JP2016183973A - Gas sensor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a gas sensor in which a connection terminal and a connector terminal to be connected to a gas sensor element are connected without welding, productivity is improved and the number of components is reduced.SOLUTION: A gas sensor 200 comprises: a separator 40; a connection terminal 30; a base part having a main body part 101 surrounding the separator and a connector part 103; and a connector terminal 60 held by the connector part and extending in a direction crossing an axial direction. A rear end part of the connection terminal includes a first connection part 31 connected to the connector terminal and an end part at the separator side of the connector terminal includes a second connection part 61 connected to the first connection part. One of the first and second connection parts constitutes an insertion piece 61g and the other constitutes a female part 31g to which the insertion piece is inserted. An elastic part is formed on at least one of the insertion piece and the female part. The insertion piece is fitted to the female part and thereby the elastic part bends, so that the first and second connection parts are elastically connected.SELECTED DRAWING: Figure 3

Description

  The present invention relates to a gas sensor including a gas sensor element that detects the concentration of a gas to be detected.

A gas sensor is attached to an intake system (for example, an intake pipe or an intake manifold) or an exhaust system of an internal combustion engine such as a diesel engine or a gasoline engine, and a concentration of a specific gas is monitored to control a combustion state or the like. And as a gas sensor generally used for such control, the external thread part provided in the outer side of the case (main metal fitting) which accommodates a gas sensor element was perforated in the wall surface of an intake system or an exhaust system It is fixed to the internal thread by screwing.
By the way, when a vehicle equipped with an internal combustion engine collides, it is necessary to secure the distance between the bonnet and the engine parts for the purpose of improving safety. Therefore, it is necessary to shorten the protruding length of the gas sensor to the outside of the intake system. It has become. However, the gas sensor described above has a limitation in that the length of the gas sensor protruding outward from the intake system is shortened because the connection terminal and the lead wire for extracting the detection output of the gas sensor element are drawn to the rear end side of the gas sensor. .
For this reason, a connector portion that extends in a direction intersecting the axial direction from a separator disposed on the rear end side of the gas sensor element as in Patent Document 1 is provided, and the so-called lateral direction in which the detection output of the gas sensor element is guided to the connector portion. A take-out type gas sensor is known. According to this gas sensor, it is possible to reduce the protruding length when the gas sensor is attached to the intake system by reducing the axial height of the gas sensor.

JP 2011-145270 A

By the way, the horizontal type gas sensor described in Patent Document 1 has a separator equipped with a connection terminal on the rear end side of the gas sensor element, and takes out a detection output from the connection terminal. The lead frame extending in the lateral direction is welded to the rear end of the connection terminal, and the lead frame is further welded to the connector terminal extending from the connector portion. For this reason, in the case of a side-by-side type gas sensor, there is a problem that the number of parts to be welded increases due to an increase in the number of welding points and the need for a lead frame. On the other hand, since the gas sensor element becomes high temperature by being heated by its own heater or exposed to exhaust gas or the like, it is preferable to use a heat resistant metal for the connection terminal connected to the gas sensor element. On the other hand, since the connector terminal is required to have low internal resistance and high conductivity, it is generally preferable to use a copper-based material. As described above, if the materials of the connection terminal and the connector terminal are different, welding may be difficult.
Therefore, the present invention provides a gas sensor capable of improving productivity and reducing the number of parts by connecting the connection terminal connected to the gas sensor element and the connector terminal held by the connector part without welding. The purpose is to do.

  In order to solve the above-described problems, the gas sensor of the present invention extends in the axial direction, has a detection unit for detecting a specific gas component in the gas to be measured at its front end side, and has an electrode pad at its rear end side. A gas sensor element, a metal shell that surrounds the gas sensor element in a radial direction, and holds the gas sensor element, an insulating separator that arranges a rear end side of the gas sensor element in its insertion hole, and the insertion A connecting terminal inserted through the hole and extending in the axial direction and electrically connected to the electrode pad, a main body portion surrounding the separator, and intersecting the axial direction from the main body portion A base portion having a connector portion that is extended in a direction and removable from an external device, and is held by the connector portion and extends in a direction intersecting the axial direction. A connector terminal that is inserted through the inside and outside of the gas sensor, wherein a rear end portion of the connection terminal includes a first connection portion that is electrically connected to the connector terminal, and the separator terminal side of the connector terminal is provided on the separator side. The end portion includes a second connection portion electrically connected to the first connection portion, and the first connection portion and / or the second connection portion are bent and arranged in parallel with each other, and the first connection portion and One of the second connection portions constitutes an insertion piece, the other constitutes a female portion into which the insertion piece is inserted, and at least one of the insertion piece and the female portion includes the first connection portion and the first connection portion. An elastic part capable of bending in a direction intersecting with the direction in which the two connecting parts are arranged is formed, the insertion piece is fitted into the female part, and the elastic part is bent in the intersecting direction. And the first connection portion and the A second connecting portion is elastically connected.

  According to this gas sensor, the first connection portion and the second connection portion are elastically connected by fitting the insertion piece into the female portion and bending in the direction in which the elastic portion intersects. Thereby, the detection output of a gas sensor element can be taken out to a connector terminal via a connection terminal. Therefore, in the side-by-side gas sensor, the connection terminal and the connector terminal can be electrically connected without welding, and productivity can be improved. In addition, the lead frame for welding the connection terminal and the connector terminal becomes unnecessary, and the number of parts is reduced.

One of the first connection part and the second connection part may be bent and arranged in parallel with each other, or both may be bent and arranged in parallel with each other. At this time, the first connection portion and the second connection portion may be arranged in parallel or may not be arranged in parallel.
Moreover, the elastic part may be provided in any one among an insertion piece and a female part, and may be provided in both. Furthermore, the number of elastic portions is not limited to one, and a plurality of elastic portions may be provided.

Moreover, the gas sensor of Claim 1 WHEREIN: While the said 2nd connection part comprises the said insertion piece, it is good for the said 1st connection part to comprise the female part.
According to this gas sensor, the first connection part is normally fixed to the separator, and the first connection part is connected to the second connection part so that the second connection part is fitted to the first connection part. To do. For this reason, since a 2nd connection part becomes an insertion piece, a 2nd connection part does not contact a separator and the chip | tip of a separator can be prevented.

Further, in the gas sensor according to claim 2, the second connection portion is bent, the insertion piece extends in the axial direction, and the female portion of the first connection portion is located in the insertion hole. It is good to have.
According to this gas sensor, since the female portion of the first connection portion is fixed to the insertion hole extending in the axial direction and the insertion piece of the second connection portion is inserted, insertion (fitting) is easy and reliable.

  The gas sensor of the present invention includes a gas sensor element that extends in the axial direction, has a detection unit for detecting a specific gas component in the gas to be measured on its front end side, and has an electrode pad on its rear end side. A metal shell that surrounds the gas sensor element in the radial direction and holds the gas sensor, an insulating separator that arranges a rear end side of the gas sensor element in its insertion hole, and is inserted into the insertion hole and is inserted into the insertion hole. A connecting terminal that extends in the axial direction and whose tip is electrically connected to the electrode pad, a main body that surrounds the separator, and extends from the main body in a direction that intersects the axial direction. A base portion made of an insulating material having a connector portion that can be pulled out, and held in the connector portion, extending in a direction intersecting the axial direction, and passing through the inside and outside of the connector portion A connector terminal, and a rear end portion of the connection terminal includes a first connection portion electrically connected to the connector terminal, and an end portion of the connector terminal on the separator side is the connector terminal. A second connection part electrically connected to the first connection part, wherein the first connection part and / or the second connection part are bent and arranged in parallel with each other, the first connection part and the second connection; At least one of the parts is formed with an elastic part capable of bending in a direction intersecting with the extending direction of the first connection part and the second connection part, and the first connection part and the second connection part Is connected between the surface of the separator or the inner surface of the base portion and the other connection portion, and the elastic portion is bent in the intersecting direction, whereby the first connection Part and the second connection part are elastically connected There.

  According to this gas sensor, the first connecting portion and the second connecting portion are sandwiched between the other connecting portion and the surface of the separator or the inner surface of the base portion, and are bent in a direction in which the elastic portions intersect with each other. The connecting portion is elastically connected. Thereby, the detection output of a gas sensor element can be taken out to a connector terminal via a connection terminal. Therefore, in the side-by-side gas sensor, the connection terminal and the connector terminal can be electrically connected without welding, and productivity can be improved. In addition, the lead frame for welding the connection terminal and the connector terminal becomes unnecessary, and the number of parts is reduced.

One of the first connection part and the second connection part may be bent and arranged in parallel with each other, or both may be bent and arranged in parallel with each other. At this time, the first connection part and the second connection part may be arranged in parallel, or may be arranged in an intersecting direction instead of in parallel.
Moreover, the elastic part may be provided in any one among a 1st connection part and a 2nd connection part, and may be provided in both. Furthermore, the number of elastic portions is not limited to one, and a plurality of elastic portions may be provided.

Further, in the gas sensor according to claim 4, the second connection portion may constitute the one connection portion, and the first connection portion may constitute the other connection portion.
According to this gas sensor, the first connecting portion is fixed to the separator, and the first connecting portion and the second connecting portion are connected so that the second connecting portion is fitted to the first connecting portion. . For this reason, a 2nd connection part can connect reliably from the surface of a separator, the inner surface of a base | substrate part, and a 1st connection part because a 2nd connection part becomes one connection part.

