Airbag cushion construction

An airbag cushion comprising:

• a front panel comprising a first unitary piece of material having a set of first yarns;
• a first side panel connected with the front panel, wherein the first side panel comprises a second piece of material distinct from the first piece of material, wherein the second piece of material comprises a set of second yarns that extend at an angle of at least about 30 degrees relative to the set of first yarns of the front panel;
• and
• a second side panel connected with the front panel, wherein the second side panel comprises a third piece of material distinct from the first and second pieces of material, wherein the third piece of material comprises a set of third yarns that extend at an angle of at least about 30 degrees relative to the set of first yarns of the front panel,
• wherein the airbag is configured to be inflated such that the first yarns of the front panel include a first portion that runs substantially laterally relative to a car, and the first yarns of the front panel further include second and third portions that run substantially longitudinally relative to the car such that the first, second, and third portions of the first yarns at least partially define a first volume, and wherein the first and second side panels at least partially define a second volume that is configured to expand to a greater degree than the first volume.

An airbag cushion configured to be deployed such that, when deployed, the airbag comprises,

• a front face, a first side face, a second side face, and a top face that cooperate to at least partially define a first volume, wherein each of the front, first side, second side, and top faces is substantially rectangular;
• and
• a substantially triangular first side panel connected to the first side face, a substantially triangular second side panel connected to the second side face, and at least a portion of a rear panel connected with the first and second side panels, wherein the first side panel, the second side panel, and the rear panel cooperate to define a second volume,
• wherein each of the first and second side faces comprises a set of first yarns that are substantially parallel to a plane defined by the top face, and wherein each of the first and second side panels comprises two sets of yarns that are perpendicular to one another and that are non-parallel to the plane defined by the top face such that the first and second side panels are configured to stretch more than the first and second side faces during restraint of a vehicle occupant.

A method for constructing an airbag cushion, comprising:

• providing a first substantially triangular side panel;
• providing a second substantially triangular side panel, wherein the second side panel is approximately the same size and shape as the first side panel such that the first and second side panels can be nested together into a substantially rectangular shape;
• providing a substantially rectangular rear panel;
• providing a front panel having a flap, the front panel shaped such that multiple front panels can be nested together by positioning a plurality of front panels in a first row abutting one another and a plurality of front panels in a second row abutting one another, wherein the front panels in the second row are offset and upside down relative to the front panels in the first row, such that a flap of a front panel in the first row fits within a gap between flaps of front panels in the second row and a flap of a front panel in the second row fits within a gap between flaps of front panels in the first row;
• reconfiguring the rear panel such that it has at least two faces;
• connecting the first side panel to the rear panel and the front panel;
• and
• connecting the second side panel to the rear panel and the front panel such that the first side panel is positioned opposite from the second side panel.