Corrosion-proof battery terminal and cable connector therefor

Claim 2

A battery and cable connector therefor, said connector comprising a noncorroding, elastomeric cap having first and second open ends and an opening between said ends, an annular sealing projection protruding from said first end, said projection being defined by inner and outer walls, said inner wall also defining a truncated cone-shaped hollow at said first open end the cross sectional diameter of which hollow increases from a minimum near the center of the cap to a maximum farthest from the center of the cap, an apertured, electrically conductive contact element in said opening between said ends and at least partially embedded in said cap, a threaded bolt having a first flange engaging said element, said bolt extending through said element and said opening for securing said connector to said battery, said battery including a wall at least partially defining a container, a conductive terminal passing through and in sealing engagement with said wall, an outwardly facing portion of said terminal having an interiorly threaded socket engaging said threaded bolt, an annular groove including a sealing edge surrounding said socket and engaging said projection on said cap, the diameter of said groove at said edge being at lEast equal to said minimum diameter of said hollow and not substantially more than said maximum diameter of said hollow and the depth of said groove being sufficient to insure at least line-contact between said sealing edge and said inner wall of said projection to universally provide a seal between said connector and said terminal regardless of minor dimensional variations from one connector to the next and one terminal to the next, which seal protects said terminal from environmental corrosive attack.

Claim 3

A battery and cable connector therefor, said connector comprising a noncorroding, elastomeric cap having first and second open ends and an opening extending between said ends, an annular sealing projection protruding from said first end, said projection being defined by inner and outer walls, said inner wall also defining a truncated cone-shaped hollow at said first open end, the cross sectional diameter of which hollow increases from a minimum near the center of the cap to a maximum farthest from the center of the cap, an apertured electrically conductive contact element in said opening between said ends and at least partially embedded in said cap, said element including opposing turn-resistant tangs in biting engagement with the terminal of said battery to resist rotation of said connector with respect to said battery, a threaded bolt having a first flange engaging said element, said bolt extending through said element and said opening for securing said connector to said battery, said battery including a wall at least partially defining a container, a conductive terminal passing through and in sealing engagement with said wall, an outwardly facing portion of said terminal having an interiorly threaded socket engaging said threaded bolt, an annular groove including a sealing edge surrounding said socket and engaging said projection on said cap, the diameter of said groove at said edge being at least equal to said minimum diameter of said hollow and not substantially more than said maximum diameter of said hollow and the depth of said groove being sufficient to insure at least line-contact between said sealing edge and said inner wall of said projection to universally provide a seal between said connector and said terminal regardless of minor dimensional variations from one connector to the next and one terminal to the next which seal protects said terminal from environmental corrosive attack.

Claim 4

A battery and cable connector therefor, said connector comprising a noncorroding, elastomeric cap having first and second open ends and an opening extending between said ends, an annular sealing projection protruding from said first end, said projection being defined by inner and outer walls, said inner wall also defining a truncated cone-shaped hollow at said first open end, the cross sectional diameter of which hollow increases from a minimum near the center of the cap to a maximum farthest from the center of the cap, an apertured electrically conductive contact element in said opening between said ends and at least partially embedded in said cap, said element including opposing turn-resistant tangs in biting engagement with the terminal of said battery to resist rotation of said connector with respect to said battery, a threaded bolt having a first flange engaging said element, said bolt extending through said element and said opening for securing said connector to said battery, said battery including a wall at least partially defining a container, a conductive terminal passing through and in sealing engagement with said wall, an outwardly facing portion of said terminal having an interiorly threaded socket engaging said threaded bolt, an annular groove including a sealing edge surrounding said socket and engaging said projection on said cap, the diameter of said groove at said edge being at least equal to said minimum diameter of said hollow and not substantially more than said maximum diameter of said hollow and the depth of said groove being sufficient to insure at least line-contact between said sealing edge and said inner wall of said projection to universally provide a seal between said connector and said terminal regardless of minor dimensional variations from one connector to the next and one terminal to the next which seal protects said terminal from environmental corrosive attack.

