Battery Terminal Sealing Component for Environmental Protection and Heat Dissipation
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Solution Overview
Problem
Commercial and industrial batteries, especially those in large vehicles, face damage from harsh environmental conditions such as heat, humidity, and chemical exposure, leading to reduced service life and increased malfunction due to lack of effective protection for battery terminals and interconnects.
Innovation Solution
An interface sealing component with a base member that mates with both the battery surface and cover, forming an interior volume to enclose terminals and prevent environmental damage, allowing for improved heat dissipation without the need for a dedicated enclosure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a battery box or dedicated enclosure is used to protect terminals from environmental conditions, then reliability is improved, but heat dissipation deteriorates due to restricted air circulation
Solution Approach 1:
The sealing system is segmented into a base member with sealing surfaces that contacts the battery housing, and a separate cover member that seals the terminal area. This segmentation allows the sealing function to be localized to the terminal region without enclosing the entire battery array, thus protecting terminals from environmental damage while maintaining open air circulation for heat dissipation.
2Reliability
If multiple separate sealing components are used for each battery terminal, then reliability is improved, but device complexity increases
Solution Approach 1:
Multiple sealing functions are merged into a single integrated base member and cover member assembly. The base member includes multiple sealing surfaces that contact the battery housing around multiple terminals, and the cover member provides a single sealing interface. This merging reduces the number of separate sealing components while maintaining comprehensive protection of all terminals, thus simplifying the device without compromising reliability.
3Device complexity
If a single battery cover protects multiple batteries, then device complexity is reduced, but manufacturing precision requirements increase to ensure proper sealing
Solution Approach 1:
The base member incorporates multiple localized sealing surfaces, each tailored to contact a specific region of the battery housing around individual terminals. Each sealing surface has specific geometric features (such as tapered surfaces and complementary contours) designed for precise mating with corresponding surfaces on the battery housing. This local quality approach ensures that each sealing interface achieves proper sealing through localized geometric conformity, enabling a single cover to protect multiple batteries while maintaining manufacturing precision at each sealing location.
Data Source
AI summary
An interface sealing component for enclosing electrical battery cable between a cover and an array of batteries includes a base member having a first side shaped to matingly engage a battery surface of one or more batteries. A second side of the interface sealing component is opposite the first side, and is shaped to matingly engage a battery cover so that the base member forms an interior volume between the battery surface and the battery cover. Each battery surface has at least one terminal disposed on the battery surface into the interior volume through a base aperture in the base member. In this manner, the interface sealing component and battery cover can seal a number of battery terminals from outside environmental conditions, such as dust, moisture, or chemical exposure that can damage the battery terminals and reduce the operating life of the battery.