Sensor and method for manufacturing same

Patent metadata

Field	Value
Publication number	US-11768168-B2
Application number	US-202016986483-A
Country	US
Kind code	B2
Filing date	Aug 6, 2020
Priority date	Aug 7, 2019
Publication date	Sep 26, 2023
Grant date	Sep 26, 2023

Abstract

A sensor ( 1 ) comprising: a sensor element ( 10 ); metal terminals; and a front side separator ( 90 ) and a rear side separator ( 95 ) to hold the metal terminals, the metal terminals each include a front side metal terminal ( 30 ) and a rear side metal terminal ( 40 ) respectively held by the front side separator and the rear side separator, a first connection portion ( 33 ) is provided on a rear side of the front side metal terminal, a second connection portion ( 43 ) is provided on a front side of the rear side metal terminal, and an axis P 2 of one of the first and the second connection portion, in all of the plurality of metal terminals, is displaced toward a radially outer side of the sensor element relative to an axis P 1 of a counterpart thereof, and the first connection portion and the second connection portion are in contact with each other.

First claim

What is claimed is:

1. A sensor comprising:
a sensor element extending in an axial direction;
a plurality of metal terminals configured to be electrically connected to the sensor element; and
a separator having a tubular shape, the separator being configured to surround a rear side of the sensor element and configured to hold the metal terminals, wherein
the separator includes a front side separator and a rear side separator respectively disposed on a front side and a rear side in the axial direction,
the metal terminals each include a front side metal terminal and a rear side metal terminal respectively held by the front side separator and the rear side separator,
a first connection portion that is a male terminal or a female terminal is provided on a rear side of the front side metal terminal,
a second connection portion that is a male terminal or a female terminal and that serves as a counterpart terminal to be fitted to the first connection portion is provided on a front side of the rear side metal terminal, and
a central axis in the axial direction of one of the first connection portion and the second connection portion, in all of the plurality of metal terminals, is displaced toward a radially outer side of the sensor element relative to a central axis in the axial direction of a counterpart thereof, and the first connection portion and the second connection portion are in contact with each other at only along a contact line extending in the axial direction of the first connection portion.

2. The sensor as claimed in claim 1 , wherein
one of each first connection portion and each second connection portion is the male terminal, and a central axis in the axial direction of the male terminal, in all of the plurality of metal terminals, is displaced toward the radially outer side relative to a central axis in the axial direction of a counterpart thereof.

3. The sensor as claimed in claim 2 , wherein
the first connection portion and the second connection portion are welded to each other at the contact line.

4. The sensor as claimed in claim 1 , wherein
when, viewed in the axial direction, a predetermined line segment that passes through a center of gravity of the sensor element and that does not pass through the first connection portion and the second connection portion is drawn, the central axis of one of the first connection portion and the second connection portion is displaced so as to be farther away from the line segment relative to the central axis of the counterpart thereof.

5. The sensor as claimed in claim 1 , wherein the first connection portion has a circular or polygonal cross section in a direction perpendicular to the axial direction, and the second connection portion has a circular or polygonal cross section in a direction perpendicular to the axial direction.

6. A method for manufacturing a sensor,
the sensor including
a sensor element extending in an axial direction,
a plurality of metal terminals configured to be electrically connected to the sensor element, and
a separator having a tubular shape, the separator being configured to surround a rear side of the sensor element and configured to hold the metal terminals,
the separator including a front side separator and a rear side separator respectively disposed on a front side and a rear side in the axial direction,
the metal terminals each including a front side metal terminal and a rear side metal terminal respectively held by the front side separator and the rear side separator,
a first connection portion being provided on a rear side of the front side metal terminal, the first connection portion being a male terminal or a female terminal,
a second connection portion being provided on a front side of the rear side metal terminal, the second connection portion being a male terminal or a female terminal and serving as a counterpart terminal to be fitted to the first connection portion,
the method comprising:
a terminal insertion step of inserting the front side metal terminal into the front side separator and inserting the rear side metal terminal into the rear side separator; and
a terminal fitting step of, after the terminal insertion step, assembling the rear side separator to a rear side of the front side separator, and, during the assembling, inserting one of the first connection portion and the second connection portion into the other of the first connection portion and the second connection portion, thereby assembling the front side metal terminal and the rear side metal terminal to each other, wherein
after the terminal fitting step, when the front side separator and the rear side separator are viewed with axes thereof aligned with each other, a central axis in the axial direction of one of the first connection portion and the second connection portion, in all of the plurality of metal terminals, is displaced toward a radially outer side of the sensor element relative to a central axis in the axial direction of a counterpart thereof, and the first connection portion and the second connection portion are in contact with each other at only along a contact line extending in the axial direction of the first connection portion.

7. The method for manufacturing the sensor as claimed in claim 6 , wherein
after the terminal insertion step and before the terminal fitting step, when the front side separator and the rear side separator are viewed with the axes thereof aligned with each other, the central axis of one of the first connection portion and the second connection portion, in all of the plurality of metal terminals, is displaced toward the radially outer side of the sensor element relative to the central axis of the counterpart thereof.

8. The method for manufacturing the sensor as claimed in claim 6 , wherein
in the terminal fitting step, at least one of the first connection portion and the second connection portion is moved such that the central axis of the first connection portion and the central axis of the second connection portion are aligned with each other, and then one of the first connection portion and the second connection portion is inserted into the other of the first connection portion and the second connection portion.

9. The method for manufacturing the sensor as claimed in claim 6 , wherein the first connection portion has a circular or polygonal cross section in a direction perpendicular to the axial direction, and the second connection portion has a circular or polygonal cross section in a direction perpendicular to the axial direction.

Assignees

• Ngk Spark Plug Co

Inventors

• Liu Sunchao
• Oba Takehiro

Classifications

• G01N27/4062 Primary

  Electrical connectors associated therewith · CPC title

• G01M15/104

  using oxygen or lambda-sensors (testing catalytic converters F01N3/18, F01N11/007) · CPC title

• G01N27/407

  for investigating or analysing gases {(G01N27/411 takes precedence)} · CPC title

• G01N27/4071 Primary

  using sensor elements of laminated structure · CPC title

• G01N33/0036

  specially adapted to detect a particular component (physical analysis of gaseous biological material G01N33/497) · CPC title