Poleshoes - Insulated Terminals For 12V Lead Acid Batteries

thingiverse

I favor using vintage 12-volt car batteries for various projects requiring more portable power than what standard small rechargeable Nickel-Metal Hydride or Lithium-Ion batteries can offer. One problem I faced was finding a clean way to connect the cable to the battery without exposing the metal surfaces to potentially hazardous short circuits, as conventional battery clamps tend to do. My objective in this modest project is to create insulated battery terminals for linking cables to standard 12-volt lead-acid batteries efficiently and safely. The designed terminals cater to applications where 12-volt car batteries are used to power low-current devices, with load currents limited to approximately 20 amps. A typical example of such a project is harnessing energy collected by solar panels using an old vehicle battery. These insulating pole shoes establish reliable electrical connections while keeping the poles safely isolated, preventing accidental short circuits from occurring. To secure an insulated stranded wire with a 1.5mm² cross-sectional area to one end, remove about 20 millimeters of insulation and insert it into the vertical hole until it is flush with the horizontal hole. Then thread the bare copper core through the vertical hole into the interior of the pole shoe and carefully spread out its strands for optimal contact with the battery's internal metal component. For an even more secure grasp on the cable, tie a small knot in the very tip of the insulated portion before pushing it past the first hole. Finish the process by pressing the insulating poles firmly onto the tapered terminals of the car batteries and fasten them securely using M3x12 screws with corresponding nuts. To improve aesthetic appeal, print the positive terminal (+) using bright red filament, while the negative one (-) should be done in either dark green or solid black. Updated files (2014-08-05) have been posted which take into account the cone's smaller diameter for the negative pole. For improved functionality and additional visual confirmation, engraved "+" and "-" signs now appear on top of each insulating pole. Additional updates to this design now include an integrated fuse holder in a modified version uploaded (2014-08-06), effectively preventing risks of fire resulting from unintended electrical surges. To assemble the pole shoes using my Prusa RepRap 3D printer, set the nozzle at 0.4mm width and extrusion height of 0.56mm and layer thickness at 0.25mm to achieve proper alignment and durability. Since ABS can stretch more freely than other plastics during tightening operations, it's ideal for creating flex within the terminals. A successful outcome hinges on proper tension of pole shoes while printing and securely locking the internal structure by means of tiny screws. Printing was accomplished with settings similar as previous models: Settings are listed as follows: - Temperature 205c Material used ABS.