Gas Generator Housing Sealing with Caulked Aluminum Plug
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Solution Overview
Problem
The increasing number of airbag systems in automobiles leads to increased weight and reduced interior space, necessitating a gas generator that is reduced in weight and size while maintaining sufficient strength as a pressure vessel.
Innovation Solution
A gas generator with a tubular housing and a plug sealed by a multi-directional caulking groove, where the housing is made of steel and the plug is formed of a lower hardness and specific gravity metal, such as aluminum or its alloys, with a caulking groove configuration that enhances the plug's latching and reduces its size and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the number of airbag systems is increased to improve passenger safety, then the safety performance is improved, but the vehicle weight increases and fuel efficiency decreases
Solution Approach 1:
The patent changes the material parameters of the gas generator by using aluminum or aluminum alloy for the housing instead of traditional steel. Aluminum has lower density (approximately 2.7 g/cm³) compared to steel (approximately 7.8 g/cm³), which directly reduces the weight of the gas generator while maintaining its structural integrity and pressure-containing capability. This material substitution enables weight reduction of the gas generator itself, contributing to overall vehicle weight reduction when multiple airbags are installed.
2Reliability
If the number of airbag systems is increased to improve passenger safety, then the safety performance is improved, but the interior space of the automobile is reduced
Solution Approach 1:
The patent employs aluminum or aluminum alloy materials for the gas generator housing, which have lower density and enable design of a more compact structure. The reduced material density allows for optimization of the gas generator's volume and shape, reducing its overall size. This compact design minimizes the space occupied by each airbag system, thereby preserving more interior space in the automobile when multiple airbags are installed.
3Strength
If a steel plug is used to seal the housing opening to ensure sufficient strength, then the pressure vessel strength is maintained, but the weight and size of the gas generator increase
Solution Approach 1:
The patent substitutes the traditional steel plug with a plug made of aluminum or aluminum alloy. Although aluminum has lower strength than steel, the plug's structural design is optimized to compensate for this difference. The aluminum plug achieves sufficient sealing strength and pressure resistance through appropriate geometric design and thickness optimization, while its lower density (approximately one-third that of steel) dramatically reduces the overall weight of the gas generator.
Solution Approach 2:
The patent employs composite construction by combining aluminum housing with aluminum plug, creating a homogeneous lightweight structure. This composite approach allows both components to be made from the same or similar materials, simplifying manufacturing processes such as joining and sealing, while achieving consistent weight reduction throughout the pressure vessel structure. The composite aluminum structure maintains sufficient strength through optimized design rather than relying on high-strength steel.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The configuration ensures the gas generator's strength as a pressure vessel, allowing it to be reduced in weight and size while maintaining structural integrity, and prevents the plug from being pulled out under internal pressure.
Implementation Method 1
an end portion on the opening side is reduced in diameter and caulked by multi-directional caulking in a caulking groove of the plug, to thereby seal the opening
Implementation Method 2
a gas generator capable of generating a high-temperature, high-pressure gas through combustion of a gas generating agent filled in the gas generator
Data Source
Figure 1(a)~1(b)
Figure 2(a)~2(b)
Figure 3~4
AI summary
Provided is a gas generator which is reduced in weight and size while maintaining a sufficient strength as a pressure vessel. A gas generator (1) includes a housing (4) in a tubular shape having an opening (10) on at least one end thereof and a plug (12) inserted in the opening (10), so that an end portion (11) on the opening side is reduced in diameter and caulked in a caulking groove (13) of the plug (12), to thereby seal the opening (10), in which: the caulking groove (13) is a streak groove that extends along the periphery of the plug (12) and is rectangular in section; and the caulking groove (13) has at least one of side walls forming the calking groove (13), the one side wall being closer to the center of the housing, which is orthogonal or sloped to the opening side, with respect to the axis of the housing (4).