U.S. patent application number 09/795544 was filed with the patent office on 2002-01-24 for process and apparatus for inflating airbags and remediating toxic waste gases.
Invention is credited to Dunne, Stephen R..
Application Number | 20020007887 09/795544 |
Document ID | / |
Family ID | 23343157 |
Filed Date | 2002-01-24 |
United States Patent
Application |
20020007887 |
Kind Code |
A1 |
Dunne, Stephen R. |
January 24, 2002 |
Process and apparatus for inflating airbags and remediating toxic
waste gases
Abstract
Molecular sieve zeolites are incorporated in the inflator device
to assist in the inflation of airbags in passenger vehicles. The
pre-loading of the molecular sieve zeolites with gases such as air
or nitrogen or carbon dioxide provides for rapid airbag inflation
and following inflation, additionally provides the remediation of
at least a portion of the toxic waste gases generated by the
exploding inflator device. Molecular sieve zeolites, particularly
zeolites X, having been exchanged with lithium or calcium, provide
high-capacity gas storage and enhanced toxic waste gas adsorption.
The use of molecular sieve zeolites reduces risk of injury to
occupants of vehicles from exposure to hot, toxic waste gases
following airbag deployment.
Inventors: |
Dunne, Stephen R.;
(Algonquin, IL) |
Correspondence
Address: |
JOHN G TOLOMEI, PATENT DEPARTMENT
UOP LLC
25 EAST ALGONQUIN ROAD
P O BOX 5017
DES PLAINES
IL
60017-5017
US
|
Family ID: |
23343157 |
Appl. No.: |
09/795544 |
Filed: |
February 28, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09795544 |
Feb 28, 2001 |
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09342758 |
Jun 29, 1999 |
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6251200 |
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Current U.S.
Class: |
149/96 ;
280/736 |
Current CPC
Class: |
C06B 23/02 20130101;
C06B 45/00 20130101; C06D 5/06 20130101; C06B 23/04 20130101 |
Class at
Publication: |
149/96 ;
280/736 |
International
Class: |
C06B 035/00 |
Claims
I claim:
1. An explosive airbag inflator comprising a pyrotechnic to produce
a generated gas comprising toxic compounds and a zeolite molecular
sieve having been pre-loaded with a stored gas wherein the zeolite
molecular sieve is disposed in a zeolite layer adjacent to the
pyrotechnic wherein upon detonation, a sufficient amount of zeolite
molecular sieve is present to reduce the temperature of the
generated gas and to scavenge at least a portion of said toxic
compounds.
2. The explosive airbag inflator of claim 1 wherein the pyrotechnic
is disposed in a pyrotechnic layer and said zeolite layer is
contained by a membrane.
3. The explosive airbag inflator of claim 1 wherein the toxic
compounds in the generated gas are selected from the group
consisting of oxides of nitrogen, carbon monoxide, and mixtures
thereof.
4. The explosive airbag inflator of claim 1 wherein the zeolite
molecular sieve is maintained at a storage pressure of between
about one atmosphere and about 100 atmospheres.
5. The explosive airbag inflator of claim 1 wherein the storage gas
with which the zeolite is pre-loaded comprises nitrogen or carbon
dioxide.
6. The explosive airbag inflator of claim 1 wherein the zeolite
molecular sieve is pre-loaded with carbon dioxide.
7. The explosive airbag inflator of claim 1 wherein the zeolite
molecular sieve comprises a highly exchanged zeolite X with a
cation selected from the group consisting of sodium, lithium,
calcium and mixtures thereof.
8. The explosive airbag inflator of claim 1 wherein the zeolite
molecular sieve comprises a particle size between about 1.4 and
about 2.0 mm.
9. The explosive airbag inflator of claim 1 wherein the zeolite
molecular sieve comprises a highly exchanged zeolite X having been
at least 67 percent exchanged with a cation selected from the group
consisting of lithium, calcium and mixtures thereof.
10. The explosive airbag inflator of claim 1 wherein the
pyrotechnic is disposed in a cup having a hollow interior and said
zeolite layer is disposed over said pyrotechnic and a membrane is
disposed over said zeolite layer to maintain a storage pressure
within the cup of between about one atmosphere and about 70
atmospheres.
11. The explosive airbag inflator of claim 1 wherein the
pyrotechnic is selected from a group consisting of sodium azide,
nitrocellulose, and mixtures thereof.
12. A process for reducing the temperature of an inflating airbag,
said process comprising: a) detonating an airbag inflator
comprising a pyrotechnic adjacent to a zeolite molecular sieve,
said molecular sieve being pre-loaded with a stored gas comprising
air or carbon dioxide, said pyrotechnic providing a generated gas
comprising toxic compounds to inflate the inflating airbag; b)
desorbing and expanding the stored gas from the zeolite molecular
sieve to cool the generated gas and fluidizing at least a portion
of the zeolite molecular sieve; and c) adsorbing at least a portion
of the toxic compounds on the zeolite molecular sieve.
