JP2018013474A - Gas sensor and manufacturing method of gas sensor - Google Patents

Abstract

An object of the present invention is to provide a gas sensor capable of suppressing a decrease in elasticity of a terminal fitting due to heat transfer from a separator and reliably connecting an electrode pad of a sensor element to the terminal fitting, and a method of manufacturing the same. A gas sensor including a sensor element having an electrode pad, a terminal fitting, and a separator, wherein the terminal fitting includes a lead wire connecting portion, a main body portion, and a main body portion. And a resilient portion 22c connected to the tip of the protruding piece portion and connected to the electrode pad. The protruding piece portion 22 is located on the opposite side of the main body portion and the protruding piece portion from the resilient portion. The main surface 21a and the sub surface 22a are respectively defined as surfaces, and the area S1 of the first opposing surface F1 of the main surface opposing the insertion hole 90h of the separator is the second opposing surface F2 of the sub surface opposing the insertion hole. , And at least a part of the second opposing surface is in contact with the inner peripheral surface of the separator forming the insertion hole, and the first opposing surface is separated from the inner peripheral surface. [Selection diagram] FIG.

Description

  The present invention relates to a gas sensor including a sensor element for detecting the concentration of a gas to be detected and a method for manufacturing the gas sensor.

As a gas sensor for detecting the concentration of oxygen or NOx in exhaust gas of an automobile or the like, one having a plate-like sensor element using a solid electrolyte is known.
As this type of gas sensor, a plurality of electrode pads are provided on the outer surface on the rear end side of the plate-like sensor element, and a terminal metal fitting is electrically contacted to each of the electrode pads to output a sensor output signal from the sensor element to the outside. What takes out or supplies electric power to the heater laminated | stacked on the sensor element is widely used (patent document 1).
Here, as shown in FIG. 19, the terminal fitting 200 has, for example, a U-shaped strip shape obtained by cutting and raising a metal plate, and the leading end of the main surface 200a is folded back toward the sensor element (not shown). Thus, a folded portion 202 is formed which is elastically connected to the electrode pad of the sensor element. On the other hand, a caulking portion 204 for caulking the tip of the lead wire is formed on the rear end side of the terminal fitting 200. The terminal fitting 200 itself is inserted and held in the insertion hole 1300 h of the ceramic separator 1300.

Japanese Patent Laying-Open No. 2015-129727 (FIG. 5)

By the way, when the folding | turning part 202 contact | connects the electrode pad of a sensor element, the reaction force F is received to radial direction outward from an electrode pad. Therefore, in order to overcome this reaction force F, the main surface 200a of the terminal fitting 200 needs to be in firm surface contact with the wall surface of the insertion hole 1300h of the separator 1300.
However, when the separator 1300 receives exhaust gas or the like and becomes high temperature, heat is transferred from the separator 1300 to the terminal fitting 200 through the main surface 200a, and the terminal fitting 200 may also become high temperature. Then, the folded portion 202 of the terminal metal fitting 200 is softened or creep-deformed and the elasticity is lowered, and the reliability of the electrical connection with the sensor element may be lowered.
Therefore, the present invention provides a gas sensor and a gas sensor manufacturing method that can suppress a decrease in elasticity of the terminal fitting due to heat transfer from the separator and can reliably connect the electrode pad of the sensor element and the terminal fitting. For the purpose.

  In order to solve the above problems, the gas sensor of the present invention has a plate shape extending in the axial direction, and has a sensor element having an electrode pad on the outer surface on the rear end side, and extends in the axial direction, and is electrically connected to the electrode pad. A terminal fitting to be connected; a cylindrical separator having an insertion hole for holding the terminal fitting; and a rear end side of the sensor element; and a rear end of the separator connected to a rear end side of the terminal fitting A lead wire pulled out to the side, wherein the terminal fitting is connected to the lead wire connecting portion connected to the lead wire, and a main body extending in the axial direction connected to the distal end side of the lead wire connecting portion A protrusion piece projecting in a direction intersecting the axial direction from the tip end side of the main body portion, and connected to the tip of the protrusion piece portion, and is folded back toward the sensor element to be elastic to the electrode pad An elastic portion to be connected, a surface of the main body portion located on the opposite side to the side where the elastic portion is present is a main surface, and the side of the protruding piece portion where the elastic portion is present; The surface located on the opposite side is the sub surface, the portion of the main surface that faces the insertion hole of the separator is the first facing surface, and the portion of the sub surface that faces the insertion hole is the second. When the opposing surface is used, an area S1 of the first opposing surface is larger than an area S2 of the second opposing surface, and at least a part of the second opposing surface forms the insertion hole. The first opposing surface is in contact with a surface and is separated from the inner peripheral surface of the insertion hole.

According to this gas sensor, when at least a part of the second facing surface is in contact with the insertion hole (wall surface thereof), the folded portion facing the second facing surface generates a reaction force F radially outward from the electrode pad of the sensor element. When received, this reaction force can be firmly supported. As a result, the electrode pad and the terminal fitting can be stably electrically connected while maintaining the elastic force of the folded portion.
Further, since the area S2 is smaller than the area S1, a part or the whole of the area S2 is in contact with the insertion hole (the wall surface) or closer to the insertion hole (the wall surface) than the first facing surface, and from the separator. The area of the second facing surface that is likely to receive heat can be made relatively small, and heat transfer from the separator to the entire terminal fitting can be reduced. The entire surface of the second facing surface may be in contact with the inner peripheral surface of the insertion hole (the inner peripheral surface of the separator).
On the other hand, since the first opposed surface having a large area is separated from the insertion hole (the inner peripheral surface of the separator), the first opposed surface having a relatively larger area than the second opposed surface is made to be larger than the second opposed surface. The space between the separator and the separator can be thermally insulated with air. As a result, heat transfer from the separator to the entire terminal fitting can be reduced.
As described above, the folded portion of the terminal fitting is prevented from being softened or creep-deformed by heat transfer from the separator, and the elasticity is reduced, and the electrode pad of the sensor element and the terminal fitting can be reliably electrically connected. .

In the gas sensor of the present invention, a minimum distance d1 between the first facing surface and the insertion hole may be wider than a maximum distance d2 between the second facing surface and the insertion hole.
According to this gas sensor, the first opposed surface having a relatively larger area than the second opposed surface is surely separated from the insertion hole (wall surface thereof) more than the second opposed surface, and is insulated from the separator with air. can do. As a result, heat transfer from the separator to the entire terminal fitting can be further reduced.
In this gas sensor, the second facing surface has the maximum distance d2, that is, the entire second facing surface does not contact the insertion hole (wall surface thereof), and a part of the second facing surface is the insertion hole (wall surface thereof). ) Is shown.

