Gas Sensor Swaging Sequence for Alignment
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Solution Overview
Problem
Existing methods for manufacturing gas sensors using swaging to fix an elastic body to a tubular body often result in inadequate sealing properties and misalignment of connections, leading to potential electrical connectivity issues.
Innovation Solution
A method involving radial swaging of the tubular body and elastic body at multiple sections, where the swaged section closer to the open end is primarily swaged first, reducing misalignment and ensuring better sealing by controlling the pressure and alignment of the elastic body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multi-stage swaging is performed to fix the elastic body to the tubular body, then the elastic body is securely fixed, but excessive axial elongation or misalignment occurs leading to poor sealing properties and connection misalignment
Solution Approach 1:
The patent applies preliminary action by performing the first swaging operation at the open end side before the second swaging operation at the connection side. This sequence pre-positions the elastic body and reduces its freedom of movement before the connection-side swaging, preventing misalignment and excessive elongation that would occur if both swaging operations were performed simultaneously or in reverse sequence.
2Strength
If strong swaging force is applied to fix the elastic body, then the elastic body is securely fixed, but the connections between connector and leads become misaligned or damaged
Solution Approach 1:
The patent segments the swaging process into two distinct stages: first swaging at the open end side, then swaging at the connection side. This segmentation allows the fixing strength to be applied in a controlled sequence, where the first stage prepares the elastic body and the second stage applies the primary fixing force without causing connection misalignment or damage.
Solution Approach 2:
The first swaging operation at the open end side serves as a preliminary action that pre-compresses and positions the elastic body before the main fixing operation at the connection side. This preliminary compression reduces the elastic body's tendency to deform or misalign during the subsequent connection-side swaging, protecting the electrical connections.
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 approach enhances sealing properties and electrical connectivity by minimizing misalignment and excessive force on connections, preventing leaks and connection failures while maintaining the rubber plug's position and durability.
Implementation Method 1
radially swaging the tubular body and the elastic body at a plurality of swaged sections including a swaged section located on the connection side and a swaged section located closer to the open end than the swaged section located on the connection side
Data Source
AI summary
Among first and second swaged sections, the second swaged section begins to be swaged prior to the first swaged section. Hence, a strong force can be prevented from acting on a rubber plug in a free state at a time and the first swaged section can begin to be swaged in such a state that a portion of the rubber plug that corresponds to the second swaged section is aligned as compared to the case where the first and second swaged sections begin to be simultaneously swaged. This prevents the position of the rubber plug from being significantly varied during swaging and also prevents the rubber plug from protruding from an outer tube.