Patent Description:
In order to protect passengers in the event of a vehicle collision, it is well known that vehicles are equipped with one or a plurality of airbags. These airbags include, for example, various forms such as: a so-called driver airbag which expands from near the center of the steering wheel of an automobile so as to protect a driver; a curtain airbag which deploys downward along an inner side of a window of the automobile so as to protect passengers during collisions in a transverse direction of the vehicle, as well as when overturning and during rollover accidents; and a side airbag which is deployed between the passenger and a side panel so as to protect the passenger upon impact in the transverse direction of the vehicle. The present invention relates to a side airbag device and a vehicle seat provided with same.

The side airbag device described in Patent Document <NUM> below has a main airbag and an auxiliary airbag, and is configured to restrain an occupant as quickly as possible by expanding and deploying the auxiliary airbag prior to the main airbag. Note that there are other inventions apart from the invention described in Patent Document <NUM> of a side airbag device provided with an auxiliary airbag in addition to a main airbag. From the Patent Document <NUM> it is known a vehicle seat with a side airbag device comprising all features of the preamble of claim <NUM>. From the Patent Document <NUM> it is known a side airbag device including a pre-push chamber with the inflator stowed inside and deploying primarily on the occupant side of the side frame, and a main chamber that is connected to the pre-push chamber and deploys primarily to toward the fromnt side of the side frame. From the patent document <NUM> it is known another vehicle seat with a side airbag device comprising all features of the preamble of claim <NUM>.

Herein, the side airbag device is stowed in a side supporting part of a seat. Therefore, there are many restrictions on the shape and size, and thus the airbag device packaging must be compact. However, by making the airbag compact, a problem occurs where the deployment behavior of the airbag is adversely affected.

Also, ensuring that the airbag is deployed reliably and quickly is an important issue.

In light of that described above, an object of the present invention is to provide: a vehicle seat comprising a side airbag device capable of properly and quickly deploying the airbag, as in claim <NUM>.

Another object of the present invention is to provide a method of manufacturing a vehicle seat that contributes to reliable and rapid deployment of an airbag, as in claim <NUM>. Means for Solving the Problem.

The present invention is vehicle seat comprising a side airbag device secured to a side frame, including an airbag that restrains an occupant by expanding and deploying, an inflator that supplies expansion gas to the airbag, and a bracket that holds the airbag and the inflator which is connected to the side frame. The airbag includes a pre-push chamber with the inflator stowed inside and deploys primarily on the occupant side (inner side) of the side frame, and a main chamber that is connected to the pre-push chamber and deploys primarily toward the front of the side frame. The bracket includes a first surface that faces the direction of travel of the vehicle (forward) and a second surface that faces the center side of the seat (inner side) in the width direction of the vehicle. In addition, at least the main chamber is arranged on top of the first surface of the bracket when the airbag is in a folded and/or rolled stowed state. In a stowed state, the pre-push chamber of the airbag can be arranged on the second surface of the bracket. The pre-push chamber of the airbag is then preferably configured to deploy toward the occupant side with the second surface of the bracket as a reaction surface. As with the main chamber, the pre-push chamber is supported from behind in the deployment direction, which ensures that the airbag deploys in the desired deployment direction (inner side) quickly and reliably. The main chamber is partitioned into a forward chamber and a rear chamber. Furthermore, a reference line L0 can be set along the rear edge of the rear chamber when viewed from the side in the vehicle width direction. The rearward chamber can be configured such that at least one of the shoulder protecting region protecting the shoulder area and the waist protecting region protecting the waist area of the occupant seated in the seat reaches near the front end of the forward chamber. The reference line L0 is set, for example, to correspond to an inclination angle (D0) at the upper region of the first surface of the bracket when viewed from the side of the vehicle.

Here, "side frame" refers to a frame positioned inside the bulging portions (side support) on both the left and right sides of the frame that makes up the framework of the vehicle seat.

The main chamber of the airbag preferably deploys forward with the first surface of the bracket forward as a reaction force surface. This ensures that the main chamber is supported from the rear in the deployment direction and the airbag will be deployed reliably and quickly in the desired deployment direction (forward).

Here, the setting of the rear edge of the rear chamber along the reference line L0 is not limited to the case where the sewing that demarcates the rear edge coincides with the reference line L0 over the entire area, but also includes the case where the reference line L0 and the rear edge of the rear chamber coincide within a certain range. For example, the area where the reference line L0 and the rear edge of the rear chamber preferably overlap on at least <NUM>% or more of the entire vertical area (height) of the airbag.