In the gas sensor of the present invention, a portion of the insertion hole that faces the main surface may be located on a radially outer side than a portion that faces the sub surface.
According to this gas sensor, the interval between the insertion hole and the main surface can be further increased, and heat transfer from the separator to the entire terminal fitting can be further reduced.

In the gas sensor of the present invention, the main surface of the terminal fitting may be positioned radially inward from the sub surface.
According to this gas sensor, the interval between the insertion hole and the main surface can be further increased, and heat transfer from the separator to the entire terminal fitting can be further reduced.

In the gas sensor of the present invention, a first step portion is formed between a portion of the insertion hole that faces the main surface and a portion that faces the sub surface, and the sub surface of the terminal fitting is the main surface. And the second stepped portion, the main surface is located radially outside the sub-surface, and the main surface or the second stepped portion is locked to the first stepped portion, and the terminal fitting May be positioned.
According to this gas sensor, the portion of the insertion hole that faces the main surface is located on the outer side in the radial direction than the portion that faces the sub surface, so that the interval between the insertion hole and the main surface can be further increased. Further, since the first step portion is also used for positioning the terminal fitting, it is not necessary to separately provide a positioning portion for the terminal fitting on the separator, and productivity is improved without complicating the shape of the separator.

  A gas sensor manufacturing method according to a first aspect of the present invention is the gas sensor manufacturing method, wherein the sensor element has one or more pairs of electrode pads on a front surface and a back surface, Hold one or two or more pairs of terminal fittings, each having a contact portion electrically connected to the electrode pad across the electrode pad, in the insertion hole of the separator so that the contact portions face each other. A gas sensor manufacturing method comprising: an accommodating space for accommodating the separator along the axial direction; and when the separator and the terminal fitting are accommodated in the accommodating space, Using a first jig in which a plane portion having a predetermined thickness arranged at a corresponding position is erected from the bottom surface of the housing space along the rear end side of the separator, and from the rear end side of the first jig, the separator A separator containing step of inserting the flat portion at a position corresponding to the facing surface of the insertion hole of the separator, and the flat portion interposed between the contact portions. A terminal fitting holding step of inserting and holding each of the terminal fittings from the rear end side of the separator to the insertion hole, and a jig removing step of releasing the first jig relative to the separator toward the front end side. And having.

  According to the gas sensor manufacturing method of the first aspect, when attaching one or more pairs of terminal fittings to the separator so that the contact portions face each other, the planar portion of the first jig is interposed between the contact portions. Therefore, it can suppress that the terminal metal fittings which oppose contacted and entangled, suppress damage and a deformation | transformation of a terminal metal fitting, and can improve workability | operativity.

  In the gas sensor manufacturing method according to the second aspect of the present invention, the sensor element has one or more pairs of the electrode pads on the front surface and the back surface, and each of the electrode pads is electrically connected to the sensor element. A gas sensor manufacturing method for holding one or two or more pairs of terminal fittings each having a contact portion connected to the elastic portion in the insertion hole of the separator so that the contact portions face each other. A lead wire insertion step of inserting a lead wire connected to each of the terminal fittings through the insertion hole of the separator and projecting from a tip end side of the insertion hole; and A terminal fitting connecting step for connecting the terminal fitting and a holding space for containing the terminal fitting along the axial direction so as to be the same as a holding position of the terminal fitting in the separator. When the terminal fitting is accommodated in the accommodation space, a plane portion having a predetermined thickness arranged at a position corresponding to the opposing surfaces of the contact portions is erected along the axial direction from the bottom surface of the accommodation space, Using a second jig having an inner diameter of the housing space equal to or less than the maximum outer diameter of the front end of the separator, the planar part is interposed between the contact parts from the rear end side of the second jig. A terminal fitting housing step for housing the terminal fitting, a separator contacting step for bringing the leading end of the separator into contact with the rear end of the second jig while pulling the lead wire to the rear end side, and the second jig. A terminal fitting holding step of inserting and holding the terminal fitting through the insertion hole from the front end side of the insertion hole of the separator in contact with the rear end; and the second jig relative to the separator A jig detaching step for detaching to the tip side. To.

  According to the gas sensor manufacturing method of the second aspect, when attaching one or more pairs of terminal fittings to the separator so that the contact portions face each other, the planar portion of the second jig is interposed between the contact portions. Therefore, it can suppress that the terminal metal fittings which oppose contacted and entangled, suppress damage and a deformation | transformation of a terminal metal fitting, and can improve workability | operativity.

  According to the present invention, it is possible to obtain a gas sensor that can suppress a decrease in elasticity of the terminal fitting due to heat transfer from the separator and can reliably electrically connect the electrode pad of the sensor element and the terminal fitting.

It is sectional drawing which follows the axial direction of the gas sensor which concerns on the 1st Embodiment of this invention. It is a perspective view of the terminal metal fitting in a 1st embodiment. It is a rear view of the terminal metal fitting in a 1st embodiment. It is sectional drawing which shows the state which inserted and hold | maintained the terminal metal fitting in 1st Embodiment in the penetration hole of a separator. It is a perspective view of the terminal metal fitting in the 2nd Embodiment of this invention. It is sectional drawing which shows the state which inserted and hold | maintained the terminal metal fitting in 2nd Embodiment through the penetration hole of a separator. It is a perspective view of the terminal metal fitting in the 3rd Embodiment of this invention. It is sectional drawing which shows the state which inserted and hold | maintained the terminal metal fitting in 3rd Embodiment through the penetration hole of a separator. It is a perspective view of a sensor element. It is a top view of the 1st jig | tool used by embodiment of a 1st viewpoint. It is sectional drawing which follows the AA line of FIG. It is a figure which shows the state which penetrated the terminal metal fitting to the separator accommodated in the 1st jig | tool. It is process drawing of the manufacturing method of the gas sensor which concerns on embodiment of a 1st viewpoint. It is a top view of the 2nd jig | tool used by embodiment of a 2nd viewpoint. It is sectional drawing which follows the BB line of FIG. It is a figure which shows the state which accommodated the terminal metal fitting in the 2nd jig | tool. It is process drawing of the manufacturing method of the gas sensor which concerns on embodiment of a 2nd viewpoint. It is a figure which shows the state which the terminal metal fitting blurred in the parallel arrangement direction with respect to the plane part. It is a perspective view of the conventional terminal metal fitting.

Hereinafter, embodiments of the present invention will be described.
1 is an overall cross-sectional view of the gas sensor (oxygen sensor) 1 according to the first embodiment of the present invention along the direction of the axis O, FIG. 2 is a perspective view of the terminal fitting 20, and FIG. 3 is a rear view of the terminal fitting 20. 4 is a cross-sectional view showing a state in which the terminal fitting 20 is inserted and held in the insertion hole 90 h of the first separator 90. FIG. 4 shows a cross section along the line AA in FIG. 1 and perpendicular to the direction of the axis O.
The gas sensor 1 is an oxygen sensor that detects the oxygen concentration in the exhaust gas of automobiles and various internal combustion engines.

