Method and apparatus for attaching sensors to a seat assembly

• US 20050110312A1
• Filed: 12/01/2004
• Published: 05/26/2005
• Est. Priority Date: 03/02/2000
• Status: Active Grant

• Current Assignee: Continental Automotive GmbH (Continental AG)
• Original Assignee: Continental Automotive GmbH (Continental AG)
• Inventors: Pinkos, Andrew F.
• Granted Patent: US 7,264,309 B2
• Time in Patent Office: Days
• US Class Current: 297/216.100
• CPC Class Codes: B60N 2/002 Seats provided with an occupancy detection means mounted therein or thereon detection means responsive to presence or absence of children B60N2/266
• CPC Class Codes: B60N 2/5825 by hooks, staples, clips, snap fasteners or the like

Abstract

A vehicle seat assembly includes a sensor assembly that is used to provide data for an occupant classification system. The data is used to determine such characteristics as seat occupant weight and position. These characteristics are used to control deployment of a safety restraint mechanism such as an airbag. The sensor assembly is part of a mat that is placed on top of a foam cushion used to form a seat bottom. Fasteners are used to permanently attach the mat to the foam to restrict lateral and vertical movement of the mat relative to the foam.

Claims

1. A sensor assembly for a vehicle seat comprising:

a mat including a plurality of sensors and a mounting portion that is attachable to a seat cushion; and

at least one fastener inserted through said mounting portion for receipt within the seat cushion to permanently attach said mat to the seat cushion and restrict lateral and vertical movement of said mat relative to the seat cushion.

2. The assembly as set forth in claim 1 wherein the seat cushion is made from foam and includes a top surface and a bottom surface, said mat being supported on said top surface.

3. The assembly as set forth in claim 2 wherein said mounting portion comprises a plurality of ear extensions formed about the circumference of said mat and spaced apart from each other.

4. The assembly as set forth in claim 2 wherein said at least one fastener is comprised of a plurality of fasteners each having a body portion and a head portion with a larger diameter than said body portion, said head portion engaging a top surface of said mat when said fasteners are inserted through said mounting portion.

5. The assembly as set forth in claim 4 wherein said body portion extends at an angle relative to said head and terminates at a barbed distal end that does not extend beyond said bottom surface of said foam.

6. The assembly as set forth in claim 5 wherein said foam includes a plurality of angled bores for receiving said fasteners.

7. The assembly as set forth in claim 4 wherein said head is a top head and said body portion extends at a right angle relative to said top head and terminates at a distal end having a bottom head that engages said bottom surface of said foam.

8. The assembly as set forth in claim 2 wherein said foam includes a central area and a pair of side bolsters having a greater thickness than said central area, said central area and said bolsters being separated from each other by trenches.

9. The assembly as set forth in claim 8 wherein said mounting portion extends into said trenches and said at least one fastener comprises a plurality of rings that secure said mounting portions to a structural member embedded in the foam of said trenches.

10. The assembly as set forth in claim 2 wherein said at least one fastener comprises a first member having a plurality of hooks and a second member having a plurality of rings with one of said first or second members being integrally formed within said foam and the other of said first or second members being joined to said mounting portion such that when said mat is placed on said top surface of said foam said hooks engage said rings to attach said mat to said foam.

11. The assembly as set forth in claim 2 wherein said at least one fastener comprises a spiral member having a head portion and a resilient spiral body section that screws into said foam to secure said mat to said foam.

12. The assembly as set forth in claim 11 wherein said spiral body section is formed from a wire having a circular cross-section.

13. The assembly as set forth in claim 11 wherein said spiral body section is formed from plastic having a rectangular cross-section.

27. The assembly as set forth in claim 1 wherein said at least one fastener includes a first portion for engaging a surface of said mounting portion and a second portion at least partially embedded in the seat cushion.

28. The assembly as set forth in claim 27 wherein said mat includes a central body portion for supporting said sensors and wherein said mounting portion comprises a plurality of ear extensions formed about a perimeter of said central body portion with said second portion of said fastener being inserted directly through said ear extensions.

31. The assembly as set forth in claim 1 wherein said mounting portion and said fastener cooperate to define a predetermined permanent attachment position between said fastener and said seat cushion such that said mat and fastener hold said sensors in said predetermined position while said sensors generate data for an occupant classification system.

