An airbag cushion is manufactured with a rear fabric panel and two front fabric panels. Each front fabric panel has a projecting tether portion to be sewn to an inner face of the rear fabric panel. The front fabric panels are, firstly, superimposed on each other. A back first end of the projecting tether portion is sewn to a part of a periphery of the front fabric panel, to form a second stitch portion in a recessed shape. A front second end of the tether portion is then sewn to the inner face of the rear fabric panel. A periphery of the rear fabric panel is, in addition, sewn to a periphery of the front fabric panel corresponding to the periphery of the rear fabric panel, to form a third stitch portion.

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Patent
   RE46909
Priority
Sep 22 2006
Filed
Mar 18 2013
Issued
Jun 26 2018
Expiry
Sep 11 2027
Inventors
Tabushi, H…
Assg.orig
Autoliv De…
Assg.curr
Autoliv De…
Entity
Large
Referenced by
0
References
47
Maint.:
all paid
DESCRIPTION OF THE P…
First Embodiment
Second Embodiment
Third Embodiment
Fourth Embodiment
Fifth Embodiment
7. An airbag cushion, comprising:
a first front fabric panel portion;
a second front fabric panel portion;
a rear fabric panel;
a recessed stitch portion where the first front fabric panel portion is sewn to the second front fabric panel portion;
a first peripheral stitch portion where a part of a periphery of the first front fabric panel, a periphery of the second front fabric panel, portion and a part of a periphery of the rear fabric panel are sewn;
a second peripheral stitch portion where a part of a periphery of the second front fabric panel portion and a part of a periphery of the rear fabric panel are sewn;
a first tether portion that joins the recessed stitch portion to an a first inner face of the rear fabric panel; and
a second tether portion that joins the recessed stitch portion to an a second inner face of the rear fabric panel that is different than the first inner face, wherein the first and second inner faces of the rear fabric panel oppose one another.
1. A manufacturing method of manufacturing an airbag cushion, comprising the steps of:
superimposing a first front fabric panel of the airbag cushion on a second front fabric panel of the airbag cushion, wherein the first front fabric panel protrudes a first tether portion protrudes from the first front fabric panel and the second front fabric panel protrudes a second tether portion protrudes from the second front fabric panel;
sewing a part of a periphery of the superimposed first and second front fabric panels;
sewing a back first end of the first tether portion and directly to a back first end of the second tether portion together;
sewing a front second end of the first tether portion to an a first inner face of a rear fabric panel of the airbag cushion;
sewing a front second end of the second tether portion to an a second inner face of the rear fabric panel;
sewing a part of a periphery of the rear fabric panel to a part of a periphery of the first front fabric panel; and
sewing a part of a periphery of the rear fabric panel to a part of a periphery of the second front fabric panel.
0. 35. A method of manufacturing an airbag cushion, comprising the steps of:
superimposing a first front fabric panel of the airbag cushion on a second front fabric panel of the airbag cushion, wherein a first tether portion protrudes from the first front fabric panel and a second tether portion protrudes from the second front fabric panel;
sewing a part of a periphery of the superimposed first and second front fabric panels;
sewing a first end of the first tether portion to a first end of the second tether portion;
sewing a second end of the first tether portion to a first inner face of a rear fabric panel of the airbag cushion;
sewing a second end of the second tether portion to a second inner face of the rear fabric panel;
sewing a part of a periphery of the rear fabric panel to a part of a periphery of the first front fabric panel; and
sewing a part of a periphery of the rear fabric panel to a part of a periphery of the second front fabric panel, wherein:
the second inner face of the rear fabric panel is different than the first inner face of the rear fabric panel; and
the first and second inner faces oppose one another.
0. 24. An airbag cushion comprising:
a rear fabric panel and at least one front fabric panel sewn together, the rear fabric panel including a left lateral side, a right lateral side, and a rear side, the left and right lateral sides extending from the rear side toward the at least one front fabric panel;
a peripheral stitch portion where a part of a periphery of the rear fabric panel and a part of a periphery of the at least one front fabric panel corresponding to the part of the periphery of the rear fabric panel are sewn; and
two tether portions that project from the at least one front fabric panel and are sewn to the rear fabric panel, wherein:
the two tether portions each include a first end that is joined to the at least one front fabric panel and a second end that is stitched to the rear fabric panel;
the second end of one of the tether portions is sewn to an inner face of the right lateral side of the rear fabric panel, and the second end of the other one of the tether portions is sewn to an inner face of the left lateral side of the rear fabric panel; and
the first end of one of the tether portions is sewn directly to the first end of the other one of the tether portions.
0. 34. An airbag cushion comprising:
a rear fabric panel and at least one front fabric panel sewn together, the rear fabric panel including a left lateral side, a right lateral side, and a rear side, the left and right lateral sides extending from the rear side toward the at least one front fabric panel;
a peripheral stitch portion where a part of a periphery of the rear fabric panel and a part of a periphery of the at least one front fabric panel corresponding to the part of the periphery of the rear fabric panel are sewn; and
two tether portions that project from the at least one front fabric panel and are sewn to the rear fabric panel, wherein:
the two tether portions each include a first end that is joined to the at least one front fabric panel and a second end that is stitched to the rear fabric panel;
the second end of one of the tether portions is sewn to an inner face of the right lateral side of the rear fabric panel, and the second end of the other one of the tether portions is sewn to an inner face of the left lateral side of the rear fabric panel; and
at least one of the tether portions and at least a portion of the at least one front fabric panel are defined by a continuous fabric member.
0. 37. An airbag cushion, comprising:
a first front fabric panel portion;
a second front fabric panel portion;
a rear fabric panel;
a recessed stitch portion where the first front fabric panel portion is sewn to the second front fabric panel portion;
a first peripheral stitch portion where a part of a periphery of the first front fabric panel portion and a part of a periphery of the rear fabric panel are sewn;
a second peripheral stitch portion where a part of a periphery of the second front fabric panel portion and a part of a periphery of the rear fabric panel are sewn;
a first tether portion that joins the recessed stitch portion to a first inner face of the rear fabric panel; and
a second tether portion that joins the recessed stitch portion to a second inner face of the rear fabric panel that is different than the first inner face, wherein:
the rear fabric panel includes a left lateral side, a right lateral side, and a rear side;
