阅读说明：本技术 用于密封安全气囊充气机基座的系统和方法 (System and method for sealing airbag inflator base ) 是由 A·R·拉森 于 2020-04-22 设计创作，主要内容包括：本发明公开了系统和方法,其中在安全气囊充气机基座(102)的内部与外部环境之间形成密封件(150)。膜密封件(150)的聚合物构件(152)可以与安全气囊充气机的启动器(110)的电连接器的包覆模制件(130)形成固态粘结。此外,膜密封件的粘合膜(154)可以在至少部分地围绕凹陷部设置的位置处粘结到安全气囊充气机基座,包覆模制件通过该凹陷部将启动器联接到安全气囊充气机基座。(Systems and methods are disclosed in which a seal (150) is formed between the interior of an airbag inflator base (102) and the external environment. The polymer member (152) of the film seal (150) may form a solid state bond with an overmold (130) of an electrical connector of an initiator (110) of an airbag inflator. In addition, an adhesive film (154) of the film seal may be bonded to the airbag inflator base at a location disposed at least partially around a recess through which the overmold couples the initiator to the airbag inflator base.)

1. A sealed airbag inflator (30) comprising:

a base (102) for supporting the device,

an actuator (110) disposed at least partially within the base (102);

an overmold (130) coupling the base (102) to the initiator (110); and

a film seal (150) comprising a substrate (152) and an adhesive (154), characterized in that the film seal (150) is coupled to the base (102) via the adhesive (154) and the substrate (152) is coupled to the overmold (130) such that the film seal (150) forms a seal between the base (102) and the overmold (130).

2. The sealed airbag inflator (30) of claim 1, wherein during assembly, the substrate (152) at least partially melts and resolidifies between the base (102) and the overmold (130) to bond with the overmold (130).

3. The sealed airbag inflator (30) of any of claims 1 and 2, wherein the seal between the base (102) and the overmold (130) inhibits passage of gas or liquid from an exterior of the sealed airbag inflator (30) to an interior of the sealed airbag inflator (30).

4. The sealed airbag inflator (30) of any of claims 1 to 3, wherein the seal between the base (102) and the overmold (130) inhibits passage of gas or liquid between the base (102) and the overmold (130).

5. The sealed airbag inflator (30) of any of claims 1 to 4, wherein the adhesive (154) is an adhesive film formed from a suitable heat-bond film, a contact-bond film, or a combination thereof.

6. The sealed airbag inflator (30) of any of claims 1 to 5, wherein the base (102) comprises an aperture (106) such that the initiator (110) is disposed at least partially through the aperture (106), and wherein the overmold (130) is disposed between the base (102) and the initiator (110) so as to be coupled to the base (102) and the initiator (110) at the aperture (106).

7. The sealed airbag inflator (30) of claim 6, wherein a portion of the overmold (130) is configured to be melted such that the overmold (130) partially fills the aperture (106).

8. The sealed airbag inflator (30) of claim 7, wherein the overmold (130) forms a seal between the base (102) and the initiator (110) upon melting of the portion of the overmold (130).

9. The sealing airbag inflator (30) of claim 8, wherein the seal between the base (102) and the initiator (110) inhibits passage of gas or liquid from an exterior of the sealing airbag inflator (30) to an interior of the sealing airbag inflator (30) between the base (102) and the initiator (110).

10. The sealed airbag inflator (30) of any of claims 1 to 9, further comprising a solid state bond between the substrate (152) and the overmold (130) such that a seal is formed between an interior of the sealed airbag inflator (30) and an exterior of the sealed airbag inflator (30).

11. The sealed airbag inflator (30) of claim 10, wherein the seal between the interior of the sealed airbag inflator (30) and the exterior of the sealed airbag inflator (30) inhibits passage of gas or liquid from the exterior of the sealed airbag inflator (30) to the interior of the sealed airbag inflator (30).

12. The sealed airbag inflator (30) of any of claims 1 to 11, wherein the overmold (130) is formed from a thermoplastic nylon and the substrate (152) is a polymeric substrate formed from a nylon compatible with the thermoplastic nylon.

Technical Field

The present disclosure relates generally to the field of automotive protection systems. More particularly, the present disclosure relates to airbag systems configured to deploy in response to a collision event.

Drawings

Embodiments of the invention will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that the drawings depict only typical embodiments and are not therefore to be considered to be limiting of the scope of the disclosure, the embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings.

Fig. 1 is a perspective view of a steering wheel assembly of a vehicle having an inflatable airbag assembly according to an embodiment of the present disclosure.

