Battery Terminal Cover Chamfer for Tolerance-Absorbing Rotation Stop
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Solution Overview
Problem
Existing battery terminal assembly systems face issues with proper rotation regulation due to manufacturing errors in dimensional tolerances between the battery post and housing components, leading to potential interference with electric wires and damage from vibrations.
Innovation Solution
A battery terminal cover with a chamfered rotation stop portion that contacts the corner of the battery wall, absorbing dimensional tolerances to ensure proper rotation and prevent interference with peripheral components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the first rotation stop portion contacts the side surface of the battery housing to regulate rotation, then the battery terminal rotation is controlled, but manufacturing errors cause the battery terminal to rotate extra and interfere with peripheral components
Solution Approach 1:
The patent introduces a second rotation stop portion as an intermediary element that contacts the battery wall to provide an additional constraint on battery terminal rotation. This mediator works together with the first rotation stop portion to compensate for dimensional tolerance variations, ensuring reliable rotation regulation even when manufacturing precision varies within acceptable ranges.
Solution Approach 2:
The patent designs the rotation stop portions with beforehand cushioning by creating a clearance between the battery terminal and the rotation stop portions. This clearance acts as a tolerance buffer that absorbs dimensional variations before they can cause interference with peripheral components, preventing the extra rotation problem caused by manufacturing errors.
2Adaptability or versatility
If the battery terminal is allowed to rotate freely to accommodate tolerance, then manufacturing tolerance is absorbed, but the battery terminal may rotate to an incorrect position causing interference with electric wires
Solution Approach 1:
The second rotation stop portion serves as an intermediary constraint that works with the first rotation stop portion to define a precise rotational range. This intermediary element ensures that the battery terminal can accommodate tolerance variations while being prevented from rotating to positions that would cause interference with electric wires or other peripheral components.
Solution Approach 2:
The patent applies preliminary action by pre-positioning the rotation stop portions at specific locations on the battery housing and battery wall. These pre-positioned constraints establish the correct rotational limits before assembly, ensuring that the battery terminal stops at the proper position while absorbing tolerance variations, thereby preventing harmful interference with electric wires.
3Reliability
If the contact surface is positioned to absorb tolerance, then proper rotation stopping is achieved, but the contact surface must be placed out of the moving region of the mating connector
Solution Approach 1:
The patent resolves the positioning constraint by utilizing another dimension - the vertical height dimension of the battery housing. The contact surface is positioned on the battery wall at a height that places it outside the horizontal moving region of the mating connector. This dimensional relocation allows the contact surface to accurately absorb tolerance for rotation stopping without interfering with connector movement in the horizontal plane.
Data Source
AI summary
A battery terminal cover includes a cover portion and a rotation stop portion. The rotation stop portion has a contact surface formed by chamfering. The contact surface is formed at a position out of a moving region of a mating connector with respect to a connector provided on the battery terminal. The contact surface contacts a corner part of a battery wall to regulate rotation of the battery terminal in a direction toward the battery wall. The contact surface is formed to absorb a dimensional tolerance between the battery post and a wall surface of the battery wall and a dimensional tolerance between the battery post and a side surface of the battery wall. The wall surface and the side surface forms the corner part.