Multi-Material Contact Element for Gas Sensor Thermal Expansion
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Solution Overview
Problem
Existing contact elements for gas sensors face challenges in efficiently managing thermal and mechanical expansions, leading to increased assembly complexity and costs, as well as wear on crimping tools during electrical conductor connection.
Innovation Solution
A contact element with tailored sections made of specific materials (heat-resistant nickel-based alloys for high contact force, corrosion-resistant steels for crimping, and cold-worked steels for expansion compensation, integrated through electron beam or laser welding, simplifying manufacturing and assembly by reducing the number of parts and tool wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the contact element is made entirely of heat-resisting material, then high contact force and long service life are achieved, but crimping operation becomes difficult and tool wear increases
Solution Approach 1:
The contact element is divided into sections with different material properties: the contact point side uses heat-resisting nickel-based alloy for high contact force, while the connection side uses corrosion-resistant steel for easy crimping. This local differentiation resolves the contradiction by optimizing each section for its specific function.
2Ease of manufacture
If the contact element is made entirely of corrosion-resistant steel, then crimping operation is facilitated, but heat resistance and contact force deteriorate
Solution Approach 1:
The contact element uses different materials in different sections: corrosion-resistant steel (e.g., 1.4303) at the connection side for easy crimping, and heat-resisting nickel-based alloy at the contact point side for maintaining contact force under thermal conditions. This resolves the contradiction by matching material properties to functional requirements.
3Reliability
If multiple separate element sections are used, then material optimization is achieved, but assembly complexity increases
Solution Approach 1:
Multiple element sections with different materials (heat-resisting section, intermediate section, connection section) are integrally bonded together to form a single unified contact element. This merging approach maintains material optimization for each section while eliminating complex assembly operations, as the integrated structure requires no additional joining steps during installation.
4Temperature
If the intermediate section accommodates thermal expansion, then thermal stress is reduced, but vibration resistance deteriorates
Solution Approach 1:
The intermediate section is designed with specific geometric parameters (arc-shaped configuration, dimensions, and material properties) that allow it to accommodate thermal expansion through controlled deformation while maintaining sufficient rigidity to resist vibrations. The cold-worked state of the steel provides high yield point to ensure deformation remains in elastic range, making cyclic deformation reversible and maintaining vibration resistance.
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 provides a cost-effective, durable contact element with reduced assembly complexity, enhanced vibration resistance, and minimized tool wear, ensuring reliable electrical connections and extended service life.
Implementation Method 1
the intermediate section... for equalization of thermal expansions... different thermal expansions of additional components, e.g., in a gas sensor, are compensated for
Implementation Method 2
the intermediate section... for equalization of thermal and/or mechanical expansions and movements
Data Source
AI summary
A contact element for contacting a contact point formed on a body includes: an element section on the contact point side for a force-locking connection to the contact point, an element section on the connection side for connection to an electrical connection conductor, and an intermediate section which connects the two element sections to one another for compensating for thermal expansions. At least the element sections on the contact point side and on the connection side are made of different integrally bonded materials having material properties which are adapted to the functionality of the corresponding element section.