Conical Battery Terminal Flange for Vibration Retention

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Solution Overview

Problem

The 'stud and post' battery terminal connections concentrate clamping force in the center, leading to a concave ring terminal shape that reduces contact area and causes the terminal to loosen, resulting in significant current loss and poor retention.

Innovation Solution

A battery cable terminal fitting with a substantially conical attachment flange that increases the contact area as a nut is tightened, distributing the force peripherally to enhance electrical and mechanical attachment, maintaining contact even under vibration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a nut is threaded on the stud to provide compressive force for clamping the ring terminal to the battery post, then the ring terminal is retained to the battery post, but the center concentrated clamping force causes the outer perimeter of the ring terminal to bend upwardly and reduces the contact area between the ring terminal and battery post

Engineering Contradiction:

Improveretention of ring terminal to battery postVSAvoidcontact area between ring terminal and battery post

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The attachment flange is formed with a conical configuration where the outer perimeter is positioned closer to the battery post than the inner perimeter. This curvature distributes the clamping force radially outward from the center, preventing the ring terminal from bending upward at the edges and maintaining maximum contact area between the terminal and battery post while ensuring reliable retention.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Strength

If center concentrated clamping force is applied to the ring terminal, then the ring terminal is clamped to the battery post, but the soft lead battery post is extruded and frictional forces for retention are reduced

Engineering Contradiction:

Improveclamping force applicationVSAvoidfrictional forces for retention

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The conical configuration of the attachment flange distributes the clamping force radially outward from the center toward the periphery. This prevents concentration of force at a single point that would extrude the soft lead battery post, thereby maintaining frictional forces necessary for reliable retention of the terminal fitting.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Reliability

If the ring terminal is concave in cross-section due to center concentrated clamping force, then the terminal is retained to the battery post, but the required contact area is reduced by approximately 55%

Engineering Contradiction:

Improveterminal retentionVSAvoidcontact area between terminal and battery post

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The attachment flange is formed with a conical configuration where the outer perimeter is positioned closer to the battery post than the inner perimeter. This geometry distributes clamping force radially outward, maintaining the terminal's contact surface flat against the battery post and preserving maximum contact area for both mechanical retention and electrical conductivity.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The conical configuration introduces a radial dimension to the force distribution, transitioning from center-concentrated (1D) to radially-distributed (2D) clamping force. This dimensional change ensures the terminal maintains full contact area with the battery post while achieving secure retention.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 conical shape increases the contact area by approximately 40%, reducing current loss and improving retention, allowing for efficient energy transfer and reuse of the terminal fitting.

Implementation Method 1

The conical configuration of the attachment flange distributes the force peripherally across the battery terminal post

Methodology Applied

Scientific EffectForce distribution: Pressure Increase

Implementation Method 2

increases the contact area by approximately 40%, reducing current loss and improving retention, allowing for efficient energy transfer

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 3

distributing the force peripherally to enhance electrical and mechanical attachment, maintaining contact even under vibration

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS7553200B2Battery terminal for a vehicle

Publication Date: 2009.06.30 PACCAR INC

AI summary

A battery cable terminal fitting is provided for a battery having a terminal post. The battery cable terminal fitting comprises an attachment flange and a conductor attachment portion extending from the attachment flange. The attachment flange has an interface area extending between the attachment flange and the terminal post when the battery cable terminal fitting is coupled to the battery. The interface area has a battery contact area that increases as a nut used to fasten the attachment flange to the terminal post is tighten.