Claim 5

A battery and cable connector therefor, said connector comprising a noncorroding, elastomeric cap having first and second open ends and an opening extending between said ends, an annular sealing projecting protruding from said first end, said projection being defined by inner and outer walls, said inner wall also defining a first truncated cone-shaped hollow at said first open end the cross sectional diameter of which hollow increases from a minimum near the center of the cap to a maximum farthest from the center of the cap, said second open end comprising a second truncated cone-shaped hollow the cross sectional diameter of which increases from a minimum near the center of the cap to a maximum farthest from the center of the cap, an apertured electrically conductive contact element in said opening between said ends and at least partially embedded in said cap, said element including opposing turn-resistant tangs in biting engagement with the terminal of said battery to resist rotation of said connector with respect to said battery, a threaded bolt having a first flange engaging said element and a second flange sealingly engaging said cap in said second hollow, said bolt extending through said element and said opening for securing said connector to said battery, said battery including a side wall defining a case, a conductive terminal passing through and in sealing engagement with said wall, an outwardly facing first portion of said terminal having an interiorly threaded socket engaging said threaded bolt, an annular groove including a sealing edge surrounding said socKet and engaging said projection on said cap, the diameter of said groove at said edge being at least equal to said minimum diameter of said first hollow and not substantially more than said maximum diameter of said first hollow and the depth of said groove being sufficient to insure at least line-contact between said sealing edge and said inner wall of said projection to universally provide a seal between said connector and said terminal regard-less of minor dimensional variations from one connector to the next and one terminal to the next which seal protects said terminal from environmental corrosive attack.

Claim 6

A battery and cable connector therefor, said connector comprising a noncorroding, elastomeric cap having first and second open ends and an opening extending between said ends, an annular sealing projecting protruding from said first end, said projection being defined by inner and outer walls, said inner wall also defining a first truncated cone-shaped hollow at said first open end the cross sectional diameter of which hollow increases from a minimum near the center of the cap to a maximum farthest from the center of the cap, said second open end comprising a second truncated cone-shaped hollow the cross sectional diameter of which increases from a minimum near the center of the cap to a maximum farthest from the center of the cap, an apertured electrically conductive contact element in said opening between said ends and at least partially embedded in said cap, said element including opposing turn-resistant tangs in biting engagement with the terminal of said battery to resist rotation of said connector with respect to said battery, a threaded bolt having a first flange engaging said element and a second flange sealingly engaging said cap in said second hollow, said bolt extending through said element and said opening for securing said connector to said battery, said battery including a side wall defining a case, a conductive terminal passing through and in sealing engagement with said wall, an outwardly facing first portion of said terminal having an interiorly threaded socket engaging said threaded bolt, an annular groove including a sealing edge surrounding said socKet and engaging said projection on said cap, the diameter of said groove at said edge being at least equal to said minimum diameter of said first hollow and not substantially more than said maximum diameter of said first hollow and the depth of said groove being sufficient to insure at least line-contact between said sealing edge and said inner wall of said projection to universally provide a seal between said connector and said terminal regard-less of minor dimensional variations from one connector to the next and one terminal to the next which seal protects said terminal from environmental corrosive attack.

Claim 7

The battery and cable connector as defined in claim 3 wherein said second end of said cap includes a radially extending annular lip, said bolt has an annular knob adjacent said second flange, and said connector includes a cover comprising a web and at least two annular concentric flanges extending from said web and defining inner and outer concentric cylinders, the inner cylinder having inwardly extending fingers engaging said knob to secure said cover to said bolt while said outer cylinder engages said lip to provide additional protection for said terminal.

Claim 8

The battery and cable connector as defined in claim 3 wherein said bolt includes an annular recess between said first flange and said threads, and said conductive element includes locking tabs extending into said aperture and said recess for loosely retaining said bolt in said aperture.

