Gas generator

Abstract

To improve durability of a die used for molding a holding part in a gas generator having the holding part comprising a resin molding part.SOLUTION: A gas generator 1 includes a housing, an igniter 40, a holding part 30 and a male type connector 130. The holding part 30 that holds the igniter 40 comprises a resin molding part including an outer covering part fixed to an outer surface of a bottom plate part of the housing. The outer covering part includes a female type connector 34 including a recessed part 35. The male type connector 130 includes a lock projection 136 on a peripheral surface of a portion inserted into the recessed part 35. The recessed part 35 has an inner peripheral surface including a lock recessed part 35a1 and a planar inner bottom surface. An axial end surface 34a that is an exposed surface exposed to outside of the female type connector 34 and is located to surround the recessed part 35 has an orientation limitation projection 37 that limits an orientation of the male type connector 130 in a direction orthogonal to an insertion direction of the male type connector 130 into the recessed part 35.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] The present invention relates to a gas generator to be incorporated in an airbag device as an occupant protection device equipped in an automobile or the like. [Background technology]

[0002] Conventionally, airbag devices, which are passenger protection devices, have become widespread from the viewpoint of protecting passengers in automobiles, etc. Airbag devices are installed for the purpose of protecting passengers from impacts that occur when a vehicle or the like crashes, and the airbag instantly inflates and deploys when a vehicle or the like crashes, so that the airbag acts as a cushion to receive the body of the passenger.

[0003] The gas generator is incorporated in the airbag device, and when a vehicle or the like crashes, an igniter is ignited by current from a control unit, and the flame generated in the igniter burns the gas generating agent, instantly generating a large amount of gas, thereby inflating and deploying the airbag. Some igniters are held by a holding part that is a resin molded part of the gas generator.

[0004] The control unit supplies electricity to the igniter by, for example, inserting a male connector of a harness for connecting the igniter and the control unit into a bottomed, generally cylindrical female connector provided in the holding part, thereby connecting the male connector to a terminal pin of the igniter. For example, JP 2017-185907 A (Patent Document 1) is an example of a document that employs such a method of supplying electricity. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2017-185907 A Summary of the Invention [Problem to be solved by the invention]

[0006] In gas generators, an assembly structure may be adopted in which an inserted male connector is held by a female connector by a so-called snap fit, in which a locking protrusion provided on the peripheral surface of the male connector engages with a locking recess provided on the inner peripheral surface of the female connector.

[0007] When a holding part having a female connector with a locking recess as an undercut is manufactured by injection molding, it is necessary to move the movable part provided in the mold from the undercut when removing the injection-molded holding part from the mold.

[0008] If a shape other than the inner peripheral surface of the female connector is given, for example if a protrusion is provided on the inner bottom surface of the female connector, the mold structure will result in a part of the movable part being made thinner than the other parts. Therefore, if no measures are taken against this, the strength of the mold cannot be sufficiently ensured.

[0009] The present invention has been made in consideration of the above-mentioned points, and aims to improve the durability of a mold used to mold a retaining portion in a gas generator having a retaining portion made of a resin molded portion. [Means for solving the problem]

[0010] A gas generator according to the present invention includes a housing, an igniter, a holding portion, and a male connector. The housing includes a top plate portion, a bottom plate portion, and a cylindrical peripheral wall portion provided with a gas outlet, and has a combustion chamber therein in which a gas generating agent is accommodated. The igniter has an ignition portion loaded with an ignition charge for burning the gas generating agent, and a terminal pin connected to the ignition portion. The holding portion is provided on the bottom plate portion and holds the igniter. The male connector is connected to the igniter. The bottom plate portion has a protruding cylindrical portion that protrudes toward the top plate portion and has a shelf portion provided at an end portion on the top plate portion side. The shelf portion is provided with an opening. The igniter is assembled to the bottom plate portion by being held by the holding portion in a state in which the ignition portion is located closer to the top plate portion than the shelf portion and the terminal pin is inserted through the opening. The holding portion is made of a resin molded portion that closes the opening and covers at least a part of each of the inner surface and the outer surface of the bottom plate portion. The resin molded portion is fixed to the ignition portion and includes an inner covering portion fixed to the inner surface of the bottom plate portion at a portion adjacent to the opening, and an outer covering portion fixed to the outer surface of the bottom plate portion at a portion defining the protruding cylindrical portion. The outer covering portion has a female connector including a concave portion exposed to the outside along the axial direction of the protruding cylindrical portion. The male connector can be inserted into the concave portion. A locking protrusion is provided on the peripheral surface of the portion of the male connector that is inserted into the concave portion. A locking recess that can lock the locking protrusion is provided on the inner peripheral surface of the concave portion. The inner bottom surface of the concave portion is flat. In the gas generator based on the present invention, an orientation control protrusion is provided on the axial end face of the female connector, which is an exposed surface exposed to the outside and positioned so as to surround the concave portion, for controlling the orientation of the male connector in a direction perpendicular to the direction in which the male connector is inserted into the concave portion.

[0011] In the gas generator according to the present invention, the male connector may have an opposing portion that opposes a part of the axial end face of the female connector when the male connector is inserted into the recessed portion, the terminal pin may consist of a pair of pins, a first pin and a second pin, and the male connector may consist of a pair of first and second terminal blades that can receive each of the pair of pins. In that case, it is preferable that when the male connector is inserted into the recessed portion in an orientation in which the first pin corresponds to the first terminal blade and the second pin corresponds to the second terminal blade, the orientation regulating protrusion does not interfere with the opposing portion, thereby enabling the male connector to be inserted into the recessed portion, and when the male connector is inserted into the recessed portion in an orientation in which the second pin corresponds to the first terminal blade and the first pin corresponds to the second terminal blade, the orientation regulating protrusion interferes with the opposing portion, thereby disabling the male connector from being inserted into the recessed portion.

[0012] In the gas generator according to the present invention, a pair of anti-rotation projections may be provided on the axial end face of the female connector at a position different from a portion where the orientation regulating projections are provided. In that case, it is preferable that the pair of anti-rotation projections are positioned to sandwich the opposing portion when the male connector is inserted into the recessed portion in an orientation in which the first pin corresponds to the first terminal blade and the second pin corresponds to the second terminal blade, thereby preventing rotation of the male connector.

[0013] In the gas generator based on the present invention, it is preferable that the male connector is provided with a seal portion made of an elastic member which, when the male connector is inserted into the recessed portion, is sandwiched between the female connector and the male connector, compressing the male connector and thereby filling the gap that arises between the female connector and the male connector, thereby liquid-tightly sealing the internal space of the recessed portion from the outside. Effect of the Invention

[0014] According to the present invention, in a gas generator having a retaining portion made of a resin molded portion, it is possible to improve the durability of the mold used to mold the retaining portion. [Brief description of the drawings]

[0015] [Figure 1] 1 is a schematic diagram of a disk-type gas generator according to an embodiment. [Diagram 2] 2A and 2B are a bottom view and a cross-sectional view of the holding part shown in FIG. [Diagram 3] 1A to 1C are a side view, a plan view, a bottom view and a cross-sectional view of a male connector according to an embodiment. [Figure 4] 1 is a schematic diagram showing a first embodiment in which a male connector is inserted into a recessed portion of a female connector. [Diagram 5] 13 is a schematic diagram showing a second embodiment in which a male connector is inserted into a recessed portion of a female connector. FIG. [Figure 6] 2A to 2C are schematic views for explaining a manufacturing process of the holding portion shown in FIG. [Figure 7] 2A to 2C are schematic views for explaining a manufacturing process of the holding portion shown in FIG. [Figure 8] 2A to 2C are schematic views for explaining a manufacturing process of the holding portion shown in FIG. [Figure 9] 11A and 11B are a bottom view and a cross-sectional view of a holding portion according to a comparative example. [Figure 10] 10A to 10C are schematic views for explaining a manufacturing process of a holding portion according to a comparative example. [Figure 11] 10A to 10C are schematic views for explaining a manufacturing process of a holding portion according to a comparative example. [Figure 12] 10A to 10C are schematic views for explaining a manufacturing process of a holding portion according to a comparative example. [Figure 13] 13 is a schematic diagram for explaining a mold used in manufacturing the holding portion according to the first modified example. FIG. [Figure 14] 10A and 10B are schematic diagrams for explaining parting lines generated in a holding portion according to a first modified example and a holding portion according to an embodiment. [Figure 15] FIG. 11 is a bottom view of a holding portion according to a second modified example. [Figure 16] FIG. 13 is a bottom view of a holding portion according to a third modified example. [Figure 17] FIG. 13 is a bottom view of a holding portion according to a fourth modified example. [Figure 18] FIG. 13 is a bottom view of a holding portion according to a fifth modified example. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0016] Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings. In the embodiment shown below, the present invention is applied to a disk-type gas generator that is suitably incorporated in an airbag device mounted on the steering wheel of an automobile. In the embodiment shown below, the same or common parts are given the same reference numerals in the drawings, and their description will not be repeated.

