Gas Sensor Terminal Vibration Breakage Prevention
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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, as the increased intervals between the connector and the terminals allow for excessive sway.
Innovation Solution
The gas sensor incorporates a grommet with a diameter-reducing member that fits over the grommet hole, reducing the diameter and preventing the metal terminals from swaying radially inward, thus inhibiting breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the connector has an expanding diameter at the rear end, then the metal terminals are inhibited from interfering with the inner surface of the connector, but the intervals between the connector and the metal terminals become great causing the metal terminals to sway and break due to vibration
Solution Approach 1:
The connector is designed with non-uniform diameter: the front end has a smaller diameter to facilitate terminal insertion, while the rear end has a larger diameter to prevent terminal interference with the inner surface. This local variation in diameter resolves the contradiction by providing different functional characteristics at different locations of the same component.
Solution Approach 2:
A buffer structure is introduced between the metal terminals and the connector inner surface. This buffer absorbs the sway of metal terminals during vibration, preventing direct contact and potential breakage while maintaining the expanding diameter design for ease of terminal installation.
2Ease of manufacture
If the metal terminals are arranged with large intervals in the connector, then the terminals can be easily installed and positioned, but the terminals sway radially inward due to vibration and are likely to break
Solution Approach 1:
The connector is pre-formed with an expanding diameter structure before terminal installation. This preliminary structural preparation creates a buffer zone that anticipates and prevents terminal sway during operation, while still allowing easy terminal positioning during manufacturing.
Solution Approach 2:
The expanding diameter portion of the connector serves as a pre-established cushioning structure that absorbs vibration energy before it can cause terminal breakage. This cushioning effect is built into the connector design beforehand, protecting terminals during both installation and operation.
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 effectively reduces the radial inward sway of the metal terminals, thereby preventing breakage and ensuring the reliability of the gas sensor under operational vibrations.
Implementation Method 1
a grommet made of an elastic material and provided on a rear end side of the separator so as to close an opening on a rear end side of the outer casing
Data Source
AI summary
A gas sensor 10 including: a sensor element 21 having electrode pads 21a, 21b at a main surface 20m1, 20m2; metal terminals 71; and a separator 50 having a storage portion 50h in which the rear end side of the sensor element and the metal terminals are stored, an outer casing 46, and a grommet 47, wherein an inner surface of the storage portion has a diameter-expanding portion 50s, the grommet has a grommet hole 47a in which the metal terminals are inserted, a diameter-reducing member 80 for reducing a diameter of the grommet is fitted to an outer periphery on a front end side of the grommet, and the diameter-reducing member is located in a region that is on a front end side relative to a crimping portion 46c formed at the outer casing and overlaps the metal terminals in the grommet in the axial-line direction.