Bent Resistor Connections for Compact Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing high-performance resistors face a trade-off between compactness and assembly friendliness, as a smaller spacing between resistor elements is desirable for a compact design but harder to assemble, while a larger spacing is more assembly-friendly but increases the structural size.
Innovation Solution
The resistor elements are configured with connections that have inner and outer portions bent at predetermined angles, allowing for double the spacing between connections on one side, facilitating assembly while maintaining the same structural size and using similar standard elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the spacing between adjacent resistor elements is reduced to achieve a compact design, then the structural size is minimized, but the assembly process becomes more difficult
Solution Approach 1:
The connection geometry is changed from a simple straight configuration to a bent configuration with inner and outer portions at different heights. This dimensional change allows the connections to be staggered vertically, effectively doubling the available lateral spacing for assembly operations while maintaining the same longitudinal spacing between resistor elements, thus resolving the contradiction between compact size and assembly ease
Solution Approach 2:
The connection is divided into distinct inner and outer portions with different spatial orientations. The inner portion is bent at a predetermined angle while the outer portion remains in a parallel plane, creating segmented connection zones that provide separate access paths for assembly tools and operations, thereby improving assembly friendliness without increasing overall structural size
2Reliability
If four different kinds of resistor elements are used to achieve proper connections, then the electrical connection requirements are met, but the device complexity increases
Solution Approach 1:
The connection geometry employs asymmetric bending where the inner portion is bent at a predetermined angle while the outer portion remains in a parallel plane. This asymmetric design creates a universal connection type that can accommodate all positioning requirements (start, end, and intermediate elements) through a single element design, eliminating the need for four different element types while maintaining reliable electrical connections
Solution Approach 2:
The bent connection design with inner and outer portions serves multiple functions simultaneously: it provides electrical connection, mechanical support, and universal compatibility for all resistor element positions. This multi-functional design allows a single type of resistor element to be used throughout the assembly, replacing the need for specialized start, end, left-hand, and right-hand intermediate elements
Data Source
AI summary
A high-performance resistor includes resistor elements electrically connected in series and each having a first and second side and a first and second end. At the first end is a first connection and provided at the second end is a second connection for connecting the resistor elements. The first and second connections each have an inner portion and an outer portion. The inner portion of the first connection is bent at a predetermined angle with respect to the first side of the resistor element. The outer portion of the first connection is in a plane which is substantially parallel to the plane of the resistor element. The inner portion of the second connection is bent at a predetermined angle with respect to the second side of the resistor element. The outer portion of the second connection is in a plane which is substantially parallel to the plane of the resistor element.