[0017] (Embodiment) Fig. 1 is a schematic diagram of a disk-type gas generator according to an embodiment. First, with reference to Fig. 1, the configuration of disk-type gas generator 1 according to the present embodiment will be described.

[0018] As shown in Fig. 1, disk-type gas generator 1 according to this embodiment has a short, substantially cylindrical housing with one axial end and the other axial end closed. An accommodating space provided inside the housing accommodates internal components such as a retaining portion 30, an igniter 40, a cup-shaped member 50, an enhancer charge 56, a gas generating agent 61, a lower support member 70, an upper support member 80, a cushion material 85, and a filter 90. A combustion chamber 60 is located in the accommodating space provided inside the housing, and mainly accommodates the gas generating agent 61 among the above-mentioned internal components.

[0019] The housing includes a lower shell 10 and an upper shell 20 as shell members. Each of the lower shell 10 and the upper shell 20 is a press-formed product formed by, for example, pressing a rolled metal plate-like member. As the metal plate-like member constituting the lower shell 10 and the upper shell 20, for example, a metal plate made of stainless steel, iron steel, aluminum alloy, stainless alloy, etc. is used, and preferably a so-called high-tensile steel plate that does not break or otherwise break even when a tensile stress of 440 MPa or more and 780 MPa or less is applied is used.

[0020] The lower shell 10 and the upper shell 20 are each formed in a generally cylindrical shape with a bottom, and are assembled and joined together with their open faces facing each other to form a housing. The lower shell 10 has a bottom plate portion 11 and a cylindrical portion 12. The upper shell 20 has a top plate portion 21 and a cylindrical portion 22.

[0021] The upper end of the cylindrical portion 12 of the lower shell 10 is inserted into the lower end of the cylindrical portion 22 of the upper shell 20 and press-fitted. Furthermore, the cylindrical portion 12 of the lower shell 10 and the cylindrical portion 22 of the upper shell 20 are joined at or near their abutment, thereby fixing the lower shell 10 and the upper shell 20. For joining the lower shell 10 and the upper shell 20, electron beam welding, laser welding, friction welding, or the like can be suitably used.

[0022] As a result, the portion of the peripheral wall of the housing closer to the bottom plate 11 is formed by the cylindrical portion 12 of the lower shell 10, and the portion of the peripheral wall of the housing closer to the top plate 21 is formed by the cylindrical portion 22 of the upper shell 20. Moreover, one end and the other end in the axial direction of the housing are closed by the bottom plate 11 of the lower shell 10 and the top plate 21 of the upper shell 20, respectively.

[0023] A protruding tubular portion 13 is provided in the center of the bottom plate portion 11 of the lower shell 10, protruding toward the top plate portion 21. The protruding tubular portion 13 is a portion to which the igniter 40 is fixed via a holding portion 30. The protruding tubular portion 13 is formed in a substantially cylindrical shape with a bottom, and has a tubular portion 13a and a shelf portion 13b provided at the end of the tubular portion 13a on the top plate portion 21 side.

[0024] The shelf portion 13b is provided with an opening 15 having a point-asymmetric shape (for example, a D-shape, a barrel shape, an oval shape, or the like) in a plan view. The opening 15 is a portion through which a pair of terminal pins 42 of the igniter 40 are inserted.

[0025] A recess 14 defined by a cylindrical portion 13a and a shelf portion 13b is formed in the center of the bottom plate portion 11 of the lower shell 10. The recess 14 is a portion that serves as a space for providing a female connector 34 including a recessed portion 35 in the holding portion 30.

[0026] The igniter 40 is for generating a flame, and includes an ignition unit 41 and the pair of terminal pins 42 described above. The ignition unit 41 contains an ignition charge that ignites and burns to generate a flame when activated, and a resistor for igniting the ignition charge. The pair of terminal pins 42 are connected to the ignition unit 41 to ignite the ignition charge. In the following, one of the pair of terminal pins 42 is also referred to as a first pin 42a, and the other is also referred to as a second pin 42b.

[0027] The ignition section 41 comprises a squib cup formed in a cup shape, and a base which closes the open end of the squib cup and through which a pair of terminal pins 42 are inserted and held. A resistor (bridge wire) is attached to connect the tips of the pair of terminal pins 42 inserted into the squib cup, and an ignition charge is loaded into the squib cup so as to surround the resistor or be in close proximity to the resistor.

[0028] The resistor is generally made of nichrome wire, etc. The ignition charge is generally made of ZPP (zirconium potassium perchlorate), ZWPP (zirconium tungsten potassium perchlorate), lead tricinate, etc. The squib cup and base are generally made of metal or plastic.

[0029] When a collision is detected, a predetermined amount of current flows through the resistor via the terminal pin 42. When a predetermined amount of current flows through the resistor, Joule heat is generated in the resistor, and the ignition charge begins to burn. The high-temperature flame generated by the combustion explodes the squib cup containing the ignition charge. The time from when the current flows through the resistor to when the igniter 40 is activated is generally 2 milliseconds or less when nichrome wire is used for the resistor.

[0030] The igniter 40 is assembled to the bottom plate portion 11 with the ignition portion 41 positioned closer to the top plate portion 21 than the shelf portion 13b and inserted from the inside of the lower shell 10 so that the terminal pin 42 passes through the opening 15 provided in the shelf portion 13b.

[0031] In detail, a holding portion 30 made of a resin molded portion is provided around the protruding tube portion 13 provided on the bottom plate portion 11. The igniter 40 is held by the holding portion 30 and fixed to the bottom plate portion 11. The configuration of the holding portion 30 and its periphery will be described in detail later.

[0032] A cup-shaped member 50 is attached to the bottom plate portion 11 so as to cover the protruding tube portion 13, the holding portion 30, and the igniter 40. The cup-shaped member 50 has a generally cylindrical shape with a bottom, the end on the bottom plate portion 11 side being open. The cup-shaped member 50 includes a transfer chamber 55 in which a transfer charge 56 is accommodated. The cup-shaped member 50 is arranged to protrude into a combustion chamber 60 in which a gas generating agent 61 is accommodated, so that the transfer chamber 55 faces the ignition portion 41 of the igniter 40.

[0033] The cup-shaped member 50 has a top wall portion 51 and a side wall portion 52 which define the above-mentioned flame transfer chamber 55, and an extension portion 53 which extends radially outward from the open end side of the side wall portion 52.

[0034] The extension portion 53 is formed to extend along the inner surface of the bottom plate portion 11 of the lower shell 10. In detail, the extension portion 53 has a curved shape to follow the shape of the inner bottom surface of the bottom plate portion 11 at the portion where the protruding tubular portion 13 is provided and in the vicinity thereof, and includes a tip portion 54 extending in a flange shape at its radially outer portion.

[0035] The tip portion 54 of the extension portion 53 is disposed between the bottom plate portion 11 and the lower support member 70 along the axial direction of the housing. As a result, the tip portion 54 is sandwiched between the bottom plate portion 11 and the lower support member 70 along the axial direction of the housing.

[0036] The lower support member 70 is in a state where it is pressed toward the bottom plate portion 11 by the gas generating agent 61, the cushion material 85, the upper support member 80, and the top plate portion 21 arranged above it. Therefore, the tip portion 54 of the extension portion 53 of the cup-shaped member 50 is in a state where it is pressed toward the bottom plate portion 11 by the lower support member 70, and the cup-shaped member 50 is fixed to the bottom plate portion 11. This prevents the cup-shaped member 50 from falling off the bottom plate portion 11, even without using crimping or press-fitting to fix the cup-shaped member 50.

