Sensor terminal module, module, fluid container, electrical functional element, steering wheel, method, and device

Abstract

The present invention relates to an electrical functional element (10) for connection to an object (100).

Description

[Technical Field]

[0001] The present invention relates to an electrical element (hereinafter also referred to as functional element) according to the preamble of claim 1, an object according to the preamble of claim 10, a module according to the preamble of claim 12 and a method according to the preamble of claim 23. [Background technology]

[0002] In the prior art, electrical elements are typically connected to objects by sewing, gluing, laminating, or other laborious and costly techniques. These conventional connection techniques for electrical elements are costly, slow down the manufacturing process, and are visible and tactile, which can cause undesirable visual and tactile shape deviations of the object to which the electrical elements are attached. Summary of the Invention [Problem to be solved by the invention]

[0003] The problem underlying the present invention is therefore to improve the connection of electrical elements to objects. [Means for solving the problem]

[0004] The above object is achieved by an electrical element of the type mentioned in the introduction, which is designed to be connected to the object by ultrasonic welding.

[0005] The ability to connect electrical elements to objects via ultrasonic welding can significantly accelerate the manufacturing process compared to other common manufacturing techniques, such as sewing, gluing, and / or laminating. For example, the manufacturing process of connecting electrical elements to objects via ultrasonic welding can be up to four times faster than sewing or gluing. Additionally, ultrasonic welding is an extremely precise manufacturing technique that leaves no visible or tactile marks on the electrical elements and / or the objects to which they are connected. In this manner, reliable, precise, nearly invisible, and nearly tactilely imperceptible connections between electrical elements and objects can be achieved quickly and at low cost.

[0006] Preferably, ultrasonic welding is performed using an ultrasonic welding device. Preferably, the ultrasonic welding device includes at least one sonotrode and / or at least one anvil and / or at least one workpiece receptacle for receiving an electrical component and / or object. Ultrasonic welding involves the introduction of ultrasonic waves at a frequency of 40 kHz to 70 kHz and an amplitude of 5 μm to 50 μm into the components to be welded in a point-like and / or linear fashion. This generates frictional heat, melting the components to be joined in a point-like and / or linear fashion and, preferably under pressure, thereby joining them in a material-bonding manner, thereby enabling the components and / or objects to be welded together precisely. Ultrasonic welding does not require auxiliary means such as adhesives and consumes little energy, making it a cost-effective and environmentally friendly joining method. Furthermore, the precise control technology of the ultrasonic welding device ensures consistent quality with precise and reproducible results. Because the preparation and waiting times for heating and cooling of the tool and the objects to be connected together are extremely short, the objects can be connected together in a fraction of a second, which results in significant time savings.

[0007] In preferred embodiments of the electric element, the electric element is configured as an electric conductor, a sensor element, an electric terminal, a shielding element against electromagnetic interference, or an electric heating device. The electric conductor can be a substantially one-dimensional, elongated element that extends straight or curved. The electric conductor is preferably at least partially electrically conductive. The electric conductor is preferably configured as a resistance heating wire, a shielding conductor, an antenna, or a sensor conductor.

[0008] In another preferred embodiment of the electric element, the electric element is designed to be connected to the support element, particularly by ultrasonic welding, and the electric element is preferably designed to be connected to the support element in a layer pattern. The support element is preferably designed to support one or more electric elements, particularly flat heating devices, shielding devices, sensor devices, and / or electrical terminals. The support element is preferably formed as a flat layer made of a polymer material, as a wall of an inflatable fluid container, particularly a massage device and / or a pneumatic bladder of a vehicle seat, as an electric layer of a shielding device, as a cover for a vehicle seat and / or other vehicle interior, or as a fleece or foil. The support element, especially when the support element is a flat layer, is preferably 0.1 mm to 3 mm thick, particularly 0.1 mm to 1 mm thick, and particularly preferably 0.1 mm to 0.6 mm thick. The support element preferably has a melting temperature higher than the temperature occurring during ultrasonic welding, preferably above 200°C, particularly above 250°C, and particularly preferably above 400°C.

[0009] Preferably, the support element is designed to support electrical elements on some of its sides. If the support element is formed as a layered support element, it preferably supports electrical elements on both of its opposing surfaces, thereby easily electrically insulating these electrical elements from one another; the layered support element is preferably a two-dimensional element, even if it extends in a third dimension, for example by curvature. If the support element supports electrical conductors on both of its surfaces, the thickness of the support element is preferably at least 50% of the combined thickness of the two thickest conductors on each of its surfaces. Depending on the depth to which such electrical conductors penetrate the support element during ultrasonic welding, it may be preferable to select a minimum thickness of the support element that corresponds to at least the sum of the thickness of the thickest conductor on one surface of the support element and the thickness of the thickest conductor on the opposite surface of the support element. This prevents the support element from being damaged or even completely separated from one of the two sides during ultrasonic welding. Preferably, the support element is made at least in part of an electrically insulating material, such as polyurethane, and / or of an extensible material, where extensible means that such a material allows the support element to be stretched by at least 5 to 15% without damage to the material, at least without significant damage. The extensibility of the material of the support element is particularly important when the support element is a component of a vehicle steering wheel, in particular as a support element for a heating element, a shielding element, or a capacitive sensor element.

[0010] Preferably, at least one electrical conductor is mounted on the support element in a layered pattern, the pattern being determined by the function of the electrical conductor. To construct such a layered pattern, the at least one electrical conductor is preferably provided on the support element in an at least partially wavy pattern, particularly in the form of a sinusoidal wave. Such a pattern allows the electrical conductor to compensate for mechanical stresses and thereby avoid damage. A sinusoidal wave pattern is particularly well suited for heating the electrical conductor. Additionally, the electrical conductor can be provided on the support element in a zigzag pattern, which includes multiple straight sections and / or multiple intermediate bends, for example, of 90°. Preferably, at least two electrical conductors are arranged parallel to each other in the regions of the straight sections and / or intermediate bends. Preferably, the distance between two parallel-arranged electrical conductors is less than 5 mm, particularly less than 2 mm, and particularly preferably 1 mm or less. Particularly when arranging shielding conductors, minimizing the distance between the conductors ensures good shielding of electromagnetic influences. Additionally, at least one electrical conductor may be arranged on the support element in a U-shaped pattern, the U-shaped pattern including straight sections and / or bends of substantially 180° therebetween, with the spacing between adjacent electrical conductors preferably being less than 1 mm.

[0011] In another preferred embodiment of the electric element, the electric element is formed as a monofilament electric conductor or a multifilament electric conductor including several partial strands. The monofilament and / or multifilament electric conductor comprises at least one, preferably at least two, preferably three layers, particularly preferably at least one conductive wire and / or at least one protective layer and / or at least one melting layer. The conductive wire is preferably formed as the conductive core of the electric conductor. The conductive core is preferably formed from a metal, in particular from copper or a copper alloy, or from steel or an iron alloy. Preferably, the protective layer at least partially surrounds the conductive wire. Preferably, the melting layer at least partially surrounds the conductive wire and / or the protective layer. Preferably, the electric wire functions as a heating wire, a sensor wire, an antenna, or a shielding wire. In particular, the electric wire can function as a capacitive presence detector. In addition, the electric wire can be used as a shielding wire, in particular to shield a presence detector from the influence of a heating device.

[0012] Multifilament electrical conductors preferably include or are composed of multiple conductive partial strands, each preferably formed as a monofilament electrical conductor, as described above. Each multifilament electrical conductor preferably includes multiple conductive wires and / or multiple protective layers and / or multiple fusing layers. Preferably, multifilament electrical conductors include 1 to 150, particularly 2 to 8, conductive wires and / or protective layers and / or fusing layers. Preferably, multifilament electrical conductors include at least one conductive wire functioning as a heating wire, at least one conductive wire functioning as a sensor, and / or at least one non-conductive support element, particularly made from mineral fibers, preferably glass. Multifilament electrical conductors have the advantage over monofilament conductors of a similar diameter of increasing adhesion to the support element, especially when the multifilament conductor does not have an outer jacket. The at least one protective layer can serve to electrically insulate the conductive wires and / or perform a mechanical function, such as protecting the conductive wires against mechanical loads, for example, by absorbing tension and / or bending forces, especially during ultrasonic welding processes. The protective layer preferably consists at least partially of a polymeric material and at least partially covers and / or surrounds the core.

[0013] The protective layer preferably has a melting temperature above 220°C, preferably above 240°C. The protective layer is at least partially less than 0.5 mm thick, in particular less than 0.1 mm thick, and particularly preferably less than 0.01 mm thick. The conductive wire is preferably configured so that a curvature radius of 1 mm is possible, for example, with a wire diameter of less than 0.2 mm. Such a conductive wire, especially when configured as a heating wire, preferably has an electrical resistance of 0.5 Ω / m to 3 Ω / m, in particular 1 to 2 Ω / m, and particularly preferably 1.2 Ω / m to 1.8 Ω / m.

[0014] The melt layer can be formed as a fixing layer and / or as an additional insulating layer. The melt layer preferably at least partially covers the core and / or the protective layer. The melt layer is preferably formed from a polymer material. The melt layer preferably has a lower melting temperature than the protective layer, preferably below 250°C, particularly below 200°C, and is at least 20°C, preferably 50°C, lower than the melting temperature of the protective layer. The melt layer is preferably at least partially less than 0.5 mm thick, particularly less than 0.1 mm, particularly preferably less than 0.01 mm. Preferably, the melt layer is used to precisely melt the melt layer in an ultrasonic welding process, and a material-bonding connection can be created by contacting the melted melt layer with a region of the object, preferably one that has also been melted, and thus fusing them together. These layers can be formed, in particular, as a lacquer.

[0015] In one development of the electrical element, the sensor element is configured as a temperature sensor, a pressure sensor, or a presence detector. The sensor element configured as a temperature sensor is particularly designed to monitor the temperature of a heating element and / or a heating conductor, and the temperature sensor is particularly configured as an NTC sensor, a thermostat, or a thermistor. The pressure sensor is preferably designed to monitor the pressure of an inflatable fluid container. The presence detector (hands-on detection) is preferably designed to detect a vehicle occupant, in particular the hands of the vehicle occupant, and / or the movement of the vehicle occupant. The presence detector is preferably configured as a capacitive sensor, including capacitor plates formed as fibers or foils for detecting changes in capacitance in the vicinity of the sensor. The sensor element is preferably a component of a sensor device, in particular a sensor device for temperature monitoring and / or for indicating a specific temperature threshold. The sensor arrangement preferably comprises at least one sensor and at least one supply line, which supplies energy and / or signals to the sensor and / or transfers data from the sensor to a control device, which can be for example a vehicle control unit (ECU) or can be a component of the object used to connect the sensor. Preferably, the sensor arrangement has at least one sensor with two supply lines connecting the sensor to two different potentials, the sensor and the two supply lines being part of an electric circuit, and the sensor being a switching device controlling the current through this electric circuit.

