Current-Limiting Wiring Terminal for Spark-Free Battery Connection
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Solution Overview
Problem
Conventional wiring terminals are prone to generating electric sparks due to voltage differences between batteries and external devices, posing safety risks during connection.
Innovation Solution
A wiring terminal design incorporating a metal lug, current-limiting circuit board, and metal spring plate that limits current flow and maintains a safe distance, along with a rubber-coated member for insulation, to prevent sparks and ensure safe connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal lug is directly connected to the battery electrode, then the electrical connection is simple and low-resistance, but electric sparks are generated due to voltage difference and electron acceleration
Solution Approach 1:
A current-limiting circuit board is introduced as an intermediary component between the metal lug and the battery electrode. This circuit board limits the current magnitude during connection, preventing electron acceleration and spark generation while maintaining electrical connectivity. The intermediary component resolves the contradiction by enabling safe current flow without direct metal-to-electrode contact.
Solution Approach 2:
The harmful function of direct metal-to-electrode contact is extracted and replaced. Instead of allowing direct connection that causes sparks, the metal lug is separated from direct electrode contact by introducing the current-limiting circuit board. This extraction of the harmful direct-contact function eliminates spark generation while preserving the essential electrical connection function.
2Reliability
If a current-limiting circuit board is added to prevent sparks, then wiring safety is improved, but the device complexity increases
Solution Approach 1:
The current-limiting circuit board is merged with the wiring terminal structure, integrating the safety function into the existing component framework. By combining the circuit board with the metal lug assembly rather than treating it as a separate added component, the overall structural complexity is minimized while achieving the current-limiting safety function.
Solution Approach 2:
The current-limiting function is applied locally at the critical connection point between the metal lug and battery electrode, rather than requiring system-wide complexity. The circuit board is positioned specifically where spark generation occurs, providing targeted safety intervention without complicating the entire wiring system.
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 design effectively prevents electric sparks by controlling current flow and maintaining a safe distance, enhancing safety and reliability during the wiring process.
Implementation Method 1
a current-limiting circuit board, configured to limit a magnitude of a current
Implementation Method 2
a metal spring plate spaced from the metal lug in a first direction, where the metal spring plate is electrically connected to the current-limiting circuit board. When the metal lug is pressed, the metal spring plate is in conduction connection with the metal lug
Data Source
AI summary
A wiring terminal includes a metal lug, a current-limiting circuit board, and a metal spring plate. The metal lug is electrically connected to one end of a wire body of the conducting wire. The current-limiting circuit board is configured to limit a magnitude of a current, and is electrically connected to the one end of the wire body of the conducting wire. The metal spring plate is spaced from the metal lug in a first direction. The metal spring plate is electrically connected to the current-limiting circuit board. When the metal lug is pressed, the metal spring plate can be in conduction connection with the metal lug, and a resistance of the metal lug is smaller than that of the current-limiting circuit board. The wiring terminal can resolve a problem of emergence of electric sparks in a wiring process, reduce potential safety hazards, and implement a safe and reliable connection.