Sensor assembly and method of forming the same

• US 20060220657A1
• Filed: 04/04/2005
• Published: 10/05/2006
• Est. Priority Date: 04/04/2005
• Status: Active Grant

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Ngin, Sywong, Mitchell, Charles
• Granted Patent: US 7,352,191 B2
• Time in Patent Office: Days
• US Class Current: 324/609
• 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: H05K 1/189 characterised by the use of a flexible or folded printed circuit H05K3/326 takes precedence
• CPC Class Codes: H05K 3/326 the printed circuit having integral resilient or deformable parts, e.g. tabs or parts of flexible circuits H05K3/365 takes precedence
• CPC Class Codes: Y10T 29/49169 Assembling electrical component directly to terminal or elongated conductor
• CPC Class Codes: Y10T 29/49174 Assembling terminal to elongated conductor

Abstract

A sensor assembly includes a sensing element electrically connected to a conductor of a flexible multiconductor cable using a conductive patch, which is electrically connected to the conductor. A method of forming a sensor assembly includes electrically connecting an electrically conductive patch to a sensing element and electrically connecting a conductor of a multiconductor cable to the electrically conductive patch.

Claims

1. A sensor assembly comprising:

a sensing element;

an electrically conductive patch electrically connected to the sensing element; and

a cable including a plurality of conductors,

wherein the electrically conductive patch is positioned between the cable and the sensing element, and wherein a conductor of the cable is electrically connected to the electrically conductive patch,

and wherein the cable is secured to the electrically conductive patch using an adhesive.

3. The sensor assembly of claim 1, and further comprising:

a pad material positioned between the electrically conductive patch and the cable.

4. The sensor assembly of claim 1, and further comprising:

a pad material positioned adjacent the sensing element.

5. The sensor assembly of claim 4, wherein the pad material is a foam material.

6. The sensor assembly of claim 4, and further comprising a substantially liquid impervious, vapor permeable material covering at least a portion of the pad material.

7. The sensor assembly of claim 4, wherein the pad material comprises a portion of a vehicle seat assembly.

8. The sensor assembly of claim 7, and further comprising an outer cover fitted over at least part of the vehicle seat assembly.

9. The sensor assembly of claim 1, wherein the cable is a flat cable, and wherein the plurality of conductors are mutually insulated.

10. The sensor assembly of claim 1, wherein the electrically conductive patch includes a metallized nonwoven material.

11. The sensor assembly of claim 1, wherein at least some of the conductors of the cable are electrically connected to an electronic control unit.

2. (canceled)

12. A sensor mat assembly comprising:

a pad material;

a first sensing element electrically connected to a first electrically conductive patch on a first side of the pad material;

a second sensing element electrically connected to a second electrically conductive patch on a second side of the pad material, wherein the first and second sides of the pad material oppose one another; and

a flat cable including a first conductor and a second conductor, and wherein the first conductor is electrically connected to the first electrically conductive patch and the second conductor is electrically connected to the second electrically conductive patch.

13. The sensor mat assembly of claim 12, wherein the flat cable and the first sensing element are on opposing sides of the pad material, and wherein the first conductor projects through the pad material to electrically connect to the first electrically conductive patch.

14. The sensor mat assembly of claim 12, wherein each electrically conductive patch includes a metallized nonwoven material.

15. The sensor mat assembly of claim 12, where the flat cable runs along the first side of the pad material.

16. The sensor mat assembly of claim 12, wherein the flat cable runs along both the first and second opposed sides of the pad material.

17. The sensor mat assembly of claim 12, and further comprising a substantially liquid impervious, vapor permeable material covering at least a portion of the pad material.

18. The sensor mat assembly of claim 12, wherein the sensor assembly comprises a portion of a vehicle seat assembly.

19. A method of forming a sensor assembly, the method comprising:

electrically connecting an electrically conductive patch to a sensing element; and

electrically connecting a longitudinally-extending conductor of a multiconductor cable to the electrically conductive patch by applying an adhesive to secure the cable to the electrically conductive patch, thereby forming an electrical connection between the conductor and the sensing element.