Note that a non-expanding region can be formed further behind the rear edge of the rear chamber. The bracket can include a plate-shaped first plate with a first surface and a plate-shaped second plate with a second surface. The inflator can then be secured to the second plate. In addition, the bracket can be arranged such that the first plate and second plate are generally orthogonal when viewed in a cross section perpendicular to the longitudinal direction.

Various aspects of airbag structures applied to the side airbag device of the present invention are explained below.

The rear chamber is configured such that the shoulder protecting region, which protects the shoulder area of the occupant seated in the seat, reaches near the front end part of the forward chamber. The shoulder protecting region of the airbag is tucked in or folded toward the center of the main chamber using a first line (L1) as a crease, which is orthogonal to the reference line (L0) and extends from near the front end part of the shoulder protecting region to near the rear end of the rear chamber. The airbag is folded or rolled from the front end side to the rear end side in the direction of the first line (L1). Then when the airbag is retained by the bracket, the reference line (L0) is arranged along the first surface of the first plate.

Here, "tucked in" refers to a state in which the edge of the airbag is pushed, folded, or inserted into the interior of said airbag.

The first aspect as described above can have a structure such that the folded or rolled lower end part of the airbag is further folded upwardly into a Z-shaped cross section with a second line (L2) and a third line (L3) that are parallel to the first line (L1) as creases.

The rear chamber is configured such that the waist protecting region, which protects the waist area of the occupant seated in the seat, reaches near the front end part of the forward chamber. The lower end part of the waist protecting region of the airbag is tucked in or folded toward the center of the main chamber using a fourth line (L4) as a crease, which extends from near the front end part of the waist protecting region to near the rear end of the rear chamber. The tucked in or folded lower end part of the airbag is folded upwardly in a cross-sectional Z shape so that a fifth line (L5), which is orthogonal to the reference line (L0), becomes the fold of the bottom edge. The airbag is folded or rolled along the fifth line (L5) from the front end side to the rear end side. Then when the airbag is retained by the bracket, the reference line (L0) is arranged along the first surface of the first plate.

The second aspect as described above can have a structure such that the airbag is folded with the upper end part towards the center of the main chamber using a sixth line (L6) that is parallel to the fifth line (L5) as a crease, before being folded or rolled.

The rear chamber is configured such that the waist protecting region, which protects the waist area of the occupant seated in the seat, reaches near the front end part of the forward chamber. The lower end part of the waist protecting region of the airbag is tucked in or folded toward the center of the main chamber using a fourth line (L4) as a crease, which extends from near the front end part of the waist protecting region to near the rear end of the rear chamber. The airbag is folded or rolled along the fourth line (L4) from the front end side to the rear end side. Then when the airbag is retained by the bracket, the reference line (L0) is arranged along the first surface of the first plate.

The third aspect as descried above can have a structure such that the upper end part of the airbag is folded towards the center of the main chamber using a seventh line (L7) that extends in the front-rear direction as a crease, before being folded or rolled.

In addition, when a point P0 is the point where the reference line (L0) and the front edge of the folded or rolled region intersect, a region forward of the reference line (L0) is folded rearward using an eighth line (L8), which passes through the point (P0) and is orthogonal to the seventh line (L7), as a foremost crease.

The side airbag device of the present invention can be further provided with a flexible cover member covering the folded airbag.

The cover member can have a first through-hole to be engaged with a stud bolt of the inflator and a second through-hole to be circled around the folded airbag and again engaged with said stud bolt.

The cover member preferably has slits that into which the upper and lower portions of the first plate are inserted, respectively. Thus, by providing a slit through which the first plate is inserted, when the airbag module is encircled by the cover member, unnecessary space formed between the cover member and the airbag and between the cover member and the bracket is reduced, thereby enabling the compressed airbag to be retained without loosening. This is particularly effective when the first plate and second plate are mutually orthogonal in a cross section perpendicular to the longitudinal direction of the bracket, as there is no wasted space formed by both plates.

The manufacturing method of the vehicle seat according to the present invention includes: a step of preparing an airbag that includes a pre-push chamber with the inflator stowed inside and deploys primarily on the occupant side (inner side) of the side frame, and a main chamber that is connected to the pre-push chamber and deploys primarily toward the front of the side frame; a step of preparing a bracket which, when connected to the side frame, has a first surface that faces toward the direction of travel of the vehicle (forward) and a second surface facing the center of the seat in the width direction of the vehicle; a step of folding and/or rolling the airbag into a stowed state; and a step of retaining the airbag with respect to the bracket such that at least the main chamber of the airbag in a stowed state is positioned on the first surface of the bracket.

The bracket can include a plate-shaped first plate with a first surface and a plate-shaped second plate with a second surface. The inflator can then be secured to the second plate.

The following is an explanation of the manufacturing method of the side airbag device according to the present invention, as described above.

