A hollow article such as an active bolster for an automobile is formed of an injection molded panel having a ridge and furrow adjacent a panel perimeter and an injection molded sheet having a bonding section at a sheet outer periphery, wherein the bonding section is within the furrow. An injection molded bond is formed between the bonding section and furrow, wherein a compression area where the sheet overlies a region of the panel adjacent the furrow is configured to constrain the bond to the furrow. An associated process and system facilitates mold alignment, part alignment, material strength, design adaptability, efficient processing, reduced labor, increased production rates, reduced energy consumption per part, aesthetically pleasing surfaces, and reduces or eliminates the need for a separate welding operation.

A method of manufacturing a folded body of an airbag, which is inflated by allowing an inflation gas, including: an inflow opening through which the inflation gas is allowed to flow; and an attachment portion of the circumferential edge of the inflow opening, the airbag being formed as a folded body having a folded shape of being gathered to an upper side of the attachment portion, the attachment portion being attached to an attachment seat of a storage portion, the method includes: folding the airbag, in the state of raising a temperature of the airbag, to form a pre-folded body; heating and compressing the pre-folded body, and cooling and compressing the pre-folded body, which is heated and compressed, to form the folded body.

Described are joint designs, tooling, and molding methods for a hollow object, such as an automobile bolster. The methods and structures provide a process and system that facilitates mold alignment, part alignment, material strength, design adaptability, efficient processing, reduced labor, increased production rates, reduced energy consumption per part, aesthetically pleasing surfaces, and reduces or eliminates the need for welding.

A tool comprising two tool halves formed by at least one upper tool and at least one lower tool, which together form a cavity for producing an airbag assembly with a flap component and a chute channel component. The cavity has a flap cavity and a chute channel cavity, wherein, in the lower tool, a first cavity wall section is formed which partially borders the flap cavity, and second cavity wall sections are formed which border the chute channel cavity. The tool also has at least one bending element which can be moved between an insertion position and a bending position and is designed to introduce sections of a material web, attached to the first cavity wall section and protruding over the chute channel cavity with one section, into the chute channel cavity when moving from the insertion position into the bending position.

The present invention provides a method and system for manufacturing an airbag. The manufacturing method includes the following steps: creating a 3D printing model, and providing an inner mold; determining the number of 3D printing nozzles and a positional relationship between each 3D printing nozzle and the inner mold according to the 3D printing model, and assigning a printing task to each 3D printing nozzle; controlling each 3D printing nozzle to execute a respective printing task on an outer surface of the inner mold so as to form a ply on the outer surface of the inner mold; and removing the 3D printing nozzles and the inner mold after all printing tasks are completed, so as to remove the ply from the outer surface of the inner mold. The ply forming the airbag is directly formed by means of 3D printing, thereby avoiding the steps of cutting and sewing in the conventional process, so that the reliability of the airbag is improved and the mass production efficiency is improved.

An airbag cushion has a plurality of base fabrics and adhesive joints for bonding each of the plurality of base fabrics, wherein the adhesive joint includes a sealing adhesive, a tensile strength (S1) between the base fabric and the adhesive joint is 500 N/5 cm or more, and an application width (L1) and an application thickness (L2) of the adhesive joint satisfy inequality (1): $\begin{array}{cc}L1L250{\mathrm{mm}}^2.& \left(1\right)\end{array}$