Radial flow disc inflator

An inflatable airbag module, comprising:

• an inflatable cushion;
• and
• an inflator in fluid communication with the inflatable cushion, wherein the inflator comprises:
• a base member and a diffuser member coupled together to form a body, wherein the diffuser member comprises a sidewall with an exit port formed therein and a ceiling;
• a combustion chamber at least substantially enclosing a quantity of gas generant, the combustion chamber comprising a cap with an opening formed therein;
• an initiator assembly coupled to the base member and disposed at least partially within the combustion chamber to be in sufficient communication with the quantity of gas generant to initiate a reaction for producing a supply of inflation gas during deployment;
• and
• a filter element in fluid communication with the opening in the combustion chamber cap and positioned between the combustion chamber cap and the diffuser member ceiling, the filter element including at least one barrier and a plurality of apertures positioned to cause inflation gas from the combustion chamber to travel from the opening in the combustion chamber cap to the exit port along a tortuous path including at least one debris pocket and at least one impact region.

A method of forming an airbag cushion inflator, the method comprising:

• forming a filter comprising at least one barrier and a plurality of apertures positioned and configured to direct a flow of inflation gas along a tortuous path including at least one debris pocket and at least one impact region;
• disposing the filter in an inflator body in fluid communication with an opening in a combustion chamber cap, and between the combustion chamber cap and a diffuser member ceiling;
• and
• wherein forming the filter comprising at least one barrier and a plurality of apertures positioned and configured to direct a flow of inflation gas along a tortuous path including at least one debris pocket and at least one impact region comprises:
• forming the filter comprising a cylindrical barrier configured to encircle the opening in the combustion chamber cap, and sized to extend between the combustion chamber cap and the diffuser member ceiling.