Pull Bar Battery Terminal Clamp With Composite Alloy Body
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Solution Overview
Problem
Battery terminal clamps in vehicles are exposed to harsh conditions such as road tar, vibration, extreme temperatures, and corrosive elements, leading to reliability issues and neglect, necessitating a design that is rugged, corrosion-resistant, easy to maintain, and cost-effective.
Innovation Solution
A battery terminal clamp design featuring a conductive copper-iron-phosphorus alloy body with a simple, low-profile structure, including upper and lower pull bars with angled ramps, and a threaded bolt for secure clamping, allowing for easy assembly and operation, while being resistant to corrosion and environmental factors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional battery terminal clamp designs are used, then basic clamping function is provided, but reliability and corrosion resistance deteriorate under harsh conditions
Solution Approach 1:
The clamp body is constructed from a composite material structure combining a corrosion-resistant outer shell ( zinc-aluminum alloy or stainless steel) with a conductive inner core (copper or copper alloy). This composite construction provides both corrosion resistance and electrical conductivity, resolving the contradiction between reliability under harsh conditions and resistance to harmful environmental factors.
2Strength
If complex clamp designs with multiple parts are used, then clamping power may be improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The invention merges multiple functions into a single integrated clamp body structure. The pull bar, clamping arms, and fastening mechanism are combined into one piece or few pieces, eliminating the need for multiple separate parts while maintaining strong clamping power through optimized structural geometry and material properties.
Solution Approach 2:
The clamp body is segmented into functional zones with varying thickness and density - thicker sections where strength is needed for clamping, and thinner sections where weight reduction is beneficial. This strategic segmentation provides high clamping power without requiring a uniformly complex structure throughout the entire component.
3Strength
If rugged and heavy clamp construction is used, then durability under vibration and harsh conditions is improved, but the clamp profile increases and may not fit within under-hood confines
Solution Approach 1:
The clamp employs a thin-walled but strategically reinforced structure with ribbed or fluted geometry that provides high strength-to-volume ratio. The thin walls are sufficient for protection while the reinforced ribs provide structural integrity against vibration, achieving durability without excessive profile.
4Ease of manufacture
If simple clamp design with few parts is used, then ease of manufacture and assembly is improved, but corrosion resistance and reliability may deteriorate
Solution Approach 1:
The single-piece clamp body is constructed from composite materials that inherently provide both corrosion resistance and electrical conductivity. This eliminates the need for complex multi-part assemblies with multiple joints and fasteners, achieving ease of manufacture while maintaining reliability through material selection rather than structural complexity.
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 provides a robust, reliable, and corrosion-resistant connection that withstands harsh conditions, ensuring consistent performance and ease of maintenance, thereby enhancing the reliability of electrical connections in vehicles.
Implementation Method 1
A generally vertically disposed bolt or other threaded element may extend through the top planar element, the upper pull bar, and the lower pull bar. The bolt or threaded element is threadably secured to either the upper pull bar or the lower pull bar. The bolt or threaded element may be rotated in the clockwise or counterclockwise direction. As a result of this threaded securement of the bolt or threaded element to the upper or lower pull bar, the rotation of the bolt enables the upper and lower pull bars to move either towards or away from each other, respectively.
Implementation Method 2
The body portion may be made of a conductive material... Preferably, the design of a battery terminal clamp should be simple, with as few parts and as few moving parts, as possible. The design should be corrosion resistant, easy to fabricate and assemble, and relatively inexpensive to manufacture.
Data Source
AI summary
A battery terminal clamp, comprising a body portion made of a conductive material and having top and bottom planar elements. The battery terminal clamp includes a first pull bar, and also includes a second pull bar positioned below the first pull bar. A threaded element extends through the upper pull bar and the lower pull bar, and facilitates the movement of the upper and lower pull bar towards and away from each other, so as to close and open the clamp.