Elastomeric Battery Cable Sleeve for Strain Relief
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Solution Overview
Problem
Automotive battery cables experience fatigue and corrosion at the connection point due to relative motion and exposure to external elements, with existing solutions like heat shrink sleeves being cumbersome, time-consuming, and costly.
Innovation Solution
An automotive battery cable with a sleeve comprising a soft elastomeric first portion for buffering motion and a rigid second portion for sealing, featuring a body with contour features to deform and match the attachment point, and a hinge mechanism for secure closure, which absorbs energy, dampens motion, and prevents contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a heat shrink sleeve is installed to provide strain relief and sealing, then the electrical wire is protected from fatigue and corrosion, but the installation process becomes cumbersome, time-consuming and costly
Solution Approach 1:
The protective covering is divided into two distinct portions: a soft elastomeric first portion that buffers relative motion and absorbs vibrations, and a rigid second portion that provides sealing and structural support. This segmentation allows each portion to perform its specific function optimally while simplifying the overall installation process compared to traditional heat shrink sleeves
Solution Approach 2:
The sleeve combines two different materials with complementary properties: soft elastomeric material for strain relief and vibration damping, and rigid material for sealing and structural integrity. This composite structure achieves both protection and ease of installation by eliminating the need for heat shrinking while maintaining reliability
2Ease of manufacture
If the electrical wire is exposed to facilitate terminal connection, then the terminal can be securely attached, but the exposed wire becomes vulnerable to corrosion from external elements
Solution Approach 1:
The sleeve is designed to be installed before final terminal attachment, with the first portion already in place to protect the exposed electrical wire. The contour features of the body are adapted to allow deformation and compression against the attachment point, creating a seal that prevents moisture ingress while the terminal is being attached and secured
Solution Approach 2:
The protective covering provides localized protection exactly where needed - at the attachment point between the terminal and electrical wire. The body includes contour features that deform to match the shape of the attachment point, creating a precise seal around the exposed wire area without requiring full coverage of the entire cable
3Reliability
If the terminal is secured to the battery, then electrical connection is established, but motion of the battery cable causes sharp bends in the electrical wire at the connection point
Solution Approach 1:
The soft elastomeric first portion of the sleeve is installed beforehand to buffer relative motion between the battery cable and terminal. This cushioning layer absorbs vibrations and prevents sharp bends in the electrical wire at the connection point, protecting the wire from fatigue failure while maintaining reliable electrical connection
Solution Approach 2:
The sleeve changes the mechanical parameters at the connection point by introducing a compliant elastomeric layer that increases flexibility and reduces stress concentration. This material parameter change allows the connection to accommodate motion without creating sharp bends that would lead to wire fatigue
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 sleeve effectively reduces fatigue and corrosion by absorbing energy and vibrations, providing a secure seal against external contaminants, and preventing sharp bending of the electrical wire, while being easier and less costly to implement than traditional heat shrink solutions.
Implementation Method 1
The first portion includes a body and a neck, the body including an inner surface having contour features adapted to allow the body to deform and compress against the attachment point... adapted to buffer relative motion of the electrical wire and the terminal
Implementation Method 2
the body to deform and compress against the attachment point and matching the shape of the attachment point
Implementation Method 3
a second portion made from a rigid material and encircling the body of the first portion and compressing the body onto the attachment point to seal the attachment point within the first portion
Data Source
AI summary
An automotive battery cable includes an electrical wire, a terminal crimped onto a distal end of the electrical wire, and a sleeve positioned on the electrical wire and extending over an attachment point between the terminal and the electrical wire, the sleeve including a first portion including a body and a neck, the body including an inner surface having contour features adapted to allow the body to deform and compress against the attachment point and matching the shape of the attachment point to sealingly encapsulate the attachment point, and the neck extending from the body around and along the electrical wire, and a second portion encircling and compressing the body onto the attachment point to seal the attachment point within the first portion and to provide a positive stop to limit relative motion of the electrical wire and the terminal at the attachment point.