In FIG. 1, the gas sensor 1 includes a cylindrical metal shell 138 having a screw portion 139 for fixing to an exhaust pipe formed on the outer surface, and an axis O direction (longitudinal direction of the gas sensor 1: vertical direction in the figure). A sensor element 10 having an extending plate shape, a cylindrical ceramic sleeve 106 disposed so as to surround the periphery of the sensor element 10 in the radial direction, and an inner space on the front end side of the sensor element 10 are provided at a rear end portion of the sensor element 10. A ceramic cylindrical first separator 90 arranged in a state of surrounding the periphery, and four terminal fittings 20 (in FIG. 1) that are inserted and held through an insertion hole 90h that penetrates the first separator 90 in the direction of the axis O. Only two are shown).
Further, as will be described later, a ceramic cylindrical second separator 160 is disposed in contact with the rear end side of the first separator 90.
The first separator 90 corresponds to a “separator” in the claims.

The four insertion holes 90h of the first separator 90 communicate with the internal space on the front end side of the first separator 90, and each terminal fitting 20 faces the outer surface on the rear end side of the sensor element 10, and It is electrically connected to the electrode pad 10a formed on the surface.
In addition, two electrode pads 10 a are arranged in the width direction on both surfaces of the rear end side of the sensor element 10. Each electrode pad 10a can be formed as a sintered body mainly composed of Pt, for example.
On the other hand, the gas detector 11 at the tip of the sensor element 10 is covered with a porous protective layer 14 such as alumina.

  The metal shell 138 is made of stainless steel, has a through-hole 154 that penetrates in the axial direction, and has a substantially cylindrical shape that has a shelf 152 that protrudes radially inward of the through-hole 154. The sensor element 10 is disposed in the through hole 154 so that the tip of the sensor element 10 protrudes from the tip of the sensor element 10. Further, the shelf portion 152 is formed as an inwardly tapered surface having an inclination with respect to a plane perpendicular to the axial direction.

In addition, inside the through hole 154 of the metal shell 138, a substantially annular shaped ceramic holder 151 made of alumina surrounding the radial periphery of the sensor element 10, a powder filling layer 153 (hereinafter also referred to as a talc ring 153), And the above-mentioned ceramic sleeve 106 is laminated | stacked from the front end side to the rear end side in this order.
Further, a caulking packing 157 is disposed between the ceramic sleeve 106 and the rear end portion 140 of the metal shell 138. Note that the rear end portion 140 of the metal shell 138 is crimped so as to press the ceramic sleeve 106 toward the distal end side via the crimping packing 157.

  On the other hand, as shown in FIG. 1, a metal (for example, stainless steel) 2 having a plurality of holes and covering the protruding portion of the sensor element 10 on the outer periphery of the front end side (lower side in FIG. 1) of the metal shell 138. An external protector 142 and an internal protector 143, which are heavy protectors, are attached by welding or the like.

An outer cylinder 144 is fixed to the outer periphery of the rear end side of the metal shell 138. Further, the four terminal fittings 20 (only two are shown in FIG. 1) of the sensor element 10 are electrically connected to the opening on the rear end side (upper side in FIG. 1) of the outer cylinder 144, respectively. A rubber grommet 170 in which lead wire insertion holes (not shown) through which four lead wires 146 (only two are shown in FIG. 1) are inserted is disposed.
The lead wire 146 is pulled out from the rear end side of the terminal fitting 20 to the rear end side of the first separator 90, and further pulled out to the outside of the gas sensor 1 through the insertion hole (not shown) of the second separator 160 and the grommet 170. ing.

A first separator 90 is disposed on the rear end side (upward in FIG. 1) of the sensor element 10 protruding from the rear end portion 140 of the metal shell 138, and the flange portion 90p protrudes radially outward from the outer surface. Is provided. The first separator 90 is held inside the outer cylinder 144 by the flange portion 90p coming into contact with the outer cylinder 144 via the holding member 169.
Further, the second separator 160 is disposed between the grommet 170 and the first separator 90, and the second separator 160 presses the first separator 90 toward the front end side by the elastic force of the grommet 170. As a result, the flange 90p is pressed toward the holding member 169 side, and the first separator 90 and the second separator 160 are held inside the outer cylinder 144.

FIG. 2 is a perspective view of the terminal fitting 20. In the present embodiment, the gas sensor 1 has four terminal fittings 20, but as shown in FIG. 4, all of these four terminal fittings 20 are adjacent to each other in the first separator 90. Since it is a line-symmetric shape, it demonstrates using the one terminal metal fitting 20 (position I of the upper left of FIG. 4) among these.
4 is symmetrical with respect to the terminal fitting 20 at the position I with the line along the surface direction of the sensor element 10 as an axis. The terminal fitting 20 at the lower right position III in FIG. 4 is line-symmetric with respect to the terminal fitting 20 at the position II with a line perpendicular to the surface direction of the sensor element 10 as an axis. 4 is symmetrical with respect to the terminal fitting 20 at the position I with a line perpendicular to the surface direction of the sensor element 10 as an axis.

As shown in FIG. 2, the terminal fitting 20 extends in the direction of the axis O as a whole, and is connected to the lead wire connection portion 23 connected to the lead wire 146 (see FIG. 1), and connected to the distal end side of the lead wire connection portion 23. A main body portion 21 extending in the direction, a projecting piece portion 22 projecting in a direction (width direction in FIG. 1) intersecting the direction of the axis O from the front end side of the main body portion 21, and a front end of the projecting piece portion 22 An elastic portion 22c that is folded back toward the element 10 and elastically connected to the electrode pad is integrally provided. Of the elastic portion 22c, a protrusion directly in contact with the electrode pad is defined as a contact portion 21p.
The surface of the main body 21 that is located on the side opposite to the side where the elastic portion 22c is present is referred to as a main surface 21a, and the surface of the protruding piece 22 that is located on the side opposite to the side where the elastic portion 22c is present. This is the sub surface 22a.
The terminal fitting 20 can be manufactured, for example, by punching out a single metal plate (Inconel (registered trademark) or the like) and then bending it into a predetermined shape, but is not limited thereto.

