Re: [SilverStreak] Newbie battery question

[<waymark1@xxxxxxxx>]

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