[0037] The cup-shaped member 50 has no openings in either the top wall portion 51 or the side wall portion 52, and surrounds a transfer chamber 55 provided therein. The cup-shaped member 50 bursts or melts in response to a pressure increase in the transfer chamber 55 and conduction of the generated heat when the transfer charge 56 is ignited by the operation of the igniter 40, and has a relatively low mechanical strength.

[0038] For this reason, the cup-shaped member 50 is preferably made of a metal member such as aluminum or an aluminum alloy, or a resin member such as a thermosetting resin represented by epoxy resin, polybutylene terephthalate resin, polyethylene terephthalate resin, polyamide resin (e.g., nylon 6, nylon 66, etc.), polypropylene sulfide resin, polypropylene oxide resin, etc.

[0039] In addition to the above, the cup-shaped member 50 may be made of a metal member having high mechanical strength, such as iron or copper, with an opening in the side wall portion 52, with a sealing tape attached to close the opening. The method of fixing the cup-shaped member 50 is not limited to the above-mentioned fixing method using the lower support member 70, and other fixing methods may be used.

[0040] The transfer charge 56 filled in the transfer chamber 55 is ignited by the flame generated by the operation of the igniter 40, and generates heat particles by burning. The transfer charge 56 is required to be capable of reliably starting the combustion of the gas generating agent 61. For this reason, the transfer charge 56 generally used is a composition made of a metal powder / oxidizer such as B / KNO3, B / NaNO3, Sr(NO3)2, etc., a composition made of titanium hydride / potassium perchlorate, a composition made of B / 5-aminotetrazole / potassium nitrate / molybdenum trioxide, etc.

[0041] The enhancer charge 56 may be in a powder form or may be formed into a predetermined shape using a binder. The enhancer charge 56 formed using a binder may have various shapes, such as granular, cylindrical, sheet, spherical, single-hole cylinder, multi-hole cylinder, tablet, and the like.

[0042] In the space inside the housing, in the space surrounding the portion in which the above-mentioned cup-shaped member 50 is disposed, there is positioned a combustion chamber 60 containing a gas generating agent 61. In detail, as described above, the cup-shaped member 50 is disposed so as to protrude into the combustion chamber 60 formed inside the housing, and the space provided in the portion facing the outer surface of the side wall portion 52 of this cup-shaped member 50 and the space provided in the portion facing the outer surface of the top wall portion 51 form the combustion chamber 60.

[0043] A filter 90 is disposed along the inner circumference of the housing in a space radially surrounding the combustion chamber 60 in which the gas generating agent 61 is accommodated. The filter 90 has a cylindrical shape. The filter 90 is disposed so that its central axis substantially coincides with the axial direction of the housing.

[0044] The gas generating agent 61 is an agent that generates gas by being ignited by thermal particles generated by the operation of the igniter 40 and burning. As the gas generating agent 61, it is preferable to use a non-azide gas generating agent, and the gas generating agent 61 is generally formed as a molded body containing a fuel, an oxidizer, and an additive.

[0045] The fuel may be, for example, a triazole derivative, a tetrazole derivative, a guanidine derivative, an azodicarbonamide derivative, a hydrazine derivative, or a combination of these. In particular, nitroguanidine, guanidine nitrate, cyanoguanidine, 5-aminotetrazole, or the like is preferably used.

[0046] Examples of the oxidizing agent include basic nitrates such as basic copper nitrate, perchlorates such as ammonium perchlorate and potassium perchlorate, and nitrates containing a cation selected from alkali metals, alkaline earth metals, transition metals, and ammonia. Examples of the nitrates that are preferably used include sodium nitrate and potassium nitrate.

[0047] Examples of additives include binders, slag formers, and combustion control agents. Examples of binders that can be suitably used include organic binders such as metal salts of carboxymethylcellulose and stearates, and inorganic binders such as synthetic hydrotalcite and acid clay. Examples of slag formers that can be suitably used include silicon nitride, silica, and acid clay. Examples of combustion control agents that can be suitably used include metal oxides, ferrosilicon, activated carbon, and graphite.

[0048] The shape of the molded body of the gas generating agent 61 may be various, such as granular, pellet-like, cylindrical, or other granular shapes, or disk-like shapes. In addition, for cylindrical molded bodies, perforated molded bodies having through holes inside the molded body (for example, a single-hole cylindrical shape or a multi-hole cylindrical shape) are also used. These shapes are preferably selected appropriately according to the specifications of the airbag device in which the disk-type gas generator 1 is incorporated, and it is preferable to select an optimal shape according to the specifications, such as a shape in which the gas generation rate changes over time when the gas generating agent 61 is burned. In addition to the shape of the gas generating agent 61, it is preferable to appropriately select the size and filling amount of the molded body taking into consideration the linear burning rate, pressure exponent, and the like of the gas generating agent 61.

[0049] The filter 90 can be made of, for example, metal wire such as stainless steel or steel wound and sintered, or a mesh material woven with metal wires and pressed into a compact shape. Specific examples of the mesh material that can be used include knitted wire mesh, plain woven wire mesh, and an assembly of crimped metal wires.

[0050] Also, a perforated metal plate wound around the filter 90 can be used. In this case, the perforated metal plate can be, for example, an expanded metal plate in which staggered cuts are made in a metal plate and the cuts are expanded to form holes and processed into a mesh-like shape, or a hook metal plate in which holes are made in a metal plate and burrs formed around the holes are crushed and flattened. In this case, the size and shape of the holes can be appropriately changed as necessary, and holes of different sizes and shapes can be included in the same metal plate. In addition, as the metal plate, for example, a steel plate (mild steel) or a stainless steel plate can be suitably used, and a non-ferrous metal plate such as aluminum, copper, titanium, nickel, or an alloy thereof can also be used.

[0051] The filter 90 functions as a cooling means for cooling the gas generated in the combustion chamber 60 by removing the high temperature heat of the gas when the gas passes through the filter 90, and also functions as a removing means for removing residues (slag) and the like contained in the gas. Therefore, in order to sufficiently cool the gas and prevent the residues from being discharged to the outside, it is necessary to ensure that the gas generated in the combustion chamber 60 passes through the filter 90. The filter 90 is disposed away from the cylindrical parts 12, 22 of the upper shell 20 and the cylindrical part 12 of the lower shell 10, which constitute the peripheral wall part of the housing, so that a gap 28 of a predetermined size is formed between the filter 90 and the cylindrical parts 12, 22.

[0052] A plurality of gas outlets 24 are provided in the cylindrical portion 22 of the upper shell 20 in a portion facing the filter 90. The plurality of gas outlets 24 are for directing the gas that has passed through the filter 90 to the outside of the housing.

[0053] Moreover, a metal sealing tape 26 is attached as a sealing member to the inner peripheral surface of the cylindrical portion 22 of the upper shell 20 so as to close the plurality of gas ejection ports 24. As this sealing tape 26, an aluminum foil with an adhesive material applied to one side or the like can be suitably used, and the sealing tape 26 ensures the airtightness of the combustion chamber 60.

[0054] A lower support member 70 is disposed near the end of the combustion chamber 60 on the bottom plate portion 11 side. The lower support member 70 has an annular shape, and is disposed substantially between the filter 90 and the bottom plate portion 11 so as to cover the boundary between the filter 90 and the bottom plate portion 11. As a result, the lower support member 70 is positioned between the bottom plate portion 11 and the gas generating agent 61 near the end of the combustion chamber 60.

[0055] The lower support member 70 has an abutment portion 72 erected so as to abut against the inner peripheral surface of the axial end portion located on the bottom plate portion 11 side of the filter 90, and a bottom portion 71 extended radially inward from the abutment portion 72. The bottom portion 71 is formed so as to extend along the inner bottom surface of the bottom plate portion 11 of the lower shell 10. In detail, the bottom portion 71 has a shape bent so as to follow the shape of the inner bottom surface of the bottom plate portion 11 including the portion where the protruding tubular portion 13 is provided, and includes a tip portion 73 erected on the radially inner portion.

