Cold-Formed Battery Terminal Insert Confinement
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Solution Overview
Problem
Existing battery terminals lack a secure and efficient method for connecting battery cables, particularly in cold-formed designs, which can lead to instability and inadequate confinement of inserts, affecting rotational and vertical motion.
Innovation Solution
A cold-formed side wall battery terminal with a cavity and insert configuration, where the insert is positioned with a base near the cavity bottom and a flange extending radially outward, is confined by the body's upper surface, bottom surface, and outer edge, using a band of body material to trap the flange and prevent rotation and vertical movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a cold-formed battery terminal design is used, then manufacturing efficiency and cost are improved, but the secure confinement of inserts and prevention of rotational/vertical motion deteriorates
Solution Approach 1:
The battery terminal is divided into distinct functional segments: the cold-formed body structure and the separate insert component. This segmentation allows the body to be efficiently cold-formed while the insert provides specialized confinement features, resolving the contradiction between manufacturing efficiency and connection stability.
Solution Approach 2:
The insert is pre-formed with specific geometric features (flanges, sides, base) that will later confine the battery cable. This preliminary action allows the insert to be prepared independently through efficient cold-forming processes, while its pre-designed geometry ensures reliable cable confinement and motion prevention during final assembly.
2Device complexity
If a simple cold-formed body structure is used, then device complexity is reduced, but the ability to prevent rotational and vertical motion of inserts deteriorates
Solution Approach 1:
The insert features locally concentrated geometric elements (flanges at specific positions, side walls, base structure) that provide confinement functionality only where needed. This local quality approach maintains overall structural simplicity while achieving reliable cable retention through strategically placed geometric features.
Solution Approach 2:
The insert acts as an intermediary component between the cold-formed body and the battery cable. It mediates the connection by providing a structured interface that prevents rotational and vertical motion, allowing the simple body structure to achieve stable cable confinement through the insert's geometric mediation.
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
This configuration enhances the secure connection of battery terminals to battery cables by inhibiting rotational and vertical motion, ensuring a stable and reliable interface, suitable for various battery terminal types, including side, vertical, and top mounts.
Implementation Method 1
A band of body material about the upper portion of the cavity is also formed at this time. The band of body material is cold formed such that it confines the flange of the insert within the body
Data Source
AI summary
A cold formed battery terminal and a method for forming the like having a body defining a cavity and an insert formed of a material different than the body confined in the cavity. The insert includes an insert base, at least one side wall, and at least one flange extending radially outward from the side wall.