The gas sensor according to claim 5, wherein the second connection portion is bent and extends along the axial direction, and the second connection portion is connected to the inner surface of the insertion hole of the separator and the first connection. It is good to arrange between the parts.
According to this gas sensor, since the other connecting portion of the first connecting portion is fixed to the insertion hole extending in the axial direction and the second connecting portion is clamped, the clamping can be performed easily and reliably.

In the gas sensor according to the aspect of the invention, it is preferable that the connection terminal is made of a material having higher heat resistance than the connector terminal.
The connection terminal connected to the gas sensor element that becomes high temperature by being heated by its own heater or exposed to exhaust gas or the like is made of a heat resistant material rather than the connector terminal, thereby improving the heat resistance of the connection terminal.

  In the gas sensor of the present invention, it is preferable that the connector terminal is made of a copper-based material, and the connection terminal is made of stainless steel or a Ni-based alloy.

In the gas sensor of the present invention, the base portion may be an insulator that can be accommodated by inserting itself into the main body, and further includes an insulator in which a part of the connector terminal is embedded.
Since a part of the connector terminal is embedded in the insulator, the base body can be easily assembled by inserting the assembly holding the connector terminal in the insulator into the main body.

In the gas sensor of the present invention, it is preferable that a plurality of the connection terminals are held by the separator. Even in the case of a gas sensor having a plurality of connection terminals, the configuration of the present invention can be easily obtained by holding the separator on a separator.
In the gas sensor of the present invention, it is preferable that a plurality of the connector terminals are held on the base portion. Even in the case of a gas sensor having a plurality of connector terminals, the configuration of the present invention can be easily obtained by holding the separator on a separator.

  In the gas sensor according to the aspect of the invention, it is preferable that the elastic portion is a spring portion in which one end portion is a free end. By setting it as such a spring part, the elastic force of an elastic part increases and a 1st connection part and a 2nd connection part are connected reliably.

  According to the present invention, by connecting the connection terminal connected to the gas sensor element and the connector terminal held by the connector portion without welding, the productivity can be improved and the number of parts can be reduced.

It is a perspective view which shows the structure of the gas sensor which concerns on 1st Embodiment. It is a disassembled perspective view of a gas sensor. It is sectional drawing which follows the AA line of FIG. It is an expansion perspective view of a connection terminal. It is an expansion perspective view of a connector terminal and an insulator. It is process drawing which shows an example of the manufacturing method of the gas sensor which concerns on the 1st Embodiment of this invention. FIG. 7 is a process drawing following FIG. 6. It is sectional drawing which shows the structure of the gas sensor which concerns on 2nd Embodiment. In 2nd Embodiment, it is process drawing which shows the aspect which connects a 1st connection part and a 2nd connection part. It is sectional drawing which shows the structure of the gas sensor which concerns on 3rd Embodiment. It is process drawing which shows the aspect which connects a 1st connection part and a 2nd connection part in 3rd Embodiment. It is sectional drawing which shows the structure of the gas sensor which concerns on 4th Embodiment. In 4th Embodiment, it is process drawing which shows the aspect which connects a 1st connection part and a 2nd connection part. It is sectional drawing which shows the structure of the gas sensor which concerns on 5th Embodiment. In 5th Embodiment, it is process drawing which shows the aspect which connects a 1st connection part and a 2nd connection part. It is sectional drawing which shows the structure of the gas sensor which concerns on 6th Embodiment. In 6th Embodiment, it is process drawing which shows the aspect which connects a 1st connection part and a 2nd connection part. It is a fragmentary sectional view showing the composition of the gas sensor concerning a 7th embodiment. It is a fragmentary sectional view showing the composition of the gas sensor concerning an 8th embodiment.

  Hereinafter, embodiments of the present invention will be described.

1 is a perspective view of a gas sensor 200 according to the first embodiment of the present invention, FIG. 2 is an exploded perspective view of the gas sensor 200, FIG. 3 is a cross-sectional view taken along line AA in FIG. 1, and FIG. FIG. 5 is an enlarged perspective view of the connector terminal 60 and the insulator 107. FIG.
Note that the axis O direction (indicated by a one-dot chain line) of the gas sensor element 10 is shown as a vertical direction, and the rear end portion 12 side of the gas sensor element 10 is on the rear end side of the gas sensor element 10 (and the gas sensor) and the opposite side thereof. The detection part 11 (refer FIG. 3) side of a certain gas sensor element 10 is demonstrated as the front end side of the gas sensor element 10 (and gas sensor). A direction perpendicular to the direction of the axis O is appropriately referred to as a “radial direction”.
Further, in FIG. 3 and the corresponding drawings after FIG. 8, only one connection terminal and connector terminal are shown for the sake of simplicity, but actually, as shown in FIG. 2, FIG. A plurality of connection terminals and connector terminals (each five in the embodiment of the present invention) are provided.

  As shown in FIGS. 1 and 2, the gas sensor 200 includes an element assembly 130 (see FIG. 6A) including the gas sensor element 10 and the metal shell 50, and a separator assembly 120 fixed to the rear end side of the element assembly 130. (See FIG. 6A), a metal outer cylinder 110 surrounding the separator assembly 120, a main body 101 accommodated in the outer cylinder 110, and a base body having a connector 103 extending in the radial direction from the main body 101 105, an insulator 107 accommodated in the main body 101 and the connector 103, a metal cover 140 that covers the main body 101, and a metal flanged casing 150 that covers a part of the outer cylinder 110.

  The flanged casing 150 has a cylindrical body 153 and a pair of semicircular flange portions 151 extending radially outward from the cylindrical body 153. One flange hole 151h is opened in each flange portion 151, and a screw (not shown) inserted through the flange hole 151h is screwed into a screw hole provided in a body to be attached to the gas sensor 200 (for example, an intake system of an internal combustion engine). By stopping, the gas sensor 200 can be attached to the attachment target. A concave groove 153b (see FIG. 7G) is formed in the cylindrical body 153 along the circumferential direction, and a seal member (O-ring) 90 is externally fitted in the concave groove. Therefore, when the gas sensor 200 is inserted and attached to the opening of the attachment object of the gas sensor from the front end side, the seal member 90 is crushed by the wall surface of the attachment object, and the attachment object and the flanged casing 150 (cylinder 153) It is designed to seal between.

The base body part 105 includes a main body part 101, a neck part 102, and a connector part 103. The main body part 101, the neck part 102 and the connector part 103 are made of an insulating polymer material (resin) having a good moldability, for example, nylon ( Registered trademark). Note that the base portion 105 only needs to have insulating properties, and may be formed of other materials (for example, ceramics). Further, the insulator 107 is also included in the “base portion 105” when it is housed in the main body 101 and the connector 103.
The main body 101 is formed in a substantially cylindrical shape so as to cover the periphery of the separator assembly 120. Further, a substantially rectangular connector portion 103 extends radially outward from the main body portion 101 via a substantially rectangular neck portion 102. The connector portion 103 is a male connector having an opening 104 facing radially outward, and a mating connector (in this example, a female connector) of an external device can be inserted and removed in the radial direction at the opening 104. .
An insulator 107 is accommodated inside the main body 101 and the connector 103. When the insulator 107 is inserted into the main body portion 101 and the connector portion 103 along the radial direction from the opening 104 during assembly, the end portion 107a of the insulator 107 on the separator 40 side becomes the inner surface 101a of the main body portion 101 (see FIG. 3). The insulator 107 is positioned. The insulator 107 holds a plurality (5 in this example) of connector terminals 60. The connector terminal 60 extends in a direction intersecting the axis O direction (radial direction) and passes through the inside and outside of the connector portion 103. The connector terminal 60 will be described later.

  The outer cylinder 110 includes a front cylinder 110a having a slightly larger diameter than the separator assembly 120 and a rear cylinder 110e provided on the rear end side of the front cylinder 110a and having a diameter larger than that of the front cylinder 110a. A stepped portion extending in parallel to the radial direction so as to connect the outer cylinder 110e and the rear cylinder 110e is a receiving portion 110b for placing the main body 101. The front end side of the separator assembly 120 is accommodated in the front cylinder 110a, and the rear end side of the separator assembly 120 protrudes from the front cylinder 110a to the rear end and is accommodated in the rear cylinder 110e (FIG. 6 ( d)). Further, a cylindrical main body 101 is fitted in the annular space between the rear cylinder 110e and the rear end side of the separator assembly 120 so as to be placed on the receiving part 110b, and the main body 101 is separated from the separator assembly. The rear end side of 120 (and eventually the rear end portion of the gas sensor element 10) is surrounded (see FIG. 7E).

A rear end portion of the separator 40 is exposed at the rear end of the separator assembly 120, and connection terminals (five in this example) 30 protrude from the separator 40 toward the rear end side (details will be described later).
An extension portion 110c having a U-shaped cross section extends radially outward from the rear cylinder 110e, the peripheral edge of the extension portion 110c is an open end portion, and the rear end side of the extension portion 110c is open. Therefore, when the base body part 105 is accommodated in the rear cylinder 110e, the main body part 101 is accommodated in the rear cylinder 110e, the neck part 102 is accommodated in the extension part 110c, and the connector part 103 appears on the radially outer side of the extension part 110c. It comes to put out. Further, the rear end side of the main body 101 protrudes beyond the rear cylinder 110e.
Further, the front end portion of the front cylinder 110a is externally fitted to the enlarged diameter portion 57 (see FIG. 3) of the metal shell 50, both are crimped and welded, and the outer cylinder 110 is fixed to the metal shell 50. (Details will be described later).

