Battery Terminal Assembly With High-Resistance Spark Prevention
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Solution Overview
Problem
The connection of battery terminals to vehicle batteries, particularly lithium batteries, often results in spark generation due to low resistance, posing a risk of injury and damage.
Innovation Solution
A battery terminal design featuring a short-prevention member made of high-resistance material, which is detachably attached to the terminal and positioned to contact the post first during assembly, preventing spark generation by maintaining equal potential and ensuring stable current conduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a battery terminal is connected directly to a lithium battery post, then electrical connection is achieved, but strong sparks occur due to low resistance
Solution Approach 1:
A short-prevention member made of high-resistance material is introduced as an intermediary element between the battery terminal and the lithium battery post. This mediator prevents direct low-resistance contact that causes sparks, while still allowing electrical connection to be established safely.
Solution Approach 2:
The short-prevention member is designed to make initial contact with the post before the main battery terminal body is fully assembled. This preliminary action ensures that the high-resistance element is in place first, preventing spark generation during the connection process.
2Reliability
If a compressing and clamping force is applied to couple the battery terminal to the post, then electrical connection is established, but the coupling force is weakened by vibration or external force
Solution Approach 1:
The battery terminal design incorporates a dynamic clamping mechanism that can adapt to vibrations and external forces. The structure allows for maintained contact pressure despite environmental disturbances, ensuring stable electrical connection throughout operation.
3Reliability
If a compressing and clamping force is applied to couple the battery terminal to the post, then electrical connection is established, but the post is damaged by too strong coupling
Solution Approach 1:
The design optimizes the compression force parameters to achieve adequate electrical connection without exceeding the post's structural limits. The short-prevention member and clamping mechanism are designed to apply precisely controlled forces that ensure connection stability while preventing post damage.
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
Effectively prevents spark generation when connecting to lithium batteries, reducing the risk of injury and allowing safe use with both lithium and lead-acid batteries by selectively using the high-resistance element.
Implementation Method 1
a short-prevention member detachably provided on the post terminal and provided as a high-resistance element to prevent spark generation when assembled to the post
Data Source
AI summary
A battery terminal includes a post terminal provided to electrically connect a cable to a post of a battery by being coupled to the post of the battery by a compressing and clamping force applied thereto in a state in which the cable is connected to the post terminal, and a short-prevention member detachably provided on the post terminal and provided as a high-resistance element to prevent spark generation when assembled to the post.