Offset Pole Socket Structure to Prevent Voids and Cut Weight
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Solution Overview
Problem
Conventional offset pole sockets for lead-acid energy storage systems are heavy, prone to voids and gas pockets, and have poor mechanical properties, leading to reduced energy density and electrical conductivity.
Innovation Solution
The design features a connecting element with a groove in its lower region and a contacting element with a labyrinth area, providing improved tensile load protection and sealing, while reducing material usage and weight through a unique shape and groove arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional offset terminal bushings are integrally cast from solid lead, then mechanical strength is achieved, but weight increases and energy density decreases
Solution Approach 1:
The terminal bushing is divided into a hollow cylindrical shell structure rather than being solid, creating segmented walls with controlled thickness. This segmentation reduces material usage and weight while maintaining structural integrity through the distributed wall design.
Solution Approach 2:
The terminal bushing combines lead alloy material with a hollow structural design, creating a composite structure that optimizes the balance between mechanical strength and weight. The hollow structure with strategic rib reinforcements creates a composite geometry that provides strength-to-weight ratio improvement.
2Stability of the object's composition
If conventional offset terminal bushings are cast from solid lead, then structural integrity is achieved, but cavities and air inclusions form reducing mechanical properties
Solution Approach 1:
The hollow cylindrical structure with controlled wall thickness and strategic rib segmentation creates a design that facilitates more uniform material distribution during casting, reducing the formation of cavities and air inclusions while maintaining structural integrity through the distributed reinforcement ribs.
3Strength
If conventional offset terminal bushings are cast from solid lead, then structural strength is achieved, but shrinkage cracks and inclusions form reducing electrical conductivity
Solution Approach 1:
The hollow cylindrical structure with optimized wall thickness and strategic rib segmentation creates a more uniform cooling pattern during casting, reducing thermal gradients that cause shrinkage cracks and inclusions, thereby improving electrical conductivity while maintaining structural strength.
4Strength
If offset pole sockets are designed with conventional solid structure, then mechanical strength is achieved, but material costs and production time increase
Solution Approach 1:
The hollow cylindrical structure with strategic rib segmentation is designed to be cast in a single operation, eliminating the need for multiple assembly steps. The segmented wall design with ribs provides structural strength equivalent to solid structures but with reduced material volume, decreasing casting time and material costs.
5Strength
If offset pole sockets are designed with waist and grooves, then resistance to tensile loads is improved, but structural complexity increases
Solution Approach 1:
The waist feature with circumferential grooves segments the cylindrical structure into distinct zones, creating a stepped configuration that provides mechanical interlocking with housing material. This segmentation increases resistance to tensile and torque loads while the grooves facilitate single-operation casting, actually simplifying the manufacturing process despite the increased geometric complexity.
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 2
AI summary
Pole socket (100) for an energy storage system comprising a connecting element (30) with a first end region and a second end region, a connection element (10, 10') which is arranged at the first end region of the connecting element (30) and which is designed to make electrical contact with the electrical loads, and a contact-making element (20) which is arranged at the second end region of the connecting element (30) and is designed to make electrical contact with a pole shaft, wherein the connection element (10, 10') extends in a first direction of extent from the connecting element (30), and wherein the contact-making element (20) extends in a second direction of extent from the connecting element (30), wherein the second direction of extent runs parallel and in the opposite direction to the first direction of extent in such a way that the contact-making element (20) is arranged offset from the connection element (10, 10'), wherein the connection element (10, 10') has an upper region for making contact with the electrical loads and a lower region which is designed to engage with a material of a housing (200), wherein at least one groove (12a, 12b) is arranged in the lower region.