Abstract: A terminal includes a spine extending along a longitudinal axis from a first end to a second end and extending along a lateral axis, which is perpendicular to the longitudinal axis, from a first edge to a second edge. An attachment portion at the first end provides fixation to an electrical conductor. A contact portion extends from the second end and cantilevers over the spine such that the contact portion is spaced apart from the spine in a direction along a vertical axis which is perpendicular to both the longitudinal axis and the lateral axis. A locking tab extends from the first edge and has a locking tab attachment end which is fixed to first edge and which extends toward, and is aligned with, the contact portion in a direction parallel to the vertical axis. The locking tab also has a free end which flares outward beyond contact portion.

Abstract: A terminal includes a spine extending along a longitudinal axis from a first end to a second end and extending along a lateral axis, which is perpendicular to the longitudinal axis, from a first edge to a second edge. An attachment portion at the first end provides fixation to an electrical conductor. A contact portion extends from the second end and cantilevers over the spine such that the contact portion is spaced apart from the spine in a direction along a vertical axis which is perpendicular to both the longitudinal axis and the lateral axis. A locking tab extends from the first edge and has a locking tab attachment end which is fixed to first edge and which extends toward, and is aligned with, the contact portion in a direction parallel to the vertical axis. The locking tab also has a free end which flares outward beyond contact portion.

Abstract: A gas sensor includes a metallic shell extending along a shell axis and defining a shell attaching surface that is substantially perpendicular to the shell axis; a metallic shield extending along a shield axis and defining a shield attaching surface that is substantially perpendicular to the shield axis; and a ceramic sensing element extending along a sensing element axis, the sensing element being rigidly fixed at a first axial location of the sensing element to the shell and the sensing element being laterally supported by the shield at a second axial location of the sensing element that is axially spaced apart from the first axial location. The shield is attached to the shell at an interface formed between the shield attaching surface and the shell attaching surface, thereby accommodating misalignment between the shield axis and the shell axis. A method of making the gas sensor is also provided.

Abstract: A gas sensor includes a metallic shell with a shell aperture extending therethrough along an axis; a metallic glass holder metallurgically sealed to the shell in order to prevent gases from passing between the glass holder and the shell, the glass holder including a glass holder aperture extending axially therethrough; a ceramic sensing element extending through the shell aperture and through the glass holder aperture; and a glass seal which seals between the sensing element and the glass holder in order to prevent gases from passing between the sensing element and the glass holder. A method of making the gas sensor is also provided.

Abstract: An electrical connector assembly having a connector body and a conductive terminal disposed within a cavity in the connector body. The terminal is held within the cavity by a rigid stop tab and a flexible lock tab that engage the ends of the connector body. A flexible bias tab having a fixed end attached to the body of the terminal and a free end extending outward laterally from the body of the terminal is configured to engage an inner wall of the cavity and urge the body of the terminal into contact with an opposite inner wall of the cavity, thereby inhibiting lateral movement of the terminal within the cavity. The bias tab may further limit rotational movement of the terminal within the cavity. The bias tab and/or any other feature of the terminal do not engage a locking feature located within the cavity.

Abstract: A gas sensor includes a metallic shell extending along a shell axis and defining a shell attaching surface that is substantially perpendicular to the shell axis; a metallic shield extending along a shield axis and defining a shield attaching surface that is substantially perpendicular to the shield axis; and a ceramic sensing element extending along a sensing element axis, the sensing element being rigidly fixed at a first axial location of the sensing element to the shell and the sensing element being laterally supported by the shield at a second axial location of the sensing element that is axially spaced apart from the first axial location. The shield is attached to the shell at an interface formed between the shield attaching surface and the shell attaching surface, thereby accommodating misalignment between the shield axis and the shell axis. A method of making the gas sensor is also provided.

