Gas Sensor Terminal Mounting Jig to Prevent Contact Entanglement
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Solution Overview
Problem
During the mounting of metal terminals in a gas sensor's separator, there is a risk of contact and entanglement, leading to breakage or deformation, which complicates the manufacturing process and affects workability.
Innovation Solution
The use of a mounting jig with a flat portion that interposes between the opposed contact regions of the metal terminals, preventing them from coming into contact and entanglement, and includes features like separator restriction parts to prevent rotation and positional displacement, ensuring reliable electrical connection and improved workability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If metal terminals are mounted directly in the separator without a mounting jig, then the mounting process is simple, but the metal terminals may contact and entangle, leading to breakage or deformation
Solution Approach 1:
A mounting jig is introduced as an intermediary tool during the mounting process. The jig includes a holding portion that securely holds the metal terminal and a flat portion that prevents contact between opposed metal terminals. This intermediary device enables reliable mounting without direct handling that could cause entanglement and breakage.
Solution Approach 2:
The mounting jig is prepared in advance with the holding portion and flat portion configured to prevent contact between metal terminals before the actual mounting occurs. The jig预先 establishes the correct positioning and spacing, ensuring that metal terminals are mounted without entanglement from the start.
2Reliability
If a mounting jig with flat portion is used to prevent metal terminal contact, then metal terminal integrity is improved, but the device complexity increases
Solution Approach 1:
The mounting jig is segmented into distinct functional portions: a holding portion for securing the metal terminal and a flat portion for preventing contact between opposed terminals. This segmentation allows each portion to perform its specific function efficiently while keeping the overall structure manageable and not overly complex.
3Reliability
If metal terminals are held in insertion hole before sensor element insertion, then electrical connection is ensured, but workability deteriorates due to breakage risk
Solution Approach 1:
The mounting jig serves as an intermediary device that enables reliable electrical connection while improving workability. The jig's holding portion secures the metal terminal in the insertion hole, and the flat portion prevents contact with opposed terminals, eliminating the breakage risk that previously deteriorated workability.
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 method effectively suppresses breakage or deformation of the metal terminals and enhances workability by maintaining the integrity of the terminals during the mounting process, ensuring reliable electrical connections and improved manufacturing efficiency.
Implementation Method 1
the metal terminals including bent portions elastically bent at front end sides
Data Source
AI summary
Disclosed is a manufacturing method of a gas sensor. The gas sensor has a plate-shaped sensor element with at least one pair of electrode pads, a separator disposed around the sensor element, and at least one pair of opposed metal terminals held in an insertion hole of the separator and electrically connected at contact regions thereof to the respective electrode pads. The manufacturing method includes mounting the metal terminals in the insertion hole of the separator with use of a mounting jig. The mounting jig has a flat portion interposed between the contact regions of the metal terminals during the mounting of the metal terminals in the separator so as to prevent contact and entanglement of the opposed metal terminals.