The lead wire connecting portion 23 is a known crimping terminal portion having a cylindrical shape, and the lead wire 146 is electrically connected by inserting and crimping the lead wire 146 with the conductive wire exposed in the tube. Connected.
The main body 21 has an L-shaped cross section, and the outer side of the other width direction (opposite to the sub surface 22a) of the main surface 21a is folded back 90 degrees to form a guide portion 21b. And the lead wire connection part 23 is integrally connected to the rear end side of the main surface 21a. In this respect, the guide portion 21b which is a surface of the main body portion 21 to which the lead wire connecting portion 23 is not connected does not correspond to the “main surface”. The guide portion 21b serves as a guide when the terminal fitting 20 is inserted into the insertion hole 90h of the first separator 90. The main body 21 secures the strength of the terminal fitting 20 as a base portion of the terminal fitting 20.
The outer side of the other width direction (opposite side of the guide portion 21b) of the main surface 21a is folded back in the same direction as the guide portion 21b to form a connection portion 22b that is integrally connected to the sub surface 22a. It is parallel to the main surface 21a. Furthermore, the protruding piece 22 has an elastic portion 22c that is folded back from the front end of the sub-surface 22a toward the sensor element 10 toward the rear end side and elastically connected to the electrode pad 11a (see FIGS. 1 and 9). ing. The elastic portion 22c is elastically bent in the radial direction with respect to the sub surface 22a.

As shown in FIG. 9, the sensor element 10 has a plate shape extending in the direction of the axis O, and the tip portion 10s is a gas detection portion 10a for detecting the oxygen concentration, and the gas detection portion 10a is a porous protective layer. 14 is covered. The sensor element 10 itself has a known configuration, and although not shown, the gas detector having an oxygen ion permeable solid electrolyte body and a pair of electrodes, and the gas detector are heated and maintained at a constant temperature. And a heater unit.
Two electrode pads 11a and 11b are arranged in the width W direction on the rear end side of one main surface (front surface) 10A of the sensor element 10, and a sensor output signal from the gas detection unit is a lead portion (not shown). ) Through these electrode pads 11a and 11b. In addition, two electrode pads 12a and 12b are arranged in the width direction on the rear end side of the other main surface (back surface) 10B provided so as to face the main surface 10A, via a lead portion (not shown). Power is supplied to the heater.
Each electrode pad 11a, 11b, 12a, 12b has a rectangular shape that is long in the direction of the axis O, and can be formed as a sintered body mainly composed of Pt, for example. In the present embodiment, the electrode pads 11a and 11b and the electrode pads 12a and 12b arranged on each surface of the sensor element 10 are opposed to each other via the sensor element 10 and are specifically paired. Is a pair of electrode pads 11a and electrode pads 12a facing each other, and another pair of electrode pads 11b and electrode pads 12b facing each other. That is, in the present embodiment, a total of two pairs of electrode pads 11a, 11b, 12a, and 12b are provided.

  The above-described four terminal fittings 20 (terminal fittings 20a, 20b, 20c, 20d are held in the insertion hole 90h of the separator 90, and among these, the terminal fittings 21a, 20c facing each other with the sensor element 10 interposed therebetween. And the terminal fittings 20b and 20d facing each other across the sensor element 10 correspond to “a pair of terminal fittings” (see FIG. 4), that is, in this embodiment, a total of two pairs of terminal fittings 21a, 20b, 20c, 20d.

FIG. 3 shows a rear view of the terminal fitting 20. A portion of the main surface 21a that faces the insertion hole 90h of the first separator 90 (the inner peripheral surface of the first separator 90) is defined as a first facing surface F1, and the area of the first facing surface F1 is S1 (the hatched portion in FIG. 3). ). Here, the lead wire connecting portion 23 is exposed to the rear end side of the first separator 90, and the area S1 is a region existing inside the first separator 90 in the main surface 21a. Therefore, the portion adjacent to the lead wire connecting portion 23 in the main surface 21a is excluded from S1.
Further, a portion of the sub surface 22a that faces the insertion hole 90h (the inner peripheral surface of the first separator 90) is defined as a second facing surface F2, and an area of the second facing surface F2 is defined as S2 (hatched portion in FIG. 3). . Here, the area S2 is a portion of the sub-surface 22a that exists in the first separator 90 and overlaps the elastic portion 22c in the width direction. For this reason, the connection part 22b between the sub surface 22a and the main surface 21a is excluded from S2.

Here, the area S1 is larger than the area S2. As shown in FIG. 4, at least a part of the second facing surface F2 is in contact with the insertion hole 90h (inner peripheral surface of the first separator 90), and the first facing surface F1 is inserted into the insertion hole 90h (first separator 90). Inner peripheral surface).
As described above, when at least a part of the second facing surface F2 is in contact with the insertion hole 90h, the elastic portion 22c facing the second facing surface F2 generates a reaction force F radially outward from the electrode pad 11a of the sensor element 10. When received, this reaction force F can be firmly supported. As a result, the electrode pad 11a and the terminal fitting 20 can be stably electrically connected while maintaining the elastic force of the elastic portion 22c.

Further, since the area S2 is smaller than the area S1, a part or the entire surface of the area S2 is in contact with the insertion hole 90h (the inner peripheral surface of the first separator 90), or the insertion hole 90h (of the insertion hole 90h is compared with the first facing surface F1). In the vicinity of the wall surface, the area of the second facing surface F2 that is likely to receive heat from the first separator 90 can be made relatively small, and heat transfer from the first separator 90 to the entire terminal fitting 20 can be reduced.
On the other hand, since the first opposing surface F1 having a large area is separated from the insertion hole 90h (the inner peripheral surface of the first separator 90), the first opposing surface F1 having a relatively larger area than the second opposing surface F2 is provided. The air can be insulated from the first separator 90 by being separated from the insertion hole 90h (the wall surface thereof). As a result, heat transfer from the first separator 90 to the entire terminal fitting 20 can be reduced.
As described above, the elastic portion 22c of the terminal fitting 20 is prevented from being softened or creep-deformed by heat transfer from the first separator 90 and the elasticity is reduced, and the electrode pad 11a and the terminal fitting 20 of the sensor element 10 are securely connected. Can be electrically connected.

  As shown in FIG. 4, in the first embodiment, the minimum distance d1 between the first opposing surface F1 and the insertion hole 90h (the inner peripheral surface of the first separator 90) is inserted into the second opposing surface F2. It is wider than the maximum distance d2 with respect to the hole 90h (the inner peripheral surface of the first separator 90). Thereby, the first opposing surface F1 having a relatively larger area than the second opposing surface F2 is reliably separated from the insertion hole 90h than the second opposing surface F2, and is thermally insulated from the first separator 90 with air. can do. As a result, heat transfer from the first separator 90 to the entire terminal fitting 20 can be further reduced.

