Terminal cap for accommodating terminal posts

A battery post terminal including a connector cap having a generally cylindrical outer sleeve portion, an inner sleeve portion flaring longitudinally inwardly from the inner end of the outer sleeve portion for frictional engagement with a battery terminal post, a lip outstanding from the larger end of the inner sleeve portion, and a cable connector extending generally radially from the lip.

BACKGROUND OF THE INVENTION 
As is well known to those versed in the electrical connector arts, battery 
post connectors in the past have generally required massive proportions 
beyond that essential for strength or conductivity, such proportions 
resulting in excessive costs, weight, embrittlement, and the like. 
Examples of the prior art of which applicant is aware are as follows: 
______________________________________ 
U.S. PAT. NO. PATENTEE 
______________________________________ 
1,854,328 Binder 
1,869,524 Taylor 
1,951,259 Ryalls 
2,384,211 Sutherland 
2,675,532 Quick 
2,729,802 Jordan et al. 
2,844,806 McKissick 
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The instant application is concerned with improvements over the battery 
post terminals disclosed in copending patent applications of Angelo J. 
Paolino, Ser. No. 238,059 filed Mar. 2, 1981 and Ser. No. 297,224 filed 
Aug. 28, 1981, which copending applications have the same assignee as the 
instant application. 
SUMMARY OF THE INVENTION 
It is an important object of the present invention to provide a battery 
post terminal construction, and particularly a sheet metal cap for a 
battery post terminal which is extremely simple and inexpensive to 
manufacture, capable of quick and easy multiple tap-off's adapted for 
quick and easy, but highly effective frictional engagement on and removal 
from the battery terminal posts, as well as positive connection thereto, 
if desired. 
It is still a further object of the present invention to provide a 
connector cap for a battery terminal which effects savings in materials, 
provides enhanced frictional retention on terminal posts within the wide 
range of commercial tolerances, simplifies connection to the cap of plural 
cable lugs, and which is staunch and reliable throughout a long useful 
life. 
Other objects of the present invention will become apparent upon reading 
the following specification and referring to the accompanying drawings, 
which form a material part of this disclosure. 
The invention accordingly consists in the features of construction, 
combinations of elements, and arrangements of parts, which will be 
exemplified in the construction hereinafter described, and of which the 
scope will be indicated by the appended claims.

