Brush Switch Resistor Mounting via Mold Frame Segmentation

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Solution Overview

Problem

Conventional brush switches with resistors in vehicle-mounted ECU circuits are not suitable for mass production due to the complex shape of the supporting wall part, which requires manual soldering of chip resistors, increasing manufacturing costs and reducing productivity.

Innovation Solution

A brush switch with resistors is designed where multiple resistors with different resistance values are attached to the spaces between contact point spring pieces, integrated into a mold frame, and soldered using a surface mounting device, allowing for automatic assembly and reducing manual labor.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a recessed part is installed on a side face of a complex-shaped supporting wall part to accommodate chip resistors, then the resistors can be mounted, but the structure becomes unsuitable for automatic soldering equipment and requires manual soldering

Engineering Contradiction:

Improveresistor mounting capabilityVSAvoidsuitability for automatic soldering

Core Design Contradiction:

Ease of manufactureVSExtent of automation

Solution Approach 1:

The invention divides the resistor mounting function from the complex supporting wall structure by introducing a separate mold frame component. The mold frame is a simplified, standardized structure that can be easily soldered by automatic equipment, while the complex supporting wall retains its original function of providing mechanical support and positioning. This segmentation allows the resistor mounting substrate to be automated without compromising the overall structural requirements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mold frame acts as an intermediary component between the complex supporting wall and the chip resistors. It provides a standardized mounting platform that is compatible with automatic soldering equipment, while being integrated into the existing complex structure. The mold frame mediates between the conflicting requirements of complex structural support and automated assembly compatibility.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If manual soldering is used for chip resistors, then precise placement is achieved, but production efficiency decreases and manufacturing cost increases

Engineering Contradiction:

Improveresistor placement precisionVSAvoidproduction efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The mold frame is designed with pre-formed recessed parts and positioning features that guide chip resistor placement during automatic mounting. The preliminary structuring of the mold frame ensures that automatic soldering equipment can achieve precise placement without manual intervention, maintaining manufacturing precision while enabling high-speed automated assembly.

Inventive Principle:

Principle #10Preliminary action

3Stability of the object's composition

If a complex-shaped supporting wall part is used to hold the extended part, then structural stability is achieved, but the structure is not fit for soldering by automatic equipment

Engineering Contradiction:

Improvestructural stabilityVSAvoidautomatic soldering compatibility

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The invention segments the structural support function from the resistor mounting function. The complex-shaped supporting wall part retains its original design for structural stability and mechanical support, while a separate simplified mold frame handles the resistor mounting and soldering operations. This allows each component to be optimized for its specific function without compromise.

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach enhances production efficiency and reduces manufacturing costs by enabling the use of automatic surface mounting devices, facilitating mass production while maintaining circuit stabilization and miniaturization.

Implementation Method 1

a mold frame that isolates the spaces between the multiple contact point spring pieces from one another

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Implementation Method 2

mounting and soldering chip resistors into the mold frame

Methodology Applied

Scientific EffectSoldering: Soldering

Data Source

PatentUS11164710B2Brush switch with resistors and manufacturing method thereof

Publication Date: 2021.11.02 MIC ELECTRON CO

AI summary

A brush switch with resistors includes a case, a fixed contact point pattern that is fixed to the case, a lever that is supported by the case in an inclinable manner, and a movable contact point brush that is movable by an operation of the lever such that the movable contact point either contacts to or does not contact to the fixed contact point. Wherein the fixed contact point pattern has multiple fixed contact points that are disposed separated from one another in the case, and multiple terminals each of which is connected to the multiple fixed contact points, and the movable contact point brush has multiple contact point spring pieces that separate from or contact with the multiple fixed contact points, respectively, and multiple resistors, which have different resistance values, that are attached to spaces between the multiple contact point spring pieces.