the left lateral side extends from the rear side toward one of the first and second front fabric panel portions;
the right lateral side extends from the rear side toward the other one of the first and second front fabric panel portions;
the first inner face of the rear fabric panel is disposed on one of the left and right lateral sides of the rear fabric panel; and
the second inner face of the rear fabric panel is disposed on the other one of the left and right lateral sides of the rear fabric panel.
0. 36. A method of manufacturing an airbag cushion, comprising the steps of:
superimposing a first front fabric panel of the airbag cushion on a second front fabric panel of the airbag cushion, wherein a first tether portion protrudes from the first front fabric panel and a second tether portion protrudes from the second front fabric panel;
sewing a part of a periphery of the superimposed first and second front fabric panels;
sewing a first end of the first tether portion to a first end of the second tether portion;
sewing a second end of the first tether portion to a first inner face of a rear fabric panel of the airbag cushion;
sewing a second end of the second tether portion to a second inner face of the rear fabric panel;
sewing a part of a periphery of the rear fabric panel to a part of a periphery of the first front fabric panel; and
sewing a part of a periphery of the rear fabric panel to a part of a periphery of the second front fabric panel, wherein:
the second inner face of the rear fabric panel is different than the first inner face of the rear fabric panel;
the rear fabric panel includes a left lateral side, a right lateral side, and a rear side;
the left lateral side extends from the rear side toward one of the first and second front fabric panels;
the right lateral side extends from the rear side toward the other one of the first and second front fabric panels;
the first inner face of the rear fabric panel is disposed on one of the left and right lateral sides of the rear fabric panel; and
the second inner face of the rear fabric panel is disposed on the other one of the left and right lateral sides of the rear fabric panel.
0. 38. An airbag cushion comprising:
a rear fabric panel and at least one front fabric panel sewn together, the rear fabric panel including a left lateral side, a right lateral side, and a rear side, the left and right lateral sides extending from the rear side toward the at least one front fabric panel;
a peripheral stitch portion where a part of a periphery of the rear fabric panel and a part of a periphery of the at least one front fabric panel corresponding to the part of the periphery of the rear fabric panel are sewn; and
two tether portions that project from the at least one front fabric panel and are sewn to the rear fabric panel, wherein:
the two tether portions each include a first end that is joined to the at least one front fabric panel and a second end that is stitched to the rear fabric panel;
the second end of one of the tether portions is sewn to an inner face of the right lateral side of the rear fabric panel, and the second end of the other one of the tether portions is sewn to an inner face of the left lateral side of the rear fabric panel;
the rear fabric panel includes a left rear portion, a right rear portion, and an inflator connection portion;
the left rear portion and the right rear portion are joined together along a folding line;
the inflator connection portion is joined to the left and right rear portions and projects from the left and right rear portions along the folding line; and
the inflator connection portion has longitudinal sides that each include at least one of a first side portion that is substantially parallel to the folding line and a second side portion that tapers inward toward the folding line as the inflator connection portion projects from the left and right rear portions.
2. A manufacturing method of manufacturing an airbag cushion according to claim 1, further comprising the steps of:
sewing a part of the first front fabric panel to the back first end of the first tether portion; and
sewing a part of the second front fabric panel to the back first end of the second tether portion.
3. A manufacturing method of manufacturing an airbag cushion according to claim 1, further comprising a step of:
superimposing the back first end of the first tether portion, the back first end of the second tether portion, and a part portions of the superimposed first and second front fabric panels.
4. A manufacturing method of manufacturing an airbag cushion according to claim 1, wherein:
the first tether portion is a part of and the first front fabric panel are defined by a first continuous fabric member; and
the second tether portion is a part of and the second front fabric panel are defined by a second continuous fabric member.
5. A manufacturing method of manufacturing an airbag cushion according to claim 1, further comprising the steps of:
cutting an end of the first front fabric panel; and
cutting an end of the second front fabric panel.
6. A manufacturing method of manufacturing an airbag cushion according to claim 1, further comprising a step of:
adjusting setting a depth of a recessed portion formed by sewing the back first end of the first tether portion, the back first end of the second tether portion, and the part of a periphery of the superimposed first and second front fabric panels.
8. An airbag cushion according to claim 7, wherein:
the first front fabric panel portion and the second front fabric panel portion are parts of one front fabric panel; and
the recessed stitch portion is first and second front fabric panel portions are formed by folding the one front fabric panel along a fold line.
9. An airbag cushion according to claim 7, wherein
the recessed stitch portion is formed in a recessed shape by sewing a part of a periphery of the first front fabric panel portion to a part of a periphery of the second front fabric panel portion.
10. An airbag cushion according to claim 7, wherein:
a front second end of the first tether portion is sewn to the first inner face of the rear fabric panel and a back first end of the first tether portion is sewn to the first front fabric panel portion; and
a front second end of the second tether portion is sewn to the second inner face of the rear fabric panel and a back first end of the second tether portion is sewn to the second front fabric panel portion.
11. An airbag cushion according to claim 7, wherein:
the first tether portion is a part of and the first front fabric panel portion are defined by a first continuous fabric member, and the first tether portion projects from the recessed stitch portion;
the second tether portion is a part of and the second front fabric panel portion are defined by a second continuous fabric member, and the second tether portion projects from the recessed stitch portion; and
the recessed stitch portion is positioned at a back first end of the first tether portion and at a back first end of the second tether portion.
12. An airbag cushion according to claim 7, wherein:
the first tether portion is a separate structure from the first front fabric panel portion and arranged to project projects from the recessed stitch portion; and
the second tether portion is a separate structure from the second front fabric panel portion and arranged to project projects from the recessed stitch portion.
13. An airbag cushion according to claim 7, wherein:
the first tether portion is a separate structure from the first front fabric panel portion and arranged to project projects from a vicinity of the recessed stitch portion; and