On the other hand, a bottomed cylindrical metal cover 140 whose rear end side is closed covers the rear end side of the main body 101 from the radially outer side. The metal cover 140 is slightly larger in diameter than the rear cylinder 110e, and the front end portion 140a of the metal cover 140 extends to the front end side relative to the receiving portion 110b, and surrounds the receiving portion 110b at the time of assembly so as to be inward in the radial direction. It is bent and crimped. In this way, the metal cover 140 is fixed to the outer cylinder 110, and the rear cylinder 110e and the main body 101 are covered with the metal cover 140. In addition, as shown in FIG. 2, the front end portion 140a before being bent has a peak portion protruding to the front end side and a trough portion recessed to the rear end side, which are alternately formed in a step shape, and the peak portion is bent in the radial direction. (See FIG. 3).
The metal cover 140 covers the outside of the main body 101 and is also connected to the outer cylinder 110 connected to the metal shell 50. For this reason, the heat from the metal shell 50 is transmitted to the metal cover 140 via the outer cylinder 110 and radiated to the outside, so that the heat transmitted to the main body 101 inside the metal cover 140 is reduced, and the main body 101 ( Furthermore, thermal deterioration of the base portion 105) can be suppressed.
Further, since the main body 101 is sandwiched between the outer cylinder 110 (the receiving portion 110b) and the metal cover 140, the resin main body 101 is held in the gas sensor 200 in a state where it is separated without directly contacting the metal shell 50. Thus, the thermal deterioration of the main body 101 (and the base 105 including the connector 103) can be further suppressed.

An extension part 140c having a U-shaped cross section extends outward in the radial direction of the metal cover 140, the peripheral edge of the extension part 140c is an open end, and the distal end side of the extension part 140c is open. Further, the extension portion 140c is larger than the extension portion 110c. Therefore, when the direction of the extension part 140c is aligned with the extension part 110c and the metal cover 140 is put on the extension part 110c from the rear end side, the extension part 140c surrounds the extension part 110c and the connector part is formed radially outward of the extension part 140c. 103 is displayed.
A seal member (O-ring) 94 is disposed in an annular groove formed in the rear end surface of the main body 101, and airtightly seals between the rear end facing surface of the main body 101 and the front end facing surface of the metal cover 140. ing. Similarly, a seal member (O-ring) 92 is disposed in an annular groove formed on the front end surface of the main body 101 (see FIG. 3), and between the front end facing surface of the main body 101 and the front end facing surface of the receiving portion 110b. It is airtightly sealed. The seal members 92 and 94 also have a function of stably holding the main body 101 between the outer cylinder 110 and the metal cover 140 by elastic force.

Next, the element assembly 130 and the separator assembly 120 will be described with reference to FIG. The element assembly 130 includes the gas sensor element 10 and the metal shell 50.
The gas sensor element 10 has a generally prismatic shape extending in the direction of the axis O as is well known, and a detection element for detecting the oxygen concentration and a heater for heating to activate the detection element are bonded to each other. It is a laminate. The detection element has a configuration in which a solid electrolyte body mainly composed of zirconia and a pair of electrodes mainly composed of platinum are laminated via an insulating layer in which a hollow measurement chamber is partially formed. More specifically, the detection element exposes one of a pair of electrodes formed on both surfaces of the solid electrolyte body to the outside and an oxygen pump cell in which the other electrode is disposed in the measurement chamber, and both surfaces of the solid electrolyte body. One of the formed pair of electrodes is arranged in the measurement chamber, and the other electrode is arranged in the reference gas chamber, and the output voltage of the oxygen concentration measurement cell becomes a predetermined value. As described above, the current flowing between the pair of electrodes of the oxygen pump cell is controlled to draw out oxygen in the measurement chamber or pump oxygen into the measurement chamber from the outside.
Of the oxygen pump cell, a portion of the pair of electrodes and a solid electrolyte body sandwiched between these electrodes forms a detection unit 11 through which a current corresponding to the oxygen concentration flows. On the other hand, the rear end portion 12 of the gas sensor element 10 has five electrode pads 12a (two of which are the second ones of the gas sensor element 10 in FIG. 3) for taking out the output from the detection element and supplying power to the heater. It is arranged on the surface 10b side, and the remaining three are arranged on the first surface 10a).

  A metal cup 20 having a bottomed cylindrical shape is inserted into the inside of the gas sensor element 10 a little from the center in the axial direction of the gas sensor element 10, and the detection unit 11 is opened to the bottom 25 of the cylinder bottom. It is arrange | positioned in the state protruded from. The metal cup 20 is a member for holding the gas sensor element 10 in the metal shell 50, and the distal end side peripheral portion 23 at the bottom of the cylinder is formed in a tapered shape toward the outer peripheral surface. In the metal cup 20, an alumina ceramic ring 21 and a talc ring 22 obtained by compressing and solidifying talc powder are accommodated in a state where the gas sensor element 10 is inserted. The talc ring 22 is crushed in the metal cup 20 to fill the details, whereby the gas sensor element 10 is positioned and held in the metal cup 20.

  The gas sensor element 10 integrated with the metal cup 20 is held by being surrounded by a cylindrical metal shell 50. The metal shell 50 is made of stainless steel such as SUS430. Specifically, a step portion 54 is formed on the inner periphery of the metal shell 50, and the front end side peripheral portion 23 of the metal cup 20 that holds the gas sensor element 10 is locked to the step portion 54. Further, a talc ring 26 is loaded on the inner periphery of the metal shell 50 from the rear end side of the metal cup 20 in a state where the talc ring 26 is inserted through the gas sensor element 10. A cylindrical sleeve 27 is fitted into the metal shell 50 so as to hold the talc ring 26 from the rear end side. A shoulder portion 28 having a step shape is formed on the outer periphery of the rear end side of the sleeve 27, and an annular caulking packing 29 is disposed on the shoulder portion 28.

On the other hand, a rear end portion 59 having a reduced diameter is formed on the outer peripheral rear end side of the metal shell 50, and a diameter-expanding portion 57 that expands in a step shape radially outward is formed at the tip of the rear end portion 59. ing. Furthermore, a large diameter portion 52 having a large diameter and a distal end engaging portion 56 to which an outer protector 100 and an inner protector 102 to be described later are engaged are formed on the distal end side with respect to the enlarged diameter portion 57. On the other hand, a caulking part 53 for caulking and holding the gas sensor element 10 in the metal shell 50 is formed on the rear end side of the rear end part 59.
The crimping portion 53 of the metal shell 50 is crimped so as to press the shoulder portion 28 of the sleeve 27 toward the distal end side via the crimping packing 29. Due to the formation of the caulking portion 53, the talc ring 26 pressed through the sleeve 27 is crushed in the metal shell 50 and filled in details, and the talc ring 26 and the metal cup 20 are preloaded. The metal cup 20 and the gas sensor element 10 are positioned in the metal shell 50 by the talc ring 22 and are kept airtight.

  On the other hand, the outer peripheral surface of the detection unit 11 of the gas sensor element 10 is covered with a porous protective layer 15 to protect the electrode exposed to the outside of the detection unit 11 from poisoning due to intake air or the like. Then, the outer protector 100 and the inner protector 102 are fitted to the front end engaging portion 56 of the metal shell, and are fixed by laser welding to protect the detection unit 11 housed inside. A gas introduction hole 115 is formed in the outer protector 100 (see FIG. 1), and a gas introduction hole 117 is formed in the inner protector 102. Therefore, it can suppress that the water | moisture content and oil component contained in gas adhere to the gas sensor element 10, and it can suppress that a crack and a crack arise in the gas sensor element 10. FIG. Moreover, it can suppress that the soot contained in gas adheres to the gas sensor element 10, and can suppress that the detection accuracy of the gas sensor 200 falls.

Next, the separator assembly 120 will be described. The separator assembly 120 includes a separator 40, a metal inner cylinder 121, a holding member 123, and a connection terminal 30, and is disposed on the rear end side of the metal shell 50. The separator assembly 120 has a caulking portion 125 that integrally fixes the metal inner cylinder 121 and the holding member 123 by being caulked from the radially outer side toward the radially inner side at a substantially central portion in the axis O direction. .
The separator 40 is formed in a substantially cylindrical shape by insulating ceramics or resin, and has a flange portion 41 that protrudes radially outward and an insertion hole 42 that penetrates in the axis O direction. The individual connection terminals 30 are respectively inserted into predetermined positions of the insertion holes 42, and are accommodated in the separator 40 in a state where the connection terminals 30 are isolated without contacting each other. Then, the rear end portion 12 of the gas sensor element 10 is inserted into the insertion hole 42, and the elastic portion 33 a (see FIG. 4) of the distal end portion 33 of each connection terminal 30 is electrically connected to each electrode pad 12 a of the gas sensor element 10. It is connected.
The rear end portion of the separator 40 is exposed from the rear end of the separator assembly 120, and the first connection portions 31 (five in this example) of the connection terminal 30 protrude from the rear end facing surface of the separator 40 to the rear end side. Yes.