DESCRIPTION OF THE PREFERRED EMBODIMENTS 
Referring now more particularly to the drawings, and specifically to FIG. 1 
thereof, a battery terminal construction is illustrated therein and 
generally designated 10. The terminal 10 may be substantially completely 
fabricated of ductile conductive material, such as copper or the like, and 
may include a connector cap 11 and cable connector or barrel 12 extending 
from the cap. 
More specifically, the cap 11 may be an inverted cup, cover or shell, say 
drawn or otherwise suitably formed of sheet copper and having a brim, lip 
or flange 15, provided with a radial extension or tab. The cable connector 
barrel 12 may include a tubular portion 17 receiving and suitably secured, 
as by crimping, to a cable 18, which extends into one end of the tube 17. 
The other end of the tube 17 is flattened, as at 20, or otherwise formed 
into a tab or extension for facing engagement with the cup tab or 
extension 16. The superposed tabs 16 and 20 may be suitably connected 
together, as by a rivet 21, to assure electrical continuity, and the rivet 
may be formed to define a pivotal connection between the cap and cable 
connector. 
Considering the cap 11 now more in detail, it may be drawn from flat 
material to include an outer end wall or closure 25, say of generally 
circular configuration, from which extends a peripheral side wall or 
sleeve 26, generally normal to the end wall 25. The sleeve 26 may include 
an outer sleeve end portion 27 extending directly from and integrally 
connected to the end wall 25, and being of generally cylindrical 
configuration. Stated otherwise, the outer end portion 27 of sleeve 26 may 
have zero taper. 
The sleeve 26 further includes an inner end portion 28 which extends 
longitudinally from the inner end of the outer end sleeve portion 27, 
integrally therewith, and diverges or flares in the inward direction, away 
from the cylindrical outer sleeve end portion 27. Thus, the inner sleeve 
end portion 28 defines the frustum of a cone, being generally coaxial with 
the cylindrical outer cap end portion 27. From the larger, inner end of 
the conical or flaring inner sleeve portion 28, radially thereabout, 
extends the flange or lip 15, lying generally in a plane normal to the 
axis of the sleeve. 
As best seen in FIG. 2, the flared inner end portion 28 of the sleeve 26 is 
in firm, snug frictional engagement with a received battery terminal post 
30. This engagement may be effected by manually placing the cap 11 over 
the post 30 and twisting, as by grasping the barrel 12 and/or lip 15 and 
bearing downwardly while turning. 
In FIGS. 3 and 4 are shown, in phantom, battery terminal posts 30a and 30b, 
respectively, which are of slightly different taper, which may be within 
commercial tolerances. In particular, battery terminal post 30a is of a 
greater taper and battery terminal post 30b is of a lesser taper. In 
applying cap 11a to post 30a, there is illustrated contact of the inner 
sleeve end portion 28a at the lip or flange 15a with the battery terminal 
post. 
In the embodiment of FIG. 4, the cap 11b makes contact with the battery 
terminal post 30b at the inner end of the outer sleeve end region 26b, 
where it joins with the outer end of the inner sleeve end region 28b. 
There is firm mechanical connection and intimate area engagement for 
electrical contact in both the extreme conditions of FIGS. 3 and 4, as 
well as all intermediate post taper conditions. 
It is advantageous that the overall length of cap 11 approximate the height 
of a battery terminal post; and that the length of cylindrical or pilot, 
outer end region 26 be approximately 2/3 overall length, while the length 
of the inner sleeve or flared end region 28 approximate 1/3 the overall 
length. With a flared or inner end region 28 approximately 1/3 the overall 
length, the outer end region 11 is of sufficiently small diameter to 
provide a convenient pilot for assembly through the eyes of tap-off lugs, 
as will appear presently. Also, with the flared inner end sleeve portion 
28 sufficiently short, as noted above, a plurality of stacked tap-off lug 
eyes may be circumposed about the flared sleeve portion without excessive 
gap for effective securement, also appearing presently. 
In the embodiment shown in FIG. 5, a cap is generally designated 11c and 
may be substantially similar to the cap 11 of FIGS. 1 and 2. That is, the 
cap 11c includes a generally circular end wall or closure 25c, and outer 
sleeve end portion 26c extending integrally from the periphery of end wall 
25c, and generally normal to the end wall in the configuration of a 
cylinder or tube having a taper of zero or less than the taper of a 
battery terminal post. Extending from the inner end of the outer sleeve 
end portion 26c is an inner sleeve end portion 28c which flares in the 
direction away from the outer sleeve end portion 26c, having a taper 
approximating that of a battery terminal post. Extending circumferentially 
about the larger end of the flared sleeve portion 28c is a peripheral lip, 
rim or flange 15c, which may be generally annular and without a tab or 
extension corresponding to the tab or extension of FIGS. 1 and 2. 
The cable connector 12c of FIG. 5 may include a tubular barrel 17c having 
one end region flattened, as at 20c, and centrally apertured, as at 35 to 
define an open lug or eye 36. As seen in FIG. 5, the open lug or eye 36 is 
of two superposed layers and seated firmly on the annular flange 15c. 
Further, the internal diameter of the circular aperture 35 of lug 36 may 
be such as to form a snug or force fit circumposed about the inner sleeve 
end portion 28c when the lug is seated on the flange 15c. 
In addition to the snug frictional fit of lug 36 about sleeve portion 28c, 
or as an alternative thereto, the apertured lug may be otherwise suitably 
secured to the rim or flange 15c, say by spot welding, as at 37. 
In the embodiment shown in FIG. 6, there is a connector cap 11d essentially 
similar to the connector cap 11c, including an outer sleeve end portion 
26d which may be generally cylindrical or of a taper less than that of a 
battery terminal post 30d. A flaring inner end sleeve portion 28d extends 
longitudinally inwardly from the inner end of sleeve portion 26d and is 
provided on its inner end with a generally annular circumferential flange 
15d, all of which may be the same as the cap 11c of FIG. 5. 
However, the cap 11d may include an outer end wall or closure 25d having a 
central opening, as at 40 for passing a fastener 41, such as a screw, or 
other suitable fastener into securing engagement with the post 30d. More 
specifically, the headed and threaded fastener 41 may engage through the 
outer end wall opening 40 with its threaded shank 42 entering into 
threaded engagement in a suitable hole 43 formed in the outer end of the 
terminal post 30d. With the shank 42 secured in the post 30d, the head 41 
may engage the outer surface of the end wall 25d, to secure the cap 11d in 
firm electrical contacting circumposition about the post 30d. Also shown 
in FIG. 6 are a plurality of cable connectors having apertured end lugs 
20d superposed in aligned relation with each other on the circumferential 
flange 15d and in snug, frictional or forced engagement about the flaring 
inner end sleeve portion 28d. While a pair of apertured lugs 20d are shown 
in FIG. 6 as frictionally circumposed about the inner sleeve end portion 
28d, it is understood that three or more such cable connector lugs may 
also be frictionally engaged or force fit about the flaring inner sleeve 
end portion 28d. 
If desired, the upper or outer face of the outermost lug 20d may be 
deformed inwardly into forced retaining engagement with the sleeve portion 
28d. For example, by ring staking, a bead 45 may be formed on the inner 
margin of the aperture of the uppermost lug 20d, the bead engaging the 
sleeve portion 28 to retain the uppermost lug on the sleeve portion, and 
to retain any other lugs firmly clamped in position about the sleeve 
portion 28d between the outermost lug and the flange 15d. 
From the foregoing, it is seen that the present invention provides a 
uniquely improved battery post terminal connector which is extremely 
simple in construction, economic in manufacturing steps and materials, 
durable and reliable throughout a long useful life, and which otherwise 
fully accomplishes its intended objects. 
Although the present invention has been described in some detail by way of 
illustration and example for purposes of clarity of understanding, it is 
understood that certain changes and modifications may be made within the 
spirit of the invention.