FIG. 2 is a rear perspective view of an airbag and inflator with a sealing system according to an embodiment of the present disclosure.

FIG. 3 is a cross-sectional view of the inflator of FIG. 2 taken along line 3-3 of FIG. 2, according to an embodiment of the present disclosure.

Fig. 4A is an exploded perspective view of a membrane seal of a sealing system according to an embodiment of the present disclosure.

Fig. 4B is a perspective view of the membrane seal of fig. 4A.

Fig. 5A is a partially exploded perspective view of a sealing system according to an embodiment of the present disclosure.

FIG. 5B is a perspective view of the sealing system of FIG. 5A coupled to an inflator base.

FIG. 6 is a partial cross-sectional side view of a sealing system including a membrane seal coupled to an inflator base and initiator according to an embodiment of the present disclosure.

FIG. 7A is a detailed cross-sectional view of a portion of the inflator base and initiator without the film seal taken along line 7 of FIG. 6.

FIG. 7B is a detailed cross-sectional view of a portion of the inflator base and initiator with the film seal taken along line 7 of FIG. 6.

Detailed Description

It will be readily understood that the components of the embodiments, as generally described and illustrated in the figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of various embodiments, as represented in the figures, is not intended to limit the scope of the disclosure, as claimed, but is merely representative of various embodiments. While various aspects of the embodiments are presented in drawings, the drawings are not necessarily drawn to scale unless specifically indicated.

Inflatable airbag assemblies are widely used to reduce or minimize occupant injury during a collision event. Airbag modules have been installed at various locations within a vehicle, including but not limited to in the steering wheel, in the instrument panel and/or instrument panel, within the side doors or side seats, adjacent the roof rail of the vehicle, in the overhead position, or at knee or leg positions.

During installation, the airbag is typically disposed inside the housing in a packaged state (e.g., rolled, folded, and/or otherwise compressed) or compact configuration, and may remain in the packaged state behind the cover. During a crash event, the inflator is triggered, which rapidly fills the airbag with inflation gas. The airbag can be quickly transitioned from a packaged state (e.g., a compact configuration) to a deployed state or an inflated configuration. The inflator may be triggered by an initiator, which may be triggered by any suitable device or system, and which may be responsive to and/or influenced by one or more vehicle sensors.

A typical starter may include a plurality of electrical conductors that may transmit electrical pulses to the pyrotechnic charge to combust the pyrotechnic charge. Combustion of the pyrotechnic charge may result in combustion of the pyrotechnic relay charge, and combustion of the pyrotechnic relay charge may in turn initiate combustion of the propellant pellets. The combustion of the propellant pellets may produce a volume of gas that may be directed through a plurality of ports in the housing of the filter and inflator, whereby the inflation gas may be directed into the airbag for rapid inflation and deployment of the airbag.

Some embodiments disclosed herein may provide improved sealing of an aperture of an airbag inflator base through which an initiator may be coupled to an electrical harness of a vehicle in which an airbag assembly is installed. Embodiments of the present disclosure may form a seal, such as a hermetic seal, between the interior space of the airbag inflator base and the external environment in order to limit or prevent gas (e.g., air) or liquid (e.g., moisture) from entering the interior space of the airbag inflator base from the external environment. Preventing gas or liquid from entering the interior space of the inflator base may allow for a more chemically stable environment for pyrotechnic charges, pyrotechnic relay charges, propellants, filters, etc. to provide for durability and reliable performance of the inflator.

FIG. 1 is a perspective view of a vehicle steering wheel assembly 10 having an inflatable airbag assembly 20. The steering wheel assembly 10 may include a steering column 12 and a steering wheel 14. The inflatable airbag assembly 20 may include an inflatable cushion 22 and an inflator 30. The inflatable airbag may be disposed in a packaged state in a housing within a steering wheel 14 (or other component) within a passenger compartment of the vehicle, and may deploy from the housing to a deployed state to provide occupant protection.

