Variable resistor

1. Field of the Invention

The present invention relates to a variable resistor suitable for use in, for example, detecting a tilt angle of a seat in an automobile.

2. Description of the Related Art

A related variable resistor will be described with reference to FIGS. 9 and 10 . FIG. 9 is a vertical sectional view of the main portion of the related variable resistor. FIG. 10 is a transverse sectional view of the main portion of the related variable resistor. In the structure of the related variable resistor shown in FIGS. 9 and 10 , a resistance element (not shown) and a resistance substrate 53 to which a terminal 52 is mounted are disposed in a recess of an exterior case 51 formed of an insulating material.

A rotor 55 having a sliding element 54 which slidably contacts the resistance element is mounted in the recess of the exterior case 51 . Although not shown, a stopper is disposed between the rotor 55 and the exterior case 51 for stopping the rotation of the rotor 55 .

An inner toothed portion 51 a is formed on the inner peripheral surface defining the recess of the exterior case 51 , and a groove 55 a for accommodating a planetary disc 56 formed of rubber is formed in the rotor 55 . The circular outer peripheral surface of the planetary disc 56 comes into resilient contact with the inner toothed portion 51 a.

An operating member 57 having a cross-shaped driver groove 57 a and an externally toothed gear 57 b is rotatably mounted to the top portion of the exterior case 51 . The externally toothed gear 57 b of the operating member 57 is positioned in the groove 55 a and resiliently contacts the circular outer peripheral surface of the planetary disc 56 , and pushes the planetary disc 56 against the inner toothed portion 51 a . This causes the inner toothed portion 51 a , the planetary disc 56 , and the externally toothed gear 57 b to form a reduction rotation transmission mechanism based on a planetary gear mechanism, and a clutch mechanism.

The resistance substrate 53 is secured to the lower portion of the exterior case 51 by filling the lower portion of the exterior case 51 with resin. Accordingly, the related variable resistor is formed.

In the related variable resistor having the aforementioned structure, when the operating member 57 is rotated in the direction of arrow A 1 with a driver, the externally toothed gear 57 b also rotates in the direction of arrow A 1 . Therefore, the planetary disc 56 rotates in the direction of arrow A 2 by friction between the externally toothed gear 57 b and the inner toothed portion 51 a.

When the planetary disc 56 rotates in the direction of arrow A 2 , the rotor 55 is pushed and rotates in the direction of arrow A 3 . As a result, the sliding element 54 comes into sliding contact with the resistance element, causing the resistance to vary. Continuing the rotation of the operating member 57 causes the rotor 55 to bump into the stopper at the exterior case 51 , and to stop rotating. Further continuing the rotation of the operating member 57 causes a slip to occur between the externally toothed gear 57 b and the planetary disc 56 . (Refer to, for example, Japanese Unexamined Patent Application Publication No. 5-21214.)

However, the related variable resistor comprises a clutch mechanism using the rubber planetary disc 56 . Therefore, when the rotation of the operating member 57 is continued while the rotation of the rotor 55 is stopped, the rotation of the externally toothed gear 57 b in resilient contact with the planetary disc 56 causes considerable wearing of the planetary disc 56 . As a result, in addition to not being possible to maintain the clutch mechanism and the reduction rotation transmission mechanism over a long period of time, the resistance cannot be finely because the reduction ratio in the planetary gear mechanism using one planetary disc 56 is small.

Since the related variable resistor comprises a clutch mechanism using the rubber planetary disc 56 , it has the problem that it is not possible to maintain the clutch mechanism and the reduction rotation transmission mechanism over a long period of time because when the rotation of the operating member 57 is continued while the rotation of the rotor 55 is stopped, the rotation of the externally toothed gear 57 b in resilient contact with the planetary disc 56 causes considerable wearing of the planetary disc 56 .

Accordingly, it is an object of the present invention to provide a variable resistor comprising a clutch mechanism and a reduction rotation transmission mechanism having long lives, and which can finely vary resistance.

According to a basic form of the present invention, there is provided a variable resistor comprising an operating member rotatably supported by a case and having a gear, a reduction rotation transmission mechanism including a plurality of gears for transmitting rotation of the operating member, a resistance member having a rotary member for varying resistance, and a rotation transmission member for rotating the rotary member. In the variable resistor, a plate-shaped clutch which resiliently contacts a geared wheel and the rotation transmission member is disposed between the geared wheel and the rotation transmission member, so that a clutch mechanism is formed, the geared wheel being disposed at a termination end of the reduction rotation transmission mechanism. The rotation from the operating member is transmitted to the rotary member through the reduction rotation transmission mechanism, the clutch mechanism, and the rotation transmission member to vary resistance. When the rotation of the rotation transmission member is stopped, the clutch mechanism slips to stop varying the resistance.

