JP2012230076A - Sensor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a sensor capable of suppressing an imperfect contact and a disconnected state of a sensor element retained to a sleeve, with an electrode terminal by accurately disposing a connection terminal in a cylinder hole of a separator.SOLUTION: In a gas sensor, a sensor element 10 whose periphery is surrounded with a main body metal fitting is inserted into a sleeve 20. The rear end side of the sensor element 10 and a guide part 23 of the sleeve 20 are inserted into a cylinder hole 110 of a separator 100. Lead frames 40 including terminal main bodies 41 and terminal contacts 42 are disposed in a space between the inner wall of the cylinder hole 110 and the sensor element 10. The terminal main bodies 41 and the terminal contacts 42 are juxtaposed in the thickness direction of the sensor element 10 and are inclined toward the axial line of the sensor element 10 as the inside of the cylinder hole 110 is viewed from the tip end side of the axial direction of the sensor element 10 along the axial direction.

Description

  The present invention includes a cylindrical sleeve for holding a sensor element provided with an electrode terminal portion, and a cylindrical separator in which a connection terminal connected to the electrode terminal portion is disposed, and is connected to the electrode terminal portion. The present invention relates to a sensor that is electrically connected to a terminal to form a current path.

  Conventionally, a sensor is known in which a plate-like sensor element having a detection portion formed on the tip side directed toward a measurement object is assembled. Examples of such a sensor include a gas sensor such as a full-range air-fuel ratio sensor, an oxygen sensor, and a NOx sensor, and a temperature sensor that performs temperature detection.

  As this type of sensor, there is known a gas sensor in which a ceramic cylindrical sleeve (element-side insulator) holding a sensor element is assembled in a metal shell (housing) (see, for example, Patent Document 1). ). In this gas sensor, the sensor element is glass-sealed in a state of being inserted into the sleeve, and this sleeve is further held in the metal shell (housing). Furthermore, in order to take out the output from the sensor element, a plurality of connection terminals that are in contact with and electrically connected to the electrode terminal portions of the sensor element are provided. These connection terminals are provided on the rear end side of the sensor element, and are disposed in a cylindrical separator (atmosphere side insulator) that covers the electrode terminal portion, and the connection terminals are insulated from each other by the separator.

  More specifically, an electrode terminal portion of the sensor element and a connection terminal having a plate spring capable of elastic deformation (compression deformation) are arranged in the cylindrical hole of the separator. The sensor element is held inside the cylindrical hole of the separator by bringing the leaf spring of the connection terminal into contact with the electrode terminal portion of the sensor element. The connection terminal is provided with a protruding portion that protrudes from the leaf spring and is urged toward the electrode terminal portion in order to increase the contact pressure with the electrode terminal portion to improve the connection state.

JP 2001-188060 A JP 2007-17407 A

  As described above, when the connection terminal having a large contact pressure is arranged in the cylindrical hole of the separator (specifically, the opposed terminal arrangement portion) without the sensor element being arranged, the opposed connection terminals are connected to each other. May come into contact. And when the projection part mentioned above is provided in each connection terminal, the projection parts which oppose may contact (interference). Thus, in the state which protrusion part contacted, there existed a possibility that it might be in an unstable state because the contact area was too small. In addition, due to the influence of the urging force generated by the elastic deformation, the protrusions may slide on the surfaces (curved surface portions), and the arrangement positions of the connecting terminals facing each other may be shifted.

  Further, when the sensor element is arranged in the element arrangement portion of the separator in a state where such a displacement of the connection terminal occurs, the connection terminal in the misalignment state receives an external force from the sensor element and further deforms abnormally. was there. Further, as in Patent Document 2, a gas sensor is known in which a sleeve is provided with a guide portion that restricts movement in the axial direction and width direction of a sensor element. In the gas sensor disclosed in Patent Document 2, not only the electrode terminal portion and the connection terminal of the sensor element but also the guide portion is disposed in the cylindrical hole of the separator, and the connection terminal in the misaligned state receives an external force from the guide portion. In some cases, abnormal deformation occurred.