[0056] The lower support member 70 functions as an outflow prevention means for preventing gas generated in the combustion chamber 60 from outflowing through the gap between the lower end of the filter 90 and the bottom plate portion 11 during operation without passing through the inside of the filter 90. The lower support member 70 is formed, for example, by pressing a metal plate-like member, and is preferably made of a member made of a steel plate such as ordinary steel or special steel (for example, a cold-rolled steel plate or a stainless steel plate).

[0057] Here, the tip 54 of the extension 53 of the cup-shaped member 50 described above is sandwiched and held between the bottom plate 11 and the bottom 71 along the axial direction of the housing. By configuring in this manner, the cup-shaped member 50 is fixed to the bottom plate 11 with the tip 54 of the extension 53 being pressed toward the bottom plate 11 by the bottom 71 of the lower support member 70.

[0058] An upper support member 80 is disposed at the end of the combustion chamber 60 located on the top plate portion 21 side. The upper support member 80 has a substantially disk-like shape, and is disposed between the filter 90 and the top plate portion 21 so as to cover the boundary between the filter 90 and the top plate portion 21. As a result, the upper support member 80 is positioned between the top plate portion 21 and the gas generating agent 61 in the vicinity of the end of the combustion chamber 60.

[0059] The upper support member 80 has a bottom portion 81 that abuts against the top plate portion 21, and an abutment portion 82 that stands upright from the periphery of the bottom portion 81. The abutment portion 82 abuts against the inner peripheral surface of the axial end portion of the filter 90 that is located on the top plate portion 21 side.

[0060] The upper support member 80 functions as an outflow prevention means for preventing gas generated in the combustion chamber 60 from outflowing through the gap between the upper end of the filter 90 and the top plate portion 21 during operation without passing through the inside of the filter 90. The upper support member 80, like the lower support member 70, is formed, for example, by pressing a metal plate-like member, and is preferably made of a member made of a steel plate such as ordinary steel or special steel (for example, a cold-rolled steel plate or a stainless steel plate).

[0061] An annular cushioning material 85 is disposed inside the upper support member 80 so as to come into contact with the gas generating agent 61 contained in the combustion chamber 60. As a result, the cushioning material 85 is positioned between the top plate portion 21 and the gas generating agent 61 in the portion of the combustion chamber 60 on the top plate portion 21 side, and presses the gas generating agent 61 toward the bottom plate portion 11 side.

[0062] The cushioning material 85 is provided for the purpose of preventing the gas generating agent 61 made of a molded body from being crushed by vibration, etc. The cushioning material 85 is preferably made of a member made of a ceramic fiber molded body, rock wool, foamed resin (for example, foamed silicone, foamed polypropylene, foamed polyethylene, etc.), rubber represented by chloroprene and EPDM, etc.

[0063] Next, the operation of disk-type gas generator 1 in the present embodiment described above will be described with reference to Fig. 1. Note that the operation described below is performed after male connector 130, which is a part of a harness for connecting igniter 40 to a control unit (not shown) serving as an external power source, is inserted into recessed portion 35 of female connector 34 of holding portion 30 and connected to igniter 40 (see Fig. 4).

[0064] In the event that a vehicle equipped with disk-type gas generator 1 in this embodiment collides, the collision is detected by collision detection means separately provided in the vehicle, and based on this, igniter 40 is activated by current from a control unit separately provided in the vehicle. Transfer charge 56 accommodated in transfer charge chamber 55 is ignited by a flame generated by the activation of igniter 40 and burns, generating a large amount of thermal particles. The combustion of transfer charge 56 causes cup-shaped member 50 to burst or melt, and the above-mentioned thermal particles flow into combustion chamber 60.

[0065] The gas generating agent 61 contained in the combustion chamber 60 is ignited and burned by the flowing hot particles, generating a large amount of gas. The gas generated in the combustion chamber 60 passes through the inside of the filter 90, during which time the heat is removed by the filter 90 and the gas is cooled, and the slag contained in the gas is removed by the filter 90 and flows into the gap 28.

[0066] As the pressure in the space inside the housing rises, sealing tape 26 closing gas outlet 24 provided in upper shell 20 breaks, and gas is ejected to the outside of the housing through gas outlet 24. At that time, multiple gas outlets 24 are opened in stages, and the ejected gas is introduced into an airbag provided adjacent to disc-type gas generator 1, inflating and deploying the airbag.

[0067] Fig. 2(A) is a bottom view of the holding part shown in Fig. 1. Fig. 2(B) and Fig. 2(C) are schematic cross-sectional views taken along lines IIB-IIB and IIC-IIC shown in Fig. 2(A), respectively. Next, a detailed configuration of the holding part 30 according to this embodiment will be described with reference to Fig. 2 and the above-mentioned Fig. 1.

[0068] 1 and 2, the holding part 30 is a resin molded part formed by injection molding (more specifically, insert molding) using a mold. The holding part 30 is formed by adhering an insulating fluid resin material to the bottom plate part 11 so as to reach from a part of the inner surface to a part of the outer surface of the bottom plate part 11 through the opening 15 provided in the bottom plate part 11 of the lower shell 10, and then solidifying the material.

[0069] The retaining portion 30 has an inner covering portion 31 covering part of the inner surface of the bottom plate portion 11 of the lower shell 10, an outer covering portion 32 covering part of the outer surface of the bottom plate portion 11 of the lower shell 10, and a connecting portion 33 located within an opening 15 provided in the bottom plate portion 11 of the lower shell 10 and continuous with the inner covering portion 31 and the outer covering portion 32, respectively.

[0070] The holding portion 30 is fixed to the bottom plate portion 11 on the surfaces of the inner covering portion 31, the outer covering portion 32 and the connecting portion 33 that face the bottom plate portion 11.

[0071] Moreover, the inner covering portion 31 is fixed to the side and bottom surfaces of the portions of the ignition portion 41 of the igniter 40 near the lower end, and to the surface of the portion of the terminal pin 42 of the igniter 40 near the upper end. The outer covering portion 32 is fixed to the surface of the portion of the terminal pin 42 near the upper end.

[0072] As a result, the opening 15 is closed by the pair of terminal pins 42 and the holding portion 30, and the sealing performance at this portion is ensured, thereby ensuring airtightness of the space inside the housing. As described above, the opening 15 is formed in an asymmetrical shape in a plan view. Therefore, by embedding the opening 15 with the connecting portion 33, the opening 15 and the connecting portion 33 also function as a rotation prevention mechanism that prevents the holding portion 30 from rotating relative to the bottom plate portion 11.

[0073] A pair of through holes 36 are provided through the inner covering portion 31, the outer covering portion 32 and the connecting portion 33. The pair of through holes 36 are portions through which a pair of terminal pins 42 are inserted.

[0074] The outer covering portion 32 has a female connector 34 located in a recess 14 provided in the bottom plate portion 11 of the lower shell 10. The female connector 34 includes a concave portion 35 that is exposed to the outside along the axial direction of the protruding tube portion 13.

[0075] A portion of the terminal pin 42 of the igniter 40 near the lower end is exposed and disposed within the recessed portion 35. A male connector 130, which will be described later, is inserted into the recessed portion 35, thereby achieving electrical continuity between the core wire of the harness and the terminal pin 42.

[0076] The inner circumferential surface 35a of the recessed portion 35 is provided with a plurality of locking recesses 35a1 capable of locking the locking protrusions 136 provided on the male connector 130. In this embodiment, three locking recesses 35a1 of the same shape are arranged at rotationally symmetric positions of 120° when viewed along the axial direction of the holding portion 30.

[0077] The axial end face 34a of the female connector 34 is an exposed surface exposed to the outside, and is positioned so as to surround the recessed portion 35. The axial end face 34a is provided with an orientation regulating protrusion 37 having a generally rectangular shape in plan view. Furthermore, a pair of rotation prevention protrusions 38 having a generally rectangular shape in plan view are provided on a position of the axial end face 34a different from the portion where the orientation regulating protrusion 37 is provided. The orientation regulating protrusion 37 and the pair of rotation prevention protrusions 38 will be described in detail later.

