Inflatable curtain cushion

A safety restraint apparatus for protecting occupants of a vehicle, the apparatus comprising:

• a first cushion portion having deflated and inflated configurations, the first cushion portion being adapted to receive gas from a source of pressurized gas, the first cushion portion further being positioned proximate a first lateral surface of the vehicle in the inflated configuration, so as to provide protection from lateral impact;
• a second cushion portion having deflated and inflated configurations, the second cushion portion being positioned proximate a second lateral surface of the vehicle in the inflated configuration, so as to provide protection from lateral impact;
• a first sail portion connected between the first and second cushion portions, the first sail portion being attached to the first and second cushion portions in substantially gastight fashion to provide passage of gas from the first cushion portion into the second cushion portion;
• wherein the first sail portion is fabricated separately from the first and second cushion portions, the first sail portion being attached to the first and second cushion portions, and the first and second cushion portions each comprise a polymer coating covering at least a portion of an inner surface of the first and second cushion portions, the polymer coatings of the first and second cushion portions each being RF welded to a corresponding polymer coating on an outer surface of the first sail portion;
• wherein the first sail portion is fabricated substantially of a material different from that used to substantially fabricate the first and second cushion portions.

A safety restraint apparatus for protecting occupants of a vehicle, the apparatus comprising:

• a source of pressurized gas;
• a first cushion portion having deflated and inflated configurations, the first cushion portion being adapted to receive gas from the source, the first cushion portion comprising a polymer coating covering at least a portion of an inner surface of the first cushion portion being positioned proximate a first lateral surface of the vehicle in the inflated configuration, so as to protect an occupant of a front seat of the vehicle from lateral impact;
• a supply tube comprising a polymer coating covering at least a portion of an outer surface of a first end of the supply tube, the supply tube being connected between the first cushion portion and the source and adapted to provide a substantially unrestricted flow of gas therebetween, the supply tube being fabricated separately from the first cushion portion and formed of a substantially flexible material;
• and
• wherein the supply tube is attached to the first cushion portion by an attachment method chosen from the group consisting of sewing, RF welding, chemical bonding, and adhesive bonding;
• wherein the first cushion portion and the supply tube are substantially constructed of different materials.

A method for manufacturing a safety restraint apparatus for a vehicle, the method comprising:

• providing a first cushion portion adapted to receive and retain pressurized gas, the first cushion portion having a first sail port;
• providing a second cushion portion adapted to receive and retain pressurized gas, the second cushion portion having a second sail port;
• providing a first sail portion adapted to permit passage of gas between first and second ends of the first sail portion;
• and
• connecting the first sail portion to the first and second cushion portions to form an integral safety restraint apparatus adapted to provide side impact protection for an occupant of the vehicle;
• wherein connecting the first sail portion to the first and second cushion portions comprises attaching the first end of the first sail portion to the first sail port and attaching the second end of the first sail portion to the second sail port;
• wherein the first sail portion is fabricated substantially of a material different from that used to substantially fabricate the first and second cushion portions.

A method for manufacturing a safety restraint apparatus for a vehicle, the method comprising:

• providing a first cushion portion adapted to receive gas from a source of pressurized gas, the first cushion portion comprising a first sail port having an attachment surface, wherein the first cushion is disposable to inflate proximate a first lateral surface of the vehicle to provide lateral impact protection;
• providing a first sail portion comprising a first end and a second end, wherein the first end comprises an attachment surface;
• and
• RF welding the attachment surface of the first end of the first sail portion to the attachment surface of the first sail port to enable the first sail portion to convey gas from the first cushion portion to a second cushion portion disposable to inflate proximate a second lateral surface of the vehicle to provide lateral impact protection;
• wherein the first sail portion is fabricated substantially of a material different from that used to substantially fabricate the first cushion portion.

A safety restraint apparatus for protecting occupants of a vehicle, the apparatus comprising:

• a first cushion portion having deflated and inflated configurations, the first cushion portion being adapted to receive gas from a source of pressurized gas;
• a second cushion portion having deflated and inflated configurations;
• a first sail portion connected between the first and second cushion portions, the first sail portion being adapted to provide passage of gas from the first cushion portion into the second cushion portion;
• wherein the first sail portion is fabricated substantially of a material different from that used to substantially fabricate the first and second cushion portions.

A method for manufacturing a safety restraint apparatus for a vehicle, the method comprising:

• providing a first cushion portion adapted to receive and retain pressurized gas, the first cushion portion having a first sail port;
• providing a second cushion portion adapted to receive and retain pressurized gas, the second cushion portion having a second sail port;
• providing a first sail portion adapted to permit passage of gas between first and second ends of the first sail portion, wherein the first sail portion is fabricated substantially of a material different from that used to substantially fabricate the first and second cushion portions;
• and
• attaching the first end of the first sail portion to the first sail port and attaching the second end of the first sail portion to the second sail port to form an integral safety restraint apparatus.