Claim 9

A cable connector for the terminal of a lead-acid storage battery, said connector comprising a noncorroding, elastomeric cap having first and second open ends and an opening between said ends, an annular sealing projection protruding from said first end and adapted to be received in a mating annular groove circumscribing said terminal, said projection being defined by inner and outer walls, said inner wall also defining a first truncated cone-shaped hollow at said first open end the cross sectional diameter of which hollow increases from a minimum near the center of the cap to a maximum farthest from the center of the cap, said inner wall being adapted to engage a sealing edge of said groove, said second open end comprising a second truncated cone-shaped hollow the cross sectional diameter of which increases from a minimum near the center of the cap to a maximum farthest from the center of the cap, an electrically conductive contact element having an aperture therein in said opening between said ends and at least partially embedded in said cap, said element including opposing turn-resistant tangs for bitingly engaging said terminal of said battery to resist rotation of said connector with respect to said battery, a threaded bolt having a first flange for engaging said element and a second flange for sealingly engaging said cap in said second hollow, said bolt extending through said aperture and said opening in said cap for securing said connector to a threaded socket in said battery terminal.

Claim 10

A cable connector for the terminal of a lead-acid storage battery, said connector comprising a noncorroding, elastomeric cap having first and second open ends and an opening between said ends, an annular sealing projection protruding from said first end and adapted to be received in a mating annular groove circumscribing said terminal, said projection being defined by inner and outer walls, said inner wall also defining a first truncated cone-shaped hollow at said first open end the cross sectional diameter of which hollow increases from a minimum near the center of the cap to a maximum farthest from the center of the cap, said inner wall being adapted to engage a sealing edge of said groove, said second open end comprising a second truncated cone-shaped hollow the cross sectional diameter of which increases from a minimum near the center of the cap to a maximum farthest from the center of the cap, an electrically conductive contact element having an aperture therein in said opening between said ends and at least partially embedded in said cap, said element including opposing turn-resistant tangs for bitingly engaging said terminal of said battery to resist rotation of said connector with respect to said battery, a threaded bolt having a first flange for engaging said element and a second flange for sealingly engaging said cap in said second hollow, said bolt extending through said aperture and said opening in said cap for securing said connector to a threaded socket in said battery terminal.

Claim 11

A battery case including a conductive terminal forming a part of at least one wall of said case; said terminal comprising a conductive plug passing through and in intimate, sealing contact with an aperture-defining surface in the remainder of said wall; said plug having an inner end inside said case to fuse to the battery''s electrochemical elements and an outer end outside said case to join to a battery cable connector; said plug having an interiorly threaded socket recessed in said outer end to engage a threaded bolt on said connector; said wall having an annular groove surrounding said socket and defining a terminal face including said outer end; and said groove providing a sealing edge with said face and being adapted to receive a tapered, annular elastomeric sealing projection on said connector such that said edge engages said sealing projection in an interference-fit seal around said socket to substantially isolate said face and said socket from corrosive environmental attack when joined with said connector regardless of minor dimensional variations from one connector to the next and one terminal to the next.

Claim 12

A battery case including a conductive terminal forming a part of at least one wall of said case; said terminal comprising a conductive plug passing through and in intimate, sealing contact with an aperture-defining surface in the remainder of said wall; said plug having an inner end inside said case to fuse to the battery''s electrochemical elements and an outer end outside said case to join to a battery cable connector; said plug having an interiorly threaded socket recessed in said outer end to engage a threaded bolt on said connector; said wall having an annular groove surrounding said socket and defining a terminal face including said outer end; and said groove providing a sealing edge with said face and being adapted to receive a tapered, annular elastomeric sealing projection on said connector such that said edge engages said sealing projection in an interference-fit seal around said socket to substantially isolate said face and said socket from corrosive environmental attack when joined with said connector regardless of minor dimensional variations from one connector to the next and one terminal to the next.