13. An explosive airbag inflator apparatus comprising: a cup having
a hollow interior and an open end; a layer of pyrotechnic disposed
in said hollow interior; a layer of zeolite molecular sieve
pre-loaded with nitrogen or carbon dioxide disposed on said layer
of pyrotechnic; and, a membrane or rupture disk disposed over said
layer of zeolite molecular sieve.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a Division of application Ser. No.
09/342,758 filed Jun. 29, 1999, now allowed, the contents of which
are hereby incorporated by reference.
FIELD OF INVENTION
[0002] This invention relates to automobile passive restraint
safety devices and, more particularly, to pyrotechnic gas generator
units for inflating automobile airbags.
BACKGROUND OF THE INVENTION
[0003] Large numbers of people are killed or injured annually in
automobile accidents wherein the driver and/or passengers are
thrown forward so as to impact against solid surfaces within the
vehicle. Consequently, there has been considerable development of
passive restraint systems for use with these vehicles. The term
"passive" means that the driver or passenger need not do anything
to benefit from the device, as opposed to seat belts which are
considered to be an "active" restraint system. One system which has
been extensively investigated senses rapid deceleration of the
vehicle such as that which occurs upon a primary impact between an
automobile and, for example, another car. It thus initiates
inflation of a bag between the interior surface of the car and the
vehicle occupant prior to the occurrence of any secondary collision
between the driver and/or passengers and the interior of the car.
Airbags have been in widespread use for more than a decade, but
accounts of injuries and fatalities caused by their explosive
deployment have raised concerns about their safety. Airbag
inflation speeds of nearly 200 miles per hour or more are common to
compensate for the driver's or the passenger's forward motion
during a frontal impact. Inflation of the bag must therefore occur
within milliseconds of the primary impact in order to restrain any
occupants before they are injured due to secondary collisions
against the solid surfaces within the vehicle
[0004] As noted above, there are in the prior art various devices
which cause a protective bag to inflate in front of an automobile
driver or passenger to cushion the impact with the steering wheel,
dashboard or other interior vehicle surface. Usually the device is
activated by an inertial switch responsive to a primary crash
impact This inertial switch in turn causes an inflator apparatus to
quickly inflate a collapsed bag into a protective position in front
of the driver or passenger.
[0005] The inflating gas is generally supplied either from a source
of compressed air or other compressed gas, such as shown in Chute,
U.S. Pat. No. 3,411,808 and Wissing et al., U.S. Pat. No.
3,413,013, and a number of other patents in the crash restraint
field. In several other prior art patents (e.g., U.S. Pat. No.
3,880,447 to Thorn et al.; U.S. Pat. No. 4,068,862 to Ishi et al.;
U.S. Pat. No. 4,711,466 to Breed; and U.S. Pat. No. 4,547,342; U.S.
Pat. No. 4561675 and U.S. Pat. No. 4,722,551 to Adams et al.), the
bag is inflated by igniting a pyrotechnic propellant composition
and directing the gaseous combustion products produced thereby
directly into the bag.
[0006] The first technique discussed above for inflating an airbag
requires a reservoir of gas stored at a very high pressure, which
may be discharged into the bag as soon as an impact is sensed. In
order to obtain a sufficient volume of gas for inflating a vehicle
occupant restraint bag, however, a relatively large reservoir of
gas, at pressures of 3000 psi or more is required. To open the gas
reservoir in the very short time interval required for ensuring the
safety of the vehicle occupants, explosive arrangements have been
employed in the prior art for bursting a diaphragm or cutting
through a structural portion of the reservoir. Such explosive
arrangements have significant inherent safety problems, such as the
production of shrapnel by the explosion, as well as the relatively
high sound level reached within the passenger compartment due to
the explosion. The psychological factor of having these explosives
in each automobile also cannot be ignored.
[0007] The second technique discussed above employs a pyrotechnic
gas generator, or explosive gas generator, having a rapidly burning
propellant composition stored therein for producing substantial
volumes of hot gaseous products which are then directed into the
inflatable bag. Some compositions are available which produce a
sufficiently low temperature combustion gas such that the gas may
be substantially directed into the bag without danger to the
vehicle's occupants. Other systems produce a high temperature
combustion product requiring means for cooling the gas before it is
introduced into the bag.
[0008] Many forms of gas generators or inflators utilizing
combustible solid fuel gas generating compositions for the
inflation of crash protection, i.e., "airbag", restraint systems
are known in the prior art. Commonly encountered features among
generators utilized for this purpose include: (1) an outer metal
housing, (2) a gas generant composition located within the housing,
(3) means to ignite the gas generant responsive to a signal
received from a sensor positioned at a location removed from the
inflator, and (4) means to filter and to cool the gas, positioned
between the propellant composition and a plurality of gas discharge
orifices defined by the generator housing.
