Gas Sensor Terminal Sloping Surface Prevents Disengagement
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Solution Overview
Problem
Existing gas sensors face challenges in maintaining a stable electrical connection between metal terminal members and electrode pads due to potential misalignment or vibration, which can lead to disengagement and reduced connection reliability.
Innovation Solution
The gas sensor incorporates a metal terminal member with a body portion and an element abutting portion that is bent towards the electrode pad, featuring a sloping surface on at least one end portion to prevent disengagement even when the terminal member moves out of place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the element abutting portion has a narrow width, then the metal terminal member can be compact, but the contact point cannot be secured stably and the element abutting portion may move out of place
Solution Approach 1:
The element abutting portion is designed with a curved surface instead of a flat surface. This curved configuration allows the element abutting portion to maintain continuous contact with the electrode pad even when displaced, preventing disengagement while maintaining a compact structure. The curvature enables the element to adapt to positional variations without losing electrical connection.
2Reliability
If the element abutting portion has an increased width, then the element abutting portion is prevented from coming off the sensor element, but the structure becomes less compact
Solution Approach 1:
The curved surface of the element abutting portion provides mechanical interlocking with the electrode pad, preventing the element from coming off without requiring excessive width. The curvature creates a natural retention mechanism that maintains connection reliability while preserving compact dimensions.
3Reliability
If the element abutting portion is bent toward the electrode pad with sufficient pressing force, then electrical connection is maintained, but the element abutting portion may abut against the sensor element surface and disengage
Solution Approach 1:
The curved surface of the element abutting portion is specifically designed to prevent abutment against the sensor element surface. The curvature allows the element to bend and press against the electrode pad without creating harmful contact points that would cause disengagement. This geometric design eliminates the harmful effect while maintaining the necessary pressing force for electrical connection.
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 ensures that the electrical connection between the metal terminal member and the electrode pad is maintained, even under conditions of misalignment or vibration, thereby enhancing connection reliability.
Implementation Method 1
a portion of the element abutting portion being in contact with the electrode pad in a state in which the element abutting portion is elastically deflected
Data Source
AI summary
A gas sensor including a plate-shaped sensor element having an electrode pad on an outer surface of the sensor element on a rear end side thereof, and a metal terminal member electrically connected to the electrode pad. The metal terminal member includes a body portion and an element abutting portion extending from the body portion and bent toward the electrode pad. A portion of the element abutting portion is in contact with the electrode pad in a state in which the element abutting portion is elastically deflected. The element abutting portion has a flat main surface facing the sensor element, and a sloping surface provided on at least one of end portions in a width direction of the metal terminal member. The sloping surface is connected to the main surface and extends toward an opposite side in a thickness direction of the element abutting portion.