Fold-back Joint Bending for Chip Resistor Stability
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Solution Overview
Problem
Conventional chip type variable resistors face issues with deformation and reduced rotation angle due to the design of the fold-back joint and stopper piece, which increases weight and complexity when attempting to enhance strength and prevent deformation.
Innovation Solution
The fold-back joint is bent downward to form an upright U-shape, and the stopper piece is formed with a lower projecting height and integrated with the internal terminal electrode plate for enhanced strength and adhesion, preventing deformation and maintaining rotation efficiency without increasing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the width of the fold-back joint is increased to prevent deformation, then the reliability of the rotor structure is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The fold-back joint is bent downward from the upper surface of the second plate, changing the spatial orientation of the joint. This downward bending creates a more stable structural configuration that resists deformation without requiring an increase in the width of the joint, thereby maintaining manufacturing simplicity while improving reliability
2Reliability
If the width of the fold-back joint is increased to prevent deformation, then the reliability of the rotor structure is improved, but the weight of the rotor increases
Solution Approach 1:
By bending the fold-back joint downward, the patent achieves improved structural stability through a three-dimensional configuration rather than increasing the two-dimensional width. This allows the joint to resist deformation forces more effectively without adding extra material, thereby preventing weight increase while maintaining reliability
3Reliability
If the width of the stopper piece is increased to enhance strength against tilting, then the reliability of the stopper piece is improved, but the rotation angle of the rotor is reduced
Solution Approach 1:
The stopper piece is positioned to interact with the downward-bent fold-back joint in a vertical dimension. This vertical positioning allows the stopper piece to provide sufficient strength against tilting forces without requiring an increase in width that would constrain the rotor's rotation angle, thus maintaining both reliability and rotational freedom
4Reliability
If the projecting height of the stopper piece is increased to reach the fold-back joint, then the reliability of the stopper piece is improved, but the strength of the stopper piece against tilting is reduced
Solution Approach 1:
The downward bending of the fold-back joint creates a new vertical reference level. The stopper piece is designed to reach this new level with an appropriate projecting height that does not require excessive height. The downward bend provides additional structural support that compensates for the reduced projecting height, thereby maintaining reliability while improving strength against tilting
Data Source
AI summary
In a chip type variable electronic part including an insulating substrate, and an adjustment rotor made of a metal plate rotatably mounted on an upper surface of the insulating substrate, in which the rotor is constituted of a first plate formed in a bowl shape to receive a screwdriver that rotates the rotor, and a second plate superposed on an upper surface of the first plate and integrally coupled thereto via a fold-back joint, and the second plate includes a screwdriver engagement hole perforated therein for the screwdriver to be fitted in, the fold-back joint is bent downward from an upper surface of the second plate, thereby preventing deformation of the fold-back joint when the rotor is rotated with the screwdriver.