[0009] One such gas generator includes an annular combustion
chamber which is bounded by a welded outer casing or housing
structure. The combustion chamber encloses a rupturable container
or cartridge that is hermetically sealed and which contains a solid
gas generant in pelletized form, surrounded by an annular filter
assembly. The device further includes a central ignition or
initiator zone and a toroidal filter chamber adjoining and
encircling the combustion chamber. An inner casing or housing
structure is located in close surrounding and supporting
relationship to the rupturable container, the inner casing being
formed by a cylinder having uniformly spaced peripheral ports or
orifices near one end. These orifices provide exit holes to
facilitate the flow of gas from the combustion chamber.
[0010] EP-0842828A1 discloses an apparatus for enhancing the
operation of an airbag generator based on the use of an explosive
device combined with an oxide or zeolite molecular sieve which is
coated or applied to the interior surface of a chamber containing
stored gas to assist in supplying gas to the airbag in the final
phase of the airbag deployment
[0011] Pyrotechnic devices generate gases at high temperatures and
produce potentially toxic materials. It is an objective of the
present invention to reduce the amount of toxic gases generated
during the deployment of an airbag to protect the occupant or
driver of the vehicle.
[0012] It is an objective to reduce the potential hazard to a
driver or passenger of a vehicle employing passive restraints by
reducing the temperature of the gases generated by a pyrotechnic
inflator.
[0013] It is an objective of the present invention to provide a
safe method of storing gas and to provide a process for scavenging
of toxic gases generated in the deployment of an airbag system.
SUMMARY OF THE INVENTION
[0014] The present invention provides two novel improvements to
airbag inflators of the prior art to significantly reduce the
potential hazard to the driver or passenger of the vehicle. By the
pre-loading of the molecular sieve zeolites with gases such as air,
nitrogen, or carbon dioxide, the invention provides for rapid
airbag inflation by the rapid desorption of this pre-loaded gas.
This additional amount of gas evolved reduces the amount of
explosive required to inflate the bag which reduces the amount of
toxic gases generated by the explosion itself, and the expansion of
the stored gas provides a substantial amount of cooling. Following
the evolution of the stored gas and combined with the heat provided
by the explosion, the adsorbent is now in an activated form and
moving freely, or fluidized, within the airbag. It is at this
point, the adsorbent additionally provides the remediation of toxic
waste gases generated by the exploding inflator device. Molecular
sieve zeolites, particularly zeolite X, having been exchanged with
lithium or calcium provide both high-capacity gas storage and
enhanced toxic waste gas adsorption. The use of molecular sieve
zeolites reduces risk of injury to occupants of vehicles from
exposure to hot, toxic waste gases following airbag deployment.
[0015] In one embodiment, the present invention is an explosive
airbag inflator comprising a pyrotechnic to produce a generated gas
and a zeolite molecular sieve which was pre-loaded with a stored
gas. The generated gas comprises toxic compounds. The zeolite
molecular sieve is disposed in a zeolite layer adjacent to the
pyrotechnic. Upon detonation, a sufficient amount of zeolite
molecular sieve is present to reduce the temperature of the
generated gas and to scavenge at least a portion of the toxic
compounds passed to the airbag.
[0016] In another embodiment, the present invention is an explosive
airbag inflator comprising a cup having a hollow interior and an
open end, a layer of pyrotechnic disposed in the hollow interior, a
layer of zeolite molecular sieve pre-loaded with nitrogen or carbon
dioxide and disposed on the layer of pyrotechnic, and a membrane or
rupture disk disposed over the layer of zeolite molecular
sieve.
[0017] In a further embodiment, the present invention is a process
for reducing the temperature of an inflating airbag. The process
comprises the steps of detonating an airbag inflator comprising a
pyrotechnic adjacent to a zeolite molecular sieve. The molecular
sieve was pre-loaded with a stored gas. The pyrotechnic provides a
generated gas which comprises toxic compounds. The stored gas from
the zeolite molecular sieve is desorbed and expanded in the
detonation to cool the generated gas and to fluidize at least a
portion of the zeolite molecular sieve. At least a portion of the
toxic compounds is adsorbed on the zeolite molecular sieve.
BRIEF DESCRIPTION OF THE DRAWING
[0018] The FIGURE is a side view of the apparatus of the present
invention.
