Apparatus and method for providing combustible gas inflator

A combustible gas inflator, comprising:

• an enclosure configured to receive and store the combustible gas, the enclosure having an outer wall, the outer wall having an exterior surface, an interior surface, and a fill aperture extending therethrough, the fill aperture having a first aperture portion, a second aperture portion, and a third aperture portion, the first aperture portion being proximate the exterior surface, the second aperture portion being proximate the interior surface, and the third aperture portion being disposed between the first and second aperture portions, wherein the first aperture portion is larger than the second aperture portion and the third aperture portion, and the third aperture portion is larger than the second aperture portion;
• and
• a sealing member configured to seal the fill aperture, the sealing member having a first electrically non-conductive portion and a second electrically conductive portion, said second electrically conductive portion including an extension portion embedded within the first electrically non-conductive portion, the first portion being configured to sealingly engage a portion of the second aperture portion and the second portion being configured to sealingly engage a portion of the third aperture portion, wherein the first portion seals the combustible gas within the enclosure and the second portion is configured to be welded to the enclosure by a welding process which would ignite the combustible gas if the combustible gas was exposed to the welding process.

A method for sealing an inflator, the inflator having an enclosure configured to receive and store a combustible gas, the enclosure having an outer wall, the outer wall having an exterior surface, an interior surface, and a fill aperture extending therethrough, the fill aperture comprising a first aperture portion proximate the exterior surface and a second aperture portion proximate the interior surface, wherein the first aperture portion is larger than the second aperture portion, the method comprising:

• inserting a first electrically non-conductive portion of a sealing member into the second aperture portion of the fill aperture and creating a press-fit seal therebetween, a second electrically conductive portion including an extension portion embedded within the first electrically non-conductive portion of the sealing member prior to inserting the first electrically non-conductive portion into the second aperture portion, the first portion being inserted after the combustible gas has been stored within the enclosure, wherein the press-fit seal prevents the combustible gas from escaping from the enclosure;
• and
• welding the second electrically conductive portion of the sealing member to the outer wall of the enclosure by a welding process which would ignite the combustible gas if the combustible gas were exposed to the welding process, wherein a permanent seal is formed between the second electrically conductive portion and the outer wall.

A method for sealing an inflator, the inflator having an enclosure configured to receive and store a combustible gas, the enclosure having an outer wall, the outer wall having an exterior surface, an interior surface, and a fill aperture extending therethrough, the fill aperture having a first aperture portion proximate the exterior surface and a second aperture portion proximate the interior surface and a third aperture portion disposed between the first and second aperture portions, wherein the first aperture portion is larger than the second aperture portion and the third aperture portion, and the third aperture portion is larger than the second aperture portion, the method comprising:

• inserting a first electrically non-conductive portion of a sealing member into the second aperture portion of the fill aperture after the combustible gas has been stored within the enclosure, a second electrically conductive portion including an extension portion embedded within the first electrically non-conductive portion of the sealing member prior to inserting the first electrically non-conductive portion into the second aperture portion, wherein the first electrically non-conductive portion prevents the combustible gas from escaping from the enclosure;
• and
• welding the second electrically conductive portion of the sealing member to the outer wall proximate the third aperture portion, wherein a permanent seal is formed between the second electrically conductive portion and the outer wall.

A combustible gas inflator, comprising:

• an enclosure configured to receive and store the combustible gas, the enclosure having an outer wall, the outer wall having an exterior surface, an interior surface, and a fill aperture extending therethrough, the fill aperture having a first aperture portion, a second aperture portion, and a third aperture portion, the first aperture portion being proximate the exterior surface, the second aperture portion being proximate the interior surface, and the third aperture portion being disposed between the first and second aperture portions, wherein the first aperture portion is larger than the second aperture portion and the third aperture portion, and the third aperture portion is larger than the second aperture portion;
• a sealing member configured to seal the fill aperture, the sealing member having a first portion and a second portion, the first portion being configured to sealingly engage a portion of the second aperture portion and the second portion being configured to sealingly engage a portion of the third aperture portion, wherein the first portion seals the combustible gas within the enclosure and the second portion is configured to be welded to the enclosure by a welding process which would ignite the combustible gas if the combustible gas was exposed to the welding process;
• wherein the second portion extends along an axis, second portion comprises a tapered portion that tapers outwardly away from the axis, the enclosure having a first surface defining the first aperture portion and a second surface defining the third aperture portion, the tapered portion being configured to sealingly engage an edge formed by the first surface and the second surface.