Further, as shown in FIG. 4, in the first embodiment, the insertion hole 90 h of the first separator 90 has a main portion between a portion facing the main surface 21 a and a portion facing the sub surface 22 a. The first step portion 90d is formed so that the portion facing the surface 21a is located on the radially outer side than the portion facing the sub surface 22a.
On the other hand, the sub surface 22a of the terminal fitting 20 is connected to the main surface 21a via the connection portion 22b, and the main surface 21a is located on the outer side in the radial direction than the sub surface 22a. And the end surface of the width direction of the main surface 21a latches to the 1st step part 90d, and the terminal metal fitting 20 is positioned. The connecting portion 22b corresponds to a “second step portion” in the claims.

Thus, since the site | part which opposes the main surface 21a is located in the radial direction outer side rather than the site | part which opposes the sub surface 22a, the space | interval of the penetration hole 90h and the main surface 21a can be enlarged more, and the above-mentioned Due to the effect of air insulation, heat transfer from the first separator 90 to the entire terminal fitting 20 can be further reduced. Further, since the first step portion 90d is also used for positioning the terminal fitting 20, it is not necessary to separately provide a positioning portion for the terminal fitting 20 in the first separator 90, and the first separator 90 can be produced without complicating the shape. Improves.
In addition, the shape of the connection part 22b may be along the first step part 90d, and the terminal fitting 20 may be positioned by locking the connection part 22b to the first step part 90d.

Next, a gas sensor according to a second embodiment of the present invention will be described with reference to FIGS. Since the gas sensor according to the second embodiment of the present invention is the same as the gas sensor according to the first embodiment except that the shape of the terminal fitting 30 is different, the same as the gas sensor according to the first embodiment. The same reference numerals are given to the components, and description thereof is omitted.
FIG. 5 is a perspective view of the terminal fitting 30, and FIG. 6 is a cross-sectional view showing a state in which the terminal fitting 30 is inserted and held in the insertion hole 90 h of the first separator 90. 6 shows the same cross section as FIG.

As shown in FIG. 5, the terminal fitting 30 extends in the direction of the axis O as a whole, the lead wire connecting portion 33, the main body portion 31 connected to the tip end side of the lead wire connecting portion 33, and the axis line O from the tip end side of the main body portion 31. A protrusion piece 32 protruding in a direction crossing the direction and an elastic part 32c connected to the tip of the protrusion piece 32 and folded back toward the sensor element 10 and elastically connected to the electrode pad are integrally provided. Yes.
A surface of the main body 31 that is located on the side opposite to the side where the elastic part 32c is present is defined as a main surface 31a, and a surface of the protruding piece 32 that is located on the side opposite to the side where the elastic part 32c is present. Let it be the sub surface 32a.
The lead wire connecting portion 33 is substantially the same as the lead wire connecting portion 23 in the first embodiment.
The main body 31 has an L-shaped cross section, and the outer side in one width direction (opposite to the sub surface 32a) of the main surface 31a is folded back 90 degrees to form a guide portion 31b. And the lead wire connection part 33 is connected to the rear end side of the main surface 31a.
The outer side in the other width direction (opposite side to the guide portion 31b) of the main surface 31a is connected to the sub surface 32a directly (without the connection portion 22b or the like). Furthermore, the protruding piece 32 has an elastic portion 32c that is folded back from the sub surface 32a toward the sensor element 10 and elastically connected to the electrode pad 11a (see FIG. 1).
In addition, the boundary line of the main surface 31a and the subsurface 32a is shown with a broken line in FIG.

Thus, since the main surface 31a and the sub surface 32a are flush with each other, if the portion of the insertion hole 90h facing the same is flush, at least part of the second facing surface F2 is inserted into the insertion hole 90h (first The first opposing surface F1 cannot be separated from the insertion hole 90h (the inner peripheral surface of the first separator 90). Therefore, a portion of the insertion hole 90h that faces the main surface 31a is located on the radially outer side than a portion that faces the sub surface 32a.
Thereby, at least a part of the second opposing surface F2 is brought into contact with the insertion hole 90h (the inner peripheral surface of the first separator 90), and the first opposing surface F1 is connected to the insertion hole 90h (the inner peripheral surface of the first separator 90). Therefore, the heat transfer from the first separator 90 to the entire terminal fitting 30 can be reduced. Further, since the main surface 31a and the sub surface 32a are flush with each other, the productivity is improved without complicating the shape of the terminal fitting 30.
Furthermore, when the main surface 31a and the sub surface 32a are flush with each other, the insertion hole 90h and the main surface 31a are compared with the case where the main surface 21a is located radially outside the sub surface 22a as in the first embodiment. And the heat transfer from the first separator 90 to the entire terminal fitting 20 can be further reduced.

Next, a gas sensor according to a third embodiment of the present invention will be described with reference to FIGS. The gas sensor according to the third embodiment of the present invention is the same as the gas sensor according to the first embodiment except that the shapes of the terminal fitting 40 and the first separator 92 are different, and therefore the first embodiment. The same components as those of the gas sensor according to the present invention are denoted by the same reference numerals and description thereof is omitted.
FIG. 7 is a perspective view of the terminal fitting 40, and FIG. 8 is a cross-sectional view showing a state in which the terminal fitting 40 is inserted and held in the insertion hole 92 h of the first separator 92. FIG. 8 shows a cross section similar to FIG.

As shown in FIG. 7, the terminal fitting 40 extends in the direction of the axis O as a whole, on the outer side in the width direction of the main surface 41a, the lead wire connecting portion 43, the main body portion 41 connected to the tip end side of the lead wire connecting portion 43. The protruding piece portion 42 having the sub-surface 42a connected to the main surface 41a and the elastic portion 42c connected to the tip of the protruding piece portion 42 and folded back toward the sensor element 10 and elastically connected to the electrode pad are integrally formed. I have.
A surface of the main body 41 that is located on the side opposite to the side where the elastic portion 42c is present is defined as a main surface 41a, and a surface of the protruding piece 42 that is located on the side opposite to the side where the elastic portion 42c is present. Let it be the sub surface 42a.

The lead wire connecting portion 43 is substantially the same as the lead wire connecting portion 23 in the first embodiment.
The main body 41 has an L-shaped cross section, and the outer side of one width direction (opposite side to the sub surface 42a) of the main surface 41a is folded back 90 degrees to form a guide portion 41b. And the lead wire connection part 43 is connected to the rear end side of the main surface 41a.
The outer side of the other width direction (opposite side to the guide part 41b) of the main surface 41a forms a connection part 42b that is folded back in the opposite direction to the guide part 21b and is connected to the sub surface 22a. It is parallel to 41a. Furthermore, the protruding piece 42 has an elastic portion 42c that is folded back from the sub surface 42a toward the sensor element 10 and elastically connected to the electrode pad 11a (see FIG. 1).
On the other hand, in the insertion hole 92h of the first separator 92, a portion facing the main surface 21a and a portion facing the sub surface 22a are flush with each other.