Abstract: A gas sensor includes a metallic shell with a shell aperture extending therethrough along an axis; a metallic glass holder metallurgically sealed to the shell in order to prevent gases from passing between the glass holder and the shell, the glass holder including a glass holder aperture extending axially therethrough; a ceramic sensing element extending through the shell aperture and through the glass holder aperture; and a glass seal which seals between the sensing element and the glass holder in order to prevent gases from passing between the sensing element and the glass holder. A method of making the gas sensor is also provided.

Abstract: A gas sensor with a high temperature electrical connector is provided. The electrical connector incorporates a ceramic connector body having a pair of opposing ceramic body portions which each house a plurality of conductive terminals. The body portions are in pivoting engagement and fixed in a connector body retainer which also enables their pivoting, hinged movement. The pivoting engagement permits the ceramic body portions and terminals to hinge open to receive a gas sensor with a low insertion force and a hinge closed to provide the desired contact force.

Abstract: A ceramic connector body for a high temperature electrical connector, such as those used in high temperature gas sensors, incorporates a pair of opposing ceramic body portions which are operative for pivoting engagement and to be fixed in a connector body retainer which also enables their pivoting, hinged movement. The pivoting engagement permits the ceramic body portions to hinge open to receive a gas sensor with a low insertion force and a hinge close to provide the desired contact force. The ceramic body portions are also operative to house conductive terminals which provide electrical contact for power and signal communication with a gas sensor.

Abstract: A connector body retainer for a high temperature electrical connector used in a high temperature gas sensor retains the ceramic body portions while also permitting their hinged movement. The connector body retainer includes a pair of retainer bands each having a generally u-shaped or c-shaped profile with a base portion and a pair of opposed extending legs, the legs of each band extending toward the other in opposing arrangement to provide the retainer, with each retainer band having an outer surface, an inner surface, a hinge end and an insertion end. The legs of the respective bands which are in opposing arrangement are joined together by a respective pair of outwardly arched hinges proximate the hinge end and will allow the ceramic body portions to hinge open to receive a gas sensor at a relatively low insertion force and hinge closed to provide a relatively higher contact force.

Abstract: A ceramic connector body for a high temperature electrical connector, such as those used in high temperature gas sensors, incorporates a pair of opposing ceramic body portions which are operative for pivoting engagement and to be fixed in a connector body retainer which also enables their pivoting, hinged movement. The pivoting engagement permits the ceramic body portions to hinge open to receive a gas sensor with a low insertion force and a hinge close to provide the desired contact force. The ceramic body portions are also operative to house conductive terminals which provide electrical contact for power and signal communication with a gas sensor.

Abstract: A sealed joint for a gas sensor as described which includes a sensor shell having an attachment portion and a sealing portion. The sealing portion has an inner recessed section and an outer protruding section terminating at a free end of the shell, the outer protruding section having an outer section diameter which is greater than the diameter of the inner section. The sealed joint also has an upper shield having a shell portion disposed around the sealing portion of the shell and a connector portion which extends upwardly away from the shell portion. The sealed joint includes a first radial crimp of the upper shield proximate the inner recessed section and a second radial crimp of the upper shield in the connector portion proximate the shell portion, such that the second crimp has a crimp diameter which is less than the outer section diameter of the shell.

Abstract: A connector body retainer for a high temperature electrical connector used in a high temperature gas sensor retains the ceramic body portions while also permitting their hinged movement. The connector body retainer includes a pair of retainer bands each having a generally u-shaped or c-shaped profile with a base portion and a pair of opposed extending legs, the legs of each band extending toward the other in opposing arrangement to provide the retainer, with each retainer band having an outer surface, an inner surface, a hinge end and an insertion end. The legs of the respective bands which are in opposing arrangement are joined together by a respective pair of outwardly arched hinges proximate the hinge end and will allow the ceramic body portions to hinge open to receive a gas sensor at a relatively low insertion force and hinge closed to provide a relatively higher contact force.

