Two-Step Taper Hole Ceramic Sensor Unit for Lead Wire Insertion
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Solution Overview
Problem
The existing ceramic member units with one-step taper hole portions face difficulties in inserting lead wires due to bending and slipping issues, leading to poor insertability, and the formation of such holes can result in die breakage during manufacturing.
Innovation Solution
A ceramic member unit with a two-step taper hole portion or a combination of a straight portion and a deeper-side taper hole portion, where the taper angle increases towards the insertion opening, improving the guide and preventing the lead wire from slipping out, and a manufacturing process that reduces die edge breakage by using a less sharpened die edge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a one-step taper hole portion is used to guide lead wire insertion, then the lead wire can be guided radially inward, but the lead wire may bend and slip off from the insertion opening
Solution Approach 1:
The single taper hole portion is divided into two separate taper hole portions with different taper angles. The first taper hole portion (with smaller taper angle) provides gentle guidance to prevent bending, while the second taper hole portion (with larger taper angle) provides strong retention to prevent slipping off. This segmentation allows each portion to perform its specific function optimally.
Solution Approach 2:
Different regions of the insertion section are given different taper angles to suit different functional requirements. The region closer to the introduction opening uses a smaller taper angle for gentle guidance, while the region closer to the insertion opening uses a larger taper angle for secure retention. This local differentiation of geometric properties solves the contradiction between guidance and retention.
2Manufacturing precision
If a sharp die edge portion is used to form the taper hole, then precise hole formation is achieved, but the die edge may break during manufacturing
Solution Approach 1:
The die edge is modified by adding a rounded portion, changing the geometric parameter from sharp to rounded. This rounded edge portion is less prone to breakage during the pressing operation while still capable of forming the desired taper hole shape in the green compact. The parameter change from sharp to rounded resolves the contradiction between precision and durability.
3Strength
If a horizontal portion is added to the taper hole to prevent die breakage, then die durability is improved, but the lead wire cannot be inserted further due to lack of radial guidance
Solution Approach 1:
Instead of using a horizontal portion that blocks insertion, the solution segments the taper hole into two tapered portions, each providing radial guidance through their respective taper angles. Both portions maintain the guidance function while distributing the mechanical stress differently, avoiding die breakage without compromising insertability.
Solution Approach 2:
Rather than adding a horizontal portion to stop the die from breaking, the invention inverts the approach by using rounded die edges to prevent breakage while maintaining the tapered guidance shape. This inverts the problem-solving approach from modifying the hole shape to modifying the die shape.
Data Source
AI summary
A ceramic member unit includes at least insertion members and a ceramic member having insertion sections into which the insertion members are inserted respectively. Each of the insertion sections has at least an insertion opening which opens on a deeper side of an introduction opening in the surface of the ceramic member while communicating with the introduction opening and into which the insertion member can be inserted. The insertion section further has taper hole portions becoming narrower toward the insertion opening in a communication region between the introduction opening and the insertion opening. The taper hole portions are connected to the insertion opening while increasing in a taper angle toward the insertion opening.