Surface Mount Initiator Assembly for Automotive Airbag Inflators
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Solution Overview
Problem
Current initiator devices for automotive airbag inflators are complex and costly, requiring multiple components and redundant seals, which increases manufacturing costs and complexity.
Innovation Solution
The development of a surface mountable initiator assembly where multiple initiators are directly mounted onto a single board, utilizing surface mount technology (SMT) for electrical connections and integration with the inflator device, reducing the need for redundant seals and complex mounting techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional initiator devices are used with multiple components and redundant seals, then reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple initiator components into a single integrated surface mount initiator assembly. The initiator housing, seals, and mounting features are merged into one compact unit that can be directly mounted on the inflator circuit board, eliminating the need for separate mounting brackets, multiple seals, and complex assembly procedures while maintaining reliability through careful integration of sealing features into the unified structure.
Solution Approach 2:
The surface mount initiator assembly serves multiple functions simultaneously: it provides electrical connection through the circuit board mounting, mechanical support through integrated mounting features, sealing through integrated gaskets, and initiator function through the pyrotechnic charge. This multi-functionality reduces the number of separate components needed while maintaining all necessary functions.
2Reliability
If traditional initiator mounting methods are used, then hermeticity is maintained, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The sealing features are merged directly into the initiator housing structure itself, with integrated gaskets and sealing surfaces that become part of the unified mounting assembly. This eliminates separate sealing components and reduces assembly steps while maintaining hermeticity through the integrated sealing design.
Solution Approach 2:
The patent replaces complex mechanical sealing systems with a simplified surface mount configuration where sealing is achieved through integrated gaskets and direct mounting to the circuit board. This substitution of the traditional mechanical mounting and sealing system with a surface mount electronic component approach simplifies manufacturing while maintaining hermeticity.
3Adaptability or versatility
If multiple separate initiators are used in dual stage inflators, then adaptability is improved, but device complexity and cost increase
Solution Approach 1:
Multiple initiator assemblies are merged onto a single circuit board platform, sharing common mounting structures, electrical connection methods, and sealing approaches. This allows dual-stage and adaptive inflator configurations to maintain adaptability while reducing overall assembly complexity through standardized mounting procedures and integrated circuit board design.
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 approach simplifies the manufacturing process, reduces costs by eliminating redundant seals and complex assembly methods, and allows for strategic placement of initiators within the inflator, while maintaining the necessary chamber wall strength and hermeticity.
Implementation Method 1
Upon actuation, the first igniter element is in reaction initiating communication with the first igniter material
Data Source
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AI summary
An initiator assembly includes an SMI assembly board onto which at least a first and a second initiator are surface mounted. The first and second initiators each include a respective surface mount initiator board with which a respective igniter element is respectively mounted. Corresponding multi-initiator assemblies for automotive airbag inflator devices as well as automotive airbag inflator device combinations are also provided.