Resin-Molded Battery Terminal With Current Sensor Torque Stability
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Solution Overview
Problem
The existing battery terminal designs require multiple assembly processes and additional space for current sensors, leading to increased workload and potential separation issues due to high fastening torque, which affects the durability and appearance of the terminal.
Innovation Solution
A battery terminal with integrated current sensors using resin molding, featuring a tapered connection part and reinforcement beads to secure the sensor and prevent separation, while maintaining the compactness and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the current sensor is assembled to the end terminal separately, then the current sensor can be provided at a position distant from the battery post, but the number of assembly processes increases and more space is required
Solution Approach 1:
The current sensor assembly is merged with the battery terminal into a single integrated structure. The sensor housing is formed by resin molding that directly integrates the current sensor mounting position with the battery terminal body, eliminating the need for separate assembly of the current sensor to the end terminal. This reduces the number of assembly processes while maintaining the functional separation needed for current sensing.
2Strength
If high fastening torque is applied to secure the connection, then the connection strength is improved, but peeling occurs at the contact part between metal surface and resin surface causing separation
Solution Approach 1:
The connection structure employs local quality differentiation through the tapered connection part design. The connection part has a wider cross-sectional area at the base and gradually tapers toward the end terminal, creating a stress distribution gradient. This tapered geometry, combined with reinforcement beads formed by resin molding, concentrates strength at critical locations while distributing fastening forces to prevent peeling at the metal-resin interface. The local reinforcement allows high fastening torque to be applied without causing separation.
3Ease of manufacture
If the battery terminal part is formed by bending a conductive metal plate, then the manufacturing flexibility is improved, but the embrace part cannot be formed at the integration position and rear position
Solution Approach 1:
The battery terminal employs a composite structure where a conductive metal plate forms the basic terminal body through bending, and a resin material is molded to form the embrace part and integration position structures. The resin molding is applied to specific regions of the metal plate, creating a metal-resin composite structure. This allows the embrace part to be formed at the integration position and rear position, combining the electrical conductivity and formability of metal with the structural stability and molding precision of resin.
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 integrates current sensors with battery terminals, enhancing strength and preventing separation, ensuring reliable performance and repetitive use under vibration, and maintaining a compact design.
Implementation Method 1
The current sensor has a substantially annular core and a Hall element
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
The present invention refers to a battery terminal with current sensor comprising: a battery terminal part that is formed by a conductive metal plate, and a current sensor that is integrated with the battery terminal part by a resin molding. The battery terminal part includes a first plate part and a second plate part, which are opposed to each other by bending the conductive metal plate, a post part that is to be connected to a battery post of a battery and an embrace part that is formed at the post part and restrains the first plate part and the second plate part from being widened therebetween. A part to be resin-molded which corresponds to a part to which the current sensor is integrated by the resin molding, and a connection part, which corresponds to a part of connecting the part to be resin-molded to the first plate part, are formed at one side of the embrace part in the first plate part.