[0016] Furthermore, particularly preferred are electrical elements according to the present invention in which the electrical terminal is formed as a conductive base, in particular as a metal plate and / or as a portion of a conductive foil, and the electrical terminal is designed to be connected to an electrical device. The conductive base is preferably formed rectangular or square. The conductive base is preferably connected to an internal electrical element of the electrical device, for example, to the internal conductor strands of a heating device, a sensor device, or a shielding device. The conductive base is preferably connected to an external electrical conductor to an external power source, which is preferably arranged remotely from the electrical device. The electrical terminal is preferably formed from at least 50% copper and / or at least 50% iron and / or at least 50% of the material of the connected internal conductor strands and / or at least 50% of the material of the connected external conductor strands, and the internal and / or external conductor strands and / or the electrical terminal preferably consist of at least 80%, in particular at least 95%, copper. Preferably, the electrical terminal can be connected to the internal conductor strands of the electrical device and / or the external conductor strands of the power source by soldering and / or resistance welding.

[0017] Furthermore, an electric element according to the present invention is advantageous in that the electrical shielding element includes at least one support element and at least one shielding conductor. Preferably, the shielding conductor is configured as an electrical conductor. Preferably, the shielding device is designed to reduce or completely eliminate the effects of electromagnetic influences, especially when it is arranged between a heating device and a sensor device. Preferably, the shielding device is a component of a multilayer sandwich structure consisting of a heating device for warming the hands of a vehicle driver, a sensor device for monitoring the driver's hands, and a shielding device for separating the heating device from the sensor device to avoid electromagnetic effects. Preferably, the shielding device includes a support element according to claim 3 and / or an electric conductor according to claim 4. Preferably, the support element and the shielding conductor are connected to each other by ultrasonic welding. Preferably, the shielding conductor is connected to the support element without stitches or seams. The support element can support the shielding conductor together with the sensor conductor and / or the heating conductor. Preferably, the shielding conductor, the sensor conductor and / or the heating conductor are attached to opposing surfaces of the support element and / or are embedded from opposing sides of the support element, and / or the different conductors follow different layer patterns and / or the conductors maintain a minimum distance from each other, which distance is sufficient to electrically insulate the conductors from each other and the total thickness of the conductors is less than the thickness of the common support element.

[0018] In another preferred embodiment of the electric element according to the present invention, the electric heating device comprises at least one support element, at least one electric heating resistor, and at least one electric heating conductor. Preferably, the electric heating device is designed to heat an object in a vehicle interior, in particular a vehicle instrument panel, a vehicle door, an armrest, a vehicle seat cushion or cushioning, or the surface of a steering wheel, a battery heating device, a patient heating device, in particular a disposable heating blanket. Preferably, the heating resistor and / or the heating conductor are attached to the support element without stitches or seams, in particular by ultrasonic welding. The heating conductor is preferably at least partially connected to the support element. The heating device preferably comprises at least one heating conductor attached to a support element formed as a foil support, which can be attached to the object to be heated. The heating device preferably has at least one heating conductor, which is attached to a support element formed as a foil support, which can be or is attached to the cover of the object to be heated, and in particular when the diameter of the heating conductor is smaller than the thickness of the support element, the heating device is preferably arranged between the object and its cover, so that the heated object can be produced efficiently and without surface damage.

[0019] The heating device preferably includes at least one heating conductor, which is attached directly to the cover of the object, and is preferably positioned between the object and its cover, thereby allowing the use of the thinnest possible heating conductor, which enables the operation of the heating device with the least possible energy loss. The heating device preferably includes at least one heating conductor, which is attached to the surface of the object to be heated. The heating device preferably includes at least one heating conductor, which is attached to the object by at least partially embedding the heating conductor in the surface of the object. This allows for the creation of plastic parts with embedded conductors, such as steering wheels, door trims, or headrest side pads, when such objects are at least partially made of polymeric materials, particularly thermoplastic materials, and such objects preferably have at least one attachment zone that can be welded to the heating conductor by ultrasonic welding. Preferably, the heating conductor is formed as a multifilament heating conductor, and at least one of these multifilament heating conductors has at least two, preferably three, layers.

[0020] Preferably, the heating device includes at least one sensor terminal module and / or a connection area for connection to a voltage source. Preferably, the heating conductor is provided directly on the heatable cover, in particular without an intermediate layer, for example made of a cushioning material. Preferably, the heating conductor is at least partially made of metal. Preferably, the monofilament heating conductor has a diameter of less than 1 mm, in particular less than 0.1 mm, and particularly preferably less than 0.01 mm. Preferably, the heating conductor and the support element together form a heating layer, the support element being preferably made of an insulating material with a thickness of at least 0.7 mm, and the heating conductor, preferably with a thickness of at most 0.2 mm, being embedded in the support element.

[0021] In another preferred embodiment of the electrical element according to the present invention, at least two electrical terminals and at least one sensor together form an electrical element configured as a sensor terminal module. The sensor of the sensor terminal module preferably has at least two electrical supply lines, with a first supply line connected to a first electrical terminal and a second supply line connected to a second electrical terminal. Preferably, the sensor terminal module is sealed for protection against external influences, such as moisture, and in particular is welded between two support elements, for example between two foils, by ultrasonic welding. Preferably, the sensor terminal module is designed to be connected to a heating device, a shielding device, and / or a sensor device. Preferably, the at least one supply line and the electrical terminal form an integral part including at least one conductive plate, at least one foil, and / or at least one film. Preferably, the sensor terminal module is connected to a support element, in particular to a support element of a heating device, a shielding device, or a sensor device. The sensor terminal module reduces the number of parts and assembly steps. The sensor terminal module can include at least three electrical terminals. The sensor terminal module further includes at least two ends of an electrical conductor for connecting another electrical element, instead of the sensor, to an external voltage source. The first of these ends can be connected to one of the first and second electrical terminals, and / or the second end can be connected to a third terminal, thereby enabling two different electrical elements, such as the sensor and the heating device, to operate independently of each other. Such ends of the electrical conductor can be, for example, ends of a heating conductor, a ground line, a shielding device, and / or a connecting line for a capacitor layer of a capacitive sensor. Preferably, the ends of the electrical conductor are ends of the same heating conductor, a ground line for an electromagnetic shielding device, and a connecting line for a capacitor layer of a capacitive sensor. In this way, the required space for the connection area can be significantly reduced, for example, from approximately 60 mm x 100 mm to approximately 30 mm x 30 mm for a flat heating device formed by conventional pressing of the heating conductor rather than ultrasonic welding.

[0022] Preferably, the sensor terminal module includes a terminal support in addition to a support element for another electrical element, thereby simplifying assembly when there are more than two electrical terminals. Preferably, the sensor terminal module includes at least one electrical conductor. Preferably, the sensor terminal module includes a sensor device for monitoring at least one electrical element and / or at least one electrical conductor. Preferably, the sensor device monitors a supply line connecting the sensor to the electrical terminal, which supply line and the electrical conductor are electrically and mechanically connected to the same electrical terminal, thereby enabling precise measurements due to the proximity of the sensor to the electrical conductor. Preferably, the sensor is positioned at a distance of less than 2 cm, particularly less than 5 cm, and particularly preferably less than 2 mm, from the electrical conductor. Preferably, the electrical conductor forms at least one loop-shaped portion, and the sensor is at least partially surrounded by this loop-shaped portion. Preferably, the sensor device includes a guide device for guiding a portion of the electrical conductor at least partially around the sensor in a predetermined manner, the guide device forming at least a portion of a circle, particularly a semicircle. Preferably, the sensor device includes at least one sensor positioned at the center of the circular portion so formed, which positioning allows measurements to be close to the sensor to be precise, yet still far enough away to still allow stable control.

[0023] The problem underlying the present invention is further solved by an object of the type mentioned at the beginning, in which an electric element is connected to the object by ultrasonic welding. Preferably, the electric element is formed according to one of the above-mentioned embodiments. Therefore, for further advantages and variants of the object according to the invention, please refer to the advantages and variants of the electric element according to the invention.

[0024] In a preferred embodiment of the object according to the invention, the object is configured as a vehicle interior component, a heatable vehicle component, a steering wheel, an inflatable fluid container, or a vehicle seat component. The vehicle interior component is preferably configured as an instrument cluster, an armrest, a door trim, or a vehicle roof. The inflatable fluid container is preferably configured as a bladder, which can be preferably filled with air. The vehicle seat component is preferably configured as a seat cover, a headrest, a side headrest, or a seat side pad.

[0025] The problem underlying the present invention is further solved by a module of the type mentioned at the beginning, in which the electric elements and the objects of the module are connected to each other by ultrasonic welding. Preferably, the electric elements are formed according to one of the above-mentioned embodiments. Preferably, the objects are formed according to one of the above-mentioned embodiments. Therefore, for advantages and variants of the module according to the present invention, please refer to the advantages and variants of the electric elements and / or objects. Dynamic functions are preferably functions of the module that require the module to actively influence certain operating parameters, in particular fluid flow and / or current.

[0026] In preferred embodiments of the module according to the invention, the module is configured as a detection module for detecting heater heat in a steering wheel, or a detection module for detecting heater heat in vehicle trim, or a heater contouring module for a vehicle seat, or a heater massage module for a vehicle seat, or an inflatable fluid container with an integrated heating device, or a sealed electrical connection area, or a sensor terminal module.

[0027] In another preferred embodiment of the module according to the invention, at least one of the dynamic functions of the module is to warm a person, or to recognize the presence of a person, or to massage a person, or to adjust the contour of a body support device, or to adjust the volume of an inflatable fluid container. Preferably, the person to be warmed and / or recognized and / or massaged is a vehicle occupant of a vehicle, in particular the driver of the vehicle. The body support device can be formed, for example, as a spine support for the vehicle occupant.

[0028] In another preferred embodiment of the module according to the invention, the module is configured as a presence detector module, in particular for detecting the presence and / or movement of a human body part. Preferably, the presence detector module includes a sensor for recognizing changes in an electric field, which can also be a magnetic field. Preferably, the presence detector module includes a sensor conductor that detects changes in the electromagnetic field around the sensor conductor, in particular changes caused by the presence of moisture in the body part of a vehicle occupant, and / or detects pressure changes around the sensor conductor, in particular changes caused by the weight of the monitored body part. Preferably, the presence detector module includes at least one support element, in particular a support element as defined in claim 3. Preferably, the sensor conductor of the presence detector module as defined in claim 4 is configured. Preferably, the sensor conductor and the support element are connected to each other, in particular by ultrasonic welding and / or without stitches and seams, as defined in claim 3. The support element of the presence detector module can further support a shielding conductor and / or a heating conductor. The presence detector module may be constructed substantially like the shielding device according to claim 7 .

