Gas Generator Surface Heating Element Ignition

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Solution Overview

Problem

Existing gas generators for airbag systems face issues with uneven combustion and deformation due to the small ignition surface area of conventional electric igniters, leading to non-uniform ignition and reduced performance.

Innovation Solution

A gas generator design utilizing a molded article with a single or multiple combustion starting end surfaces ignited by a surface heating element, which is in contact with the combustion starting end surface, allowing for controlled and uniform combustion without deformation, and optionally coated with resin or rubber for enhanced durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a conventional electric igniter with small ignition surface area is used, then the device complexity is reduced, but the combustion uniformity deteriorates leading to uneven ignition and deformation

Engineering Contradiction:
Improveignition device structureVSAvoidcombustion uniformity
Core Design Contradiction:
Device complexityVSManufacturing precision

Solution Approach 1:

A resin layer is introduced as an intermediary substance between the electric igniter and the gas generating agent. This resin layer has a larger surface area than the igniter, allowing more uniform heat distribution across the combustion starting end surface. The resin acts as a heat transfer mediator that eliminates direct contact between the igniter and gas generating agent, preventing deformation while ensuring uniform combustion initiation across the entire surface.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Manufacturing precision

If the ignition surface area is increased to improve combustion uniformity, then the combustion uniformity improves, but the device complexity increases

Engineering Contradiction:
Improvecombustion uniformityVSAvoidignition system structure
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The surface area parameter of the ignition interface is changed by introducing a resin layer with a larger surface area than the electric igniter itself. This parameter change allows the combustion to start uniformly across a larger area without requiring a more complex ignition system structure. The resin layer's surface area is specifically designed to match or exceed the combustion starting end surface area of the gas generating agent.

Inventive Principle:
Principle #35Parameter changes

3Productivity

If direct contact between igniter and gas generating agent is maintained, then the ignition efficiency is high, but deformation occurs due to impact and heat concentration

Engineering Contradiction:
Improveignition efficiencyVSAvoidstructural integrity
Core Design Contradiction:
ProductivityVSStrength

Solution Approach 1:

The resin layer serves as a protective intermediary that prevents direct contact between the electric igniter and the gas generating agent. This intermediary layer distributes the thermal energy and mechanical impact over a larger area, preventing localized deformation while maintaining efficient ignition. The resin layer is designed to be thermally conductive enough to transfer heat effectively but physically separate the two components to avoid deformation.

Inventive Principle:
Principle #24Intermediary (Mediator)

4Device complexity

If a small ignition surface is used, then the device structure is simple, but the gas generation amount becomes unstable

Engineering Contradiction:
Improveignition structureVSAvoidgas generation consistency
Core Design Contradiction:
Device complexityVSReliability

Solution Approach 1:

The resin layer acts as a mediator that ensures consistent and uniform ignition across the entire combustion starting end surface, leading to stable and reproducible gas generation. By distributing the ignition source uniformly across the interface, the resin layer eliminates variations in combustion initiation that would otherwise occur with a small-point ignition source, ensuring consistent performance.

Inventive Principle:
Principle #24Intermediary (Mediator)

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 solution ensures uniform and reproducible gas generation, reducing the risk of deformation and improving the overall performance of the gas generator by using a surface heating element for ignition, which maintains contact with the combustion starting end surface and can be adjusted for varying combustion surface areas.

Implementation Method 1

the ignition means being a surface heating element

Methodology Applied
Scientific EffectJoule heating: Joule Heating

Implementation Method 2

a molded article for generating gas on combustion

Methodology Applied
Scientific EffectCombustion: Combustion

Data Source

PatentUS7637533B2Gas generator
Publication Date: 2009.12.29 DAICEL CORP
  • US7637533B2 patent drawing
  • US7637533B2 patent drawing
  • US7637533B2 patent drawing

AI summary

A gas generator includes:a housing having a gas discharge port;a molded article of gas generating composition disposed within the housing and generating gas on combustion, the molded article of the gas generating composition having a single or plural combustion starting end surfaces where ignition and combustion is started by the ignition means;ignition means provided within the housing and igniting and burning the molded article of the gas generating composition; andthe ignition means being a surface heating element which is in contact with the combustion starting end surface.