Battery Terminal Sealing via Labyrinth Rings and Torque Ring
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Solution Overview
Problem
Existing battery terminals lack effective sealing and mechanical stability, and their assembly process is complex and not very precise, especially when inserting the terminal post into the lead bushing, which requires a conductive adhesive and results in low friction and unreliable connections.
Innovation Solution
A battery terminal design featuring a mounting section embedded within the battery cover, with a torque ring and labyrinth rings for enhanced stability and sealing, allowing for easy assembly and reduced material thickness while maintaining high retention forces, and a method of injection molding using a pin to control the flow of plastic material for precise sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the terminal post diameter is significantly smaller than the lead bushing diameter to simplify insertion, then ease of assembly is improved, but mechanical stability and connection reliability deteriorate due to the gap requiring conductive adhesive
Solution Approach 1:
The terminal post diameter is changed to match the lead bushing diameter, eliminating the gap that previously required conductive adhesive. This parameter change maintains ease of assembly while improving connection reliability through direct metal-to-metal contact.
Solution Approach 2:
The conductive adhesive intermediary is removed from the connection process. By making the terminal post diameter equal to the lead bushing diameter, the invention eliminates the need for adhesive filling, achieving both reliable electrical connection and mechanical stability without additional materials.
2Device complexity
If the terminal is held only by its outer wall within the battery cover, then device complexity is reduced, but mechanical stability and retention force deteriorate
Solution Approach 1:
The terminal embedding transitions from a one-dimensional outer wall fit to a three-dimensional embedding where both outer and inner walls are surrounded by battery cover material. This dimensional change provides enhanced stability and retention force without significantly increasing structural complexity.
Solution Approach 2:
The terminal is nested within the battery cover material, with the battery cover material surrounding both the outer wall and inner wall of the terminal's mounting section. This nesting structure provides enhanced mechanical stability and retention force.
3Ease of operation
If the terminal post diameter is smaller than the lead bushing diameter, then ease of insertion is improved, but manufacturing precision deteriorates due to gap filling requirements
Solution Approach 1:
The terminal post diameter parameter is changed to equal the lead bushing diameter, eliminating the gap that complicates manufacturing precision. This change maintains ease of insertion while achieving precise metal-to-metal contact without adhesive filling.
4Strength
If more material is used to increase terminal embedding depth, then mechanical stability is improved, but material usage and weight increase
Solution Approach 1:
The battery cover material partially surrounds the terminal's mounting section, embedding both outer and inner walls without completely encasing the terminal. This partial embedding provides sufficient mechanical stability while minimizing material usage and weight.
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 provides improved sealing and mechanical stability, simplifies the assembly process, and reduces material usage while ensuring secure connections and increased retention forces, enhancing the overall reliability and efficiency of battery terminals.
Implementation Method 1
The mounting section is for holding the terminal within a battery cover, into which it preferably is injection molded
Implementation Method 2
The circular edge at the inner wall of the terminal between the upper section and the lower section is in contact with the pin of the molding tool and ensures sealing of the area into which the battery cover's material can flow
Implementation Method 3
At the mounting section, the outer wall preferably has at least one circumferential projection forming a labyrinth
Data Source
AI summary
A terminal for a battery has a mounting section and a contacting section. There is a torque ring between the mounting section and the contacting section. The mounting section is for holding the terminal within a battery cover, into which it preferably is injection molded. The terminal is a hollow body, which has an outer surface and an inner surface. At the contacting section, the outer surface is conically shaped. At the mounting section, the outer surface has at least one labyrinth ring forming a labyrinth. The inner surface comprises at least two sections. An upper section is essentially surrounded by the contacting section, and preferably has a conical shape. A lower section is essentially surrounded by the mounting section. The lower section preferably has a concave cross-sectional shape. Between the upper section and the lower section, there is an edge. The edge at the inner surface may be essentially surrounded by the torque ring at the outer surface.