the second tether portion is a separate structure from the second front fabric panel portion and arranged to project projects from a vicinity of the recessed stitch portion.
14. An airbag cushion according to claim 7, wherein
the recessed stitch portion is sewn formed by sewing on a back first end of the first tether portion, on a back first end of the second tether portion, on a part of periphery of the first front fabric panel portion with a an exception of the first peripheral stitch portion, and on a part of periphery of the second front fabric panel portion with a an exception of the second peripheral stitch portion.
15. An airbag cushion according to claim 8, wherein
the recessed stitch portion is sewn on a back end of the first tether portion, on a back end of the second tether portion, formed by sewing on a part of periphery of the first front fabric panel portion with a an exception of the first peripheral stitch portion, and on a part of periphery of the second front fabric panel portion with a an exception of the second peripheral stitch portion.
16. An airbag cushion according to claim 9, wherein
the recessed stitch portion is sewn formed by sewing on a back first end of the first tether portion, on a back first end of the second tether portion, on a part of periphery of the first front fabric panel portion with a an exception of the first peripheral stitch portion, and on a part of periphery of the second front fabric panel portion with a an exception of the second peripheral stitch portion.
17. An airbag cushion according to claim 10, wherein
the recessed stitch portion is sewn formed by sewing on a back first end of the first tether portion, on a back first end of the second tether portion, on a part of periphery of the first front fabric panel portion with a an exception of the first peripheral stitch portion, and on a part of periphery of the second front fabric panel portion with a an exception of the second peripheral stitch portion.
18. An airbag cushion according to claim 11, wherein
the recessed stitch portion is sewn formed by sewing on a back first end of the first tether portion, on a back first end of the second tether portion, on a part of periphery of the first front fabric panel portion with a an exception of the first peripheral stitch portion, and on a part of periphery of the second front fabric panel portion with a an exception of the second peripheral stitch portion.
19. An airbag cushion according to claim 12, wherein
the recessed stitch portion is sewn formed by sewing on a back first end of the first tether portion, on a back first end of the second tether portion, on a part of periphery of the first front fabric panel portion with a an exception of the first peripheral stitch portion, and on a part of periphery of the second front fabric panel portion with a an exception of the second peripheral stitch portion.
20. An airbag cushion according to claim 13, wherein
the recessed stitch portion is sewn formed by sewing on a back end of the first tether portion, on a back end of the second tether portion, on a part of periphery of the first front fabric panel portion with a an exception of the first peripheral stitch portion, and on a part of periphery of the second front fabric panel portion with a an exception of the second peripheral stitch portion.
0. 21. An airbag cushion according to claim 7, wherein:
the first front fabric panel portion and the first tether portion are defined by a first continuous fabric member;
the second front fabric panel portion and the second tether portion are defined by a second continuous fabric member; and
the first continuous fabric member is sewn to the second continuous fabric member at locations where the first and second front fabric panel portions intersect the first and second tether portions, respectively, to form the recessed stitch portion.
0. 22. An airbag cushion according to claim 7, wherein:
the first tether portion has a first end that is joined to the first front fabric panel portion and a second end that is sewn to the first inner face of the rear fabric panel;
the second tether portion has a first end that is joined to the second front fabric panel portion and a second end that is sewn to the second inner face of the rear fabric panel; and
the first end of the first tether portion is sewn directly to the first end of the second tether portion.
0. 23. An airbag cushion according to claim 8, wherein the recessed stitch portion is formed by stitching along guide marks on the first and second front fabric panel portions that are substantially parallel to and spaced apart from the fold line.
0. 25. An airbag cushion according to claim 24, wherein
the second end of the one of the tether portions is sewn to a substantial midpoint of the inner face of the right lateral side of the rear fabric panel in an orthogonal direction to a folding line between the left and right lateral sides of the rear fabric panel, and the second end of the other one of the tether portions is sewn to a substantial midpoint of the inner face of the left lateral side of the rear fabric panel in an orthogonal direction to the folding line.
0. 26. An airbag cushion according to claim 25, wherein a guide mark for sewing is printed at the substantial midpoint of the inner face of the right lateral side of the rear fabric panel to which the one of the tether portions is sewn, and at the substantial midpoint of the inner face of the left lateral side to which the other one of the tether portions is sewn.
0. 27. An airbag cushion according to claim 24, wherein the tether portions are separate structures from the at least one front fabric panel.
0. 28. An airbag cushion according to claim 27, wherein the tether portions are attached to the at least one front fabric panel via stitching.
0. 29. An airbag cushion according to claim 24, wherein the tether portions are formed from the same material as the at least one front fabric panel.
0. 30. An airbag cushion according to claim 24, wherein the tether portions are formed from a different material than the at least one front fabric panel.
0. 31. An airbag cushion according to claim 24, wherein the two tether portions are joined to one another at an intersection between the at least one front fabric panel and the two tether portions.
0. 32. An airbag cushion according to claim 24, wherein the two tether portions are joined directly to the at least one front fabric panel.
0. 33. An airbag cushion according to claim 24, wherein a first continuous fabric member defines a first front fabric panel of the at least one front fabric panel and a first tether portion of the two tether portions, and a second continuous fabric member defines a second front fabric panel of the at least one front fabric panel and a second tether portion of the two tether portions.
0. 39. An airbag cushion according to claim 38, wherein the longitudinal sides of the inflator connection portion each include both of the first and second side portions.
0. 40. An airbag cushion according to claim 38, wherein the left and right rear portions have lower peripheries that are stitched to portions of the longitudinal sides of the inflator connection portion and that are substantially perpendicular to the folding line.
rightBack First end of tether portion
  • 20 Front Fabric Panel
  • 30 Rear Fabric Panel
  • 31L Left Rear Portion
  • 31R Right Rear Portion
  • 32 Inflator Connection Portion
  • 33 Inflator Inlet
  • 34 Fourth Guide Mark
  • 133 Arc-Shaped Peripheral Portion
  • 134 L-Shaped Peripheral Portion
  • 141 First Stitch Portion
  • 151 Second Stitch Portion (Recessed Stitch Portion)
  • 161 Third Stitch Portion (Peripheral Stitch Portion)
  • 341 Fourth Stitch Portion

