Method and apparatus for attaching sensors to a seat assembly

• US 7,048,338 B2
• Filed: 02/20/2001
• Issued: 05/23/2006
• Est. Priority Date: 03/02/2000
• Status: Expired due to Fees

• Current Assignee: Siemens Automotive Corporation (Siemens AG)
• Original Assignee: Siemens VDO Automotive Corporation (Siemens AG)
• Inventors: Pinkos, Andrew F.
• Primary Examiner(s): Brown, Peter R.
• Application Number:
  US09/788,827
• Publication Number:
  US 20020063465A1
• Time in Patent Office: 1,918 Days
• Field of Search: 297/217.1, 297/217.2, 297/217.3, 297/216.1, 297/216.14, 297/284.1, 297/284.2, 297/452.6, 297/180.12, 297/218.2, 297/218.1, 297/218.5, 280/730.1, 280/730.2, 565/3, 565/59, 569/3, 569/4, 542/4, 571/3, 340/665, 340/666, 340/667, 411/275, 411/230, 411/936
• US Class Current: 297/452.6
• 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 2/0025 by using weight measurement
• CPC Class Codes: B60N 2/0033 mounted on or in the foam cushion
• 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 seat cushion and sensor assembly for a vehicle seat comprising:

a mat including a plurality of sensors and a mounting portion for attachment to a seat cushion wherein the seat cushion is made from foam and includes said top surface and bottom surface, said mat being supported on said top surface, and wherein said mounting portion comprises a plurality of ear extensions formed about the circumference of said mat and spaced apart from each other; and

at least one fastener inserted through said mounting portion and into said seat cushion to permanently attach said mat to said seat cushion and restrict lateral and vertical movement of said mat relative to said seat cushion, said at least one fastener comprising a head portion engaging a top surface of said mat and a body portion embedded in said seat cushion, wherein said mounting portion and said at least one fastener cooperate to define a predetermined permanent attachment position between said at least one fastener and said seat cushion such that said mat and said at least one fastener hold said plurality of sensors in said predetermined permanent attachment position while said plurality of sensors generate data for an occupant classification system.

2. A seat cushion and sensor assembly for a vehicle seat comprising:

a mat including a plurality of sensors and a mounting portion for attachment to a seat cushion 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; and

at least one fastener inserted through said mounting portion and into said seat cushion to permanently attach said mat to said seat cushion and restrict lateral and vertical movement of said mat relative to said seat cushion 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 plurality of fasteners is inserted through said mounting portion, and said body portion extending at an angle relative to said head portion and terminating at a barbed distal end that does nor extend beyond said bottom surface of said foam.

3. The assembly as set forth in claim 2 wherein said foam includes a plurality of angled bores for receiving said plurality of fasteners.

4. A seat cushion and sensor assembly for a vehicle seat comprising:

a mat including a plurality of sensors and a mounting portion for attachment to a seat cushion, the seat cushion being made from foam and including a top surface and a bottom surface, said mat being supported on said top surface 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 portion extending into said trenches; and

at least one fastener inserted through said mounting portion and into said seat cushion to permanently attach said mat to said seat cushion and restrict lateral and vertical movement of said mat relative to said seat cushion wherein said at least one fastener includes an upper portion engaging at least one of a top surface or a bottom surface of said mat and a lower portion embedded in said seat cushion, and wherein 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.

5. 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, wherein said mat includes a central body portion for supporting said plurality of sensors and wherein said mounting portion comprises a plurality of ear extensions formed about a perimeter of said central body portion; 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, said at least one fastener including a first portion directly engaging a top or bottom surface of said mat and a second portion embedded within said cushion wherein said plurality of sensors is permanently attached to said mat and wherein said mounting portion and said at least one fastener cooperate to simultaneously attach said mat and said plurality of sensors to said foam to define a permanent attachment interface between said at least one fastener and said foam in a predetermined position such that said at least one fastener holds said mat and said plurality of sensors in said predetermined position while said plurality of sensors generate the data for the occupant classification system.

6. The assembly as set forth in claim 5 wherein said first portion comprises a first member having a plurality of hooks and said second portion comprises 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 bottom surface of 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.

7. The assembly as set forth in claim 5 wherein said at least one fastener comprises a plurality of fasteners each having a top head portion forming said first portion and a bottom head portion interconnected by a shaft forming said second portion, said 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 top surface of said mat and said bottom head portion rests against said bottom surface of said foam.

8. The assembly as set forth in claim 5 wherein said at least one fastener comprises a plurality of fasteners having a head portion forming said first portion and a spiral body portion forming said second portion that is rotated into engagement with said foam such that said head portion rests against said top surface of said mat.

9. 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 wherein said foam includes a plurality of angled bores;

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 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 and wherein said fasteners are inserted through said mounting portion into said angled 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.

10. 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 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.

11. A seat cushion and sensor assembly for a vehicle seat comprising:

a mat including a plurality of sensors and a mounting portion for attachment to a seat cushion; and

at least one fastener inserted through said mounting portion and into said seat cushion to permanently attach said mat to said seat cushion and restrict lateral and vertical movement of said mat relative to said seat cushion, said at least one fastener including a first portion for engaging a top surface of said mounting portion and a second portion at least partially embedded in the seat cushion, said first portion having a greater diameter than said second portion, and 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.

12. 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 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; 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 wherein said at least one fastener includes a first portion for engaging a top 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 wherein said first portion has a greater diameter than said second portion.