Claim 13

A battery and connector assembly comprising: a battery case having a plurality of walls defining a compartment for electrochemical cell elements; a conductive plug integral with and forming a part of at least one of the side walls of the battery, which plug extends through and is in sealing engagement with the remainder of the side wall; one end of the plug facing outwardly of the case and forming a terminal of the battery; the other end of the plug facing said compartment; electrochemical cell elements in the compartment; strap means joining said elements; a fused connection between the strap means and the other end of the plug; an internally threaded socket in the one end; an annular groove in said wall having a sealing edge surrounding the socket; terminal connector means including a non-corroding cap, a threaded bolt extending through said cap and an annular, tapered, elastomeric lip on the cap surrounding the bolt; a sealing surface on the tapered lip; said lip and said groove mating in tongue-in-groove fashion such that the sealing edge of the groove engages the sealing surface of the elastomeric lip in an interference-fit seal around the socket regardless of minor dimensional variations from one cap to the next and one groove to the next, which seal protects the terminal from corrosive enviornmental attack.

Claim 14

A battery and connector assembly comprising: a battery case having a plurality of walls defining a compartment for electrochemical cell elements; a conductive plug integral with and forming a part of at least one of the side walls of the battery, which plug extends through and is in sealing engagement with the remainder of the side wall; one end of the plug facing outwardly of the case and forming a terminal of the battery; the other end of the plug facing said compartment; electrochemical cell elements in the compartment; strap means joining said elements; a fused connection between the strap means and the other end of the plug; an internally threaded socket in the one end; an annular groove in said wall having a sealing edge surrounding the socket; terminal connector means including a non-corroding cap, a threaded bolt extending through said cap and an annular, tapered, elastomeric lip on the cap surrounding the bolt; a sealing surface on the tapered lip; said lip and said groove mating in tongue-in-groove fashion such that the sealing edge of the groove engages the sealing surface of the elastomeric lip in an interference-fit seal around the socket regardless of minor dimensional variations from one cap to the next and one groove to the next, which seal protects the terminal from corrosive enviornmental attack.

Claim 15

A battery and detachable connector assembly comprising: a battery case having a plurality of walls defining a compartment for electrochemical cell elements; a conductive plug integral with and forming a part of at least one of the side walls of the battery, which plug extends through and is in sealing engagement with the remainder of the side wall, the remainder of the side wall being nonconductive; one end of the plug facing outwardly of the case and forming a terminal of the battery; the other end of the plug facing said compartment; electrochemical cell elements in the compartment; strap means joining said elements; a fused connection between the strap means and the other end of the plug; an internally threaded socket in the one end; an annular groove in said wall forming a sealing edge surrounding the socket; terminal connector means including a non-corroding cap, a threaded bolt extended through said cap and an annular, tapered, elastomeric lip on the cap surrounding the bolt; a sealing surface on the tapered lip; said lip and said groove mating such that the sealing edge of the groove engages the sealing surface of the lip in an interference-fit seal around the socket regardless of minor dimensional variations from one cap to the next and one groove to the next, which seal protects the terminal from corrosive environmental attack.

Claim 16

A battery and detachable connector assembly comprising: a battery case having a plurality of walls defining a compartment for electrochemical cell elements; a conductive plug integral with and forming a part of at least one of the side walls of the battery, which plug extends through and is in sealing engagement with the remainder of the side wall, the remainder of the side wall being nonconductive; one end of the plug facing outwardly of the case and forming a terminal of the battery; the other end of the plug facing said compartment; electrochemical cell elements in the compartment; strap means joining said elements; a fused connection between the strap means and the other end of the plug; an internally threaded socket in the one end; an annular groove in said wall forming a sealing edge surrounding the socket; terminal connector means including a non-corroding cap, a threaded bolt extended through said cap and an annular, tapered, elastomeric lip on the cap surrounding the bolt; a sealing surface on the tapered lip; said lip and said groove mating such that the sealing edge of the groove engages the sealing surface of the lip in an interference-fit seal around the socket regardless of minor dimensional variations from one cap to the next and one groove to the next, which seal protects the terminal from corrosive environmental attack.

Claim 17

The battery and connector assembly as defined in claim 9 wherein the sealing edge is formed on the conductive plug.

Claim 18

The battery and connector assembly as defined in claim 9 wherein the sealing edge is formed on a portion of the remainder of the wall which surrounds the conductive plug.

