Gas Generator Ignition Unit With Hermetic Membrane Sealing

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Solution Overview

Problem

Existing gas generators for vehicle safety systems require complex and costly sealing measures to prevent environmental influences, as the holding element and base are made from different materials, limiting the selection and application of sealants for effective sealing between these components.

Innovation Solution

A gas generator design featuring a membrane that hermetically seals an inner opening of the holding element, eliminating the need for external sealing and allowing for a compact, space-saving, and cost-effective ignition unit with a plastic injection-molded base and igniter, where the membrane is made of metal and connected via a radially peripheral weld, ensuring reliable sealing and easy manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a sealant is applied from outside to seal the holding element and base, then sealing effectiveness is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvesealing effectivenessVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Instead of applying sealant from the outside environment to seal the holding element and base, the patent inverts the approach by providing an internally formed plastic base that inherently seals the holding element from the inside. The plastic base is injection-molded to the holding element, creating a sealed structure without requiring external sealant application.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The plastic base serves a dual function: it holds the igniter in place and simultaneously provides the sealing function against environmental influences. This self-service approach eliminates the need for separate sealing components or processes, as the base structure itself performs both mechanical support and sealing tasks.

Inventive Principle:

Principle #25Self-service

2Reliability

If a sealant is applied from outside to seal the holding element and base, then sealing effectiveness is improved, but manufacturing time and cost increase

Engineering Contradiction:

Improvesealing effectivenessVSAvoidmanufacturing time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent merges the sealing function with the base structure by making the base itself from plastic material that provides both mechanical support and sealing. This combination eliminates the need for separate sealing steps, reducing manufacturing time while maintaining effective sealing against environmental influences.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The plastic base performs the sealing function inherently through its material properties and structural design, eliminating the need for external sealant application and curing processes. This self-sealing capability significantly reduces manufacturing time and process complexity.

Inventive Principle:

Principle #25Self-service

3Adaptability or versatility

If different materials are used for holding element and base, then functional requirements are met, but sealant selection is limited

Engineering Contradiction:

Improvefunctional adaptabilityVSAvoidsealant application ease

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent employs the holding element and base made from the same plastic material, creating homogeneity in material composition. This eliminates the material compatibility issues that arise with different materials, allowing for straightforward sealing through injection molding without complex sealant selection or adhesion concerns.

Inventive Principle:

Principle #33Homogeneity

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

This design enhances the sealing efficiency and reliability of the gas generator, reducing manufacturing costs and complexity while providing a compact, space-saving solution that is resistant to environmental influences, allowing for efficient gas generation and deployment in vehicle safety systems.

Implementation Method 1

a membrane being provided which hermetically seals an inner first opening of the holding element

Methodology Applied

Scientific EffectHermetic sealing:

Implementation Method 2

the base being formed by one single plastic injection molding so that the igniter is embedded in the base and the base is injection-molded to the holding element

Methodology Applied

Scientific EffectInjection molding:

Implementation Method 3

the membrane is made of metal and connected via a radially peripheral weld

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS12122319B2Gas generator particularly for a vehicle safety system

Publication Date: 2024.10.22 ZF AIRBAG GERMANY GMBH

AI summary

The disclosure relates to a gas generator—for a vehicle safety system, comprising an ignition unit including a holding element, an igniter and a base. The base is formed by one single plastic injection molding such that the igniter is embedded in the base and the base is injection-molded to the holding element. A membrane which hermetically seals an inner first opening of the holding element is provided.