[0029] In one development of the module according to the invention, the module configured as a detection module for detecting heater heat in a steering wheel and / or a detection module for detecting heater heat in a vehicle trim includes at least one sensor device and / or at least one heating device and / or at least one shielding device, preferably together forming a sandwich structure. Preferably, the detection module for detecting heater heat has at least one electrical conductor with a thickness of 0.05 mm to 1.5 mm, particularly 0.1 mm to 0.5 mm, and particularly preferably 0.1 mm to 0.3 mm, preferably configured as a heating conductor, a sensor conductor, or a shielding conductor. Preferably, the electrical conductor is configured as a multifilament conductor, preferably with 1 to 10 filaments for the sensor conductor, 1 to 3 filaments for the shielding conductor, and / or 1 to 100 filaments for the heating conductor. The detection module for detecting heater heat in a steering wheel preferably has an elongation of at least 5% to 15%, without affecting, particularly damaging, the electrical components or adjacent modules.

[0030] The detection module for detecting heater heat can be incorporated into a vehicle door trim, armrest, or headrest. The detection module for detecting heater heat preferably includes a support element formed as a heater support element, preferably made of an insulating material having a thickness of at least 0.7 mm, and a heating conductor, preferably having a thickness of less than 0.2 mm, attached to and / or embedded in the heater support element. The detection module for detecting heater heat preferably includes a sensor support element, preferably made of an insulating material having a thickness of less than 0.7 mm, and a sensor conductor having a diameter less than 0.2 mm, attached to or embedded in the sensor support element. The detection module for detecting heater heat preferably further includes a shield support element, preferably made of an insulating material having a thickness of at least 0.7 mm, and a shield conductor, preferably having a thickness of less than 0.2 mm, attached to or embedded in the shield support element. Preferably, the detection module for detecting heater heat includes a heater-shield support element combining a heating conductor and a shielding conductor, the heating conductor and the shielding conductor being respectively attached to opposing surfaces of the combined support element, and / or a sensor-shield support element combining a sensor conductor and a shielding conductor, the sensor conductor and the shielding conductor being respectively attached to opposing surfaces of the combined support element.

[0031] Furthermore, a module according to the present invention, in which the module is configured as a device for adjusting the seat contour of a vehicle seat, is particularly preferred. This device allows the contour of the vehicle seat to be dynamically adapted to various situations. In particular, the vehicle seat can be adapted to the anatomy of a specific vehicle occupant, e.g., the driver. The device can adjust the vehicle seat, for example, in response to driving maneuvers, in particular when driving around curves. The device can prevent the vehicle occupant from sitting in the same seat position for long periods of time to ensure their health. The seat adjustment can also react to protect the driver, for example, against fatigue or an imminent vehicle collision. The device can be used to massage the vehicle occupant, in particular by increasing the temperature and / or increasing the pressure. Preferably, the device includes at least one, in particular a plurality of, inflatable fluid reservoirs, which allow the seat contour to be individually adjusted.

[0032] Furthermore, the module of the present invention is advantageous if the module is formed as an inflatable fluid container and / or comprises at least one, preferably several, inflatable fluid containers, preferably to which at least one electrical conductor can be connected, particularly by ultrasonic welding, and / or if the at least one or several inflatable fluid containers comprise at least one sensor terminal module, preferably welded and / or sealed, by ultrasonic welding. Preferably, the inflatable fluid container is formed as a pneumatic bladder that can be filled with gas, preferably air, and the bladder has a heating conductor, preferably welded to the bladder, particularly on the inside, and the pneumatic bladder comprises a sensor terminal module, preferably welded between two layers of the bladder, so that the sensor terminal module is protected against external influences. In particular, at least one electrical conductor is welded to the inside of the fluid container.

[0033] Preferably, the fluid container can be filled with a fluid, in particular air, and thus is inflatable. Preferably, a predetermined amount of air is filled into the fluid container during a specific operating phase, such as when turning a corner or during other vehicle maneuvers. The inflatable fluid container preferably has at least one flexible wall that is impermeable to the fluid being filled, thereby allowing the shape and / or contour of the fluid container wall and / or the entire fluid container to be individually adapted by changing the amount of fluid in the fluid container. The fluid container wall is preferably made at least in part of a material that is not damaged by ultrasonic welding. Preferably, such a wall is made of a polymer material, preferably polyurethane. Preferably, such a wall has a melting temperature higher than the melting temperature of at least one layer of an electrical conductor attached to the wall, the melting temperature of at least one wall being preferably 20°C higher, particularly preferably at least 50°C higher, than the melting temperature of the electrical conductor.

[0034] The wall of such a fluid container preferably has a thickness greater than that of one or more electrical conductors connected to the fluid container. Preferably, the wall has a thickness of 0.1 mm to 5 mm, in particular 0.1 mm to 2 mm, particularly preferably 1 mm to 2 mm. The inflatable fluid container is preferably formed as a fluid bladder, in particular as an air bladder. The inflatable fluid container is preferably produced by welding at least two layers, preferably made of flexible wall material, at the edges of the flexible wall material. Preferably, these layers have similar dimensions. Preferably, welding the two layers produces a gas-fillable, in particular air-fillable, bladder. Preferably, the fluid container includes one or more electrical elements, in particular one or more electrical elements as described above, and / or the one or more electrical elements can be connected to the fluid container, in particular by ultrasonic welding.

[0035] In particular, the fluid container can include an electric heating element, a temperature sensor for monitoring the temperature of the heating element, a temperature sensor for monitoring the temperature of the vehicle occupant, a pressure sensor for monitoring the pressure in the inflatable fluid container, a presence detector for detecting a human body part, and / or a shielding device for shielding the heating device from electromagnetic influences, particularly in the direction of the vehicle occupant or the presence detector. Preferably, these electric elements, particularly the pressure sensor and / or temperature sensor, e.g., an NTC sensor, are integrated on and / or within the fluid container, welded to the fluid container, particularly by ultrasonic welding, and / or embedded in the fluid container. Furthermore, it is preferred to combine the inflatable fluid container with a heating device to realize a combined seat contouring and / or seat temperature adjustment device that enhances the comfort of the vehicle seat by means of massage, seat contouring, and (um) simultaneous heating functions. The device for adjusting the seat contour of a vehicle seat preferably has at least one of the features already described above for the inflatable fluid container.

[0036] In another preferred embodiment of the module according to the present invention, the module is formed as an inflatable fluid container with an integrated heating device, where multiple inflatable fluid containers and at least one heating device together preferably form a combined heater-massage module and / or combined heater-contouring module for a vehicle seat. Preferably, at least one of the multiple fluid containers has a heating conductor welded to the fluid container by ultrasonic welding, and the heating conductor is connected, particularly welded, to at least one layer of the fluid container inside the fluid container. Preferably, at least one of the fluid containers includes a sealed sensor terminal module. The inflatable fluid container with an integrated heating device preferably has at least one heating conductor integrated, preferably welded, to a flexible wall of the fluid container, and the heating conductor is preferably embedded inside the flexible wall, which faces the vehicle occupant when installed in the vehicle and warms the vehicle occupant. The integrated heating device may include a heating conductor and a separate support element. The heating device may comprise, for example, a plastic multifilament, a fleece support, and / or a heating conductor made of steel or copper, which may be sewn onto any flexible and / or flat support element. If the heating conductor is provided on a separate support element, particularly by sewing, this separate support element may be laminated onto the flexible wall of the fluid container.

[0037] However, a heating conductor made of copper, formed as a multifilament electrical conductor, attached directly to the wall of the fluid container by ultrasonic welding without a separate support element and / or embedded in the wall from inside the fluid container, is particularly preferred. The placement of the heating conductor within the fluid container protects the heating conductor against mechanical loads, particularly shear movements outside the fluid container. If the heating device is attached to the fluid container externally, it can be laminated onto the fluid container externally using a separate support element, as described above. However, if the heating conductor is attached directly to the wall of the fluid container or at least partially embedded in the wall of the fluid container by ultrasonic welding, the service life can be significantly extended. By integrating the heating function into the fluid container, a combined heater-massage module and / or combined heater-contouring module can be realized in the vehicle seat.

[0038] In another preferred embodiment of the module according to the present invention, the module is configured as an electrical connection area, which is sealed against external influences by welding two protective layers together, preferably by ultrasonic welding. The sealed electrical connection area preferably includes an electrical terminal module or an electrical sensor terminal module, as already described above. Preferably, the electrical connection area serves to electrically connect at least one occupant detector, a heating device, a sensor device, particularly for detecting pressure or temperature, and / or a shielding device. The electrical connection area is preferably arranged between the layers to be welded. At least one of the layers can be a support element for an electrical element connected to an external voltage source or, for example, an external controller via such a connection area.

[0039] Furthermore, at least one of the protective layers can be a separate protective layer made of a suitable, preferably sealable, material. Furthermore, at least one of the protective layers can consist of at least a portion of the wall of the fluid container. Preferably, the sealed electrical connection area completely seals at least one electrical terminal, preferably the entire electrical terminal module, thereby eliminating the need for time-consuming gluing or coating of contact surfaces or even shrink tubing. If the fluid container is provided with a sealed electrical connection area, the two protective layers are extensions of the walls of the fluid container, preferably the upper and lower walls of the fluid container. Preferably, the electrical terminal and / or the sensor are sealed between these two layers. If the fluid container is provided with a sensor terminal module and / or a sealed electrical connection area, preferably, at least one sensor of such a sensor terminal module is disposed within the fluid container, while the connection area of ​​such a sensor terminal module is enclosed within the sealed electrical connection area. This allows for accurate measurements and extremely simple assembly. Such an arrangement is particularly advantageous when the fluid container includes a heating device and / or a temperature sensor and / or a pressure sensor and / or a presence detector within the fluid container.

[0040] In one development of the module according to the invention, the module is formed as a massager, which is formed by welding two protective layers together, preferably by ultrasonic welding. The massager can be a general massager that does not necessarily have to be associated with a vehicle. The massager can also be suitable for a bed, massage table, operating table, or couch, for example. The massager can include the above-mentioned modules and / or electrical elements, in particular heating devices, and / or one or more fluid containers with or without integrated sealed connection areas, sensors, and other components, in particular seat contourers.

