Gas Sensor Elastic Terminal Connection Without Welding
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Solution Overview
Problem
The existing lateral-lead-out-type gas sensors face challenges in productivity and component count due to the need for welding connection and connector terminals, which are made of different materials, and the complexity of their assembly.
Innovation Solution
A gas sensor design that connects the connection terminals to the connector terminals without welding, using an elastic connection mechanism where one or both of the connection portions are bent to form an insertion piece and a female portion, allowing for elastic connection and reducing the need for a lead frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connection terminals and connector terminals are connected by welding, then reliable electrical connection is achieved, but productivity deteriorates and manufacturing complexity increases
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical insertion system. The connection terminal has an insertion piece that fits into a female portion of the connector terminal, establishing electrical connection through mechanical contact rather than welding. This substitution eliminates the need for welding equipment and processes, thereby improving productivity while maintaining reliable electrical connection.
Solution Approach 2:
The patent introduces an elastic portion as an intermediary element between the insertion piece and the female portion. This elastic portion provides contact pressure to ensure reliable electrical connection while accommodating material differences between connection terminals (heat-resistant metal) and connector terminals (copper-based material). The elastic intermediary enables reliable connection without requiring welding despite material incompatibility.
2Temperature
If connection terminals are made of heat-resistant metal, then high temperature resistance is achieved, but electrical conductivity deteriorates compared to copper-based materials
Solution Approach 1:
The patent applies different material qualities to different parts of the connection system. The connection terminal (exposed to high temperature near the gas sensor element) is made of heat-resistant metal, while the connector terminal (requiring low resistance for electrical connection) is made of copper-based material. The elastic portion serves as a transition zone that accommodates the material difference. This local differentiation of material properties allows each component to optimize for its specific functional requirements.
3Reliability
If multiple welds are required for connecting terminals, then reliable electrical connection is achieved, but manufacturing complexity increases and production efficiency deteriorates
Solution Approach 1:
The patent merges the connection terminal and connector terminal into a single assembly unit through the elastic connection mechanism. Instead of requiring separate welding operations for each terminal connection, the insertion piece fitting into the female portion creates a unified electrical connection system in one step. This merging of connection operations simplifies the manufacturing process while maintaining reliable electrical connection across all terminals.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design improves productivity by eliminating the need for welding and reduces the number of components, while ensuring reliable electrical connection and preventing chipping of the separator.
Implementation Method 1
at least one of the insertion piece and the female portion has an elastic portion elastically bendable in a direction intersecting a direction of juxtaposition of the first connection portion and the second connection portion; and the insertion piece is fitted into the female portion such that the elastic portion elastically bends in the intersecting direction, whereby the first connection portion and the second connection portion are elastically connected
Data Source
AI summary
A gas sensor (200) in which individual ones of connection terminals (30) have, at a rear end portion, a first connection portion (31) connected to a corresponding connector terminal (60). Individual ones of the connector terminals have, at an end portion on a side toward separator (40), a second connection portion (61) connected to the first connection portion. One of the first and second connection portions assumes the form of an insertion piece (61g), and the other assumes the form of a female portion (31g) into which the insertion piece is inserted. At least one of the insertion piece and the female portion has an elastic portion (31a). The insertion piece is fitted into the female portion, and the elastic portion thereby elastically bends, whereby the first and second connection portions are elastically connected.