Adjustable Battery Connector Clamp for Variable Terminal Posts
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Solution Overview
Problem
Existing battery connectors are not easily adjustable for different battery terminal diameters, requiring multiple types and configurations, which is costly and inefficient, and pose safety risks due to potential electrical failures and slow connection/release times.
Innovation Solution
A battery connector with a clamp body and insulating actuator featuring adjustable ramps that allow the terminal post aperture to be adjusted for various diameters, ensuring secure and efficient connection and disconnection, while also providing a safe and ergonomic design for auxiliary lead attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed-size connector is used, then the manufacturing and inventory cost is reduced, but the connector cannot accommodate different battery terminal diameters
Solution Approach 1:
The connector incorporates an adjustable aperture mechanism that allows the opening size to be dynamically changed to accommodate different battery terminal diameters. The aperture can be adjusted between multiple size configurations, transforming a static connector into a dynamic one that adapts to various terminal sizes without requiring multiple different connector types.
Solution Approach 2:
The connector design allows changing the geometric parameter of the aperture size. By providing an adjustable aperture that can be configured to different diameters, the connector modifies its physical dimensions to match various battery terminal sizes, enabling a single connector design to replace multiple fixed-size variants.
2Manufacturing precision
If multiple connector types are maintained for different terminal sizes, then the fit precision is improved, but the device complexity and inventory requirements increase
Solution Approach 1:
The connector is designed with universal adaptability through its adjustable aperture feature, allowing a single connector design to perform multiple functions across different battery terminal sizes. This multi-functionality eliminates the need to maintain separate connector variants for each terminal diameter, reducing inventory complexity while preserving precise fit capability.
3Reliability
If a secure clamp connection is implemented, then the electrical reliability is improved, but the connection and release time increases
Solution Approach 1:
The connector design incorporates preliminary positioning features that guide the connector into proper alignment with the battery terminal before final clamping engagement. This preliminary action ensures that the connector is pre-positioned correctly, allowing for quicker and more reliable connection without requiring complex adjustment procedures during the clamping process.
Data Source
AI summary
A battery connector for a battery having a terminal post, the battery connector including a main body with a terminal clamp end and a lead end, the battery connector further comprising: a clamp body including: a conductive body for conducting charge from the lead end to the terminal clamp end; a lead mount disposed at the lead end for mounting a lead; an arcuate wall which provides a battery terminal post aperture for receiving the terminal post; a substantially insulating clamp actuator; an adjuster including first and second cooperating ramps, the first ramp mounted on the arcuate wall and the second ramp mounted on the clamp actuator, at least one ramp or flange being movable between a wide position and a narrow position, wherein the clamp actuator is configured to cooperate with the clamp body to close the arcuate wall around the terminal post by a relative movement between the insulating clamp actuator and the clamp body. The battery connector also provides a lead mounting zone at the lead end and a lead end closure for controlling access to the auxiliary lead end for connecting and disconnecting the one or more auxiliary leads without disconnecting the connector from the terminal post.