[0078] Here, the inner bottom surface 35b of the recessed portion 35 is configured to be flat. By configuring it in this way, it is possible to improve the durability of the mold used to mold the holding portion 30, but this point will be described in detail later.

[0079] As the raw material of the holding part 30 formed by injection molding, a resin material having excellent heat resistance, durability, corrosion resistance, etc. after hardening is suitably selected and used. In this case, it is possible to use not only thermosetting resins such as epoxy resins, but also thermoplastic resins such as polybutylene terephthalate resin, polyethylene terephthalate resin, polyamide resin (e.g., nylon 6, nylon 66, etc.), polypropylene sulfide resin, polypropylene oxide resin, etc. When these thermoplastic resins are selected as raw materials, it is preferable to include glass fiber or the like as a filler in these resin materials in order to ensure the mechanical strength of the holding part 30 after molding. However, if sufficient mechanical strength can be ensured with only the thermoplastic resin, it is not necessary to add the above-mentioned filler.

[0080] During molding of the holding portion 30, the igniter 40 is inserted from inside the lower shell 10 so that the terminal pin 42 passes through the opening 15, and in this state, the above-mentioned fluid resin material is poured in to fill the space between the igniter 40 and the lower shell 10. As a result, the igniter 40 is fixed to the bottom plate portion 11 via the holding portion 30.

[0081] The above-mentioned injection molding may also be performed using the lower shell 10 in which an adhesive layer is provided in advance at a predetermined position on the surface of the bottom plate portion 11 in the portion that will be covered by the holding portion 30. The adhesive layer can be formed by applying adhesive to a predetermined position on the bottom plate portion 11 in advance and curing the adhesive.

[0082] In this way, the hardened adhesive layer is positioned between the bottom plate portion 11 and the holding portion 30. Therefore, it is possible to more firmly fix the holding portion 30, which is made of a resin molded portion, to the bottom plate portion 11. Therefore, if the adhesive layer is provided in an annular shape along the circumferential direction so as to surround the opening 15 provided in the bottom plate portion 11, it is possible to ensure higher sealing performance in that portion.

[0083] As the adhesive to be applied in advance to the bottom plate portion 11, an adhesive containing as a raw material a resin material that has excellent heat resistance, durability, corrosion resistance, etc. after hardening is preferably used, and for example, an adhesive containing as a raw material a cyanoacrylate-based resin or a silicone-based resin is particularly preferably used. In addition to the above-mentioned resin materials, phenol-based resins, epoxy-based resins, melamine-based resins, urea-based resins, polyester-based resins, alkyd-based resins, polyurethane-based resins, polyimide-based resins, polyethylene-based resins, polypropylene-based resins, polyvinyl chloride-based resins, polystyrene-based resins, polyvinyl acetate-based resins, polytetrafluoroethylene-based resins, acrylonitrile butadiene styrene-based resins, acrylonitrile styrene-based resins, acrylic resins, polyamide-based resins, polyacetal-based resins, polycarbonate-based resins, polyphenylene ether-based resins, polybutylene terephthalate-based resins, polyethylene terephthalate-based resins, polyolefin-based resins, polyphenylene sulfide-based resins, polysulfone-based resins, polyethersulfone-based resins, polyarylate-based resins, polyether ether ketone-based resins, polyamide imide-based resins, liquid crystal polymers, styrene-based rubbers, olefin-based rubbers, and the like can be used as the above-mentioned adhesives.

[0084] Figures 3(A) to 3(C) are a side view, a plan view, and a bottom view, respectively, of a male connector according to an embodiment. Figure 3(D) is a schematic cross-sectional view taken along line IIID-IIID in Figure 3(B). Next, a detailed configuration of male connector 130 according to this embodiment will be described with reference to Figure 3.

[0085] 3(A) to 3(D), male connector 130 has a barrel-shaped main body 131, an opposing portion 132, and a cable 133. Male connector 130 constitutes a part of a harness for connecting igniter 40 and a control unit (not shown) serving as an external power source.

[0086] The main body 131 is a portion that is inserted into the recessed portion 35 of the female connector 34. The facing portion 132 is a portion that faces a part of the axial end surface 34a of the female connector 34 when the main body 131 is inserted into the recessed portion 35. The cable 133 extends outward from the facing portion 132 when viewed along the axial direction of the main body 131.

[0087] The main body 131 includes a pair of first terminal blades 131a and second terminal blades 131b capable of receiving the first pin 42a and the second pin 42b that constitute the terminal pin 42, respectively.

[0088] A locking protrusion 136 protruding outward from the peripheral surface 131c of the main body 131 is provided on the peripheral surface 131c. When the male connector 130 is inserted into the recessed portion 35, the locking protrusion 136 is locked in a locking recess 35a1 on the inner peripheral surface 35a of the recessed portion 35. As a result, the male connector 130 is assembled to the female connector 34 by a so-called snap fit consisting of the locking protrusion 136 and the locking recess 35a1.

[0089] The number of locking projections 136 is not particularly limited as long as it is the same as the number of locking recesses 35a1, and may be one or more. In this embodiment, three locking projections 136 having the same hook shape are arranged at rotationally symmetric positions of 120° when viewed along the axial direction of main body 131.

[0090] A substantially annular seal portion 134 is provided on the circumferential surface 131c of the main body portion 131. The seal portion 134 is for liquid-tightly sealing the internal space of the recessed portion 35 from the outside. There are no particular limitations on the material of the seal portion 134 as long as it is elastic. In the present embodiment, the seal portion 134 is made of rubber.

[0091] Fig. 4(A) is a schematic diagram showing a first state in which the male connector is inserted into the recessed portion of the female connector, and Fig. 4(B) is a schematic cross-sectional view taken along line IVB-IVB in Fig. 4(A). Fig. 5(A) is a schematic diagram showing a second state in which the male connector is inserted into the recessed portion of the female connector, and Fig. 5(B) is a schematic cross-sectional view taken along line VB-VB in Fig. 5(A). Next, with reference to Figs. 4 and 5, the assembly of the male connector 130 to the female connector 34 in this embodiment will be described.

[0092] As shown in FIG. 4, the male connector 130 is assembled to the female connector 34 by snap-fitting the locking protrusion 136 of the main body 131 with the locking recess 35a1 of the recess 35, with the main body 131 inserted into the recess 35 of the female connector 34.

[0093] In this state, the pair of anti-rotation protrusions 38 are positioned to sandwich the opposing portion 132 when viewed along the axial direction of the main body portion 131. This makes it possible to effectively prevent the male connector 130 from rotating when an external force or the like is applied to the male connector 130. The pair of anti-rotation protrusions 38 also function as guides that guide the insertion of the male connector 130 into the recessed portion 35 when the male connector 130 is inserted into the recessed portion 35.

[0094] Furthermore, in the above state, the seal portion 134 provided on the main body portion 131 is compressed by being sandwiched between the opposing portion 132 of the male connector 130 and the axial end face 34a of the female connector 34. In this way, the seal portion 134 fills the gap that occurs between the opposing portion 132 and the axial end face 34a, thereby making it possible to liquid-tightly seal the internal space of the recessed portion 35 from the outside. As a result, the connection between the igniter 40 and the control unit is reliably performed.

[0095] As described above, the terminal pin 42 is made up of a pair of the first pin 42a and the second pin 42b, and the main body 131 is made up of a pair of the first terminal blade 131a and the second terminal blade 131b.

[0096] Therefore, possible ways in which male connector 130 is inserted into recessed portion 35 are a first way (see Figure 4) in which male connector 130 is inserted into recessed portion 35 in an orientation in which first pin 42a corresponds to first terminal blade 131a and second pin 42b corresponds to second terminal blade 131b, and a second way (see Figure 5) in which male connector 130 is inserted into recessed portion 35 in an orientation in which second pin 42b corresponds to first terminal blade 131a and first pin 42a corresponds to second terminal blade 131b.

[0097] Here, the orientation of male connector 130 in a direction perpendicular to the insertion direction of male connector 130 into recessed portion 35 differs by 180° between the first and second modes, and thus the direction in which cable 133 is drawn out also differs by 180°. Therefore, from the viewpoint of workability when assembling male connector 130 to female connector 34, it is desirable to configure the connector so that the above-mentioned assembly is possible only in one of the above-mentioned two modes.