DETAILED DESCRIPTION OF THE INVENTION
[0019] Inside airbags are pyrotechnic materials which produce gas
to fill the airbag with the products of a chemical reaction. Most
pyrotechnics used in airbags employ chemical reactions which
produce nitrogen such as sodium azide or nitrocellulose. In
pyrotechnic systems for airbag inflation, when the main chemical
component in the airbag inflator is sodium azide, the sodium azide
is mixed together with potassium nitrate and silicon dioxide. This
mixture is generally ignited by means of an electrical impulse
which results in a detonation or deflagration that liberates a
predetermined volume of predominantly nitrogen gas which fills the
airbag. The detonation proceeds according to the following major
chemical reaction:
2NaN.sub.3.fwdarw.2Na+3N.sub.2 (1)
[0020] The sodium by-product of reaction reacts with potassium
nitrate to generate additional amounts of nitrogen according to the
following reaction:
10Na+2KNO.sub.3.fwdarw.K.sub.2O+5Na.sub.2O+N.sub.2 (2)
[0021] The combination of equations (1) and (2) provide an
opportunity for the following third reaction to take place:
K.sub.2O+Na.sub.2O+SiO.sub.2.fwdarw.alkaline silicate (3)
[0022] The alkaline silicate, or glass, produced by reaction (3) is
a stable compound which does not burn any further. All of these
reactions are highly exothermic and occur very rapidly resulting in
the production of hot gases. Generally, the components of a
pyrotechnic device provide an explosion that releases hot gas at a
rate which is sufficient to fill a driver-side airbag (about 35 to
40 liters in volume) within about 35 milliseconds from the time the
pyrotechnic device is fired. Other pyrotechnic devices known in the
art with different pyrotechnic formulations may evolve more heat
and deliver hot gases at even higher temperatures.
[0023] The present invention is directed to the cooling of gases
generated by airbag inflators which employ pyrotechnics to provide
a generated gas to inflate the airbag. When pyrotechnics are
detonated, they produce a generated gas at high temperatures.
Pyrotechnics such as sodium azide produces primarily nitrogen gas.
Nitrocellulose on detonation produces nitrogen and oxides of
nitrogen and carbon monoxide. The reactions produced on detonation
of the pyrotechnics are highly exothermic and produce gases at
temperatures approaching 3000.degree. C. U.S. Pat. No. 3,912,561 to
Doin et al. discloses the gas generating pyrotechnic composition
which comprises a fuel selected from the group consisting of alkali
metal azides and alkaline earth metal azides combined with an
alkali metal oxidant, a nitrogenous compound, and optionally an
additive such as silica for reacting with the solid combustion
residues. The contents of U.S. Pat. No. 3,912,561 are herein
incorporated by reference.
[0024] Airbags generally range in size from as low as 30 liters for
a small driver-side airbag up to about 70 liters for a
passenger-side airbag. These airbags must be inflated in a
sufficiently short period of time, preferably less than about 50
milliseconds (ms), which prevents injury to the driver or the
passenger from striking the inside of the vehicle. Inflation time
for a driver-side airbag is typically about 35 ms and inflation
time for a passenger-side airbag is about 55 ms. Longer inflation
times for the passenger-side are permitted because of the longer
pathway between the occupant and the interior surface of the
vehicle. If the airbag is inflated too aggressively, the bag itself
will become hazardous to the driver and passengers. Therefore,
typical airbags must be inflated rapidly and allowed to begin a
deflation process all within a very short period time. It is
believed that the problem of handling airbag deployment can be
viewed by recognizing the definition of pressure. Pressure is the
net rate of momentum transfer per unit area. Furthermore, the
characteristic of the gas assures us that the distribution of
molecular velocities is a function of gas temperature. Thus, higher
temperatures have higher velocities and higher distributions of gas
velocities. Therefore, a higher average molecular velocity implies
a higher average pressure and a more aggressive deployment. For a
40-liter airbag, the total gas release potential is about 1.12
moles of nitrogen from the gas generated by the pyrotechnic which
is equivalent to about 70 grams of a typical sodium azide compound
of the prior art.
[0025] When the pyrotechnic produces or generates the gas to
inflate the airbag, the generated gases are produced at the
temperature of the reaction which typically ranges between about
2400.degree. and about 2700.degree. C. As these gases are produced,
they undergo an expansion into the airbag which provides some
cooling. However, the cooling provided by this natural expansion of
the generated gases into the airbag still results in very hot gases
entering the airbag. If the gas generated by the pyrotechnic is
cooled to a still lower temperature, then additional moles of gas
are required to inflate the airbag. The present invention provides
the cooling of the hot generated gases by absorbing some of the
heat by desorbing the stored gases from the zeolite molecular
sieve. It is the heat of desorption of the stored gases which
provides the cooling. Additional cooling is provided by the further
expansion of the stored gases into the airbag while providing
additional moles of gas to maintain the safe inflation of the
airbag within the very short deployment time required.
