Overmolded body for pyrotechnic initiator and method of molding same

1. An automotive pyrotechnic initiator, comprising:

a) an initiator subassembly including a can loaded with a pyrotechnic charge, and a header assembly having an igniter wire and a connector end; and,

b) a molded, integral, unitary electrically-nonconductive overmoloed body connected to and surrounding substantially all of said initiator subassembly except for an exposed portion of said connector end, wherein said body provides structural support and installation orientation features.

2. The initiator of claim 1 , wherein said connector end of said header aooembly comprises two electrode pins.

3. The initiator of claim 2 , wherein said electrode pins project outwardly from said body.

4. The initiator of claim 3 , wherein one of said electrode pins is a ground pin and the other is an isolated electrode pin.

5. The initiator of claim 4 , wherein said body and said electrode pins together form a serviceable or non-serviceable integral automotive airbag initiator connector.

6. The initiator of claim 5 , wherein said header assembly is a glass-to-metal sealed header assembly.

7. The initiator of claim 6 , wherein said body is made of nylon.

8. The initiator of claim 1 , wherein said body is made of nylon.

9. The initiator of claim 1 , wherein said header assembly is a glass-to-metal sealed header assembly.

10. A method for making an automotive pyrotechnic initiator having an overmolded body, comprising the steps of:

a) providing an initiator subassembly including a can loaded with a pyrotechnic charge, and a header assembly having an igniter wire and a connector end; and,

b) molding an integral, unitary, electrically-nonconductive, nonconductive, overmolded body around said subassembly, such that said body is connected to and surrounds substantially all of said initiator subassembly except for an exposed portion of said connector end, wherein said body provides structural support and installation orientation features.

11. The method of claim 10 , wherein said step of providing includes providing an initiator subassembly wherein said connector end at said header assembly comprises two electrode pins.

12. The method of claim 11 , wherein said step of providing includes providing an initiator subassembly that includes a ground pin and an isolated electrode pin.

13. The method at claim 11 , wherein said step of molding includes molding said body such that an exposed portion of each of said electrode pins projects outwardly from said body.

14. The method of claim 11 , wherein said step of molding includes injecting molten material into a mold in which said initiator subassembly is placed.

15. The method of claim 14 , wherein said step of molding includes injecting molten material into said mold under pressure.

16. The method of claim 15 , wherein said step of providing includes providing an initiator subassembly wherein said can is tightly and substantially completely loaded with said pyrotechnic charge.

17. The method at claim 14 , wherein said step of providing includes providing an initiator subassembly having an upper region, and wherein said step of molding includes injecting said molten material at said upper region of said initiator subassembly, and allowing said molten material Lo flow downwardly a long said subassembly.

18. The method of claim 17 , wherein said step of molding includes injecting molten material into said mold under pressure.

19. The method of claim 17 , wherein said header assembly a glass-to-metal sealed header assembly.

20. The method at claim 10 , wherein said step of molding includes injecting molten nylon.