RE: [SilverStreak] Newbie battery question

["Ken Wilson" <ke5dfr@xxxxxxxxxxxxx>]

I will agree that there are SPECIALITY greases for electrical connections.
I use them all of the time on my ham radio connections and antenna joints.
But for a normal car battery connection, it is not worth the effort or cost
of the conductive greases.  Plain old axle grease does a fine job and is
available everywhere.

Ken Wilson
KE5DFR
Cypress, Texas

-----Original Message-----
From: sslist-admin@tompatterson.com [mailto:sslist-admin@tompatterson.com]
On Behalf Of waymark1@juno.com
Sent: Friday, April 18, 2008 4:35 AM
To: sslist@tompatterson.com
Subject: Re: [SilverStreak] Newbie battery question

Sorry, I didn't come up with this idea on my own. I originally got it from
my basic electricity and basic electronics teacher at Maplewood High school
in Nashville, Tn. He was a retired radio and electric power engineer (not a
lifetime schoolteacher). I'd provide his name but that was over 40 years ago
and I don't recall it; he was rather elderly then. I do remember that he
drove a Jag XKE.

It is true that there are specialized lubricants for moving electrical
contacts.

The heat conductive grease used on CPU and other semiconductor to heat sink
mating surfaces is not applied a lubricant but as a contact improvement and
corrosion protectant. If aluminum powder is used, it is certainly not
intended as a lubricant - when aluminum powder oxidizes it becomes corundum,
the same stuff as is used on Alox (aluminum oxide) abrasive sheets and
grinding wheels. The aluminum provides most of the heat conduction and the
grease provides sealing against oxygen to prevent corrosion of the (usually)
aluminum heat sinks, semiconductor cases, and the aluminum powder in the
grease.
Other thermal greases or pastes are nonconductive of electrical current
while highly conductive of heat. Zinc oxide is one ingredient that conducts
heat but not electricity.

That (most) greases are hydrocarbons does not mean they are conductive. The
plastic insulation used on most wiring is composed of hydrocarbon and it is
decidedly nonconductive. Pure carbon and graphite (carbon allotrope) are
fair conductors and are commonly used as dynamic contacts. Many motor and
generator brushes, distributor rotor contacts, etc., are made of
carbon-graphite mixed with other materials.

The heavily loaded contact between the trailer coupler and the hitch ball
would seem to provide an excellent ground connection; however, experience is
that it is a poor and intermittent connection. Why? The grease or oil that
is on the surfaces of the coupler and ball is an insulator (dielectric).
Failure to have a wire ground between the trailer and tow vehicle causes
"fluting" - pitting of the surfaces from arcing as the contact makes and
breaks. Going without grease or oil causes galling - microscopic pressure
welding or seizing - of the surfaces. Rust also appears rapidly. Rust is an
excellent fine abrasive. Special grades are called "jeweler's rouge." So a
lubricant is necessary to reduce mechanical wear, but will cause
electrically induced wear due to arcing through the insulative grease film
between the parts. And, of course, flickering markers and taillights.

Common bearing and chassis grease is not designed to be used for electrical
contact protection. Special greases are used by automotive and equipment
contacts to improve contact by preventing corrosion. An example is the
grease you find when unplugging automotive computer and electronic equipment
connectors. Commonly instructions will be found to the effect that you are
warned not to wipe the grease off the contacts (unless, of course, you have
a tube or can of the special contact grease to provide a replacement
coating). The grease that comes in the bulb sockets should not be wiped off
or out either, particularly not to be regreased with common bearing and
chassis grease. There is usually enough grease in the sockets (since
manufacturers began greasing the sockets) for bulb replacements for the life
of the vehicle.
One specialized paste is sold for spark plug terminals, distributor rotor
contacts and tips, distributor cap posts and tips, distributor cap towers,
etc.

"Dielectric" means "insulating."

Battery terminals and clamps are a particular problem area for grease
between the mating surfaces because they have a relatively large contact
area and low contact pressure per area. Chassis grounds do not present such
a potential of high resistance from grease contamination as they usually are
provided with toothed washers that will bite through any grease and dig into
the chassis metal for a good contact.

I have personally experienced smoking battery clamps caused by ordinary
lubricating grease raising the resistance of the connection. Thoroughly
removing all grease, wirebrushing the post and clamp inner surface, and
reconnecting fixed the problem. A coating of grease over the connection,
worked into the recesses and then the excess wiped off, protects from future
corrosion.

