Gas Sensor Terminal Structure for Vibration-Stable Contact
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Solution Overview
Problem
The existing gas sensors face instability in electrical connections due to the risk of metal terminals shifting from their axial line, especially under vehicle vibrations, caused by clearance between the metal terminal and the insertion hole, leading to potential disconnection and unstable electrical contact.
Innovation Solution
A gas sensor design featuring a metal terminal with a main body and an elastic portion folded towards the sensing element, supported by front-end and rear-end restricting portions that contact the insertion hole walls, preventing further movement and maintaining axial alignment, thereby stabilizing the electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If clearance is left between the metal terminal and the insertion hole to enable smooth insertion, then the ease of assembly is improved, but the metal terminal shifts from the axial line under vibration, causing unstable electrical connection
Solution Approach 1:
The metal terminal is segmented into three functional parts: a main body for electrical connection, an elastic portion for maintaining contact pressure, and positioning portions for axial alignment. This segmentation allows each part to perform its specific function independently, resolving the contradiction between easy insertion and stable connection.
Solution Approach 2:
Different portions of the metal terminal have different properties: the elastic portion provides flexibility and contact pressure, the positioning portions provide rigid axial alignment, and the main body provides electrical conductivity. This local differentiation of properties allows the terminal to simultaneously achieve easy insertion and stable electrical connection.
2Reliability
If the metal terminal is made rigid to maintain stable electrical connection, then the reliability is improved, but the ease of insertion into the insertion hole deteriorates
Solution Approach 1:
The metal terminal transitions from a completely rigid structure to a dynamic structure with an elastic portion that can deform. This elasticity allows the terminal to be easily inserted into the insertion hole while maintaining stable electrical connection through elastic recovery force, resolving the contradiction between rigidity and ease of insertion.
Solution Approach 2:
The physical state of the metal terminal is changed by introducing elasticity into the elastic portion. This parameter change from completely rigid to elastically deformable allows the terminal to be easily inserted while maintaining stable electrical connection through elastic recovery, resolving the contradiction between rigidity and ease of insertion.
3Reliability
If the metal terminal is positioned close to the electrode pad to reduce moment, then the electrical connection stability is improved, but the risk of contact with the sensing element increases
Solution Approach 1:
The positioning portions extend in the axial direction (another dimension) rather than only in the radial direction. This axial positioning allows the metal terminal to be held at an optimal distance from the electrode pad, reducing moment while preventing contact with the sensing element, thus resolving the contradiction between connection stability and contact risk.
Solution Approach 2:
The positioning portions act as intermediary elements that mediate between the metal terminal and the insertion hole. These positioning portions contact the insertion hole wall to provide axial positioning, indirectly controlling the distance between the metal terminal and the electrode pad, thus resolving the contradiction between connection stability and contact risk.
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
The solution ensures the metal terminal is securely held within the separator, maintaining stable electrical connections even under vibration, reducing the moment acting on the contact point and enhancing the reliability of the connection between the electrode pad and the metal terminal.
Implementation Method 1
an elastic portion that is integrally connected to the main body, the elastic portion being folded toward the sensing element and elastically connected to the electrode pad at a predetermined contact point
Data Source
AI summary
A gas sensor includes a sensing element having an electrode pad a metal terminal, and a separator that has insertion holes in which the metal terminal is held. The metal terminal includes a main body and an elastic portion that is integrally connected to the main body and is elastically connected to the electrode pad at a predetermined contact point. The main body includes a front-end-side restricting portion and a rear-end-side restricting portion that restrict the movement of the main body by contacting wall surfaces of the insertion hole when the main body moves in a direction intersecting the direction of an axial line. The contact point is located between the front-end-side restricting portion and the rear-end-side restricting portion in the direction of the axial line. The front-end-side restricting portion and the rear-end-side restricting portion are connected to each other so that a flat board portion is interposed therebetween.