Current Sensing Resistor With Middle Slot For Resistance Stability
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Solution Overview
Problem
Conventional current sensing resistors face manufacturing challenges due to the use of multiple materials and processes like soldering, which complicates material characterization and affects resistance stability, making it difficult to fully demonstrate the material characteristics of the resistor substrate.
Innovation Solution
A current sensing resistor is fabricated using a single highly electrically conductive metal or alloy with strategically designed slots to control resistance stability, featuring a middle slot and side slots that divide the metal plate into current and sensing terminals, allowing for easier material selection and improved manufacturing convenience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional current sensing resistors use fixed connection of different materials (metal plates with side portions) through soldering or adhering, then the structure can be assembled, but the manufacturing process becomes time-consuming and difficult to control material characteristics, affecting resistance stability
Solution Approach 1:
The patent merges multiple separate components (metal plate with fixed resistance and side portions with high electrical conductivity) into a single integral molded resistor substrate. This eliminates the need for soldering or adhering operations, reduces manufacturing complexity, and ensures consistent material characteristics throughout the entire resistor structure, thereby improving both resistance stability and manufacturing convenience.
Solution Approach 2:
The patent uses a molded resistor substrate that integrates different functional regions (fixed resistance portion and high electrical conductivity side portions) into a single composite structure. This allows the substrate to demonstrate the full material characteristics of the molding material while achieving the desired electrical properties through structural design rather than material assembly.
2Adaptability or versatility
If conventional current sensing resistors use multiple materials and extra materials for fixed connection, then the structure can be assembled, but the material characteristics of the resistor substrate cannot be fully demonstrated
Solution Approach 1:
The patent combines all functional elements into a single integral molded structure, eliminating the need for separate side portions and connection materials. This allows the resistor substrate to fully demonstrate the material characteristics of the molding material while reducing structural complexity.
Solution Approach 2:
The molded resistor substrate serves multiple functions simultaneously: it provides the fixed resistance, the high electrical conductivity paths, and the structural support, all within a single universal component that fully demonstrates the capabilities of the molding material.
3Ease of manufacture
If the current terminals of the first portion and the second portion have a length greater than that of the sensing terminals, then the manufacturing is more convenient, but the structure becomes asymmetric
Solution Approach 1:
The patent deliberately introduces asymmetry into the resistor substrate structure by making the current terminals longer than the sensing terminals. This asymmetric design optimizes the electrical performance and manufacturing convenience while maintaining the integral molded structure, demonstrating that functional requirements can drive structural asymmetry without compromising the benefits of single-material construction.
Data Source
AI summary
The present invention relates to a current sensing resistor made by an electrically conductive metal plate, and the current sensing resistor comprising: a middle portion; a first portion with a first slot located at one side of the middle portion; and a second portion with a second slot located at the other side of the middle portion opposite to the first portion; wherein each of the first and second portions is divided into a current terminal and a sensing terminal by the first and second slots respectively, and the current terminals of the first and second portions have a length greater than that of the sensing terminals of the first and second portions; characterized in that the middle portion has a middle slot and the length of the middle slot can be used for controlling the stability of resistance for the current sensing resistor.