Abstract:
A battery and battery condition indicator are provided with a seal as monolithic structures whereby the indicator is inserted in an opening in the battery and sealed there against via ribs in the battery confronted by a surface of the indicator and/or ribs on the indicator embedded in a surface of the battery defining the opening.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application is a continuation-in-part of U.S. Ser. No. 11/103,707 filed on Apr. 12, 2005, which claimed the benefits of U.S. Provisional Application Ser. No. 60/599,796, filed on Aug. 6, 2004; and this application further claims the benefits of U.S. Provisional Application Ser. No. 60/776,774, filed on Feb. 24, 2006, and U.S. Provisional Application Ser. No. 60/789,097 filed on Apr. 4, 2006. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The present invention relates generally to hydrometers and fluid level sensors in storage batteries; and more particularly, the invention pertains to the structures for establishing a seal between the device and the storage battery opening in which it is held.  
       BACKGROUND OF THE INVENTION  
       [0003]     Battery condition indicators are used in lead/acid storage batteries of many types, including those installed in motor vehicles. Known battery condition indicators function as hydrometers detecting changes in the specific gravity indicative of the electrical charge condition of the battery, and provide a visual indication of the charge condition. Battery condition indicators also can detect changes in the electrolyte level in the battery and provide a visual indication if the electrolyte level is below a predetermined minimum level. It is known to provide both charge condition and electrolyte level detection functions in the same battery condition indicator.  
         [0004]     A known battery condition indicator is inserted in an opening through the cover for the cell of a battery and provides a head with a visual window for looking into the indicator. A cage or box is immersed in the fluid electrolyte, if the battery is adequately filled. One or more floatable indicator body is contained in a channel or channels in the cage and responds to different battery conditions to rise or fall in the channels. A light-transmissive rod extends between the head of the indicator and the cage with the floatable bodies. A conical tip at the end of the light-transmissive rod has a tip adjacent the channels in which the one or more floatable bodies move. The floatable bodies are of different colors to provide different visual cues when visible through the indicator. A battery condition indicator having one floatable body can provide visual cues for a satisfactorily charged battery with satisfactory electrolyte level, a different visual cue for a satisfactory electrolyte level but a low battery charge and a third cue if the electrolyte level is low. By providing more floatable bodies responsive to different specific gravities, high and low fluid levels can be indicated as well as low, fair and satisfactory electric charge.  
         [0005]     Battery condition indicators as described have worked well, but are not without disadvantages. Installation of the indicator in a battery cover is known use an additional component in the way of a gasket or malleable collar to seal the interface between the indicator and the battery cover opening in which it is installed. The use of multiple components complicates installation. A relatively large hole is required in the battery cover to accommodate the indicator and a separate, independent seal associated with the indicator and the opening in the battery. The requirement for a relatively large opening limits the available locations for the indicator in the battery. Further, if intimate contact is lost along a portion of the seal, contaminate infiltration or leakage can occur. It is known to perform a wash cycle during a late stage in the manufacture of a battery, and wash water can be trapped in small crevices, such as around the indicator. During subsequent battery handling, seepage of the trapped wash water can give an erroneous impression that the battery has leaked, leading to re-testing and/or re-processing the battery.  
       SUMMARY OF THE INVENTION  
       [0006]     The present invention provides a battery condition indicator with an integral seal configuration as part of the indicator.  
         [0007]     In one aspect thereof, the present invention provides a fluid container with an outer element defining an opening and an indicator for indicating a condition of a fluid in the container. The indicator is disposed in the opening and includes a response assembly, an indicator head at which exhibited changes are visualized and a light transmissive body connecting the response assembly and the indicator head. Sealing structures established between the indicator and the outer element include a plurality of ribs integral with the indicator and/or the outer element.  
         [0008]     The indicator head and the indicator body are made of a first material and the outer element is made of a second material, the second material being softer than the first material. The plurality of ribs includes a rib embedded in the outer element and/or crushed by the indicator.  
         [0009]     In another aspect thereof, the present invention provides a battery condition indicator with a response assembly, a light transmissive body attached to the response assembly, a head at an end of the light transmissive body opposite the response assembly; and at least one circumferential sealing rib disposed on the body between the head and the response assembly. The rib includes an outermost sealing surface, a lead-in face adjacent the sealing surface and directed toward the response assembly, and a trailing face adjacent the sealing surface and directed toward the head. The lead-in face is sloped more gradually than the trailing face.  