The front end 121a of the metal inner cylinder 121 is crimped to the rear end 59 in a state of covering the rear end 59 of the metal shell 50 and is fixed by welding. On the other hand, the rear end 121 e of the metal inner cylinder 121 is bent radially inward and engaged with the flange 41. Further, the separator 40 and the holding member 123 are disposed inside the metal inner cylinder 121, and the rear end facing surface of the holding member 123 is engaged with the flange portion 41. The holding member 123 is a metallic cylindrical member, and biases the separator 40 radially inward by the elastic force of the rear end portion formed in a bent shape, and biases the flange portion 41 toward the rear end side. To do. Further, the holding member 123 is crimped from the outside of the metal inner cylinder 121 toward the inside in the radial direction together with the metal inner cylinder 121 to form a crimped portion 125, and is fixed to the metal inner cylinder 121.
The separator 40 is not directly fixed to the metal shell 50 and the metal inner cylinder 121 but is held and fixed in the metal inner cylinder 121 by the metal inner cylinder 121 and the holding member 123. By configuring in this way, poor contact between the connection terminal 30 and the connector terminal 60 due to vibration or displacement of the separator 40 due to vibration or impact on the gas sensor 200 is suppressed.

Next, the connection terminal 30 and the connector terminal 60, which are characteristic portions of the first embodiment, will be described with reference to FIGS. The connection terminal 30 in FIG. 4 indicates the connection terminal 30 disposed in the center among the five connection terminals 30 illustrated in FIGS. 2 and 5.
As shown in FIG. 4, the connection terminal 30 includes a first connection part 31 extending in the axis O direction, a plate-like intermediate part 32 extending in the radial direction on the distal end side of the first connection part 31, and the intermediate part 32. It has the front-end | tip part 33 extended in an axis line O direction at the front end side, and is formed in the substantially crank shape seeing from the side surface. The first connection portion 31 is bent in an L shape from the intermediate portion 32 and rises in the axis O direction, and side portions that are bent in an L shape from both ends in the width direction of the main portion 31b and extend in the radial direction. 31c and an opposing portion 31d that is bent in an L shape from the side portion 31c along the main portion 31b and is close to each other, and is a box-shaped female portion 31g having a substantially square-shaped cross section. . Further, an elastic portion 31a that is bent from the rear end to the front end side of the main portion 31b is formed. The elastic part 31a is located inside the box-shaped first connection part 31, and is elastically bent in a direction approaching the main part 31b. The elastic part 31a is a spring part whose end on the tip side is a free end. By setting it as a spring part, the elastic force of the elastic part 31a increases, and the 1st connection part 31 and the 2nd connection part 61 are connected reliably. As will be described later, the direction in which the elastic portion 31a bends is a direction that intersects with the direction in which the first connection portion 31 and the second connection portion 61 are arranged (in the first embodiment, the direction of the axis O). Further, an elastic portion 33a that bends from the front end of the front end portion 33 toward the rear end side is formed, and this elastic portion 33a is pressed and electrically connected to each electrode pad 12a of the gas sensor element 10.
In addition, although the connection terminal 30 of FIG. 4 had the intermediate part 32, in four connection terminals 30 arrange | positioned other than the center among the five connection terminals 30 shown in FIG.2 and FIG.5, The intermediate portion 32 is not formed. The intermediate portion 32 may be set as appropriate according to the relative position between the first connecting portion 31 and the tip portion 33.
Further, in the connection terminal 30, the rear end portion of the first connection portion 31 protrudes toward the rear end side from the surface facing the rear end of the separator 40, and other portions are held inside the insertion hole 42 of the separator 40. Yes.

  On the other hand, as shown in FIG. 5, the connector terminals (five in this example) 60 are held by the insulator 107 while being separated from each other. The connector terminal 60 is a plate-like intermediate portion 62 that extends in the radial direction and is embedded in the insulator 107, and an end portion that extends from the intermediate portion 62 toward the separator 40, and is bent into an L shape, and is in the direction of the axis O A second connecting portion 61 having an insertion piece 61g extending in the direction from the insulator 107 and a male portion 63 protruding radially outward from the insulator 107. And the male part 63 protrudes from the insulator 107, whereby a male connector is formed. Although omitted in FIG. 5, as shown in FIG. 3, the intermediate portion 62 is bent in a crank shape and connected to the male portion 63, and the male portion 63 extends in parallel with the intermediate portion 62 while being intermediate. It is located on the tip side of the part 62 (that is, substantially in the center of the connector part 103 in the axis O direction).

Although details will be described with reference to FIG. 6, in the first embodiment, the base body portion 105 (the main body portion 101) is fitted into the rear cylinder 110e assembled with the separator assembly 120 from the rear end side (see FIG. 6). 6 (d)). At this time, the insertion piece 61g is disposed around the axis of the main body 101 and is opposed to the connection terminal 30 protruding to the rear end side of the separator 40.
Therefore, when the base portion 105 is fitted into the rear cylinder 110e, the second connection portion 61 is inserted (fitted) from the direction of the axis O to the first connection portion 31 (the insertion piece 61g is fitted to the female portion 31g. ), The elastic portion 31a is pressed, and the elastic portion 31a is bent in the radial direction. As a result, the first connection part 31 and the second connection part 61 are elastically connected. Thereby, the detection output of the gas sensor element 10 can be taken out to the connector terminal 60 via the connection terminal 30. Therefore, in the side-by-side gas sensor, the connection terminal 30 and the connector terminal 60 can be electrically connected without welding, and productivity can be improved. Further, the lead frame for welding the connection terminal 30 and the connector terminal 60 becomes unnecessary, and the number of parts is reduced.

In the first embodiment, the second connection portion 61 is bent and extends in the direction of the axis O, and is arranged in parallel with the first connection portion 31 so that both can be connected.
As shown in the first embodiment, the second connection portion 61 includes an insertion piece 61g, and the first connection portion 31 includes a female portion 31b. That is, the first connection part 31 having the female part 31g is fixed to the separator 40, and the first connection part 31 and the second connection part are fitted so that the second connection part 61 is fitted to the first connection part 31. 61 is connected. For this reason, the 2nd connection part 61 does not contact the separator 40 because the 2nd connection part 61 becomes the insertion piece 61g, and the chip | tip of the separator 40 can be prevented.
Further, the second connecting portion 61 is bent and has an insertion piece 61g extending in the axis O direction. When the female portion 31g of the first connecting portion 31 is located in the insertion hole 42, the second connecting portion 61 extends in the axis O direction. Since the female part 31g of the first connection part 31 is fixed to the extending insertion hole 42 and the second connection part 61 is inserted, the insertion (fitting) becomes easy and reliable.

Since the gas sensor element 10 is heated by being heated by its own heater or being exposed to exhaust gas or the like, in the first embodiment, the connection terminal 30 connected to the gas sensor element 10 is connected to the connector terminal 60 from the connector terminal 60. Is also made of a material having heat resistance. In this case, since the materials of the connection terminal 30 and the connector terminal 60 are different, welding becomes difficult. However, in the present invention, since the connection terminal 30 and the connector terminal 60 are not required to be welded, they are made of different materials. However, electrical connection can be easily performed.
As the connection terminal 30, stainless steel or Ni-based alloy (for example, SUS631, Inconel (registered trademark)), which is a heat-resistant metal, can be used. As the connector terminal 60, a copper-based material such as brass can be used.

Next, an example of a method for manufacturing the gas sensor 200 according to the first embodiment of the present invention will be described with reference to FIGS.
First, the element assembly 130 is formed by a known method. Further, as described above, the connection terminal 30 is inserted and held in the insertion hole 42 of the separator 40, and the separator 40 and the holding member 123 are accommodated in the metal inner cylinder 121. Then, at a substantially central portion of the metal inner cylinder 121 in the axis O direction, caulking is performed from the outside in the radial direction to fix the holding member 123 in the metal inner cylinder 121 and to form the separator assembly 120 holding the separator 40.
Next, as shown in FIG. 6A, the separator assembly 120 is inserted into the rear end of the element assembly 130 from the front end side, and the rear end portion 12 of the gas sensor element 10 is inserted into the insertion hole 42 of the separator 40. To do. Thereby, the front-end | tip part (not shown) of each connection terminal 30 is electrically connected to each electrode pad 12a of the gas sensor element 10, respectively. Further, the front end portion 121 a of the metal inner cylinder 121 is fitted to the outside of the rear end portion 59 of the metal shell 50, and the front end portion 121 a comes into contact with the stepped portion between the rear end portion 59 and the enlarged diameter portion 57 and is positioned. The In this state, the tip 121a is crimped from the outside in the radial direction and welded to fix the separator assembly 120 to the metal shell 50, that is, the element assembly 130.
Next, as shown in FIG. 6B, when the outer cylinder 110 is inserted into the separator assembly 120 from the front end side, the front end side of the separator assembly 120 is accommodated in the front cylinder 110a and the front end portion of the front cylinder 110a. Is fitted to the outside of the enlarged diameter portion 57 of the metal shell 50, and the front end portion of the front cylinder 110a is positioned in contact with the stepped portion between the enlarged diameter portion 57 and the large diameter portion 52. In this state, the front end portion of the front cylinder 110 a is crimped from the outside in the radial direction and welded to fix the outer cylinder 110 to the metal shell 50.

