Gas Sensor Metal Terminal Neck Design for Vibration Stress
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Solution Overview
Problem
Existing gas sensors with metal terminals connected through a second neck portion with a smaller axial cross-sectional area experience stress concentration and breakage or bending during vehicle vibrations, due to wobbling and uneven force application.
Innovation Solution
A gas sensor design featuring a metal terminal with a central portion and lead wire connection portion connected through a neck portion with a larger cross-sectional area, where the central portion is engaged with a separator, reducing wobbling and stress concentration, and incorporating an elastic member to hold the lead wire, thereby distributing stress effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the second neck portion is inclined with respect to the axial line direction, then the central axis alignment is improved, but stress concentration and breakage occur during vibration
Solution Approach 1:
The patent changes the geometric parameters of the neck portion by increasing its cross-sectional area and modifying its shape to be substantially perpendicular to the axial line, rather than inclined. This parameter change reduces stress concentration during vibration while maintaining adequate central axis alignment through the overall structure design.
Solution Approach 2:
The patent designs the neck portion with a larger cross-sectional area and perpendicular orientation beforehand to cushion against the harmful effects of vibration-induced stress. This preventive design ensures that stress is distributed more evenly during vehicle travel, preventing breakage before it occurs.
2Ease of operation
If the cross-sectional area of the second neck portion is reduced, then the lead wire connection is improved, but stress concentrates and causes breakage
Solution Approach 1:
The patent applies local quality by designing different portions of the metal terminal with different cross-sectional areas appropriate to their functions. The neck portion has a larger cross-sectional area to withstand stress, while the lead wire connection portion maintains adequate size for connection, with the transition optimized to distribute stress evenly.
Solution Approach 2:
The patent changes the cross-sectional area parameter of the neck portion to be larger than in conventional designs, which prevents stress concentration while still allowing effective lead wire connection through the connection portion.
3Reliability
If the second neck portion is made perpendicular to the axial line, then stress distribution is improved, but manufacturing complexity increases
Solution Approach 1:
The patent simplifies the manufacturing process by designing the neck portion to be substantially perpendicular to the axial line, which is easier to manufacture than an inclined configuration. This perpendicular orientation also improves stress distribution during vibration, achieving both manufacturing ease and reliability.
Data Source
AI summary
A gas sensor includes a sensor element, metal terminals, a tubular separator holding the metal terminals, lead wires connected to rear ends of the metal terminals, and an elastic member that holds the lead wires extending rearward from the separator. Each metal terminal includes a forward end portion electrically connected to an electrode portion, a central portion, and a lead wire connection portion. The forward end portion or the central portion is held by the separator. The central portion and the lead wire connection portion are connected to each other through a neck portion. The rearward-facing rearmost surface of the central portion is engaged with a forward-facing surface of the separator, and the circumferential length of a first connection portion between the central portion and the neck portion is longer than the circumferential length of a second connection portion between the lead wire connection portion and the neck portion.