In a first form based on the basic form, the clutch comprises a wave washer formed of a metallic plate having a spring characteristic.

In a second form based on the basic form, the geared wheel has a through hole in a central portion, the rotation transmission member has a plurality of stopping portions which are stopped by the geared wheel as a result of inserting the stopping portions in the through hole, and the rotation transmission member is combined with the geared wheel by the stopping portions.

In a third form based on the second form, the clutch has an annular portion having an opening in a central portion, and is interposed between the rotation transmission member and the geared wheel by inserting the stopping portions in the opening.

In a fourth form based on the second form, the case has a protrusion, and the stopping portions are prevented from being dislodged from the geared wheel by positioning the protrusion in the through hole of the geared wheel.

In a fifth form based on the basic form, the variable resistor further comprises a holding member for holding the resistance member, in which a stopper for stopping the rotation of the rotation transmission member is disposed between the rotation transmission member and the holding member.

In a sixth form based on the fifth form, the holding member has a connection conductor for connecting a terminal disposed at the resistance member, and a resistance value of the resistance member is provided to the outside of the case through the connection conductor.

In a seventh form based on the fifth form, the holding member is caught and stopped by the case by a stopper protrusion of the case.

In an eighth form based on the basic form, the rotary member has a hole in a central portion, and the rotation transmission member has a shaft inserted in the hole of the rotary member to transmit the rotation to the rotary member.

In a ninth form based on the basic form, the case comprises first and second case portions, a protrusion disposed at one of the first and second case portions, and a stopper arm disposed at the other of the first and second case portions, the case is a box case obtained by catching and stopping the protrusion and the stopper arm with respect to each other, and the case accommodates at least the reduction rotation transmission mechanism, the rotation transmission member, the clutch mechanism, and the resistance member.

In a tenth form based on the ninth form, the operating member is held between the first and second case portions, and at least one of the gears of the reduction rotation transmission mechanism is rotatably supported by a shaft formed by a protrusion disposed at either one of the first and second case portions.

In an eleventh form based on the ninth form, at least one of the gears of the reduction rotation transmission mechanism is rotatably supported by the operating member.

As mentioned above, the variable resistor comprises an operating member rotatably supported by a case and having a gear, a reduction rotation transmission mechanism including a plurality of gears for transmitting rotation of the operating member, a resistance member having a rotary member for varying resistance, and a rotation transmission member for rotating the rotary member. In the variable resistor, a plate-shaped clutch which resiliently contacts a geared wheel and the rotation transmission member is disposed between the geared wheel and the rotation transmission member, so that a clutch mechanism is formed, the geared wheel being disposed at a termination end of the reduction rotation transmission mechanism. The rotation from the operating member is transmitted to the rotary member through the reduction rotation transmission mechanism, the clutch mechanism, and the rotation transmission member to vary resistance. When the rotation of the rotation transmission member is stopped, the clutch mechanism slips to stop varying the resistance.

Accordingly, when a plate-shaped clutch is interposed between the flat portions of the geared wheel and the rotation transmission member, less wearing occurs than in a related variable resistor. Therefore, it is possible to maintain the clutch mechanism and the reduction rotation transmission mechanism over a long period of time, so that, not only is the variable resistor highly reliable, but also it can finely vary the resistance due to a large reduction ratio achieved by the reduction rotation transmission mechanism comprising a plurality of gears.

Since the clutch comprises a wave washer formed of a metallic plate having a spring characteristic, the clutch can be made more durable, so that the clutch mechanism and the reduction rotation transmission mechanism can be maintained over a long period of time. Thus, a highly reliable variable resistor is provided.

Since the geared wheel has a through hole in a central portion, the rotation transmission member has a plurality of stopping portions which are stopped by the geared wheel as a result of inserting the stopping portions in the through hole, and the rotation transmission member is combined with the geared wheel by the stopping portions, the rotation transmission member and the geared wheel in an integrated state can be incorporated into the case, so that high productivity is achieved.

Since the clutch has an annular portion having an opening in a central portion, and is interposed between the rotation transmission member and the geared wheel by inserting the stopping portions in the opening, the rotation transmission member, the geared wheel, and the clutch can be easily integrated. In the integrated state, they can be incorporated into the case, so that high productivity is achieved.