The shoulder protecting region of the rear chamber, which protects the shoulder area of the occupant seated in the seat, reaches near the front end part of the forward chamber. The manufacturing method further includes: a step where the shoulder protecting region of the airbag is tucked in or folded toward the center of the main chamber using a first line (L1) as a crease, which is orthogonal to the reference line (L0) and extends from near the front end part of the shoulder protecting region to near the rear end of the rear chamber; a step where the airbag is folded from the front edge towards the rear edge in a direction nearly orthogonal to the first line (L1) as a longitudinal direction; and a step where the airbag is retained on the bracket such that the reference line (L0) is positioned along the first surface of the first plate.

A step where the folded or rolled lower end part of the airbag is further folded upwardly into a Z-shaped cross section with a second line (L2) and a third line (L3) that are parallel to the first line (L1) as creases can be further included.

The waist protecting region of the rear chamber, which protects the waist area of the occupant seated in the seat, reaches near the front end part of the forward chamber. The manufacturing method further includes: a step where the lower end part of the waist protecting region of the airbag are tucked in or folded toward the center of the main chamber using a fourth line (L4) as a crease, which extends from near the front end part of the waist and shoulder protecting regions to near the rear end of the rear chamber; a step where the tucked in or folded lower end part of the airbag is folded upwardly into a Z-shaped cross section so that a fifth line (L5), which is orthogonal to the reference line (L0), becomes the fold of the bottom edge; a step where the airbag is folded or rolled from the front edge towards the rear edge in a direction orthogonal to the fifth line (L5) as a longitudinal direction; and a step where the airbag is retained on the bracket such that the reference line (L0) is positioned along the first surface of the first plate.

Before folding or rolling the airbag, the upper end part can be folded towards the center of the main chamber using a sixth line (L6), which is parallel to the fifth line (L5), as a crease.

The waist protecting region of the rear chamber, which protects the waist area of the occupant seated in the seat, reaches near the front end part of the forward chamber. The manufacturing method further includes: a step where the lower end part of the waist protecting region of the airbag is tucked in or folded toward the center of the main chamber using a fourth line (L4) as a crease, which extends from near the front end part of the waist protecting region to near the rear end of the rear chamber; a step where the airbag is folded or rolled along the fourth line (L4) from the front end side to the rear end side; and a step where the airbag is retained by the bracket such that the reference line (L0) is positioned along the first surface of the first plate.

A step can be further included where before folding or rolling, the upper end part of the airbag is folded towards the center of the main chamber using a seventh line (L7), which extends in the front-rear direction, as a crease.

Regarding the manufacturing method according to the present invention as described above, the following step using a cover member can be added. In other words, a step can be further included where the folded airbag is covered by a flexible cover member.

Here, the manufacturing method can further include: a step where a first through-hole of the cover member engages with a stud bolt of the inflator; and a step where a second through-hole circles around the folded airbag and engages with said stud bolt.

A step can be further included where the upper and lower portions of the first plate are inserted into the pair of slits formed on the upper and lower portions of the cover member, respectively.

In the specification and claims of the present application, the direction in which the occupant is facing (the direction of vehicle travel) when the occupant is seated in the seat in a normal posture is referred to as "forward" and the opposite direction is referred to as "rear", and the axis of the coordinate is referred to as the "front-rear direction". Moreover, when the passenger is seated in the seat in a regular posture, the right of the passenger is referred to as the "right direction," the left of the passenger is referred to as the "left direction," and the direction indicating the coordinate axis is referred to as the "left and right direction. " In the left-right direction, a region on an occupant side from a side frame of the seat shall be referred to as "inside", and a region opposite from the occupant as viewed from the side frame shall be referred to as "outside". Similarly, when the passenger is seated in the seat in a regular posture, the head direction of the passenger is referred to as "up," the waist direction of the passenger is referred to as "down," and the direction indicating the coordinate axis is referred to as the "vertical direction.

The side airbag apparatus according to the present invention includes a type which is deployed on the door side of (outside) the seat, along with a type which is deployed on the vehicle center side of the seat. A side airbag device of a type which is deployed on the vehicle center side of the seat, for example, is referred to as a far side airbag, front center airbag, rear center airbag, and the like.

The vehicle seat with the side airbag device according to the embodiments of the present invention mounted thereon will be described with reference to the accompanying drawings.

<FIG> is a perspective view primarily illustrating an external shape of a vehicle seat used as the vehicle seat according to the present invention, with an illustration of an airbag device (airbag module) <NUM> omitted. <FIG> is a perspective view illustrating an internal structure (seat frame) functioning as a framework of the vehicle seat illustrated in <FIG>, with an illustration of the airbag device (airbag module) <NUM> omitted herein as well. <FIG> is a schematic side surface view of the vehicle seat according to the present invention, illustrating a condition where the airbag device (airbag module) <NUM> is stowed on a side surface (near side) near a left side seat door as observed from the outside in the vehicle width direction.

