Inflators and method for manufacturing inflators

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

an outer housing;

a divider plate secured within the outer housing to define a first chamber and a second chamber of the outer housing, the divider plate having an orifice disposed therein, the orifice providing fluid communication between the first chamber and the second chamber, the divider plate being joined to the outer housing by a deformation resistance weld, the deformation resistance weld being formed by contacting the outer housing with a first electrode at an exterior portion of the outer housing proximate to the divider plate, contacting the divider plate with a second electrode disposed within the outer housing, and applying a voltage through the first and second electrodes to adhere a portion of the outer housing to a portion of the divider plate; and

a closure assembly configured to seal the first chamber at a first end of the outer housing, the closure assembly having a closure housing and an outlet plate disposed within the closure housing, the outlet plate having an outlet opening configured to receive a burst disk, the outlet plate being joined to the closure housing by contacting the outlet plate with a third electrode disposed about the outlet plate, contacting an exterior portion of the closure housing with a fourth electrode, and forming a deformation resistance weld between the closure housing and the outlet plate,

wherein the outer housing is joined to the outlet plate remote from the closure housing at the first end of the outer housing, and

wherein the first chamber has a first volume of compressed inflation gas and the second chamber has a second volume of compressed inflation gas, the second volume being smaller than the first volume, the second chamber being configured to route compressed inflation gas therein to the first chamber through the orifice of the divider plate.

2. The inflator of claim 1 , wherein the divider plate is remotely disposed from both a first end and a second end of the outer housing, wherein the first chamber is defined by a first annular wall section of the outer housing and the divider plate, the second chamber is defined by a second annular wall section of the outer housing and the divider plate, and the first and second annular wall sections are integrally formed and adjoined at a notch section of the outer housing proximate to the divider plate, and wherein the notch section is formed as a radial depression extending into the outer housing.

3. The inflator of claim 2 , wherein the divider plate is formed with a centrally protruding portion extending longitudinally into the second chamber from an annular flange that is secured to the notch section of the outer housing by the deformation resistance weld, and wherein a surface of the annular flange of the divider plate that generally faces the first chamber and an inner surface of the notch section that generally faces the second chamber define respective joining surfaces that are abutted against one another when the deformation resistance weld is formed.

4. The inflator of claim 2 , wherein the divider plate is formed with a centrally protruding portion extending longitudinally into the second chamber from an annular flange that is secured to the notch section of the outer housing by the deformation resistance weld, wherein a surface of the annular flange of divider plate that generally faces the first chamber and an inner surface of the notch section that generally faces the second chamber define respective joining surfaces that are abutted against one another when the deformation resistance weld is formed, and wherein the second electrode has an opening configured to receive the centrally protruding portion of the dividing plate therein and is disposed within the first chamber of the outer housing when the divider plate is joined to the outer housing.

5. The inflation device of claim 1 , wherein the divider plate is positioned in a desired location relative to the outer housing utilizing at least one of the first and second electrodes when the deformation resistance weld is formed.

6. The inflator of claim 1 , further comprising an end plate joined to the second chamber at a second end of the outer housing, the end plate being configured with a fill passageway for allowing inflation gas to pass into the second chamber.

7. The inflator of claim 6 , wherein the closure housing is in fluid communication with the inflatable cushion in a side airbag module, and wherein the closure housing is configured to supply inflation gas to the inflatable cushion.

8. An inflator for inflating an inflatable cushion of an airbag module, the inflator comprising:

an outer housing;

a divider plate secured within the outer housing to define a first chamber and a second chamber of the outer housing, the divider plate having an orifice disposed therein, the orifice providing fluid communication between the first chamber and the second chamber, the divider plate being joined to the outer housing by a weldment disposed between the outer housing and the divider plate; and

a closure assembly configured to seal the first chamber at a first end of the outer housing, the closure assembly having a closure housing and an outlet plate disposed within the closure housing, the outlet plate having an outlet opening configured to receive a burst disk, the outlet plate being joined to the closure housing by a second weldment disposed between the closure housing and the outlet plate,

wherein the outer housing is joined to the outlet plate remote from the closure housing at the first end of the outer housing, and

wherein the first chamber has a first volume of compressed inflation gas and the second chamber has a second volume of compressed inflation gas, the second volume being smaller than the first volume, the second chamber being configured to route compressed inflation gas therein to the first chamber through the orifice of the divider plate.