Sensor Terminal Metal Fitting Positioning Mechanism
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Solution Overview
Problem
Existing gas sensors, such as those used in motor vehicle engines, face instability and electrical connection failures due to terminal metal fittings moving or twisting within the sensor's terminal surrounding member, leading to unreliable connections under external forces and vibrations.
Innovation Solution
The sensor design incorporates a terminal surrounding member divided into front and rear sections with protruding piece portions that fit between these sections, preventing movement and twisting of terminal metal fittings, thereby stabilizing their position and maintaining electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If terminal metal fittings are formed long and narrow to pass through terminal holes, then they can be inserted into the terminal surrounding member, but they become susceptible to twisting and rotating about their longitudinal axes
Solution Approach 1:
The patent applies preliminary action by forming protruding pieces on the terminal metal fittings before insertion, and providing recess portions in the terminal surrounding member in advance. These protruding pieces fit into the recess portions to prevent twisting and rotation about the longitudinal axis, addressing the stability issue before the fitting is fully installed and subjected to external forces.
2Strength
If hooks are provided at front ends of terminal metal fittings to fit in recess portions, then resistance to pulling and twisting forces is improved, but the fittings can still move towards the front end side
Solution Approach 1:
The patent segments the terminal metal fitting into distinct functional portions: a terminal connecting portion for electrical connection, a fitting main body, and protruding pieces for positional restraint. This segmentation allows each portion to perform its specific function - the hooks provide resistance to pulling forces while the protruding pieces prevent both frontward movement and twisting, thereby achieving comprehensive positional stability.
3Reliability
If terminal metal fittings are pressed against electrode terminals by spring characteristics, then electrical connection is established, but the connections become unreliable under vibration and external forces
Solution Approach 1:
The patent applies preliminary action by pre-positioning the terminal metal fittings using the protruding pieces that fit into recess portions. This preliminary positional restraint ensures that the fittings remain properly aligned and pressed against the electrode terminals even when subjected to vibration and external forces during operation, thereby maintaining reliable electrical connections throughout the sensor's service life.
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
This design effectively prevents terminal metal fittings from moving or twisting, ensuring stable electrical connections and reducing the risk of connection failures even under external forces and vibrations.
Implementation Method 1
The terminal connecting portion 53 is pressed against the electrode terminal 25 provided on a side surface of the sensor element 21 positioned in a hole portion provided at a center of the terminal surrounding member 71 by the spring characteristics of the terminal connecting portion 53.
Data Source
AI summary
A sensor including a sensor element including a plurality of electrode terminals, terminal metal fittings, a terminal surrounding member, and lead wires connected to respective terminal metal fittings. The terminal surrounding member is divided into a front side surrounding member and a rear side surrounding member in the front-rear direction, and a rear end face of the front side surrounding member abuts a front end face of the rear side surrounding member. At least one of the terminal metal fittings includes a protruding piece portion protruding in a lateral direction and held between the rear end face of the front side surrounding member and the front end face of the rear side surrounding member.