Multi-purpose and tunable pressure chamber for pyrotechnic actuator
A pressurized gas-powered actuator includes a housing and a piston movably positioned within the housing. The piston has a drive pocket formed therein. A gas generator is positioned exterior of the piston and in fluid communication with the drive pocket.
1. A method of forming an actuator, the method comprising the steps of:
providing a hollow tube;
inserting at least one core within the tube so as to define an annular plenum between the tube and the core;
positioning a filler material within the annular plenum, thereby forming a sleeve of filler material defining a chamber therein; and
removing the core from the chamber.
2. The method of claim 1 further comprises the step of providing a drive pocket fluidly communicating with said chamber at a first end of the tube.
3. The method of claim 1 wherein said positioning step comprises the steps of:
providing a filler material comprising a polymeric melt;
inserting the polymeric melt within the annular plenum; and
cooling the polymeric melt to form a polymeric sleeve to define the chamber within the polymeric sleeve.
4. The method of claim 1 wherein said positioning step comprises the steps of:
providing a filler material comprising an uncured polymeric material;
inserting the uncured polymeric material within the annular plenum; and
curing the polymeric material to form a polymeric sleeve to define the chamber within the polymeric sleeve.
5. The method of claim 1 further comprises the step of:
providing an actuator housing;
positioning the hollow tube and sleeve of filler material within the housing; and
securing a gas generator within the housing so as to form a gas-tight seal between the gas generator and the housing, and such that the gas generator is in fluid communication with the chamber.
6. The method of claim 1 wherein the chamber extends from a first end of the housing to a second end of the housing opposite the first end.
7. The method of claim 6 wherein the chamber has a first portion with a first diameter and a second portion with a second diameter different from the first diameter.
8. The method of claim 6 wherein the chamber has a constant diameter along an entire length of the chamber.
9. The method of claim 1 wherein the at least one core comprises a first core having a first diameter and a second core having a second diameter, wherein the first diameter is larger than the second diameter.
10. The method of claim 2 wherein the drive pocket is incorporated into a drive pocket attachment formed as a part separate from the hollow tube or sleeve of filler material and attachable to the hollow tube or sleeve of filler material.
11. The method of claim 2 wherein the drive pocket is incorporated into a drive pocket attachment formed as a part separate from the chamber.
12. The method of claim 2 wherein a largest radially outermost dimension of the chamber is less than a largest radially outermost dimension of the drive pocket.
13. The method of claim 2 wherein a largest radially outermost dimension of the chamber is less than a largest radially outermost dimension of the drive pocket.
14. The method of claim 1 wherein the chamber is tapered along at least a portion of an axial length of the chamber.
15. The method of claim 5 further comprising a drive pocket interposed between the gas generator and the chamber.
16. The method of claim 1 wherein the hollow tube comprises a metal.
17. The method of claim 1 wherein said method further comprises the step of positioning a plug at a predetermined location within the sleeve of filler material so as to define a limit of an expansion cavity.