Next, as shown in FIG. 6C, when the insulator 107 holding the connector terminal 60 is inserted into the connector portion 103 along the radial direction from the opening 104, the end portion 107a of the insulator 107 becomes the main body portion. The insulator 107 is positioned in contact with the inner surface 101a of the 101. At this time, the insertion piece 61 g of the second connection portion 61 located on the end portion 107 a side of the insulator 107 is disposed around the axis of the main body portion 101.
Then, as shown in FIG. 6D, when the base portion 105 is inserted into the outer cylinder 110 (rear cylinder 110e) from the front end side, the separator 40 is positioned on the axis of the rear cylinder 110e. Then, the base body portion 105 (main body portion 101) is placed on the receiving portion 110b via the seal member 92. As a result, the second connection portion 61 of the corresponding connector terminal 60 is fitted into the first connection portion 31 of each connection terminal 30 protruding to the rear end side of the separator 40 (the insertion piece 61g is fitted to the female portion 31g. The connection terminal 30 and the connector terminal 60 can be electrically connected without welding.

Next, as shown in FIG. 7 (e), the metal cover 140 is externally fitted to the outer cylinder 110 (rear cylinder 110 e) through the seal member 94 from the opening on the tip end side. Then, as shown in FIG. 7 (f), the crest portion of the tip end portion 140 a of the metal cover 140 is bent and crimped radially inward so as to surround the receiving portion 110 b, and the metal cover 140 is fixed to the outer cylinder 110. At the same time, the main body 101 is sandwiched between the outer tube 110 (the receiving portion 110b) and the metal cover 140. In this way, the rear cylinder 110e and the main body 101 are covered with the metal cover 140.
Next, as shown in FIG. 7G, when the flanged casing 150 is externally fitted to the element assembly 130 from the rear end side, the flanged casing 150 is provided at the front end of the cylindrical body 153 and extends radially inward. The flat portion 153a is positioned in contact with the stepped portion between the large-diameter portion 52 and the tip engaging portion 56 of the metal shell 50. In this state, the cylindrical body 153 is crimped from the radially outer side in the vicinity of the large-diameter portion 52 and welded to fix the flanged casing 150 to the metal shell 50, that is, the element assembly 130.
Further, as shown in FIG. 7 (h), a seal member (O-ring) 90 is externally fitted into the concave groove 153b, and the gas sensor 200 is completed.

Examples of the object to which the gas sensor 200 is attached include various internal combustion engines, and in particular, an intake system of an internal combustion engine of a vehicle such as an automobile. Here, the intake system is an intake passage from the intake intake port to the intake port of the internal combustion engine. For example, an intake pipe and an intake manifold branched from the intake pipe and connected to the intake port of the internal combustion engine Can be mentioned. In addition to fresh air (fresh air that does not include exhaust), the intake air includes a mixed gas in which part of the exhaust gas is recirculated (recirculated) to the intake system and mixed with fresh air.
Moreover, although the gas sensor element 10 of the said embodiment is what is called a full range air-fuel ratio sensor, an oxygen sensor (lambda sensor) and a NOx sensor other than an air-fuel ratio sensor can be used.
In addition, when the internal combustion engine is controlled by detecting the specific gas concentration on the intake side, the internal combustion engine can be controlled more accurately than when the gas sensor is provided on the exhaust side to detect the specific gas concentration in the exhaust. This is because the control according to the specific gas concentration in the exhaust is feedback control, whereas the control according to the specific gas concentration on the intake side can be handled before combustion.

Next, the configuration of the gas sensor 300 according to the second embodiment of the present invention will be described with reference to FIGS. The gas sensor 300 is the same as that of the first embodiment except that the connection terminal 30 and the connector terminal 60 in the first embodiment are changed to the connection terminal 330 and the connector terminal 360, respectively, and the insulator 107 is changed to the insulator 307. Therefore, the same components as those in the first embodiment are denoted by the same reference numerals, and detailed description thereof is omitted.
FIG. 8 is a cross-sectional view showing a configuration of the gas sensor 300, and corresponds to FIG. 3 of the first embodiment. In this figure, the connection terminal 330 includes a first connection portion 331 extending in the direction of the axis O, a plate-like intermediate portion 332 extending in the radial direction by bending the tip of the first connection portion 331 into an L shape, and an intermediate portion 332. And a distal end portion 333 extending in the direction of the axis O on the distal end side. The connection terminal 330 is formed in a substantially crank shape when viewed from the side, and the distal end portion 333 is the same as the distal end portion 33 of the first embodiment.
As shown in FIG. 9, the first connection portion 331 is bent in an L shape from the intermediate portion 332 and extends in the axis O direction, and is bent in an L shape on the rear end side of the first connection portion 331. And a female portion 331g extending in the radial direction. The female portion 331g protrudes further toward the rear end side than the rear end facing surface of the separator 40. The female portion 331g includes a main portion 331b, a side portion 331c that is bent in an L shape from one end in the width direction (along the radial direction) of the main portion 331b and extends to the rear end side, and a main portion 331b from the side portion 331c. And a counter portion 331d that is bent in an L shape so that the cross section is U-shaped. Further, the radially outer end of the main portion 331b is folded back to the opposite side in the radial direction to form an elastic portion 331a. The elastic part 331a is located inside the U-shaped first connection part 331, and is elastically bent in a direction approaching the main part 331b (that is, the tip side).
On the other hand, the connector terminals (five in this example) 360 are held by the insulator 307 while being separated from each other. The connector terminal 360 is a plate-like intermediate portion 362 that extends in the radial direction and is embedded in the insulator 307, and an end portion that protrudes from the intermediate portion 362 toward the separator 40 and extends in parallel with the intermediate portion 362. It has a connection portion 361 and a male portion 363 that is connected to the intermediate portion 362 and protrudes radially outward from the insulator 307. The male part 363 and the intermediate part 362 are the same as those in the first embodiment.

As shown in FIG. 9, in the second embodiment, the first insertion point (fitting) direction of the connector terminal 360 (the second connection portion 361) to the first connection portion 331 is the first direction. Different from the embodiment.
That is, the first connection portion 331 (female portion 331g) opens in the radial direction, and the connector terminal 360 (second connection portion 361 (insertion piece 361g) thereof) can be inserted in the radial direction. Here, a notch 307 a is formed on the tip-facing surface of the end portion of the insulator 307 on the separator 40 side. A protrusion 101b corresponding to the notch 307a is formed at the end of the main body 101 on the neck 102 side. The manufacturing method is slightly different from that of the first embodiment. After the separator assembly 120, the element assembly 130, and the outer cylinder 110 are assembled, first, the main body 101 (base member 105) before the insulator 307 is mounted. ) Is previously fitted into the rear cylinder 110e, and then the insulator 307 is inserted from the opening 104 into the connector portion 103 along the radial direction. As a result, the notch 307a abuts against the protrusion 101b, the insulator 307 is positioned, and the second connection portion 361 (insertion piece 361g) is fitted into the first connection portion 331 (female portion 331g) to be elastic. As a result of pressing the portion 331a and bending the elastic portion 331a in the direction of the axis O, the first connection portion 331 and the second connection portion 361 are elastically connected, and the connection terminal 330 and the connector terminal 360 are not welded. Can be electrically connected.

  In the second embodiment, the direction in which the elastic portion 331a bends is a direction (that is, the direction of the axis O) that intersects the direction (radial direction) in which the first connecting portion 331 and the second connecting portion 361 are arranged. is there. Further, the first connection portion 331 is bent in the radial direction and arranged in parallel with the second connection portion 361 so that both can be connected.

Next, the configuration of the gas sensor 400 according to the third embodiment of the present invention will be described with reference to FIGS. The gas sensor 400 is the same as the first embodiment except that the connection terminal 30 and the connector terminal 60 in the first embodiment are changed to the connection terminal 430 and the connector terminal 460, respectively. The same reference numerals are given to the same components, and detailed description thereof is omitted.
FIG. 10 is a cross-sectional view showing the configuration of the gas sensor 400, and corresponds to FIG. 3 of the first embodiment. In this figure, the connection terminal 430 includes a first connection portion 431 extending in the direction of the axis O, a plate-shaped intermediate portion 432 that is bent in an L shape on the distal end side from the first connection portion 431 and extends in the radial direction, A distal end portion 433 that is bent in an L shape on the distal end side from the intermediate portion 432 and extends in the direction of the axis O. The connection terminal 430 is formed in a substantially crank shape when viewed from the side, and the distal end portion 433 is the same as the distal end portion 33 of the first embodiment.
Of the connection terminals 430, the rear end portion of the first connection portion 431 protrudes toward the rear end side with respect to the rear end facing surface of the separator 40, and the front end portion, the intermediate portion 432, and the front end portion 433 of the first connection portion 431 are It is held inside the insertion hole 42 of the separator 40. However, the distal end portion of the first connection portion 431 is in the insertion hole 42 and is separated from the inner surface of the insertion hole 42.

