Electric Connection Structure for Fuel Injector Sensors
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Solution Overview
Problem
The existing electric connection structures for pressure sensors in fuel injectors face challenges in precise rotational positioning of terminals, leading to random orientations, which complicates electrical connections and hinders miniaturization due to large terminal pitches required for welding.
Innovation Solution
The proposed electric connection structure employs strip-like first terminals arranged in parallel with alternating offsets, allowing for increased welding space or reduced pitches between terminals by distributing welding parts on both sides, and includes resin-molded components with specific width dimensions and gap sizes to facilitate secure connections without overlapping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If all input/output terminals and relay terminals are welded on the same side, then the connection structure is simple, but the welding space is limited and terminal pitches must be large
Solution Approach 1:
The patent transitions from single-sided welding to multi-sided welding by distributing relay terminals at different positions around the pressure sensor body. This spatial distribution across multiple dimensions creates additional welding spaces without increasing overall device complexity, effectively resolving the contradiction between structural simplicity and available welding area.
2Area of stationary object
If large pitches between terminals are used, then welding space is sufficient, but the overall size of the connector cannot be reduced
Solution Approach 1:
The patent applies local quality by positioning relay terminals at specific locations around the pressure sensor body where space is available, rather than requiring uniform large pitches between all terminals. This allows adequate welding space at critical locations while maintaining compact overall connector dimensions through optimized local terminal placement.
3Strength
If the pressure sensor is screw-fixed to achieve electrical connection, then mechanical fixation is secure, but rotational positioning becomes random and precise alignment is lost
Solution Approach 1:
The patent introduces relay terminals as intermediary elements that mediate between the pressure sensor terminals and the connector terminals. These relay terminals are positioned at multiple locations around the pressure sensor body, creating multiple potential connection points that increase the probability of achieving proper electrical alignment during assembly, thereby compensating for random rotational positioning while maintaining secure mechanical fixation.
Data Source
AI summary
An electric connection structure includes a plurality of strip-like first terminals and a plurality of second terminals welded to ends in a longitudinal direction of the first terminals. The first terminals are arranged in parallel with intervals therebetween. The first terminals are arranged so that at least a part thereof faces each other. The first terminals are arranged to be offset in the longitudinal direction alternately so that the ends of the first terminals in the longitudinal direction project. The second terminals are welded to the ends in the projected sides in the longitudinal direction in the first terminal.