  If the connection terminal is deformed abnormally, there is a risk of causing a contact failure (or disconnection state) between the connection terminal and the sensor element (electrode terminal portion). For this reason, in the past, an operator has positioned and arranged the connection terminals accurately at the terminal arrangement portions facing each other, but the skill of the operator is required.

  The present invention has been made in order to solve the above-mentioned problems, and the connection terminal is accurately arranged in the cylindrical hole of the separator so that the contact with the electrode terminal portion of the sensor element held by the sleeve is poor or disconnected. It aims at providing the sensor which can suppress this.

  The sensor according to one aspect of the present invention has a plate shape extending in the axial direction, one end side is directed to the measurement object, and an electrode terminal portion is formed on a surface in the thickness direction orthogonal to the axial direction on the other end side. The sensor element, a metal shell surrounding the sensor element so that one end side and the other end side of the sensor element protrude in the axial direction, and the sensor element is inserted into its own shaft hole, A cylindrical main body portion disposed between the sensor element and the metal shell, and stands upright from the main body portion so as to protrude to the other end side in the axial direction, and are orthogonal to the axial direction and the thickness direction, respectively. A sleeve having a guide portion for restricting movement of the sensor element in the width direction, a second end side of the sensor element, and a cylindrical hole for inserting the guide portion, and a cylindrical shape made of an insulating material A separator and the separator A plate-like terminal main body extending in the axial direction and connected to one end of the terminal main body and extending to bend or curve toward the other end A connection terminal having a terminal contact portion that contacts the electrode terminal portion, and when the connection terminal is viewed from the one end side in the axial direction along the axial direction, the terminal body The portion and the terminal contact portion are arranged so as to be aligned along the thickness direction, and are inclined toward the axis.

  According to the sensor of one aspect of the present invention, when the terminal main body portion and the terminal contact portion of the connection terminal are viewed in the cylinder hole along the axial direction from one end side in the axial direction of the sensor element, The sensor elements are arranged along the thickness direction and are inclined toward the axis of the sensor element. That is, the opposing connection terminals are each arranged toward the center of the separator. Thereby, the effect | action that the terminal contact parts which oppose in the cylinder hole of a separator mutually contact (interference) is suppressed, and a connection terminal can be arrange | positioned in a separator correctly. Therefore, even if a sensor element is arrange | positioned in the cylinder hole of a separator, it can prevent that a connection terminal deform | transforms. Further, even when the guide portion of the sleeve is disposed in the cylindrical hole of the separator, the connection terminal can be prevented from being deformed. As a result, it is possible to prevent contact failure and disconnection with the electrode terminal portion of the sensor element.

  Further, in the sensor according to one aspect of the present invention, the separator includes a positioning portion that contacts a surface of the terminal main body opposite to the side where the terminal contact portion extends, in the cylindrical hole, and the positioning The part may be an inclined surface facing the axis.

  Thus, by providing the separator with a positioning portion that is an inclined surface facing the axis of the sensor element, the terminal main body portion and the terminal contact portion of the connection terminal are simply disposed in the cylindrical hole of the separator. The sensor elements are arranged along the thickness direction of the sensor element and can be inclined toward the axis of the sensor element. Therefore, it is possible to accurately arrange the connection terminal in the cylindrical hole of the separator without complicating the configuration of the sensor.

1 is a longitudinal sectional view of a gas sensor 1. FIG. 1 is a perspective view showing an external appearance of a sensor element 10. FIG. It is a perspective view which shows the external appearance of the separator 100. 3 is a plan view seen from the front end side of the separator 100. FIG. 2 is a perspective view showing an appearance of a lead frame 40. FIG. 2 is a front view of a set of lead frames 40. FIG. FIG. 10 is a perspective view showing an appearance of a lower assembly 99. It is the top view seen from the front end side of the separator 100 in which the sensor element 10 and the sleeve 20 were inserted.

  Embodiments of a sensor embodying the present invention will be described below with reference to the drawings. First, the structure of the gas sensor 1 as an example will be described with reference to FIG. In FIG. 1, the axis O direction (indicated by a one-dot chain line) of the gas sensor 1 is shown as a vertical direction, and the front end portion 11 side of the sensor element 10 held inside is the front end side of the gas sensor 1 and the rear end portion 12 side. The description will be made as the rear end side of the gas sensor 1.

