Battery Terminal Clamp Assembly for Higher Pull-Off Force
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Solution Overview
Problem
Conventional battery terminal clamps face challenges such as premature failure due to harsh vehicle electrical environments, including space constraints, vibration, and temperature fluctuations, leading to increased repair and warranty costs, and they also generate significant scrap material during manufacturing.
Innovation Solution
The battery terminal clamp assembly features a clasping mechanism with a securement assembly that increases the pull-off force beyond current USCAR specifications and reduces material waste by over 35% through a more efficient forming process, incorporating a unique slit configuration and securement system that applies a spreading effect for enhanced retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional battery terminal clamps are used, then the manufacturing process generates significant scrap material, but the pull-off force and securement are insufficient for harsh vehicle environments
Solution Approach 1:
The clamp body is divided into two separate wall assemblies (first wall assembly and second wall assembly) that are formed independently and then joined together. This segmentation allows each assembly to be optimized for strength while reducing material waste during forming, as each piece can be more efficiently utilized without excessive scrap generation.
Solution Approach 2:
The first wall assembly and second wall assembly are joined together through interlocking features (protrusions and recesses) to form a complete clamp structure. This merging combines the strength benefits of multiple formed pieces while maintaining material efficiency, achieving high pull-off force without the scrap generation problems of conventional single-piece clamps.
2Reliability
If conventional single-piece clamps are used, then manufacturing is simpler, but the clamp fails prematurely under vibration and temperature fluctuations
Solution Approach 1:
By dividing the clamp into two separately formed wall assemblies, each assembly can be optimized for its specific functional requirements, improving overall durability under vibration and temperature fluctuations. The segmentation allows for better stress distribution and reduced premature failure points.
Solution Approach 2:
The wall assemblies incorporate nested interlocking features where protrusions from one assembly fit into recesses of the other, creating a integrated structure that maintains simplicity of installation while achieving enhanced reliability through the combined strength of multiple optimized components.
3Ease of operation
If conventional clamps are installed, then installation is straightforward, but the clamps become dislodged in the field due to harsh operating conditions
Solution Approach 1:
The wall assemblies are pre-formed with specific geometric features (curved surfaces, flares, and interlocking protrusions/recesses) that automatically engage and lock together during installation. This preliminary structuring ensures proper alignment and securement without requiring complex installation procedures, while the design inherently resists dislodging under vibration and temperature changes.
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 solution provides a battery terminal clamp assembly with improved durability and reliability, reducing material costs and scrap generation while ensuring secure connection and increased pull-off force, addressing the limitations of conventional clamps in harsh vehicle environments.
Implementation Method 1
the securement assembly applies a spreading effect for enhanced retention
Data Source
AI summary
A vehicle battery terminal clamp assembly features a clasping mechanism and a securement assembly. The clasping mechanism includes a top wall with an upper battery post aperture and an upper slit, a bottom wall with a lower battery post aperture and a lower slit, and a front wall integrally extending between the top and bottom walls and including a front slit, and wherein the upper slit, the lower slit, and the front slit are arranged to form a continuous slit that extends from the upper battery post aperture, across the front wall and to the lower battery post aperture. The upper and lower battery post apertures are configured to receive an extent of a post extending from the vehicle battery. The securement assembly applies less than a nominal compressive force on the clasping mechanism, wherein the top wall of the clasping mechanism is substantially parallel with the bottom wall of the clasping mechanism. In contrast, when the securement assembly applies a sufficient compressive force on the clasping mechanism, the top wall of the clasping mechanism is not substantially parallel with the bottom wall of the clasping mechanism which increases the “pull-off force” of the inventive battery terminal clamp assembly.