Variable Diameter Spring Gas Duct for Rapid Ignition

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Solution Overview

Problem

Existing gas generators for vehicle occupant protection systems face challenges in quickly breaking open the igniter cap and transporting ignition gas to the fuel bed efficiently, leading to potential delays in gas deployment.

Innovation Solution

A gas generator design featuring a spring with multiple sections of varying outer diameters, arranged in the combustion chamber, which expands to create a gas duct and allows rapid ignition of the pyrotechnic solid propellant bed by directing the ignition gas from the igniter through the spring's interior, eliminating the need for additional booster charges and materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a displaceable wall part is used to create a gas duct, then gas discharge is prevented from being insufficient, but the complexity of the device increases and the ignition gas transport speed is reduced

Engineering Contradiction:
Improvegas discharge sufficiencyVSAvoiddevice complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent removes the displaceable wall part from the system and replaces it with a spring that is already present in the combustion chamber. The spring's coils naturally form the gas duct structure, eliminating the need for additional moving wall components while maintaining reliable gas discharge functionality.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The spring serves multiple functions simultaneously: it acts as a structural support element, forms the gas duct through its coil structure, and provides the displacement mechanism to direct ignition gas toward the fuel bed. This multi-functionality eliminates the need for separate displaceable wall parts.

Inventive Principle:
Principle #6Universality (Multi-functionality)

2Reliability

If a displaceable wall part is used to create a gas duct, then gas discharge is prevented from being insufficient, but the ignition gas transport speed is reduced

Engineering Contradiction:
Improvegas discharge sufficiencyVSAvoidignition gas transport speed
Core Design Contradiction:
ReliabilityVSSpeed

Solution Approach 1:

The patent removes the displaceable wall part and uses the spring's coil structure to form the gas duct. This eliminates the mechanical delay associated with wall displacement while maintaining sufficient gas discharge through the spring's inherent structure.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The spring is pre-positioned in the combustion chamber with its coils forming the gas duct structure before ignition occurs. When ignition happens, the spring is already in place to immediately channel the ignition gas toward the fuel bed, eliminating the time delay required for wall displacement.

Inventive Principle:
Principle #10Preliminary action

3Productivity

If the spring has varying outer diameters in different sections, then the gas flow direction and ignition efficiency are improved, but the manufacturing complexity increases

Engineering Contradiction:
Improveignition efficiencyVSAvoidease of manufacture
Core Design Contradiction:
ProductivityVSEase of manufacture

Solution Approach 1:

The spring features varying outer diameters in different sections to optimize local gas flow characteristics. The first section has a larger diameter to accommodate initial gas expansion, while subsequent sections have progressively smaller diameters to direct and concentrate the gas flow toward the fuel bed, improving ignition efficiency through localized geometric optimization.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The spring's varying diameter design creates a dynamic gas flow path that adapts to the expanding gas volume during ignition. The gradual diameter reduction along the spring sections optimizes gas velocity and direction at different stages of the ignition process, enhancing overall ignition efficiency.

Inventive Principle:
Principle #15Dynamics

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 ensures rapid ignition and deployment of the gas bag, reducing resistance to gas flow and enabling efficient ignition of the pyrotechnic solid propellant bed from a side other than the flame front, thus enhancing the speed and effectiveness of gas generation.

Implementation Method 1

A spring (30) is arranged in the combustion chamber (17), which can be expanded by the flow of gas generated when the gas generator (10) is activated in the direction of an end (22) of the combustion chamber (17) remote from the igniter (15)

Methodology Applied
Scientific EffectGas flow expansion: Pressure Gradient

Implementation Method 2

a combustion chamber (17) with a bed of pyrotechnic solid propellant (18)

Methodology Applied
Scientific EffectPyrotechnic combustion: Combustion

Data Source

PatentEP3356189B1Gas generator, in particular for a vehicle occupant protection system, spring for arranging in a gas generator, airbag module, and vehicle occupant protection system
Publication Date: 2022.08.17 ZF AIRBAG GERMANY GMBH
  • EP3356189B1 patent drawingFigure 1
  • EP3356189B1 patent drawingFigure 2

AI summary

The invention relates to a gas generator (10), in particular for a vehicle occupant protection system, comprising at least an igniter (15) and a combustion chamber (17) containing a pyrotechnic solid fuel bed (18), wherein a spring (30) is arranged in the combustion chamber (17), which spring can be elongated in the direction of an end (22) of the combustion chamber (17) remote from the igniter (15) by a gas flow produced when the gas generator (10) is activated. According to the invention, the spring (30) has a plurality of spring segments (31, 32, 33) having outside diameters (Q1, Q2, Q3) of different size, wherein each spring segment (31, 32, 33) has a plurality of spring turns.