Battery Terminal Cover with Elastic Plug and Tether
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Solution Overview
Problem
Existing battery terminal designs lack effective protection against undesired electrical contact between positive and negative terminals, which can lead to short circuits and reduced battery life.
Innovation Solution
A cap or cover with a base and top formed from elastically deformable, electrically insulating material, featuring a plug with a foot and peak portion that deform to securely engage with the terminal tabs, preventing contact and ensuring secure retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing battery terminal designs are used, then the battery structure is simple, but the terminals are vulnerable to undesired electrical contact and short circuits
Solution Approach 1:
The terminal cover is divided into two separate components: a base portion that covers the terminal body and a top portion that contains the plug. These portions are connected by a tether, allowing them to function as a unified protective assembly while maintaining manufacturing simplicity. The segmentation enables each part to be optimized for its specific function.
Solution Approach 2:
The plug is nested within the top portion of the cover, which itself is connected to the base. This nested structure allows the protective elements to be compactly arranged while maintaining their individual functions. The plug sits inside the top portion, creating a layered protective arrangement.
2Object-affected harmful factors
If a protective cover is added to the battery terminal, then protection against short circuits is improved, but the device complexity increases
Solution Approach 1:
The base and top portions are merged into a single removable assembly connected by a tether. This allows the entire protective structure to be installed and removed as one unit, simplifying the user interaction despite the multiple internal components. The merging of components through the tether connection reduces the operational complexity.
Solution Approach 2:
The tether acts as an intermediary element connecting the base and top portions. It allows the two components to remain connected while permitting relative movement, serving as a flexible mediator that maintains the structural integrity of the cover assembly while allowing for manufacturing and assembly flexibility.
3Strength
If the plug is made to securely engage with terminal tabs, then retention is improved, but the material requirements become more stringent
Solution Approach 1:
The plug utilizes elastic deformation as a key parameter change mechanism. By making the plug material elastically deformable, it can be inserted through the terminal tabs in a deformed state and then spring back to its original shape, creating a secure mechanical interference fit. This parameter change from flexible during insertion to rigid during retention solves the retention problem while maintaining manufacturability.
Solution Approach 2:
The plug is designed as a flexible elastic member that can deform during insertion and then recover its shape to create retention. This flexible structure allows the plug to adapt to the terminal tab geometry and create a secure fit through elastic recovery, rather than requiring precise rigid tolerances or complex fastening mechanisms.
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 protects the battery terminals from short circuits, enhances safety, and extends battery life by preventing unwanted electrical connections.
Implementation Method 1
A cap configured to cover a terminal of a battery may include a base and a top having a plug and a cavity. The cavity is configured to receive the terminal and the plug is configured to retain the top on the terminal. A tether has a first end fixed to the base and a second end fixed to the top and connects the top to the base. The base is configured to retain the top to the terminal when the top is both connected to the terminal and separate from the terminal.
Implementation Method 2
A cap configured to cover a terminal of a battery may include a base and a top having a plug and a cavity. The cavity is configured to receive the terminal and the plug is configured to retain the top on the terminal.
Data Source
AI summary
A cap configured to cover a terminal of a battery includes a base and a top having a plug and a cavity. The cavity is configured to receive the terminal and the plug is configured to retain the top on the terminal. A tether has a first end fixed to the base and a second end fixed to the top and connects the top to the base. The base is configured to retain the top to the terminal when the top is both connected to the terminal and separate from the terminal.