    • DESCRIPTION OF THE PREFERRED EMBODIMENTS
    First Embodiment

    Hereunder, embodiments of the present invention will be described referring to the drawings. An airbag cushion according to the present invention is manufactured with two front fabric panels and a rear fabric panel. FIG. 1 is a plan view showing a shape of the front fabric panel. In FIG. FIGS. 1 and 3, a numeral numerals 10 designates and 20 designate the front fabric panel panels. The front fabric panel 10 is made from a cloth woven with a nylon fiber, and is cut to make the plan view of the front fabric panel into an ocarina-like shape. The front fabric panel 10 is configured with a head portion 13 that is a substantial semi-elliptic shape, a tether portion 11 that is projecting in an opposite direction to the head portion 13, and an intermediate portion 12 that is a rectangular shape to join the head portion 13 and the tether portion 11. The front fabric panel 10 is formed in a similar shape to the other front fabric panel 20 (Ref. FIG. 3).

    The tether portion 11 is a rectangular shape. Further, the tether portion 11 is longitudinally printed, at the side, first guide marks 14, 14, . . . that are indicated by void circles are longitudinally printed at the side of the tether portion 11. As it will be described later, a longer side of the tether portion 11 is sewn to an inner face of the rear fabric panel, to prevent the rear fabric panel from moving away from the front fabric panel 10 beyond a predetermined distance when the airbag cushion is inflated and deployed. The first guide marks 14, 14, . . . are used to sew the tether portion 11 to the inner face of the rear fabric panel in a proper alignment. Further, the tether portion 11 has a back first end 160 that is linear, at another side opposite to the side printed on which the first guide marks 14, 14, . . . are printed. As it will be described later, second guide marks 15, 15, . . . are printed on the back first end 160. It should be noted that this embodiment is explained with the printed first guide marks 14, 14, . . . for ease of illustration. Thus However, in various embodiments, the first guide marks 14, 14, . . . may not be printed for visualization. Also, it should be noted that the tether portion 11 may be another suitable shape, although this embodiment is explained with the tether portion 11 of a rectangular shape. For example, the tether portion 11 may be such a trapezoidal shape that the side printed with the first guide marks 14, 14, . . . is shorter than the opposite side formed with the back first end 160.

    The intermediate portion 12 is a rectangular shape, and is joined to the back first end 160 of the tether portion 11 at the side and to the head portion 13 at other side opposite to the back first end 160. The joining of intermediate portion 12 to the head portion 13 is at an upper position than relative to a center position of the substantial semi-elliptic-shaped head portion 13. The periphery of the head portion 13 and the intermediate portion 12 is configured from an arc-shaped peripheral portion 133 that is sewn to a periphery of the rear fabric panel and substantial L-shaped peripheral portions 134, 134 where the front fabric panel 10 is sewn to the front fabric panel 20.

    The front fabric panel 10 has the second guide marks 15, 15, . . . printed along the L-shaped peripheral portions 134, 134, and the linear back first end 160, while the second guide marks 15, 15, . . . are used to sew the front fabric panel 10 to the front fabric panel 20 in a proper alignment. Each of the second guide marks 15, 15, . . . , indicated by a panel rectangle, is used to sew the front fabric panel 10 to the front fabric panel 20 and thereby form the front fabric panels 10, 20 in a recessed shape in the plan view. A recessed direction of the each second guide mark 15 of the front fabric panels 10, 20 is the same as a projecting direction of the tether portion 11. Furthermore, the front fabric panel 10 has third guide marks 16, 16, . . . , which are indicated by void triangles, printed along the arc-shaped peripheral portion 133 of the head portion 13.

    The third guide marks 16, 16, . . . are used to sew the rear fabric panel to the arc-shaped peripheral portion 133 of the front fabric panel 10 in a proper alignment, while being different from the second guide marks 15, 15, . . . that are used to sew the front fabric panel 10 to the front fabric panel 20 in a proper alignment.

    FIG. 2 is a plan view showing a shape of the rear fabric panel. In FIG. 2, a numeral 30 designates the rear fabric panel whose silhouette looks like an elephant with the ears, the nose, and the head. The rear fabric panel 30 is made from a cloth woven with a nylon fiber, as well as the front fabric panel 10. While having a folding line indicated by dash-dot lines at the center, the rear fabric panel 30 includes a left rear portion or left lateral side 31L and, a right rear portion or right lateral side 31R, and a rear or back side 31B, with the left and right rear portions 31L and 31R extending from the back side 31B toward the front fabric panels 20 and 10, respectively. In addition, the rear fabric panel 30 includes an inflator connection portion 32 projecting downward along the folding line, and is symmetrical with respect to the folding line. The inflator connection portion 32 has a first longitudinal side 32L, a second longitudinal side 32R, and an inflator inlet 33 at the upper center. Each of the first and second longitudinal sides 32L and 32R includes a first side portion 32F that is substantially parallel to the folding line and a second side portion 32S that tapers inward toward the folding line as the inflator connection portion 32 projects from the left and right rear portions 31L and 31R. The inflator inlet 33 is formed in a circular shape by cutting. Through the inflator inlet 33, gas from a gas generator (not shown) is injected into the airbag cushion when the airbag cushion is deployed.

    The rear fabric panel 30 has fourth guide marks 34, 34, . . . , which are indicated by void diamond shapes, printed along a periphery of the inflator connection portion 32 and lower peripheries of the left rear portion 31L and the right rear portion 31R. As shown in FIG. 2, the lower peripheries of the left and right rear portions 31L and 31R are substantially perpendicular to the folding line. The fourth guide marks 34, 34, . . . are used to sew one longitudinal side of the inflator connection portion 32 to the lower periphery of the left rear portion 31L and the other longitudinal side of the inflator connection portion 32 to the lower periphery of the right rear portion 31R, in a proper alignment. The fourth guide marks 34, 34, . . . for the one longitudinal side of the inflator connection portion 32 is are printed symmetrically with respect to other fourth guide marks 34, 34, . . . for the other longitudinal side of the inflator connection portion 32.

    An arc-shaped peripheral portion 133a of the left rear portion 31L corresponds to the arc-shaped peripheral portion 133 of the front fabric panel 10. The left rear portion 31L has the third guide marks 16, 16, . . . , which are indicated by void triangles, printed along the peripheral portion with exception of the portion where the fourth guide marks 34, 34, . . . are printed. Further, the left rear portion 31L has the first guide marks 14, 14, . . . , which are indicated by the void circles, printed at in a row extending through the substantial center or substantial midpoint of the left rear portion 31L in an orthogonal direction to the folding line. The first guide marks 14, 14, . . . on the inner face of the left rear portion 31L correspond to the first guide marks 14, 14, . . . printed along one side (front second end) of the projecting tether portion 11 opposite from the front fabric panel 10, as shown in FIG. 1. The right rear portion 31R has the first guide marks 14, 14, . . . , the third guide marks 16, 16, . . . and the fourth guide marks 34, 34, . . . that are printed at the symmetrical positions with those on the left rear portion 31L, respectively. It should be noted that this embodiment is explained with the first guide marks 14, 14, . . . , the second guide marks 15, 15, . . . , the third guide marks 16, 16, . . . , and the fourth guide marks 34, 34, . . . printed on the front fabric panels 10, 20 or the rear fabric panel 30, for ease of illustration. As described above, in various embodiments, the first guide marks 14, 14, . . . , the second guide marks 15, 15, . . . , the third guide marks 16, 16, . . . , and the fourth guide marks 34, 34, . . . may not be printed for visualization.