  A gas sensor 1 illustrated in FIG. 1 is attached to an exhaust pipe (not shown) of an automobile. The gas sensor 1 is an oxygen sensor that outputs a signal corresponding to the oxygen concentration in the exhaust gas when the tip 11 of the sensor element 10 held inside is exposed to the exhaust gas flowing through the exhaust pipe.

  The gas sensor 1 includes a sensor element 10, a metal shell 50, a sleeve 20, a separator 100, and four lead frames 40. The sensor element 10 is a narrow and plate-shaped (strip-shaped) element extending in the direction of the axis O (in FIG. 1, the horizontal direction on the paper is shown as the thickness direction, and the front and back direction on the paper is shown as the width direction). The metal shell 50 is a metal cylindrical body in which a screw portion 51 for fixing to the exhaust pipe is formed on the outer surface. The sleeve 20 is a ceramic cylindrical body disposed so as to surround the sensor element 10 (specifically, the radial periphery). The separator 100 is an alumina cylindrical body disposed in a state of surrounding the periphery of the rear end portion of the sensor element 10. The four lead frames 40 are connection terminals arranged between the sensor element 10 and the inner peripheral wall of the separator 100.

  On the distal end portion 11 side of the sensor element 10, a detection portion directed to the gas to be measured is formed. In order to protect the detector from poisoning by exhaust gas, the protective layer 9 is covered so as to cover the outer surface. Four electrode terminal portions 31 to 34 to be described later are formed on the rear end portion 12 side of the sensor element 10. The four lead frames 40 are electrically connected to the four electrode terminal portions 31 to 34 by being disposed in the cylindrical holes 110 of the separator 100. Each lead frame 40 is also electrically connected to a lead wire 66 disposed inside the gas sensor 1 from the outside. Thereby, a current path of a current flowing between the external device to which each lead wire 66 is connected and the electrode terminal portions 31 to 34 is formed.

  The configuration of the sensor element 10 will be described with reference to FIG. In addition, the sensor element 10 is a well-known thing, A schematic structure is shown below. As shown in FIG. 2, the sensor element 10 includes an element portion 18 formed in a plate shape extending in the axis O direction (left and right direction in FIG. 2) and a heater formed in a plate shape extending in the axis O direction. 19 are laminated to form a plate shape having a rectangular axial cross section.

  The element part 18 is provided with a detection part in which a porous electrode (detection electrode and reference electrode) is arranged at the tip part 11 (specifically, the tip side of the solid electrolyte substrate). This solid electrolyte substrate is made of zirconia in which yttria is dissolved as a stabilizer, and the porous electrode is mainly made of Pt. The heater 19 is formed by sandwiching a heating resistor pattern mainly composed of Pt between insulating substrates mainly composed of alumina. In the present embodiment, the entire surface of the tip 11 including the surface of the electrode exposed to the exhaust gas in the sensor element 10 is covered with the protective layer 9 (see FIG. 1).

  Of the outer surface of the sensor element 10, the first side surfaces 14 and 15 are the front and back surfaces and the second side surfaces 16 and 17 are the left and right surfaces. In other words, the first side surfaces 14 and 15 are both side surfaces facing the thickness direction orthogonal to the axial direction of the sensor element 10, and the second side surfaces 16 and 17 are both side surfaces facing the width direction of the sensor element 10. Four electrode terminal portions 31 to 34 are formed on the first side surfaces 14 and 15 of the rear end portion 12. Specifically, two electrode terminal portions 31 and 32 are formed on the rear end side (right side in FIG. 2) of the first side surface 14, and two electrode terminal portions 33 and 34 are formed on the rear end side of the first side surface 15. Is formed. The electrode terminal portions 31 and 32 are formed in the element portion 18, one of which is connected to the detection electrode, and the other electrode terminal portion is connected to the reference electrode. The electrode terminal portions 33 and 34 are formed in the heater 19 and are respectively connected to both ends of the heating resistor pattern via vias (not shown) that traverse the heater 19 in the thickness direction.

