Airbag module with light weight airbag cushion

1. An airbag module, comprising:

an inflatable airbag cushion having a first panel and a second panel interconnected by a seam around peripheries thereof to form an inlet and an inflatable chamber;

an inflator for inflating the airbag cushion; and

a support having a first end and a second end;

wherein the first end is coupled to the first panel at a first joint without the use of stitching and the second end is coupled to the second panel at a second joint without the use of stitching;

wherein the first and second joints are provided between the seam and an inflatable chamber formed by the first and second panels;

wherein the inlet is configured to receive inflation gas directly from the inflator and to communicate the inflation gas into the inflatable chamber; and

wherein the support is positioned adjacent a portion of the seam where the inlet transitions from the inlet to the inflatable chamber.

2. The airbag module of claim 1 , wherein the support includes a fold provided between the first and second ends thereby creating two portions with each of the two portions containing one of the first end and the second end and each of the two portions being located on a side of the fold.

3. The airbag module of claim 2 , wherein, prior to inflation and deployment of the airbag, the first end of the support is positioned adjacent to the second end of the support.

4. The airbag module of claim 3 , wherein the fold extends parallel to the seam.

5. The airbag module of claim 2 , wherein the support further includes a stitch located between the fold and the ends of the support, wherein the stitch is configured to stitch the two portions of the support together.

6. The airbag module of claim 1 , wherein the first panel is coupled to the first end of the support using an adhesive or structural sealant, and the second panel is coupled to the second end of the support using an adhesive or structural sealant.

7. The airbag module of claim 1 , wherein the support is located near the inflator and acts as a heat shield to protect the seam from inflation gas during airbag deployment.

8. The airbag module of claim 1 , wherein the support is coupled to the first panel at a third joint located between the first joint and the seam, and wherein the support is coupled to the second panel at a fourth joint located between the second joint and the seam.

9. The airbag module of claim 1 , wherein the support is positioned adjacent a portion of the seam that forms a corner where the inlet widens into the inflatable chamber.

10. The airbag module of claim 1 , further comprising a second support;

wherein the second support has a first end and a second end;

wherein the first end of the second support is coupled to the first panel at a third joint without the use of stitching, and the second end of the second support is coupled to the second panel at a fourth joint without the use of stitching;

wherein the third and fourth joints are provided between the seam and the inflatable chamber formed by the first and second panels;

wherein the second support is positioned adjacent a portion of the seam where the inlet transitions from the inlet to the inflatable chamber and is positioned generally on an opposite side of the inlet from where the first support is positioned.

11. The airbag module of claim 10 , wherein the first support is positioned adjacent a first portion of the seam that forms a first corner where the inlet widens into the inflatable chamber, and the second support is positioned adjacent a second portion of the seam that forms a second corner whether the inlet widens into the inflatable chamber, the second corner being positioned generally opposite to the first corner across the inlet.

12. The airbag module of claim 1 , wherein the support extends a distance no longer than 100 mm along the portion of the seam.

13. An airbag module, comprising:

an inflatable airbag cushion having a first panel and a second panel interconnected by a seam;

an inflator for inflating the airbag cushion; and

a support having a first end and a second end;

wherein the first end is coupled to the first panel at a first joint without the use of stitching and the second end is coupled to the second panel at a second joint without the use of stitching;

wherein the first and second joints are provided between the seam and an inflatable chamber formed by the first and second panels;

wherein the support includes a fold provided between the first and second ends thereby creating two portions with each of the two portions containing one of the first end and the second end and each of the two portions being located on a side of the fold;

wherein the support further includes a stitch located between the fold and the ends of the support, wherein the stitch is configured to stitch the two portions of the support together; and

wherein the stitch is a tear stitch that is configured to tear under relatively low loading and generally not impede deployment of the airbag.

14. An airbag module, comprising:

an inflatable airbag cushion having a first panel and a second panel interconnected by a seam;

an inflator for inflating the airbag cushion; and

a support having a first end and a second end;

wherein the first end is coupled to the first panel at a first joint without the use of stitching and the second end is coupled to the second panel at a second joint without the use of stitching;

wherein the first and second joints are provided between the seam and an inflatable chamber formed by the first and second panels; and

wherein the support is coupled to the first panel at a third joint located between the first joint and the seam, and wherein the support is coupled to the second panel at a fourth joint located between the second joint and the seam.

15. The airbag module of claim 14 , wherein the support is a single, unitary member, and a first portion of the support is coupled to a second portion of the support with a stitch.

16. The airbag module of claim 15 , wherein the support includes a fold, and the stitch is positioned further away from the fold than all of the first, second, third, and fourth joints.

17. The airbag module of claim 15 , wherein the support includes a fold, and the stitch is positioned between the fold and at least one of the first, second, third, and fourth joints.

18. An inflatable airbag cushion for use in an airbag module, the airbag cushion comprising:

at least two panels that includes a first panel and a second panel coupled together at a seam; and

a support having a first end and a second end;

wherein the first end is coupled to the first panel at a first joint without the use of stitching and the second end is coupled to the second panel at a second joint without the use of stitching;

wherein the first and second joints are provided between the seam and an inflatable chamber formed by the first and second panels; and

wherein a first portion of the support is coupled to a second portion of the support with a tear stitch, the tear stitch configured to allow the first and second portions of the support to separate from each other during inflation of the airbag cushion.

19. The airbag module of claim 18 , wherein the first panel is coupled to the first end of the support using an adhesive or structural sealant, and the second panel is coupled to the second end of the support using an adhesive or structural sealant.

20. The airbag cushion of claim 18 , wherein the support includes a fold provided between the first and second ends.

21. The airbag module of claim 20 , wherein the tear stitch is positioned further away from the fold than at least one of the first and second joints.

22. The airbag cushion of claim 20 , wherein the first end is configured adjacent to the second end and the fold is configured to extend in a direction opposing the first and second ends.

23. The airbag cushion of claim 22 , wherein the fold extends parallel to the seam.

24. The airbag cushion of claim 23 , wherein the tear stitch is located between the fold and the ends.

25. The airbag module of claim 24 , wherein the tear stitch that is configured to tear under relatively low loading.