Abstract: A low profile sensor assembly for use in a vehicle occupant sensing system that comprises a base, an upper slide member, and at least one intermediate guide member. Also disclosed is a low profile sensor assembly for use in a vehicle occupant sensing system that comprises a base with an outer step and a receptacle, and the low profile sensor assembly also comprises an upper slide member with a lower flange and a retainer. The outer step is adapted to accept the lower flange, and the receptacle is adapted to accept the retainer. The intermediate guide member, the outer step, and the receptacle each allow the respective upper slide member to move further toward the base. Thus, when the low profile sensor assembly is incorporated into a vehicle seat assembly, the low profile sensor assembly is less likely to detrimentally affect the comfort level of the vehicle seat assembly.

Abstract: A vehicle occupant sensing system adapted for detecting a condition of a vehicle seat assembly including at least one emitter and at least one sensor disposed spaced relative to the emitter. The sensor is operable to detect relative distance between the emitter and the sensor to thereby detect the condition of the vehicle seat assembly. The vehicle occupant sensing system also includes at least one sensor assembly having a base and an upper slide member moveable toward and away from the base. The upper slide member includes at least one interference member that generates an interference fit between the emitter and the interference member to thereby securely mount the emitter to the upper slide member. The vehicle occupant sensing system may be employed in a vehicle seat to detect a condition of the vehicle seat.

Abstract: A vehicle occupant sensing system for a vehicle seat assembly that includes at least one emitter and at least one sensor operable to detect relative distance between the sensor and the emitter to thereby detect a condition of the vehicle seat assembly. The vehicle occupant sensing system also includes a biasing pad adapted so as to be disposed below a seat cushion of the vehicle seat assembly so as to deflect in response to deflection of the seat cushion. The biasing pad supports at least one of the emitter and the sensor such that the emitter and the sensor are biased away from each other and such that one of the emitter and the sensor are supported for movement toward and away from the other.

Abstract: A method of determining an equivalent output value for a failed sensor in a vehicle seat having an occupancy sensing system. The method includes the steps of sensing the output of each sensor in an array of sensors that detect a physical presence in the seat. If the output of the sensor falls below a predetermined value, exceeds a predetermined value, or remains fixed the sensor is classified as inoperative. The method then calculates an equivalent sensor output value for any sensor classified as inoperative and applies the sensor array output values for each operable sensor in the array and the calculated equivalent output value for any inoperative sensor to a neural net. Then, the applied sensor output values are recognizing as falling within one of a group of predetermined classification patterns that represent a physical presence in the seat defined by size, weight, and physical orientation.

Abstract: A vehicle occupant sensing system including a circuit carrier, an electric circuit with leads, and a sensor with a body and a plurality of formed terminals. Each of the terminals has a lower portion spaced a predetermined distance away from a plane defined by the bottom surface of the body. Moreover, the system has a plurality of conductive connectors each including a blade extending into the circuit carrier and into electrical communication with a lead of the electric circuit. The body is supported on the circuit carrier, and the terminals are supported by the top end of the connector. Also included is a method of manufacturing the same. The formed terminals allow the sensor to be more easily positioned relative to the connector, thereby facilitating assembly. Also, the connectors support the terminals when the connector attaches to the terminal, thereby inhibiting damage to the terminals that could otherwise occur.

Abstract: A method of recognizing and classifying the occupancy in a vehicle seat having an occupancy sensing system, including the steps of sensing the output of an array of sensors that detect a physical presence in a seat and applying the sensor array output as a vector representation to a neural net that was trained using a learning vector quantization algorithm. The method also includes the step of recognizing the sensor array output as falling within one of a group of predetermined classification patterns that represent a physical presence in the seat defined by size, weight, and physical orientation.

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.

Abstract: A low profile sensor assembly for use in a vehicle occupant sensing system that comprises a base, an upper slide member, and at least one intermediate guide member. Also disclosed is a low profile sensor assembly for use in a vehicle occupant sensing system that comprises a base with an outer step and a receptacle, and the low profile sensor assembly also comprises an upper slide member with a lower flange and a retainer. The outer step is adapted to accept the lower flange, and the receptacle is adapted to accept the retainer. The intermediate guide member, the outer step, and the receptacle each allow the respective upper slide member to move further toward the base. Thus, when the low profile sensor assembly is incorporated into a vehicle seat assembly, the low profile sensor assembly is less likely to detrimentally affect the comfort level of the vehicle seat assembly.

Abstract: A vehicle occupant sensing system for detecting a condition of a vehicle seat assembly having a lower seat cushion supported by a seat pan. The system has a tray with a plurality of pedestals disposed between the seat pan and the cushion. The system also has a plurality of sensor assemblies, each defining a force responsive axis and disposed between the lower seat cushion and tray. The pedestals support some of the sensor assemblies such that the force responsive axes of the sensor assemblies are substantially aligned with the occupant's weight load. Furthermore, the system may be employed in a seat assembly to detect a condition thereof. The tray allows addition of safety features in the vehicle seat assembly such that the seat more effectively retains the occupant, and yet the tray positions the sensor assemblies to be responsively aligned with the occupant's weight load despite these additional features.

Abstract: A low profile sensor assembly for use in a vehicle occupant sensing system that comprises a base, an upper slide member, and at least one intermediate guide member. Also disclosed is a low profile sensor assembly for use in a vehicle occupant sensing system that comprises a base with an outer step and a receptacle, and the low profile sensor assembly also comprises an upper slide member with a lower flange and a retainer. The outer step is adapted to accept the lower flange, and the receptacle is adapted to accept the retainer. The intermediate guide member, the outer step, and the receptacle each allow the respective upper slide member to move further toward the base. Thus, when the low profile sensor assembly is incorporated into a vehicle seat assembly, the low profile sensor assembly is less likely to detrimentally affect the comfort level of the vehicle seat assembly.

Abstract: A vehicle occupant sensing system including a circuit carrier, an electric circuit with leads, and a sensor with a body and a plurality of formed terminals. Each of the terminals has a lower portion spaced a predetermined distance away from a plane defined by the bottom surface of the body. Moreover, the system has a plurality of conductive connectors each including a blade extending into the circuit carrier and into electrical communication with a lead of the electric circuit. The body is supported on the circuit carrier, and the terminals are supported by the top end of the connector. Also included is a method of manufacturing the same. The formed terminals allow the sensor to be more easily positioned relative to the connector, thereby facilitating assembly. Also, the connectors support the terminals when the connector attaches to the terminal, thereby inhibiting damage to the terminals that could otherwise occur.

Abstract: A vehicle occupant sensing system for detecting a condition of a vehicle seat assembly having a lower seat cushion supported by a seat pan. The system has a tray with a plurality of pedestals disposed between the seat pan and the cushion. The system also has a plurality of sensor assemblies, each defining a force responsive axis and disposed between the lower seat cushion and tray. The pedestals support some of the sensor assemblies such that the force responsive axes of the sensor assemblies are substantially aligned with the occupant's weight load. Furthermore, the system may be employed in a seat assembly to detect a condition thereof. The tray allows addition of safety features in the vehicle seat assembly such that the seat more effectively retains the occupant, and yet the tray positions the sensor assemblies to be responsively aligned with the occupant's weight load despite these additional features.

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.