Process improves reliability of thin film igniters in safety devices
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Process improves reliability of thin film igniters in safety devices senting a potential market of $800 million A new process for fabricating the bridge to $1 billion for airbags igniters. Growth wire or thermal element within a pyroin the airbag igniter market will be driven technic igniter, which improves its reliby an increase in automobile production, ability, has been developed by Odyssian growing penetration of airbags into lowTechnology and Rose-Hulman Institute end automobile models, and rising deof Technology (RHIT). These igniters mand for new cars in developing nations. are used to trigger pyrotechnic devices The technology in automotive airbags so they inflate Traditional pyrotechnic igniters include quickly, in parachute safety devices, and metal filaments that can develop kinks by the military for initiating the chemical and other flaws during the manufacturing reaction that is the source of power for process. Such flaws can lead to uneven thermal batteries, which power missile heating of the filament resulting in igninavigation and control systems. tion failure. Manufactured flaws are difThe new process replaces convenficult to detect because the filaments are tional igniter filament bridge wire with so small (0.05 mm in diameter) and no thin film patterns of heat-generating mainspection process can test whether the terials. Such thin film patterns can be device will reliably ignite since igniting designed to ignite (and prevent ignition) a pyrotechnic igniter is an irreversible of various pyrotechnic powder formulaprocess. tions within specified time and energy The thin film igniter technology derequirements. When compared to conveloped by Odyssian Technology and ventional spot-welded bridge wire, thin RHIT eliminates problematic metal filfilm bridge patterns offer the advantages aments, which will provide lower cost of reducing cost, increasing reliability, and more reliable igniters than currently and improving design flexibility. available. Missile navigation systems Pyrotechnic igniters are used in both often rely upon the use of igniters to military and non-military products. Noninitiate a thermal battery that provides military applications include automothe necessary power. Unlike alkaline tive airbags, parachute release devices, batteries used in common consumer quick deploy flotation vests, precisely electronics, thermal batteries are inert, controlled demolition devices, and sosolid-state devices that do not use liquid phisticated firework displays. electrolytes that can corrode or leak from Military applications include use in their casings over time. Long shelf life missile navigation systems, smart weapand reliability make thermal batteries the ons, advanced antitank weapons, aircraft most common device to power missile ejection systems, and satellite thrusters navigation and control systems. and actuators. The military igniter business is estimated to be in excess of $100 million per year in the United States alone. According to market analysis conducted by Global Industry Analysts, Inc.
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