Vehicle occupant sensing system and method of electrically attaching a sensor to an electrical circuit

• US 7,034,709 B2
• Filed: 12/30/2003
• Issued: 04/25/2006
• Est. Priority Date: 06/26/2003
• Status: Expired due to Fees

• Current Assignee: Lear Corporation
• Original Assignee: Lear Corporation
• Inventors: Nathan, John F., Ricard, Christopher T., Young, Oliver
• Primary Examiner(s): Hofsass, Jeffery
• Assistant Examiner(s): LAI, ANNE VIET NGA
• Application Number:
  US10/748,514
• Publication Number:
  US 20040262958A1
• Time in Patent Office: 847 Days
• Field of Search: 340665-667, 280/735, 701/45, 73862041-862046, 180/273, 177/210.EM, 324/207.2
• US Class Current: 340/667
• 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: B60R 21/01516 using force or pressure sensing means
• CPC Class Codes: G01G 19/4142 for controlling activation of safety devices, e.g. airbag systems electrical circuits for triggering safety arrangements in case of vehicle accidents B60R21/015
• CPC Class Codes: G01G 21/28 Frames, Housings
• CPC Class Codes: G01G 23/005 Means for preventing overload
• CPC Class Codes: G01G 3/04 using a plurality of springs

Abstract

A vehicle occupant sensing system for detecting a condition of a vehicle seat. The system includes a circuit carrier, an electric circuit with a plurality of leads, and at least one sensor that has a plurality of terminals. Also, the system includes a plurality of conductive connectors associated with the corresponding terminals and leads. The connectors each include a body disposed for electrical communication with the associated terminal and include at least one deformable blade. The blade extends into the circuit carrier and into electrical communication with the associated lead of the circuit, thereby mechanically attaching the conductive connector to the carrier while providing electrical communication between the sensor and the circuit. Also included is a method of manufacturing the same. By piercing the carrier and the circuit, the blade establishes a more robust mechanical and electrical connection for the sensor, thereby increasing the operating life of the system.

Claims

1. A vehicle occupant sensing system for detecting a condition of a vehicle seat, said system comprising:

a circuit carrier and an electric circuit supported by said circuit carrier, said electric circuit presenting a plurality of leads;

at least one low profile sensor assembly having a housing that includes a fixed base, an upper slide member, and at least one intermediate guide member disposed between said upper slide member and said base, said upper slide member and said at least one intermediate guide member supported for movement toward and away from said fixed base in response to movement of said vehicle seat;

at least one sensor operatively supported by said circuit carrier and fixed relative to said upper slide member and said base and operable to detect movement of said upper slide member toward and away from said base, said at least one sensor including a plurality of terminals corresponding to said plurality of leads presented by said electric circuit; and

a plurality of conductive connectors associated with said corresponding plurality of terminals and leads, said conductive connectors each including a body disposed for electrical communication with the associated terminal and including at least one deformable blade extending into said circuit carrier and into electrical communication with the associated lead of said electric circuit, thereby mechanically attaching said conductive connector to said circuit carrier while providing electrical communication between said at least one sensor and said electric circuit.

2. A vehicle occupant sensing system as set forth in claim 1, wherein said at least one deformable blade comprises a first portion, a second portion and a third portion, and wherein said first portion extends into and through said circuit carrier and into electrical communication with the associated lead of said electric circuit, and said second portion is bent such that said third portion extends into said circuit carrier and into electrical communication with the associated lead of said electric circuit.

3. A vehicle occupant sensing system as set forth in claim 1, wherein said body of said conductive connector comprises at least one arm adapted to contact the associated terminal to thereby establish mechanical and electrical communication with the associated terminal.

4. A vehicle seat comprising:

a lower seat cushion including an upper surface and a lower surface spaced from said upper surface;

a circuit carrier disposed adjacent said lower surface of said lower seat cushion;

an electric circuit supported by said circuit carrier, said electric circuit presenting a plurality of leads;

at least one low profile sensor assembly having a housing that includes a fixed base, an upper slide member, and at least one intermediate guide member disposed between said upper slide member and said base, said upper slide member and said at least one intermediate guide member supported for movement toward and away from said fixed base in response to said lower surface of said seat cushion;

at least one sensor operatively supported by said circuit carrier adjacent said at least one low profile sensor assembly, said at least one sensor fixed relative to said upper slide member and said base and adapted to detect a condition of the vehicle seat based on the response of said at least one low profile sensor assembly, said at least one sensor including a plurality of terminals corresponding to said plurality of leads presented by said electric circuit; and

a plurality of conductive connectors associated with said corresponding plurality of terminals and leads, said conductive connectors each including a body disposed for electrical communication with the associated terminal and including at least one deformable blade extending into said circuit carrier and into electrical communication with the associated lead of said electric circuit, thereby mechanically attaching said conductive connector to said circuit carrier while providing electrical communication between said at least one sensor and said electric circuit.

5. A vehicle seat as set forth in claim 4, wherein said at least one deformable blade comprises a first portion, a second portion and a third portion, and wherein said first portion extends into and through said circuit carrier and into electrical communication with the associated lead of said electric circuit, and said second portion is bent such that said third portion extends into said circuit carrier and into electrical communication with the associated lead of said electric circuit.

6. A vehicle seat as set forth in claim 4, wherein said body of said conductive connector comprises at least one arm adapted to contact the associated terminal to thereby establish mechanical and electrical communication with the associated terminal.

7. A method of manufacturing a vehicle occupant sensing system for detecting a condition of a vehicle seat, the vehicle occupant sensing system comprising:

a circuit carrier and an electric circuit supported by said circuit carrier, said electric circuit presenting a plurality of leads;

at least one low profile sensor assembly having a housing that includes a fixed base, an upper slide member, and at least one intermediate guide member disposed between said upper slide member and said base, said upper slide member and said at least one intermediate guide member supported for movement toward and away from said fixed base in response to movement of said vehicle seat;

at least one sensor operatively supported by said circuit carrier and fixed relative to said upper slide member and said base and operable to detect movement of said upper slide member toward and away from said base, said at least one sensor including a plurality of terminals corresponding to said plurality of leads presented by said electric circuit; and

a plurality of conductive connectors associated with said corresponding plurality of terminals and leads, said conductive connectors each including a body disposed for electrical communication with the associated terminal and including at least one deformable blade;

wherein said method of manufacturing comprises the step;

a) extending said at least one deformable blade into said circuit carrier and into electrical communication with the associated lead of said electric circuit, thereby mechanically attaching said conductive connector to said circuit carrier.

8. A method of manufacturing a vehicle occupant sensing system as set forth in claim 7, wherein step (a) comprises the steps:

1) extending a first portion of said at least one blade into and through said circuit carrier and into electrical communication with the associated lead of said electric circuit;

2) bending a second portion of said at least one blade; and

3) extending a third portion of said at least one blade into said circuit carrier and into electrical communication with the associated lead of said electric circuit.