Sensor assembly and method of forming the same

Abstract

A sensor assembly includes a sensing element electrically connected to a conductor of a flexible multiconductor cable using a conductive patch, which is electrically connected to the conductor. A method of forming a sensor assembly includes electrically connecting an electrically conductive patch to a sensing element and electrically connecting a conductor of a multiconductor cable to the electrically conductive patch.

1 . A method of forming a sensor assembly, the method comprising:
 electrically connecting an electrically conductive patch to a sensing element; and   electrically connecting a longitudinally-extending conductor of a multiconductor cable to the electrically conductive patch, thereby forming an electrical connection between the conductor and the sensing element.   
   
   
       2 . The method of  claim 1 , and further comprising securing a pad material to at least part of the multiconductor cable. 
   
   
       3 . The method of  claim 2 , wherein the pad material is a foam material. 
   
   
       4 . The method of  claim 2 , wherein the pad material is secured to at least part of the multiconductor cable using a means selected from a group consisting of an adhesive, thermal bonding, or a mechanical attachment. 
   
   
       5 . The method of  claim 2 , and further comprising:
 placing a substantially liquid impervious, vapor permeable material over at least a portion of the pad material.   
   
   
       6 . The method of  claim 2 , and further comprising:
 aligning the pad material in a recess in a vehicle seat assembly; and   placing an outer cover over at least part of the vehicle seat assembly.   
   
   
       7 . The method of  claim 1 , wherein electrically connecting the longitudinally-extending conductor of the multiconductor cable to the electrically conductive patch comprises:
 cutting at least part of the conductor in a substantially lateral direction;   cutting at least part of the multiconductor cable adjacent the conductor in a substantially longitudinal direction to form a tab having three sides which are not connected to the cable, wherein the lateral and longitudinal directions are substantially perpendicular to each other, and wherein the tab is capable of protruding from the cable; and   removing an insulating layer from at least part of the tab.   
   
   
       8 . The method of  claim 7 , wherein the insulating layer is removed from the tab using a means selected from a group consisting of a laser, heat, and mechanical abrasion. 
   
   
       9 . The method of  claim 7 , and further comprising:
 securing at least part of the tab to the electrically conductive patch.   
   
   
       10 . The method of  claim 1 , wherein the cable and the sensing element are positioned on opposing sides of a pad material, and wherein at least part of the tab projects through the pad material. 
   
   
       11 . The method of  claim 1 , wherein the electrically conductive patch includes a metallized nonwoven material. 
   
   
       12 . A method of forming a sensor mat assembly, the method comprising:
 providing a first sensing element;   electrically connecting a first electrically conductive patch to the first sensing element;   electrically connecting a first conductor of a multiconductor cable to the first electrically conductive patch;   securing at least part of a first side of a pad material to the cable;   securing a second sensing element to a second side of the pad material, wherein the first side of the pad material opposes the second side;   electrically connecting a second electrically conductive patch to the second sensing element; and   electrically connecting a second conductor of the multiconductor cable to the second electrically conductive patch.   
   
   
       13 . The method of  claim 12 , wherein electrically connecting the first conductor to the first conductive patch comprises:
 cutting at least part of the first conductor in a substantially lateral direction;   cutting at least part of the multiconductor cable adjacent the first conductor in a substantially longitudinal direction to form a tab having three sides which are not connected to the cable, wherein the lateral and longitudinal directions are substantially perpendicular to each other, and wherein the tab is capable of protruding from the cable; and   removing an insulating layer from at least part of the tab.   
   
   
       14 . The method of  claim 12 , wherein electrically connecting the second conductor to the second conductive patch comprises:
 cutting at least part of the second conductor in a substantially lateral direction;   cutting at least part of the multiconductor cable adjacent the second conductor in a substantially longitudinal direction to form a tab having three sides which are not connected to the cable, wherein the lateral and longitudinal directions are substantially perpendicular to each other, and wherein the tab is capable of protruding from the cable; and   removing an insulating layer from at least part of the tab.   
   
   
       15 . The method of  claim 12 , wherein the first and second electrically conductive patches each include a metallized nonwoven material. 
   
   
       16 . The method of  claim 12 , and further comprising securing a second side of the pad material to the cable. 
   
   
       17 . The method of  claim 12 , wherein at least part of the first side of the pad material is secured to the cable using a means selected from a group consisting of an adhesive, thermal bonding, or a mechanical attachment. 
   
   
       18 . The method of  claim 12 , and further comprising:
 placing a substantially liquid impervious, vapor permeable material over at least a portion of the pad material.   
   
   
       19 . The method of  claim 12 , and further comprising:
 aligning the pad material in a recess in a vehicle seat assembly; and   placing an outer cover over at least part of the vehicle seat assembly.