Battery Post Terminal Clamp With Vertical Wedge Tightening
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Solution Overview
Problem
Existing battery terminal assemblies struggle to reliably couple to battery posts of varying shapes and sizes, and traditional horizontal drive mechanisms are ergonomically disadvantageous in automotive assembly lines.
Innovation Solution
A battery post terminal assembly that uses a vertical drive mechanism and a modular design with a clamp mechanism, allowing it to conform to battery posts of irregular shapes and sizes, ensuring secure and ergonomic attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional battery post terminals are used with separate nuts and fastening components, then the assembly can be manufactured, but the assembly process becomes time-consuming and labor-intensive
Solution Approach 1:
The patent combines multiple separate fastening components (post, nut, and fastening mechanism) into a single integrated battery post terminal assembly. The terminal incorporates a built-in fastening mechanism that eliminates the need for separate nuts and fastening components, thereby reducing assembly time and increasing productivity while maintaining structural integrity.
Solution Approach 2:
The battery post terminal assembly is designed to perform multiple functions: it provides electrical connection (terminal function) and mechanical fastening (fastening mechanism) in a single component. This multi-functionality reduces the number of parts needed and simplifies the assembly process, directly addressing the productivity issue.
2Reliability
If multiple separate components are used for battery post terminals, then manufacturing flexibility is maintained, but the risk of corrosion and structural failure increases
Solution Approach 1:
By integrating the fastening mechanism directly into the terminal structure, the patent reduces the number of connection points where corrosion could occur. The single integrated assembly minimizes exposed surfaces and potential failure points compared to multiple separate components, thereby improving reliability and corrosion resistance.
Solution Approach 2:
The terminal assembly utilizes composite construction with a polymer body and metal fastening elements, creating a structure that combines the corrosion resistance of polymers with the mechanical strength of metals. This composite approach enhances overall reliability while reducing susceptibility to galvanic corrosion between dissimilar metals.
3Strength
If complex fastening mechanisms are used to ensure secure connections, then connection strength is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The integration of the fastening mechanism into the terminal body allows for optimized connection strength without adding external complexity. The unified structure enables direct load paths and efficient force distribution, achieving strong connections while keeping the overall design simple and manufacturable.
Data Source
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AI summary
A battery post terminal assembly includes a conductive band and a clamp mechanism. The conductive band includes a first free end and a second free end. The conductive band defines an aperture for receiving a battery post of a battery. The clamp mechanism includes a wedge member that defines a recess between a first surface and a second surface thereof. The recess has an open end and a closed end that is narrower than the open end. The first surface is convex. The first free end and the second free end are positioned in the recess. The first free end is movable along the first surface toward the closed end to be moved by the first surface toward the second free end to tighten the conductive band around the battery post.