FIG. 2 is a rear perspective view of the inflator 30 including the sealing system 100. For reference, the inflatable cushion 22 is shown in an at least partially inflated state. The inflator 30 may include an inflator base 102, and the inflator base 102 may include a connector pocket 104. The connector pocket 104 may further include a starter hole (not shown, but see, e.g., starter hole 106 in fig. 3). An overmold 130 (e.g., a polymeric overmold 130) may pass through and couple to the inflator 30 at or near the connector pocket 104 and/or the initiator aperture 106. In some embodiments, the overmold 130 may be coupled to the inflator base 102 and the electrical connector receptacle 108, for example, at a location between each of the inflator base 102 and the electrical connector receptacle 108. An actuator (see, e.g., actuator 110 in fig. 3) may be coupled to the electrical connector receptacle 108. Two electrical conductors 122 of the initiator 110 are shown for reference. In other embodiments, the electrical connector receptacle 108 may include other suitable numbers of electrical conductors (e.g., one, three, four, etc.) coupled to the actuator 110. As shown, the film seal 150 may be coupled to at least a portion of the polymer overmold 130 and/or the inflator base 102. For example, the film seal 150 may be coupled at a location between the overmold 130 and each of the inflator bases 102.

FIG. 3 is a cross-sectional view of the inflator 30 taken along line 3-3 of FIG. 2. The inflator 30 may include an initiator 110 and a secondary pyrotechnic load 114. The initiator 110 may include a primary pyrotechnic load 112, a secondary pyrotechnic load 114, and/or an electrical conductor 122. In the event of a collision, an electrical signal may be communicated or sent to the initiator 110 via the electrical conductor 122. An electrical signal may be passed through a bridgewire across the distal end of the electrical conductor 122 in order to ignite the primary pyrotechnic load 112. The primary pyrotechnic load 112 may then ignite a secondary pyrotechnic load 114, which in turn may ignite a gas generating reactant 116. The initiator 110 may be coupled (e.g., fixedly coupled) to the inflator base 102, the secondary pyrotechnic load 114, at least in part, by at least a portion of the overmold 130.

The overmold 130 may also form at least a portion of the electrical connector receptacle 108 to couple the electrical conductors 122 of the initiator 110 to an electrical connector (not shown). The film seal 150 may be coupled to at least a portion of the outer surface 103 of the inflator base 102 and may surround or be disposed around at least a portion of the connector pocket 104 so as to be coupled between at least a portion of the overmold 130 and the inflator base 102. As shown, the film seal 150 is at least partially disposed between each of the connector pocket 104 and the overmold 130 of the inflator base 102.

While the inflator 30 of fig. 1-3 is of a type commonly referred to as a disc-type inflator, the present disclosure may be used with other types of inflators (e.g., tubular inflators) for any type of airbag. Further, while the present disclosure is directed to inflators having initiators, inflators having more than one initiator are also within the scope of the present disclosure.

Fig. 4A shows an exploded view of the membrane seal 150 of the sealing system 100. The film seal 150 may include a substrate 152 (e.g., a polymer substrate 152) and an adhesive film or bonding film 154. The polymer substrate 152 may be formed from one or more of a polyamide (nylon) member (e.g., PA6 nylon film) or other thermoplastic or thermoset material. Other suitable materials for forming the polymeric substrate 152 are also within the scope of the present disclosure. Adhesive film 154 may be formed from, but is not limited to, a high strength flexible nitrile phenolic based thermoplastic adhesive film or any other suitable adhesive thermal or compression bonding means. Polymer substrate 152 and adhesive film 154 may be formed in an annular or ring-like shape, wherein polymer substrate 152 and adhesive film 154 may have similar outer diameters. The polymer substrate 152 may be flat or pre-formed (e.g., as shown in FIG. 4A) prior to coupling to the inflator base 102. The polymer substrate 152 and the adhesive film 154 may be coupled together such that the outer diameters are aligned or substantially aligned to form the membrane seal 150. In some embodiments, the outer diameters of polymer substrate 152 and adhesive film 154 may be different. For example, the outer diameter of polymer substrate 152 may be greater than the outer diameter of adhesive film 154.

Fig. 4B is a perspective view of the membrane seal 150 of the sealing system 100. As shown, polymer substrate 152 and adhesive film 154 have been coupled together in a coupled configuration such that the outer diameters of polymer substrate 152 and adhesive film 154 are substantially aligned. An adhesive surface of adhesive film 154 may couple adhesive film 154 and polymer substrate 152 to form film seal 150. In addition, the adhesive surface of the adhesive film 152 may help to retain the film seal 150 as a single or unitized component until further coupled or mounted to an inflator base (see, e.g., the inflator base 102 of fig. 5A and 5B). The membrane seal 150 includes a central opening or aperture. The central opening or aperture of the film seal 150 may be configured to align, conform, and/or otherwise correspond with the connector recess 104 and/or the initiator aperture 106 of the inflator base 102. (see fig. 3, 5) additionally, the central opening or aperture of the film seal 150 may be configured to surround, conform to, or otherwise correspond to the overmold 130 of the initiator 110.

