Gas Sensor Separator Segmentation for Rotation-Stable Contact Alignment
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Solution Overview
Problem
Existing gas sensors face issues with connection reliability between electrode pads and metal terminals due to rotational misalignment caused by vehicle vibrations, leading to contact failures, and insertion difficulties due to tight clearance in the separator design, affecting productivity.
Innovation Solution
A gas sensor design with a separator having distinct storage spaces with varying rotation allowable angles, allowing easy insertion and maintaining stable connections by restricting relative rotation between the sensor element and separator, using a first storage space with a larger clearance for easy assembly and a second storage space with restricted rotation to prevent misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the separator uses a straight-shaped storage space with constant dimensions, then rotational stability is improved, but insertion difficulty increases due to small clearance
Solution Approach 1:
The storage space is divided into two distinct segments: a first storage space with larger clearance for easy insertion, and a second storage space with rotation restriction walls for rotational stability. This segmentation allows each part to fulfill its specific function without compromise
Solution Approach 2:
Different regions of the storage space are given different geometric properties. The first storage space has larger clearance for ease of insertion, while the second storage space has rotation restriction walls for rotational stability. Each local region is optimized for its specific purpose
2Reliability
If the sensor element is held close to the design position with tight clearance, then connection reliability is improved, but insertion difficulty increases
Solution Approach 1:
The storage space is segmented into insertion and holding zones. The first storage space provides generous clearance for easy insertion, while the second storage space with rotation restriction walls ensures the sensor element is held precisely at the design position for reliable connections
Solution Approach 2:
The rotation restriction walls are pre-positioned in the second storage space to prevent rotational movement before the sensor element is fully inserted and secured. This preliminary constraint ensures proper alignment is maintained throughout the insertion process
3Manufacturing precision
If the separator rotates due to vibration, then misalignment occurs between metal terminals and electrode pads, but the initial design position provides optimal contact
Solution Approach 1:
Rotation restriction walls are built into the second storage space to preemptively counteract the harmful effect of vibration-induced rotation. These walls prevent the separator from rotating relative to the sensor element, maintaining optimal alignment between metal terminals and electrode pads during vehicle operation
Data Source
AI summary
A gas sensor (200) including a sensor element (10) having electrode pads (11a-12b); a separator (166); and a plurality of metal terminals (21a, 21b, 22a, 22b) each having a body portion (21a1) and a front end portion (21a2), and being insulated from each other by the separator. The separator has an element storage portion (168) penetrating in the axial-line direction or recessed toward a rear side from a front facing surface of the separator, the element storage portion has a first storage space (168a) at a front side thereof and a second storage space (168b) at a rear side thereof, the second storage space has a rotation restriction wall (168w) configured such that a relative rotation allowable angle 2θ between the sensor element and the separator is smaller than in the first storage space, and the rear end side of the sensor element is stored in the second storage space.