Sensor Terminal Connection with Chamfered Rear Edge

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Solution Overview

Problem

Conventional sensor terminal connection structures risk damaging electrode terminals during insertion due to high insertion resistance and force, leading to unreliable electrical connections.

Innovation Solution

A sensor design with chamfers on the rear end surface and side surfaces, where the rear ends of the electrode terminals are spaced apart from the chamfer's front end, and a flat surface is present between the electrode terminals and the chamfer, reducing insertion resistance and preventing damage by distributing the force applied by metallic terminal members.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If metallic terminal members with intensive spring quality are used to press against electrode terminals, then electrical connection reliability is improved, but insertion resistance increases and undesirable deformation of terminal members occurs

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidinsertion resistance

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies preliminary action by forming chamfers on the rear end surface of the sensor element before insertion. These chamfers act as pre-prepared geometric features that guide the metallic terminal members during insertion and reduce the peak contact forces. The chamfers are positioned to engage first, distributing the insertion force over a longer period and preventing sudden high-force impacts on the electrode terminals, thereby reducing insertion resistance while maintaining connection reliability.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If metallic terminal members are pressed strongly against electrode terminals, then connection reliability is improved, but damage to electrode terminals occurs during insertion

Engineering Contradiction:

Improveconnection reliabilityVSAvoiddamage to electrode terminals

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent implements beforehand cushioning by introducing chamfers on the rear end surface that act as cushioning elements during insertion. These chamfers are positioned to engage with the metallic terminal members before the main body of the element, absorbing and distributing the insertion force. This cushioning effect prevents sudden high-force impacts from reaching the electrode terminals, thereby preventing damage while ensuring reliable electrical connections are established.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The chamfers serve as intermediary elements between the metallic terminal members and the electrode terminals. During insertion, the chamfers first contact the terminal members and act as mediators that distribute the force over time and space. This intermediary action prevents direct high-force contact between the terminal members and electrode terminals, reducing damage risk while maintaining connection reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Device complexity

If the gap between facing metallic terminal members is made small, then structural compactness is improved, but insertion resistance increases

Engineering Contradiction:

Improvestructural compactnessVSAvoidinsertion resistance

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The patent applies preliminary action by pre-forming chamfers on the rear end surface of the sensor element. These chamfers are positioned to engage with the metallic terminal members before the main insertion force is applied. The chamfers act as preliminary contact points that distribute the insertion force over a longer period, reducing peak contact pressures. This allows the gap between terminal members to remain small for structural compactness while the chamfers mitigate the insertion resistance issue by extending the contact time.

Inventive Principle:

Principle #10Preliminary action

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 design effectively reduces insertion resistance and prevents damage to the electrode terminals, ensuring reliable electrical connections by distributing the force applied during insertion, thereby enhancing the stability and reliability of the terminal connection.

Implementation Method 1

metallic terminal members elastically deformed and pressed against corresponding electrode terminals

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS7340942B2Sensor including a sensor element having electrode terminals spaced apart from a connecting end thereof

Publication Date: 2008.03.11 NITERRA CO LTD

AI summary

A sensor having a terminal connection structure in which an elongated sensor element (21) is inserted, from its rear end through relative movement, into a metallic-terminal-member retainer. Metallic terminal members (51) are elastically deformed and pressed against corresponding electrode terminals (25) formed on side surfaces (26) of the sensor element. A chamfer (28) is formed on a rear edge of sensor element (21). Rear ends (25b) of the electrode terminals (25) are biased from the chamfer (28) toward a front end of the element (21). A flat surface (26b) is present between the rear ends (25b) of the electrode terminals (25) and a front end (28a) of the chamfer (28). During insertion of the element (21), a large force generated when the metallic terminal members (51) pass over the chamfer (28) is not directly applied to the rear ends (25b) of the electrode terminals (25), thereby preventing damage to the electrode terminals (25).