On the other hand, the connector terminals (five in this example) 460 are held by the insulator 107 while being separated from each other. The connector terminal 460 is a plate-like intermediate portion 462 that extends in the radial direction and is embedded in the insulator 107, and an end portion that extends from the intermediate portion 462 toward the separator 40, and is bent into an L shape, and is in the axis O direction. A second connecting portion 461 having a female portion 461g extending to the middle portion 362, and a male portion 463 projecting radially outward from the insulator 107 while being connected to the intermediate portion 362. The male part 463 and the intermediate part 462 are the same as those in the first embodiment.
As shown in FIG. 11, the female portion 461g is connected to the intermediate portion 462 and is bent in an L shape from both ends in the width direction of the opposing portion 461d. It has a side part 431c that extends in the radial direction and a main part 461b that is bent in an L shape along the opposite surface from the side part 431c and is close to each other. Further, an elastic portion 461a that is bent from the front end of the main portion 461b toward the rear end side is formed. The elastic portion 461a is located between the main portion 461b and the facing portion 461d, and is elastically bent in a direction (radial direction) approaching the main portion 461b.

As shown in FIG. 11, in the third embodiment, the first embodiment is that the first connection portion 431 (insertion piece 431g) is inserted into the connector terminal 460 (the female portion 461g of the second connection portion 461). Although different from the form, the insertion (fitting) direction is the direction of the axis O and is the same as that of the first embodiment. That is, the insertion piece 431g can be inserted in the direction of the axis O between the main portion 461b of the female portion 461g and the facing portion 461d. Here, in the third embodiment, the insulator 107 and the body portion 101 to which the insulator 107 is assembled are the same as those in the first embodiment, and the separator assembly 120 is assembled in the same manner as in the first embodiment. The base portion 105 (the main body portion 101) is fitted into the rear cylinder 110e from the rear end side (see FIG. 6D). At this time, the female portion 461g of the second connection portion 461 is inserted into the insertion hole 42 of the separator 40, and the first connection portion 431 in the insertion hole 42 is inserted (fitted) into the second connection portion 461 from the axis O direction. (The insertion piece 431g is fitted into the female portion 461), presses the elastic portion 461a, and the elastic portion 461a bends in the radial direction. As a result, the first connection portion 431 and the second connection portion 461 are elastically connected, and the connection terminal 430 and the connector terminal 460 can be electrically connected without welding.
Although the facing portion 461d of the female portion 461g bends in the radial direction, when the second connecting portion 461 is inserted into the insertion hole 42 of the separator 40, the main portion 461b and the facing portion 461d are respectively the inner surfaces of the insertion hole 42. Therefore, the distance between the main portion 461b and the facing portion 461d does not increase, and the first connection portion 431 can be securely held.

  In the third embodiment, the direction in which the elastic portion 461a bends is a direction that intersects the direction in which the first connection portion 431 and the second connection portion 461 are arranged (the direction of the axis O). In addition, the second connection portion 461 is bent in the direction of the axis O and is arranged in parallel with the first connection portion 431 so that both can be connected.

Next, the configuration of a gas sensor 500 according to the fourth embodiment of the present invention will be described with reference to FIGS. Since the gas sensor 500 is the same as the second embodiment except that the connection terminal 330 and the connector terminal 360 in the second embodiment are changed to the connection terminal 530 and the connector terminal 560, respectively, the second embodiment. The same reference numerals are given to the same components, and detailed description thereof is omitted.
FIG. 12 is a cross-sectional view showing the configuration of the gas sensor 500, and corresponds to FIG. 8 of the second embodiment. In this figure, the connection terminal 530 includes a first connection portion 531 extending in the axis O direction, a plate-like intermediate portion 532 bent in an L shape from the first connection portion 531 and extending in the radial direction, and an intermediate portion 432. A distal end portion 533 that is bent in an L shape on the distal end side and extends in the direction of the axis O. The connection terminal 530 is formed in a substantially crank shape when viewed from the side, and the distal end portion 533 is the same as the distal end portion 333 of the second embodiment.
As shown in FIG. 12, the first connection portion 531 is bent in an L shape from the intermediate portion 532 and extends in the axis O direction, and is formed in an L shape on the rear end side of the first connection portion 531. It has the insertion piece 531g which is bent and extends in the radial direction. The insertion piece 531g protrudes to the rear end side from the rear end facing surface of the separator 40.

On the other hand, the connector terminals (five in this example) 560 are held by the insulator 307 while being separated from each other. The connector terminal 560 includes a plate-like intermediate portion 562 that extends in the radial direction and is embedded in the insulator 307, and an end portion that protrudes from the intermediate portion 562 toward the separator 40 and extends in parallel with the intermediate portion 562. A connecting portion 561 and a male portion 563 that protrudes radially outward from the insulator 307 while being connected to the intermediate portion 562 are provided. The male part 563 and the intermediate part 562 are the same as in the second embodiment. The insulator 307 is the same as that in the second embodiment.
As shown in FIG. 13, the second connection portion 561 is a main portion 561b that is connected to the intermediate portion 562 and extends in the radial direction, and is a separate member from the main portion 561b, and is located on the distal end side of the main portion 561b. It consists of the female part 561g which has the part 561b and the opposing part 561d laminated | stacked on the axis O direction and integrated by welding. The facing portion 561d has its rear end portion 561e stacked with the main portion 561b, and a portion closer to the axis O than the rear end portion 561e is crank-shaped and spaced apart in the axis O direction from the main portion 561b. It is parallel to. Similarly, a portion of the main portion 561b that is closer to the axis O than a portion where the main portion 561b is stacked with the rear end portion 561e is spaced from the main portion 561b in a crank shape and in the direction of the axis O.
Furthermore, the end portions of the main portion 561b and the facing portion 561d are bent so as to approach each other to form a pair of elastic portions 561a. In this way, the female portion 561g of the second connection portion 561 is formed in a clip shape, and the pair of elastic portions 561a are moved in the direction of the axis O (the directions approaching each other) by the elastic force between the main portion 561b and the facing portion 561d. It bends elastically to open and close.

  As shown in FIG. 13, in the fourth embodiment, the insertion piece 531g of the first connection portion 531 is inserted into the connector terminal 560 (the female portion 561g of the second connection portion 561), the first connection portion 531. This is different from the second embodiment in that the insertion piece 531g is sandwiched between the pair of elastic portions 631a. That is, the insertion piece 531g of the first connection portion 531 can be inserted in the radial direction between the pair of elastic portions 561a. Here, in the fourth embodiment, the insulator 307 and the main body 101 to which the insulator 307 is assembled are the same as those in the second embodiment. Therefore, as in the second embodiment, when the insulator 307 is inserted into the connector portion 103 from the opening 104 along the radial direction during assembly, the notch 307a abuts on the protrusion 101b, and the insulator 307 is positioned. At the same time, the first connection portion 531 is inserted (fitted) into the second connection portion 561 (the insertion piece 531g is fitted into the female portion 561g), presses the pair of elastic portions 561a, and the elastic portion 561a becomes the axis O. Bend in the direction. As a result, the first connection portion 531 and the second connection portion 561 are elastically connected, and the connection terminal 530 and the connector terminal 560 can be electrically connected without welding.

  In the fourth embodiment, the direction in which the elastic portion 561a bends is a direction that intersects the direction in which the first connection portion 531 and the second connection portion 561 are arranged (radial direction). Further, the first connection portion 531 is bent in the radial direction and arranged in parallel with the second connection portion 561 so that both can be connected.

  Next, the configuration of a gas sensor 600 according to the fifth embodiment of the present invention will be described with reference to FIGS. Since the gas sensor 600 is the same as the first embodiment except that the connection terminal 30 in the first embodiment is changed to the connection terminal 630, the same reference numerals are given to the same components as those in the first embodiment. Detailed description will be omitted. The connector terminal 60 is the same as that in the first embodiment.

FIG. 14 is a cross-sectional view showing the configuration of the gas sensor 500, and corresponds to FIG. 3 of the first embodiment. In this figure, the connection terminal 630 includes a first connection portion 631 extending in the direction of the axis O, a plate-like intermediate portion 632 bent in an L shape from the first connection portion 631 and extending in the radial direction, and an intermediate portion 632. And a distal end portion 633 that is bent in an L shape on the distal end side and extends in the direction of the axis O. The connection terminal 630 is formed in a substantially crank shape when viewed from the side, and the tip portion 633 is the same as the tip portion 33 of the first embodiment.
As shown in FIG. 15, the first connection portion 631 has a main portion 631b that is connected to the intermediate portion 632 and rises in the direction of the axis O, and an elastic portion 631a that bends from the rear end facing surface of the main portion 631b toward the front end. ing. The elastic portion 631a is located between the main portion 631b and the inner surface 42a of the insertion hole 42 of the separator 40, and is elastically bent in a direction approaching the main portion 631b. Of the connection terminals 630, the rear end side of the first connection portion 631 protrudes toward the rear end side from the rear end facing surface of the separator 40, and the other portions are held inside the insertion holes 42 of the separator 40. . The surface of the main portion 631b opposite to the elastic portion 631a is in contact with the inner surface 42a of the insertion hole 42, while the surface of the main portion 631b on the elastic portion 631a side is separated from the inner surface 42a of the insertion hole 42. ing.
On the other hand, the connector terminals (in this example, five) 60 are the same as in the first embodiment, and the insulator 107 that holds the connector terminals 60 is also the same as in the first embodiment. And the 2nd connection part 61 of the connector terminal 60 is bent in the L-shape toward the front-end | tip of the axis line O direction.