Claim 19

A battery comprising: a battery case having a plurality of walls defining a compartment; electrochemical cell elements including strap means in the compartment; a conductive plug integral with and forming a part of at least one of the side walls of the battery, which plug passes through and is in intimate sealing contact with an aperture-defining surface in the remainder of the side wall, the remainder of the side wall being nonconductive; one end of the plug having a face thereon on the outside of the case forming a terminal of the battery which is adapted to engage a battery cable connector having a non-corroding cap and an annular, tapered, elastomeric lip and sealing surface on said cap; the other end of the plug facing said compartment; a fused connection between the strap means and said other end of the plug; an internally threaded socket in said one end adapted to engage a threaded bolt extending through said cap substantially centrally of said lip; an annular groove in said wall forming a sealing edge surrounding the socket adapted to engage the sealing surface of the lip in an interference-fit seal around the socket to protect said face and said socket from corrosive environmental attack when engaged with said connector regardless of minor dimensional variations from one cap to the next and one groove to the next.

Claim 20

A battery comprising: a battery case having a plurality of walls defining a compartment; electrochemical cell elements including strap means in the compartment; a conductive plug integral with and forming a part of at least one of the side walls of the battery, which plug passes through and is in intimate sealing contact with an aperture-defining surface in the remainder of the side wall, the remainder of the side wall being nonconductive; one end of the plug having a face thereon on the outside of the case forming a terminal of the battery which is adapted to engage a battery cable connector having a non-corroding cap and an annular, tapered, elastomeric lip and sealing surface on said cap; the other end of the plug facing said compartment; a fused connection between the strap means and said other end of the plug; an internally threaded socket in said one end adapted to engage a threaded bolt extending through said cap substantially centrally of said lip; an annular groove in said wall forming a sealing edge surrounding the socket adapted to engage the sealing surface of the lip in an interference-fit seal around the socket to protect said face and said socket from corrosive environmental attack when engaged with said connector regardless of minor dimensional variations from one cap to the next and one groove to the next.

Claim 21

A battery having a case including a conductive terminal forming a part of at least one wall of said case and electrochemical elements in said case; said terminal comprising a conductive plug passing through and in intimate sealing contact with an aperture-defining surface in the remainder of said wall; said plug having an inner end inside said case and fused to said electrochemical elements and an outer end outside said case to join to a battery cable connector; said plug having an interiorly threaded socket recessed in said outer end to engage a threaded bolt on said connector; said wall having an annular groove surrounding said socket and defining a terminal face including said outer end; and said groove providing a sealing edge with said face and being adapted to receive a tapered, annular elastomeric sealing projection on said connector such that said edge engages said sealing projection in an interference-fit seal around said socket to protect said face and said socket from corrosive environmental attack when joined with said connector regardless of minor dimensional variations from one connector to the next and one terminal to the next.

Claim 22

A battery having a case including a conductive terminal forming a part of at least one wall of said case and electrochemical elements in said case; said terminal comprising a conductive plug passing through and in intimate sealing contact with an aperture-defining surface in the remainder of said wall; said plug having an inner end inside said case and fused to said electrochemical elements and an outer end outside said case to join to a battery cable connector; said plug having an interiorly threaded socket recessed in said outer end to engage a threaded bolt on said connector; said wall having an annular groove surrounding said socket and defining a terminal face including said outer end; and said groove providing a sealing edge with said face and being adapted to receive a tapered, annular elastomeric sealing projection on said connector such that said edge engages said sealing projection in an interference-fit seal around said socket to protect said face and said socket from corrosive environmental attack when joined with said connector regardless of minor dimensional variations from one connector to the next and one terminal to the next.

Claim 23

A cable connector for the terminal of a storage battery, said connector comprising: a non-corroding, elastomeric cap having open ends and an opening between said ends, an annular sealing projection protruding from one of said ends and adapted to be received in an annular groove circumscribing said terminal; said projection having an inner wall defining a first truncated cone-shaped hollow the cross sectional diameter of which increases from a minimum near the center of the cap to a maximum farthest from the center of the cap, and adapted to engage a sealing edge of said groove in an interference-fit; an electrically conductive contact element having an aperture therein in said opening between said ends and at least partially embedded in said cap; said element including turn-resistant tangs for bitingly engaging said terminal of said battery to resist rotation of said connector with respect to said battery; a threaded bolt extending through said aperture and having a flange for engaging said element and substantially sealing-off said aperture and said terminal when said bolt securely engages a threaded socket in said battery terminal.