Since the case has a protrusion, and the stopping portions are prevented from being dislodged from the geared wheel by positioning the protrusion in the through hole of the geared wheel, reliable mounting of the rotation transmission member is achieved, so that the mounting can be highly resistant to vibration and shock.

Since the variable resistor further comprises a holding member for holding the resistance member, and has a stopper for stopping the rotation of the rotation transmission member disposed between the rotation transmission member and the holding member, the demand for different rotation ranges can be satisfied by only changing the holding member, so that the variable resistor can easily provide a variety of rotation ranges and the resistance member can be used in common without being changed, as a result of which costs are reduced.

Since the holding member has a connection conductor for connecting a terminal disposed at the resistance member, and a resistance value of the resistance member is provided to the outside of the case through the connection conductor, the holding member is changed in order to achieve a different form of external connection, so that the variable resistor can easily allow a variety of forms of external connection.

Since the holding member is caught and stopped by the case by a stopper protrusion of the case, the holding member is easily mounted to the case, and good productivity is achieved.

Since the rotary member has a hole in a central portion, and the rotation transmission member has a shaft inserted in the hole of the rotary member to transmit the rotation to the rotary member, after incorporating the resistance member into the case, the shaft of the rotation transmission member can be inserted into the hole in the rotary member, so that proper assembly is achieved.

Since the case comprises first and second case portions, a protrusion disposed at one of the first and second case portions, and a stopper arm disposed at the other of the first and second case portions, the case is a box case obtained by catching and stopping the protrusion and the stopper arm with respect to each other, and the case accommodates at least the reduction rotation transmission mechanism, the rotation transmission member, the clutch mechanism, and the resistance member, the case is easily assembled and high dust resistance is achieved.

Since the operating member is held between the first and second case portions, and at least one of the gears of the reduction rotation transmission mechanism is rotatably supported by a shaft formed by a protrusion disposed at either one of the first and second case portions, the operating member is reliably held, at least one of the gears is easily mounted and supported, and good productivity is achieved.

Since at least one of the gears of the reduction rotation transmission mechanism is rotatably supported by the operating member, a proper gear space factor is achieved, so that the case can be reduced in size.

FIG. 1 is a plan view of a variable resistor in accordance with the present invention;

FIG. 2 is a bottom view of the variable resistor in accordance with the present invention;

FIG. 3 is a sectional view of the main portion of the variable resistor in accordance with the present invention;

FIG. 4 is a perspective view of the variable resistor in accordance with the present invention resulting from removal of a second case portion;

FIG. 5 is an exploded perspective view of the variable resistor in accordance with the present invention;

FIG. 6 is a sectional view of a resistance member of the variable resistor in accordance with the present invention;

FIG. 7 is a plan view of a first case portion of the variable resistor in accordance with the present invention;

FIG. 8 is a plan view of a geared wheel of the variable resistor in accordance with the present invention;

FIG. 9 is a vertical sectional view of the main portion of a related variable resistor; and

FIG. 10 is a transverse sectional view of the main portion of the related variable resistor.

The figures used to describe a variable resistor in accordance with the present invention are FIGS. 1 to 8 . FIG. 1 is a plan view of the variable resistor in accordance with the present invention. FIG. 2 is a bottom view of the variable resistor in accordance with the present invention. FIG. 3 is a sectional view of the main portion of the variable resistor in accordance with the present invention. FIG. 4 is a perspective view of the variable resistor in accordance with the present invention resulting from removal of a second case portion. FIG. 5 is an exploded perspective view of the variable resistor in accordance with the present invention. FIG. 6 is a sectional view of a resistance member of the variable resistor in accordance with the present invention. FIG. 7 is a plan view of a first case portion of the variable resistor in accordance with the present invention. FIG. 8 is a plan view of a geared wheel of the variable resistor in accordance with the present invention.

For the sake of easier understanding of the drawings, in FIGS. 3 , 4 , and 5 , first to third gears and teeth (bumpy portions) of the geared wheel are not illustrated.

The structure of the variable resistor in accordance with the present invention will be described with reference to FIGS. 1 to 8 . A box case 1 , which is a product molded out of synthetic resin, has first and second case portions 2 and 3 that are combined and integrated together. The lower first case portion 2 has a bottom wall 2 a , a side wall 2 b extending upward from the outer periphery of the bottom wall 2 a and defining an accommodation portion, a relatively large hole 2 c in the bottom wall 2 a , a shaft 2 d disposed close to the hole 2 c and protruding from the bottom wall 2 a , a plurality of lead-out holes 2 e disposed in the bottom wall 2 a so as to be in parallel opposite to the shaft 2 d with the hole 2 c in between, a pair of stopper protrusions 2 f disposed on the bottom wall 2 a so as to be on both sides of the lead-out holes 2 e , a protrusion 2 g disposed on the bottom wall 2 a so as to be interposed between the stopper protrusions 2 f , a cylindrical portion 2 h protruding outward (downward) from the bottom wall 2 a so as to surround the lead-out holes 2 e , a plurality of protrusions 2 j disposed at the outer peripheral surface of the side wall 2 b , and a recess 2 k disposed in the bottom wall 2 a so as to be close to the protrusion 2 g and to face the hole 2 c.