As illustrated in <FIG> and <FIG>, seen as the location, the vehicle seat according to the present example is configured by: a seat cushion <NUM> of a part on which an occupant is seated; a seat back <NUM> forming a backrest; and a headrest <NUM> connected to the upper end of the seat back <NUM>.

As illustrated in <FIG>, a seat back frame 1f forming a skeleton of the seat is provided inside the seat back <NUM>, a pad <NUM> (refer to <FIG>) made of a urethane foam material or the like is provided on a surface and periphery thereof, and a surface of the pad <NUM> is covered with a skin <NUM> such as leather, fabric, or the like. A seating frame 2f is provided on a bottom side of the seat cushion <NUM>. Similar to the seat back <NUM>, a pad made of a urethane foam material or the like is provided on an upper surface and periphery thereof, and a surface of the pad is covered by the skin <NUM> (<FIG>) such as leather, fabric, or the like. The seating frame 2f and the seat back frame 1f are connected via a reclining mechanism <NUM>.

As illustrated in <FIG>, the seat back frame 1f is configured in a frame shape by: a side frame <NUM> arranged so as to be separated into the left and right and extending in a vertical direction; an upper frame connected to an upper end part of the side frame <NUM>; and a lower frame connected to a lower end part thereof. A cushion member is provided outside a headrest frame to configure the headrest <NUM>.

<FIG> is a cross sectional view illustrating the structure of the vehicle seat according to the present invention, corresponding to a part of a cross section in an A1-A1 direction of <FIG>. The side frame <NUM> can be molded of resin or metal and, as illustrated in <FIG>, can be formed into an L-shaped cross sectional shape or a U-shaped cross sectional shape. An airbag module (side airbag device) <NUM> is secured to the inside (seat center side) and front side of the side frame <NUM>.

As illustrated in <FIG>, the seat back <NUM> includes a side supporting part <NUM> which swells in the vehicle traveling direction (vehicle front) on a vehicle width direction side part (end part). A urethane pad <NUM> is arranged inside the side supporting part <NUM>, and the side airbag device <NUM> is stored in a gap of the urethane pad <NUM>. The side airbag device <NUM> includes: an airbag <NUM> that restrains an occupant when expanded and deployed; and an inflator <NUM> that supplies an expansion gas to the airbag <NUM>.

Seams <NUM>, <NUM>, <NUM> of the skin <NUM> of the seat back <NUM> are interwoven and connected by sewing. Note that the front seam <NUM> is cleft when the airbag is deployed. Furthermore, a start region <NUM> is formed in the side supporting part <NUM> as a starting point when the side supporting part <NUM> bends towards the occupant side due to the expansion of a second chamber <NUM> (refer to <FIG>). The start region <NUM> can be any one of a notch, recess, or thin region, or combinations thereof. The start region <NUM> may be formed at only a urethane <NUM> part inside the side supporting part <NUM>. Furthermore, the start region <NUM> can be omitted.

The compressed airbag <NUM> is secured to the side frame <NUM> via the brackets <NUM> and <NUM>. Details of the brackets <NUM> and <NUM> are described below.

The airbag <NUM> may be covered by a soft cover made of fabric (see <FIG>). The airbag <NUM> can appropriately use an appropriate compressing method other than folding into a bellows shape, or rolling ("folding" includes rolling). Details are described below. Note that in <FIG>, reference code <NUM> indicates a door trim.

<FIG> is a schematic side view of the vehicle seat according to the present invention, illustrating a condition where the airbag is deployed as observed from the outside in the vehicle width direction. As illustrated in <FIG>, the airbag <NUM> is provided with a main chamber <NUM> that deploys toward the front of the side support part <NUM> and a pre-push chamber <NUM> that deploys to the inside of the main chamber <NUM> in the width direction of the vehicle.

<FIG> is a schematic diagram of the structure of the side airbag device according to the present invention, illustrating the deployed state of the airbag <NUM> corresponding to the cross section in the A2-A2 direction of <FIG>.

As described above, the airbag <NUM> comprises the main chamber <NUM> that deploys toward the front of the side support part <NUM> of the seat, and the pre-push chamber <NUM> that houses the inflator <NUM> and begins to deploy prior to the main chamber <NUM> to the inside of the main chamber <NUM> in the vehicle width direction.

An internal vent hole (not shown) is provided in the partitioning part (boundary portion) between the main chamber <NUM> and the pre-push chamber <NUM>, through which expansion gas flows from the pre-push chamber <NUM> to the main chamber <NUM>.

