Lead-Acid Battery Terminal Bushing for Leak and Torque Resistance
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Solution Overview
Problem
Lead acid batteries face challenges with acid leakage and torque resistance at the battery terminal bushing interface, where the different materials used for the housing and terminal post do not naturally fuse, leading to potential electrolyte leakage and deformation under torque loads.
Innovation Solution
The battery terminal bushing features a body with sealing rings and anti-torque patterns, providing a labyrinth seal to prevent acid leakage and increased surface area to resist torque, with anti-torque features embedded in the polymer housing material to enhance torque resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a battery bushing is used to connect the polymer housing and metal terminal post, then the battery terminal can be formed, but acid leakage occurs through the interface because the materials do not naturally fuse
Solution Approach 1:
A sealing ring is introduced as an intermediary element between the polymer housing and metal terminal post. The sealing ring creates a labyrinth seal that prevents acid from penetrating through the interface, solving the problem of acid leakage that occurs when dissimilar materials (polymer and metal) are directly connected without natural fusion.
2Ease of operation
If the battery terminal is fastened with a battery cable, then power can be accessed, but the terminal experiences torque that can deform the bushing
Solution Approach 1:
Anti-torque features are added to the bushing structure, increasing the surface area from a simple cylindrical interface to a multi-dimensional engagement pattern. This dimensional enhancement distributes the torque load across a larger area and creates mechanical interlocking that resists rotational forces applied during battery cable fastening.
3Adaptability or versatility
If vehicle travel causes jostling and movement, then the battery operates in real conditions, but the battery cable torques the terminal and associated bushing
Solution Approach 1:
The anti-torque features are pre-built into the bushing structure before installation, providing proactive resistance to torque forces. This preemptive design cushioning ensures that when vehicle travel causes jostling and movement, the bushing is already equipped with enhanced structural features to resist the torque forces that will be applied during normal operation.
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 effectively prevents electrolyte leakage and provides improved resistance to torque, withstanding over 150 inch-pounds of torque, thus ensuring a secure and reliable connection in lead acid batteries.
Implementation Method 1
One or more sealing rings surround the body between the insertion end and the exterior end... providing a labyrinth seal to prevent acid leakage
Implementation Method 2
An anti-torque pattern is provided on one or more surfaces of the body configured to engage and be contained within the battery housing material... providing increased surface area to resist torque
Data Source
AI summary
A battery terminal bushing is disclosed. The battery terminal bushing comprises a body having an insertion end and an exterior end opposite the insertion end. One or more sealing rings surround the body between the insertion end and the exterior end. A terminal post connector segment is provided on the insertion end of the body. An anti-torque pattern is provided on one or more surfaces of the body configured to engage and be contained within the battery housing material. A lead acid battery comprising the battery terminal bushing is also disclosed.