Fig. 5A is a partially exploded perspective view of the sealing system 100. The film seal 150 including the polymer substrate 152 coupled to the adhesive film 154 may be coupleable or configured to be coupled to the inflator base 102. The membrane seal 150 may be aligned concentrically or substantially concentrically with the connector pocket 104. In some embodiments, the adhesive film 154 may be coupled to (e.g., pressed onto) at least a portion of the inflator base 102, and then the polymer substrate 152 is applied to the adhesive film 154. The adhesive film 154 may be heated or reheated (before or after application of the polymer substrate 152) to bond or at least partially bond the adhesive film 154 to the inflator base 102. By way of example, in one embodiment, the polymer substrate 152 may be adhered to the inflator base 102 by a contact adhesive means. In one embodiment, the inflator base 102 may be heated such that the polymer substrate 152 is attached to the inflator base 102. In one embodiment, a molding process may be employed whereby a combination of clamping force and heat is applied to adhere the polymer substrate 152 to the inflator base 102.

FIG. 5B is a perspective view of the sealing system 100 assembled or coupled to the inflator base 102. With the membrane seal 150 coupled to the inflator base 102, the polymer substrate 152 and the adhesive film 154 may be disposed concentrically or substantially concentrically with respect to one another. Additionally, the polymer substrate 152 and the adhesive film 154 may be disposed concentrically or substantially concentrically with respect to the connector pocket 104 of the inflator base 102.

FIG. 6 is a cross-sectional side view of the membrane seal 150 assembled to or coupled to the inflator base 102 and initiator 110. The primary pyrotechnic load 112, the secondary pyrotechnic load 114, and the electrical conductors 122 of the initiator 110 are shown for reference. As shown, the actuator 110 has been partially disposed or passed through the connector recess 104, the actuator aperture 106, and the central opening or aperture of the membrane seal 150. The overmold 130 may be assembled or coupled to the inflator base 102 by applying heat (e.g., via injection molding) to couple the film seal 150 to the inflator base 102 and to position or secure the initiator 110 within the connector pocket 104 and initiator aperture 106. Injection molding for assembling the overmold 130 to the inflator base 102 may melt, or at least partially melt, the adhesive film 154 and form a bond to the surface of the inflator base 102 and to the polymer substrate 152. In addition, injection molding of overmold 130 may result in polymer substrate 152 melting or at least partially melting and forming a bond (e.g., a solid state bond) between at least a portion of polymer substrate 152 and at least a portion of overmold 130.

The overmold 130 may be formed from an engineering thermoplastic nylon, such as Acrylonitrile Butadiene Styrene (ABS), Polycarbonate (PC), or Polymethylmethacrylate (PMMA). The polymer substrate (see 152 in fig. 5A, 7B) may be formed of nylon that is compatible with the particular engineering thermoplastic nylon of the overmold 130. By way of example and not limitation, the ABS overmold 130 may be coupled to a polymer substrate 152 of ABS, ABS/PC, PMMA, or Styrene Acrylonitrile (SAN). Similarly, the overmold 130 of PC may be coupled with a polymer substrate 152 of ABS/PC, polybutylene terephthalate (PBT), PC/PBT, or PMMA. Likewise, an overmold 130 of PMMA may be coupled with a polymer substrate 152 of ABS, ABS/PC, PC/PBT, PMMA, or SAN. Other material combinations are also contemplated by the present disclosure.

FIG. 7A is a detailed cross-sectional view of a portion of the initiator-inflator assembly 100 without the sealing system of FIG. 6. The area shown in fig. 7A is identified by line 7 in fig. 6. The initiator 110, the primary pyrotechnic load 112, the secondary pyrotechnic load 114, and the electrical conductors 122 of the initiator 110 are shown for reference. An overmold 130 may be used to fixedly position the actuator 110 within the connector pocket 104 and the actuator aperture 106. Without the membrane seal 150 of the present disclosure, there may be a leakage of gas and/or liquid (e.g., air and/or moisture) as indicated by arrows 140. As shown, the leak 140 may extend or progress along the interface between the overmold 130 and the inflator base 102. Any gas and/or liquid that may flow into or enter the interior of the airbag inflator may interfere with the proper operation of the airbag inflator.