  Returning to FIG. 1, the metal shell 50 includes a cylindrical hole 59 that penetrates in the direction of the axis O, and a shelf 57 that protrudes radially inward of the cylindrical hole 59 and faces the distal end portion 11 side of the sensor element 10. The shelf 57 is formed as an inwardly tapered surface having an inclination with respect to a plane perpendicular to the axis O direction. The metal shell 50 is configured to hold the sensor element 10 inserted through the cylindrical hole 59. Specifically, the front end portion 11 (that is, the detection portion) protrudes outside the front end side of the cylindrical hole 59, and the rear end portion 12 (that is, the electrode terminal portions 31 to 34) extends outside the rear end side of the cylindrical hole 59. The sensor element 10 is fixed inside the metal shell 50 so as to protrude.

  Inside the cylindrical hole 59 of the metal shell 50, the annular ceramic holder 56, the powder filling layers 53 and 58, and the sleeve 20 are arranged in this order from the front end side of the gas sensor 1 so as to surround the circumference of the sensor element 10 in the radial direction. It is laminated toward the end side. A caulking ring 62 is disposed between the sleeve 20 and the rear end portion 54 of the metal shell 50. A metal holder 79 is disposed between the ceramic holder 56 and the shelf 57 of the metal shell 50. The rear end portion 54 of the metal shell 50 is crimped so as to press the sleeve 20 against the distal end side of the gas sensor 1 via the crimping ring 62.

  The sleeve 20 presses the powder filling layer 58 toward the tip side and is accommodated inside the metal shell 50. The sleeve 20 has a main body portion 21 formed in a multistage cylindrical shape, and the main body portion 21 is provided with a shaft hole 22 through which the sensor element 10 is inserted. Furthermore, a pair of guide portions 23 extending toward the rear end along the axial direction of the sleeve 20 are provided on the rear end side of the main body portion 21 (see FIG. 7). Element grooves 25 that are continuous from the inner periphery of the shaft hole 22 are provided on the inner side surface of each guide portion 23 in order to guide both ends of the sensor element 10 in the width direction (both side edges in the thickness direction).

  In a state where the sleeve 20 is housed on the rear end side of the metal shell 50, the rear end portion 54 of the metal shell 50 is bent inward and crimped, and the sleeve 20 is attached to the metal shell 50 via the crimping ring 62. It is pressed toward the tip side. The gap around the sensor element 10 is filled with the powder filling layers 53 and 58 compressed and deformed by the pressing, and the sensor element 10 is hermetically held and fixed in the metal shell 50. In the state where the sleeve 20 is accommodated in the metal shell 50, the external terminals 31 to 34 provided on the rear end portion 12 of the sensor element 10 are exposed from the gap between the pair of guide portions 23 to the rear end side. .

  Returning to FIG. 1, the outer periphery of the metal shell 50 on the front end side (lower side in FIG. 1) covers the front end portion 11 of the sensor element 10 and has a plurality of holes (for example, stainless steel). These protectors (external protector 80 and internal protector 90) are attached by welding or the like. The external protector 80 and the internal protector 90 cover the detection unit provided at the tip 11 of the sensor element 10.

  On the other hand, an outer cylinder 65 is fixed to the outer periphery of the rear end side (upper side in FIG. 1) of the metal shell 50. Further, the separator 100 is disposed in the outer cylinder 65 so that the periphery is surrounded by the outer cylinder 65. The separator 100 is disposed on the radially outer side of the rear end portion 12 of the sensor element 10 (that is, around the electrode terminal portions 31 to 34). Details of the separator 100 will be described later.

  Further, a grommet 75 that closes the rear end side opening of the outer cylinder 65 is disposed on the rear end side of the separator 100. The grommet 75 has four lead wire insertion holes 76 for taking out the four lead wires 66 electrically connected to the electrode terminal portions 31 to 34 to the outside (two of them are shown in FIG. 1). ) Is formed.

  Next, the configuration of the separator 100 will be described with reference to FIGS. 3 and 4. FIG. 4 shows a state in which the separator 100 in which the lead frame 40 is disposed is viewed from the front end side along the axis O direction. In the following description, the upper direction, the lower direction, the left direction, and the right direction in FIG. 4 are defined as the front direction, the rear direction, the left direction, and the right direction of the separator 100, respectively.

