Fluid Supply, Filter Pack Used Therein and Method of Assembly

The present invention relates to fluid supplies for inflatable vehicle occupant restraint systems, and more particularly, to a filter pack for use therein and a method for assembling the filter pack in the fluid supply.

In general, vehicle occupant restraint systems utilize some type of crash sensor which senses the rapid deceleration which occurs when the vehicle is involved in a collision. The collision signal from the sensor actuates a fluid supply which provides a quantity of inflation gas to inflate an expansible confinement and restrain the vehicle occupant. Restraint systems of the class described may be positioned in the dashboard for deployment in the passenger compartment of the vehicle or may have the fluid supply and confinement portion located on the steering wheel to restrain the driver. In the latter case, it is necessary that the fluid supply fit compactly adjacent the steering wheel hub, without extending too far toward the driver, or radially toward the rim of the steering wheel. Therefore, while the present invention is equally adapted for many occupant restraint systems, it is especially useful for such a system which is located on the steering wheel, and will be described in connection therewith. It is also well adapted for systems which utilize the combustion of solid gas-generating materials as the source of the inflation gas, especially when such gas generating materials produce gaseous combustion products including both the generating gas and particles of varying sizes.

Among the prior art fluid supplies for occupant restraint systems are those exemplified by German Pat. No. 2,325,310, in which the generated gas flows radially out of a cylindrical housing. Another type of fluid supply is exemplified by U.S. application Ser. No. 459,529, filed Apr. 10, 1974, now Pat. No. 3,984,126, and assigned to the assignee of the present invention, showing a generally cylindrical housing from which the generated gas flows axially out of one end of a cylindrical housing. Among the common features of most such prior art fluid supplies are the inclusion of a mass of combustible gas generating material and some type of filter disposed between the combustible material and the fluid discharge ports defined by the housing.

Among the problems associated with the prior art fluid supplies has been the tendency for the filters to become clogged with the fine particles of fly ash which comprise a certain, relatively small percent of the combustion product when the gas generating material burns. If sufficient clogging of the filter occurs, the flow area through which the generating gas is discharged may be restricted to the point that excessive pressure builds up within the housing, thus presenting the possibility of the fluid supply exploding rather than directing a controlled flow of inflating gas into the confinement.

Another problem relates to the phenomenon of "channelling" which occurs whenever a gap exists between the filter pack and either the outside wall of the fluid supply or the central support member. Such a gap permits a fow of the generated gas to pass around rather than through the filter, carrying hot combustion particles which may then pass through the fluid discharge port into the inflatable confinement, causing damage to the confinement and, possibly, injury to the vehicle occupant.

Accordingly, it is an object of the present invention to provide an improved fluid supply for use in a vehicle occupant restraint system which minimizes undesirable clogging of the filter pack by the various sized combustion particles.

It is a more specific object of the present invention to provide a filter pack for use in a fluid supply wherein clogging of the filter is minimized by filtering progressively finer combustion particles as the combustion products pass downstream, through the filter, toward the fluid discharge port of the fluid supply.

It is another object of the present invention to provide a fluid supply, a filter pack and an improved assembly method therefor which minimizes the problem of channelling by substantially preventing the occurrence of gaps between the periphery of the filter pack and the fluid supply housing.

These and other objects of the present invention, which will become apparent upon a reading of the following detailed description, are accomplished by the provision of a fluid supply for inflating vehicle occupant restraint systems. The fluid supply comprises a housing defining a fluid discharge port, combustible gas generating means within the housing, and means operable to activate the gas generating means. A filter means is disposed between the gas generating means and the fluid discharge port, and includes a plurality of layers of filter material, each of the layers being at least as porous as the next adjacent downstream layer.

In accordance with another aspect of the present invention, the plurality of layers of filter material includes an upstream group of layers comprising fibres having diameters in the range of about 50 microns to about 150 microns and a downstream group of layers comprising fibres having diameters in the range of about 1 micron to about 20 microns.

In accordance with still another aspect of the present invention, the filter pack comprises a plurality of layers of filter material wherein each successive layer comprises fibres having diameters from about 1 to about 4 times the diameter of the fibres in the next adjacent downstream layer.

