Multiple panel airbag and method

Abstract

An airbag cushion for use in a vehicle restraint system is provided. The airbag cushion is formed from a notched body panel and a front panel. The preferred construction reduces substantially the elongation of the air bag cushion upon impact or collision of the vehicle in which it is installed. A method of forming the cushion according to the present invention is also provided.

What is claimed is:  
     
         1 . A simplified airbag cushion for use in a vehicle restraint system, the cushion comprising: 
 a notched body panel and a front panel,    said notches of said body panel being seamed together along abutting edges thereof to fold said body panel and form a desired profile,    said body panel and said front panel being seamed together along corresponding boundary edges of said body panel and around the perimeter of said front panel thereby forming an inflatable structure.    
     
     
         2 . The cushion as recited in  claim 1 , wherein said front panel is substantially rectangular.  
     
     
         3 . The cushion as in  claim 2 , wherein said rectangular front panel is of an elongated rectangular geometry wherein said geometry has a length dimension greater than its width dimension.  
     
     
         4 . The cushion as recited in  claim 3 , wherein said length dimension is at least 30 percent greater than said width dimension.  
     
     
         5 . The cushion as recited in  claim 4 , wherein said length dimension is at least twice as great as said width dimension.  
     
     
         6 . The cushion as recited in  claim 1 , wherein said body panel and said front panel each comprise a woven fabric.  
     
     
         7 . The cushion as recited in  claim 6 , wherein the woven fabric which comprises said body panel exhibits permeability characteristics which differ from the fabric which comprises said front panel.  
     
     
         8 . The cushion as recited in  claim 6 , wherein the woven fabric which comprises said body panel section is an uncoated fabric and the woven fabric which comprises said front panel is a coated fabric.  
     
     
         9 . The cushion as recited in  claim 8 , wherein said coated fabric is coated with a disperse polymer, such as polyamide or urethane having a dry add on weight of not greater than about 0.4 ounces per square yard.  
     
     
         10 . The cushion as recited in  claim 6 , wherein the fabric which comprises at least one of said body panel and said front panel section is woven from a plurality of multifilament synthetic yarns.  
     
     
         11 . The cushion as recited in  claim 10 , wherein said multifilament synthetic yarns are characterized by a yarn linear density of about 840 denier or less.  
     
     
         12 . The cushion as recited in  claim 6 , wherein the woven fabric which comprises said body panel is uncoated, and the woven fabric which comprises said front panel is uncoated.  
     
     
         13 . The cushion as recited in  claim 6 , wherein the woven fabric which comprises said front panel is characterized by an air permeability of about 1-3 cubic feet per minute per square foot of fabric at a differential pressure of about 0.5 inches of water.  
     
     
         14 . The cushion as recited in  claim 1 , wherein said first and second notches are V-shaped and in intermediate boundary edges of said body panel.  
     
     
         15 . The cushion as recited in  claim 14 , wherein each of said first and second notches subtend an angle of about 90 degrees.  
     
     
         16 . The cushion as recited in  claim 1 , wherein said body panel comprises at least one panel section.  
     
     
         17 . The cushion as recited in  claim 1 , wherein said front panel is substantially square.  
     
     
         18 . The cushion as recited in  claim 1 , wherein said front panel has rounded corners.  
     
     
         19 . The cushion as recited in  claim 1 , wherein said front panel is one piece.  
     
     
         20 . The cushion as recited in  claim 1 , wherein said body panel is asymmetrical.  
     
     
         21 . The cushion as recited in  claim 1 , wherein said front panel is joined to said body panel by at least one straight seam.  
     
     
         22 . The cushion as recited in  claim 1 , wherein said front panel is joined to said body panel by one continuous seam.  
     
     
         23 . The cushion as recited in  claim 1 , wherein an inflator opening is located in said body panel.  
     
     
         24 . The cushion as recited in  claim 23 , wherein the apex of each notch is located substantially on the centerline of said inflator opening.  
     
     
         25 . The cushion as recited in  claim 1 , wherein said notches are of substantially equal size.  
     
     
         26 . In a vehicle restraint system, the improvement comprising the cushion of  claim 1 .  
     
     
         27 . In an airbag module, the improvement comprising the cushion of  claim 1 .  
     
     
         28 . An airbag cushion formed of panels as shown in at least one of FIGS.  20 - 29  of the drawings.  
     
     
         29 . In an airbag, the improvement comprising a notched body panel.  
     
     
         30 . A simplified airbag cushion for use in a vehicle restraint system, the cushion comprising: 
 a notched body panel and a front panel,    said notches of said body panel being seamed together along abutting edges thereof to fold said body panel and form a desired profile, and    said body panel and said front panel being seamed together along corresponding boundary edges of said body panel and around the perimeter of said front panel thereby forming an inflatable structure whereby said seamed notches prevent said body panel from uncontrollable expansion by at least about 30%.    
     
     
         31 . A simplified airbag cushion for use in a vehicle restraint system, the cushion comprising: 
 a notched body panel having notches in the sides thereof and an inflator opening;    a front panel;    said notches of said body panel being seamed together along abutting edges thereof to fold said body panel and form a desired profile, and    said body panel and said front panel being seamed together along corresponding boundary edges of said body panel and around the perimeter of said front panel by at least one substantially straight seam forming an inflatable structure wherein said seamed notches prevent the body panel from excessive expansion to prevent said front panel from hitting the occupant of the vehicle with excessive force upon inflation of the air bag cushion.    
     
     
         32 . A notched body panel for use in an airbag cushion of a vehicle restraint system, comprising: 
 a body panel having at least one notch in each side thereof.