Sensor assembly and method of forming the same

#The present invention relates to a sensor assembly. More particularly, the present invention relates to a sensor assembly including a sensing element connected to a conductor of a multiconductor cable using a conductive patch. In addition, the present invention relates to a method of forming a sensor assembly.

#Sensor assemblies may be used to monitor the position, orientation, presence, or size of a person or object within a defined space. The position, orientation, presence, or size of a person or object in the defined space may affect the impedance around a sensing element of a sensor assembly. A current may be applied to one or more sensors, and an electronic control unit (“ECU”) may measure the impedance changes in an electric field around each sensing element in order to gather information about the position, orientation, presence, or size of a person. For example, a sensor assembly may be used in a vehicle seat to help regulate the deployment of air bags.

#A sensor assembly generally includes an array of electrode sensors (or other suitable sensing elements) arranged about the defined space, where each sensor is electrically connected to the ECU. Each sensor is typically connected to the ECU using a conductive wire which is electrically connected to the sensor using an eyelet and rivet securing means or by “crimping” the sensor and wire together. Typically, there is one discrete conductive wire per sensor, and so each sensor assembly has multiple, but separate, conductive wires. When used in a vehicle seat, the sensors may be attached to a flexible pad material, such as a polyurethane foam mat, which may then be used to form part of the vehicle seat.

#The present invention will be further explained with reference to the drawing figures listed below, where like structure is referenced by like numerals throughout the several views.

#FIG. 1 is a perspective view of a sensor mat assembly in accordance with the present invention, where a sensor array is arranged on opposing sides of a foam mat and a flat cable positioned between layers of foam.

#FIG. 2 is an exploded perspective view of a first exemplary embodiment of a sensor mat assembly in accordance with the present invention, where a foam mat is positioned between a flat cable and a sensing element.

#While the above-identified figures set forth several embodiments of the invention, other embodiments are also contemplated, as noted in the discussion. In all cases, this disclosure presents the invention by way of representation and not limitation. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art, which fall within the scope and spirit of the principles of the invention.

#The present invention is a sensor assembly including a sensing element, a flexible multiconductor cable, and an electrically conductive patch, where the electrically conductive patch electrically connects the sensing element and a conductor of the cable. The electrically conductive patch is positioned between the cable and the sensing element. The cable may be used to connect the sensing element to an ECU. The present invention is also a method of forming the inventive sensor assembly. Although the present invention is described in reference to a vehicle seat, other applications of the present invention in which it may be desirable to gather information about the position, orientation, presence, or size of a person within a defined space are also contemplated.

#A flexible multiconductor cable in accordance with the present invention is preferably a flexible flat cable. A “flat cable” is a cable including a plurality of mutually insulated conductors, where the cable preferably has generally flat top and bottom surfaces and a non-cylindrical cross-section. The conductors are preferably aligned in a common plane than being grouped together or around a common axis to form a circular cross-section. The conductors are typically bound together (while being aligned in a common plane), which may increase the structural integrity and strain relief capabilities of the flat cable. The conductors may be any suitable shape, such as round or flat. Although a cable having a cylindrical cross-section may be used with the present invention, a flat cable is preferred because such a cable may be a more efficient use of space and a flat cable may be more comfortable to a vehicle occupant sitting on the vehicle seat.