         [0010]     In a still further aspect thereof, the present invention provides a vehicle battery with a battery cover defining an opening, a lip inwardly of an outer surface of the opening and a bore extending through the cover from the lip. At least one annular rib is disposed on the lip directed toward the opening. An electrolyte conditions indicator is disposed in the cover and includes a head disposed against the annular rib on the lip and a body extending inwardly in the battery from the head. The indicator body includes at least one circumferential rib at least partly embedded in the cover within the bore.  
         [0011]     An advantage of the present invention is providing a seal as integral parts of a battery condition indicator and battery, thereby simplifying assembly and installation of the indicator in the battery.  
         [0012]     Another advantage of the present invention is providing a battery condition indicator seal arrangement to facilitate location of the indicator in an optimal location in the battery.  
         [0013]     Still another advantage of the present invention is providing a battery condition indicator which inhibits contaminant infiltration into the battery even under conditions in which the full seal integrity has been compromised.  
         [0014]     Other features and advantages of the invention will become apparent to those skilled in the art upon review of the following detailed description, claims and drawings in which like numerals are used to designate like features. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]      FIG. 1  is a perspective view of a battery condition indicator in accordance with the present invention;  
         [0016]      FIG. 2  is an enlarged view of the upper portion of the battery condition indicator shown in  FIG. 1 , showing the side opposite the side shown in  FIG. 1 ;  
         [0017]      FIG. 3  is a further enlarged fragmentary portion of the battery condition indicator shown in  FIGS. 1 and 2 , the portion illustrated in  FIG. 3  being that indicated by circle  3  in  FIG. 2 ;  
         [0018]      FIG. 4  is a cross-sectional view of a battery condition indicator as shown  FIG. 1 , but shown installed in a battery; and  
         [0019]      FIG. 5  is an enlarged view of the portion of the indicator and battery within the circle designated with the number  5  in  FIG. 4 . 
     
    
       [0020]     Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use herein of “including”, “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof, as well as additional items and equivalents thereof.  
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0021]     Referring now more specifically to the drawings and to  FIG. 1  in particular, numeral  10  designates a fluid condition indicator, and, more specifically, a battery electrolyte condition indicator in accordance with the present invention. Indicator  10  is installed in a battery  12  ( FIG. 4 ) to indicate the condition of electrolyte (not shown) in battery  12 .  
         [0022]     Indicators of the type to be described can be used in vessels or containers other than lead/acid storage batteries, although the use in such batteries is an advantageous use of the present invention. Indicators  10  can be used to detect fluid level changes in a variety of containers or vessels and also may be used to detect changes in other fluid conditions.  
         [0023]     Indicator  10  includes a light transmissive body  14  between a response assembly  16  and a head  18 . Light transmissive body  14  is formed of a light transmitting material such as, for example, acrylic, glass, styrene or other clear, partially clear or tinted material.  
         [0024]     Response assembly  16  is connected to light transmissive body  14  and includes a cage or box  20  defining a trough or track  22  containing a floatable body  24 . Track  22  has lower and higher portions relative to an end of body  14 , allowing floatable body  24  to rise or fall in fluid in which it is immersed, depending on the specific gravity of the fluid and the surface level of the fluid.  
         [0025]     As known to those skilled in the art, floatable body  24  moves along track  22  in response to changing conditions of a fluid in which it is placed. In response to pre-established changes in specific gravity, floatable body  24  may be adjacent or distant from an end or tip (not shown) of light transmissive body  14 .  
         [0026]     As those skilled in the art will understand readily, the present invention can be used with a variety of styles and configurations for response assembly  16 . Thus, response assemblies having multiple floatable bodies and trough configurations of different shapes also can be used with the present invention, as can other styles, configurations and shapes for body  14 .  
         [0027]     Indicator head  18  defines a window  26  for peering into indicator  10 . Head  18  can be a single piece of clear plastic or the like and can be formed as a monolithic body with light transmissive body  14 .  