  As shown in FIGS. 3 and 4, the separator 100 includes a cylindrical hole 110 that penetrates in the direction of the axis O, and a flange portion 101 that protrudes radially outward from the outer surface. The separator 100 is disposed inside the outer cylinder 65 by the flange portion 101 coming into contact with the support member 64 provided inside the outer cylinder 65 (see FIG. 1). The support member 64 is a substantially cylindrical metal fitting along the inner periphery of the outer cylinder 65.

  In the present embodiment, the sensor element 10 is disposed substantially at the center of the cylindrical hole 110 when the separator 100 is viewed from the distal end side along the axis O direction. At this time, the axis of the sensor element 10 substantially coincides with the center of the cross section (that is, the axis O) of the separator 100 (specifically, the cylinder hole 110), and the width direction of the sensor element 10 coincides with the left-right direction of the separator 100. (See FIG. 8). A pair of rib portions 111 projecting inward are formed on two inner wall surfaces of the cylindrical hole 110 facing the first side surfaces 14 and 15 (see FIG. 2) of the sensor element 10. Each rib portion 111 forms a boundary between two frame placement portions 120 for individually placing the two lead frames 40 in an electrically insulated state. That is, the four frame placement portions 120 are formed in the cylindrical hole 110 by the rib portions 111.

  Specifically, the two frame placement portions 120 formed on the left and right sides of the rib portion 111 on the front side (upper side in FIG. 4) face the first side surface 14 of the sensor element 10 placed in the cylindrical hole 110. Then, an arrangement region of the two lead frames 40 connected to the electrode terminal portions 31 and 32 is formed. The two frame placement portions 120 formed on the left and right sides of the rib portion 111 on the rear side (the lower side in FIG. 4) face the first side surface 15 of the sensor element 10 placed in the cylindrical hole 110, respectively. An arrangement region of two lead frames 40 connected to the terminal portions 33 and 34 is formed.

  In each frame placement portion 120, a positioning portion 121 is formed by a part of the inner peripheral wall of the cylindrical hole 110 extending in parallel with the axis of the separator 100. Each positioning part 121 is an inclined surface formed so as to face the center of the separator 100 (that is, the axis O) when the separator 100 is viewed from the front end side along the axis O direction.

  Specifically, in the two frame placement portions 120 formed on the left and right sides of the front rib portion 111, the positioning portions 121 provided on the left and right sides (left lower direction in FIG. 4) and right rear (in FIG. 4), respectively. It is slightly inclined to the lower right). In the two frame placement portions 120 formed on the left and right sides of the rear rib portion 111, the positioning portions 121 provided on each of them are on the left front (upper left direction in FIG. 4) and on the right front (upper right direction in FIG. 4). Each is slightly inclined.

  On the front end surface of the separator 100, four locking groove portions 122 formed in a form connected to the respective frame placement portions 120 are formed. Each locking groove 122 is substantially L-shaped and extends radially outward from between the rib portion 111 and the positioning portion 121 in each frame placement portion 120 when the separator 100 is viewed from the front end side along the axis O direction. Are formed respectively. Each locking groove 122 can be provided with a frame locking portion 46 (see FIG. 4), which will be described later.

  Further, in the cylindrical hole 110, two inner wall surfaces facing the second side surfaces 16 and 17 (see FIG. 2) of the sensor element 10 are respectively circular when the separator 100 is viewed from the front end side along the axis O direction. A pair of element support portions 130 are formed in an arc shape. Each element support portion 130 is a wall portion that positions the guide portion 23 at a position along the end surface in the width direction of the sensor element 10 disposed in the cylindrical hole 110.

  The configuration of the lead frame 40 will be described with reference to FIGS. 5 and 6. In FIG. 6, two lead frames 40 that are symmetric are shown. However, each part has the same shape except for left-right symmetry, and will be described below using the same reference numerals. As shown in FIG. 5 and FIG. 6, each lead frame 40 includes a terminal main body portion 41 made of a long plate-like member extending in the direction of the axis O, and from the front end side to the rear end side of the terminal main body portion 41. And a terminal contact portion 42 extending to bend (or bend). The terminal contact portion 42 is formed with a protrusion 43 that contacts one of the electrode terminal portions 31 to 34 of the sensor element 10 on the surface opposite to the surface facing the terminal main body portion 41.