20. The method of claim 19, and further comprising securing a pad material to at least part of the multiconductor cable.

21. The method of claim 20, wherein the pad material is a foam material.

22. The method of claim 20, wherein the pad material is secured to at least part of the multiconductor cable using a means selected from a group consisting of an adhesive, thermal bonding, or a mechanical attachment.

23. The method of claim 20, and further comprising:

placing a substantially liquid impervious, vapor permeable material over at least a portion of the pad material.

24. The method of claim 20, and further comprising:

aligning the pad material in a recess in a vehicle seat assembly; and

placing an outer cover over at least part of the vehicle seat assembly.

25. The method of claim 19, wherein electrically connecting the longitudinally-extending conductor of the multiconductor cable to the electrically conductive patch comprises:

cutting at least part of the conductor in a substantially lateral direction;

cutting at least part of the multiconductor cable adjacent the conductor in a substantially longitudinal direction to form a tab having three sides which are not connected to the cable, wherein the lateral and longitudinal directions are substantially perpendicular to each other, and wherein the tab is capable of protruding from the cable; and

removing an insulating layer from at least part of the tab.

26. The method of claim 25, wherein the insulating layer is removed from the tab using a means selected from a group consisting of a laser, heat, and mechanical abrasion.

27. The method of claim 25, and further comprising:

securing at least part of the tab to the electrically conductive patch.

28. The method of claim 19, wherein the cable and the sensing element are positioned on opposing sides of a pad material, and wherein at least part of a tab projects through the pad material.

29. The method of claim 19 wherein the electrically conductive patch includes a metallized nonwoven material.

30. A method of forming a sensor mat assembly, the method comprising:

providing a first sensing element;

electrically connecting a first electrically conductive patch to the first sensing element;

electrically connecting a first conductor of a multiconductor cable to the first electrically conductive patch;

securing at least part of a first side of a pad material to the cable;

securing a second sensing element to a second side of the pad material, wherein the first side of the pad material opposes the second side;

electrically connecting a second electrically conductive patch to the second sensing element; and

electrically connecting a second conductor of the multiconductor cable to the second electrically conductive patch.

31. The method of claim 30, wherein electrically connecting the first conductor to the first conductive patch comprises:

cutting at least part of the first conductor in a substantially lateral direction;

cutting at least part of the multiconductor cable adjacent the first conductor in a substantially longitudinal direction to form a tab having three sides which are not connected to the cable, wherein the lateral and longitudinal directions are substantially perpendicular to each other, and wherein the tab is capable of protruding from the cable; and

removing an insulating layer from at least part of the tab.

32. The method of claim 30, wherein electrically connecting the second conductor to the second conductive patch comprises:

cutting at least part of the second conductor in a substantially lateral direction;

cutting at least part of the multiconductor cable adjacent the second conductor in a substantially longitudinal direction to form a tab having three sides which are not connected to the cable, wherein the lateral and longitudinal directions are substantially perpendicular to each other, and wherein the tab is capable of protruding from the cable; and

removing an insulating layer from at least part of the tab.

33. The method of claim 30, wherein the first and second electrically conductive patches each include a metallized nonwoven material.

34. The method of claim 30, and further comprising securing a second side of the pad material to the cable.

35. The method of claim 30, wherein at least part of the first side of the pad material is secured to the cable using a means selected from a group consisting of an adhesive, thermal bonding, or a mechanical attachment.

36. The method of claim 30, and further comprising:

placing a substantially liquid impervious, vapor permeable material over at least a portion of the pad material.

37. The method of claim 30, and further comprising:

aligning the pad material in a recess in a vehicle seat assembly; and

placing an outer cover over at least part of the vehicle seat assembly.

38. A sensor assembly comprising:

a sensing element;

an electrically conductive patch electrically connected to the sensing element; and

a cable including a plurality of conductors,

wherein the electrically conductive patch is positioned between the cable and the sensing element, and wherein a conductor of the cable is electrically connected to the electrically conductive patch,

and wherein the conductor is connected to the electrically conductive patch at an angle not orthogonal to the electrically conductive patch.

39. (canceled)