Manufacturing method of airbag cushion, and the airbag cushion

Abstract

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.

What is claimed is: 
     
       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. 
 
     
     
       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:
 adjustingsetting a depth of a recessed portion formed by sewing the backfirst end of the first tether portion, the backfirst end of the second tether portion, and the part of a periphery of the superimposed first and second front fabric panels. 
 
     
     
       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. 
 
     
     
       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. 
 
     
     
       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.    
     
     
       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.    
     
     
       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.  
     
     
       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.  
   
     
     
       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.    
     
     
       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.  
     
     
       27. An airbag cushion according to claim 24, wherein the tether portions are separate structures from the at least one front fabric panel.  
     
     
       28. An airbag cushion according to claim 27, wherein the tether portions are attached to the at least one front fabric panel via stitching.  
     
     
       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.  
     
     
       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.  
     
     
       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.  
     
     
       32. An airbag cushion according to claim 24, wherein the two tether portions are joined directly to the at least one front fabric panel.  
     
     
       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.  
     
     
       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.  
   
     
     
       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.  
   
     
     
       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.  
   
     
     
       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.  
   
     
     
       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.  
   
     
     
       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.  
     
     
       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.