  In 3rd Embodiment, since the main surface 41a of the terminal metal fitting 40 is located in a radial inside rather than the sub surface 42a, the space | interval of the insertion hole 92h and the main surface 41a can be enlarged, and a 1st separator Heat transfer from 92 to the entire terminal fitting 40 can be reduced. Further, for example, even though the portion of the insertion hole 92h of the first separator 92 facing the main surface 21a and the sub surface 22 is flush, at least a part of the second facing surface F2 is inserted into the insertion hole 92h (first separator 92). The first opposing surface F1 can be separated from the insertion hole 92h (the inner peripheral surface of the first separator 92). Moreover, since the site | part which opposes the main surface 41a and the subsurface 42a is the same among the insertion holes 92h of the 1st separator 92, productivity improves without complicating the shape of the insertion holes 92h.

Next, a method for manufacturing a gas sensor according to an embodiment of the first aspect of the present invention will be described with reference to FIGS.
10 is a plan view of the first jig 300 used in the embodiment of the first aspect, FIG. 11 is a sectional view taken along the line AA of FIG. 10, and FIG. 12 is a separator ( The figure which shows the state which penetrated the terminal metal fittings 20a, 20b, 20c, 20d to the 1st separator) 90, FIG. 13: is process drawing of the manufacturing method of the gas sensor which concerns on embodiment of a 1st viewpoint.

As shown in FIGS. 10 and 11, the first jig 300 has a bottomed cylindrical shape, and has a cylindrical accommodation space 300 h that opens toward the upper surface at the center. Furthermore, a substantially H-shaped protrusion 310 in a top view protrudes upward from the center of the bottom surface 300b of the housing space 300h. The protrusion 310 is formed at a position corresponding to the insertion hole 90 h in the center of the separator 90.
The protruding portion 310 has a central prism portion 314, two plate-like planar portions 312 extending on the same surface in opposite directions from the opposing surfaces of the prism portion 314, and both ends of the projecting portion 310 extending vertically from both ends of each planar portion 312. Two side walls 316 that are flush with the other opposing surface of the prism portion 314 are provided. The prism portion 314 and the side wall portion 316 protrude from the plate surface of the flat portion 312. The two flat portions 312 are opposed surfaces of the contact portions 21p of the pair of terminal fittings 20a and 20c, and opposed surfaces of the contact portions 21p of the other pair of terminal fittings 20b and 20d (see FIG. 12). It is formed in the position corresponding to. Further, the protruding portion 310 protrudes above the upper surface 302 of the first jig 300.
Furthermore, a part of the peripheral edge of the housing space 300h forms a straight portion 300s to prevent the separator 90 described later from rotating in the circumferential direction.
The prism portion 314 and the side wall portion 316 correspond to a “terminal fitting restricting member” in the claims, and the straight portion 300 s corresponds to a “first restricting member” in the claims.
The 1st jig | tool 300 and the protrusion part 310 can be made from metals, such as stainless steel, for example.

  As will be described in detail later, in the terminal fitting holding step of the gas sensor manufacturing method according to the embodiment of the first aspect, as shown in FIG. 12, four terminal storage holes 90a of the separator 90 stored in the first jig 300 are provided. ˜90d, the terminal fittings 20a, 20b, 20c, and 20d are respectively inserted. At this time, the prism portion 314 and the side wall portion 316 are in contact with the side surfaces of the terminal fittings 20a, 20b, 20c, and 20d (surfaces intersecting the surface of the elastic portion 22c) and restrict movement of each terminal fitting in the width direction. In addition, it is possible to prevent displacement of each terminal fitting in the separator 90 (in the first jig 300).

Next, with reference to FIG. 13, the detail of the manufacturing method of the gas sensor which concerns on embodiment of a 1st viewpoint is demonstrated. In FIG. 13, only one pair of terminal fittings 20a and 20c is shown, but the other pair of terminal fittings 20b and 20d is the same except that they are hidden behind the sheet of FIG.
First, the separator 90 is accommodated along the axial direction from the rear end side (upper side) of the first jig 300, and the flat portion 312 is inserted into the insertion hole 90h of the separator 90 at a position corresponding to the facing surface ( FIG. 13 (a), (b): Separator accommodation step).
Next, the terminal fittings 20a and 20c are inserted and held from the rear end side of the separator 90 into the insertion hole 90h so that the flat surface portion 312 is interposed between the contact portions 21p (the above-described facing surface) (FIG. 13B). ), (C): terminal fitting holding step). Here, it is assumed that the lead wire 146 is previously crimped to the lead wire connecting portion 23 of the terminal fittings 20a and 20c.
Next, the first jig 300 is released relatively to the front end side (lower side) with respect to the separator 90 (FIG. 13D: jig removing step).

Thus, in the embodiment of the first aspect, when attaching one or more pairs of terminal fittings 20a, 20c (or 20b, 20d) to the separator 90 so that the contact portions 21p face each other, Since the flat portion 312 of the first jig 300 is interposed therebetween, the opposing terminal fittings 20a, 20c (or 20b, 20d) are prevented from coming into contact with each other, and the terminal fitting is prevented from being damaged or deformed. Workability can be improved.
In the present embodiment, when the separator 90 is accommodated in the first jig 300 in the separator accommodating step of FIG. 13B, the flat surface portion 312 protrudes to the rear end side from the rear end of the separator 90. Thereby, since the terminal fittings 20a and 20c (or 20b and 20d) are inserted through the insertion holes 90h in the next terminal fitting holding step from the beginning, the opposing terminal fittings (contact portions 21p) are separated by the plane portion 312. It can suppress reliably that terminal metal fittings contact and become entangled.

In this embodiment, as shown in FIGS. 10 and 12, the first jig 300 has a straight portion 300s, and the separator 90 is a second straight portion (second regulating member) that engages with the straight portion 300s. 90t. Thereby, it can prevent that the separator 90 rotates in the circumferential direction in the 1st jig | tool 300, and it can suppress that a terminal metal fitting contacts and becomes entangled by rotation of the separator 90. FIG.
Furthermore, in the present embodiment, the thickness of the flat portion 312 is thinner than the thickness between the pair of electrode pads 11a, 12a (or 11b, 12b) on the front and back surfaces of the sensor element 10. Thereby, the space | interval of the terminal metal fittings (contact part 21p) which opposes by the plane part 312 spreads, and plastically deforms, and the subsequent contact pressure with the electrode pads 11a and 12a (or 11b and 12b) of the sensor element 10 falls. Therefore, it is possible to suppress a decrease in reliability of electrical connection.