[0026] The additional stored gas is supplied by pre-loading an
inert gas such as nitrogen or carbon dioxide on a zeolite molecular
sieve. Nitrogen is preloaded on a zeolite molecular sieve such as
zeolite X by activating the zeolite molecular sieve in the
conventional manner and exposing the zeolite molecular sieve at an
elevated adsorption pressure ranging from about 5 to about 70
atmospheres (atm) to a gas stream comprising nitrogen. More
preferably, the elevated adsorption pressure comprises a pressure
between about 30 and about 70 atm. The zeolite molecular sieve
capacity for nitrogen at about 68 atm is about 12.6 weight percent.
Preferably, the zeolite molecular sieve comprises a highly
exchanged zeolite X with a cation selected from the group
consisting of sodium, lithium, calcium and mixtures thereof. More
preferably, the zeolite molecular sieve comprises a highly
exchanged zeolite X having been at least 67 percent exchanged with
a cation selected from the group consisting of lithium, calcium and
mixtures thereof. Most preferably, the zeolite molecular sieve
comprises a highly exchanged zeolite X having been at least 80
percent exchanged with a cation selected from the group consisting
of lithium, calcium and mixtures thereof. Preferably, the zeolite
molecular sieve comprises a particle size between about 1.4 and
about 2.0 mm.
[0027] The stored gas can comprise nitrogen or carbon dioxide.
Carbon dioxide has the added advantage in this application in that
carbon dioxide can be stored as adsorbed gas on the sieve, or
encapsulated into the zeolite molecular sieve. By the term
"encapsulated," it is meant that the zeolite molecular sieve is
activated in the conventional manner and exposed to a gas stream
comprising carbon dioxide at a high adsorption pressure of about 60
to 80 atm and a high adsorption temperature around 125.degree. C.
(400 Kelvin) to about 177.degree. C. (450 Kelvin) to adsorb the
carbon dioxide, depending upon the amount of carbon dioxide to be
stored. Following the adsorption step, the zeolite molecular sieve
is pore closed by quickly cooling the zeolite molecular sieve to
about room temperature and slowly reducing the pressure to about 1
to about 5 atm. Carbon dioxide capacities of up to about 20 weight
percent of the zeolite molecular sieve can be achieved in this
manner When encapsulation is employed for example with carbon
dioxide, preferably the zeolite molecular sieve is selected from
the group consisting of potassium exchanged zeolite A, potassium
exchanged erionite, sodium exchanged clinoptilolite, and mixtures
thereof. Carbon dioxide can be stored or encapsulated and employed
in an airbag system at relatively low pressure (about 1 to about 5
atm) compared to the pressure required to store nitrogen or other
inert gas.
[0028] Once the zeolite molecular sieve has been pre-loaded with
the stored gas, the zeolite molecular sieve should be maintained at
a storage pressure to maintain the level of the stored gas in the
zeolite molecular sieve This is accomplished by sealingly covering
the zeolite molecular sieve with a membrane or a rupture disk which
will maintain the desired pressure of the stored gas.
[0029] According to the present invention, the zeolite molecular
sieve is positioned adjacent to the pyrotechnic such that on
detonation, a portion of the heat of the pyrotechnic reaction will
be employed to desorb the stored gas from the zeolite molecular
sieve. In addition, the force of the pyrotechnic detonation is
employed to fluidize at least a portion of the zeolite molecular
sieve into the airbag with the generated and stored gases. As the
now desorbed zeolite molecular sieve cools, it adsorbs toxic
compounds generated in the detonation such as oxides of nitrogen
and carbon monoxide. The evolution of the stored gas from the
zeolite molecular sieve provides cooling of the gases passed to the
airbag and it provides the additional gas required to quickly
inflate the airbag to compensate for the cooler gas in the airbag.
Preferably, the pre-loaded zeolite molecular sieve is 25 to about
70 weight percent of the pyrotechnic charge mass.
[0030] Zeolitic molecular sieves in the calcined form may be
represented by the general formula:
Me.sub.2/nO:Al.sub.2O.sub.3:xSiO.sub.2
[0031] where Me is a cation, x has a value from about 2 to
infinity, and n is the cation valence. Typical well-known zeolites
which may be used include: chabazite--also referred to as zeolite
D, clinoptilolite, EMC-2, zeolite L, ZSM-5, ZSM-11, ZSM-18, ZSM-57,
EU-1, offretite, faujasite, erionite, ferrierite, mordenite,
zeolite A, ZK-5, zeolite rho, zeolite Beta, boggsite, and
silicalite. The adsorbent of the present invention will be selected
from these zeolite adsorbents, cation exchanged forms of these
zeolites, and mixtures thereof.