Abstract: A gas sensor with a high temperature electrical connector is provided. The electrical connector incorporates a ceramic connector body having a pair of opposing ceramic body portions which each house a plurality of conductive terminals. The body portions are in pivoting engagement and fixed in a connector body retainer which also enables their pivoting, hinged movement. The pivoting engagement permits the ceramic body portions and terminals to hinge open to receive a gas sensor with a low insertion force and a hinge closed to provide the desired contact force.

Abstract: A high temperature electrical connector suitable for use in a high temperature gas sensor. The electrical connector incorporates a ceramic connector body having a pair of opposing ceramic body portions which each house a plurality of conductive terminals. The body portions are in pivoting engagement and fixed in a connector body retainer which also enables their pivoting, hinged movement. The pivoting engagement permits the ceramic body portions and terminals to hinge open to receive a gas sensor with a low insertion force and a hinge closed to provide the desired contact force. The ceramic body portions may also include a taper section in a pivot portion with a taper angle that may be varied to control the pivoting, hinged movement of the electrical connector.

Abstract: A gas sensor seal (40) comprising a body (122), an upper portion having a flange (124), and at least one channel (130). The flange (124) has an extension (131) that extends from the upper portion, a bend (129) which extends from the extension (131) along the body (122), and a protrusion (128) which extends from the bend (129) toward the body (122). The channel (130) extends through the body (122) from the upper portion to a lower surface (126). A method for using the gas sensor seal (40) within a sensor (10) is also provided.

Abstract: A gas sensor comprises a first electrode and a second electrode; and an electrolyte disposed between the first electrode and the second electrode. The electrolyte is shaped into a cylinder having an axial open end portion, an axial middle portion, and an axial closed end portion. The axial closed end portion has a uniform wall thickness equal to or less than about 1.5 millimeters. A radial transition in an interior region of the electrolyte between the middle and the closed end portions forms a shoulder. Processes for sensing exhaust gas generally includes disposing the gas sensor in an exhaust stream, contacting the closed end portion of the sensor with exhaust gas, and creating an electromotive force. The sensor activates quickly due to the close proximity to a rod heater and the low thermal mass resulting from the small inner diameter and thin wall section of the closed end portion.

Abstract: A gas sensor having a substantially round to rectangular cross sectional transition includes a heater having a connection portion that has a characteristic cross sectional geometry, a heating portion that has a characteristic cross sectional geometry, and a transition portion disposed intermediate the connection and heating portions. The transition portion has a cross sectional geometry that is variable along a length thereof to effectuate a smooth transition between the connection portion and the heating portion. Typically, the cross sectional geometry of the connection portion is substantially rectangular in shape, while the cross sectional geometry of the heating portion is substantially round.

Abstract: Disclosed is an exhaust oxygen sensor including a component requiring electricity to operate such as a heater or oxygen electrode. The first electrical terminal is provided in electrical contact with the component and wherein the electrical terminal has at least one male prong. The second electrical terminal in electrical contact with a wire for delivering electrical power from an external source is also provided. The second electrical terminal has at least one female connector or receptacle. The male prong and the female connector are constructed and arranged so at least one of the first and second electrical terminals is removable with respect to the other terminal. The sensor may include a threaded nut slidably received over a tubular housing, constructed and arranged to be threaded onto a threaded exhaust manifold boss without rotating the housing.

Abstract: The invention includes a flat plate exhaust sensor including a flat plate sensing element which is carried by a first ceramic insulator having at its upper end an upwardly extending annular ring. The annular ring defines a disc-shaped recess which is filled with a glass seal. Thus, the glass seal extends from the flat plate sensor to the annular ring of the ceramic insulator. The sensor includes an upper tubular shell which includes at the lower end a leg portion which extends inside an inner wall of a lower tubular shell. The leg portion includes a foot which is bent to match an outwardly extending sloped annular shoulder formed on an upper insulator. The upper insulator is seated on the glass seal. An intermediate gasket is formed by an active metal braze gasket between the foot and the outwardly extending sloped annular shoulder of the upper insulator. An external seal is provided by a braze ring which joins an upper end of the lower tubular shell to the upper tubular shell.