  As shown in FIG. 15, the fifth embodiment is different from the first embodiment in that the second connecting portion 61 is sandwiched between the elastic portion 631 a and the inner surface 42 a of the insertion hole 42 of the separator 40. . Here, in the fifth embodiment, the insulator 107 and the main body 101 to which the insulator 107 is assembled are the same as those in the first embodiment, and the separator assembly 120 is assembled in the same manner as in the first embodiment. The base portion 105 (the main body portion 101) is fitted into the rear cylinder 110e from the rear end side (see FIG. 6D). At this time, the second connection portion 61 of the connector terminal 60 is inserted between the elastic portion 631a of the first connection portion 631 and the inner surface 42a of the insertion hole 42, and the second connection portion 61 is held by the inner surface 42a. The elastic part 631a is pressed, and the elastic part 631a is bent in the radial direction. As a result, the first connection portion 631 and the second connection portion 61 are elastically connected, and the connection terminal 630 and the connector terminal 60 can be electrically connected without welding.

The inner surface 42a of the insertion hole 42 of the separator 40 corresponds to the “surface of the separator” in the claims.
In the fifth embodiment, the direction in which the elastic portion 631a bends is a direction that intersects the direction in which the first connection portion 631 and the second connection portion 61 are arranged (the direction of the axis O). Further, the second connecting portion 61 is bent in the direction of the axis O and is arranged in parallel with the first connecting portion 631 so that both can be connected.

Next, the configuration of a gas sensor 700 according to the sixth embodiment of the present invention will be described with reference to FIGS. 16 and 17. The gas sensor 700 is the same as the first embodiment except that the connection terminal 30 and the connector terminal 60 in the first embodiment are changed to the connection terminal 730 and the connector terminal 760, respectively. The same reference numerals are given to the same components, and detailed description thereof is omitted.
FIG. 16 is a cross-sectional view showing the configuration of the gas sensor 700 and corresponds to FIG. 3 of the first embodiment. In this figure, the connection terminal 730 includes a first connection portion 731 extending in the direction of the axis O, a plate-like intermediate portion 732 bent in an L shape from the first connection portion 731 and extending in the radial direction, and an intermediate portion 732. A distal end portion 733 that is bent in an L shape on the distal end side and extends in the direction of the axis O. The connection terminal 630 is formed in a substantially crank shape when viewed from the side, and the distal end portion 733 is the same as the distal end portion 33 of the first embodiment. The first connection portion 731 is bent in an L shape from the intermediate portion 732 and extends in the direction of the axis O, and is bent in an L shape on the rear end side of the first connection portion 731 and extends in the radial direction. It has a main portion 731b and an elastic portion 331a in which the radially outer end of the main portion 731b is folded back to the opposite side in the radial direction. The elastic portion 731a is elastically bent in a direction approaching the main portion 731b (front end side).
Of the connection terminal 730, the rear end side of the first connection portion 731 protrudes toward the rear end side from the rear end facing surface of the separator 40, and the other portions are held inside the insertion hole 42 of the separator 40. .
On the other hand, the connector terminals (five in this example) 760 have the same configuration as that of the first embodiment except for the second connection portion 761, and the insulator 107 that holds the connector terminal 60 is also the same as that of the first embodiment. is there. The second connection portion 761 of the connector terminal 760 extends in the radial direction in parallel with the intermediate portion 762 while contacting the inner surface 107a of the insulator 107, and the tip-facing surface (plate surface) of the second connection portion 761 is exposed. I'm out. The connector terminal 760 is insert-molded in the insulator 107, and the rear end facing surface (plate surface) of the second connecting portion 761 is embedded and fixed in the resin of the insulator 107.

  As shown in FIG. 17, the sixth embodiment is different from the first embodiment in that the second connecting portion 761 is sandwiched between the elastic portion 731 a and the inner surface 107 a of the insulator 107. Here, in the sixth embodiment, the insulator 107 and the main body 101 to which the insulator 107 is assembled are the same as those in the first embodiment, and the separator assembly 120 is assembled as in the first embodiment. The base body part 105 (the main body part 101) is fitted into the rear cylinder 110e from the rear end side. At this time, the second connection portion 761 of the connector terminal 760 is placed on the rear end side of the elastic portion 731a of the first connection portion 731 to press the elastic portion 761a, and the elastic portion 761a bends in the axis O direction. As a result, the first connection portion 731 and the second connection portion 761 are elastically connected, and the connection terminal 730 and the connector terminal 760 can be electrically connected without welding.

The inner surface 107a of the insulator 107 corresponds to the “inner surface of the base portion” in the claims.
Note that in the sixth embodiment, the direction in which the elastic portion 731a bends is a direction that intersects the direction in which the first connection portion 731 and the second connection portion 761 are arranged (radial direction). In addition, the first connection portion 731 is bent in the radial direction and arranged in parallel with the second connection portion 761 so that both can be connected.

  Next, with reference to FIG. 18, the structure of the gas sensor 800 which concerns on the 7th Embodiment of this invention is demonstrated. The gas sensor 800 is the same as that of the first embodiment except that the connection terminal 30, the connector terminal 60, and the insulator 107 in the first embodiment are changed to the connection terminal 830, the connector terminal 860, and the insulator 807, respectively. Therefore, the same components as those in the first embodiment are denoted by the same reference numerals, and detailed description thereof is omitted.

FIG. 18 is a cross-sectional view showing the configuration of the gas sensor 800, and corresponds to FIG. 3 of the first embodiment. In FIG. 18, only the configuration in the vicinity of the connection terminal 830 and the connector terminal 860 is shown, and the other components are omitted.
The connection terminal 830 includes a first connection portion 831 extending in the direction of the axis O, a plate-like intermediate portion 832 that is bent in an L shape from the first connection portion 831 and extends in the radial direction, and on the distal side from the intermediate portion 832. A distal end portion 833 that is bent in an L shape and extends in the direction of the axis O. The connection terminal 830 is formed in a substantially crank shape when viewed from the side, and the tip portion 833 is the same as the tip portion 33 of the first embodiment.
Of the connection terminals 830, the rear end portion of the first connection portion 831 protrudes toward the rear end side with respect to the rear end facing surface of the separator 40, and the other portions are held inside the insertion holes of the separator 40. .

On the other hand, the connector terminals (five in this example) 860 are held by the insulator 807 while being separated from each other. The connector terminal 860 includes a plate-shaped intermediate portion 862 that extends in the radial direction and is embedded in the insulator 807, a second connection portion 861 that is bent in an L shape from the intermediate portion 862 and extends in the axis O direction, and an insulator. And a male part (not shown) protruding radially outward from 807. The male part and the intermediate part 862 are the same as those in the first embodiment.
Here, the insulator 807 has an overhanging portion 807 b that protrudes toward the distal end side on the axis O side than the second connection portion 861. A side surface 807a of the overhang portion 807b extends in parallel with the main surface 861b while being separated from the main surface 861b. The second connection portion 861 includes a main surface 861b extending in the direction of the axis O and an elastic portion 861a that bends from the front end to the rear end of the main surface 861b. The elastic portion 861a faces the overhang portion 807b, and is elastically bent in a direction away from the main surface 861b (a direction approaching the overhang portion 807b).

  The seventh embodiment is different from the first embodiment in that the first connection portion 831 is sandwiched between the elastic portion 761a of the second connection portion 761 and the side surface 807a of the insulator 807. Here, in the seventh embodiment, the main body 101 to which the insulator 807 is assembled is the same as that of the first embodiment, and in the rear cylinder 110e to which the separator assembly 120 is assembled as in the first embodiment. Next, the base body part 105 (the main body part 101) is fitted from the rear end side. At this time, the first connection portion 831 is inserted (fitted) from the direction of the axis O between the second connection portion 861 and the side surface 807a of the insulator 807 (see the arrow in FIG. 18), and presses the elastic portion 861a. Then, the elastic portion 761a bends in the direction of the axis O. As a result, the first connection portion 831 and the second connection portion 861 are elastically connected, and the connection terminal 830 and the connector terminal 860 can be electrically connected without welding.

The side surface 807a of the insulator 807 corresponds to the “inner surface of the base portion” in the claims.
Note that in the seventh embodiment, the direction in which the elastic portion 861a bends is a direction that intersects the direction in which the first connection portion 831 and the second connection portion 861 are arranged (the direction of the axis O). In addition, the second connection portion 861 is bent in the direction of the axis O and is arranged in parallel with the first connection portion 831 so that both can be connected.

