Gas Sensor Metal Terminal Asymmetric Surface Design
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Solution Overview
Problem
The existing gas sensors face a reliability issue due to heat transfer from the separator, which causes the metal terminal's elasticity to decrease, leading to a risk of electrical connection failure with the sensing element.
Innovation Solution
The gas sensor design includes a metal terminal with a lead-wire-connecting portion, a main body, a protruding piece, an elastic portion, and opposed surfaces with different areas to maintain elasticity and reduce heat transfer, ensuring stable electrical connection by minimizing contact with the separator's inner surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the metal terminal is in firm surface contact with the separator to withstand reaction force, then the electrical connection reliability is improved, but heat transfer from the separator to the metal terminal increases causing elasticity loss
Solution Approach 1:
The metal terminal's surface is divided into two distinct regions: a first surface area that contacts the separator and a second surface area that faces the electrode pad. This segmentation allows the contact surface to be optimized for mechanical support while minimizing the area exposed to heat from the separator, thus resolving the contradiction between connection reliability and heat transfer.
Solution Approach 2:
Different regions of the metal terminal are given different functional qualities: the first surface (contacting the separator) is designed for mechanical support and stability, while the second surface (facing the electrode pad) is designed to minimize heat exposure and maintain elasticity. This local differentiation of surface properties allows the terminal to simultaneously achieve firm contact and heat resistance.
2Stability of the object's composition
If the metal terminal contacts the separator inner surface to maintain position, then the structural stability is improved, but the elasticity of the metal terminal decreases due to heat exposure
Solution Approach 1:
The terminal structure is segmented into multiple surfaces with different functions: the first surface provides positional stability through separator contact, while the second surface maintains elasticity by minimizing heat exposure. This segmentation allows simultaneous achievement of stability and elasticity.
Solution Approach 2:
The metal terminal features an asymmetric surface configuration where the first surface area (contacting separator) and second surface area (facing electrode pad) have different sizes and orientations. This asymmetry optimizes the terminal for both stability (through separator contact) and elasticity preservation (by reducing heat-exposed area).
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 effectively maintains the elasticity of the metal terminal, ensuring a stable electrical connection between the electrode pad and the metal terminal, even under high-temperature conditions, by reducing heat transfer and preventing creep-deformation.
Implementation Method 1
an elastic portion that is connected to an end of the protruding piece, that is folded toward the sensing element, and that is elastically connected to the electrode pad
Implementation Method 2
the first opposed surface is separated from the inner circumferential surface of the insertion hole
Data Source
AI summary
A gas sensor includes a sensing element that includes an electrode pad, a metal terminal, and a separator. The metal terminal includes a lead-wire-connecting portion, a main body, a protruding piece that protrudes from a front-end side, and an elastic portion connected to an end of the protruding piece and to the electrode pad. An area S1 of a first opposed surface of a primary surface facing an insertion hole of the separator is larger than an area S2 of a second opposed surface of a secondary surface facing the insertion hole, and a part of the second opposed surface contacts an inner circumferential surface of the separator forming the insertion hole, and the first opposed surface is separated from the inner circumferential surface, where surfaces of the main body and the protruding piece that are located opposite the elastic portion are the primary surface and the secondary surface.