Lead-Acid Battery Bushing Structure for Residual Stress Relief
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Solution Overview
Problem
The existing bushing designs for lead-acid batteries face strength reduction and potential breakage due to high residual stress when an external force is applied, especially when the terminal portion is offset from the bushing main body.
Innovation Solution
A bushing design featuring a cylindrical main body with a columnar terminal portion having a pedestal with a recessed cavity on its bottom surface, which reduces residual stress and enhances strength by allowing uniform cooling and material reduction, while a smaller cross-sectional area in the coupling portion helps in overcurrent protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the terminal portion is offset from the bushing main body portion and integrally coupled, then the bushing structure can accommodate external terminals, but the residual stress increases and the bushing strength decreases
Solution Approach 1:
The terminal portion is divided into two segments: a pedestal portion integrally coupled to the bushing main body, and a connecting portion for external terminal attachment. This segmentation allows the offset configuration for adaptability while managing stress distribution through the coupling portion design.
Solution Approach 2:
The coupling portion is designed with specific local properties including a cross-sectional area smaller than other portions to facilitate overcurrent protection, and is positioned at a location that optimizes stress distribution. This local quality enhancement addresses the strength issue while maintaining the offset configuration benefits.
2Reliability
If the coupling portion has a smaller cross-sectional area, then overcurrent protection is improved, but the structural strength may be reduced
Solution Approach 1:
The smaller cross-sectional area of the coupling portion, which could be seen as a weakness, is actually designed to be the overcurrent protection mechanism. When excessive current flows, this portion fuses first, protecting the battery. The design converts what appears to be a structural weakness into a beneficial safety feature.
Solution Approach 2:
The cross-sectional area parameter of the coupling portion is specifically optimized to be smaller than other portions of the bushing. This parameter change enables the overcurrent protection function while the overall bushing structure maintains sufficient strength through proper design of other components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design effectively increases the strength of the bushing, reduces material usage and weight, and prevents breakage under external forces, while allowing easy visual inspection for overcurrent fusion and preventing internal fragmentation.
Implementation Method 1
the pedestal portion has a recessed cavity portion on a bottom surface of the pedestal portion... the residual stress of the pedestal portion is relaxed as compared with a case where the cavity portion is not provided
Data Source
AI summary
A bushing (40A) for a lead-acid battery includes: a cylindrical bushing main body portion (41) that can be fitted to a pole (45); and a columnar terminal portion (50) located at a position offset from the bushing main body portion (41) in plan view, in which the terminal portion (50) includes: a pedestal portion (52) integrally coupled to the bushing main body portion (41) via a coupling portion; and a connecting portion (51) which is located on the pedestal portion (52) and to which an external terminal is connected, and in which the pedestal portion (52) has a recessed cavity portion (53) on a bottom surface of the pedestal portion (52).