source provides the gas; anda filter module made from a sheet wrapped in a spiral configuration comprising a first layer and a second layer, at least a portion of the second layer being wrapped around at least a portion of the first layer to define a generally tubular shape; wherein: the first layer comprises a first plurality of holes and a first plurality of dimples that protrudes toward the second layer to maintain an open spacing between the first layer and the second layer for the gas to flow along a tortuous pathway through the open spacing, wherein each dimple of the first plurality of dimples is spaced from each hole of the first plurality of holes; andthe second layer comprises a second plurality of holes, each hole of the second plurality of holes which is not aligned radially with each hole of the first plurality of holes. 16. The airbag assembly of claim 15, wherein the dimples of the first plurality of dimples are arranged such that each dimple of the first plurality of dimples is substantially between and substantially equidistant from two adjacent holes of the first plurality of holes. 17. The airbag assembly of claim 15, wherein the second layer further comprises a second plurality of dimples that protrude toward the exterior wall to maintain spacing between the second layer and one of the exterior wall and a third layer of the filter module. 18. The airbag assembly of claim 15, wherein the first plurality of holes is offset along an axis of the generally tubular shape from the second plurality of holes. 19. The airbag assembly of claim 15, wherein the exterior wall comprises a plurality of apertures, one of which is the first aperture, wherein the plurality of apertures is offset along an axis of the generally tubular shape from at least one selection from the group consisting of the second plurality of holes, and a third plurality of holes of a third layer that generally encircles the second layer.

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