Compact multi-level inflator

A method of forming a multi-level inflator for an air bag or other safety restraint device, comprising:

• providing an elongated pressure vessel having an indentation near the mid-portion thereof for defining a primary gas generating portion with a first open end and a gas storage portion with a second open end;
• inserting a support ring and primary grain trap in said primary gas generating portion adjacent to said indentation;
• inserting primary gas generating energetics in said primary gas generating portion adjacent to said primary grain trap;
• securing an igniter body having an initiator mounted on the inner end thereof to said first open end of said pressure vessel;
• either before, after or simultaneously with the assembly of said primary energetics and said igniter body, securing a pressure vessel closure to the second open end of said pressure vessel, said pressure vessel closure having an aperture therethrough and a primary rupture disk secured thereto to close said aperture;
• and
• mounting a secondary inflator of the all-pyrotechnic type on said closure and said pressure vessel, said secondary inflator comprising a secondary housing having a secondary initiator and secondary gas generating energetics disposed therein, and a choke plate disposed between said secondary energetics and said pressure vessel closure, said choke plate having an opening therethrough and a secondary rupture disk secured thereto to close said opening.

An inflator for an air bag or other safety restraint device, comprising:

• an elongated pressure vessel having a primary gas generating portion with a first open end and a gas storage portion with a second open end;
• said primary gas generating portion having a primary initiator and primary gas generating energetics disposed therein, said initiator being mounted on an igniter body secured to and closing said pressure vessel at said first open end;
• a pressure vessel closure secured to said second end of said pressure vessel, said closure having an aperture therethrough and a primary rupture disk secured thereto to close said aperture;
• said gas storage portion having an inert gas therein under a predetermined pressure;
• and
• a manifold secured to said pressure vessel and said closure, said manifold comprising a plurality of exit apertures in communication with said closure aperture;
• wherein a choke washer is mounted on the interior portion of said pressure vessel closure and comprises an opening therethrough in alignment with said closure aperture, and said primary rupture disk is positioned between said choke washer opening and said closure aperture.

A multi-level inflator for an air bag or other safety restraint device, comprising:

• an elongated pressure vessel having a primary gas generating portion with a first open end and a gas storage portion with a second open end;
• said primary gas generating portion having a primary initiator and primary gas generating energetics disposed therein, said initiator being mounted on an igniter body secured to and closing said pressure vessel at said first open end;
• a pressure vessel closure secured to said second end of said pressure vessel, said closure having an aperture therethrough and a primary rupture disk secured thereto to close said aperture;
• said gas storage portion having an inert gas therein under a predetermined pressure;
• and
• a secondary inflator of the all-pyrotechnic type secured to said pressure vessel and closure at said second end, said secondary inflator comprising a secondary housing having a secondary initiator and secondary gas generating energetics disposed therein, and a choke plate positioned between said secondary energetics and said pressure vessel closure, said choke plate having an opening therethrough and a secondary rupture disk secured thereto to close said opening;
• wherein an apertured secondary grain trap is disposed in said secondary housing between said secondary energetics and said choke plate.

A multi-level inflator for an air bag or other safety restraint device, comprising:

• an elongated pressure vessel having a primary gas generating portion with a first open end and a gas storage portion with a second open end;
• said primary gas generating portion having a primary initiator and primary gas generating energetics disposed therein, said initiator being mounted on an igniter body secured to and closing said pressure vessel at said first open end;
• a pressure vessel closure secured to said second end of said pressure vessel, said closure having an aperture therethrough and a primary rupture disk secured thereto to close said aperture;
• said gas storage portion having an inert gas therein under a predetermined pressure;
• and
• a secondary inflator of the all-pyrotechnic type secured to said pressure vessel and closure at said second end, said secondary inflator comprising a secondary housing having a secondary initiator and secondary gas generating energetics disposed therein, and a choke plate positioned between said secondary energetics and said pressure vessel closure, said choke plate having an opening therethrough and a secondary rupture disk secured thereto to close said opening;
• wherein a debris screen is secured to the outer portion of said pressure vessel closure and is in communication with said closure aperture, said choke plate is in engagement with the outer end of said debris screen, and said secondary inflator housing comprises a manifold portion having a plurality of exit apertures surrounding and in communication with said debris screen.

A multi-level inflator for an air bag or other safety restraint device, comprising:

• an elongated pressure vessel having a primary gas generating portion with a first open end and a gas storage portion with a second open end;
• said primary gas generating portion having a primary initiator and primary gas generating energetics disposed therein, said initiator being mounted on an igniter body secured to and closing said pressure vessel at said first open end;
• a pressure vessel closure secured to said second end of said pressure vessel, said closure having an aperture therethrough and a primary rupture disk secured thereto to close said aperture;
• said gas storage portion having an inert gas therein under a predetermined pressure;
• and
• a secondary inflator of the all-pyrotechnic type secured to said pressure vessel and closure at said second end, said secondary inflator comprising a secondary housing having a secondary initiator and secondary gas generating energetics disposed therein, and a choke plate positioned between said secondary energetics and said pressure vessel closure, said choke plate having an opening therethrough and a secondary rupture disk secured thereto to close said opening;
• wherein said pressure vessel closure further comprises a choke washer having an opening therethrough in alignment with said closure aperture, and said primary rupture disk is disposed between said choke washer opening and said closure aperture.