An exhaust vent V (not shown) is formed on the front end part of the main chamber <NUM> for exhausting the gas to the outside. Note that at least one exhaust vent for exhausting the gas to the outside can be formed on a front end part of the pre-push chamber <NUM>, similar to the main chamber <NUM>.

The main chamber <NUM> is partitioned into a forward chamber 34F and a rear chamber 34R by a partition panel 134c. An internal vent V34d is formed in the partition panel 134c for the expansion gas to flow from the rear chamber 34R to the forward chamber 34F.

<FIG> is a rear view (A) and a side view (B) of the structure of the brackets <NUM> and <NUM> employed in the airbag device according to the present invention. Note that the rear view (A) illustrates a view observed from the rear of the vehicle, and the side view (B) illustrates a view observed from the outer side of the vehicle seat (opposite side of the occupant). In <FIG>, for the purpose of clarifying the shape and arrangement of the brackets <NUM> and <NUM>, the airbag <NUM> is omitted and only the inflator <NUM> is shown.

The brackets (<NUM>, <NUM>) are provided with a first plate <NUM> extending in a vertical direction and a second plate <NUM> through which two stud bolts 32a, 32b that are connected to the inflator <NUM> are inserted through, such that the second plate <NUM> is directly secured to the side frame <NUM>. These types of brackets are generally arranged such that the first plate <NUM> and second plate <NUM> are orthogonal when viewed in a cross section perpendicular to the longitudinal direction (see <FIG> and <FIG>), and the first plate <NUM> and the second plate <NUM> are connected to each other by welding or the like.

The first plate <NUM> of the bracket has a first surface 54a that faces the vehicle traveling direction, and a main fold portion (main chamber <NUM>) of the airbag <NUM> in a stowed state is arranged along the first surface 54a. At this time, when the long and thin compressed airbag <NUM> expands and deploys in the vehicle traveling direction, the first surface 54a of the first plate <NUM> is a reaction force surface, and thus the airbag <NUM> reliably and quickly deploys in a forward direction.

On the other hand, the second plate <NUM> of the bracket has a second surface 52a facing the occupant side, and mainly the pre-push chamber <NUM> of the airbag <NUM> is arranged on said second surface 52a. When the pre-push chamber <NUM> is deployed, the second surface 52a of the second plate <NUM> becomes a reaction force surface, causing the pre-push chamber <NUM> to deploy reliably and quickly in the direction of the occupant (inner side).

In <FIG>, the reference sign "D0" indicates a direction in which a majority of the upper portion of the first plate <NUM> extends. In addition, as will be explained in detail later, the airbag <NUM> is arranged and stowed so that the reference line L0 (such as in <FIG>) set on the airbag <NUM> coincides with this direction D0. Furthermore, the line H0 in <FIG> and <FIG> corresponds to the reference line L0 when observed from the vertical direction.

<FIG> are plan views (side views) illustrating the structure of the airbag <NUM> employed in the side airbag device of embodiment <NUM> of the present invention when viewed from the occupant side. As can be more readily understood in conjunction with <FIG>, the airbag <NUM> has a pre-push chamber <NUM> where the inflator <NUM> is stowed inside and deploys primarily on the occupant side (inner side) of the side frame <NUM>, and a main chamber <NUM> that is connected to the pre-push chamber <NUM> and deploys primarily toward the front of the side frame <NUM>. Each chamber <NUM> (34F, 34R) and <NUM> are compartmentally formed by stitches S1, S2, S3.

As described previously, the main chamber <NUM> is partitioned into a forward chamber 34F and a rear chamber 34R. Furthermore, the reference line L0 is set along the rear edge of the rear chamber 34R when viewed from the side in the vehicle width direction. Note, a non-expanding region is formed further behind the rear edge (L0) of the rear chamber 34R. The non-expanding region has an opening <NUM> into which the inflator <NUM> is inserted and an opening <NUM> through which the upper stud bolt 32a of the inflator <NUM> passes.

The rear chamber 34R of the main chamber <NUM> is configured such that the shoulder protecting region 34Ra protecting the shoulder area of the occupant seated in the seat reaches near the front end part of the forward chamber 34F.

<NUM>(A), <NUM>(B), <FIG> are plan views (side views) illustrating the steps in folding the airbag <NUM> employed in the side airbag device according to embodiment <NUM> of the present invention. <FIG> are plan views (side views) illustrating the steps in which the brackets (<NUM>, <NUM>) are attached to the airbag <NUM> according to embodiment <NUM> of the present invention.