  The terminal contact portion 42 is bent inward in the radial direction at the connection side end portion 44 connected to the tip of the terminal main body portion 41 and is turned to the rear end side. The connection side end portion 44 is configured to be elastically deformed in response to an external force, and in the free state of the lead frame 40 (a state in which no external force is applied), an open side end that is a rear end portion of the terminal contact portion 42. The portion 45 is held away from the terminal body portion 41. The protrusion 43 is pressed against the sensor element 10 by the pressing force generated by the elastic deformation of the connection side end 44.

  On the distal end side of the terminal main body 41, a frame locking portion 46 formed so as to be disposed in the locking groove 122 (see FIG. 3) of the separator 100 is provided. The frame locking portion 46 extends from the front end side surface of the terminal main body portion 41 in a direction perpendicular to the plate surface and is bent so as to have a portion parallel to the plate surface. Further, a protruding piece 47 is provided that extends laterally from the terminal main body 41 and slightly curves toward the terminal contact portion 42 along the extending direction. At the rear end side of the terminal main body 41, a base portion 48 is provided to fix the lead wire 66 by caulking and to electrically connect the lead wire (stranded wire) 66A in the lead wire 66 by caulking. ing.

  Next, a method for manufacturing the gas sensor 1 will be described. In the manufacturing process of the gas sensor 1, first, the lower assembly 99 is manufactured. Specifically, the sensor element 10 is inserted into the metal holder 79, and further, the ceramic holder 56 and the powder filling layer 53 are disposed in the gap between the metal holder 79 and the sensor element 10, and the powder filling layer 53 is compressed. The sensor element 10 is fixed to the metal holder 79. Next, the metal holder 79 to which the sensor element 10 is fixed is engaged with the shelf 57 of the metal shell 50, and then the powder filling layer 58, the sleeve 20, and the caulking ring in the gap between the sensor element 10 and the metal shell 50. The sensor element 10 is fixed to the metal shell 50 by arranging 62 in order from the front end side and caulking the rear end portion 54 of the metal shell 50. Thereby, the lower assembly 99 shown in FIG. 7 is completed. The external protector 80 and the internal protector 90 are welded to the metal shell 50 before the sensor element 10 is assembled to the metal shell 50.

  On the other hand, an upper assembly is manufactured using the separator 100, the lead frame 40, and the like. First, the lead wire 66 is inserted into the lead wire insertion hole 76 of the grommet 75 and the cylindrical hole 110 of the separator 100 from the rear end side toward the front end side. The separator 100 is already inserted into the support member 64. Thereafter, the core wire on the distal end side of the lead wire 66 is crimped to the base portion 48 of the lead frame 40. In this state, each lead frame 40 moves from the distal end side of the cylindrical hole 110 to the frame placement portion 120 so that the back surface (the surface opposite to the terminal contact portion 42) of the terminal main body portion 41 moves along the positioning portion 121. Inserted into. At this time, the lead frame 40 is arranged in the frame arrangement portion 120 by the frame engagement portion 46 being engaged in the engagement groove portion 122.

  As shown in FIG. 4, when the four lead frames 40 are arranged in the corresponding frame arrangement portions 120, the pair of lead frames 40 are arranged in the front-rear direction, and the protrusions 43 are arranged in the front-rear direction. Opposite the direction. However, in a state where the lead frame 40 is arranged in the frame arrangement part 120, the back surface of the terminal main body part 41 is supported in surface contact with the positioning part 121. Therefore, each lead frame 40 is held in a manner slightly inclined toward the center of the separator 100 (that is, the axis O) according to the direction in which the positioning portion 121 is formed.

  Thereafter, the separator 100 and the grommet 75 are inserted into the outer cylinder 65, and the outer cylinder 65 is crimped. Thereby, the support member 64 supports the separator 100, and the outer cylinder 65 holds the separator 100. Thereby, the upper assembly is completed.