In accordance with yet another aspect of the present invention, a layer of support screen is pressed into the housing adjacent the fluid discharge port and a plurality of layers of filter material are then pressed into the housing adjacent the support screen. Finally, a relatively thin, perforated plate is positioned within the housing adjacent the layers of filter material. Preferably, the steps of pressing are accomplished with a force in the range of about 4 tons to about 6 tons.

FIG. 1 is a fragmentary cross-sectional view taken through a vehicle steering wheel utilizing a fluid supply made in accordance with the present invention.

FIG. 2 is a cross-sectional view taken through the fluid supply of FIG. 1.

FIGS. 3 and 4 are semi-schematic, cross-sectional illustrations of the equipment employed in practicing the method of the present invention.

Referring now to the drawings, which are for the purpose of illustrating preferred embodiments of the present invention, and not for limiting the same, FIG. 1 is a fragmentary cross-sectional view of a vehicle steering wheel, it being understood that the present invention is usable with occupant restraint systems for protecting the occupants of many types of vehicles, including, but not limited to automobiles, trucks, boats, airplanes and the like.

Referring still to FIG. 1, an occupant restraint system, generally designated 11, is illustrated positioned on a steering wheel, generally designated 13. The occupant restraint system 11 is preferably positioned near the hub of the steering wheel 13 which also includes a steering column 15 and oppositely disposed spokes 17 extending to, and supporting the steering wheel rim (not shown). The central portion of the steering wheel 13 defines a chamber 19 and a shoulder surface 21. Within the chamber 19 is located the inflator (or fluid supply), generally designated 23. Surrounding the fluid supply 23 is an inflatable confinement 25, the peripheral edge of which is secured between the shoulder surface 21 and an outer flange 27 disposed circumferentially about the fluid supply 23. The inflatable confinement 25 is stored within an enclosure 29 which is easily rupturable to permit the expansion of the confinement 25, the rupturing of the enclosure 29 being accomplished by the use of perforations, a weakened portion, or other suitable means. When a collision signal is sent to some type of electro-explosive means well known in the art, disposed within the inflator or fluid supply 23, the propellant or other combustible material contained therein is ignited and the resulting generated inflation gas passes from the fluid supply (as will be described in greater detail subsequently), inflating the confinement 25 and forcing open the enclosure 29.

The cross-sectional view shown in FIG. 2 illustrates the fluid supply 23 in greater detail. The fluid supply 23 comprises a cover member 31 which is threadably connected to a base member 33. The cover member 31 terminates in an outwardly-extending portion which comprises the outer flange 27. The cover member 31 and base member 33 are centrally supported and axially restrained by a stud 35 including a threaded portion 37 whic threadedly engages the internal threads of a specially configured nut 39, which fits into a centrally disposed opening in the base member 33. The stud 35 includes a hexagonal head portion 41 in engagement with the surface of a deformable diffuser 42 which directs the inflation gas radially outward and is described in greater detail in copending U.S. application Ser. No. 459,529, filed Apr. 10, 1974, now U.S. Pat. No. 3,984,126, and which is assigned to the assignee of the present invention. The nut 39 includes a generally flat end surface 43, and the base member 33 includes a shoulder surface 44, the purpose of which surfaces will be described subsequently.

The cover member 31 defines a plurality of passages or apertures 45, which may be placed in any one of a number of patterns about the upper portion of the cover member 31. Preferably, the apertures 45 are distributed generally uniformly about the surface of the cover member 31 and are of sufficient number and size to provide suitable passage means for the inflation fluid to pass from the housing of fluid supply 23, then be directed by the diffuser 42. Because the pressure generated by the combustion of the propellant may reach about 3500 psi (2.415 .times. 10.sup.9 Pa) or more, it is desirable that the cover member 31 and base member 33 be made from pressure vessel steel, and in the subject embodiment, the outside diameter of the cover member 31 is about 4 inches (10.2 cm), while the wall thickness of the pressure vessel steel is about 0.156 inches (0.39 cm).

