Switch-Embedded Jumper Clamp for Safe Battery Connection
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Solution Overview
Problem
Existing jumper cables and wires pose a risk of inadvertent electronic power transfer and arcing, leading to damage and safety hazards, especially in high-amperage applications like car batteries, due to improper connections and lack of safety features.
Innovation Solution
Integration of a switch mechanism into the clamp handles that allows current flow only when the clamp jaws are opened by squeezing, providing a safe and intuitive way to manage electrical continuity, preventing accidental short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional jumper cables without integrated switches are used, then ease of operation is maintained, but safety and risk of inadvertent power transfer deteriorate
Solution Approach 1:
The patent combines the clamp mechanism and switch into a single integrated unit. The clamp handle serves as the switch actuator, merging two previously separate functions (clamping and switching) into one component. This reduces device complexity while maintaining safety, as the integrated design eliminates the need for separate switches and reduces the number of manual operations required.
Solution Approach 2:
The clamp is designed to automatically activate the circuit closure function when squeezed. The mechanical action of closing the clamp automatically triggers the switch closure through integrated mechanical or magnetic coupling, eliminating the need for a separate manual switching operation. This self-service mechanism maintains safety while simplifying operation.
2Reliability
If a separate switch is integrated into the jumper cable, then safety improves, but ease of operation deteriorates due to additional manual steps
Solution Approach 1:
The switch and clamp are merged into a single integrated unit where the clamp handle directly actuates the switch. This eliminates the need for separate manual switching steps, as the same squeezing motion that closes the clamp also closes the circuit. The merged design maintains safety while improving ease of operation by reducing the number of discrete actions required.
Solution Approach 2:
The clamp automatically performs the switching function through its own mechanical action. When the user squeezes the clamp to close it onto the terminal, the mechanical force automatically actuates the switch closure mechanism. This self-service approach eliminates the need for a separate manual switching step, maintaining safety while simplifying the operational sequence.
3Ease of operation
If clamp handles are made spring-tensioned for automatic closure, then ease of operation improves, but control over current flow timing deteriorates
Solution Approach 1:
The spring-tensioned clamp mechanism is merged with the switch actuation mechanism. The spring provides the force for automatic closure while simultaneously providing the actuation force for the switch. This merged design ensures that the clamp can only close (and thus activate current flow) when the user intentionally squeezes the handles, maintaining both ease of operation and control over current flow timing.
Solution Approach 2:
The spring-tensioned clamp automatically provides the mechanical force needed to actuate the switch upon user initiation. When the user squeezes the handles, the spring releases stored energy to complete the closure motion and simultaneously actuate the switch. This self-service mechanism maintains control over current flow timing while requiring minimal user effort, improving ease of operation without sacrificing reliability.
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
Enhances safety for both electronic components and users by ensuring current flow only when the clamp is intentionally activated, reducing the risk of damage and hazards associated with improper connections.
Implementation Method 1
hand-operated, spring-tensioned, battery terminal clamps
Implementation Method 2
clamp with an integrated switch that allows current to flow (or in certain applications, not flow) based on a relative position of the clamp handles
Data Source
AI summary
A clamp includes a first and second handle parts that are pivotable relative to each other and biased closed. A first electrical contactor is associated with the first handle part, and a second electrical contactor is associated with the second handle part. The first electrical contactor and the second electrical contactor are positioned such that in the closed position of the clamp, a circuit connection between the first electrical contactor and the second electrical contactor is open, and in the open position, the circuit connection is closed.