  Next, the lower assembly 99 and the upper assembly are assembled. Specifically, the front end side of the outer cylinder 65 is externally fitted to the rear end side of the metal shell 50. As a result, the rear end portion 12 of the sensor element 10 held by the lower assembly 99 and the guide portion 23 of the sleeve 20 are inserted into the cylindrical hole 110 of the separator 100 held by the upper assembly. At this time, the sensor element 10 is formed in the cylindrical hole 110 so that the pair of guide portions 23 protruding from the rear end side of the sleeve 20 moves along the pair of element support portions 130 formed on the separator 100. Inserted from the tip side. That is, the sleeve 20 (and thus the sensor element 10) is guided into the cylindrical hole 110 while the guide portion 23 restricts the movement of the sensor element 10 in the axial direction and the width direction.

  As shown in FIG. 8, the guide portions 23 are positioned at positions along the second side surfaces 16 and 17 of the sensor element 10 by the pair of element support portions 130 in the cylindrical hole 110. As a result, the sensor element 10 is supported in the cylinder hole 110 at an appropriate position (that is, the center of the cross section of the cylinder hole 110) and in an appropriate direction (the width direction of the sensor element 10 is parallel to the left-right direction of the separator 100). The When the sensor element 10 is disposed at an appropriate position and orientation of the cylindrical hole 110, the sensor element 10 is properly sandwiched in the thickness direction by the two pairs of the lead frames 40 disposed opposite to each other in the front-rear direction of the separator 100. . The protrusions 43 of the four lead frames 40 are in contact with and electrically connected to the corresponding electrode terminal portions 31 to 34, respectively.

  Thereafter, the gas sensor 1 is completed by crimping the front end side of the outer cylinder 65 and the rear end side where the grommet 75 is disposed, and further laser welding the front end side of the outer cylinder 65 to the metal shell 50.

  As described above, in the gas sensor 1 of the present embodiment, the sensor element 10 surrounded by the metal shell 50 is inserted into the main body 21 of the sleeve 20. The sleeve 20 has a guide portion 23 that restricts movement of the sleeve 20 in the axial direction and the width direction of the sensor element 10. The rear end side of the sensor element 10 and the guide portion 23 of the sleeve 20 are inserted into the cylindrical hole 110 of the separator 100. A terminal main body 41 of the lead frame 40 is disposed between the inner wall of the cylindrical hole 110 and the sensor element 10. The lead frame 40 has a terminal contact portion 42 that extends from the terminal main body portion 41 so as to bend or curve and contacts the electrode terminal portions 31 to 34.

  The terminal main body portion 41 and the terminal contact portion 42 have a thickness of the sensor element 10 when the inside of the cylindrical hole 110 is viewed along the axial direction from the tip end side in the axial direction (that is, the axis O direction) of the sensor element 10. They are arranged along the direction and are inclined toward the axis of the sensor element 10 (that is, the axis O). That is, the opposing lead frames 40 are respectively arranged toward the center of the separator 100. Thereby, the effect | action which the terminal contact parts 42 which oppose in the cylinder hole 110 of the separator 100 mutually contacts (interference) is suppressed, and the lead frame 40 can be arrange | positioned in the separator 100 correctly. Therefore, even if the sensor element 10 is disposed in the cylindrical hole 110 of the separator 100, the lead frame 40 can be prevented from being deformed. Further, even if the guide portion 23 of the sleeve 20 is disposed in the cylindrical hole 110 of the separator 100, the lead frame 40 can be prevented from being deformed. As a result, contact failure with the electrode terminal portions 31 to 34 of the sensor element 10 and disconnection can be prevented.

  In addition, the separator 100 includes a positioning portion 121 that contacts the surface of the terminal main body 41 opposite to the side where the terminal contact portion 42 extends, and the positioning portion 121 is inclined toward the axis O. Surface. As described above, by providing the separator 100 with the positioning portion 121 that is an inclined surface facing the axis O, the terminal main body portion 41 of the lead frame 40 and the terminal contact portion 42 can be simply disposed in the cylindrical hole 110 of the separator 100. The terminal contact portions 42 are arranged so as to be aligned along the thickness direction of the sensor element 10 and can be inclined toward the axis of the sensor element 10. Therefore, the lead frame 40 can be accurately arranged in the cylindrical hole 110 of the separator 100 without complicating the configuration of the gas sensor 1.