[0041] Furthermore, a module according to the invention is preferred which is a combined heater recognition module, in particular for a steering wheel for warming and recognition of the driver's hands, the heater recognition module comprising at least one heating conductor, at least one sensor conductor and / or at least one shielding conductor, which are preferably welded together on one support element or separately on several support elements by ultrasonic welding.

[0042] The problem underlying the present invention is further solved by a method of the type mentioned at the beginning, in which an electric element and an object are connected to one another by ultrasonic welding and / or soldering and / or thermal welding, in particular thermocompression. Preferably, within the scope of the method according to the present invention, at least one electric element according to one of the above-mentioned embodiments is welded to at least one object according to one of the above-mentioned embodiments, resulting in a module according to one of the above-mentioned embodiments. Therefore, with regard to the advantages and variants of the method according to the present invention, reference is made to the advantages and variants of the electric element according to the present invention, the object according to the present invention and the module according to the present invention.

[0043] Ultrasonic welding is understood to mean a connection by exposing at least one object to be connected to pressure and / or vibrations in the ultrasonic frequency range. Connections by ultrasonic welding enable good attachment between electrical elements, particularly electrical conductors, and a support substrate, especially a support substrate of a flat support element. This fixation by forming a material-bonding connection, especially an adhesive bond, is particularly strong when the electrical conductor, e.g., a coating of a melting layer conductor, and the support material of the support element are fused together by ultrasonic welding. Soldering refers to attachment by adding molten material, for example, containing conductive material and / or at least 50% tin, lead, and / or other metals and / or alloys with a melting temperature below 500°C, preferably below 300°C. Preferably, the melting temperature of the solder material is higher than the melting temperature of the components to be connected, so that the components to be connected are not damaged during joining. Heat welding refers to attachment by melting a material, preferably at least one of the components to be connected together and / or an additional material containing at least 50% iron, aluminum and / or other metals and / or conductive alloys with a melting temperature above 250°C. [Brief explanation of the drawings]

[0044] [Figure 1] 1 is a schematic cross-sectional view of an electrical element formed as a multifilament electrical conductor. [Figure 2a] FIG. 1 is a plan view of a layer pattern of electrical conductors on a support element. [Figure 2b] FIG. 10 is a plan view of another layer pattern of electrical conductors on a support element. [Figure 3] FIG. 1 is a plan view of a module formed as a sensor terminal module. [Figure 4] 1 is a plan view of a module formed as a connection area; [Figure 5] FIG. 10 is a plan view of a sensor terminal module connected to electrical conductors on a support element. [Figure 6] 1 is a perspective view of an apparatus for adjusting the seat contour of a vehicle seat having multiple fluid reservoirs; [Figure 7] FIG. 10 is a plan view of a welded sensor terminal module with a connection area welded to a fluid container with integrated electrical conductors. [Figure 8] FIG. 1 is a perspective view of an inflated fluid container with an integrated heating device. DETAILED DESCRIPTION OF THE INVENTION

[0045] Preferred embodiments of the present invention will now be described and explained in detail with reference to the accompanying drawings.

[0046] FIG. 1 shows an electrical functional element 10 formed as a multifilament electrical conductor 12a. The multifilament electrical conductor 12a includes seven partial strands 14, each formed as a monofilament electrical conductor 12b. Each monofilament electrical conductor 12b, which together form the multifilament electrical conductor 12a, includes three layers: a conductive wire 16, a protective layer 18, and a melting layer 20. Each conductive wire 16 forms the core of each monofilament electrical conductor 12b. The conductive wire 16 is completely surrounded by the protective layer 18, which serves as an insulating layer for insulating the wire 16, particularly against electrical influences. Furthermore, the protective layer 18 can protect the wire 16 from mechanical damage. The wire 16 and the protective layer 18 surrounding the wire 16 are also completely surrounded by the melting layer 20. The melt layer 20 is designed to be precisely melted by heat supply, in particular by ultrasonic welding, thereby allowing one, several or all of the monofilament electrical conductors 12b and / or multifilament electrical conductors 12a to be materially bondedly attached to the support element 22 and / or to the object 100 by fusing them with the support element 22 and / or to the object 100.

[0047] Preferably, the melting temperature of the melting layer 20 is lower than the melting temperature of the protective layer 18, so that only the melting layer 20 melts during ultrasonic welding for attachment of the electrical conductors 12a, 12b, while the protective layer 18 remains intact. The conductive wire 16 can be formed, for example, from copper, a copper alloy, steel, or other iron alloys. One, more, or all of the monofilament conductors 12b and / or the monofilament electrical conductors 12a are designed to function, for example, as conductive wires for heating devices, for sensor devices, as antennas for shielding devices, in particular as heating wires, as sensor wires, and / or as shielding wires.

[0048] 2a and 2b each show an electrical functional element 10 formed as an electrical conductor 12 and mounted in different layer patterns on a support element 22. The electrical conductor 12 can be formed as a monofilament electrical conductor 12b or a multifilament electrical conductor 12a. In particular, the electrical conductor 12 can be formed, for example, as a heating conductor for a heating device, a sensor conductor for a sensor device, or a shielding wiring for a shielding device, and / or can form a heating device, a sensor device, or a shield together with the support element 22. Preferably, multiple electrical conductors 12 mounted on the support element 22 can be combined, in particular a combined heater-sensor device, heater-sensor-shielding device, or sensor-shielding device, for example, by multiple support elements 22 each forming a sandwich structure with at least one electrical conductor 12.

[0049] Furthermore, multiple electrical conductors 12 can be arranged adjacent to and spaced apart from one another on the common support element 22, with at least one of the multiple electrical conductors 12 configured as a heating conductor, another conductor 12 configured as a sensor conductor, and / or yet another conductor 12 configured as a shielding conductor. The heating conductor can be designed, for example, to heat a vehicle occupant of a vehicle. The sensor conductor can be designed to detect the presence of a vehicle occupant and / or to detect the heater heat of the heating conductor. The shielding conductor is designed to shield the sensor conductor from interference, particularly electromagnetic influences, of the heating conductor, enabling interference-free monitoring of the heater heat and / or detection of the presence of a vehicle occupant.

[0050] The support element 22 is preferably formed as a flat and / or planar support element 22. In particular, the support element 22 is formed as a foil or fleece. Preferably, the support element 22 is designed to support at least one electrical conductor 12 on both of its opposing surfaces. Preferably, the support element 22 is designed so that at least one electrical conductor 12 can be materially connected to the support element 22 by ultrasonic welding on at least one of its surfaces, in particular weldable and / or fused. Preferably, the support element 22 is formed so that it is not damaged during ultrasonic welding to attach at least one conductive conductor 12, in particular by selecting an appropriate thickness of the support element 22. For example, the support element 22 can be at least 50% thicker than the sum of the two thickest electrical conductors 12 to be attached to the support element 22 by ultrasonic welding, in particular when attaching electrical conductors 12 on both surfaces of the support element 22. The support element 22 is preferably formed from an electrically insulating material, in particular polyurethane.

[0051] In FIG. 2a, electrical conductors 12 are mounted on a support element 22 and arranged in a layer pattern. The electrical conductors 12 have a plurality of parallel loops, including straight and curved portions, to form the layer pattern. The parallel loops of the electrical conductors 12 form rows of loops, and the rows of loops are spaced apart and adjacent to each other. In FIG. 2b, another layer pattern of one or more conductive conductors 12 mounted on a support element 22 is seen. In FIG. 2b, the one or more electrical conductors 12 are formed in a zigzag pattern, including straight portions and curved portions connecting the straight portions. The electrical conductors 12 and / or portions of the electrical conductors 12 extend parallel, adjacent to each other, and spaced apart from each other. The layer pattern is preferably selected so that adjacent electrical conductors 12, particularly heating and sensor conductors, do not influence and / or interfere with each other as much as possible. In particular, a distance is selected between two adjacent conductors 12 that minimizes mutual influence and / or interference.

[0052] FIG. 3 illustrates the module 200 configured as a sensor terminal module 210. The sensor terminal module 210 further includes the module 200 configured as a connection region 208. The sensor terminal module 210 and the connection region 208 each include a plurality of variously configured electrical elements 10. The sensor terminal module 210 includes a sensor element 24, an electrical conductor 12, and electrical terminals 28a, 28b. The electrical terminals 28a, 28b together form the connection region 208. Preferably, the sensor element 24 and the connection region 208, together with the electrical terminals 28a, 28b, form the sensor terminal module 210. The sensor element 24 can be configured, inter alia, as a temperature sensor or a pressure sensor. The temperature sensor is preferably designed to detect the temperature of a heating device. The pressure sensor is preferably designed to detect the pressure in the fluid container 102 and / or the pressure generated by a vehicle occupant residing in the vehicle seat.

[0053] Furthermore, the sensor element 24 can be formed as a presence detector that detects the presence and / or movement of a vehicle occupant and / or a body part of a vehicle occupant. The sensor element 24 can be connected to supply lines 26a, 26b via electrical terminals 28a, 28b. The supply line 26a has an end connected, particularly soldered, to the electrical terminal 28a. The supply line 26b has an end connected, particularly soldered, to the electrical terminal 28a. The supply lines 26a, 26b can connect the sensor element 24 to, for example, a control device, particularly a vehicle control device, and / or to an energy supplier, particularly a battery and / or a power grid, so that the sensor element 24 can be supplied with energy and / or data via the supply lines 26a, 26b. The supply lines 26a, 26b are further designed to transmit sensor data, such as temperature data and / or pressure data, detected by the sensor element 24 to the control device, particularly a vehicle control device.

[0054] The electrical terminals 28a are further connected to the electrical conductor 12, together with the supply line 26a, by thermal welding, soldering, or ultrasonic welding. The electrical conductor 12 can be formed, for example, as a heating conductor, a sensor conductor, and / or a shielding conductor. The electrical conductor 12 has a curved profile that extends around the sensor element 24 with a profile that substantially corresponds to the sensor element 24, particularly in the form of a loop. The portion of the electrical conductor 12 visible in FIG. 3 can be connected to and / or attached to the support element 22, particularly by ultrasonic welding, and can be a component of, for example, a heating device, a sensor device, and / or a shield. Preferably, the electrical terminals 28a, 28b are formed from at least 50% copper, or at least 50% iron, or at least 50% of the material of the supply lines 26a, 26b attached thereto. The supply lines 26a, 26b can be inner conductor strands of an electrical device and / or outer conductor strands of a power source.

