Airbag module with integrated gas generation

1. An airbag module, comprising:

a cover with a flange and a pocket;

an upper retainer ring with at least one hole;

a gas generant container including gas generant propellant, at least a portion of the gas generant container being positioned within the pocket;

a lower retainer ring positioned below the cover; and

an inflatable cushion,

wherein the gas generant propellant becomes functional as a gas generation source after the cover is secured to the lower retainer ring,

wherein the cover is positioned between the upper retainer ring and the gas generant container, the cover including at least one exit hole in the flange in alignment with the at least one hole of the upper retainer ring, and

wherein gas generated by the gas generant propellant flows through flow orifices in the cover and out the at least one exit hole into the inflatable cushion to inflate the cushion.

2. The airbag module of claim 1 , wherein the gas generant container includes an upper cup attached to a lower cup such that the gas generant propellant is positioned in a space formed by the upper and lower cups.

3. The airbag module of claim 2 , wherein the upper cup is configured to be positioned inside and directly adjacent the pocket of the cover.

4. The airbag module of claim 1 , further comprising an initiator and a bore body seal, wherein the initiator is positioned within the bore body seal.

5. The airbag module of claim 4 , wherein the initiator and bore body seal extend from the lower retainer ring and into a hole in the gas generant container.

6. The airbag module of claim 1 , wherein the gas generant container includes two sets of holes, the first set of holes positioned to face the pocket such that gas generated by the gas generant propellant flows into the pocket via orifices to inflate the cushion, and the second set of holes includes at least one hole remote from the first set of holes and positioned to receive an initiator configured to ignite the gas generant propellant.

7. The airbag module of claim 6 , wherein orifices in the cover facing the first set of holes are dimple shaped orifices.

8. The airbag module of claim 7 , wherein each dimple shaped orifice includes a cover plate.

9. The airbag module of claim 8 , wherein the cover includes a centrifugal collector channel.

10. The airbag module of claim 7 , wherein the dimple shaped orifices are configured to guide the generated gas along an internal surface of the cover via flow orifices.

11. The airbag module of claim 10 , wherein the flow orifices are configured such that a flow path of the generated gas includes first and second volumes of high pressure connected by a volume with supersonic gas flow.

12. The airbag module of claim 11 , wherein the first volume is located adjacent the first set of holes in the gas generant container.

13. The airbag module of claim 11 , wherein the second volume is located downstream from the first volume and includes the volume of gas next to the at least one exit hole in the cover.

14. The airbag module of claim 1 , wherein the gas generant propellant is contained within a hermetically sealed package.

15. An airbag module, comprising:

a cover with a flange and a pocket;

an upper retainer ring with at least one hole;

a gas generant container including gas generant propellant, at least a portion of the gas generant container being positioned within the pocket;

a lower retainer ring positioned below the cover; and

an inflatable cushion;

wherein the gas generant propellant becomes functional as a gas generation source after the cover is secured to the lower retainer ring, and

wherein the gas generant container includes an upper cup attached to a lower cup such that the gas generant propellant is positioned in a space formed by the upper and lower cups;

wherein the upper cup is crimped closed to the lower cup,

wherein the cover is positioned between the upper retainer ring and the gas generant container, the cover including at least one exit hole in the flange in alignment with the at least one hole of the upper retainer ring, and

wherein gas generated by the gas generant propellant flows through flow orifices in the cover and out the at least one exit hole into the inflatable cushion to inflate the cushion.

16. A method of assembling an airbag module, comprising:

providing a cover with a flange and a pocket;

providing a gas generant container with a gas generant propellant;

providing an upper retainer ring and a lower retainer ring;

attaching an inflatable cushion to the upper or lower retainer ring;

positioning the gas generant container within the pocket of the cover; and

attaching the cover to the lower retainer ring, whereby the gas generant propellant becomes functional as a gas generation source only after the cover is attached to the lower retainer ring,

wherein the cover is positioned between the upper retainer ring and the gas generant container, the cover including at least one exit hole in the flange in alignment with at least one hole of the upper retainer ring, and

wherein gas generated by the gas generant propellant flows through flow orifices in the cover and out the at least one exit hole into the inflatable cushion to inflate the cushion.

17. The method of claim 16 , further comprising:

inserting an initiator into an aperture of the gas generant container.

18. The method of claim 17 , wherein the initiator is positioned in a bore body seal.

19. The method of claim 18 , wherein the initiator and bore body seal extend from an aperture in the lower retainer ring.

20. The method of claim 16 , further comprising:

pre-packaging the gas generant propellant in a hermetically sealed package prior to positioning the gas generant propellant in the gas generant container.