Inclined Spring Terminal Layout for Stable Gas Sensor Contact
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing gas sensors face challenges in maintaining a stable electrical connection between spring terminals and the sensor element due to perpendicular flexing of arm sections, which can lead to contact failure and displacement, especially when mounted on vehicles where size reduction is necessary.
Innovation Solution
The gas sensor design incorporates inclined spring terminals with arm sections that flex in a direction inclined relative to the outer surface of the terminal contact portions, ensuring stable contact and reducing the likelihood of contact failure by restricting the sliding direction and increasing the inclination angle with respect to the normal of the terminal contact surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the arm section of the spring terminal flexes perpendicular to the sensor element surface, then the electrical connection is established, but the contact stability deteriorates and displacement occurs
Solution Approach 1:
The patent changes the flexing direction parameter of the spring terminal arm section from perpendicular to inclined relative to the sensor element surface. This parameter modification prevents the arm section from sliding off the terminal contact portion while maintaining electrical contact, thereby resolving the contradiction between establishing electrical connection and maintaining contact position stability.
2Adaptability or versatility
If the sensor size is reduced for vehicle mounting, then the adaptability improves, but the contact stability between spring terminals and sensor element deteriorates
Solution Approach 1:
By changing the flexing direction parameter to inclined, the patent enables stable electrical connection even in compact sensor designs with reduced size. The inclined flexing direction provides a mechanical constraint that prevents contact failure, allowing the sensor to maintain reliability while adapting to space-constrained vehicle mounting environments.
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 maintains a favorable electrical connection state between the spring terminals and the sensor element, preventing contact failure and ensuring reliable operation, even when the sensor element is inserted into the insulator, thus enhancing the sensor's performance and durability.
Implementation Method 1
Each spring terminal includes a holding section, which is retained in the associated retaining groove, and an arm section. As viewed in an insertion direction of the sensor element into the insertion hole, at least one of the spring terminals includes an inclined spring terminal, and a flexing direction of the arm section of the inclined spring terminal with respect to the holding section is inclined with respect to an outer surface of the associated terminal contact portion.
Data Source
AI summary
A gas sensor includes a sensor element, spring terminals, and a spring insulator. The spring terminals are formed of bendable wire. The spring insulator includes an insertion hole in which a proximal section of the sensor element is inserted and retaining grooves, which communicate with the insertion hole. The spring terminals each include a holding section retained in the associated retaining groove and an arm section, which extends from the holding section and comes into contact with the associated one of terminal contact portions of the sensor element while flexing with respect to the holding section. When viewed in an insertion direction of the sensor element to the insertion hole, a flexing direction of the arm section of each spring terminal with respect to the holding section is inclined with respect to the outer surface of the associated terminal contact portion.