The upper second case portion 3 has an upper wall 3 a , a side wall 3 b extending downward from the outer periphery of the upper wall 3 a and defining the accommodation portion, a large hole 3 c formed in the upper wall 3 a , a protrusion 3 d disposed at the upper wall 3 a and forming a shaft, and a plurality of stopper arms 3 f extending downward from the side wall 3 b and having openings 3 e.

By bringing the side walls 2 b and 3 b together and snappingly stopping the protrusions 2 j by the openings 3 e in the stopper arms 3 f , the first and second case portions 2 and 3 are fitted together, so that the case 1 having the accommodation portion therein is formed.

When the first and second case portions 2 and 3 are fitted together, the holes 2 c and 3 c oppose each other.

A holding member 4 comprises an insulating base 5 and connection conductors 6 a and 6 b mounted to the insulating base 5 . The insulating base 5 has a recess 5 a formed in the top surface, two holes 5 b and 5 c formed apart from each other, and upwardly protruding stoppers 5 d . The insulating base 5 is placed on the bottom wall 2 a while the protrusion 2 g is disposed and positioned in the hole 5 c . Both sides of the insulating base 5 are snappingly stopped by the pair of stopper protrusions 2 f and mounted to the bottom wall 2 a.

Here, the connection conductor 6 b is positioned in the cylindrical portion 2 h , becomes an outgoing terminal for a connector, and is lead out from the case 1 .

A resistance member 7 has an arcuate resistance element (not shown), and comprises an insulating plate 9 having a plurality of terminals 8 buried therein, a sliding element 10 which comes into sliding contact with the resistance element, a rotary member 11 having a non-circular hole 11 a (D-shaped in the embodiment) formed in the center thereof, and a cover 12 which is mounted to the insulating plate 9 while covering the resistance element and the sliding element 10 and which supports the rotary member 11 .

The resistance member 7 is mounted to the holding member 4 by soldering the terminal 8 to the connection conductor 6 a with the insulating plate 9 being disposed and positioned in the recess 5 a.

A rotary transmission member 13 , which is a product molded out of synthetic resin, has a flat portion 13 a , a plurality of stopping portions 13 b protruding upward from the flat portion 13 a , a shaft 13 c which protrudes downward from the center of the flat portion 13 a and which is non-circular (D-shaped in the embodiment), and a stopper 13 d protruding outward from the outer periphery of the flat portion 13 a.

The rotation transmission member 13 is inserted while the non-circular shaft 13 c engages the hole 11 a of the non-circular rotary member 11 , and is mounted while an end of the shaft 13 c is passed through the hole 5 b of the insulating base 5 and is positioned in the recess 2 k in the bottom wall 2 a . When the rotation transmission member 13 is rotated, the rotary member 11 rotates through the shaft 13 c and the sliding element 10 comes into sliding contact with the resistance element, so that the resistance is varied. When the rotation transmission member 13 is rotated within a predetermined range, the stopper 13 d bumps into the stopper 5 d of the holding member 4 , so that the rotations of the rotation transmission member 13 and the rotary member 11 are stopped.

A plate-shaped clutch 14 comprises a wave washer formed of a metallic plate having a spring characteristic, and has an annular portion 14 b having an opening 14 a in the central portion thereof. The clutch 14 is combined and integrated with the rotation transmission member 13 by inserting the stopping portions 13 b of the rotation transmission member 13 into the opening 14 a . The clutch 14 may also be formed of felt instead of a wave washer.

A geared operating member 15 has a cylindrical portion 15 a , a first gear 15 b disposed around the outer periphery of the cylindrical portion 15 a , and a spline groove 15 c disposed in a hollow of the cylindrical portion 15 a . The operating member 15 is rotatably supported between the holes 2 c and 3 c of the respective first and second case portions 2 and 3 .