[0055] FIG. 4 illustrates the module 200 configured as a connection area 208. The connection area 208 includes various electrical elements 10. In particular, the connection area 208 is formed by three electrical terminals 28a-28c, with the electrical terminal 28a connecting the supply line 26a and the electrical conductor 12, the electrical terminal 28b connecting the supply line 26b and another electrical conductor 12, and the electrical terminal 28c connecting the supply line 26c. Preferably, the supply lines 26a-26c and the electrical conductor 12 are heat-fused, soldered, or ultrasonically welded to the respective electrical terminals 28a-28c. Preferably, the electrical terminals 28b and 28c are components of the sensor element 24, as shown in FIG. 3. Preferably, the supply lines 26b and 26c form an electrical circuit with the sensor element 24, which can function as a switching device, allowing the sensor element to control the flow of current in the electrical circuit by breaking and closing the electrical circuit.

[0056] The terminal module is particularly cost-effective when at least one (external) supply conductor 26a-c is connected to at least one (internal) electrical conductor 12 via terminals 28a-c. The terminals serve as flat anchoring surfaces pre-attached to the support material. This connection method requires less manual labor than soldering or crimping, since all contact and connector zones are located in the same plane as the other electrical functional elements in a module. Furthermore, during assembly, material and force only need to be applied to the terminals 28a-c perpendicular to this plane.

[0057] Ultrasonic welding has the advantage that, unlike heat welding or soldering, the electrical resistance of the embedded conductor remains virtually unchanged because the heating of the conductor is not sufficient to significantly change the conductor's material structure.

[0058] FIG. 5 shows a sensor terminal module 210 having a connection region 208 and a sensor element 24, which is connected via the connection region 208 to an electrical conductor 12 configured as a heating conductor. The electrical conductor 12 configured as a heating conductor is mounted on a carrier element 22, which is formed, for example, from a foil made of a polymer, and is materially connected to the carrier element 22, in particular by ultrasonic welding. Preferably, the sensor terminal module and the heating conductor together form a heating device 214. The sensor terminal module and / or the electrical conductor 12 configured as a heating conductor together with the sensor terminal module are supplied with electrical energy from a voltage source and / or data from a control device, in particular a vehicle control device, via supply lines 26 connected to the sensor terminal module and the electrical conductor 12 via electrical terminals 28. Sensor data, such as pressure or temperature data, detected by the sensor element 24 can be transmitted to the control device via the supply lines. The heating device 214 formed from the sensor terminal module 210 and the electrical conductor 12 formed as a heating conductor can be materially connected, for example, to the inflatable fluid container 102, in particular by ultrasonic welding, in which case the support element 22 is a component of the fluid container 102. The inflatable fluid container 102, in particular together with the heating device 214 composed of the sensor terminal module 210 and the heating conductor, can in particular form the heater contouring module 204 and / or the heater massage module 206.

[0059] FIG. 6 shows an apparatus 212 for adjusting the seat contour of a vehicle seat, or module 200 formed as a seat contouring module for short. The apparatus 212 for adjusting the seat contour of a vehicle seat includes a plurality of inflatable fluid containers 102, ten in the illustrated exemplary embodiment. Such an apparatus 212 having a plurality of fluid containers 102 is preferably arranged in one or more vehicle seats of a vehicle, is integrated in particular into the seat cushion and / or into a seat cover, and is designed to dynamically adapt the seat contour of the vehicle seat, in particular in response to driving maneuvers such as cornering, and / or to massage a vehicle occupant seated in the vehicle seat. The inflatable fluid containers 102 can be inflated separately and independently of one another with precisely predetermined amounts of air to adapt the seat contour and / or massage the vehicle occupant. One or more of the fluid containers 102 can include a heating device 214, a sensor device, and / or a shield.

[0060] 7 shows a portion of an inflatable fluid container 102 that can be filled with air and / or have air suctioned from it via a fluid line 106, thereby allowing the amount of air contained in the fluid container 102 to be individually adjusted. If the fluid container 102 is a component of a seat contouring device, the contour of a vehicle seat can be individually adapted by inflating and / or suctioning air from the fluid container 102 via the fluid line 106, and the fluid container 102 can also be a component of a vehicle seat massager for massaging a vehicle occupant. The fluid container 102 shown in FIG. 7 further comprises a sensor terminal module 210 including a connection region 208 and a sensor element 14, and an electrical conductor 12 that is preferably formed as a heating conductor.

[0061] The supply line 26 and the electrical conductor 12 formed as a heating conductor are electrically and / or signal-transmittingly connected to each other and to the sensor element 14 via the connection region 208 of the sensor terminal module 210. The sensor terminal module 210, together with the electrical conductor 12, preferably forms a heating device 214. The inflatable fluid container 102 is preferably formed as a bladder that can be filled with air, and the fluid container is formed from two flexible, air-permeable walls. The flexible walls of the fluid container 102 are preferably made of a polymer material, in particular polyurethane, and are formed into the bladder-formed fluid container 102 by welding the flexible walls at their edges. Preferably, at least one flexible wall of the fluid container 102 serves as a support element 22 for the electrical conductor 12 formed as a heating conductor, and the electrical conductor 12 is connected to the flexible wall of the fluid container 102 that serves as the support element 22, preferably by ultrasonic welding. In particular, the electrical conductors 12 on the surface located inside the flexible wall of the fluid container 102 are welded by ultrasonic welding to the flexible wall used as support element 22 in such a way that the electrical conductors 12 are at least partially, preferably completely, embedded in the flexible wall of the fluid container 102. In this way, the electrical conductors 12 are electrically insulated and protected against other external influences, in particular mechanical damage.

[0062] The sensor element 14 can be configured as a temperature sensor for monitoring the temperature of the electrical conductor 12, which is configured as a heating conductor, or as a pressure sensor for monitoring the pressure in the inflatable fluid reservoir 102. Preferably, the inflatable fluid reservoir 102, the electrical conductor 12, and the sensor terminal module 210 form a combined seat contouring and seat temperature control device that enhances the comfort of the vehicle seat by combining contouring and massaging functions with heating functions. The sensor terminal module 210, and in particular the connection area 208, are welded between two protective layers. These protective layers are preferably layers of material already used for the module, such as the airtight walls of the massage bladder.

[0063] The sensor element 14 can at least partially protrude from the welded area into the interior of the fluid container 102. The remaining components of the sensor terminal module 210, in particular the connection area 208, are welded between two protective layers such that the sensor terminal module 210 and / or the connection area 208 are sealed and thereby protected against external influences, in particular moisture, electrically insulated, and protected against mechanical damage.

[0064] The two protective layers between which the sensor terminal module 210 and / or the sealed connection area 208 are welded are preferably portions of the flexible wall of the fluid container 102 that protrude beyond the welded rim that forms the sac of the fluid container 102. Furthermore, the protective layer can be a separate protective layer that is not connected or welded to the fluid container 102 or that is subsequently attached to the fluid container 102. Preferably, the sealed welded electrical connection area 208 and / or the sealed welded sensor terminal module 210 completely seals the at least one electrical terminal 28, 28a-28c, and by welding between the two protective layers, laborious, particularly time-consuming and costly, gluing or coating or even the use of shrink tubing for protection of the connection area 208 and / or the sensor terminal module 210 can be avoided.

[0065] 8 shows an inflated fluid enclosure 102, which includes an integrated heating device 214. The fluid enclosure 102 and the heating device 214 together form a heater contouring module 204 and / or a heater massage module 206. The heating device 214 includes an electrical conductor 12 formed as a heating conductor, which is embedded in the upper flexible wall of the fluid enclosure 102 by ultrasonic welding inside the flexible wall. A sensor terminal module 210, which is used to supply electrical energy to the sensor element 14 and the heating conductor, is welded to the sealing area 108 between the extension of the flexible wall of the fluid enclosure 102, thereby sealing the sensor terminal module, and in particular the connection area 208 of the sensor terminal module 210, against environmental influences. By welding, particularly embedding, the heating conductor of the heating device 214 inside the flexible wall of the fluid container 102, and by welding and sealing the sensor terminal module 210 in the sealing area 108 formed from an extension of the flexible wall of the fluid container 102, the heating device 214 and the fluid container 102 form an integral part, thereby facilitating assembly, particularly in, for example, a vehicle seat.

[0066] Furthermore, by combining the heating device with a fluid container for a seat contourer and / or massager of the vehicle seat, it is possible to simultaneously massage, adapt the seat contour, and / or warm the vehicle occupant, thereby significantly increasing the comfort of the vehicle occupant. Furthermore, instead of or in addition to the heating device 214, the fluid container 102 can include at least one sensor device, for example using a sensor conductor, in particular a capacitive sensor, and / or a shield, in particular using a shield conductor, and the sensor conductor of the sensor device and / or the shield conductor of the shielding device can likewise be connected to the fluid container 102 by ultrasonic welding and / or the shield conductor and / or the sensor conductor can be supplied with data and / or energy using the same or a separate sensor terminal module 210. Instead of embedding the heating conductor and / or the sensor conductor and / or the shield conductor in the flexible wall of the fluid container 102, they can also be laminated from the outside to the surface of the wall of the fluid container 102 using a separate support element 22.

[0067] The present invention relates to an electrical functional element (10) for connection to an object (100), preferably whereby the electrical functional element (10) is designed to be connected to the object (100) by ultrasonic welding.

[0068] The term "ultrasonic welding" refers in particular to - a weld seam created along a line by fusing two layers together, - an elongated melt zone of individual layers into which separate bodies, especially electrical conductors, are embedded during the softening of the melt zone, and in which the bodies are held after the hardening of the melt zone means.

[0069] Part 2 of the specification

[0070] The present invention provides 1. An electrical element attached to an object; 2. An object having at least one electrical element attached thereto; 3. A module that has at least -electrical elements, -Objects, and - at least two different dynamic functions 4. How to attach electrical elements to an object It relates to at least one of the following:

[0071] Preferably, such electrical elements include: - conductor strands, -sensor, -electrical connectors, - shielding devices against electromagnetic influences, - Electric heating device At least one of the following is true:

[0072] Preferably, such an object comprises: - Vehicle interior parts, In particular, instruments, armrests, door covers or vehicle roofs, - heated vehicle components, -Steering wheel, - an inflatable fluid container, - Vehicle seats, in particular seat covers, head restraints or side head restraints At least one of the following is true:

[0073] Preferably, such a module comprises: -Heater presence detection module for steering wheels, - Heater presence detection module for vehicle panels; - a heater contouring module for a vehicle seat; - heater massage modules for vehicle seats, - an inflatable fluid container with an integrated heating device; - sealed electrical connection areas, -Sensor terminal module At least one of the following is true:

[0074] Preferably, such dynamic functionality is: - Warming people, -Detecting people, - Massaging people, - Adjusting the contours of the body support device; -adjusting the volume of an inflatable fluid container At least one of the following is true: Preferably, such a body is a human body. Preferably, such a person is a vehicle occupant, in particular the driver.