Fig. 7B is a detailed cross-sectional view of a portion of the sealing system 100. The primary pyrotechnic load 112, the secondary pyrotechnic load 114, and the electrical conductors 122 of the initiator 110 are shown for reference. At least a portion of the initiator 110 may be disposed through the connector recess 104 and the initiator aperture 106 of the inflator base 102. The film seal 150 may be disposed concentrically or substantially concentrically around the connector pocket 104 and may be coupled between a portion of the outer surface 103 of the inflator base 102 and a portion of the overmold 130. In other words, the membrane seal 150 may be disposed such that, when disposed, the membrane seal 150 at least partially surrounds the initiator aperture 106 and/or the initiator 110 and is then bonded by a thermal molding process.

The overmold 130 may be assembled or coupled to at least a portion of the inflator base 102 and the initiator 110. In some embodiments, the polymeric overmold 130 may be coupled to the inflator base 102. The injection molding process may melt at least a portion of the polymer substrate 152 of the film seal 150 and by melting to form a bond (e.g., a solid state bond) between the polymer substrate 152 and the overmold 130. The injection molding process may also cause or cause at least a portion of adhesive film 154 to melt, thereby forming a bond between adhesive film 154 and polymer substrate 152, and/or a bond between adhesive film 154 and a surface of inflator base 102. The coupling may establish, form, or create a seal between the external environment and an internal region enclosed within the inflator (see, e.g., inflator 30 of fig. 2 and 3). In various embodiments, the coupling may establish, form or create or form a seal (e.g., a gas-tight seal) between the external environment and the interior of the inflator 30, thereby preventing or limiting the ingress of gas and/or liquid into the interior of the inflator 30.

In some embodiments, the seal may inhibit, prevent, or resist the passage of gas (e.g., air). In certain embodiments, the seal may inhibit, prevent, or impede the passage of liquid (e.g., moisture or water). The seal may inhibit, prevent, or resist the passage of objects from the interior of the inflator to the exterior of the inflator. The seal may inhibit, prevent, or resist the passage of objects from the exterior of the inflator to the interior of the inflator.

The seal may be submerged at a predetermined depth in the liquid (e.g., 1 meter, 2 meters, 3 meters, etc.) and may inhibit, prevent, or resist the passage of liquid from the exterior of the inflator to the interior of the inflator. In various embodiments, the seal may be submerged in the liquid for a period of time (e.g., 1 hour, 1 day, 1 week, etc.) and may remain sealed. The seal may be configured to inhibit, prevent, or resist the ingress of gas and/or liquid into the inflator through a space provided between the base and the overmold and/or initiator. By way of further example, the nature of the seal may be such that a helium tracer leak test may be employed for the test embodiment. Helium tracer leak testing involves injecting helium into an assembled and otherwise sealed inflator base and diffuser such that the helium is trapped within the inflator base/diffuser assembly and a vacuum is applied from the outside. The transmission of helium gas to the exterior of the inflator base/diffuser assembly is measured. The target helium permeability through the seal may be less than 0.0001 cc/sec at 20 degrees c under a standard ATM with 100% helium concentration inside the inflator.

In other embodiments, the seal created between the overmolded nylon and nylon substrate may be a fusion bond.

In some embodiments, a sealed airbag inflator may include a base, an initiator disposed partially within the base, an overmold coupling the base to the initiator, and/or a film seal including a substrate and an adhesive film, the film seal coupled to the base via the adhesive film, and the substrate coupled to the overmold such that the film seal forms a seal between the base and the overmold. The seal between the base and the overmold may inhibit, prevent, or resist the passage of gas and/or liquid from the exterior of the sealed airbag inflator to the interior of the sealed airbag inflator. For example, a seal between the base and the overmold may inhibit, prevent, or resist the passage of gases and/or liquids between the base and the overmold.

In certain embodiments, an adhesive film may be coupled to an outer surface of the base. The base may include an aperture such that the actuator is disposed therethrough, and wherein the overmold is disposed between the base and the actuator to couple to the base and the actuator at the aperture. A portion of the overmold may be configured to melt such that the overmold partially fills the hole. Further, the overmold may form a seal between the base and the actuator when the portion of the overmold melts. The seal between the base and the initiator may inhibit, prevent, or resist the passage of gas and/or liquid from the exterior of the sealed airbag inflator to the interior of the sealed airbag inflator between the base and the initiator.

The sealed airbag inflator may further include a bond between the adhesive film and the base. The sealed airbag inflator may further include a solid state bond between the substrate and the overmold. In addition, the bonds and solid state bonds may form a seal between the interior of the sealed airbag inflator and the exterior of the sealed airbag inflator. The seal between the interior of the sealed airbag inflator and the exterior of the sealed airbag inflator may inhibit, prevent, or resist the passage of gas and/or liquid from the exterior of the sealed airbag inflator to the interior of the sealed airbag inflator.