Aluminum wire, used on some RVs years ago (I hope no longer), is a special
case. The oxide of aluminum is a total insulator, unlike the oxide of
copper, which is a fiar conductor. Aluminum wire connections require a
special corrosion inhibitor paste. The device connection screw clamps bite
into the wire so that no paste is in between the wire and the clamp screw.
(Certain devices specify that no paste be used on their connections.)

Acid corrosion of battery posts and clamps is due to damaged seals around
the bases of the posts (like from beating on the posts, picking the battery
up by the posts) or overcharging of the battery. Ideally, no acid ever exits
the battery. Protective coating of the terminals is in recognition that in
vehicular applications "ideal" does not happen, not for long. Also,
corrosive mists blow all over the vehicle from road spray, ocean salt air,
air pollution, etc. This is bad enough over the entire vehicle. Add
electricity and it is worse.

Petroleum greases soften, crack and can even dissolve "rubber" radiator and
heater hoses. Only a grease approved for vulcanized latex rubber, such as
castor (old fashioned vegetable grease), silicone or PAO grease made for
internal brake cylinder lubrication, may be used on such parts. Grease sold
for use INSIDE brake cylinders (on parts that contact brake fluid), NOT
"caliper slider" or brake pad backing plate grease, is such a grease.

An example of the recognition of the problem of grease insulation of static
(nonmoving, like a clamp on a battery post) electric contacts:

"ANTI-CORROSIVE BATTERY TERMINAL

"BACKGROUND OF THE INVENTION Technical Field This invention relates, in
general, to corrosion protective covers for battery posts and, more
particularly, to covers utilizing grease as an anti-corrosive medium.

"The driving public is well aware of the continuing problems with battery
post corrosion and the resultant electrical power loss because of wire
erosion and poor contact points. Another common problem, experienced by
operators of large trucks and commercial vehicles, is the lack of post
contacts on a battery for connection to other batteries, auxiliary
equipment, etc.

"One of the earlier efforts at providing a protective cover was the
invention of J. A. Johnson, U.S. Patent No. 1,686,817, consisting of two
complemental parts which were filled with grease and then clamped [NOTE -->]
together about a battery post. A problem inherent with the Johnson device
was the problem of obtaining good electrical contact because of the grease
in that the grease had to be applied before clamping.

"A device that is still widely used and quite effective is the fibrous
washer of F.G. Dewey, U.S. Patent No. 1,671,016, which is impregnated with
acid resisting grease and which surrounds the base of the battery post. The
Dewey device fails to protect the entire post.
[These are those red and green washers sold by automotive and marine battery
dealers.]

"A later device which does cover the post is that of H. D. Weaver, U.S.
[NOTE -->] Patent No. 2,269,296. The Weaver device suffers from the same
problem as Johnson in that the post receiving socket must be coated with
grease before placement, with resultant poor contact area. Weaver utilizes a
tapered screw to make electrical contact after the grease placement.

"Other relevant inventions are those of W. T. Hasting, U.S. Patent No.
1,541,495; J. K. Schaefer , U.S. Patent No. 2,119,294; W. M. Osborn, U.S.
Patent No. 3,152,854; and A. P. Bailey, U.S. Patent No. 3,795,891.

[NOTE -->] "None of the inventions solve the problem of utilizing a
corrosion resistant grease to protect the entire surface of the battery post
and still provide grease free electrical contacts.

"DISCLOSURE OF THE INVENTION The present invention comprises an anti-
corrosive battery terminal including a terminal block with battery post
[NOTE -->] receiving socket and provided with a grease fitting for injection
of grease within the socket after the block is clamped to the battery post
by screw clamps. It is therefore a primary object of the present invention
to provide an anti-corrosive battery terminal which includes a terminal
block with post receiving socket which may be filled with grease after
clamping contacts are made with the post. More particularly it is an object
of the present invention to provide an [NOTE -->] anti-corrosive battery
terminal which includes a terminal block with socket and with screw clamps
for making secure "dry" contact with the battery post before the addition of
grease to the enveloping socket.

"Even more particularly, it is an object of the present invention to provide
an anti-corrosive battery terminal which includes a terminal [NOTE -->]
block with a grease fitting for injection of grease into a post receiving
socket after electrical contacts are made to the post.

"Another object of the present invention is to provide an anti- corrosive
battery terminal which includes a plurality of terminal contact posts.

"It is an additional object of the present invention to provide an
anti-corrosive battery terminal having contact posts which make direct
contact with the battery post.

"Additional objects and advantages will become apparent and a more thorough
and comprehensive under- standing may be had from the following description
taken in conjunction with the accompanying drawings forming a part of this
specification.

"BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a battery
terminal made according to the present invention, shown mounted to a battery
post; the post and socket being shown in outline.

"FIG. 2 is a sectional view taken along line 2-2 of FIG. 1.