Next, with reference to FIG. 19, the structure of the gas sensor 900 which concerns on the 8th Embodiment of this invention is demonstrated. Since the gas sensor 900 is the same as the second embodiment except that the connection terminal 30 and the connector terminal 60 in the first embodiment are changed to the connection terminal 930 and the connector terminal 960, respectively, the second embodiment. The same reference numerals are given to the same components, and detailed description thereof is omitted.
FIG. 19 is a cross-sectional view illustrating a configuration of the gas sensor 900, and corresponds to FIG. 8 of the second embodiment. In FIG. 19, only the configuration in the vicinity of the connection terminal 930 and the connector terminal 960 is shown, and the other components are omitted.
The connection terminal 930 includes a first connection portion 931 that extends in the direction of the axis O, a plate-shaped intermediate portion 932 that is bent in an L shape from the first connection portion 931 and extends in the radial direction, and a distal end side from the intermediate portion 932. And a distal end portion 933 that is bent in an L shape and extends in the direction of the axis O. The connection terminal 930 is formed in a substantially crank shape when viewed from the side, and the distal end portion 933 is the same as the distal end portion 333 of the second embodiment.
As shown in FIG. 19, the first connection portion 531 is bent in an L shape from the intermediate portion 532 and extends in the axis O direction, and is formed in an L shape on the rear end side of the first connection portion 531. It is bent and extends in the radial direction. Further, in the connection terminal 930, the first connection portion 931 protrudes toward the rear end side from the surface facing the rear end of the separator 40, and other portions are held inside the insertion hole of the separator 40. Further, the distance between the first connecting portion 931 and the rear end facing surface 40b of the separator 40 is narrower than the height in the axial direction from the main portion 961b of the connector terminal 960 to the elastic portion 961a.

On the other hand, the connector terminals (five in this example) 960 are held by insulators (not shown) while being separated from each other. The connector terminal 960 includes a plate-like intermediate portion (not shown) that extends in the radial direction and is embedded in an insulator (not shown), and an end portion that projects from the intermediate portion toward the separator 40, and is in the radial direction. And a male part (not shown) projecting radially outward from the insulator.
The second connecting portion 961 includes a main portion 961b extending in the radial direction and connected to the intermediate portion, and an elastic portion 961a folded back from the end of the main portion 961b toward the intermediate portion. The elastic portion 861a is elastically bent in a direction away from the main surface 961b (that is, the rear end side).

  The eighth embodiment differs from the second embodiment in that the second connection portion 961 is inserted (fitted) between the first connection portion 931 and the rear end facing surface 40b of the separator 40. . Here, in the eighth embodiment, as in the second embodiment, the main body portion 101 (base portion 105) before the insulator is mounted is fitted in the rear cylinder 110e in which the separator assembly 120 is assembled. After that, the insulator 307 is inserted from the opening 104 into the connector 103 along the radial direction. At this time, the second connection portion 961 is inserted (fitted) from the radial direction between the first connection portion 931 and the rear end facing surface 40b of the separator 40 (see the arrow in FIG. 19), and the second connection portion. The elastic portion 961a of 961 is pressed by the tip-facing surface of the first connection portion 931, and the elastic portion 961a bends in the direction of the axis O. As a result, the first connection portion 831 and the second connection portion 861 are elastically connected, and the connection terminal 930 and the connector terminal 960 can be electrically connected without welding.

The rear-facing surface 40b of the separator 40 corresponds to the “separator surface” in the claims.
In the eighth embodiment, the direction in which the elastic portion 961a bends is a direction that intersects the direction in which the first connection portion 931 and the second connection portion 961 are arranged (radial direction). Further, the first connection portion 931 is bent in the radial direction and arranged in parallel with the second connection portion 961 so that both can be connected.

It goes without saying that the present invention is not limited to the above-described embodiment, but extends to various modifications and equivalents included in the spirit and scope of the present invention.
For example, instead of bending one of the first connection portion and the second connection portion and making both in parallel, the first connection portion and the second connection portion are bent together (for example, both of the first connection portion and the second connection portion are 45 Bend in the direction of the degree) and both may be parallel.

200 to 900 Gas sensor 10 Gas sensor element 11 Detection part 12 Rear end part of gas sensor element 12a Electrode pad 30 to 930 Connection terminal 31a to 961a Elastic part 31 to 931 First connection part 40 Separator 42 Separator insertion hole 42a, 42b Surface of separator 50 metal shell 60 to 960 connector terminal 61 to 961 second connection portion 101 main body portion 103 connector portion 105, 107, 307, 807 base portion 107a, 807a inner surface of base portion O axial direction

The gas sensor of the present invention includes a gas sensor element that extends in the axial direction, has a detection unit for detecting a specific gas component in the gas to be measured at its front end side, and has an electrode pad at its rear end side, A metal shell that surrounds the gas sensor element in the radial direction and holds the gas sensor, an insulating separator that arranges a rear end side of the gas sensor element in its insertion hole, and is inserted through the insertion hole into the axial direction. Can be inserted and removed by extending in the direction intersecting the axial direction from the main body part surrounding the separator and the connection terminal whose tip part is electrically connected to the electrode pad. A base portion made of an insulating material, and a connector portion, which is held by the connector portion, extends in a direction intersecting the axial direction, and passes through the connector portion. A gas sensor including a connector terminal, wherein a rear end portion of the connection terminal includes a first connection portion electrically connected to the connector terminal, and an end portion of the connector terminal on the separator side is the first connector portion. A second connecting portion electrically connected to the one connecting portion, wherein the first connecting portion and the second connecting portion are elastically connected , the connector terminal is made of a copper-based material, and the connecting terminal is ing of stainless steel or Ni-base alloy.

According to this gas sensor , the first connection portion and the second connection portion are elastically connected. Thereby, the detection output of a gas sensor element can be taken out to a connector terminal via a connection terminal. Therefore, in the side-by-side gas sensor, the connection terminal and the connector terminal can be electrically connected without welding, and productivity can be improved. In addition, the lead frame for welding the connection terminal and the connector terminal becomes unnecessary, and the number of parts is reduced.

Claims (12)

A gas sensor element that extends in the axial direction and has a detection unit for detecting a specific gas component in the gas to be measured on its front end side, and has an electrode pad on its rear end side,
A metal shell surrounding the gas sensor element in the radial direction and holding the gas sensor element;
An insulating separator that arranges the rear end side of the gas sensor element in its insertion hole;
A connection terminal that is inserted through the insertion hole and has its tip end portion extending in the axial direction and electrically connected to the electrode pad;
A base body having a main body that surrounds the separator, and a connector that extends from the main body in a direction intersecting the axial direction, and is connectable with an external device;
A connector terminal that is held by the connector portion, extends in a direction intersecting the axial direction, and passes through the inside and outside of the connector portion;
A gas sensor comprising:
A rear end portion of the connection terminal includes a first connection portion electrically connected to the connector terminal, and an end portion of the connector terminal on the separator side is electrically connected to the first connection portion. With two connections,
The first connection part and / or the second connection part are bent and arranged in parallel with each other;
One of the first connection part and the second connection part constitutes an insertion piece, the other constitutes a female part into which the insertion piece is inserted, and at least one of the insertion piece and the female part has the first An elastic part capable of bending in a direction intersecting with the direction in which the one connection part and the second connection part are arranged is formed,
The gas sensor in which the first connecting portion and the second connecting portion are elastically connected by the insertion piece being fitted to the female portion and the elastic portion being bent in the intersecting direction.   The gas sensor according to claim 1, wherein the second connection portion constitutes the insertion piece, and the first connection portion constitutes a female portion. The second connecting portion is bent and the insertion piece extends in the axial direction;
The gas sensor according to claim 2, wherein the female portion of the first connection portion is located in the insertion hole. A gas sensor element that extends in the axial direction and has a detection unit for detecting a specific gas component in the gas to be measured on its front end side, and has an electrode pad on its rear end side,
A metal shell surrounding the gas sensor element in the radial direction and holding the gas sensor;
An insulating separator that arranges the rear end side of the gas sensor element in its insertion hole;
A connection terminal that is inserted through the insertion hole and extends in the axial direction, and has its tip end electrically connected to the electrode pad;
A base portion made of an insulating material, having a main body portion surrounding the separator, and a connector portion that extends from the main body portion in a direction intersecting the axial direction and can be removed;
A connector terminal that is held by the connector portion, extends in a direction intersecting the axial direction, and passes through the inside and outside of the connector portion;
A gas sensor comprising:
A rear end portion of the connection terminal includes a first connection portion electrically connected to the connector terminal, and an end portion of the connector terminal on the separator side is electrically connected to the first connection portion. With two connections,
The first connection part and / or the second connection part are bent and arranged in parallel with each other;
At least one of the first connection part and the second connection part is formed with an elastic part capable of bending in a direction intersecting with the extending direction of the first connection part and the second connection part,
One connection portion of the first connection portion and the second connection portion is sandwiched between the surface of the separator or the inner surface of the base portion and the other connection portion, and the elastic portion is the intersection. A gas sensor in which the first connection portion and the second connection portion are elastically connected by bending in a direction to be performed.   The gas sensor according to claim 4, wherein the second connection portion constitutes the one connection portion, and the first connection portion constitutes the other connection portion. The second connection portion is bent and extends along the axial direction;
The gas sensor according to claim 5, wherein the second connection portion is disposed between an inner surface of the insertion hole of the separator and the first connection portion.   The gas sensor according to claim 1, wherein the connection terminal is made of a material that is more heat resistant than the connector terminal.   The gas sensor according to claim 1, wherein the connector terminal is made of a copper-based material, and the connection terminal is made of stainless steel or a Ni-based alloy.   The gas sensor according to claim 1, wherein the base portion is an insulator that can be accommodated by inserting itself into the main body portion, and further includes an insulator in which a part of the connector terminal is embedded.   The gas sensor according to claim 1, wherein a plurality of the connection terminals are held by the separator.   The gas sensor according to claim 1, wherein a plurality of the connector terminals are held on the base portion.   The gas sensor according to claim 1, wherein the elastic portion is a spring portion having one end portion which is a free end.

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