Molded-In Battery Terminal Design for Compact Footprint
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Storage batteries with terminals that extend outwardly from the container face challenges in tight spaces, making it difficult to replace them while maintaining adequate connection and footprint efficiency, especially in densely packed arrangements.
Innovation Solution
The battery design features battery terminals molded into the container cover, with conductive straps and tombstones that keep the terminals within the original footprint, providing a shorter current path and direct disconnectable termination within the container's footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If battery terminals extend outwardly from the battery container, then electrical connection is provided, but the footprint increases making it difficult to position replacement batteries in tight spaces
Solution Approach 1:
The terminal is nested within the battery container structure. The terminal is formed as an integral part of the container wall itself, with the terminal receiving portion created by molding the terminal material directly into the wall structure, eliminating the need for external terminal extensions.
Solution Approach 2:
The terminal structure is merged with the container wall. The terminal and container wall are formed as a single integrated component through molding processes, where the terminal receiving portion is created by molding terminal material into the wall, combining two previously separate elements into one.
2Reliability
If additional space is provided for terminal connection, then adequate termination is assured, but the battery footprint increases
Solution Approach 1:
The terminal connection structure is nested within the container wall thickness. The terminal receiving portion is formed by molding terminal material into the wall, creating a recessed connection area that does not extend beyond the original container exterior surface.
Solution Approach 2:
The terminal connection area is localized within the wall structure. The terminal receiving portion creates a localized connection zone within the wall thickness, providing adequate termination space without extending the overall footprint of the battery.
3Area of stationary object
If terminals are molded into the side wall or cover, then footprint is reduced, but terminal accessibility and connection space are limited
Solution Approach 1:
The terminal connection is achieved in the vertical dimension rather than horizontal extension. The terminal receiving portion is formed by molding into the wall, creating a vertically oriented connection recess that maintains the original horizontal footprint while providing adequate connection space.
Data Source
AI summary
A storage battery includes a generally rectangular container having opposed side walls, end walls, a bottom wall and an open top defining a container interior. The container interior is divided into a plurality of cells supporting positive and negative plates. The plates include aligned positive lugs and aligned negative lugs. A pair of conductive straps are provided. One of the straps interconnects the positive lugs while the other strap interconnects the negative lugs. A tombstone extends from each of the straps. Each tombstone is located at a position spaced inwardly from the container walls. A pair of battery terminals are supported within the container end walls. Each battery terminal is directly connected to one of the tombstones. The battery terminals are positioned between the tombstone and the container wall and include a termination location adjacent the container wall for direct disconnectable termination thereat. A cover is provided for enclosing the open end of the container.