[0075] Dynamic functions refer to functions that require the system to actively influence operating parameters, particularly fluid flow and electrical current.

[0076] Preferably, such attachment comprises: - ultrasonic welding, - soldering, and - Heat welding This is due to at least one of the following:

[0077] Ultrasonic welding refers to attachment by applying pressure and vibrations in the ultrasonic frequency range to at least one of the objects to be fastened.

[0078] Fastening by ultrasonic welding allows for a good bond between electrical elements, especially conductive strands, and the supporting substrate, e.g., the flat layer. This fastening is particularly strong when the wire coating and the substrate material fuse together as a result of the ultrasonic treatment, forming an adhesive connection.

[0079] Soldering means fastening by adding molten material, The added materials are - an electrically conductive material, at least in the solid state; - materials containing at least 50% tin, lead or other metals or alloys with a melting temperature below 500°C, preferably below 300°C; - have a melting temperature higher than at least one of the components to be fastened, and preferably higher than all of the components to be fastened At least one of the following is true:

[0080] Heat welding means fixing with molten material, and the material is - at least one of the spare parts being fixed together; - Additional materials containing at least 50% iron, aluminum, or other metals or conductive alloys with a melting temperature above 250°C At least one of the following is true:

[0081] The present invention and its components are described and explained in detail below.

[0082] FIG. 1 shows a cross-sectional view of a multifilament strand made from multiple monofilaments of insulated conductor strands.

[0083] The strands are preferably - Mainly linear long elements, ("Linear" here means "in the form of a straight or curved line.") -Mainly one-dimensional fiber elements, - Fiber or filament based spare parts At least one of the following is true:

[0084] Preferably, the strands are - Monofilament strand - Multifilament strand At least one of the following is true:

[0085] Preferably, the strands are - strands with electrical functions, in particular for heating, sensing and shielding; - Strands with a mechanical function, in particular for removing tension and bending forces from strands with an electrical function At least one of the following is true:

[0086] The electrical element can be a conductor strand. The conductor strands are at least partially conductive strands. Preferably, the conductor strands have at least one of the general characteristics of the strands.

[0087] Preferably, the conductor strands are - Resistive heaters, shield conductors, antennas, sensor conductors It is one of them.

[0088] Preferably, the conductor strands are - Monofilament strand - Multifilament strand At least one of the following is true:

[0089] The conductor strands are - one or more non-conductive strands, and - one or more conductive strands (as substrands) It may include at least one of:

[0090] This means that the conductor strands - a number of conductive (sub)strands, at least one of which is coated with two layers differing in at least one property; - a common coating of two layers that differ in at least one property, It can have: Such conductor strands are preferably selected to allow a radius of curvature of 1 mm, for example by selecting a strand diameter of less than 0.2 mm.

[0091] In particular, when the conductor strands are heater strands, such conductor strands preferably have an electrical resistance in the range of 0.5 to 3 Ω / m, preferably 1 to 2 Ω / m, and preferably 1.2 to 1.8 Ω / m.

[0092] Preferably, the monofilament conductor strand comprises: - conductive core, a first layer at least partially surrounding such core; -Second layer At least one of the following is true:

[0093] Preferably, such monofilament conductor strands comprise: - one of the sensor strands, especially the capacitive presence detector, - Shielding strands, especially those separating heating devices from presence detectors At least one of the following is true:

[0094] Preferably, such filament core is a metal filament; Preferably, at least in part - copper or copper alloys, and - steel or iron alloys, The metal filament is made from at least one of the following:

[0095] Preferably, such first filament layer comprises: - an electrical insulating layer, - A protective layer to absorb mechanical stresses such as ultrasonic vibrations At least one of the following is true:

[0096] Preferably, such first filament layer comprises: - made at least in part from polymers, - at least partially covering the core, a melting temperature above 220°C, preferably above 240°C, preferably above 300°C, - at least partially less than 0.5 mm thick, more preferably less than 0.01 mm thick, ideally less than 0.01 mm thick It has at least one of the following characteristics.

[0097] Preferably, such second filament layer comprises: - an electrical insulating layer, -Fixed layer, At least one of the following is true:

[0098] Preferably, such second filament layer comprises: - at least partially covering the core, - at least partially covering the first layer, - its melting temperature is lower than that of the first layer, preferably below 250°C, preferably below 200°C It has at least one of the following characteristics.

[0099] Preferably, such second filament layer comprises: - made at least in part from polymers, - at least partially covering the first layer, - at least partially at least indirectly covering the core, - the melting temperature is lower than that of the first layer, preferably less than 250°C, preferably less than 200°C, Preferably, the melting temperature is at least 20°C lower than the melting temperature of the first filament layer, more desirably 50°C lower. - at least partially less than 0.5 mm thick, more preferably less than 0.01 mm thick, ideally less than 0.01 mm thick It has at least one of the following characteristics.

[0100] Preferably, such multifilament strands comprise: - several strands with electrical functions, in particular for heating, sensing and shielding, - a plurality of strands with a mechanical function for removing tension and bending forces from strands with an electrical function in particular The present invention has at least one of the following: Such numbers are selected from 1 to 150. For the conductive strands / filaments, the number is preferably 2-8.

[0101] Preferably, the multifilament conductor strand comprises: - a plurality of electrical conductor strands; -heated strands, -Sensor strand, - a non-conductive support (preferably glass-containing mineral fibre) for mechanical tension The present invention has at least one of the following: - Multifilament strands have the advantage of increasing adhesion on the support compared to monofilament strands of similar diameter. This is especially true for multifilament conductor strands that do not have an outer jacket.

[0102] A support such as that shown in FIG. 2a supports a plurality of electrical functional elements. (The number is selected from one and more).

[0103] Preferably, such a support is - Flat heating devices, shielding devices, sensor devices and electrical terminals The support is at least one of the following:

[0104] Preferably, such a support is - a flat layer of polymer material, - the walls of inflatable fluid containers, in particular pneumatic bladders of massage devices or vehicle seats; - a dielectric layer of the shielding device, - Seats or other interior covers At least one of the following is true:

[0105] Preferably, when the support is a flat layer, such support has a thickness of 0.1 mm to 3 mm, preferably a thickness of 0.1 mm to 1 mm, preferably a thickness of 0.1 mm to 0.6 mm.

[0106] Such supports have a melting temperature higher than the temperature that occurs during ultrasonic welding, preferably above 200°C, preferably above 250°C, preferably above 400°C.

[0107] Preferably, such a support supports electrical elements on some of its sides. If the support is a layer fabrication, this means that the support supports electrical elements on both of its opposing surfaces. This allows such electrical elements to be easily electrically isolated from each other. By "layer fabrication" we mean an essentially two-dimensional element, even if it curves in, for example, a third dimension.

[0108] When such a support supports conductor strands on both surfaces, the thickness of the support is preferably at least 50% of the combined thickness of the thickest strands on each of the two surfaces. Depending on the depth to which such strands penetrate the support during ultrasonic welding, it may be preferable to select a minimum thickness of the support equal to at least the sum of the thickness of the thickest strand on one surface of the support and the thickness of the thickest strand on the opposing surface of the support. This avoids complete detachment of the support from the two sides.

[0109] When such a support supports a plurality of separate conductor strands, the patterns of such strands are coordinated with one another, particularly when the strands are on opposing surfaces of the support, and particularly when the thickness of the support is less than the combined thickness of the associated strands.

[0110] In such cases, the layer pattern avoids areas where the strands extend along each other, which prevents the support from being completely separated from both sides.

[0111] Preferably, such a support is at least partially - electrically insulating materials, for example polyurethane, (This allows for the elimination of additional insulating materials within the device.) -stretchable material (By "stretchable" we mean that such a material allows for an extension of the support of at least 5-15% without damage to the material, at least without significant damage. This is particularly important when the support is applied to a steering wheel, in particular as a support for a heating element, a shielding element or a capacitive sensor.) It is made from one of the

[0112] At least one strand is attached to the support in a layer pattern, the pattern being determined by the function of the strand.

[0113] Preferably, to form such a layer pattern, at least one strand is at least partially - Wave patterns, especially sine wave shapes, (Such a pattern allows the strands to compensate for mechanical stresses by following the extension of the support. Sine waves are particularly reliable for heating strands.) -It's a zigzag pattern Multiple straight line segments, Multiple intermediate bends, e.g. 90 degrees, Areas where two strands or strand portions are arranged parallel to one another, (This can be two parts of the same strand, or adjacent strands.) The distance between two such parallel strands or strand portions is less than 5 mm, preferably less than 2 mm, preferably 1 mm or less. (This is particularly suitable for shielding strands to ensure adequate shielding against electromagnetic influences.) Zigzag pattern with - A pattern that includes multiple U-turns Multiple straight line segments, Multiple intermediate bends of approximately 180 degrees, The distance between two such parallel strands or strand portions is less than 5 mm, preferably less than 2 mm, preferably 1 mm or less. (This is particularly suitable for shielding or heating strands.) A pattern with It will be placed in one of the

[0114] Preferably, the sensor comprises: - temperature sensors, in particular NTC or thermostats or thermistors, in particular for monitoring heating devices, - pressure sensors, in particular for controlling inflatable fluid containers; -Presence detectors, especially for detecting hands, persons or movements, especially capacitive detectors, representing the capacitor plates of such capacitors, especially those having at least one fabric or film. At least one of the following is true: This can be a temperature sensor as shown in FIG. 3 in an electrode as in FIG. 2b as part of a capacitance to detect the presence of a seat occupant.

[0115] Such a sensor, particularly if it is a device for monitoring temperature or for indicating a particular temperature threshold, is preferably pre-assembled to form part of the sensor device.

[0116] The sensor device preferably comprises: - at least one sensor, - at least one supply line, o Supplying energy and signals to the sensors, 〇Transmitting data from the sensor to the control device A supply line having at least one of the following functions: (Such a controller can be part of the object or external, e.g., in a vehicle ECU. The present invention has at least one of the following:

[0117] Preferably, the sensor device comprises: The device has at least one sensor including at least two supply lines connecting the sensor to two different potentials, the sensor and the two supply lines forming part of an electrical circuit, and the sensor being a switching device controlling the current through the circuit.

[0118] Preferably, the electrical terminals as in Figures 3 and 4 are conductive bases, which are - internal electrical elements of the devices to be connected, in particular conductor strands of heating, sensor or shielding devices, (internal = inside or attached to an object with electrical function) - an electrical conductor going to an external power source (External = outside of or at a distance from an object with electrical function) is connected to at least one of Such a base can be a metal plate or a piece of conductive film, preferably of square or rectangular shape.