The overmold may be formed from at least one thermoplastic or thermoset material, such as nylon. The substrate may be a polymeric substrate formed from polyamide or at least one of another thermoplastic or thermoset material. The adhesive film may be formed of at least one of a heat adhesive film and a contact adhesive film, or a combination thereof.

In certain embodiments, a film seal for an airbag inflator may include a substrate and an adhesive film coupled to the substrate, where the film seal is to be coupled to a portion of a base of the airbag inflator. Further, when the film seal is coupled to the base, the adhesive film may couple the film seal to the outer surface of the base such that the film seal is disposed around at least a portion of the aperture of the base of the airbag inflator. The aperture may receive a portion of the actuator.

When coupled to the base, the adhesive film may form a bond with the base. The substrate may be meltable such that during coupling of the substrate to the base, the substrate forms a solid state bond with an overmold coupling the initiator to the base. In addition, the bond between the base and the adhesive film and the solid state bond between the base and the overmold may form a seal between the interior of the inflator and the exterior of the inflator. For example, a seal between the interior of the inflator and the exterior of the inflator may inhibit, prevent, or resist the passage of gas and/or liquid from the exterior of the inflator to the interior of the inflator between the base of the inflator and the overmold of the connector.

In various embodiments, the substrate and adhesive film may be circular, square, triangular, or unconventional in shape. Other suitable shapes of the substrate and/or adhesive film are also within the scope of the present disclosure. The apertures or openings may extend between the substrate and the intermediate portion of each of the adhesive films.

In some embodiments, a method of sealing an aperture of an airbag inflator base through which an initiator passes may comprise: (i) coupling an adhesive film of a film seal around at least a portion of an aperture of an airbag inflator base, (ii) coupling a base of the film seal between a surface of the airbag inflator base and an overmold, wherein during coupling of an initiator to the airbag inflator base via the overmold, the base and the overmold at least partially melt such that the base and the overmold form a solid state bond, and (iii) forming a bond between the airbag inflator base and the adhesive film. The bond between the adhesive film and the airbag inflator base and the solid state bond between the substrate and the overmold may form a seal at the aperture. In certain embodiments, the seal at the aperture may be a hermetic seal. In addition, the seal at the aperture may inhibit, prevent, or resist the passage of gas and/or liquid from the exterior of the airbag inflator to the interior of the airbag inflator. In certain embodiments, forming the bond includes heating and cooling the film seal. In certain embodiments, forming the bond includes, during assembly to the airbag inflator base, pressing the film seal against the airbag inflator base such that the adhesive film is adhesively bonded to the airbag inflator base. In certain embodiments, forming the bond includes heating the airbag inflator base to inductively heat the film seal to bond the adhesive film to the airbag inflator base. In certain embodiments, forming the bond includes, during assembly, coupling the film seal to the airbag inflator base and injection molding the overmold against the airbag inflator base to apply a clamping force and heat to bond the film seal to the airbag inflator base and the overmold.

Throughout this specification, "coupled" (including coupled to, coupled with …, etc.) refers to any form of interaction between two or more entities, including mechanical interaction, electrical interaction, magnetic interaction, electromagnetic interaction, fluid interaction, and thermal interaction. The two components may be coupled to each other even if they are not in direct contact with each other.

The terms "a" and "an" may be described as one, but are not limited to one. For example, while the present disclosure may describe an inflator having an initiator, the present disclosure also contemplates that the inflator may have more than one initiator.

Reference throughout this specification to "an embodiment" or "the embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the phrases referred to, or variations thereof, as recited throughout this specification are not necessarily all referring to the same embodiment.

Similarly, it should be appreciated that in the foregoing description of embodiments, various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure. This method of disclosure, however, is not to be interpreted as reflecting an intention that any claim requires more features than are expressly recited in that claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of any single foregoing disclosed embodiment. Thus, the claims following the detailed description are hereby expressly incorporated into this detailed description, with each claim standing on its own as a separate embodiment. The present disclosure includes all permutations of the independent claims and their dependent claims.

Elements referenced in a means-plus-function format are intended to be in accordance with 35u.s.c. § 112For explanation. It will be obvious to those having skill in the art that many changes may be made to the details of the above-described embodiments without departing from the underlying principles of the invention. The embodiments of the invention in which an exclusive property or privilege is claimed are definedThe following is given.