    It will be described about the processing to manufacture the airbag cushion with the two front fabric panels 10, 20 and the rear fabric panel 30. Firstly, a processing will be described to sew together the front fabric panels 10, 20. FIG. 3 is a plan view showing a state where the two front fabric panels 10, 20 are sewn together. The front fabric panel 10 is superimposed on the front fabric panel 20 to keep the conformity in positions of the peripheral portions, as the front fabric panel 10 is substantially the same shape as the front fabric panel 20. The front fabric panel 10 and the front fabric panel 20 are then sewn together along the second guide marks 15, 15, . . . , to form second stitch portions (recessed stitch portion) 151, 151, . . . in a recessed shape which are indicated by solid rectangles. The second stitch portions 151, 151, . . . are formed along the L-shaped peripheral portions 134, 134, and the linear back first end 160, as well as the second guide marks 15, 15, . . . , to make form the front fabric panels 10, 20 in a recessed shape. Therefore, a space is the front fabric panels 10, 20 are formed in a recessed shape by sewing together the front fabric panel 10 and the front fabric panel 20. It is possible for the space to catch the head or sternum of the occupant when the airbag cushion is inflated and deployed.

    Next, another processing will be described to sew the rear fabric panel 30. FIG. 4 is a schematic perspective view showing the rear fabric panel 30 folded along the folding line. The rear fabric panel 30 shown in FIG. 2 is folded along the folding line in a direction from the sheet face toward the viewer about the folding line, to superimpose the right rear portion 31R on the left rear portion 31L. The inflator connection portion 32 and the inflator inlet 33 are also folded in the same direction (from the sheet face toward the viewer) along the folding line. As the inflator connection portion 32 is folded in a direction indicated by an arrow, the fourth guide marks 34, 34, . . . at one of the longitudinal sides of the inflator connection portion 32 are superimposed on the fourth guide marks 34, 34, . . . on the right panel 31R to sew together. Thus, fourth stitch portions 341, 341, . . . are formed, which are indicated by solid diamond shapes, by sewing the fourth guide marks 34, 34, . . . of the inflator connection portion 32 and the right panel 31R. The inflator connection portion 32 is then sewn up in the areas 321, 321 of the shorter front second end. Therefore, in a side view of the rear fabric panel 30, the inflator inlet 33 is arranged in a semicircular shape at a bottom of the rear fabric panel 30 and is opened toward outside of the rear fabric panel 30.

    Finally, another processing will be described to sew the two front fabric panels 10, 20 and the rear fabric panel 30. FIG. 5 is a schematic perspective view showing the right rear portion 31R sewn to the front fabric panel 10. The front fabric panel 10 and the front fabric panel 20 are inserted from the tether portion portions 11 into the inwardly folded rear fabric panel 30, while the second stitch portions 151, 151, . . . keep the front fabric panel 10 and the front fabric panel 20 to be sewn together. The first guide marks 14, 14, . . . along one side of the tether portion 11 projecting from the front fabric panel 10 are superimposed on the first guide marks 14, 14, . . . printed on the inner face of the right rear portion 31R, to sew up together. Thus, first stitch portions 141, 141, . . . are formed, which are indicated by solid circles, by sewing the first guide marks 14, 14, . . . of the tether portion 11 and the right panel 31R. Therefore, it is possible for the first stitch portions 141, 141, . . . to prevent the front fabric panel 10 from moving away from the right panel 31R beyond a predetermined width.

    Next, the front fabric panel 10 is folded to conform the its own arc-shaped peripheral portion 133 to the arc-shaped peripheral portion 133a of the right rear portion 31R. The third guide marks 16, 16, . . . of the front fabric panel 10 are then superimposed on the third guide marks 16, 16, . . . of the right rear portion 31R, to sew up together. Thus, third stitch portions (peripheral stitch portions) 161, 161, . . . are formed, which are indicated by solid triangles, by sewing the third guide marks 16, 16, . . . of the front fabric panel 10 and the right panel 31R. In the similar manner, the first guide marks 14, 14, . . . of the front fabric panel 20 are superimposed on the first guide marks 14, 14, . . . of the left rear portion 31L, to sew up together. Thus, other first stitch portions 141, 141, . . . (not shown) are formed by sewing the first guide marks 14, 14, . . . of the front fabric panel 20 and the left rear portion 31L. Further, the third guide marks 16, 16, . . . printed on the front fabric panel 20 are then superimposed on the third guide marks 16, 16, . . . printed on the left rear portion 31L, to sew up together. Thus, other third stitch portions 161, 161, . . . (not shown) are formed by sewing the third guide marks 16, 16, . . . of the front fabric panel 20 and the left panel 31L. It should be noted that, in this embodiment, it is explained that the tether portion portions 11 is are sewn to the right rear portion 31R or the left rear portion 31L by forming the first stitch portions 141, 141 . . . before sewing the front fabric panel 10 and the right rear portion 31R or the front fabric panel 20 and the left rear portion 31L by forming the third stitch portions (peripheral stitch portion portions) 161, 161, . . . , for illustration. Thus, the airbag cushion may be manufactured by reverse processing. In other words, after sewing the front fabric panel 10 and the right rear portion 31R or the front fabric panel 20 and the left rear portion 31L by forming the third stitch portions (peripheral stitch portion portions) 161, 161, . . . , the tether portion portions 11 may be sewn to the right rear portion 31R or the left rear portion 31L by forming the first stitch portions 141, 141 . . . , and then the inflator connection portion 32 may be sewn to the left rear portion 31L and the right rear portion 31R to form the fourth stitch portions 341, 341, . . . . In short, the sequence of the sewing process may be modified as desired, according to the manufacturing condition.

