EXHAUST GAS TEMPERATURE SENSOR

1 . A temperature sensor assembly comprising:

a temperature sensing element; and

a temperature sensor housing defining an interior cavity, wherein a distal end region of said interior cavity includes a temperature sensing element cavity defined by a closed end of said temperature sensor housing and configured to receive at least a portion of said temperature sensing element;

wherein at least a portion of said temperature sensing element cavity is shrunk around at least a portion of said temperature sensing element.

2 . The temperature sensor assembly of claim 1 , wherein at least a portion of said temperature sensing element cavity is heat shrunk around at least a portion of said temperature sensing element.

3 . The temperature sensor assembly of claim 1 , wherein at least a portion of said temperature sensing element cavity is cold shrunk around at least a portion of said temperature sensing element.

4 . The temperature sensor assembly of claim 1 , wherein said temperature sensor housing comprises:

a tip body including an open end and said closed end, said open end including a first flange portion;

a wire harness body including two end opens, wherein one of said open ends includes a second flange portion; and

a crimp coupling said first and said second flange portions together to form said temperature sensor housing.

5 . The temperature sensor assembly of claim 1 , wherein said temperature sensor assembly does not include a powder or potting material disposed within said temperature sensing element cavity.

6 . The temperature sensor assembly of claim 1 , further comprising an insulating member disposed within said temperature sensor assembly, said insulating member including at least one non-circular region disposed between said first and said second ends, and wherein said temperature sensor housing includes at least one insulator crimp configured to extend generally inwardly toward at least a portion of said non-circular region of said insulating member and prevent said insulating member from rotating relative to said temperature sensor housing.

7 . A temperature sensor assembly comprising:

a tip body including a closed end and an open end, said open end including a first flange portion;

a wire harness body including two open ends, wherein one of said open ends includes a second flange portion;

a crimp coupling said first and said second flange portions together to form a temperature sensor housing, wherein temperature sensor housing defines an interior cavity; and

a temperature sensing element disposed within at least a portion of said interior cavity.

8 . The temperature sensor assembly of claim 7 , further comprising an insulating member disposed within said temperature sensor assembly.

9 . The temperature sensor assembly of claim 8 , wherein least a portion of said insulating member includes a generally cylindrical shape including a first end, a second end, and at least one longitudinal opening extending therethrough.

10 . The temperature sensor assembly of claim 8 , wherein said insulating member includes at least one non-circular region disposed between said first and said second ends.

11 . The temperature sensor assembly of claim 10 , wherein said non-circular region includes a planar region molded into said insulator member.

12 . The temperature sensor assembly of claim 10 , wherein said temperature sensor housing includes at least one insulator crimp configured to extend generally inwardly toward at least a portion of said non-circular region of said insulating member and prevent said insulating member from rotating relative to said temperature sensor housing.

13 . The temperature sensor assembly of claim 9 , wherein interior cavity includes at least one generally conical seat configured to contact against and center said first end of said insulating member within said interior cavity.

14 . The temperature sensor assembly of claim 8 , wherein at least a portion of said tip body generally tapers such that at least a portion of said closed end has a smaller diameter than said open end, and wherein said insulating member has a tapered body which generally corresponds to said taper of said tip body.

15 . A temperature sensor assembly comprising:

a temperature sensor housing;

a temperature sensing element disposed proximate to a first end of said temperature sensor housing;

an insulating member disposed within said temperature sensor housing; and

at least one insulator crimp configured to extend generally inwardly toward at least a portion of said insulating member to prevent said insulating member from rotating relative to said temperature sensor housing;

wherein a location of said at least one insulator crimp along said temperature sensor housing is selected based on a resonant frequency of said temperature sensor assembly.

16 . The temperature sensor assembly of claim 15 , wherein at least a portion of said insulating member includes a generally cylindrical shape including a first end, a second end, and at least one longitudinal opening extending therethrough.

17 . The temperature sensor assembly of claim 16 , further comprising a conductor configured to be disposed within at least a portion of said longitudinal opening of said insulating member, said conductor having a first end electrically coupled to an element lead of said temperature sensing element and a second end electrically coupled to a wire harness assembly wire.

18 . The temperature sensor assembly of claim 15 , wherein said insulating member includes at least one non-circular region disposed between said first and said second ends.

19 . The temperature sensor assembly of claim 18 , wherein said non-circular region includes a planar region molded into said insulator member.

20 . The temperature sensor assembly of claim 15 , wherein said at least one insulator crimp is configured to contact at least a portion of said non-circular region of said insulating member.