[0119] Preferably, such electrical terminals include: - at least 50% copper, - at least 50% iron, - at least 50% of the same material as the inner conductor strands to which they are connected; and - at least 50% of the same material as the outer conductor to which it is connected It is made from at least one of the following:

[0120] Preferably, the inner conductor strands, outer conductor, and their electrical terminals are all made of at least 80% by weight copper, preferably at least 95% copper.

[0121] Preferably, such electrical terminals include: - Internal electrical elements soldered together, and - Resistance welding for external power supply is connected to at least one of

[0122] The sensor terminal module (e.g., as shown in Figures 3 and 4) - At least two electrical terminals -It is a sensor o have at least two supply lines, a first supply line connected to the first electrical terminal; The second supply line is connected to the second electrical terminal; The sensor includes: This allows for a simplified electrical connection of flat functional models such as heating devices, shielding devices or sensor devices.

[0123] Preferably, the at least one sensor supply line and the one electrical terminal form an integral part. Preferably, the integral part is made of a conductive plate, sheet or film. Preferably, the integral part is fixed to a support. Such a support can be a separate connector support or a support for an electrical module such as a heating device, a shielding device or a detection device. This reduces the number of parts and simplifies assembly.

[0124] Preferably, the sensor terminal module comprises at least -Three electrical terminals and - a sensor, a first supply line connected to the first electrical terminal; A second supply line is connected to the second electrical terminal A sensor, - at least two ends of a conductor strand for connecting an electrical element other than the sensor to an external voltage source, A first of such ends is connected to one of the first and second terminals (similar to a sensor) The second end is connected to the third terminal (different from the sensor) It has two ends. This allows two different electrical elements (such as a sensor and a heating device) to operate independently of each other using only three external supply wires instead of four.

[0125] Preferably, the ends of the conductor strands are -heated strands, - the earth line of the shielding device, and - Capacitive sensor capacitor layer connection line At least one end of the

[0126] Preferably, the two ends of the conductor strand are - a first end and a second end of the same heated strand, and - the grounding line of the electromagnetic shielding device, and - Capacitive sensor capacitor layer connection line At least one of the following is true: This reduces the space required for the connection area of ​​the surface heating device, for example. For example, the size of a wire can be significantly reduced from about 60 x 100 mm with conventional crimping to about 30 x 30 mm with the present invention.

[0127] Preferably, such a sensor terminal module has a terminal support in addition to the support for the electrical element other than the sensor, which simplifies assembly particularly when the number of terminals is more than two.

[0128] Preferably, the sensor terminal module comprises: - Electrical terminals, - conductor strands of the electrical element; - a sensor device, Electrical elements, and Conductor strand a sensor device for monitoring at least one of the - supply lines connecting the sensors to the electrical terminals and - Both the conductor strand and the supply line are electrically and mechanically attached to the same electrical terminal. This allows the sensor to be closer to the conductor strands and therefore make more precise measurements.

[0129] Preferably, such a sensor terminal module comprises: - the sensor is placed at a distance of less than 2 cm, preferably less than 5 cm, preferably less than 2 mm from the conductor strand; the conductor strand forms a loop that at least partially surrounds the sensor; -The sensor device A guide device, ■ for guiding a portion of the conductor strand at least partially around the sensor in a predetermined manner; ■ For forming at least a part of a circle, especially a semicircle A guide device; A sensor placed in the center of such a circle and The method further includes at least one of the following: This allows measurements to be taken close enough to the sensor for precision, yet far enough away for stable control.

[0130] Preferably, the heating device (as in Figures 7, 8 and 9) comprises: - surfaces inside the vehicle interior, in particular instruments, doors, armrests, pillows or cushions of vehicle seats or steering wheels, - a battery heating device, and - Patient heating devices, especially disposable, one-time use heating blankets At least one of them has a heating function.

[0131] Preferably, the heating device comprises: - a support for supporting the electrical elements; -electric heating resistors, and - Electric strands, especially heated strands The present invention has at least one of the following:

[0132] Preferably, at least one electrical element comprises: -Without stitches or seams -preferably by ultrasonic welding It is fixed to a support.

[0133] Preferably, such electrical elements are strands, fixed at least partially along their length to a support.

[0134] Preferably, the heating device comprises: - a heating strand attached to a film support, which support can be or is fixed on the object to be heated; a heating strand attached to a film support, which support can be or is fixed to the cover of the object to be heated, preferably the heating device being between the object and the cover; (If the diameter of the strands is chosen to be smaller than the thickness of the support, this allows for the production of an efficiently heated object without read-through effects on its surface.) - a heating strand attached directly to the cover of the object, preferably with the heating device between the object and its cover; (This allows for the use of particularly thin strands and low energy loss operation of the heater.) - a heating strand attached to the surface of the object to be heated, and - a heating strand attached to an object by being at least partially embedded in the surface of the object; (This allows the production of plastic parts with embedded strands, such as steering wheels, door panels or headrest side cushions, without lead-through effects on the surface, especially if such objects are made at least in part from polymeric materials, especially thermoplastic materials.) The present invention has at least one of the following: Preferably, such attachment includes at least one treatment zone subjected to ultrasonic welding.

[0135] Preferably, such a heating device comprises: - a multifilament heating strand, at least one of the filaments of which contains a two-layer coating; - sensor terminal module, a connector zone in the heating device, a connector zone for electrically connecting the heatable object to a voltage source by assembling it exactly in the intended position (for example a panel with a heating device to a door or a heating lamella to its frame); a heated strand, Attached directly to the heatable cover (no cushioning layer between them) made at least in part from metal, - Contains monofilaments with a diameter of less than 1 mm, preferably less than 0.1 mm, preferably less than 0.01 mm, - multifilaments with a diameter of less than 1 mm, preferably less than 0.1 mm, preferably less than 0.01 mm a heating strand having at least one of: The present invention has at least one of the following:

[0136] Preferably, the heater layer comprises: a support layer, preferably of insulating material, preferably at least 0.7 mm thick, - a heated strand, preferably with a diameter of less than 0.2 mm and a thickness embedded in a support layer It has.

[0137] Preferably, a shielding device (for example as in FIG. 2b) is provided between the heating device and the sensor device, in particular - a heating device for warming the hands of the driver of the vehicle, - a sensor device for monitoring the driver's hands, and - a shielding device for separating the heating device from the sensor device; Electromagnetic effects are reduced when the laminate is arranged in a multi-layer sandwich comprising:

[0138] Such a shielding device comprises a support and at least one shielding conductor, which is preferably an electrical strand.

[0139] Such a shielding device may: a support having any of the aforementioned characteristics of the support, - a shielding strand having any of the aforementioned characteristics of a conductor strand; - a shielding strand having any of the aforementioned characteristics of the heating strand; - the attachment between the support and the strand as previously described, - Shielding strands attached to the support without stitches or seams The present invention has at least one of the following:

[0140] Such a shielding device comprises a shielding conductor and -Presence detector strands, and -heating conductor and a support for supporting at least one of.

[0141] Preferably, such conductor strands of different functions are: - attached to opposite surfaces of the support, - embedded from opposite sides of the support, -following different layer patterns, - Maintain a minimum distance from each other The distance is sufficient to maintain electrical isolation from each other. - have a combined thickness that is less than the common substrate thickness At least one of them.

[0142] Preferably, the presence detection device (eg as in Figure 2b) is a sensor for detecting changes in a field, which is preferably an electric field, a magnetic field or both.

[0143] Preferably, the presence detection device comprises: - Presence detector strand for detecting the presence or movement of a human body part It has.

[0144] Preferably, such a presence detection device comprises: - indicating changes in the electromagnetic field in the vicinity of the detector strand, in particular changes caused by the presence of moisture in the body part; and - indicating pressure changes in the vicinity of the detector strand, in particular changes caused by the weight of the monitored body part; The detector strand has at least one of the following:

[0145] Such a presence detection device may include: a support having any of the aforementioned characteristics of the support, - a detector strand having any of the aforementioned characteristics of the conductor strand; - a detector strand having any of the aforementioned characteristics of the heating strand; - attachment between the support and the strand as previously described; - A detector strand that can be attached to a support without stitches or stitches The present invention has at least one of the following:

[0146] Such a presence detection device comprises a detector strand; - shielding strands, and -heating conductor and a support for supporting at least one of.

[0147] Preferably, such a presence detection device is of a structure that is quite similar to the occluded device, and therefore may incorporate the additional features described for the occluded device.

[0148] Preferably, the heater presence detection module (e.g., as in Figures 5, 7, and 8) includes: - heating equipment, - cloaking devices, and -Heating device Includes at least two of the following: Preferably, several such devices form a common module having a multi-layer sandwich structure, with at least two of such structures preferably arranged on parallel levels and in particular electrically insulated from one another, for example by a support layer (they may use the same conductors and may use them at different times, for example by multiplex switching).

[0149] Preferably, such a heater presence detection module has at least one conductive strand with a thickness along the range of 0.05 mm to 1.5 mm, preferably 0.1 mm to 0.5 mm, preferably 0.1 mm to 0.3 mm, preferably at least one of a heating strand, a sensor strand and a shielding strand.

[0150] Preferably, such conductor strands are multifilament, preferably the number of filaments in the sensor strand is 1-10, preferably the number of filaments in the shielding strand is 1-3, and preferably the number of filaments in the heating strand is 1-100.

[0151] Preferably, the heater presence sensing module for a steering wheel has an elongation of at least 5-15% without affecting the supported electrical components or module.

[0152] Such a heater presence detection module may also be embedded in a door panel, armrest or vehicle pillow.

[0153] Preferably, such a heater presence detection module comprises: a heater support, preferably of insulating material, preferably at least 0.7 mm thick, and - a heated strand attached to or embedded in a support, preferably with a diameter of less than 0.2 mm and a thickness It has.

[0154] Preferably, such a heater presence detection module comprises: a sensor support, preferably of insulating material, preferably at least 0.7 mm thick, - a sensor strand attached to or embedded in a support, preferably with a diameter of less than 0.2 mm and a thickness It has.

[0155] Preferably, such a heater presence detection module comprises: a shielding support, preferably of insulating material, preferably at least 0.7 mm thick, - shielding strands attached to or embedded in the support, preferably with a diameter of less than 0.2 mm and a thickness It has.

