Abstract: A vehicle occupant sensing system adapted for detecting a condition of a vehicle seat assembly that includes at least one emitter and at least one sensor disposed in spaced relationship to the emitter. The sensor is operable to detect relative distance to the emitter to thereby detect the condition of the vehicle seat assembly. The vehicle occupant sensing system also includes at least one sensor assembly with a base and an upper slide member slidingly supported for movement toward and away from the base. The upper slide member includes an exterior surface that is continuous to thereby block contaminants from entering the sensor assembly. Also, at least one of the emitter and the sensor is supported by 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 detecting a condition of a vehicle seat assembly that includes at least one base and at least one upper slide member supported for movement toward and away from the base. The upper slide member is movable in response to the condition of the vehicle seat assembly. The vehicle occupant sensing system further includes at least one biasing member for biasing the upper slide member away from the base. At least one of the base and the upper slide member includes at least one retention member that is adapted for retaining the biasing 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 detecting a condition of a vehicle seat assembly. The vehicle occupant sensing system includes a base, an upper slide member supported for movement toward and away from the base, and at least one guiding rib. The guiding rib extends from one of the upper slide member and the base toward the other of the upper slide member and the base so as to guide movement of the upper slide member toward and away from the base. The vehicle occupant sensing system may be employed in a vehicle seat assembly to detect a condition of the vehicle seat.

Abstract: A vehicle occupant sensing system that includes at least one sensor and at least one sensor assembly. The sensor assembly has a base and an upper slide member supported for movement toward and away from the base wherein the sensor is operable to detect movement of the upper slide member toward and away from the base. The vehicle occupant sensing system also includes at least one contamination barrier member operatively attached to the upper slide member and at least partially shielding the sensor assembly to decrease contamination of the sensor assembly. 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 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 method of tuning the output of a sensor array for a vehicle seat occupancy sensing system that is used with a neural net for occupancy classification. The method includes the step of pressing a series of seat cushion body pressure distribution forms in a series of predetermined seating positions into a particular vehicle seat to produce a series of representative sensor response patterns from the sensor array. The method also includes the steps of comparing each sensor response pattern through the neural net and determining if any of the determined sensor patterns are indistinguishable, and then determining which sensors were deflected and the amount of deflection in those sensors for the indistinguishable sensor response patterns. The method steps further include adjusting the biasing of said sensors to cause said indistinguishable patterns to diverge and be distinguishable by the neural net and repeating the above steps until the senor response patterns are distinguishable from one another.

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 that includes a sensor assembly. The sensor assembly has a housing that includes a base and an upper slide member. The upper slide member is moveable toward and away from the base. A sensor is operatively fixed relative to at least one of the upper slide member and the base and is operable to detect movement of the upper slide member toward and away from the base. Additionally, the vehicle occupant sensing system includes a variable biasing member adapted to bias the upper slide member away from the base with a force that is non-linearly related to movement of the upper slide member toward and away from the base. The vehicle occupant sensing system of the present invention may be employed in a vehicle seat assembly to detect a condition of the vehicle seat assembly.

Abstract: A method of tuning the output of a sensor array for a vehicle seat occupancy sensing system that is used with a neural net for occupancy classification. The method includes the step of pressing a series of seat cushion body pressure distribution forms in a series of predetermined seating positions into a particular vehicle seat to produce a series of representative sensor response patterns from the sensor array. The method also includes the steps of comparing each sensor response pattern through the neural net and determining if any of the determined sensor patterns are indistinguishable, and then determining which sensors were deflected and the amount of deflection in those sensors for the indistinguishable sensor response patterns. The method steps further include adjusting the biasing of said sensors to cause said indistinguishable patterns to diverge and be distinguishable by the neural net and repeating the above steps until the senor response patterns are distinguishable from one another.

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: The present invention provides a method of testing a sensor array that is incorporated into a vehicle seat. The method includes the steps of placing a seat pan and cushion assembly having a seat trim cover and a sensor array into a seat build fixture and electrically connecting the sensor array to an electrical testing device capable of determining the actuation of the sensors in the sensor array. The method further includes the steps of determining if the sensors are at a predetermined unloaded output value, activating the seat build fixture to apply compression force to the seat pan and cushion assembly, and determining if the sensors have changed output values where the change corresponds to a predetermined amount. The method also includes the steps of mounting the seat trim cover to the bottom of the seat pan in a predetermined manner to form a completed lower seat assembly and de-activating the seat build fixture to release compression force from the completed lower seat assembly.

Abstract: A vehicle seat assembly for detecting a condition of the seat assembly. The vehicle seat assembly includes a seat cushion. The vehicle seat assembly also includes a vehicle occupant sensing system having a plurality of sensor assemblies. Each sensor assembly includes a base and an upper slide member. The upper slide member is supported for movement toward and away from the base in response to a condition of the seat cushion. Additionally, the vehicle seat assembly includes at least one seat cushion insert having a topside and an underside. The seat cushion insert is disposed between the seat cushion and the sensor assemblies, and the topside has at least one planar section.

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: Accordingly, the present invention is a vehicle seat assembly including a lower seat cushion with an upper surface and a lower surface. The vehicle seat assembly also has a plurality of sensor assemblies positioned adjacent the lower surface of the lower seat cushion. The sensor assemblies are responsive to a condition of the lower seat cushion. The vehicle seat assembly also has at least one reinforcing insert disposed between at least one of the sensor assemblies and the lower surface of the lower seat cushion. One advantage of the present invention is that the reinforcing insert protects the lower seat cushion by more evenly distributing pressure from the sensor assemblies onto the lower seat cushion. As such, the lower seat cushion is less likely to prematurely wear and is thus more likely to remain comfortable to sit upon over the course of its operating lifetime.

Abstract: A vehicle seat assembly that includes a seat cushion having at least one recess disposed thereon. The vehicle seat assembly also has a plurality of sensor assemblies, each including a base and an upper slide member. The upper slide member is supported for movement toward and away from the base in response to a condition of the seat cushion. Additionally, the vehicle seat assembly includes at least one seat cushion insert disposed within the recess of the seat cushion.

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.