Comb-Pattern Variable Resistor Structure Against Slider Wear
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Solution Overview
Problem
The degradation of comb-like-pattern members in variable resistors due to repetitive contact and lateral forces during slider sliding is not adequately addressed in existing designs.
Innovation Solution
The spaces between comb-like-pattern members are filled with an insulator, and the top edge surfaces of these members are exposed through the insulator, ensuring structural integrity and reducing degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If spaces between comb-like-pattern members are left empty to maintain simple structure, then device complexity is reduced, but the comb-like-pattern members suffer degradation from repetitive lateral contact forces
Solution Approach 1:
An insulator is introduced as an intermediary substance to fill the spaces between comb-like-pattern members. This insulator mediates the interaction between the connector and comb-like-pattern members by providing lateral support and preventing direct contact that causes degradation, while maintaining the overall simplicity of the device structure.
Solution Approach 2:
The insulator is positioned in advance within the spaces between comb-like-pattern members to prevent harmful lateral contact forces before they can cause degradation. This beforehand cushioning protects the comb-like-pattern members from repetitive mechanical stress during slider operation.
2Strength
If insulator material is added to fill spaces between comb-like-pattern members, then structural support and stability are enhanced, but manufacturing complexity increases
Solution Approach 1:
The insulator filling process is merged with existing manufacturing steps. The insulator is formed as part of the base structure fabrication process, combining multiple functions (insulation, mechanical support, space filling) into a single integrated manufacturing operation rather than adding separate steps.
Data Source
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AI summary
A variable resistor 1A includes a base 11, a plurality of comb-like-pattern members 45a to 45j supported by the base 11 and extending with intervals therebetween, and a first resist layer 20 disposed on the base 11 such that spaces between the comb-like-pattern members 45a to 45j are filled with the first resist layer 20. The comb-like-pattern members 45a to 45j include upper surfaces 46 on a side opposite to the base 11, and the upper surfaces 46 are exposed through the first resist layer 20.