Plated Crimp Contact for Gas Sensor High-Temperature Slidability
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Solution Overview
Problem
Conventional crimp contacts require lubricant application to maintain slidability during crimping, which complicates the manufacturing process and can lead to measurement errors due to thermal decomposition of lubricants at high temperatures, especially in gas sensors used in harsh environments.
Innovation Solution
A crimp contact with a metal layer comprising Ag or Au on the outer surfaces of its side portions, providing enhanced and maintained slidability without lubricant, even at high temperatures, and preventing adhesion and wear of the metal mold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lubricant is applied to the sliding face of the crimper to maintain slidability, then the crimping process can be performed continuously with maintained electrical conductivity, but the manufacturing process becomes complicated and the lubricant may cause measurement errors due to thermal decomposition at high temperatures
Solution Approach 1:
The patent removes the lubricant application step from the manufacturing process by transferring the lubricating function to the crimp contact itself through plating. The sliding face of the crimper is left plain without lubricant, eliminating the complexity of lubricant application while maintaining slidability through the plated surface of the crimp contact.
Solution Approach 2:
The patent introduces a plated surface (Ag, Au, or Cu plating) on the crimp contact as an intermediary between the crimper and the crimp contact body. This plated surface acts as a mediator that provides lubricating properties during crimping, replacing the need for external lubricant application and preventing direct contact between the crimper and the base material.
2Productivity
If a lubricant is applied to the sliding face of the crimper, then slidability is maintained during continuous crimping, but the lubricant adheres to the hold portion and thermally decomposes at high temperatures causing measurement errors
Solution Approach 1:
The patent extracts the lubricant from the system by applying plating directly to the crimp contact surface. This eliminates the source of thermal decomposition products that cause measurement errors, while still enabling continuous crimping through the self-lubricating plated surface.
Solution Approach 2:
The patent uses a thin plated layer (0.1-2.0 μm) on the crimp contact that serves as a consumable lubricating surface. This thin plating layer is designed to provide lubricating properties during crimping without adhering to the hold portion, preventing thermal decomposition issues while enabling continuous production.
3Strength
If the hold portion is made of high Vickers hardness material to improve durability, then the crimp contact becomes more durable, but the slidability between the hold portion and crimper deteriorates and adhesion occurs
Solution Approach 1:
The patent applies different properties to different parts of the crimp contact. The base material (hold portion) is made of high Vickers hardness material (350 HV or more) for durability, while the plated surface layer is applied only to the sliding face area to provide low friction and prevent adhesion during crimping, creating a local quality difference that resolves the contradiction.
Solution Approach 2:
The patent creates a composite structure combining a high-hardness base material (Inconel, stainless steel, etc. with Vickers hardness ≥350 HV) with a plated surface layer (Ag, Au, or Cu plating). This composite structure provides both the durability of the hard base material and the slidability of the softer plated surface, resolving the contradiction between strength and reliability.
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
Ensures secure electrical conductivity and prevents measurement errors by maintaining slidability and heat resistance, extending the life of the metal mold and ensuring consistent crimping quality without the need for lubricant application.
Implementation Method 1
slidability gradually deteriorates between the outer surfaces of the side portions and the sliding face of the crimper as the metal molds are used repeatedly in the crimping process
Implementation Method 2
the side portions are bent toward the bottom portion side by a pair of metal molds, i.e., an anvil and a crimper
Data Source
AI summary
A crimp contact, a gas sensor including the crimp contact for outputting a signal from a sensing portion of a sensor element to an external device, and a method for manufacturing the crimp contact. The crimp contact includes a barrel portion crimped so as to fix a plurality of lead core wires (16) of an electrical lead connected to the external device. A hold portion constituting the barrel portion is formed such that the lead core wires 16 of the electrical lead are disposed in an U-shaped hold portion 77 so as to be crimped between an anvil 120 and a crimper 121. An outer surface of the U-shaped hold portion 77 has a plating layer 85 thereon to thereby constantly secure slidability between a sliding face of the crimper 121 and the outer surface of the U-shaped hold portion 77. The crimp contact is able to secure slidability between an outer surface of a hold portion and a sliding face of a crimper without applying any lubricant to the sliding face of the crimper, and can be used under a high temperature environment.