When folding the airbag <NUM>, first, as shown in FIGS. <NUM>(A) and <NUM>(B), insert the inflator <NUM> through the opening <NUM> and set said inflator <NUM> so that at least the gas discharge hole (not shown) is fully positioned inside the pre-push chamber <NUM>. Next, the shoulder protecting region 34Ra is tucked in or folded toward the center of the main chamber <NUM> using the first line L1 as a crease, which is orthogonal to the reference line (L0) and extends from near the front edge of the shoulder protecting region 34Ra to near the rear edge of the rear chamber 34R.

Next, as illustrated in FIG. <NUM>(B) and <FIG>, the airbag <NUM> is folded or rolled from the front end side toward the rear end side along the direction of the first line L1, to form rolled part <NUM>. Then, the lower end of the airbag <NUM> is further folded upwardly into a Z-shaped cross section using the second line L2 and the third line L3 as creases, which are substantially parallel to the first line L1, to form a Z-fold portion <NUM> (<FIG>).

Next, as illustrated in <FIG>, the brackets <NUM>, <NUM> are attached with respect to the compressed airbag <NUM>. Specifically, the stud bolts 32a, 32b of the inflator <NUM> are inserted into the second plate <NUM>. Thereafter, the airbag is folded so that the reference line L0 on the airbag <NUM> side contacts the first surface 54a of the first plate <NUM> (<FIG>).

<FIG>, and <FIG> are plan views (side views) illustrating the steps in folding the airbag <NUM> employed in the side airbag device according to embodiment <NUM> of the present invention. <FIG> are plan views (side views) illustrating the steps in which the brackets <NUM>, <NUM> are attached to the airbag <NUM> according to embodiment <NUM> of the present invention.

The airbag <NUM> according to embodiment <NUM> has a pre-push chamber (not shown) that stows the inflator <NUM> inside and deploys primarily on the occupant side (inner side) of the side frame <NUM>, and a main chamber <NUM> that is connected to the pre-push chamber <NUM> and deploys primarily toward the front of the side frame <NUM>. Each chamber <NUM> (134F, 314R) are compartmentally formed by stitches S1, S2. The configuration of the pre-push chamber is the same as that of the pre-push chamber <NUM> of embodiment <NUM> described above, and a duplicate description is omitted.

Similar to embodiment <NUM>, the main chamber <NUM> is partitioned into a forward chamber 134F and a rear chamber 134R. Furthermore, the reference line L0 is set along the rear edge of the rear chamber 134R when viewed from the side in the vehicle width direction. A non-expanding region is formed further behind the rear edge L0 of the rear chamber 134R. The non-expanding region has an opening <NUM> into which the inflator <NUM> is inserted and an opening <NUM> through which the upper stud bolt 32a of the inflator <NUM> passes.

The rear chamber 134R of the main chamber <NUM> is formed such that the waist protecting region 34Ra protecting the waist area of the occupant seated in the seat reaches near the front end of the forward chamber 134F.

When folding the airbag <NUM>, the inflator <NUM> is first inserted through the opening <NUM> and set inside the pre-push chamber as illustrated in <FIG>. Next, a lower end part <NUM> is formed by tucking in or folding the lower end part of the waist protecting region 134Ra toward the center of the main chamber <NUM>, using the fourth line L4 as a crease, which extends from near the front end of the waist protecting region 134Ra to near the rear end of the rear chamber 134R (<FIG>). Note that the fourth line L4 of the main chamber <NUM> is substantially parallel to the line D2 extending in the front-rear direction of the stitch line S2 that serves as a partition between the forward chamber 134F and the rear chamber 134R.

Next, as illustrated in <FIG>, the lower end part <NUM> of the airbag <NUM> is folded upwardly into a Z-shaped cross section so that the fifth line L5, which is orthogonal to the reference line L0, becomes a fold of the lower edge, thereby forming a Z-fold <NUM> (<FIG>). In this case, the airbag may be simply folded back (upwards) towards the center of the main chamber so that the fifth line L5 becomes the fold of the lower edge. Using the sixth line L6 parallel to the fifth line L5 as a crease, the upper end of the airbag <NUM> is folded (folded back) toward the center of the main chamber <NUM>.

The airbag <NUM> is then folded or rolled along the fifth line L5 (sixth line L6) (in a perpendicular direction) from the front end side to the rear end side to form a rolled part <NUM> (<FIG>).

<FIG>, and <FIG>, <FIG>, and <FIG> are plan views (side views) illustrating the steps in folding the airbag <NUM> employed for the side airbag device according to embodiment <NUM> of the present invention. <FIG> are plan views (side views) illustrating the steps in which the brackets <NUM>, <NUM> are attached to the airbag <NUM> according to embodiment <NUM> of the present invention. The airbag <NUM> used in embodiment <NUM> is structurally identical to the airbag <NUM> used in embodiment <NUM>.