    FIG. 6 is a schematic side view showing the airbag cushion equipped in the instrumental panel on an assistant driver side, in a deployed state; FIG. 7 is a schematic front view showing the airbag cushion in the deployed state; and FIG. 8 is a schematic cross-sectional view taken along a line VIII-VIII in FIG. 6. The airbag cushion, which is manufactured through the sewing processing described above, is folded in a predetermined shape and stored in an airbag cushion case 2. A gas supply pipe (not shown) of an inflator 3 is inserted to into the inflator inlet 33 shown in FIG. 5. The inflator 3 and the airbag cushion case 2 are equipped inside the instrumental panel 1 on the assistant driver side. In the case of inflating and deploying the airbag cushion because of collision or the like, the gas is supplied through the gas supply pipe (not shown) of the inflator 3, and then the supplied gas is injected into the airbag cushion through the inflator inlet 33. It should be noted that the inflator inlet 33 and the inflator connection portion 32 are not shown in FIG. 6 for abbreviation.

    The airbag cushion is inflated and deployed along the instrumental panel 1 and a front glass 4. The injected gas is loaded into a space defined by three stitch portions on the right rear portion 31R and and/or the front fabric panel 10: the second stitch portions 151, 151, . . . formed to make the front fabric panel 10 in a recessed shape, the first stitch portions 141, 141, . . . formed to prevent the front fabric panel 10 from moving away from the right rear portion 31R beyond a predetermined width, the third stitch portions 161, 161 . . . formed in to join the arc-shapes arc-shaped peripheral portion 133a of the right rear portion 31R to the arc-shaped peripheral portion 133 of the front fabric panel 10, and the fourth stitch portions 341, 341, . . . formed to join the inflator connection portion 32 to the right rear portion 31R. In the similar manner, the injected gas is loaded into a space defined by three stitch portions on the left rear portion 31L and and/or the front fabric panel 20: the second stitch portions 151, 151, . . . formed to make the front panel 20 a recessed shape, the first stitch portions 141, 141, . . . formed to prevent the front fabric panel 20 from moving away from the left rear portion 31L beyond a predetermined width, the third stitch portions 161, 161 . . . formed in to join the arc-shapesshaped peripheral portion 133a of the left rear portion 31L to the arc-shaped peripheral portion 133 of the front fabric panel 20, and the fourth stitch portions 341, 341, . . . formed to join the inflator connection portion 32 to the left rear portion 31L.

    Accordingly, as shown in FIG. 7, the airbag cushion is inflated and deployed with symmetry of the pattern in a symmetric shape, while directing the front fabric panel 10 and the front fabric panel 20 toward the occupant. Since the front fabric panel 10 and the front fabric panel 20 are sewn together via the second stitch portions 151, 151, . . . , the airbag cushion is prevented the front fabric panel 10 is prevented from moving away from the front fabric panel 20. In addition, the second stitch portions 151, 151, . . . are formed to make the front fabric panels 10, 20 in a recessed shape in side view. Accordingly, a recessed bag portion of the airbag is formed with by the intermediate portions 12, 12, while having the back end first ends 160 of the tether portion portions 11 as the end face form the bottom of the recessed portion. At the moment of inflation/deployment, the front fabric panel 10 and the front fabric panel 20 contact the shoulders or the costae of the occupant to absorb the impact. Moreover, the recessed bag catches the head or the chest to absorb the impact properly. The tether portion portions 11 configures a part are parts of the front fabric panel panels 10, 20. In other words, one of the tether portion portions 11 is a part of the front fabric panel 10, and the other one of the tether portions 11 is a part of the front fabric panel 20. In this regard, a first continuous fabric member may define the front fabric panel 10 and one of the tether portions 11, and a second continuous fabric member may define the front fabric panel 20 and the other one of the tether portions 11. Therefore, it is possible to manufacture the airbag cushion through a simplified processing, because of sewing the front end second ends of the tether portion portions 11 to the rear fabric panel.

    While the tether portions 11, 11 project from the front fabric panel 10 and the front fabric panel 20 away from the third stitch portions 161, 161, . . . , each one side (frontsecond end) of each of the tether portions 11, 11 is sewn at first stitch portions 141, 141, . . . on an inner face of (or disposed on) the left rear portion 31L or on an inner face of (or disposed on) the right rear portion 31R that is different than and opposes the inner face of the left rear portion 31L, as shown in FIGS. 6 and 8. Accordingly, it is possible to limit a spacing between the front fabric panel 10 and the right rear portion 31R, as well as a spacing between the front fabric panel 20 and the left rear portion 31L, within bounds corresponding to a spacing distance between the one side (frontsecond end) of each of the tether portion portions 11 defined by that is sewn at the first stitch portions 141, 141, . . . and the back first end 160 on the other side of each of the tether portion portions 11 defined by that is sewn at the second stitch portions 151, 151, . . . , at the moment of the inflation/deployment of the airbag cushion.

    It should be noted that, in this embodiment, it is explained to equip the airbag cushion inside the instrumental panel 1 on the assistant driver side, for illustration. For example, the airbag cushion may be equipped inside a steering wheel on a driver side, a back side of a front seat to protect an occupant on a rear seat, or a handle component of a motorcycle. Furthermore, it should be noted that this embodiment is explained to manufacture the airbag cushion with the rear fabric panel 30, the front fabric panel 10, the front fabric panel 20 and two tether portions 11, 11, for illustration. An additional fabric panel may be utilized to manufacture the airbag cushion as appropriate.

    Second Embodiment

    The first embodiment is explained to have the tether portion portions 11 that is are a part of the front fabric panel panels 10, 20. However, the tether portion portions 11 may be a separate structure from the front fabric panel panels 10, 20. FIG. FIGS. 9 is a and 10 are plan view views showing a shape of the front fabric panel panels 10a, 20a and the tether portion portions 11a according to a second embodiment. The front fabric panel panels 10a, 20a of the second embodiment is are shorter than the front fabric panel panels 10, 20 of the first embodiment by a size corresponding to the tether portion portions 11a, because the tether portion portions 11a of the second embodiment is a are separate structure structures from the front fabric panel panels 10a, 20a. The tether portion portions 11a is are formed in a rectangular shape, and made of the same material as that of the front fabric panel panels 10a, 20a or a composite material containing an elastic material such as a polyurethane fiber. On one of the tether portion portions 11a, the front fabric panel 10a is placed to arrange the back first end 160 of the tether portion 11a under the second guide marks 15 of the front fabric panel 10a. A configuration for the front fabric panel 20a is similar to the configuration for the front fabric panel 10a and, accordingly, will not be described in detail.

