Guide-Integrated Metal Terminal for Exhaust Sensor Vibration Loads
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Solution Overview
Problem
Metal terminals in automobile exhaust gas sensors are prone to damage due to repetitive loads and intense vibrations, which can lead to conduction failures and reduce the commercial value of the sensors.
Innovation Solution
A metal terminal design that includes a positioning member and a guide member integrated between the positioning and lead wire retaining members, which helps to absorb and distribute loads, preventing damage and ensuring reliable electrical connections under varying conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal terminal is used to electrically connect the sensor element and lead wire in an exhaust gas sensor, then electrical connection is achieved, but the metal terminal is prone to damage from repetitive loads and vibrations
Solution Approach 1:
The metal terminal is divided into multiple functional segments: a positioning member with guide surfaces for stable installation, a retaining member for securing the lead wire, and contact portions for electrical connection. This segmentation allows each part to optimize its specific function while distributing mechanical stresses, preventing damage from vibrations and repetitive loads.
2Device complexity
If the positioning member and lead wire retaining member are closely spaced to reduce device complexity, then the structure becomes more compact, but damage risk increases due to insufficient load distribution
Solution Approach 1:
A guide member is introduced as an intermediary element between the positioning member and the lead wire retaining member. This guide member provides guide surfaces that facilitate proper positioning and load distribution, allowing the components to be closely spaced while maintaining durability against repetitive loads and vibrations.
3Ease of manufacture
If the metal terminal structure is simplified to improve ease of manufacture, then manufacturing cost decreases, but the ability to withstand intense vibrations deteriorates
Solution Approach 1:
The metal terminal is designed as an integrated component that simultaneously performs multiple functions: electrical connection, mechanical retention of the lead wire, positioning within the sensor housing, and vibration damping. This multi-functionality is achieved through a unified structure with guide surfaces and contact portions, simplifying manufacturing while ensuring vibration resistance.
Data Source
AI summary
A metal terminal includes an element contacting portion which is disposed at one end of the metal terminal and is placed in contact with a sensor element, a lead wire retaining member which is disposed at another end of the metal terminal, and crimps and retains lead wires, a positioning member disposed between the one end and the other end and extending in a direction intersecting one direction, the positioning member positioning the metal terminal on a ceramic housing, and a guide member provided integrally with the positioning member at a site between the positioning member and the lead wire retaining member.