[0032] The term "pore opening" refers to the pore diameter of the
adsorbent within the crystal structure of the adsorbent. Zeolite
molecular sieves have pores of uniform opening, ranging from about
3 to about 10 angstroms, which are uniquely determined by the unit
structure of the crystal. These pores will completely exclude
molecules which are larger than the opening of the pore. The
preferred adsorbents for use with the present invention include
synthetic and naturally occurring zeolites with a silica-to-alumina
ratio greater than about 2 to about 3 and having a pore opening
larger than 4.3 angstroms. More particularly, synthetic and
naturally occurring zeolites having a FAU structure as defined in
the "Atlas of Zeolite Structure Types," by W. M. Meier and D. H.
Olson, issued by the Structure Commission of the International
Zeolite association, (1987), on pages 53-54 and pages 91-92, are
preferred. The above reference is hereby incorporated by reference.
Most preferably, the zeolite adsorbent for use with the present
invention will have a silica-to-alumina ratio greater than or equal
to about 2 and a pore opening greater than about 8 angstroms.
[0033] It is often desirable when using crystalline molecular
sieves that the molecular sieve be agglomerated with a binder in
order to ensure that the adsorbent will have suitable particle
size. Although there are a variety of synthetic and naturally
occurring binder materials available such as metal oxides, clays,
silicas, aluminas, silica-aluminas, silica-zirconias,
silica-thorias, silica-berylias, silica-titanias,
silica-alumina-thorias, silica-alumina-zirconias, mixtures of these
and the like, silica binders are preferred. Clay is preferred
because it may be employed to agglomerate the molecular sieve
without substantially altering the adsorptive properties of the
zeolite. The choice of a suitable binder and methods employed to
agglomerate the molecular sieves are generally known to those
skilled in the art and need not be further described herein.
[0034] The results of both laboratory evaluations using stored gas
on zeolite molecular sieve in rapid depressurization tests and
engineering simulation of stored gas and pyrotechnic gas inflators
show an advantage for combining the functions of gas storage by
zeolite adsorbents with the gas and heat releases of pyrotechnic
compounds to significantly reduce the temperature of the gas
delivered to the airbag. The zeolite hybrid generator can inflate
the airbag with nitrogen gas within time periods that are very
comparable with existing pyrotechnic devices while delivering the
gas at temperatures that are much cooler than the gas delivered by
the solely pyrotechnic devices
DETAILED DESCRIPTION OF THE DRAWING
[0035] Referring to the FIGURE, a side view of the apparatus of the
present invention is shown. According to the FIGURE, the airbag
inflator comprises a shell 10 having a bottom 15 and a surround 35
which forms the sides of the shell. The bottom is sealingly
attached to the sides of the shell forming an interior shell zone.
A layer of a pyrotechnic 25 comprising sodium, azide or
nitrocellulose is disposed on the bottom of the shell in a layer of
explosive. A layer of zeolite particles 30 is disposed above the
layer of pyrotechnic 25. The layer of zeolite is maintained at a
storage pressure of between about 30 and about 80 atm by the
placement of a rupture disk 20 over the zeolite layer. The storage
pressure will vary somewhat with the type of gas and the amount of
gas stored, as well as the cost of the shell and rupture disk
required to contain the stored gas. The rupture disk is sealingly
disposed on the wall of the shell by any means well known in the
art to hermetically seal the rupture disk to the sides of the
shell.
EXAMPLES
[0036] The following examples are meant to illustrate the advantage
of combining the gas storage of zeolite adsorbents and the use of
pyrotechnic compounds in a hybrid gas generator for inflating
airbags. Such hybrid inflators can deliver equal or greater volumes
of gas at rates which are comparable to pyrotechnic devices at gas
temperatures which are significantly lower than gas delivered by a
solely pyrotechnic device.
Example I
[0037] Based on the chemical equations presented hereinabove as
equations (1), (2), and (3), it is well known that a sodium azide
based pyrotechnic will release about 1.4 to about 1.6 moles of
nitrogen per 100 grams of the pyrotechnic charge which includes
sodium azide (NaN.sub.3), potassium nitrate (KNO.sub.3), and
silicate (SiO.sub.2) which is sufficient to deploy a driver-side
airbag in a passenger vehicle.
