Extended output inflator device

1. An inflation device for inflating an inflatable cushion of an airbag module, the inflation device comprising:

a first chamber having a first volume of inflation gas;

a second chamber having a second volume of inflation gas;

a first inflation opening for allowing the first volume of inflation gas to pass therethrough and a first sealing member, the first sealing member sealing the first inflation opening;

a second inflation opening for allowing the second volume of inflation gas to pass therethrough and a mechanically activateable pyrotechnic squib sealing the second inflation opening;

a diffuser tube in fluid communication with the first inflation opening, the second inflation opening and the inflatable cushion;

an initiator for removing a portion of the first sealing member from the first inflation opening;

a projectile moveably disposed within the diffuser tube, the projectile further comprising a tip portion configured to activate the pyrotechnic squib when the projectile is moved from a first position to a second position wherein the tip portion makes contact with the mechanically activateable pyrotechnic squib, wherein activation of the pyrotechnic squib allows fluid communication between the second chamber and the diffuser tube; and

wherein the first volume of inflation gas flows from the first chamber at a first flow rate and the second volume of inflation gas flows from the second chamber at a second flow rate, the second flow rate being smaller than the first flow rate, and wherein the first flow rate generates a force to cause the projectile to move from the first position to the second position.

2. The inflation device as in claim 1 , wherein the first volume of inflation gas comprises helium and the second volume of inflation gas comprises argon.

3. The inflation device as in claim 1 , wherein the first volume of inflation gas is selected from the group comprising helium, argon, carbon dioxide and mixtures thereof and the second volume of inflation gas is selected from the group comprising helium, argon, carbon dioxide, nitrogen and mixtures thereof and the second flow rate has a duration longer than a duration of the first flow rate.

4. The inflation device as in claim 3 , wherein the projectile further comprises a fluid passageway disposed therein, the fluid passageway providing fluid communication between diffuser tube and the second chamber.

5. The inflation device as in claim 4 , further comprising a deployable washer disposed in the diffuser tube, wherein the projectile is located between the deployable washer and the second inflation opening.

6. The inflation device as in claim 1 , further comprising a deployable washer disposed in the diffuser tube, wherein the projectile is located between the deployable washer and the second inflation opening and wherein the projectile further comprises a plurality of fluid passageways disposed therein, the fluid passageways providing fluid communication between diffuser tube and the second chamber.

7. The inflation device as in claim 6 , wherein the first chamber is located at one end of the diffuser tube and the second chamber is located at an opposite end of the diffuser tube.

8. The inflation device as in claim 1 , wherein the first chamber is located at one end of the diffuser tube and the second chamber is located at an opposite end of the diffuser tube.

9. The inflation device as in claim 1 , wherein the second inflation opening is also sealed by a ruptureable sealing member and the mechanically activateable pyrotechnic squib further comprises another projectile, which ruptures the ruptureable sealing member after activation of the mechanically activateable pyrotechnic squib.

10. The inflation device as in claim 9 , wherein the first volume of inflation gas is selected from the group comprising helium, argon, carbon dioxide, nitrogen and mixtures thereof and the second volume of inflation gas is selected from the group comprising helium, argon, carbon dioxide, nitrogen and mixtures thereof and wherein the projectile further comprises a fluid passageway disposed therein, the fluid passageway providing fluid communication between diffuser tube and the second chamber.

11. The inflation device as in claim 10 , further comprising a deployable washer disposed in the diffuser tube, wherein the projectile is located between the deployable washer and the second inflation opening.

12. An airbag module, comprising:

an inflatable cushion;

an inflation device, the inflation device comprising:

a first chamber having a first volume of inflation gas;

a second chamber having a second volume of inflation gas;

a first inflation opening for allowing the first volume of inflation gas to pass therethrough and a first sealing member, the first sealing member sealing the first inflation opening;

a second inflation opening for allowing the second volume of inflation gas to pass therethrough and a mechanically activateable pyrotechnic squib sealing the second inflation opening;

a diffuser tube in fluid communication with the first inflation opening, the second inflation opening and the inflatable cushion;

an initiator for removing a portion of the first sealing member from the first inflation opening;

a projectile moveably disposed within the diffuser tube, the projectile further comprising a tip portion configured to activate the pyrotechnic squib when the projectile is moved from a first position to a second position wherein the tip portion makes contact with the mechanically activateable pyrotechnic squib, wherein activation of the pyrotechnic squib allows fluid communication between the second chamber and the diffuser tube; and

wherein the first volume of inflation gas flows from the first chamber at a first flow rate and the second volume of inflation gas flows from the second chamber at a second flow rate, the second flow rate being smaller than the first flow rate, wherein the first flow rate generates a force to cause the projectile to move from the first position to the second position.