Next, with reference to FIGS. 14-18, the manufacturing method of the gas sensor which concerns on embodiment of the 2nd viewpoint of this invention is demonstrated.
14 is a plan view of the second jig 400 used in the embodiment of the second aspect, FIG. 15 is a cross-sectional view taken along the line BB of FIG. 14, and FIG. FIG. 17 is a process diagram of a method for manufacturing a gas sensor according to an embodiment of the second aspect, and FIG. 18 is a view showing terminal fittings 20a to 20d arranged in parallel to the flat portion 412. It is a figure which shows the state blurred in the direction.

As shown in FIGS. 14 and 15, the second jig 400 has a bottomed cylindrical shape, and has a cylindrical accommodating space 400 h that opens toward the upper surface at the center. Furthermore, two plate-like plane portions 412 protrude upward from the center of the bottom surface 400b of the housing space 400h. The flat portion 412 is formed at a position corresponding to the insertion hole 90 h at the center of the separator 90. The flat portion 412 is at least a facing surface between the contact portions 21p of the pair of terminal fittings 20a and 20c, and a facing surface between the contact portions 21p of the other pair of terminal fittings 20b and 20d (see FIG. 16). It is formed in the position corresponding to.
Further, the flat surface portion 412 protrudes above the upper surface 402 of the second jig 400.
Further, a part of the peripheral edge of the housing space 400h forms a straight portion 400s like the straight portion 300s, and forms a “first regulating member” that prevents the separator 90 from rotating in the circumferential direction. The separator 90 is similarly provided with the second straight portion (second regulating member) 90t.
The 2nd jig | tool 400 and the plane part 412 can be made from metals, such as stainless steel, for example.

As will be described in detail later, in the terminal fitting housing step of the gas sensor manufacturing method according to the second aspect of the present invention, as shown in FIG. 16, the terminal fittings 20a, 20b, 20c and 20d are respectively inserted. At this time, the plane portion 412 is inserted between the facing surfaces of the contact portions 21p of the terminal fittings 20a to 20d.
Here, as shown in FIG. 16, the terminal fittings 20 a and 20 b are arranged along the main surface direction L of the flat portion 412, and the terminal fittings 20 c and 20 d are arranged similarly on the opposite surface of the flat portion 412. The width of each of the terminal fittings 20a to 20d in the contact portion 21p is W1, and the width of the main surface of the flat portion 412 is W2.
At this time, as shown in FIG. 18, assuming that the total width (2 × W1) <W2 in the direction (parallel arrangement direction) L of the terminal fittings 20c, 20d (or 20a, 20b), the terminal fittings 20c, 20d Even if it shakes in the juxtaposed direction L, it is possible to reliably suppress contact and entanglement with the opposing terminal fittings 20a and 20b located on the opposite side beyond the flat portion 412.

  Further, as shown in the lower diagram of FIG. 16, when the maximum width in the parallel direction L of the insertion holes 90h of the separator 90 is W3, the expression 1: GL + GR = W3-W2, GL <W1 and GR <W1 is satisfied. If it does in this way, even if each terminal metal fitting 20c, 20d shakes in the juxtaposition direction L, it can suppress reliably contacting and contacting the terminal metal fitting 20a, 20b which opposes the other side over the plane part 412. In this formula, GL and GR in Equation 1 represent gaps at both ends (right side and left side) of the flat portion 412 and the insertion hole 90h. If the gaps GL and GR are smaller than W1, the terminal fittings 20c and 20d are flat. This is because it cannot enter the opposite surface of the portion 412. In addition, although the width | variety of both terminal metal fittings 20c and 20d was described as W1 here, when the width | variety of a terminal metal fitting differs, when each clearance gap GL and GR are smaller than the width | variety of the terminal nearest to each clearance gap GL and GR, respectively. good.

Next, with reference to FIG. 17, the detail of the manufacturing method of the gas sensor which concerns on embodiment of a 2nd viewpoint is demonstrated. In FIG. 17, only one pair of terminal fittings 20a and 20c is shown, but the other pair of terminal fittings 20b and 20d is the same except that they are hidden behind the sheet of FIG.
First, the lead wire 146 connected to each of the terminal fittings 20a and 20c is inserted into the insertion hole 90h of the separator 90 and protruded from the distal end side of the insertion hole 90h (lead wire insertion step). Next, the lead wire connecting portions 23 of the terminal fittings 20a and 20c are respectively crimped (electrically connected) to the tips of the lead wires 146 (FIG. 17A: terminal fitting connecting step).
Next, the terminal fittings 20a and 20c are accommodated in the accommodation space 400h from the rear end side of the second jig 400 so as to be the same as the holding positions of the terminal fittings 20a and 20c in the separator 90, and the contact portion 21p. A plane part is inserted (intervened) between each other (FIG. 17B: terminal fitting housing step).

Next, the front end of the separator 90 is brought into contact with the rear end (upper surface) 402 of the second jig 400 while pulling the lead wire 146 to the rear end side (FIG. 17C: separator contact step). Here, as illustrated in FIG. 17C, the inner diameter D <b> 1 of the housing space 400 h is set to be equal to or smaller than the maximum outer diameter D <b> 2 of the tip portion of the separator 90.
Next, the terminal fittings 20a and 20c are inserted and held in the insertion hole 90h from the front end side of the insertion hole 90h of the separator 400 that is in contact with the rear end of the second jig 400 (FIG. 17D: terminal fitting). Holding step).
Next, the second jig 400 is released relatively to the front end side (lower side) with respect to the separator 90 (FIG. 17E: jig removing process).

  Thus, also in the embodiment of the second aspect, when attaching one or more pairs of terminal fittings 20a, 20c (or 20b, 20d) to the separator 90 so that the contact portions 21p face each other, the contact portions 21p Since the flat portion 412 of the second jig 400 is interposed between the terminal fixtures 20a and 20c (or 20b and 20d) facing each other, the contact and entanglement are suppressed, and damage and deformation of the terminal fixture are suppressed. Workability can be improved.

Further, in the present embodiment, in the separator contact process of FIG. 17D, the flat portion 412 protrudes toward the rear end side from the contact portions. Thereby, when each terminal metal fitting is held in the insertion hole 90h of the separator 90, the opposing terminal metal fittings (contact portions 21p) are separated by the flat portion 412, so that the terminal metal fittings are surely in contact and entangled with each other. Can be suppressed.
Also in this embodiment, as described above, the separator 90 can be prevented from rotating in the circumferential direction in the second jig 400, and the terminal metal fittings can be prevented from coming into contact with each other due to the rotation of the separator 90.