    FIG. 10 is a plan view showing a state where the front fabric panel 10a and one of the tether portion portions 11a, as well as the front fabric panel 20a and the other one of the tether portion portions 11a, are sewn up together. The tether portions 11a, 11a are inserted into a space between the front fabric panel 10a and the front fabric panel 20a. Thus, each tether portion 11a partially overlaps the front fabric panel 10a or the front fabric panel 20a. The back first ends 160, 160 of the tether portions 11a, 11a are sewn to the front fabric panels 10a, 20a along the second guide marks 15, 15, . . . , after confirming that the back first ends 160, 160 of the tether portions 11a, 11a are located between the second guide mark marks 15 of the front fabric panel 10a and the second guide mark marks 15 of the front fabric panel 20a. Thus, the second stitch portions (recessed stitch portion portions) 151, 151, . . . are formed to make a recessed shape, which are indicated by solid triangles, by sewing the back first ends 160, 160 of the tether portions 11a, 11a and the front fabric panels 10a, 20a together to make a recessed shape. In addition, the tether portions 11a, 11a may be joined to one another at an intersection between the front fabric panels 10a, 20a and the tether portions 11a, 11a, and the tether portions 11a, 11a may be joined directly to the front fabric panels 10a, 20a. It should be noted that this embodiment is explained to have the tether portion portions 11a which is are vertically long with a rectangular shape, for illustration. The tether portion portions 11a may be horizontally long with a rectangular shape. It is possible to improve design flexibility for the tether portion portions 11a which is are configured to be a separate structure structures from the front fabric panel panels 10a, 20a. For example, it is possible to modify the material of the tether portion portions 11a to an elastic material, as appropriate. Furthermore, it is possible to simplify the processing to manufacture the airbag cushion, for by sewing together the back first ends 160, 160 of the tether portions 11a, the front fabric panel 10a and the front fabric panel 20a along the second stitch portions 151, 151, . . . at a the same time.

    Some configurations and advantages of the second embodiment are described above. Other configurations that are the same as those of the first embodiment are given the identical numerals to the first embodiment and, accordingly, those other configurations and other advantages will not described in detail.

    Third Embodiment

    According to a third embodiment, the back end portion first ends 160 of the tether portion portions 11a may be sewn separately from the second stitch portions 151. FIG. 11 is a plan view showing a shape of the front fabric panel 10a and the tether portion portions 11a according to the third embodiment. The front fabric panel 10a and the tether portion portions 11a of the third embodiment are formed in the same shapes as those of the second embodiment. The tether portion portions 11a of the third embodiment is are further made of the same material as that of the second embodiment. On one of the tether portion portions 11a, the front fabric panel 10a is placed to arrange the back first end 160 of the tether portion 11a between a front second end of the front fabric panel 10a and the second guide marks 15, 15, . . . of the front fabric panel 10a. It should be noted that the tether portion 11a may be placed on the front fabric panel 10a.

    The back first end 160 of the tether portion 11a is then sewn to a portion between the front second end of the front fabric panel 10a and the second guide marks 15, 15, . . . . Thus, fifth stitch portions 111, 111, . . . are formed by sewing the back first end 160 and the front fabric panel 10a. Therefore, it is possible to join the back first end 160 of the tether portion 11a to the front fabric panel 10a which is a separate structure from the tether portion 11a. The front fabric panel 10a and the front fabric panel 20a are then sewn together, as shown with FIG. 3 in the first embodiment, to form second stitch portions (recessed stitch portion portions) 151, 151, . . . to make a recessed shape. In this configuration, the tether portion portions 11a projects project from a vicinity of the second stitch portions 151, 151, . . . . A configuration for the front fabric panel 20a is similar to the configuration for the front fabric panel 10a and, accordingly, will not be described in detail.

    Some configurations and advantages of the third embodiment are described above. Other configurations that are the same as those of the first and second embodiments are given the identical numerals to the first and second embodiments and, accordingly, those other configurations and other advantages will not described in detail.

    Fourth Embodiment

    According to a fourth embodiment, some portions of the front fabric panel panels 10, 20 may be cut some portions, in accordance with a design. FIG. 12 is a plan view showing a shape of a front fabric panel. The tether portion 11 protruding from front fabric panel 10 of the fourth embodiment protrudes is longer than the tether portion 11 than that of the first embodiment. The tether portion 11 is a rectangular shape that projecting direction is longer in the projecting direction. In accordance with a design parameter, such as a size, an inflation tolerance, an equipped position of the airbag and the like, the tether portion 11 is cut from a direction crossing to the projecting direction.

    The tether portion 11 may be cut from a direction crossing to the projecting direction, for example, at a position indicated by the dash line or the alternate long and short dash line in FIG. 12. If the tether portion 11 needs to be longer shorter, it is cut from a direction crossing to the projecting direction, at a position indicated by the dash line near nearer the head portion 13. If the tether portion 11 needs to be shorter longer, it is cut from a direction crossing to the projecting direction, at a position indicated by the alternate long and short dash line away further from the head portion 13. The front fabric panel 20 also has the tether portion 11 cut at a position to lead leave the same length as the tether portion 11 of the front fabric panel 10, although it is not shown. If the tether portion portions 11 needs need to be further longer, each of the front fabric panel panels 10, 20 protruding from which the tether portion portions 11 protrude is utilized without cutting. These configurations allow making each of the front fabric panels 10, 20 to have the tether portion portions with suitable length in accordance with a design.

    In addition, a shape of the recessed stitch portion 151 may be changed in accordance with a design. FIG. 13 is a plan view showing a state where two front fabric panels 10, 20 are sewn together. A depth of the recessed portion of the recessed stitch portion 151 also may be changed in accordance with a design. If the tether portion portions 11 needs need to be longer, the recessed stitch portion 151 may be sewn, for example, to have a shallower depth. On the other hand, if the tether portion portions 11 needs need to be shorter, the recessed stitch portion 151 may be sewn, for example, to have a deeper depth.

    FIG. 13 is an illustration for the recessed stitch portion 151 having a shallower depth. If the tether portion portions 11 needs need to be longer, the front fabric panel 10 may be sewn to the front fabric panel 20 at a position for shallower depth of the recessed portion, i.e. at a position near nearer the head portion portions 13, to form a second stitch portion (recessed stitch portion portions) 151 indicated by solid rectangle shapes. On the other hand, if the tether portion portions 11 needs to be shorter, the front fabric panel 10 may be sewn to the front fabric panel 20 at a position away further from the head portion portions 13 for deeper depth of the recessed portion, i.e. at the second guide marks 15 indicated by void rectangular shapes in FIG. 13. These configurations allow making each the front fabric panels 10, 20 have the tether portion portions with suitable length in accordance with a design.