"FIG. 3 is a plan view of the terminal of FIG. 1.

"FIG. 4 is a sectional view of the grease fitting, with check valve, of the
present invention.

"BEST MODE FOR CARRYING OUT THE INVENTION Referring now to the drawings,
and, more particularly, to FIGS. 1, 2, and 3, an embodiment to be preferred
of an anti-corrosive battery terminal 10, made according to the present
invention, is disclosed. Battery terminal 10 is in the form of a terminal
block 20 defining a battery receiving socket 30, a grease fitting 40, and
clamp means 50.

"Terminal block 20 may be constructed of any suitable material, either
electricity conducting or insulative. It is preferred however, that the
block be made of conductive material for conduction of electricity to
terminal contact posts 55, as will hereinafter be explained. Copper and
bronze are preferred metals for construction of the block and doped
plastics, also called conducting polymers, such as polyacetylene doped with
iodine, may also be highly desirable because of its high electrical
conductivity as well as its ability to be molded. The block is preferably in
the form of of a cube, having outer surfaces including the top 21 and the
four sides, designated generally by the numeral 22, and having an
undersurface 23 on the opposing side from the top. Formed, by machining or
otherwise, on the bottom surface 23 is a battery post receiving socket 30
which is slightly larger in all dimensions than the battery post 5 of
battery 3. Also formed within block 20 is a threaded con!
 duit 27, extending between socket 30 and the outer surface of the block. In
the preferred embodiment conduit 27 extends between the socket and top
surface 21 for the placement of grease fitting 40.

"Grease fitting 40, one type of which is shown in FIG. 4, is provided with
threads mateable with the threads of conduit 27 so that the fitting may be
simply screwed into the conduit. Fitting 40, also known as a grease 'zerk,'
includes a check valve, designated generally by the numeral 45, forming an
effective seal, and also includes a post 44, rising vertically from block
20, for convenient engagement by a grease gun, not shown. While fitting 40
may be located anywhere on the block, for ready access it is mounted through
top 21 of the block.

"Also mounted on block 20 are a selected number of terminal contact posts 55
for the attachment of electrical wires leading to the starter, other
batteries, auxiliary units, etc. Contact posts 55 are constructed of any
suitable material and are preferably in the form of steel machine bolts
which are screwed into threaded apertures 57 in the block. Where block 20 is
constructed of electricity conducting material, electrical contact between
posts 55 and block 20 may be sufficient, although it is always preferred
that posts 55 make contact with the battery post 5. Where block 20 is
constructed of electricity insulative material, contact between posts 55 and
battery posts 5 must be made. It is obvious that one or more contact posts
55 may also serve as clamp means 50 for attachment of block 20 to the
battery post.

"For installation of terminal block 20 onto battery post 5, the battery post
should be clean and free of oxides and other forms of corrosion and the
interior surface of socket 30 of block 20 should also be free of grease or
other contaminants. The block is simply placed over post 5 with socket 30
surrounding the post about the sides and top. If desired, though
unnecessary, a porous fabric washer 9, well known in the art, may be placed
around the base of battery post 5. Clamping means 50, in the form of contact
post bolts 55, are then screwed into threaded apertures 57 until the
flattened, blunt end of the bolt securely engages the battery post to obtain
maximum electrical contact surface. While a single bolt may serve to clamp
the block in place to the battery post, it is recommended that at least one
other bolt 55 make contact with the post, and, as before stated, contact is
necessary where block 20 is constructed of insulative material. Once bolts
55 are in place, corrosio!
 n preventive grease, or the like, is injected through grease fitting 40
into socket 30 to completely fill the socket. Excess grease exiting the base
of the socket at the undersurface 23 of block 20 may simply be wiped away.
If porous washer 9 is in place, air readily flows through the washer to
prevent any air bubbles within the socket, and the washer soon becomes
saturated with grease to form an airtight seal. It is to be particularly
noted and is an important part of the invention that all contacts between
terminal contact posts 55 or clamping means 50 and battery post 5 are made
before the addition of any grease so that the grease, which is electrically
insulative, can in no way impair the contacts. It is also to be noted that
electrical contact can be made over a large surface area between the blunt
end of bolts 55 and the battery post. Having thus described in detail a
preferred embodiment of the present invention, it is to be appreciated and
will be apparent to those !
 skilled in the art that many physical changes could be made in!
  the app
aratus without altering the inventive concepts and principles embodied
therein. The present embodiment is therefore to be considered in all
respects as illustrative and not restrictive, the scope of the invention
being indicated by the appended claims rather than by the foregoing
description, and all changes which come within the meaning and range of
equivalency of the claims are therefore to be embraced therein."
[REFERENCE:]
http://www.wipo.int/pctdb/en/wo.jsp?IA=US1989001594&DISPLAY=DESC