[0038] An apparatus to measure and characterize the gas storage
capacity of an adsorbent was assembled. The test apparatus
comprised a high-pressure containment vessel that was attached to a
high-pressure gas cylinder with additional ports that allowed the
vessel to be depressurized either through a large-diameter port
that is controlled by a large orifice 1/4 turn ball valve, or
through a small needle valve, which in turn leads to a gas volume
measurement device commonly called a wet test meter. The former
allows a rapid and relatively non-restricted depressurization and
the latter allows a slower, controlled depressurization of the
vessel with measurement of the gas that is released. The
high-pressure vessel had an internal volume of 310 cc. The
high-pressure vessel was connected to a large orifice 1/4 turn ball
valve. The orifice of the ball valve was about 22 mm (0.85 inches)
in diameter. The pipe that connects the vessel to the valve had an
inside diameter of about 22 mm (0.88 inches). From the downstream
end of the ball valve to the atmosphere, there was a short length
of pipe having an inside diameter of about 22 mm (0.88 inches) and
at the downstream of the end of the pipe, there was an expansion
nozzle. The expansion nozzle provided a transition from an inside
diameter of about 22 mm (0.88 inches) up to an inside diameter of
about 34 mm (1.33 inches) over a length of about 15 mm (0.6
inches). Inside the vessel were two sets of 60 mesh screens. These
screens were set inside the vessel to provide an adsorbent zone
having a volume of approximately 260 cc between the screens. The
capacity of the empty high-pressure vessel was determined to
contain approximately 0.874 moles of nitrogen gas at about 68 atm
pressure and ambient temperature. It was found that the empty
high-pressure vessel could be depressurized from 68 atm to about 1
atm in about 50 milliseconds (0.050 seconds).
Example II
[0039] The adsorbent zone of Example I was filled with a first
zeolite adsorbent (A) having a FAU structure with a nominal
silica-to-alumina ratio of 2.45 and having a ratio of Li cations to
Li+Na, which is a minimum of 96 percent and typically 97 percent.
The zeolite adsorbent was characterized as small beads having a
particle size distribution characterized as 20.times.50 mesh. The
average particle size of these small beads was 0.46 mm before ion
exchange. Approximately 155 grams of activated adsorbent was added
to the high-pressure vessel. The adsorbent occupied approximately
260 cc. This left about 50 cc of non-adsorbent filled space. The
adsorbent material also had voids in the macropores and
interstitial spaces between particles that contribute non-selective
gas storage space that amounted to about 163 cc, giving a total
non-selective storage space of 214 cc. Slow depressurization
experiments showed the capacity of the high-pressure vessel filled
with the adsorbent of this Example II had a nitrogen capacity of
about 1.184 moles and required about 180 milliseconds to be
depressurized from about 68 atm to about 1 atm.
Example III
[0040] In Example III, the zeolite adsorbent of Example II was
replaced with a second zeolite adsorbent (B) comprising a FAU
structure having a silica-to-alumina ratio of approximately 2.3 and
having about 67 percent of the cation sites, normally occupied by
Na.sup.+, replaced by Ca.sup.++. About 159.2 grams of this material
was loaded into the nominal 260-cc space between the screens of the
high-pressure vessel. The material had a particle size distribution
that was characterized as 10.times.20 mesh with an average particle
size of about 1.46 mm. Slow depressurization experiments showed
that at a pressure of about 68 atm, approximately 1.122 moles of
nitrogen were released as the pressure of the vessel was reduced to
1 atm. The dynamic depressurization of the high pressure containing
the zeolite adsorbent of Example II required about 100 milliseconds
for the pressure to be reduced from about 68 atm to about 1
atm.
Example IV
[0041] In Example IV, the zeolite adsorbent of Example I was
replaced with a third zeolite adsorbent (C) comprising another FAU,
having a nominal silica-to-alumina ratio of about 2.3 and having
most of the cation sites replaced by Li so that the ratio of Li to
Li plus sodium was a minimum of 94 percent and more typically about
97 percent. This zeolite adsorbent (C) has a particle size
distribution that is characterized as 8.times.12 mesh, having an
average particle size of 1.9 mm. In the slow depressurization test,
approximately 1.2 moles of gas were released between about 68 atm
and 1 atm. Over the slow depressurization test of zeolite (C), the
stored gas dropped in temperature by 46 Kelvin. The valve remained
open until the adsorbent material had returned to room temperature.
The rapid depressurization time for depressurizing the gas from
about 68 atm to about 21.7 atm was about 28.9 milliseconds (about
0.029 seconds).
[0042] The hereinabove described experimental device deviated from
a real gas inflator in at least two important ways. Inflator
performance measurement was in all cases limited by the opening
time of the ball valve, that starts the rapid blow down, and by the
size of the orifice through which the gas flow passes. In a more
realistic experiment, there will be a larger and less restrictive
orifice and a more rapid opening time. Engineering simulations of
the results characterized the opening time of the valve from a zero
orifice time to full throat as 0.027 seconds and the orifice area
was limited by the about 21.6 mm (0.85-inch) diameter of the valve
throat. With respect to the zeolite adsorbent evaluation, it was
surprisingly discovered that there was a remarkable trend with bead
size of the adsorbent. As the bead size increased, the net
resistance to flow out of the system decreased in what appeared to
be a linear fashion.