Disposed within the cover member 31, and adjacent the passages 45, is a filter pack, generally designated 51, the function of which is to accomplish the final filtering of the generated gas before it passes from the fluid supply 23. The construction and arrangement of the various layers of the filter pack 51 are among the essential features of the present invention, and will be described in greater detail subsequently.

The remainder of the chamber within the fluid supply 23, i.e., the space defined by base member 33, is substantially filled with a means 71 for generating the inflation gas needed to expand the confinement 25. As will be understood by those skilled in the art, the present invention is not related to, or dependent upon the chemical composition of the combustible material 71. However, in the subject embodiment, the combustible material comprises an azide-base mixture, such as sodium azide (NaN.sub.3). For additional information regarding the chemical composition of combustible materials especially suited for use with the present invention, reference should be made to copending U.S. application Ser. No. 528,199, filed Nov. 29, 1974, now abandoned, by George W. Goetz, and assigned to the assignee of the present invention. Preferably, the combustible material is such that the combustion product comprises solid, porous sinters (or "clinkers") of varying sizes, rather than being wholly in the liquid or gaseous state.

In the cross-section assembly view of FIG. 2, the filter pack 51 is shown only somewhat schematically, and has not been discussed in detail in connection with the description of FIG. 2, but rather, will be described in greater detail in connection with the method of assembly illustrated in FIGS. 3 and 4.

Referring now to the semi-schematic illustrations of FIGS. 3 and 4, there is represented in FIG. 3 the assembly of the filter pack 51 into the cover member 31. This may be accomplished by placing the cover member 31 within an outer support fixture 81, with an inner support fixture and guide 83 being placed within the outer fixture 81 and in engagement with the outer flange 27. The layers of material comprising the filter pack 51 are placed within the inner fixture 83 and are pressed into the cover member 31 by means of a ram 85 which, in the subject embodiment, exerts a pressing force of about 4 tons to 6 tons, until the ram 85 and filter pack 51 are in the position shown in FIG. 4. Although the various layers comprising the filter pack 51 are illustrated in a spaced-apart relationship in FIG. 3, for ease of illustration, it will be understood by those skilled in the art that the layers will be in contact with each other when placed within the inner fixture 83, prior to being pressed into the cover member 31.

In connection with the detailed description of the filter pack 51, which will be in reference to FIG. 3, it should be noted that it is an essential feature of the present invention that as the inflation gas passes generally downstream through the filter pack 51, i.e., toward the apertures 45, progressively finer particles of the combustion products are removed from the stream of generated gas. As a result, filtering of the combustion products occurs throughout substantially the entire axial dimension of the filter pack 51, rather than occurring almost entirely on the same plane of the filter, thus causing clogging across that plane. To accomplish this progressive filtering action, the successive layers of the filter pack 51 generally decrease in porosity in the downstream direction, and preferably, each layer is at least as porous as the next adjacent downstream layer.

In the subject embodiment, the filter pack 51 includes layers of screen 101, 103 and 105, the main function of which is to provide mechanical support for the adjacent layers of filter material. Adjacent screen 105 are layers 107 and 109 of a material such as glass fiber. Next is another layer of screen 111, again for mechanical support. Adjacent screen 111 are layers 113, 115, 117 and 119, each comprising steel wool. The layers 113 through 119 are supported and separated from the combustible material 71 by a layer of screen 121 and a thin, perforated metal plate 123.