[0098] In this regard, in the present embodiment, orientation regulating projection 37 is provided at a predetermined position on axial end surface 34a of female connector 34 so as not to interfere with opposing portion 132 in the first mode (see FIG. 4), but to interfere with opposing portion 132 in the second mode (see FIG. 5). Therefore, male connector 130 can be inserted into recessed portion 35 in the first mode, but cannot be inserted into recessed portion 35 in the second mode.

[0099] With this configuration, it becomes possible for the orientation of male connector 130 in a direction perpendicular to the direction in which male connector 130 is inserted into recessed portion 35 to be regulated by orientation regulating protrusion 37 .

[0100] Furthermore, if orientation regulating projection 37 and a pair of anti-rotation projections 38 are provided on axial end face 34a of female connector 34, by specifying the position, shape, etc. of these, it becomes possible to easily determine the phase of disk type gas generator 1 during image inspection performed as an appearance inspection of disk type gas generator 1, or when disk type gas generator 1 is set in a jig in the manufacturing process of disk type gas generator 1, etc. This makes it possible to improve the manufacturing efficiency of disk type gas generator 1.

[0101] Figures 6 to 8 are schematic diagrams for illustrating a manufacturing process of the holding part according to this embodiment. Next, a manufacturing method of holding part 30 provided in disk-type gas generator 1 according to this embodiment will be described with reference to Figures 6 to 8. Note that Figures 6 to 8 show cross-sectional views of holding part 30 etc. corresponding to Figure 2(B).

[0102] First, as shown in Fig. 6, the housing is set in lower die 101. Next, prefabricated igniter 40 is set in lower die 101 from the inside of lower shell 10 so that terminal pin 42 is inserted into opening 15 provided in protruding cylindrical portion 13 of lower shell 10. Next, upper die 100 for injection molding is set.

[0103] Here, in the holding part 30 as a resin molded part manufactured by injection molding, the inner peripheral surface 35a of the concave part 35 of the female connector 34 is provided with the locking recess 35a1 as an undercut (see FIG. 2, etc.). Therefore, in this embodiment, a so-called inclined core mechanism is adopted in the lower mold 101 in order to provide the locking recess 35a1 as an undercut.

[0104] The lower die 101 has a fixed portion 102 and a plurality of movable core portions 103. The fixed portion 102 includes a fixed core portion 102a and a peripheral portion 102b. The fixed core portion 102a is a portion located in the center of the lower die 101. The plurality of movable core portions 103 are portions configured to be movable in a predetermined direction. The peripheral portion 102b is a portion located so as to surround the plurality of movable core portions 103.

[0105] The fixed core portion 102a is provided with a receiving portion for receiving the terminal pin 42. The peripheral surface of the fixed core portion 102a facing the movable core portion 103 has an inclined shape such that the fixed core portion 102a tapers toward the upper die 100.

[0106] The multiple movable core parts 103 are intended to provide locking recesses 35a1 as undercuts on the inner circumferential surface 35a of the recessed part 35 of the female connector 34. In this embodiment, three movable core parts 103 corresponding to the number of the locking recesses 35a1 are arranged at rotationally symmetric positions of 120° when viewed along the axial direction of the fixed core part 102a.

[0107] A protrusion 103a protruding outward from a portion of the side surface of the movable core part 103 facing the cylindrical part 13a of the protruding cylindrical part 13 is provided. The locking recess 35a1 is formed at a position corresponding to the protrusion 103a. A portion of the side surface of the movable core part 103 facing the peripheral surface of the fixed core part 102a has an inclined shape so as to follow the peripheral surface.

[0108] The movable core part 103 has an opposing surface 103b that faces an axial end surface 34a of the female connector 34 after injection molding. A portion of the movable core part 103 that is located closer to the upper mold 100 than the peripheral part 102b and the opposing surface 103b are exposed to the outside, and the remaining portion is housed inside the fixed part 102.

[0109] Next, a fluid resin material is poured between the upper die 100 and the lower die 101 through a gate 100a for injecting the fluid resin material provided in the upper die 100. As a result, the holding part 30 made of a resin molded part is formed as shown in FIG.

[0110] Next, as shown in FIG. 8, the movable core part 103 is moved so that the protrusions 103a of the movable core part 103 are removed from the locking recesses 35a1 of the recessed part 35.

[0111] More specifically, as described above, the portion of the side surface of the movable core part 103 facing the peripheral surface of the fixed core part 102a has an inclined shape so as to follow the peripheral surface. Therefore, by moving the movable core part 103 toward the fixed core part 102a, the movable core part 103 is simultaneously moved toward the upper die 100 (i.e., toward the upward direction in the figure). In other words, the movable core part 103 is moved obliquely upward. As a result, the protrusion part 103a of the movable core part 103 is pulled out of the locking recess 35a1 of the recess 35.

[0112] Next, upper die 100 and lower die 101 are released from holding portion 30. Through the above steps, the manufacture of holding portion 30 included in disc-type gas generator 1 is completed.

[0113] Fig. 9(A) is a bottom view of a holding part according to a comparative example, and Fig. 9(B) is a cross-sectional view taken along line IXB-IXB in Fig. 9(A). Figs. 10 to 12 are schematic views for illustrating a manufacturing process of a holding part according to a comparative example. Next, with reference to Figs. 9 to 12, a manufacturing method for holding part 30X provided in disk-type gas generator 1X according to a comparative example will be described, and advantages of the manufacturing method for holding part 30 provided in disk-type gas generator 1 according to the present embodiment described above will be described in comparison with a manufacturing method for holding part 30X provided in disk-type gas generator 1X according to the comparative example.

[0114] As shown in Figures 9(A) and 9(B), when comparing holding portion 30X of disk-shaped gas generator 1X of a comparative example with holding portion 30 of disk-shaped gas generator 1 of the present embodiment described above, firstly, the difference is that axial end face 34a of female connector 34 does not have orientation regulating projection 37 and anti-rotation projection 38 (see Figure 2, etc.), and instead has a single protrusion 39 having these functions.

[0115] Furthermore, the retaining portion 30X is different from the retaining portion 30 in that the inner bottom surface 35bX of the recessed portion 35X is not configured to be flat.

[0116] More specifically, an inner bottom surface 35bX of the recessed portion 35X includes, at its center, a protrusion 39 that is substantially T-shaped in plan view. The protrusion 39 is provided with a through hole 36 through which the terminal pin 42 is inserted.

[0117] Furthermore, the male connector (not shown) to be inserted into the recessed portion 35X is one that has a generally T-shaped recess in plan view, similar to the protrusion 39, provided in the portion of the main body 131 of the male connector 130 used in the disk-type gas generator 1 of this embodiment that faces the inner bottom surface 35bX.

[0118] When the male connector is inserted into the recess 35X, the protrusion 39 fits into the recess. Since the protrusion 39 and the recess have a generally T-shape in plan view, the orientation of the male connector in a direction perpendicular to the insertion direction of the male connector into the recess 35X is regulated by the protrusion 39 and the recess.

[0119] Here, in retaining portion 30X provided in disk-type gas generator 1X according to the comparative example, as described above, inner bottom surface 35bX of recessed portion 35X includes protrusion 39. That is, inner bottom surface 35bX of recessed portion 35X is not configured to be flat. Due to this, the configuration of lower mold 101X used in the manufacturing method of retaining portion 30X differs from that of lower mold 101 used in the manufacturing method of retaining portion 30 provided in disk-type gas generator 1 according to the present embodiment described above.

[0120] In detail, as shown in FIG. 10, in the manufacturing method of the retaining portion 30X in the comparative example, in order to provide an engagement recess 35a1 as an undercut on the inner surface 35a of the recessed portion 35X, a so-called slide core mechanism is adopted for the lower mold 101X instead of an inclined core mechanism.

[0121] The lower die 101X has a fixed portion 102X and a plurality of movable core portions 103X. The fixed portion 102X includes a fixed core portion 102aX and a peripheral portion 102bX. The fixed core portion 102aX is a portion located at the center of the lower die 101X. The plurality of movable core portions 103X are portions configured to be movable in a predetermined direction. The peripheral portion 102bX is a portion located so as to surround the plurality of movable core portions 103X.

