High Reliability Variable Resistor Device

A potentiometer assembly comprising:

• a substrate having a top surface, the top surface being electrically insulative, the substrate comprising a printed circuit board, the substrate being configured for installation within a control circuit having a control switch;
• a wiper being movably coupled to the top surface of the substrate, the wiper being configured to be operably coupled to the control switch wherein the wiper is configured to move along the top surface of the substrate in response to the control switch of the control circuit being actuated, the wiper comprising:
• a primary wiper body, the primary wiper body being electrically conductive;
• a first leg member being coupled to and extending downwardly from the primary wiper body, the first leg member being electrically conductive;
• a second leg member being coupled to and extending downwardly from the primary wiper body, the second leg member being electrically conductive;
• a secondary wiper body being electrically isolated from the primary wiper body, the secondary wiper body being electrically conductive;
• a third leg member being coupled to and extending downwardly from the secondary wiper body, the third leg member being electrically conductive;
• a coupler physically attaching the primary wiper body to the secondary wiper body such that the primary wiper body and the secondary wiper body move together along the top surface of the substrate, the coupler comprising an electrically insulative material whereby the third leg member remains electrically isolated from the first leg member and the second leg member when the primary wiper body is attached to the secondary wiper body;
• a resistive material being coupled to the top surface of the substrate, the resistive material being electrically resistive;
• a common trace being coupled to the top surface of the substrate, the common trace being spaced from the resistive material, the second leg member of the wiper contacting and moving along the common trace when the wiper moves along the substrate, the common trace being electrically conductive;
• an array of taps being coupled to the top surface of the substrate, the array of taps being electrically conductive, the array of taps being electrically coupled to the resistive material, the array of taps physically contacting and extending perpendicularly outward from the resistive material toward the common trace wherein the first leg member of the wiper contacts at least one of the array of taps while being spaced from the resistive material and wherein the wiper moves across the array of taps when the wiper moves along the substrate, the first leg member of the wiper contacting at least one of the array of taps, the array of taps being spaced from each other along a length of the resistive material wherein the array of taps forms a series of resistive changes whereby a change of resistance from one tap of the array of taps to an adjacent tap of the array of taps comprises a known increment of the series of resistive changes, the series of resistive changes being configured to adjust a setting of the control circuit;
• wherein the known increment of the series of resistive changes is linear when the array of taps are spaced equidistantly from each other;
• wherein the known increment of the series of resistive changes is non-linear when the array of taps are spaced at variable distances from each other;
• a power trace being coupled to the top surface of the substrate, the power trace being electrically conductive wherein the power trace is configured to indicate a power state of the control circuit, the third leg member of the wiper contacting the power trace when the wiper moves along the top surface of the substrate, the power trace further comprising:
• an off-state member being configured to indicate an off-power state when the third leg member of the wiper contacts the off-state member, the off-state member comprising copper;
• an on-state member being spaced from the off-state member, the on-state member being configured to indicate an on-power state when the third leg member of the wiper contacts the on-state member, the on-state member having a length being the same as a length of the top surface of the substrate over which the array of taps is positioned, the on-state member comprising copper;
• a gap being positioned between the off-state member and the on-state member, the wiper contacting the top surface of the substrate when the third leg member is positioned on the gap, the gap being configured to indicate a neutral power state when the third leg member is positioned on the gap;
• and
• a flexible material covering the common trace, the array of copper taps, and the power trace, the flexible material being positioned between the wiper and the top surface of the substrate wherein the flexible material is configured to inhibit contaminants from contacting the common trace, the array of copper taps, and the power trace, the flexible material being conductive wherein the wiper exerts a pressure downwardly on the flexible material as the wiper moves along the top surface of the substrate whereby the flexible material contacts the common trace, at least one of the array of taps, and the power trace to electrically connect the common trace to the array of taps and the power trace.