-- thetansedan@aol.com wrote:

The NO-ALOX I have been using for 20-years is available at Home Depot and is
specified for aluminum-to-aluminum connections (and some others). B I use it
on cars, etc. B I apply it to the terminals AFTER brushing them with a tool
for same (fresh bright metal) but BEFORE the connection is made. B I wipe
off the excess. B I rarely have to re-do it, even after years of use. B I
have not used grease to cover the connections for years because I get tired
of getting it on my wrists or sleeves when working around batteries. B This
has worked well for me.

I also use MIL-SPEC terminations and cabling as big as I can fit. B I
usually have someone make it for me once I have decided to overhaul the
system. B WEST MARINE is a good source for ANCOR brand, much superior to
auto parts stores.

I much appreciate Eddies comments, I wholly agree with the knowledge we are
obligated to give to others. B Mine, above, is just what I do.


-----Original Message-----
From: Ken Wilson <ke5dfr@sbcglobal.net>
To: sslist@tompatterson.com
Sent: Mon, 14 Apr 2008 12:55 am
Subject: RE: [SilverStreak] Newbie battery question

For years I have applied a coating of grease to my battery terminals when I
install a battery.  I generally use the bearing grease that is in the grease
gun.  This practice was taught to me by my Dad.  It is also a good idea to
put a thin film on light bulb bases.

Ken

Ken Wilson
KE5DFR
Cypress, Texas

-----Original Message-----
From: sslist-admin@tompatterson.com [mailto:sslist-admin@tompatterson.com]
On
Behalf Of Eddie
Sent: Saturday, April 12, 2008 6:42 PM
To: sslist@tompatterson.com
Subject: Re: [SilverStreak] Newbie battery question

Al,
That is totally incorrect. Grease is a hydrocarbon. It promotes conductivity
and it conducts electricity not much differently than the carbon brushes in
your electric drill or blender. There are specialized greases for sensitive
contact connections, which lead lugs to lead lugs are not, that are even
designed for specific types of metals. There is dielectric grease and
others. Your CPU processor must have a white grease beneath it to conduct
heat and that grease is constantly improved upon. It is basically a grease
with extremely fine aluminum powder in it. Without that grease your
processor would instantly burn up.

You are correct that grease should be liberally applied as a protective
coating over the completed assembly. You are totally incorrect to believe
the grease will interfere with the contact of the concealed lead to lead
connection. It will do three things and they are; Promote the electrical
contact connection, Totally prevent the inevitable seepage of acid corrosion
between the tapered post and tapered lug, and Allow the soft metal to move
while tightening forming a uniform shape to shape mating.

You can see the application in most every automotive 1157 and 1156 bulb on
any modern vehicle including your own. Simply remove a bulb and you will see
the industry learned in 1983 to apply a bulb grease to the entire bulb base
and socket. Bulb grease is available everywhere and no bulb including the
1995 and up pin-based bulbs should ever be installed without the grease.
Prior to the greasing of bulb bases, a constant corrosion occurred to the
base and bulb causing a loss of ground connection as well a B+ contact. As
the connection was lost, the socket heated up ruining the socket components.

Advising and reminding the good people of this forum to take the little
extra and messy step of greasing everything from batteries to bulbs, rubber
hoses that connect to radiators, their trailer connectors, and much more is
proper, correct, and professional. I am no expert, but I am a professional
and I would be totally remiss to participate in this forum, with people I
care about, have never and probably will never meet, but not share such a
simple and basic knowledge.

It is no big deal, I am not special, and I really don't care if you choose
to "do it your way". People get tired, don't want to bother, or just hate
the mess. That is absolutely ok with me, but if my old grandpa was here,
he'd make you take it all back apart and do it right. This is nothing new.

-Eddie-
Houston, TX

----- Original Message -----
From: <waymark1@juno.com>
To: <sslist@tompatterson.com>
Sent: Saturday, April 12, 2008 2:21 PM
Subject: Re: [SilverStreak] Newbie battery question


> Protective coatings like grease should be applied AFTER the connection is
made. If grease is applied before the connection is made, it may interfere
with the contact.
> At Walmart you will find both deep discharge cycle and combination
> starting/deep cycle batteries that have both wingnut and post terminals.
> Other suppliers have them too.
> Al
No virus found in this outgoing message.
Checked by AVG. 
Version: 7.5.524 / Virus Database: 269.23.2/1386 - Release Date: 4/18/2008
5:24 PM