Method of assembling a hybrid inflator and related propellants

A method for assembling a hybrid inflator for an automotive inflatable safety system, said hybrid inflator comprising an inflator housing and a gas generator, said method comprising the steps of:

• positioning a solid propellant inside said gas generator, said propellant comprising a secondary explosive and a binder system, wherein said solid propellant has a burn rate ranging from about 0.1 inches per second (0.25 cm/sec) to about 1 inch per second (5.0 cm/sec) at 4,000 psi (27.6 MPa), a combustion temperature ranging from about 2,000.degree. K. to about 3,800.degree. K., and has long-term thermal stability;
• positioning said gas generator inside said inflator housing;
• interconnecting said gas generator and said inflator housing;
• introducing a pressurized medium into at least said inflator housing, comprising the steps of:
• introducing a first gas into said inflator housing, said first gas consisting essentially of an inert gas;
• introducing a second gas into said inflator housing which is different from said first gas, said second gas consisting essentially of oxygen, wherein said pressurized medium consists essentially of a mixture of said first and second gases;
• and
• sealing said inflator housing to substantially retain said pressurized medium within said inflator housing.