Battery Bushing Anti-Twist Torque Ring Design
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Solution Overview
Problem
Existing battery bushings for rechargeable batteries face challenges with complex and costly injection molding processes, material inefficiency, and premature failure due to notch stress and complex geometries, which complicate assembly and reduce mechanical stability.
Innovation Solution
A battery bushing design featuring a mounting section with indentations and a torque ring with parallel recesses that reduce notch stress, allowing for simplified injection molding and enhanced mechanical stability through overmolding with plastic, and a hollow body with a conical shape to embed the bushing within the battery cover, providing increased retention force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a torque ring with non-parallel recesses is used to prevent twisting, then anti-twist protection is improved, but the demolding process becomes much more complicated and requires expensive molding tools
Solution Approach 1:
The patent applies asymmetry by using non-parallel recesses in the torque ring to provide anti-twist protection. The asymmetric geometry of the recesses creates directional resistance to twisting forces while still allowing for practical demolding through careful tool design.
Solution Approach 2:
The torque ring is segmented with multiple recesses that can be molded independently, allowing the molding tool to access and release each section separately during demolding, thus simplifying the overall process despite the complex geometry.
2Force
If a groove and step are added to the torque ring for torque transmission, then torque transfer capability is improved, but notch stress increases causing premature failure
Solution Approach 1:
The patent uses curved or rounded transitions at the groove and step features instead of sharp corners. This curvature reduces stress concentration at critical points while maintaining the torque transmission capability through the stepped geometry.
Solution Approach 2:
The patent modifies the geometric parameters of the groove and step features, such as increasing the radius of curvature at stress concentration points and optimizing the depth and width ratios, to reduce notch stress while preserving torque transfer functionality.
3Adaptability or versatility
If complex geometries are used in the battery bushing, then functional requirements are met, but material usage increases and manufacturing becomes more complex
Solution Approach 1:
The patent designs the battery bushing with multi-functional features where single geometric elements serve multiple purposes. For example, the torque ring with integrated recesses provides both structural support and anti-twist protection, eliminating the need for separate components and simplifying the overall geometry.
Solution Approach 2:
The patent merges multiple functional features into integrated structures. The mounting section and contacting section are combined with the torque ring features in a unified geometry that reduces the total number of discrete elements and simplifies manufacturing while meeting all functional requirements.
4Ease of operation
If the terminal post has a significantly smaller diameter than the lead bushing to simplify insertion, then insertion ease is improved, but the gap requires conductive adhesive filling adding complexity
Solution Approach 1:
The patent extracts the adhesive-filling requirement by designing a terminal post diameter that closely matches the lead bushing internal diameter. This eliminates the need for conductive adhesive filling while maintaining ease of insertion through precise dimensional control and tolerance design.
Data Source
AI summary
A battery bushing for rechargeable batteries has mounting and contacting sections and a torque ring between these sections. The torque ring or the outer surface can be endowed with several indentations. The mounting section is configured to hold the battery bushing within a battery cover, into which it is preferably injection molded. The battery bushing is a hollow body with outer and inner walls. At the contacting section, the outer wall is conically shaped. At the mounting section, the outer wall has at least one circumferential projection forming a labyrinth. The inner wall comprises at least an upper section, approximately surrounded by the contacting section and preferably having a conical shape, and a lower section approximately surrounded by the mounting section. The lower section preferably has (in a lateral sectional view) a concave shape. Between the upper and lower sections, there may be an edge or a step.