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, the shape of the insertion hole of the terminal fitting or the first separator is not limited to the above embodiment.
Examples of the gas sensor include an oxygen sensor, a full range gas sensor, and a NOx sensor.
In the above embodiment, the lead wire is directly connected (clamped) to the lead wire connecting portion 23 of the terminal fitting 20, but this is not a limitation, and for example, the lead wire is directly connected to another component by caulking or the like. The separate parts may be connected to the rear end side of the terminal fitting 20 by being inserted or the like. In this case, the connecting portion of the terminal fitting 20 connected to another component corresponds to a “lead wire connecting portion”, and the lead wire connecting portion is indirectly connected to the lead wire via another component.

The shape of the first jig or the second jig, the separator, and the terminal fitting is not limited. The terminal fittings may be one pair or two or more pairs.
Further, as a first restricting member for preventing the circumferential rotation of the separator, a positioning pin may be provided in a part of the separator front end surface or the terminal receiving space of the separator, or a plurality of the first restricting members may be provided. Good.

DESCRIPTION OF SYMBOLS 1 Gas sensor 10 Sensor element 11a, 11b, 12a, 12b Electrode pad 20, 30, 40 Terminal metal fitting 21, 31, 41 Main body part 21a, 31a, 41a Main surface 21p Contact part 22, 32, 42 Protruding piece part 22a, 32a, 42a Sub-surface 22b Second step (connection portion)
22c, 32c, 42c Elastic part 23, 33, 43 Lead wire connecting part 90, 92 Separator (first separator)
90d 1st step part 90h, 92h Insertion hole (inner peripheral surface of separator)
90t Second restriction member 146 Lead wire 300 First jig 300h, 400h Accommodation space 300b, 400b Bottom surface of accommodation space 300s, 400s First restriction member 312, 412 Planar portion 314, 316 Terminal fitting restriction member 400 Second jig O Axis F1 First opposing surface F2 Second opposing surface D1 Inner diameter of the accommodation space D2 Maximum outer diameter of the tip of the separator L Parallel arrangement direction

Claims (7)

A sensor element having a plate shape extending in the axial direction and having an electrode pad on the outer surface on the rear end side;
A terminal fitting extending in the axial direction and electrically connected to the electrode pad;
A cylindrical separator having an insertion hole for holding the terminal fitting and surrounding a rear end side of the sensor element;
A lead wire connected to the rear end side of the terminal fitting and drawn out to the rear end side of the separator,
The terminal fitting includes a lead wire connecting portion connected to the lead wire, a main body portion connected to a distal end side of the lead wire connecting portion and extending in the axial direction, and intersecting the axial direction from the distal end side of the main body portion. A protruding piece portion protruding in the direction, and an elastic portion connected to the tip of the protruding piece portion, folded back toward the sensor element and elastically connected to the electrode pad,
Of the main body portion, a surface located on the opposite side to the side where the elastic portion exists is a main surface, and among the protruding piece portions, a surface located on the opposite side to the side where the elastic portion exists is a sub surface. Face and
Further, when the portion of the main surface that faces the insertion hole of the separator is a first facing surface, and the portion of the sub surface that faces the insertion hole is a second facing surface,
An area S1 of the first facing surface is larger than an area S2 of the second facing surface;
In addition, the gas sensor is configured such that at least a part of the second facing surface is in contact with an inner peripheral surface of the separator forming the insertion hole, and the first facing surface is separated from the inner peripheral surface of the insertion hole.   2. The gas sensor according to claim 1, wherein a minimum distance d <b> 1 between the first facing surface and the insertion hole is wider than a maximum distance d <b> 2 between the second facing surface and the insertion hole.   3. The gas sensor according to claim 1, wherein a part of the insertion hole that faces the main surface is located on a radially outer side than a part of the insertion hole that faces the sub surface.   The gas sensor according to any one of claims 1 to 3, wherein the main surface of the terminal fitting is located radially inside the sub surface. Of the insertion hole, a first step is formed between a portion facing the main surface and a portion facing the sub surface,
The sub surface of the terminal fitting is connected to the main surface via a second step portion, and the main surface is located on the radially outer side than the sub surface,
The gas sensor according to claim 3, wherein the main surface or the second step portion is engaged with the first step portion to position the terminal fitting. It is a manufacturing method of the gas sensor as described in any one of Claims 1-5, Comprising: The said sensor element has the said electrode pad of 1 pair or 2 pairs or more on the surface and a back surface, and sandwiches the said sensor element. A gas sensor that holds one or two or more pairs of terminal fittings each having a contact portion electrically connected to the electrode pad in the elastic portion in the insertion hole of the separator so that the contact portions face each other. A manufacturing method of
A predetermined thickness disposed in a position corresponding to the facing surfaces of the contact portions when the separator and the terminal fitting are accommodated in the accommodating space, the accommodating space accommodating the separator along the axial direction. Using a first jig that is erected along the rear end side of the separator from the bottom surface of the housing space,
A separator accommodating step of accommodating the separator from a rear end side of the first jig, and inserting the flat portion at a position corresponding to the facing surface in the insertion hole of the separator;
A terminal fitting holding step of inserting and holding each of the terminal fittings from the rear end side of the separator to the insertion hole so that the planar portion is interposed between the contact portions;
A jig detaching step of detaching the first jig relative to the separator relative to the tip side;
The manufacturing method of the gas sensor which has this. It is a manufacturing method of the gas sensor as described in any one of Claims 1-5, Comprising: The said sensor element has the said electrode pad of 1 pair or 2 pairs or more on the surface and a back surface, and sandwiches the said sensor element. A gas sensor that holds one or two or more pairs of terminal fittings each having a contact portion electrically connected to the electrode pad in the elastic portion in the insertion hole of the separator so that the contact portions face each other. A manufacturing method of
A lead wire insertion step of inserting a lead wire connected to each of the terminal fittings through the insertion hole of the separator and projecting from a distal end side of the insertion hole;
A terminal fitting connecting step of electrically connecting the terminal fitting to the tip of the lead wire,
When the terminal fitting is accommodated in the accommodation space, the contact point is provided when the terminal fitting is accommodated along the axial direction so as to be the same as the holding position of the terminal fitting in the separator. A plane portion having a predetermined thickness arranged at a position corresponding to the opposing surfaces of the portions is erected along the axial direction from the bottom surface of the accommodating space, and the inner diameter of the accommodating space is the maximum outer diameter of the tip portion of the separator Using the following second jig,
A terminal fitting housing step of housing the terminal fitting from the rear end side of the second jig so that the flat surface portion is interposed between the contact portions;
A separator contact step in which the leading end of the separator is brought into contact with the rear end of the second jig while pulling the lead wire toward the rear end;
A terminal fitting holding step of inserting and holding the terminal fitting through the insertion hole from the front end side of the insertion hole of the separator that is in contact with the rear end of the second jig;
A jig detaching step of detaching the second jig relative to the separator toward the tip side;
The manufacturing method of the gas sensor which has this.

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