Gas Sensor Metal Terminal Vibration Breakage
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Solution Overview
Problem
The existing gas sensors with expanding diameter connectors at the rear end are prone to metal terminal breakage due to vibration during usage.
Innovation Solution
A gas sensor design featuring a taper surface on the separator's storage portion and a projection on the metal terminal that contacts the taper surface, securely fixing the terminal and inhibiting vibration-induced breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the storage portion has an expanding diameter to inhibit metal terminals from interfering with the inner surface, then the metal terminals are prevented from contacting the inner surface, but the metal terminals sway due to vibration and are likely to be broken
Solution Approach 1:
The storage portion is designed with different geometric characteristics at different locations: a front portion with a smaller diameter and a rear portion with an expanded diameter. This local differentiation allows the front portion to securely hold the metal terminal while the rear portion prevents interference with the inner surface, resolving the contradiction between stability and interference prevention.
Solution Approach 2:
The storage portion is divided into functionally distinct segments: a front storage region that contacts and stabilizes the metal terminal, and a rear expanding region that prevents terminal interference with the inner surface. This segmentation allows each portion to optimize its function independently, preventing both breakage and interference.
2Reliability
If the storage portion has a uniform small diameter to secure metal terminals, then the metal terminals are stable, but the metal terminals interfere with the inner surface of the connector
Solution Approach 1:
The storage portion implements local quality variation by having a front section with smaller diameter for terminal stability and a rear section with expanded diameter to prevent interference. This spatial differentiation of geometric properties allows simultaneous achievement of both stability and non-interference.
Solution Approach 2:
The storage portion is segmented into two functional zones: a front zone with constrained diameter that secures the metal terminal against swaying, and a rear zone with expanded diameter that creates clearance from the inner surface, eliminating interference while maintaining stability.
3Object-affected harmful factors
If the storage portion has an expanding diameter to prevent interference, then the metal terminals do not contact the inner surface, but the intervals between the connector and metal terminals become great causing swaying
Solution Approach 1:
The storage portion applies local quality differentiation where the front portion maintains a smaller diameter to ensure close spacing and positional stability of the metal terminal, while the rear portion expands to prevent interference with the inner surface, thus achieving both stability and non-interference.
Solution Approach 2:
The storage portion is divided into a front segment that provides tight clearance for terminal stability and a rear segment that provides expanded clearance to prevent interference, with the segmentation point optimized to balance both requirements simultaneously.
Data Source
AI summary
A gas sensor 10 including: a plate-shaped sensor element 20 extending in an axial-line O direction and having an electrode pad 21a, 21b at a main surface 20m1, 20m2 on a rear end side thereof; a metal terminal 71 extending in the axial-line direction and electrically connected to the electrode pad; and a separator 50 having a storage portion 50h which penetrates in the axial-line direction and in which the rear end side of the sensor element and the metal terminal are stored, thus retaining the metal terminal, wherein the storage portion has a taper surface 50s whose diameter expands toward a direction perpendicular to the main surface as approaching a rearward-facing surface of the separator, the metal terminal has a projection 75 projecting toward the taper surface, and the projection contacts with the taper surface.