Example V
Comparison of N.sub.2 Hybrid Inflator to Pyrotechnic
[0043] Based on the results of the above Examples I-IV, a
mathematical model was constructed to simulate the operation of a
hybrid zeolite inflator to compare the operation of a hybrid
zeolite system, wherein a portion of the inflation gas is provided
from storage in the zeolite and a portion of the inflation gas is
supplied from the generation of gas by a pyrotechnic and delivered
to an airbag. The heat released by the pyrotechnic device is
employed to heat the zeolite to promote the desorption of the
stored gas. The total inflation gas is the calculated gas delivery
from the model plus the gas released by the pyrotechnic device.
Literature shows driver-side airbag examples ranging from as low as
30 liters up to about 70 liters. For the purposes of this Example
V, a 40-liter volume airbag, a minimum over pressure of about
0.1283 atm, (1.88 psig), and a final gas temperature of 277.degree.
C. (550 Kelvin) are selected as the basis for comparison to the
basic pyrotechnic device.
1TABLE I Nitrogen Released from Increasing Mass of Zeolite Mass
average Pressure inside the Mass of temperature fully inflated bag
molecular Mass of gas released of the 40-liter bag sieve, to the
airbag expanded gas, at the end of grams within 50 ms, moles
.degree. C. (Kelvin) 50 ms., atm 0 0.6225 2435 (2708) 3.458 5
0.6436 1706 (1979) 2.613 10 0.6649 1305 (1578) 2.15 20 0.7083 884
(1158) 1.683 30 0.7511 652 (926) 1.4268 40 0.7906 504 (778) 1.268
50 0.8273 400 (674) 1.144 60 0.8622 324 (597) 1.055 70 0.8960 264
(537) 0.9871 50 Pyrotechnic 1.1200 MS 0.2020 Gas 0.1833 Total
1.5053
[0044] The model uses a pyrotechnic charge of about 70 grams of
NaN.sub.3 to inflate a 40-liter driver-side airbag, with
incremental added amounts of zeolite adsorbent, pre-loaded with
nitrogen. The dynamic gas release and average gas temperature of
the gas delivered to the airbag are determined by the model. When
zeolite molecular sieve which was pre-loaded with nitrogen is
incorporated into the pyrotechnic inflator over a range of from 5
to about 70 grams of zeolite, significant cooling of the product
gases resulted which still delivered an airbag pressure in a
40-liter airbag of about 1 atm. At about 50 grams of nitrogen
pre-loaded zeolite molecular sieve, the pressure delivered to the
airbag is sufficient to inflate the airbag with a desired level
while reducing the delivered temperature at 50 ms after the
detonation by a factor of about 6. The gas temperatures calculated
and shown in Tables I and II represent the temperature of the gas
at the entrance to the airbag. Significant further cooling will
take place within the airbag but is not considered in this
analysis. The results in Table I show an advantage for combining
the functions of gas storage by zeolite adsorbents with the gas and
heat releases of pyrotechnic compounds to significantly reduce the
temperature of the gas delivered to the airbag. The zeolite hybrid
generator can inflate the airbag with nitrogen gas within time
periods that are very comparable with existing pyrotechnic devices
while delivering the gas at temperatures that are much cooler than
the gas delivered by the solely pyrotechnic devices. Pressures less
about 1.13 atm inside the fully inflated airbag at the end of 50 ms
will inflate the airbag, but not aggressively enough to provide the
same performance as that of the pyrotechnic device.
Example VII
Comparison of CO.sub.2 Hybrid Inflator to Pyrotechnic
[0045] Based on the simulation of the hybrid zeolite inflator of
Example VI, a simulation for the use of zeolite pre-loaded with
stored carbon dioxide is considered. The results shown in Table II
show that the temperature of the combined generated gases and
stored gasses is reduced from about 2400.degree. to about
391.degree. C. by the placement of about 50 grams of zeolite
molecular sieve pre-loaded with carbon dioxide at a storage
pressure of about 5 atm while still generating sufficient pressure
inside the airbag at the end of a 50 ms inflation period while
reducing the delivered temperature by about a factor of 4. As in
Example VI, significant further cooling in the airbag is not
considered.
2TABLE II Mass of Nitrogen plus CO.sub.2 Released Pressure inside a
Mass of Mass averaged fully inflated Molecular temperature of the
40-liter bag Sieves, Mass of Gas Released expanded gas, at the end
of grams within 50 ms, moles .degree. C. (Kelvin) 50 ms, atm 0
0.6225 2435 (2708) 3.458 10 0.6649 1304 (1578) 2.15 50 0.8273 391
(665) 1.1286 50 Pyrotechnic 1.1200 MS 0.2300 Gas 0.0135 Total
1.3635
[0046] The addition of the carbon dioxide pre-loaded or
encapsulated molecular sieve zeoite to the inflator system at
pressures less than about 5 atm provides significant reduction in
the temperature of the gas delivered to the airbag without the need
for high-pressure gas storage in the inflator.
* * * * *