The airbag <NUM> according to embodiment <NUM> has a pre-push chamber (not shown) that stows the inflator <NUM> inside and deploys primarily on the occupant side (inner side) of the side frame <NUM>, and a main chamber <NUM> that is connected to the pre-push chamber <NUM> and deploys primarily toward the front of the side frame <NUM>. Each chamber <NUM> (134F, 314R) are compartmentally formed by stitches S1, S2.

Similar to embodiment <NUM> and embodiment <NUM>, the main chamber <NUM> is partitioned into a forward chamber 134F and a rear chamber 134R. Furthermore, the reference line L0 is set along the rear edge of the rear chamber 134R when viewed from the side in the vehicle width direction. A non-expanding region is formed further behind the rear edge L0 of the rear chamber 134R. The non-expanding region has an opening <NUM> into which the inflator <NUM> is inserted and an opening <NUM> through which the upper stud bolt 32a of the inflator <NUM> passes.

Next, as illustrated in <FIG>, the upper end part of the airbag <NUM> is folded (folded back) toward the center of the main chamber <NUM> using the seventh line L7 extending in the front-back direction as a crease to form a folded part <NUM>.

Next, the airbag <NUM> is folded or rolled from the front end side to the rear end side along the fourth line L4 to form a rolled part <NUM> (<FIG>). Then, as shown in <FIG>, the region forward of the reference line L0 is folded toward the rear so that the eighth line L8 orthogonal to the seventh line L7 passing through the point P0 where the reference line L0 and the front edge of the rolled part <NUM> intersect becomes the foremost fold. In this case, a Z-fold part may be formed by folding the region forward of the reference line L0 in a Z-shaped cross section so that the eighth line L8 becomes the foremost fold.

Next, as illustrated in <FIG>, the brackets <NUM>, <NUM> are attached relative to the compressed airbag <NUM>. Specifically, the stud bolts 32a, 32b of the inflator <NUM> are inserted into the second plate <NUM>. Thereafter, the airbag is folded so that the reference line L0 on the airbag <NUM> side touches the first surface 54a of the first plate <NUM> (<FIG>).

The configuration of a cover member (soft cover) <NUM> that surrounds the airbag module configured as described above will be described below, taking the airbag <NUM> of embodiment <NUM> as an example. Note that the cover member <NUM> can also be applied to the airbag <NUM> in embodiment <NUM> and the airbag <NUM> in embodiment <NUM>.

<FIG> is a plan view (A) of a structure of a soft cover <NUM> that can be employed in the side airbag device of the present invention, and airbag (B) in a stowed state (compressed state).

The soft cover <NUM> encloses the airbag module containing the airbags (<NUM> and <NUM>), the inflator <NUM>, and the brackets <NUM>, <NUM>. Unlike the airbags <NUM>, <NUM>, the soft cover <NUM> is configured to not require a large amount of strength, in order to tear easily when the airbags (<NUM>, <NUM>) deploy, and to not inhibit deployment of the airbags (<NUM>, <NUM>).

The soft cover <NUM> is provided with a pair of first through holes 302a, 302b that engage with the stud bolts 32a, 32b of the inflator <NUM>, and a pair of second through holes 306a, 306b that encircle the folded airbag <NUM> and are then again engaged with said stud bolts 32a, 32b. A slit <NUM> is formed between the two second through holes 306a, 306b so that the distance between the second through holes 306a, 306b can be widened.

Additionally, the soft cover <NUM> has slits 304U, <NUM> into which the upper and lower portions of the first plate <NUM> are respectively inserted.

<FIG>, and <FIG> are explanatory diagrams illustrating the steps of encircling the airbag module with the soft cover <NUM> according to the present invention. <FIG> is an explanatory diagram illustrating the state in which the airbag module is enclosed by the soft cover <NUM> according to the present invention. <FIG> is a cross-sectional view (A) in the B1-B1 direction of <FIG>, and a cross-sectional view (B) in the B2-B2 direction of <FIG>.

When the airbag module is enclosed by the soft cover <NUM>, the stud bolts 32a, 32b of the inflator <NUM> are first passed through (engaged with) the first through-holes 302a and 302b of the soft cover <NUM>, as illustrated in <FIG>.

Next, as illustrated in <FIG>, the airbag module (<NUM>, <NUM>) is encircled by the soft cover <NUM>, and then the stud bolts 32a, 32b of the inflator <NUM> are passed through (engaged with) the second through holes 306a. 306b of the soft cover <NUM>, as illustrated in <FIG>.