13. The airbag module as in claim 12 , wherein the first volume of inflation gas comprises helium and the second volume of inflation gas comprises argon and the second flow rate has a duration longer than a duration of the first flow rate.

14. The airbag module as in claim 12 , wherein the first volume of inflation gas is selected from the group comprising helium, argon, carbon dioxide, nitrogen and mixtures thereof and the second volume of inflation gas is selected from the group comprising helium, argon, carbon dioxide, nitrogen and mixtures thereof.

15. The airbag module as in claim 14 , wherein the projectile further comprises a fluid passageway disposed therein, the fluid passageway providing fluid communication between diffuser tube and the second chamber.

16. The airbag module as in claim 15 , further comprising a deployable washer disposed in the diffuser tube, wherein the projectile is located between the deployable washer and the second inflation opening.

17. The airbag module as in claim 12 , further comprising a deployable washer disposed in the diffuser tube, wherein the projectile is located between the deployable washer and the second inflation opening and wherein the projectile further comprises a plurality of fluid passageways disposed therein, the fluid passageways providing fluid communication between diffuser tube and the second chamber.

18. The airbag module as in claim 12 , wherein the first chamber is located at one end of the diffuser tube and the second chamber is located at an opposite end of the diffuser tube.

19. The airbag module as in claim 12 , wherein the first chamber is located at one end of the diffuser tube and the second chamber is located at an opposite end of the diffuser tube.

20. The airbag module as in claim 12 , wherein the second inflation opening is also sealed by a ruptureable sealing member and the mechanically activateable pyrotechnic squib further comprises another projectile, which ruptures the ruptureable sealing member after activation of the mechanically activateable pyrotechnic squib.

21. The airbag module as in claim 20 , wherein the first volume of inflation gas is selected from the group comprising helium, argon, carbon dioxide, nitrogen and mixtures thereof and the second volume of inflation gas is selected from the group comprising helium, argon, carbon dioxide, nitrogen and mixtures thereof and wherein the projectile further comprises a fluid passageway disposed therein, the fluid passageway providing fluid communication between diffuser tube and the second chamber.

22. The airbag module as in claim 21 , further comprising a deployable washer disposed in the diffuser tube, wherein the projectile is located between the deployable washer and the second inflation opening.

23. A method of providing extended inflation output to an inflatable cushion of an airbag module, the method comprising:

supplying a first volume of inflation gas from a first inflation chamber through a first inflation opening at a first flow rate;

supplying a second volume of inflation gas from a second inflation chamber through a second inflation opening at a second flow rate;

generating from the first flow rate a force for causing a projectile to activate a pyrotechnic squib sealing the second inflation opening, the projectile being moveably received within a conduit providing fluid communication between the first volume of inflation gas and second volume of inflation gas.

24. The method as in claim 23 , wherein the first volume of inflation gas is selected from the group comprising helium, argon, carbon dioxide, nitrogen and mixtures thereof and the second volume of inflation gas is selected from the group comprising helium, argon, carbon dioxide, nitrogen and mixtures thereof.

25. The method as in claim 24 , wherein the projectile further comprises a fluid passageway disposed therein, the fluid passageway providing fluid communication between conduit and the second chamber.

26. The method as in claim 23 , wherein a deployable washer is disposed in the conduit and wherein the projectile is located between the deployable washer and the second inflation opening.

27. The method as in claim 23 , wherein the second inflation opening is also sealed by a ruptureable sealing member and the mechanically activateable pyrotechnic squib further comprises a projectile, which ruptures the ruptureable sealing member after activation of the mechanically activateable pyrotechnic squib.

28. An inflation device for inflating an inflatable cushion of an airbag module, the inflation device comprising:

a projectile moveably disposed within a diffuser tube of the inflation device;

a first chamber having a first volume of inflation gas, the first chamber being in fluid communication with the diffuser tube when a sealing member of the first chamber is ruptured;

a second chamber having a second volume of inflation gas, the second chamber being in fluid communication with the diffuser tube when a pyrotechnic squib is activated by movement of the projectile into the pyrotechnic squib by the first volume of inflation gas as it flows into the diffuser.

29. The inflation device as in claim 28 , wherein the first volume of inflation gas is selected from the group comprising helium, argon, carbon dioxide, nitrogen and mixtures thereof and the second volume of inflation gas is selected from the group comprising helium, argon, carbon dioxide, nitrogen and mixtures thereof and the projectile further comprises a fluid passageway disposed therein, the fluid passageway providing fluid communication between conduit and the second chamber.

30. The inflation device as in claim 28 , wherein the first volume of inflation gas flows into the diffuser tube at a first flow rate and the second inflation gas flows into the diffuser tube at a second flow rate, the first flow rate being greater than the second flow rate and the second flow rate having a duration longer than a duration of the first flow rate.