Claim 24

A cable connector for the terminal of a storage battery, said connector comprising: a non-corroding, elastomeric cap having open ends and an opening between said ends, an annular sealing projection protruding from one of said ends and adapted to be received in an annular groove circumscribing said terminal; said projection having an inner wall defining a first truncated cone-shaped hollow the cross sectional diameter of which increases from a minimum near the center of the cap to a maximum farthest from the center of the cap, and adapted to engage a sealing edge of said groove in an interference-fit; an electrically conductive contact element having an aperture therein in said opening between said ends and at least partially embedded in said cap; said element including turn-resistant tangs for bitingly engaging said terminal of said battery to resist rotation of said connector with respect to said battery; a threaded bolt extending through said aperture and having a flange for engaging said element and substantially sealing-off said aperture and said terminal when said bolt securely engages a threaded socket in said battery terminal.

Claim 25

A battery having a terminal so located and so adapted to complement a cable-connector for the terminal that corrosive attack of the terminal by battery acid condensate and air-borne corrodants is substantially reduced, said battery comprising: a case having a plurality of walls defining a compartment for the battery''s electrochemical cell elements and including vertical walls where battery acid condensate does not collect; electrochemical cell elements in said compartment; one of said vertical walls including a conductive portion and a nonconductive portion, the said conductive portion passing through the nonconductive portion such that the portions are in intimate, liquid-tight contact one with the other; the conductive portion having an outer terminal-side forming said terminal and an inner cell-side joined to the cell elements; a fused connection adjacent the nonconductive portion joining the conductive portion''s cell-side to the cell elements; the terminal-side having a face thereon; an internally threaded socket in said face adapted to engage a threaded bolt on a battery cable connector; an annular groove in said one wall; a cable-connector-engageable edge surrounding the socket and along the circumferential periphery of said face where the face meets said groove; said Edge being adapted for interference-fit engagement with an annular tapered elastomeric lip on the cable-connector to protect the face and the socket from corrosive environmental attack when engaging the cable-connector regardless of minor dimensional variations from one groove to the next and one connector to the next.

Claim 26

A battery having a terminal so located and so adapted to complement a cable-connector for the terminal that corrosive attack of the terminal by battery acid condensate and air-borne corrodants is substantially reduced, said battery comprising: a case having a plurality of walls defining a compartment for the battery''s electrochemical cell elements and including vertical walls where battery acid condensate does not collect; electrochemical cell elements in said compartment; one of said vertical walls including a conductive portion and a nonconductive portion, the said conductive portion passing through the nonconductive portion such that the portions are in intimate, liquid-tight contact one with the other; the conductive portion having an outer terminal-side forming said terminal and an inner cell-side joined to the cell elements; a fused connection adjacent the nonconductive portion joining the conductive portion''s cell-side to the cell elements; the terminal-side having a face thereon; an internally threaded socket in said face adapted to engage a threaded bolt on a battery cable connector; an annular groove in said one wall; a cable-connector-engageable edge surrounding the socket and along the circumferential periphery of said face where the face meets said groove; said Edge being adapted for interference-fit engagement with an annular tapered elastomeric lip on the cable-connector to protect the face and the socket from corrosive environmental attack when engaging the cable-connector regardless of minor dimensional variations from one groove to the next and one connector to the next.

Claim 27

A battery as claimed in claim 15 wherein said one vertical wall includes at least two terminals of opposite polarity and the faces of the terminals are recessed beneath the outermost part of said nonconductive portion to prevent accidental electrical bridging of the terminals and direct short circuiting of the battery.

Claim 28

The battery as defined in claim 15 wherein the sealing edge is on the conductive portion of the wall.

Claim 29

The battery as defined in claim 15 wherein the sealing edge is on the nonconductive portion of the wall.