    Some configurations and advantages of the forth embodiment are described above. Other configurations that are the same as those of the first, second and third embodiments are given the identical numerals to the first, second and third embodiments and, accordingly, those other configurations and other advantages will not described in detail.

    Fifth Embodiment

    According to a fifth embodiment, the airbag has one front fabric panel 10b. FIG. 14 is a plan view showing a shape of a front fabric panel according to the fifth embodiment. The front fabric panel 10b includes two head portions 13, 13 and two intermediate portions 12, 12 joining respectively to the two head portions 13, 13. The front fabric panel 10b is a symmetrical shape relative to a substantial center in the longitudinal direction indicated by the alternate long and short dash line. The intermediate portion portions 12 is are joined to the head portion portions 13, at an upper position than relative to a center position of the substantial semi-elliptic-shaped head portion portions 13. A periphery of the head portion portions 13 joined to the intermediate portion portions 12 includes the arc-shaped peripheral portions 133, 133, . . . that are sewn to a periphery of the rear fabric panel and the substantial L-shaped peripheral portions 134, 134, . . . that are sewn together after folding the front fabric panel 10b along a position or fold line indicated by the alternate long and short dash line.

    The front panel 10 is printed the second guide marks 15, 15, . . . indicated by alternate long and short dash line void rectangle shapes, are printed at some portions of the front panel 10b. The second guide marks 15, 15, . . . are used to sew after superimposing each of the head portions 13, 13 and each of the intermediate portions 12, 12 in a proper alignment by folding. For example, the second guide marks 15, 15, . . . are printed along the periphery of the front fabric panel 10b, as shown by the void rectangle shapes. The second guide marks 15, 15, . . . are printed at the intermediate portion 12 of the front fabric panel 10b, in a vertical direction crossing to the longitudinal direction of the front fabric panel 10b, too. To adjust the depth of the recessed portion, the front panel 10 may be printed plural lines of the second guide marks 15, 15, . . . extending in the vertical direction crossing to the longitudinal direction may be printed on the front panel 10b. It should be noted that this embodiment is explained to have two lines of the second guide marks 15, 15, . . . extending in the vertical direction crossing to the longitudinal direction, for illustration. Each of the two lines of the second guide marks 15, 15, . . . extending in the vertical direction are substantially parallel to and spaced apart from the fold line indicated by the alternate long and short dash line.

    If the recessed depth should be shallower, the front fabric panel 10b may be sewn along the second guide marks 15 near nearer the head portion portions 13 to form the recessed shape. On the other hand, if the recessed depth should be deeper, the front fabric panel 10b may be sewn along the second guide marks 15 away further from the head portion portions 13, near the center, to form the recessed shape. Along Printed along the arc-shaped peripheral portion portions 133 of the head portion portions 13, of the front fabric panel 10 is printed 10b are the third guide marks 16, 16, . . . that, which are indicated by void triangle shapes. The third guide marks 16, 16, . . . are used to sew the rear fabric panel 30 and the arc-shaped peripheral portions 133, 133 of the front fabric panel 10b in a proper alignment.

    FIG. 15 is a plan view showing a state where the front fabric panel 10b is sewn. The front fabric panel 10b is folded along the alternate long and short dash line. Respective head portions 13, 13, as well as respective intermediate portions 12, 12, are properly superimposed. Then, the front fabric panel 10b is sewn along one of the lines of the second guide mark marks 15 to form a second stitch portion portions (recessed stitch portion portions) 151 and thereby form the front fabric panel 10b in a recessed shape. In FIG. 15, the front fabric panel 10b is sewn along the second guide mark marks 15 positioned away further from the head portion portions 13, to make the recessed depth deeper.

    FIG. 16 is a plan view showing a state where the front fabric panel 10b and the tether portion portions 11a are sewn together. The back end first ends 160 of the tether portion portions 11a is are sewn to a portion of the front panel 10b for folding. This embodiment is explained to have the tether portion portions 11a that is configured from two rectangular tether portions 11a, 11a, for illustration. It should be noted that one rectangular tether portion may be utilized, for example, to fold by folding along the substantial center of the one rectangular tether portion in the same manner as the front fabric panel 10b, and to be sewn sewing the folded portion as the back end 160 of the one rectangular tether portion to a portion of the front fabric panel 10, in the same manner 10b just as the first ends 160 are sewn to the front fabric panel 10b.

    One back first end 160 of the tether portion portions 11a is put on the one surface of the front fabric panel 10b, and the other back first end 160 of the tether portion portions 11a is put on the reverse surface of the front fabric panel 10b. Firstly, the one back first end 160 of the tether portion portions 11a is then sewn. Secondly, the one surface and reverse surface of the front fabric are sewn. Finally, the other back first end 160 of the tether portion portions 11a is sewn. Therefore, it is configured a sewn component is made from the front fabric panel 10b and the tether portion portions 11a. How to sew the sewn component to the rear panel 30 is in the same manner as that of the first embodiment and, accordingly, will not have been described in detail.

    Some configurations and advantages of the fifth embodiment are described above. Other configurations that are the same as those of the first, second, third and forth fourth embodiments are given the identical numerals to the first, second, third and forth fourth embodiments and, accordingly, those other configurations and other advantages will not described in detail. The embodiments of the manufacturing method of airbag cushion and the airbag cushion described herein are only preferred illustrations of the present invention. Thus, various modifications may be made thereto. Unless otherwise specified to have restrictions in the description, the present invention is not limited and restricted by the shape, the size, the arrangement and the like of the figures. In addition, phrases and terms in the description are utilized for illustration. Thus, unless otherwise specified to have restrictions in the description, the present invention is not limited and restricted by the phrases and terms.

    As this invention may be embodied in several forms wihout departing from the spirit of essential characteristics thereof, the present embodiment is therefore illustrative and not restrictive, since the scope of the invention is defined by the appended claims rather than by the description preceding them, and all changes that fall within metes and bounds of the claims, or equivalence of such metes and bounds thereof are therefore intended to be embraced by the claims.

    INVENTORS:

    Tabushi, Hiroya, Idomoto, Takeshi

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