Flat sew pattern passenger air bag

Claim 1

An air bag (20) formed from a panel of woven material, the panel comprising: a main panel portion (22) having straight parallel sides (42), a first neck portion (24) extending from a first end (26) of the main panel portion and a second neck portion (28) extending from an opposite or second end (30) of the main panel portion, the first neck portion (24) and the second neck portion (28) positioned in an overlapping, registered relationship and sewn together at first and second sew lines along mating first and second sides (48) of the first neck portion and second neck portion to define a joined neck portion, respective first ends (54) of the joined neck portion proximate respective ends of the main panel portion, positioned along a predetermined line (70) in the main panel portion defined by the first and second ends of the main panel portion positioned in an overlapping, registered relationship, the remaining parts of the main panel portion forming a single loop adjacent the predetermined line, the joined neck portion being laid flat. On the single loop with the predetermined line intermediate ends of the single loop and the aligned edges of the main panel portion are sewn together along third and fourth sew lines such that upon inflation of the air bag the joined neck portion extends away from the main panel portion and intersects a plane cutting through the single loop generally along the third and fourth sew lines.