Constant Potential Electrolytic Gas Sensor Lead Wire Guide
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Solution Overview
Problem
Existing constant potential electrolytic gas sensors face difficulties in easy manufacturing due to complex and difficult lead wire wiring, particularly with right-angled bending, hindering automation.
Innovation Solution
The sensor design includes a case with a guide that facilitates easy wiring of lead wires along the surface of electrodes, using external electrodes connected to the case body, and a method that involves introducing lead wires along a guided path to connection points, allowing for straightforward connection and integration with the electrode structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lead wires are wired with right-angled bending to connect electrodes and terminals, then electrical connection is achieved, but manufacturing complexity increases and automation becomes difficult
Solution Approach 1:
The patent applies preliminary action by pre-positioning external electrodes on the case body at locations that correspond to the electrode structure heights before lead wire installation. This allows lead wires to be directly connected without complex right-angled bending, as the connection points are already optimally positioned. The external electrodes serve as intermediate connection points that eliminate the need for difficult wiring operations.
Solution Approach 2:
The patent introduces external electrodes as intermediary elements between the lead wires and the internal electrode structure. These external electrodes extend from the outside of the case to the inside, providing accessible connection points on the case body that correspond to the electrode heights. This intermediary structure simplifies the connection process by eliminating the need for complex lead wire bending.
2Reliability
If complex right-angled bending of lead wires is performed, then electrode connections are established, but manufacturing time and labor increase
Solution Approach 1:
The external electrodes are pre-installed on the case body at positions corresponding to the electrode structure heights before lead wire connection. This preliminary positioning eliminates the need for time-consuming right-angled bending operations during assembly, significantly improving manufacturing efficiency while ensuring reliable electrical connections.
Solution Approach 2:
The external electrodes on the case body serve themselves as the connection interface, eliminating the need for complex manual wiring operations. The lead wires can be directly connected to these externally positioned electrodes without requiring difficult bending or routing through tight spaces, enabling faster and more efficient manufacturing.
3Reliability
If lead wires are bent at right angles for connection, then electrical pathways are created, but the wires experience excessive mechanical load
Solution Approach 1:
By pre-positioning external electrodes at heights corresponding to the internal electrode structure, the patent eliminates the need for sharp right-angled bends in lead wires. The lead wires can be connected in a more natural, gradual configuration that reduces mechanical stress and prevents wire damage while maintaining reliable electrical connections.
Solution Approach 2:
The external electrodes act as intermediary connection points that are positioned to minimize mechanical stress on lead wires. By providing accessible connection points on the case body that correspond to electrode heights, the system allows lead wires to connect without experiencing excessive bending loads that would compromise their mechanical strength.
Data Source
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AI summary
A constant potential electrolytic gas sensor 1 of the present invention comprises a case with a case body 21, an electrode structure 3 comprising electrodes 31, 32, 33 provided in the case body 21, lead wires 41, 42, 43 connected to the surfaces of the electrodes 31, 32, 33, and external electrodes 51, 52, 53 that extend from the outside of the case to the inside of the case, are provided in the case body 21, and are connected to the lead wires 41, 42, 43, wherein the electrodes 51, 52, 53 are arranged so that a connection point CP of the external electrode 51, 52, 53 to which the lead wire 41, 42, 43 is connected is located at a height corresponding to the electrode structure 3, and wherein the case body 21 comprises a guide 7 that guides the lead wire 41, 42, 43 along an introduction path from the outside of the case body 21 toward the electrode structure 3 via the connection point CP of the external electrode 51, 52, 53.