Next, as illustrated in <FIG>, the upper end and lower ends of the first plate <NUM> of the bracket are passed through the slits 304U, <NUM>. Then, the pre-push chamber side in which the inflator <NUM> is stowed is pulled toward the second plate <NUM> and the stud bolts 32a, 32b of the inflator <NUM> are inserted into the openings formed in the second plate <NUM> (<FIG>).

Thus, by providing slits 304U, <NUM> for inserting the first plate <NUM> in the soft cover <NUM>, when the airbag module is encircled by the soft cover <NUM>, unnecessary space between the soft cover <NUM> and airbag module, and between the soft cover <NUM> and the brackets <NUM>, <NUM>, is reduced, and the compressed airbag <NUM> can be tightly retained. This is particularly effective when the first and second plates are orthogonal to each other in a cross section perpendicular to the longitudinal direction of the brackets <NUM>, <NUM>, as there is no wasted space between the brackets <NUM>, <NUM>.

<FIG> is a cross-sectional view illustrating the airbag according to the present invention in a deployed state, where (A) illustrates the state of deployment in the initial stages, and (B) illustrates deployment in later stages. Note that in <FIG>, illustration of the seat frame <NUM> is omitted for convenience of explanation.

In the present invention with the configuration described above, as illustrated in <FIG>, the pre-push chamber <NUM> deploys inside the side supporting part <NUM> in an initial activation stage of the airbag device <NUM>, deforms such that a tip end side of the side supporting part <NUM> bends or protrudes on the vehicle side starting from the region <NUM> while the seat skin <NUM> tears from the sewn part <NUM>, and restrains so as to push the occupant inward in the vehicle width direction. When the pre-push chamber <NUM> is deployed, the surface 52a of the second plate <NUM> of the bracket acts as a reaction surface.

Deployment of the pre-push chamber <NUM> causes the front side part of the side support part <NUM> to protrude toward the occupant side, thereby avoiding or minimizing the generation of forces that would push the occupant diagonally forward from the direction of the back of their body, thereby avoiding movement of the occupant in the direction that the seatbelt is pulled out. In other words, injury to the occupant can be suppressed, and restraining performance can be maximized.

Subsequently, as illustrated in <FIG>, when the airbags (<NUM>, <NUM>) are further inflated, the main chamber <NUM> fully deploys toward the front of the vehicle to protect the occupants in the event of a collision. At this time, the surface 54a of the first plate of the bracket acts as a reaction force surface.

Claim 1:
A vehicle seat with a side airbag device (<NUM>) that is stowed inside it and secured to a seat side frame (<NUM>), comprising:
an airbag (<NUM>,<NUM>) that restrains an occupant when expanded and deployed;
an inflator (<NUM>) that supplies expansion gas to the airbag (<NUM>,<NUM>);
and a bracket (<NUM>,<NUM>) that retains the airbag (<NUM>,<NUM>) and the inflator (<NUM>) and is connected to the side frame (<NUM>), wherein
the airbag (<NUM>,<NUM>) includes a pre-push chamber (<NUM>) with the inflator (<NUM>) stowed inside and deploys primarily on the occupant side (inner side) of the side frame (<NUM>), and a main chamber (<NUM>,<NUM>) that is connected to the pre-push chamber (<NUM>) and deploys primarily toward the front of the side frame (<NUM>),
the bracket (<NUM>,<NUM>) includes a first surface (54a) that faces the direction of travel of the vehicle (forward) and a second surface (52a) that faces the center side of the seat (inner side) in the width direction of the vehicle,
and at least the main chamber (<NUM>,<NUM>) is arranged on top of the first surface (54a) of the bracket (<NUM>,<NUM>) when the airbag (<NUM>,<NUM>) is in a folded and/or rolled stowed state, wherein in a stowed state, the pre-push chamber (<NUM>) of the airbag (<NUM>,<NUM>) is arranged on top of the second surface (52a) of the bracket (<NUM>,<NUM>) wherein the pre-push chamber (<NUM>) of the airbag (<NUM>,<NUM>) deploys towards the occupant side with the second surface (52a) of the bracket (<NUM>,<NUM>) as a reaction surface,
characterized in that
the main chamber (<NUM>,<NUM>) is partitioned into a forward chamber (34F,134F) and a rear chamber (34R,134R);
a reference line (L0) is set along the rear edge of the rear chamber (34R,134R) when viewed from the side in the vehicle width direction; and
the rear chamber (34R,134R) is configured such that at least one of a shoulder protecting region (34Ra,134Ra) that protects the shoulder area, and a waist protecting region (34Ra,134Ra) that protects the waist area, respectively of an occupant seated in the seat, reaches near the front end of the forward chamber (34F,134F).