Resistor Production via Through-Hole Butt Joints
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Solution Overview
Problem
The existing method for producing resistors results in a significant amount of waste from sheet materials used for resistive elements during the stamping process.
Innovation Solution
A method involving forming through-holes in a conductive material, fitting resistive element pieces into these holes to create butt joints with the electrodes, and then stamping the joint regions to produce resistors with reduced material waste, including welding the joints and using a narrower stamping width to avoid shape deterioration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If resistive elements are stamped from sheet material, then mass production is enabled, but material waste increases significantly
Solution Approach 1:
The invention transitions from a planar stamping process to a three-dimensional assembly process. Resistive element pieces are fitted into through-holes of the conductive material, creating a vertical stacking configuration. This dimensional change allows efficient use of material by utilizing the thickness dimension rather than wasting lateral material during stamping.
Solution Approach 2:
The resistive element pieces are nested within the through-holes of the conductive material. This nesting arrangement allows the resistive elements to be positioned precisely within the electrode structure, minimizing material waste while enabling mass production through standardized through-hole configurations.
2Strength
If joint portions are welded, then strong electrical connection is achieved, but shape deterioration occurs at welding positions
Solution Approach 1:
The welding start position and welding end position are extracted from the region to be stamped. By excluding these potentially problematic welding zones from the stamping area, the invention prevents shape deterioration while maintaining the electrical connection strength provided by welding.
Solution Approach 2:
The stamping width is locally adjusted to be narrower than the width of each joint portion, specifically excluding the welding start and end positions. This localized modification of the stamping region maintains overall resistor quality while preventing shape deterioration at critical welding locations.
3Loss of substance
If resistive element pieces are fitted into through-holes, then material waste is reduced, but assembly complexity increases
Solution Approach 1:
Through-holes are pre-formed in the conductive material before the resistive element pieces are fitted. This preliminary action simplifies the assembly process by providing ready-made receptacles for the resistive elements, reducing assembly complexity while maintaining material efficiency.
Solution Approach 2:
The through-hole structure itself provides the positioning and retention mechanism for the resistive element pieces. The geometry of the through-holes is designed to automatically guide and secure the resistive elements during fitting, eliminating the need for additional complex positioning or fixing mechanisms.
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 allows for efficient mass production of resistors with butt joint structures while minimizing material waste and preventing shape deterioration at welding positions.
Implementation Method 1
The step of forming the joint portions preferably includes a step of welding two side surfaces of the resistive element piece to the respective side surfaces in the through-hole at the joint portions.
Data Source
AI summary
Provided is a method for producing a resistor, including a step of forming a through-hole in a sheet-like conductive material; a step of fitting a resistive element piece into the through-hole and thus forming joint portions where end surfaces of the resistive element piece are joined to respective side surfaces of the conductive material exposed by the through-hole; and stamping a region including the joint portions from the conductive material, thereby forming a resistor including a resistive element and a pair of electrodes.