  By the way, in the said embodiment, the gas sensor 1 corresponds to the "sensor" of this invention. The lead frame 40 corresponds to the “connection terminal” of the present invention. The present invention is not limited to the embodiment described in detail above, and various modifications may be made without departing from the scope of the present invention.

  In the above embodiment, the lead frame 40 (the terminal main body portion 41 and the terminal contact portion 42) disposed in the separator 100 is used as the sensor element by making the positioning portion 121 an inclined surface facing the opening cross-sectional center side of the cylindrical hole 110. It is inclined toward 10 axes. However, the configuration for inclining the lead frame 40 disposed in the separator 100 toward the axis of the sensor element 10 is not limited to this. For example, the positioning portion 121 formed in parallel with the width direction of the sensor element 10 may be provided with a protrusion for inclining the lead frame 40 disposed in the separator 100 toward the axis of the sensor element 10.

  In the above-described embodiment, the four lead frames 40 are disposed in the separator 100 in correspondence with the four electrode terminal portions 31 to 34 provided in the sensor element 10, but the electrode terminal portions 31 to 34 are arranged. The quantity of lead frames 40 can be changed as appropriate. In this case, the frame placement part 120, the positioning part 121, and the locking groove part 122 may be provided corresponding to the lead frames 40 placed in the separator 100, respectively.

  Moreover, in the said embodiment, the gas sensor 1 which is an oxygen sensor was illustrated as one aspect | mode of the sensor which concerns on this invention. The present invention includes a cylindrical sleeve for holding a sensor element provided with an electrode terminal portion, and a cylindrical separator in which a connection terminal connected to the electrode terminal portion is disposed, and is connected to the electrode terminal portion. Any sensor that is electrically connected to a terminal to form a current path can be applied. For example, the present invention may be applied to a gas sensor such as a full-range air-fuel ratio sensor or a NOx sensor, or a temperature sensor that detects temperature.

DESCRIPTION OF SYMBOLS 1 Gas sensor 10 Sensor element 11 Front-end | tip part 12 Rear-end part 14,15 1st side surface 16,17 2nd side surface 20 Sleeve 21 Main body part 22 Shaft hole 23 Guide part 31, 32 Electrode terminal part 33, 34 Electrode terminal part 40 Lead frame 41 Terminal body portion 42 Terminal contact portion 50 Metal shell 100 Separator 110 Tube hole 120 Frame placement portion 121 Positioning portion 122 Locking groove portion 130 Element support portion

Claims (2)

A sensor element having a plate shape extending in the axial direction, one end side directed toward the measurement object, and an electrode terminal portion formed on a surface in the thickness direction perpendicular to the axial direction on the other end side;
A metal shell surrounding the sensor element so that one end side and the other end side of the sensor element protrude in the axial direction;
The sensor element is inserted into its own shaft hole, and has a cylindrical main body disposed between the sensor element and the metal shell, and protrudes from the main body to the other end side in the axial direction. And a guide part for restricting movement of the sensor element in the width direction orthogonal to the axial direction and the thickness direction, and a sleeve,
A cylindrical separator having a cylindrical hole for inserting the other end side of the sensor element and the guide portion, and made of an insulating material;
A plate-like terminal main body portion disposed in the cylindrical hole of the separator and extending in the axial direction, connected to one end side of the terminal main body portion, and extended to bend or curve toward the other end side. A contact terminal having a terminal contact portion that contacts the electrode terminal portion,
The connection terminal is arranged so that the terminal body portion and the terminal contact portion are aligned in the thickness direction when the inside of the cylindrical hole is viewed along the axial direction from one end side in the axial direction. And the sensor is inclined toward the axis. The separator includes a positioning portion in the cylindrical hole that contacts the surface of the terminal main body portion opposite to the side on which the terminal contact portion extends,
The sensor according to claim 1, wherein the positioning portion is an inclined surface facing the axis.

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