[0122] The fixed core portion 102aX is provided with a receiving portion for receiving the terminal pin 42. In addition, a pocket portion 104 for accommodating the movable core portion 103X, which slides toward the fixed core portion 102aX as described later, is provided on the peripheral surface of the fixed core portion 102aX in a portion facing the movable core portion 103X.

[0123] The multiple movable core parts 103X are for providing locking recesses 35a1 as undercuts on the inner circumferential surface 35a of the recessed part 35X. In this comparative example, three movable core parts 103X corresponding to the number of the locking recesses 35a1 are arranged at rotationally symmetric positions of 120° when viewed along the axial direction of the fixed core part 102aX.

[0124] A protrusion 103aX protruding outward from a portion of the side surface of the movable core portion 103X facing the cylindrical portion 13a of the protruding cylindrical portion 13 is provided in the portion. The locking recess 35a1 is formed at a position corresponding to the protrusion 103aX.

[0125] Next, a fluid resin material is poured between the upper mold 100 and the lower mold 101X through a gate 100a for injecting the fluid resin material provided in the upper mold 100. This forms a holding portion 30X made of a resin molded portion, as shown in Fig. 11. The igniter 40 is fixed to the bottom plate portion 11 through the holding portion 30 thus formed.

[0126] Next, as shown in FIG. 12, the movable core part 103X is moved so that the protrusions 103aX of the movable core part 103X are removed from the locking recesses 35a1 of the recessed part 35X.

[0127] More specifically, the movable core portion 103X is slid toward the fixed core portion 102aX. The slid movable core portion 103X is housed in the pocket portion 104 provided on the peripheral surface of the fixed core portion 102aX.

[0128] Next, upper die 100 and lower die 101X are released from holding portion 30X. Through the above steps, the manufacture of holding portion 30X provided in disc-shaped gas generator 1X according to the comparative example is completed.

[0129] Here, when a slide core mechanism is adopted for the lower die 101X as described above, the movable core part 103X becomes thin-walled, which causes a problem of reduced durability of the movable core part 103X. This point will be described with reference to FIG.

[0130] The area in which the movable core part 103X can slide is limited to only the area outside the area where the terminal pin 42 of the igniter 40 is inserted and the area nearby (i.e., area R in the figure). In addition, the space defined by the inner circumferential surface 35a and the inner bottom surface 35bX of the recessed part 35X is considerably small. Therefore, when the sliding movement allowance of the movable core part 103X is taken into consideration, the movable core part 103X is considerably thinned in the sliding movement direction (i.e., the left-right direction in FIG. 11). As a result, the strength of the thinned part of the movable core part 103X cannot be sufficiently ensured, and the durability of the movable core part 103X is reduced.

[0131] In this regard, if a tilted core mechanism such as the lower mold 101 of this embodiment can be adopted for the lower mold 101X used in manufacturing the retaining portion 30X, the movable core portion constituting the tilted core mechanism can be made thicker by the amount of the sliding movement allowance of the above-mentioned movable core portion 103X, which seems to ensure the strength of the movable core portion.

[0132] However, if an inclined core mechanism is adopted when the inner bottom surface 35bX of the recessed portion 35X includes the protrusion 39 as in the comparative example, when the movable core part moves in the diagonally upward direction, it interferes with the circumferential surface of the protrusion 39. Therefore, in the configuration of the comparative example, the inclined core mechanism cannot be adopted.

[0133] On the other hand, in this embodiment, the inner bottom surface 35b of the recessed portion 35 of the holding portion 30 is flat as described above. With this configuration, it is possible to adopt a tilted core mechanism in the lower mold 101, and therefore the movable core part 103 can be made thicker than in the comparative example. As a result, the strength of the movable core part 103 can be sufficiently ensured, and the durability of the movable core part 103 can be improved.

[0134] Therefore, by adopting a configuration such as disk-type gas generator 1 of the present embodiment, in a gas generator having a retaining portion made of a resin molded portion, it is possible to improve the durability of the mold used to mold the retaining portion.

[0135] (First Modification) Fig. 13 is a schematic diagram for explaining a mold used in manufacturing a retaining part according to a first modified example. Fig. 14(A) and Fig. 14(B) are schematic diagrams for explaining parting lines generated in a retaining part according to a first modified example and a retaining part according to an embodiment, respectively. Hereinafter, with reference to Figs. 13 and 14, a disk-type gas generator 1A according to a first modified example based on the embodiment described above will be described.

[0136] As shown in FIG. 13, when compared with the disk-shaped gas generator 1 according to the embodiment described above, the disk-shaped gas generator 1A according to the first modified example differs only in the configuration of the lower mold 101A used in manufacturing the holding part 30A.

[0137] More specifically, in this modified example, the movable core part 103A does not have the opposing surface 103b (i.e., the surface that faces the axial end surface 34a of the female connector 34, as shown in Figure 7, etc.) that the movable core part 103 has in the above-mentioned embodiment.

[0138] Even when configured in this manner, effects similar to those described in the above-mentioned embodiment can be obtained, and in a gas generator having a retaining portion made of a resin molded portion, it becomes possible to improve the durability of the mold used to mold the retaining portion.

[0139] In addition, in the case of such a configuration, the number of parting lines formed in the holding portion can be reduced compared to the above-mentioned embodiment. A parting line is a minute protrusion formed in the molded product in a portion corresponding to the parting line between the dies.

[0140] 14(A), in the embodiment, the parting line PL1 extends from the inner circumferential surface 35a of the recessed portion 35 of the female connector 34 along a part of the axial end surface 34a of the female connector 34. On the other hand, in the present modification, as shown in FIG. 14(B), the parting line PL2 extends only along the inner circumferential surface 35a of the recessed portion 35 of the female connector 34, and does not extend along the axial end surface 34a of the female connector 34.

[0141] Axial end surface 34a of female connector 34 is a portion which, together with opposing portion 132 of male connector 130, sandwiches and compresses seal portion 134. For that reason, if a parting line is formed on axial end surface 34a, leakage may occur along this parting line, and sealing performance may deteriorate. In this regard, when configured as in this modified example, it is possible to effectively prevent a parting line from being formed on axial end surface 34a, as described above. Therefore, it is possible to provide disk-type gas generator 1A with improved sealing performance.

[0142] (Second Modification) Fig. 15 is a bottom view of a holding portion according to Modification 2. Hereinafter, with reference to Fig. 15, a disk-type gas generator 1B according to Modification 2 based on the above-mentioned embodiment will be described.

[0143] As shown in FIG. 15, a disk-shaped gas generator 1B according to the second modified example differs from disk-shaped gas generator 1 according to the embodiment described above only in the configuration of holding portion 30B.

[0144] More specifically, in the second modified example, an orientation regulating projection 37B provided on an axial end surface 34a of the female connector 34 of the holding portion 30B has a substantially cylindrical shape.

[0145] Even when configured in this manner, effects similar to those described in the above-mentioned embodiment can be obtained, and in a gas generator having a retaining portion made of a resin molded portion, it becomes possible to improve the durability of the mold used to mold the retaining portion.

[0146] (Third Modification) Fig. 16 is a bottom view of a holding portion according to Modification 3. Below, with reference to Fig. 16, a disk-shaped gas generator 1C according to Modification 3 based on the embodiment described above will be described.

[0147] As shown in FIG. 16, a disk-shaped gas generator 1C according to the third modified example differs from disk-shaped gas generator 1 according to the embodiment described above only in the configuration of holding portion 30C.

[0148] More specifically, in the third modified example, the orientation regulating projection 37C provided on the axial end surface of the female connector 34 of the holding portion 30C has a substantially cylindrical shape. Also, the pair of rotation prevention projections 38C have a shape extending along the circumferential direction when the holding portion 30C is viewed in a plan view.

[0149] Even when configured in this manner, effects similar to those described in the above-mentioned embodiment can be obtained, and in a gas generator having a retaining portion made of a resin molded portion, it becomes possible to improve the durability of the mold used to mold the retaining portion.