A second gear 16 has toothed portions 16 a and 16 b having different diameters and disposed at different locations in an axial direction. The second gear 16 is rotatably mounted by supporting a recess in the central portion thereof by the shaft 2 d of the first case portion 2 , and the toothed portion 16 a engages the first gear 15 b.

A third gear 17 has toothed portions 17 a and 17 b having different diameters and disposed at different locations in an axial direction. The third gear 17 is mounted so as to be rotatable around the cylindrical portion 15 a as a shaft by inserting the cylindrical portion 15 a of the operating member 15 into a hole in the central portion in the third gear 17 , and the toothed portion 17 a engages the toothed portion 16 b of the second gear 16 .

A plate-shaped geared wheel 18 serving as a fourth gear and having a flat bottom surface has a gear portion 18 a at the outer periphery and a through hole 18 b in the central portion. The geared wheel 18 is rotatably mounted by being snappingly stopped by the stopping portions 13 b of the rotation transmission member 13 that are inserted in the through hole 18 b . The gear portion 18 a engages the toothed portion 17 b of the third gear 17 .

The second gear 16 having the toothed portion 16 a engaging the first gear 15 b of the operating member 15 , the third gear 17 , and the geared wheel 18 serving as the fourth gear form a reduction rotation transmission mechanism. The rotation from the operating member 15 is reduced in speed and transmitted to the geared wheel 18 at a termination end through the second and third gears 16 and 17 .

When the geared wheel 18 is mounted by the stopping portions 13 b , the geared wheel 18 , the clutch 14 , and the rotation transmission member 13 are integrated, and the plate-shaped clutch 14 is sandwiched between the flat portions of the geared wheel 18 and the rotation transmission member 13 , so that a clutch mechanism is formed. The rotation of the geared wheel 18 is transmitted to the rotation transmission member 13 through the clutch 14 . When the rotation of the rotation transmission member 13 is stopped, a slip occurs between the geared wheel 18 and the clutch 14 or between the clutch 14 and the rotation transmission member 13 , so that the clutch mechanism slips.

When the second case portion 3 is mounted to the first case portion 2 with the geared wheel 18 being accommodated in the first case portion 2 , the protrusion 3 d forming a shaft at the second case portion 3 is positioned in the through hole 18 b of the geared wheel 18 and prevents the movement of the stopping portions 13 b , so that the stopping portions 13 are prevented from being dislodged. In addition, an end of the protrusion 3 d comes into contact with the flat portion 13 a of the rotation transmission member 13 and prevents the rotation transmission member 13 from becoming raised. Further, the protrusion 3 d is positioned at the center of the geared wheel 18 and the center of the stopping portions 13 b (rotation transmission member 13 ), so that the protrusion 3 d functions as a rotary shaft of the geared wheel 18 and the rotation transmission member 13 .

The variable resistor according to the present invention having such a structure is installed in, for example, an automobile. Rotation from a motor (not shown) is transmitted to the operating member 15 having the first gear 15 b from a rotary shaft (not shown) engaging the spline groove 15 c of the operating member 15 .

This causes the rotation of the operating member 15 to be transmitted to the rotary member 11 from the geared wheel 18 and the second and third gears 16 and 17 of the reduction rotation transmission mechanism through the clutch 14 and the rotation transmission member 13 of the clutch mechanism, so that the sliding element 10 slides on the resistance element (not shown). This causes the resistance to be finely varied, so that the tilting of a seat is adjusted.

When the rotation of the geared wheel 18 is continued, the stopper 13 d of the rotation transmission member 13 bumps into the stoppers 5 d of the holding member 4 and stops rotating, causing the rotary member 11 to also stop rotating, so that the varying of the resistance is stopped.

When the rotation of the geared wheel 18 is further continued, the clutch mechanism slips, so that the transmission of the rotation to the rotation transmission member 13 is stopped.

When the operating member 15 is rotated in a direction opposite to that above, the rotation transmission member 13 rotates in a direction in which stops of the stoppers 5 d are set out of contact through the clutch mechanism, so that the resistance is varied. Thereafter, the same operations as those described above are performed.

Although, in the embodiment of the present invention, the resistance member 7 has a cover 12 , so that a unitary structure in which the sliding element 10 slides on the resistance element is formed, the variable resistor according to the present invention is not limited thereto.

More specifically, the sliding element and the resistance element do not need to be covered with a cover. A rotary member having a resistance element may rotate with respect to a stationary sliding element.

Further, a resistance substrate having a resistance element may be mounted to, for example, the bottom wall of the case, and a sliding element which slides on the resistance element may be disposed below the rotation transmission member. In this structure, the sliding element functions as the rotary member of the resistance member.