Gas Sensor Electrode Pad Through Hole Placement
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Solution Overview
Problem
Conventional gas sensors experience electrical connection failures between electrode pads and connection terminals due to improper contact and deformation during assembly, leading to signal output issues and increased manufacturing costs.
Innovation Solution
The gas sensor design features through holes in the insulating substrate positioned within the forward end regions of the electrode pads, reducing the likelihood of contact with connection terminals and deformation, while also reducing the length of leads and the amount of noble metal used, thereby minimizing electrical connection failures and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If through holes are formed in the insulating substrate at different longitudinal positions, then the connection terminals can be positioned more flexibly, but the contact area between connection terminals and electrode pads decreases, causing electrical connection failures
Solution Approach 1:
The electrode pads are extended in the longitudinal direction before the connection terminals are assembled, creating a larger contact area in advance. This preliminary extension ensures that even when connection terminals are positioned at different longitudinal locations, they always have sufficient contact area with the electrode pads, preventing electrical connection failures while maintaining positioning flexibility.
2Ease of operation
If connection terminals are moved during assembly from rear end to forward end, then proper electrical connection can be achieved, but connection terminals may be caught by through holes and deformed, causing wire breakage
Solution Approach 1:
The electrode pads are extended toward the through holes before assembly, creating a protective barrier that guides connection terminals into proper contact areas. This preliminary extension prevents connection terminals from being caught by through holes during the moving process, eliminating deformation risks while maintaining assembly ease.
Solution Approach 2:
The extended electrode pads act as an intermediary element between the connection terminals and the through holes. This intermediary structure redirects the connection terminals away from the through holes during assembly, preventing harmful interactions while facilitating proper electrical connection.
3Ease of manufacture
If the insulating substrate uses a conventional structure with through holes, then manufacturing is simpler, but electrical connection failures and signal anomalies occur due to improper contact
Solution Approach 1:
The electrode pads are segmented into multiple regions with different longitudinal extents. Some electrode pads extend further toward the through holes while others have limited extension, allowing each pad to be optimized for its specific function while maintaining overall manufacturing simplicity.
Solution Approach 2:
Different electrode pads have different longitudinal extension characteristics tailored to their specific requirements. This local differentiation ensures that each electrode pad provides optimal contact area for its associated connection terminal while maintaining the overall simplicity of the insulating substrate structure.
Data Source
AI summary
A gas sensor element of an air/fuel ratio sensor includes a plurality of through holes formed in an insulating substrate at forward end regions of corresponding electrode pads to which the through holes are connected. In the gas sensor element, the through holes are not formed within the longitudinal rear end regions and center regions of the electrode pads. Since in each of the electrode pads, the region of the electrode pad other than its forward end region occupies a greater area than that of the forward end region, it is easy to bring connection terminals into contact with the regions of the electrode pads other than their forward end regions. Therefore, it is possible to prevent the connection terminals from coming into contact with the through holes, so as to thereby prevent occurrence of an electrical connection failure between the connection terminals and the electrode pads.