[0150] (Fourth Modification) Fig. 17 is a bottom view of a holding part according to Modification 4. Below, with reference to Fig. 17, a disk-type gas generator 1D according to Modification 4 based on the embodiment described above will be described.

[0151] As shown in FIG. 17, a disk-shaped gas generator 1D according to a fourth modified example differs from disk-shaped gas generator 1 according to the embodiment described above only in the configuration of holding section 30D.

[0152] More specifically, in the fourth modified example, a pair of anti-rotation protrusions 38D provided on the axial end surface 34a of the female connector 34 of the holding portion 30D are arranged so that their longitudinal direction coincides with the pull-out direction (see FIG. 4(A)) of the cable 133 of the male connector 130. The pair of anti-rotation protrusions 38D configured as such a guide makes it easier to insert the male connector 130 into the recessed portion 35.

[0153] Even when configured in this manner, effects similar to those described in the above-mentioned embodiment can be obtained, and in a gas generator having a retaining portion made of a resin molded portion, it becomes possible to improve the durability of the mold used to mold the retaining portion.

[0154] (Fifth Modification) Fig. 18(A) is a bottom view of a holding part according to the fifth modified example, and Fig. 18(B) is a schematic diagram showing an aspect in which a label is affixed to the holding part according to the fifth modified example. Hereinafter, with reference to Fig. 18, a disk-type gas generator 1E according to the fifth modified example based on the embodiment described above will be described.

[0155] As shown in FIG. 18(A), a disk-shaped gas generator 1E pertaining to the fifth modified example differs from the disk-shaped gas generator 1 pertaining to the embodiment described above only in the configuration of holding portion 30E.

[0156] More specifically, in the fifth modified example, a pair of anti-rotation protrusions 38E provided on the axial end face of the female connector 34 of the holding portion 30E have a shape that extends circumferentially when the holding portion 30E is viewed in a plane.

[0157] Even when configured in this manner, effects similar to those described in the above-mentioned embodiment can be obtained, and in a gas generator having a retaining portion made of a resin molded portion, it becomes possible to improve the durability of the mold used to mold the retaining portion.

[0158] 18(B), orientation restricting projection 37 and pair of anti-rotation projections 38E can also be used as guides for attaching label L to holding portion 30E. In this modification, outer surfaces of orientation restricting projection 37 and pair of anti-rotation projections 38E serve as guides for attaching label L. As label L, various types of labels can be used, such as, for example, a barcode label or a warning label indicating precautions for handling the disk-shaped gas generator.

[0159] (Other forms, etc.) The shape, configuration, size, number, material, and the like of each part shown in the above-mentioned embodiment of the present invention and its modified examples can be modified in various ways without departing from the spirit of the present invention.

[0160] Furthermore, the characteristic configurations shown in the above-mentioned embodiment of the present invention and its modified examples can naturally be combined with each other without departing from the spirit of the present invention.

[0161] As such, the above-mentioned embodiment and its modified examples disclosed herein are illustrative in all respects and are not restrictive. The technical scope of the present invention is defined by the claims, and includes all modifications within the meaning and scope equivalent to the description of the claims. [Explanation of symbols]

[0162] 1, 1A to 1E, 1X disk-type gas generator, 10 lower shell, 11 bottom plate portion, 12 cylindrical portion, 13 protruding cylindrical portion, 13a cylindrical portion, 13b shelf portion, 14 recessed portion, 15 opening portion, 20 upper shell, 21 top plate portion, 22 cylindrical portion, 24 gas outlet, 26 sealing tape, 28 gap portion, 30, 30A to 30E, 30X holding portion, 31 inner covering portion, 32 outer covering portion, 33 connecting portion, 34 female connector, 34a axial end surface, 35, 35X recessed portion, 35a inner peripheral surface, 35a1 locking recess, 35b, 35bX inner bottom surface, 36 through hole, 37, 37B, 37C orientation control protrusion, 38, 38C to 38E anti-rotation projection, 39 protrusion, 40 igniter, 41 ignition portion, 42 terminal pin, 50 cup-shaped member, 51 top wall portion, 52 side wall portion, 53 extension portion, 54 tip portion, 55 transfer chamber, 56 transfer charge, 60 combustion chamber, 61 gas generating agent, 70 lower support member, 71 bottom portion, 72 abutment portion, 73 tip portion, 80 upper support member, 81 bottom portion, 82 abutment portion, 85 cushioning material, 90 filter, 100 upper mold, 100a gate, 101, 101A, 101X lower mold, 102, 102X fixed portion, 102a, 102aX fixed core portion, 102b, 102bX surrounding portion, 103, 103A, 103X Movable core portion, 103a, 103aX protrusion portion, 103b opposing surface, 104 pocket portion, 130 male connector, 131 main body portion, 131a first terminal blade, 131b second terminal blade, 131c peripheral surface, 132 opposing portion, 133 cable, 134 seal portion, 136 locking protrusion, L label, PL1, PL2 parting lines, R area.

Claims

1. a housing including a top plate portion, a bottom plate portion, and a cylindrical peripheral wall portion provided with a gas outlet, the housing having a combustion chamber therein in which a gas generating agent is accommodated; an igniter having an ignition unit loaded with an ignition charge for burning the gas generating agent and a terminal pin connected to the ignition unit; a holding portion provided on the bottom plate portion and holding the igniter; A male connector connected to the igniter, The bottom plate portion has a protruding tubular portion that protrudes toward the top plate portion and has a shelf portion provided at an end portion on the top plate portion side, The shelf portion is provided with an opening, the igniter is assembled to the bottom plate portion by being held by the holding portion in a state in which the ignition portion is located closer to the top plate portion than the shelf plate portion and the terminal pin is inserted into the opening, the holding portion is made of a resin molded portion that closes the opening and covers at least a part of each of an inner surface and an outer surface of the bottom plate portion, the resin molding portion is fixed to the ignition portion and includes an inner covering portion fixed to the inner surface of the bottom plate portion at a portion adjacent to the opening, and an outer covering portion fixed to the outer surface of the bottom plate portion at a portion defining the protruding tubular portion, the outer covering portion has a female connector including a concave portion exposed to the outside along an axial direction of the protruding cylindrical portion, The male connector is insertable into the recess, A locking projection is provided on a peripheral surface of a portion of the male connector that is inserted into the recessed portion, An inner circumferential surface of the recessed portion is provided with a locking recess capable of locking the locking protrusion, The inner bottom surface of the recess is flat, A gas generator, wherein an orientation control protrusion is provided on an axial end face of the female connector, which is an exposed surface exposed to the outside and positioned so as to surround the concave portion, for controlling the orientation of the male connector in a direction perpendicular to the direction in which the male connector is inserted into the concave portion.

2. the male connector has an opposing portion that faces a part of the axial end surface of the female connector when the male connector is inserted into the recessed portion, The terminal pin is a pair of first and second pins, the male connector includes a pair of first and second terminal blades each capable of receiving one of the pair of pins; When the male connector is inserted into the recessed portion in an orientation in which the first pin corresponds to the first terminal blade and the second pin corresponds to the second terminal blade, the orientation control protrusion does not interfere with the opposing portion, thereby enabling the male connector to be inserted into the recessed portion, 2. The gas generator as described in claim 1, wherein when the male connector is inserted into the concave portion in an orientation in which the second pin corresponds to the first terminal blade and the first pin corresponds to the second terminal blade, the orientation control protrusion interferes with the opposing portion, making it impossible to insert the male connector into the concave portion.

3. a pair of rotation prevention projections are provided on the axial end surface of the female connector at positions different from a portion where the orientation control projections are provided; 3. The gas generator according to claim 2, wherein when the male connector is inserted into the recessed portion in an orientation in which the first pin corresponds to the first terminal blade and the second pin corresponds to the second terminal blade, the pair of anti-rotation protrusions are positioned to sandwich the opposing portions, thereby preventing rotation of the male connector.

4. 4. A gas generator as described in any one of claims 1 to 3, wherein the male connector is provided with a seal portion made of an elastic member that is compressed by being sandwiched between the female connector and the male connector when the male connector is inserted into the concave portion, thereby filling a gap that is generated between the female connector and the male connector, thereby liquid-tightly sealing the internal space of the concave portion from the outside.

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