14. A vehicle seat assembly for use with an occupant classification system comprising:

a seat bottom having a cushion formed from foam with a top surface and a bottom surface;

a mat for placement on said top surface and including a mounting portion and a plurality of sensors for generating data for the occupant classification system; and

at least one fastener for permanently attaching said mat to said foam via said mounting portion to restrict lateral and vertical movement of said mat relative to said foam.

15. The assembly as set forth in claim 14 wherein said at least one fastener comprises a first member having a plurality of hooks and a second member having a plurality of rings with one of said first or second members being integrally formed within said foam and the other of said first or second members being adhered to said mounting portion such that when said mat is placed on said top surface of said foam said hooks engage said rings to attach said mat to said foam.

16. The assembly as set forth in claim 14 wherein said at least one fastener comprises a plurality of fasteners each having a head portion and a body portion extending at an acute angle relative to said head portion to terminate at a barbed distal end.

17. The assembly as set forth in claim 16 wherein said foam includes a plurality of angled bores and wherein said fasteners are inserted through said mounting portion into said bores such that said head portion rests against a top surface of said mat and said barbed distal end does not extend beyond said bottom surface of said foam.

18. The assembly as set forth in claim 14 wherein said at least one fastener comprises a plurality of fasteners each having a top head portion and a bottom head portion interconnected by a shaft extending at a right angle relative to said top and bottom head portions and wherein said fasteners are inserted through said mounting portion and into said foam such that said top head portion rests against said mat and said bottom head portion rests against said bottom surface of said foam.

19. The assembly as set forth in claim 14 wherein said foam includes a central area and a pair of side bolsters having a greater thickness than said central area, said central area and said bolsters being separated from each other by trenches;

said mounting portions are comprised of ear extensions formed about the circumference of said mat and spaced apart from each other, said ear extensions extending into said trenches; and

said at least one fastener is comprised of a plurality of rings that secure said ear extensions to a wire embedded in the foam of said trenches.

20. The assembly as set forth in claim 14 wherein said at least one fastener comprises a plurality of fasteners having a head portion and a spiral body portion that is rotated into engagement with said foam such that said head portion rests against said mat.

29. The assembly as set forth in claim 14 wherein said mat includes a central body portion for supporting said sensors and wherein said mounting portion comprises a plurality of ear extensions formed about a perimeter of said central body portion

30. The assembly as set forth in claim 29 wherein said at least one fastener includes a first portion for engaging a surface of said ear extension and a second portion directly inserted through said ear extension such that said second portion is at least partially embedded within the seat cushion.

32. The assembly as set forth in claim 14 wherein said sensors are permanently attached to said mat and wherein said mounting portion and said fastener cooperate to simultaneously attach said mat and said sensors to said foam to define a permanent attachment interface between said fastener and said foam in a predetermined position such that said fastener holds said mat and sensors in said predetermined position while said sensors generate the data for the occupant classification system.

21. A method for attaching a sensor mat to a foam seat cushion having a top surface and a bottom surface comprising the steps of:

(a) placing the mat on the top surface; and

(b) fastening the mat to the foam with at least one fastener.

22. The method as set forth in claim 21 wherein step (b) includes screwing a plurality of fasteners with spiral bodies into the foam.

23. The method as set forth in claim 21 wherein step (b) includes forming angled bores in the foam and inserting a plurality of barbed fasteners into the bores such that once inserted the fasteners cannot be removed.

24. The method as set forth in claim 21 wherein step (b) includes forming vertical bores in the foam and inserting a plurality of double headed fasteners into the bores such that a first head is positioned adjacent the top surface and a second head is positioned adjacent the bottom surface.

25. The method as set forth in claim 21 wherein step (b) includes forming at least one trench in the foam, embedding a wire in the foam of the trench, placing a mounting portion of the mat in the trench, and securing the mounting portion to the wire with at least one ring.

26. The method as set forth in claim 21 including a fastener mechanism with a first member having a plurality of hooks and a second member having a plurality of rings and step (b) further includes forming one of the first or second members within the foam, joining the other of the first or second members to the mat, and overlaying the first and second members such that the hooks engage the rings.