Cylindrical Battery Terminal with Keyway Plug
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing automotive battery connection systems require tools for replacement and recharging, are complex, and can lead to mistakes in cable identification, potentially causing damage or injury.
Innovation Solution
A quick-connect battery connection system featuring a cylindrical battery case with keyway partitions and a plug with channel partitions, allowing tool-free engagement of cables with conical posts and sockets, maintaining the standard two-post design while ensuring secure and efficient energy transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional battery connection systems are used, then reliable electrical connection is achieved, but tool replacement is required and time is consumed
Solution Approach 1:
The plug is inserted into a recess in the battery terminal, with the plug containing sockets that receive the battery posts. This nested structure allows the connection components to be housed within each other, enabling tool-free connection while maintaining a compact design that does not significantly increase overall system complexity
Solution Approach 2:
The plug acts as an intermediary component between the battery terminal and the cable connector. The plug includes posts that engage with sockets in the terminal, and cables connect to the plug, creating an intermediate connection layer that simplifies the overall connection process and eliminates the need for tools
2Ease of operation
If quick-connect systems are implemented, then tool-free connection is achieved, but complete re-design of battery system is required
Solution Approach 1:
The battery case serves multiple functions: it acts as the terminal housing, provides the recess for the plug, and contains the keyway partitions for alignment. This multi-functionality allows the existing battery case structure to be utilized while adding quick-connect capabilities, avoiding complete re-design
Solution Approach 2:
The connection system is divided into separate modular components: the battery terminal with recess, the plug with posts and sockets, and the cable connector. This segmentation allows each component to be manufactured independently using existing processes, reducing manufacturing complexity while enabling tool-free connection
3Reliability
If sequential disconnection is followed, then short-circuiting is avoided, but time is consumed and risk of error remains
Solution Approach 1:
The keyway partitions in the battery case and corresponding channel partitions in the plug create a mechanical alignment system that physically guides the plug into the correct position. This converts the potential harm of misalignment or incorrect connection into a beneficial self-aligning mechanism, ensuring proper connection order and preventing short-circuits while speeding up the process
Solution Approach 2:
The plug and terminal design includes self-aligning features through the keyway and channel partitions that automatically guide the components into proper alignment during insertion. This self-service alignment mechanism eliminates the need for manual sequencing or complex alignment procedures, preventing short-circuits while reducing replacement time
Data Source
AI summary
An automotive battery connection system, which includes a substantially cylindrical battery case acting as a terminal for an automotive battery. The battery case includes partitions defining a keyway for cables and a center partition dividing the battery case into two case pockets. A battery positive post is situated within one of the case pockets. A battery negative post is situated in the other of the case pockets. A substantially cylindrical plug is adapted to seat on the partitions of the battery case. The plug comprises a pair of sockets defined within its base, each socket defined within one of the plug pockets shaped identical to the battery positive post and the battery negative post and sized to have the battery positive post and the battery negative post securely seat therein. Therefore, cables terminating within the base of the plug are in conductive communication with the sockets.