[0156] Preferably, such a heater presence detection module has a support, the support comprising: - a combination of a heater support and a shielding support, in which the heating strands and the shielding strands are fixed to opposite surfaces of the combination support; - a combination of a sensor support and a shield support, in which the sensor strand and the shield strand are fixed to opposite surfaces of the combination support; The support is one of:

[0157] The seat contour adjusting device (such as that shown in Figure 6) -Adjusting the seat to the specific user's anatomy; - To compensate for driving operations, Adjusting the seat to counterbalance especially when driving in curves at high speeds; - Adjusting the seat to avoid the disadvantage of the occupant maintaining the same posture for too long, - Adjusting the seat to indicate conditions such as drowsiness or to prepare the occupant for an anticipated event such as a collision; - Massaging specific areas of the sheet surface with increased temperature and pressure; The contour of the sheet can be adjusted for at least one of the following reasons.

[0158] Such seat contouring includes multiple inflatable fluid reservoirs that together adjust the seat contour, at least one of which is a reservoir heater module having an inflatable fluid reservoir with an integrated heating device, as shown in FIG.

[0159] Preferably, the inflatable fluid container can be filled with a volume of air at least during certain stages of operation. Preferably, the fluid is air.

[0160] Preferably, the inflatable fluid reservoir has at least one flexible wall that is impermeable to the contained fluid, which allows the contour of this wall and / or the fluid reservoir to be changed by changing the amount of fluid in the reservoir.

[0161] The fluid container wall is at least partially made of a material that is not damaged by ultrasonic welding. Preferably, the wall is made of a polymeric material, preferably polyurethane. Preferably, the wall has a melting temperature that is at least 20°C, preferably 50°C, higher than that of at least one coating of the supported strand.

[0162] Preferably, such fluid container walls are thicker than any of the conductor strands. Preferably, the walls are 0.1 mm to 5 mm thick, preferably 0.1 mm to 2 mm thick, preferably 1 mm to 2 mm thick.

[0163] Preferably, the inflatable fluid container is made by attaching two layers of flexible wall material together.

[0164] Preferably the layers are the same size and are sealed along their edges, preferably by welding to each other.

[0165] One of the edges can be the result of folding one relatively large sheet into two overlapping layers.

[0166] Preferably, the result is a gas-filled pouch.

[0167] Preferably, the inflatable fluid container comprises: - electric heating elements, - a temperature sensor for monitoring the temperature of such heating element; - a temperature sensor to monitor the temperature of the occupants, a pressure sensor for monitoring the pressure in the inflatable fluid container; - a presence detector for detecting a human body part, and - Shielding devices for shielding electromagnetic influences, especially from heating devices, towards occupants or presence detectors The present invention has at least one of the following: Preferably, such electrical elements and devices are integrated into the fluid container.

[0168] Preferably, the fluid container wall is provided with a sensor, preferably - Temperature sensors, thermistors, thermostats, NTC -Pressure sensor Support at least one of the following:

[0169] The seat contour adjustment device preferably comprises: - general comfort, as well as - Assists in massaging a given area by increasing temperature and pressure and a heating device for at least one of the above.

[0170] Preferably, the seat contouring device has at least one feature described for the inflatable fluid reservoir, preferably by incorporating such a fluid bladder or an additional separate assembly.

[0171] Preferably, the inflatable fluid container comprises: - embedded in the wall of the fluid container, - embedded in a fluid container from the inside, and an integrated heating device, the heating device being one of: The heating device is attached to the flexible wall of the fluid container. Preferably, it is mounted on the side of the fluid container facing the seat occupant.

[0172] If the heating device is enclosed inside the fluid vessel, it can be made from a suitable support material and heating conductor; for example - carbon multifilaments on a fleece support, - Litz wire made of steel or copper on a braided support, - Sewn heated strands on flat and flexible supports can be made from

[0173] If the heating strands are attached to a separate support, such a support can be laminated to the flexible wall of the fluid container. The simplest method is to attach the copper multifilament strands directly to the wall of the fluid container by ultrasonic welding. The strands can also be embedded into the wall from the inner surface of the fluid container. The assembly inside the fluid container protects the heater against mechanical loads, especially shear movements outside the fluid container.

[0174] If the heating device is attached to the fluid container from outside the fluid container, it can be made in any of the ways described above, but the service life can be significantly increased if the heating strands are attached directly to the wall of the fluid container or at least partially embedded in the wall of the fluid container by ultrasonic welding.

[0175] One or more of such inflatable fluid containers with integrated heating devices may include: - heater massage modules for vehicle seats, -Heated contouring module for vehicle seats At least one of the following can be formed.

[0176] Preferably, at least one of such containers is equipped with a sealed electrical termination zone as shown in FIGS.

[0177] Preferably, the sealed electrical terminal zone comprises an electrical terminal or a sensor terminal module as previously described.

[0178] Preferably, this is -Occupant detection device -Heating device -Sensor devices, especially for detecting pressure or temperature -Shielding device is used for electrical contact with at least one of the

[0179] Preferably, the sealed electrical terminal is preferably disposed between two protective layers.

[0180] Preferably, such a protective layer comprises: - a support for an electrical element or device connected via such terminals to an external voltage source or control device; - a separate protective layer of a suitable, preferably sealable, material; - an extension in the wall of a fluid container At least one of the following is true:

[0181] Preferably, the sealed electrical terminal zone is completely sealed around at least one electrical terminal, preferably around the complete terminal module. This avoids the time spent gluing or coating the contact areas or shrink tubing.

[0182] When the fluid container is provided with a sealed electrical terminal, preferably the two protective layers are extensions of the walls of the fluid container, preferably the upper and lower walls of the fluid container, and preferably the terminal is sealed between such two layers.

[0183] When the fluid container is provided with a sensor terminal module and a sealed electrical terminal zone, preferably at least one sensor of such a sensor terminal module is disposed in the fluid container, while the terminal portion of such a sensor terminal module is enclosed in the sealed electrical terminal zone, which allows for precise measurement and very easy assembly.

[0184] This is especially true for - the heater device is disposed within the fluid enclosure, and the at least one sensor is a temperature sensor; at least one sensor is a pressure sensor; and - A presence detector is placed within the fluid container This is particularly useful if at least one of

[0185] The massage device can be a general device, not necessarily limited to use in a vehicle. This includes a bed, a massage table, an operating table, or a deck chair. Such a device can have the features as described for the seat contouring device. [Explanation of symbols]

[0186] 10 Electrical Functional Elements 12, 12a, 12b Electrical conductors 14 Partial Strands 16 wires 18 Protective layer 20 molten layer 22 Support element 24 sensor elements 26, 26a~26c Supply lines 28, 28a~28c Electrical terminals 100 objects 102 Fluid container 104 Welding Area 106 Fluid Line 108 Sealing Area 200 modules 204 Heater Contouring Module 206 Heater Massage Module 208 Connection Area 210 Sensor Terminal Module 212 Equipment 214 Heating device

Claims

1. An electrical functional element (10) connected to an object (100), the connection being an ultrasonic weld; An electrical functional element characterized by:

2. The electrical functional element (10) is at least one from the following group: - electrical conductors (12, 12a, 12b), - a sensor element (24), - electrical terminals (28, 28a to 28c), - shielding elements against electromagnetic interference, - Electric heating device That is, 2. An electrical functional element (10) according to claim 1, characterized in that it

3. The electrical conductor (12, 12a, 12b) is a multifilament electrical conductor (12a) including a plurality of partial strands (14), and at least one partial strand 14 includes a fused layer (20). An electrical functional element (10) according to any one of the preceding claims, characterized in that it

4. the sensor element (24) is a temperature sensor, a pressure sensor, or a presence detector; An electrical functional element (10) according to any one of claims 2 to 4, characterized in that

5. At least one electrical terminal (28, 28a-28c) is formed as a conductive base surface; An electrical functional element (10) according to any one of claims 2 to 4, characterized in that

6. the electrical shielding element comprises at least one support element (22) and at least one shielding conductor; An electrical functional element (10) according to any one of claims 2 to 5, characterized in that

7. the electric heating device comprises at least one support element (22), at least one electric heating resistor and at least one electric heating conductor; An electrical functional element (10) according to any one of claims 2 to 6, characterized in that it

8. At least two electrical terminals (28, 28a-28c) and at least one sensor together form an electrical functional element (10) formed as a sensor terminal module (210); An electrical functional element (10) according to any one of the preceding claims, characterized in that it

9. an object (100) on which at least one electrical functional element (10) is arranged, said electrical functional element (10) being connected to said object (100) by ultrasonic welding; An object characterized by

10. Said object (100) is a vehicle component from the following group: - Vehicle interior parts, heatable vehicle components, -Steering wheel, an inflatable fluid container (102), and - Vehicle seat components That is, 10. The object (100) according to claim 9.

11. A module (200), at least one electrical functional element (10), and - comprising at least one object (100), The module (200) has at least two different dynamic functions, The electrical functional element (10) of the module (200) and the object (100) are connected to each other by ultrasonic welding. A module characterized by:

12. The module (200) has one of the following structures: - a detection module for detecting the heat of the steering wheel heater, - a detection module for detecting heater heat in the vehicle trim; - a heater contouring module (204) for the vehicle seat; - a heater massage module (206) for the vehicle seat, an inflatable fluid container (102) with an integrated heating device (214); a sealed electrical connection area (208), and -Sensor terminal module (210) is selected from 12. The module (200) of claim 11.

13. At least one of the dynamic functions of the module (200) - Warming people, -Recognizing the presence of people, - Massaging people, -adjusting the contours of the body support device; and - adjusting the volume of the inflatable fluid container (102) is selected from 13. A module (200) according to claim 11 or 12, characterized in that

14. the module is a presence detector module for recognizing at least one of both the presence and the movement of a human body part; A module (200) according to any one of claims 11 to 13, characterized in that

15. The detection module for detecting heater heat includes the following components: -sensor device, a heating device (214), and -shielding device, At least one of A module (200) according to any one of claims 11 to 14, characterized in that

16. The module (200) is a device for adjusting the seat contour of a vehicle seat. A module (200) according to any one of claims 11 to 15, characterized in that

17. The module (200) includes at least one inflatable fluid container (102), at least one electrical conductor (12, 12a, 12b), and at least one sealed sensor terminal module (210). A module (200) according to any one of claims 11 to 16, characterized in that

18. The module (200) has an inflatable fluid container (102) with an integrated heating device (214) and forms at least a portion of a heater contouring module (204) for a vehicle seat. A module (200) according to any one of claims 11 to 17, characterized in that

19. The module (200) has an electrical connection area (208) that is sealed against external influences by ultrasonic welding in at least one protective layer. A module (200) according to any one of claims 11 to 18, characterized in that

20. The module (200) has a massager containing an air bladder formed by welding two layers of material together by ultrasonic welding. A module (200) according to any one of claims 11 to 19, characterized in that

21. A method for connecting at least one electrical element (10) to at least one object (100), wherein said electrical functional element (10) and said object (100) are connected to each other by ultrasonic welding, A method characterized by:

Images