In the preferred form of the assembly method of the present invention, as represented by FIG. 4 rather than by FIG. 3, the layers of screen 101-105, 111 and 121 already have central openings to provide for stud 35. The layer of screen 101 is pressed into the cover member 31 to cause the screen 101 to conform to the internal configuration of the cover member. Subsequently, screen layers 103 and 105 are placed within the cover member in contact with the screen layer 101, then layers 107 through 121 are placed, as a group, within inner fixture 83 and are pressed into the cover member under a force of about 5 tons as described previously. Finally, the plate 123 is positioned within the cover member on top of the screen 121, but need not be pressed into place. Some type of pointed piercing tool may then be used to form a central opening in each of the layers not already having such an opening, such as the layers of fiberglas 107, 109 and 113-119. It may be seen from FIG. 3 that not all of the layers appear to have the same diameter, and in the subject embodiment, the layers of screen as well as the plate 123, have a diameter of about 3.75 inches (9.5 cm), or just slightly less than the inside diameter of the cover member 31, while the layers of filter material (both the steel wool and the glass fiber) have a diameter of about 4 inches (10.04 cm). As a result, when the filter pack is pressed into the cover member, the larger layers of steel wool and glass fiber are radially compressed to seal tightly about the inner surface of the cover member 31 and prevent channelling of the inflation gas, i.e., passage of the gas around the filter without filtration occurring.

Referring again to the detailed view of the filter pack 51 as in FIG. 3, preferably, the perforations in the plate 123 are in the range of about 2000 to 4000 microns and the openings in the screen 121 are in the range of about 500 to 1000 microns. On the downstream side of the filter pack 51, the screen 101 has a mesh size in the range of about 4 to 20 (National Bureau of Standards, U.S. Standard testing sieve, market grade or equivalent), screen 103 has a mesh size in the range of about 20 to 100, and screen 105 has a mesh size in the range of about 100 to 200. The intermediate layer of support screen 111 has a mesh size in the range of about 50 to 150.

It should be clearly understood that when reference is made to successive downstream layers of filter material being less porous, or each layer being at least as porous as the adjacent downstream layer, such reference is to only the layers of material which are included for the purposes of filtering, i.e., layers 107, 109, 113, 115, 117 and 119. Layers 113 through 119 preferably comprise fibers having diameters in the range of 50 microns to about 100 microns, whereas layers 107 and 109 comprise fibers having diameters in the range of about 1 micron to about 20 microns. It will be appreciated by those skilled in the art that the particular construction and arrangement of the various support screens (101 - 105, 111 and 121), and even the inclusion thereof, are optional and not of the essence of the preset invention, although it is the presently preferred practice to include some form of support means between the filter pack 51 and the apertures 45 to prevent te filter material from being blown through the apertues by the force of the combustion. Instead, the primary feature of the present invention is the progressive change in the porosity of the layers of filter material, with each successive layer comprising fibers having diameters preferably from about 1 to about 4 times the diameter of the fibers in the next adjacent downstream layer.

In connection with the following examples, it should be noted that for the layers of screen, porosity is given in terms of mesh size, i.e., the number of openings in the screen per linear inch, whereas, for the filter material, porosity is expressed in terms of fiber size, but because the layers were pressed into the cover member under about 5 tons of force, there is substantial proportionality between fiber size, inter-fiber space, and hence, porosity, It should also be noted that in the subsequent examples, the number and arrangement of layers of filter material was not exactly as is shown in FIG. 3. However, the layers have been referred to by the reference numerals utilized in FIG. 3 to the extent that the examples are consistent therewith.

The un-numbered layer of glass fiber, as well as layer 109 were a high temperature glass fiber sold under the trade name "Cerafelt" by Johns-Manville Corp. and layer 107 was another high temperature glass fiber sold under the trade name "Q-Felt," also by Johns-Manville. The filter pack of this Example was observed to provide satisfactory results.

For this Example, the filer pack was identical to that of Example A, except that the two layers of Cerafelt had the glass shot washed out, leaving essentially only the fibers. Better filering results wre observed with this filter pack.

In this Example, layers 101-105 and 121 and 123 were identical to Example A and the remaining layers were as follows:

The un-numbered layer of glass fiber as well as layer 113 were a high-temperature fiberglas sold under the trade name "PH Blanket" by Carborundum Corp., and the layer 109 was another high temperature, washed glass fiber sold under the trade name "Lo Con," also by Carbonundum. This filter pack provided the best filtering of the three Examples.

The invention has been described with reference to a preferred embodiment. Obviously, modifications and alterations will occur to others upon reading and understanding of the specification. It is our intention to include all such modifications and alterations insofar as they come within the scope of the present invention.