         [0028]     Body  14  in the exemplary embodiment includes a seal structure  40  and a tapering length  42  extending from seal structure  40  to response assembly  16 . Head  18  is wider than seal structure  40  and provides a peripheral under surface  44  outwardly of seal structure  40 . Body  14  includes four wings  50 ,  52 ,  54  and  56  in cruciate arrangement. Tapering length  42  of body  14  can be described as a cruciate cone or cruciate frustum with elongated tapering portions of wings  50 ,  52 ,  54  and  56 . Seal structure  40  is a cruciate cylinder, including upper portions of wings  50 ,  52 ,  54  and  56  that are of substantially consistent diameter throughout the length of seal structure  40 . Three spaced plate-like bodies  62 ,  64  and  66  defining circular perimeters and triangular-like gussets between adjacent wings  50 ,  52 ,  54  and  56  are provided at spaced locations along the length of seal structure  40 . Each body  62 ,  64 ,  66  defines a circular outer edge or rib  72 ,  74 ,  76 , respectively, encircling body  14  and disposed outwardly of outer edges of wings  50 ,  52 ,  54 ,  56 . As seen most clearly in  FIG. 3 , each outer edge includes an outermost sealing surface  80 , a lead-in face  82  with respect to the insertion of indicator  10  in battery  12  and a trailing face  84 . Lead-in face  82  and trailing face  84  are adjacent opposite sides of outermost sealing surface  80 . Lead-in face  82  is more gradually sloped than trailing face  84 , thereby facilitating easy insertion of indicator  10  in battery  12 .  
         [0029]     While described herein as separate bodies or structures, it should be understood that wings  50 ,  52 ,  54  and  56 , including the lower tapering portions thereof in tapering length  42  and the upper portions in seal structure  40 , together with seal plates  62 ,  64 ,  66  can be provided as a single monolithic body formed in a mold. Accordingly, plates  62 ,  64  and  66  also can be described each as including triangular segments or gussets between wings  50 ,  52 ,  54  and  56 , with an outer peripheral ring portion outwardly of wings  50 ,  52 ,  54  and  56 .  
         [0030]     The present invention can be used on indicator bodies of types other than that of the exemplary embodiment having four wings  50 ,  52 ,  54 ,  56 . Bodies having more than four wings or less than four wings also can be used, as well as body types not having wings. While three seal bodies  62 ,  64 ,  66  have been shown and described in the exemplary embodiment, more than three or fewer than three seal bodies  62 ,  64 ,  66  can be used.  
         [0031]     Battery  12  defines an opening  90  with a radially inwardly oriented lip  92  and a bore  94  extending therefrom. Bore  94  is slightly smaller in diameter than opening  90 , thereby defining lip  92 . One or more annular ring  96 ,  98  is provided on lip  92 , two such annular rings  96 ,  98  being illustrated in the exemplary embodiment. Rings and  96 ,  98  project from an upper surface of lip  92  toward opening  90 . It should be understood that the aforedescribed structures for opening  90 , lip  92  and bore  94  can be provided in a top or cover portion of battery  12 , or at another convenient location in another suitable outer element of battery  12  or other fluid container.  
         [0032]     Sealing plates  62 ,  64 ,  66  are of slightly narrower diameter than head  18  to slide past lip  92  and into bore  94  while head  18 , and more specifically undersurface  44  thereof, engages lip  92 . However, bore  94  and the diameters of seal plates  62 ,  64 ,  66  are selected to provide a sealing interference fit of seal plates  62 ,  64 , and  66  against the surface of bore  94 . In one form of the invention, battery cover  92  is of material softer than light transmissive body  14 , and seal plates  62 ,  64  and  66  are of a diameter larger than bore  94  such that seal plates  62 ,  64 ,  66  and more specifically the outer edges or ribs  72 ,  74 ,  76  thereof embed at least partly in the surface of bore  94 , as illustrated in  FIG. 4 . Accordingly, body  18 , and more specifically seal plates  62 ,  64 ,  66  may be made of a rigid, clear polymer, such as an acrylic polymer, and battery cover  12  may be made of softer material, such as polypropylene. The shapes of ribs  72 ,  74 ,  76 , with lead-in faces  82  that are sloped more gradually and trailing faces  84  that are sloped more abruptly, facilitate insertion of indicator  10  while inhibiting withdrawal or dislodgement after indicator  10  is firmly seated relative to battery  12 .  
         [0033]     Under surface  44  of head  18  confronts and rests against lip  92 , and, more specifically, on annular ribs  96 ,  98 . Ribs  96 ,  98  can be sufficiently narrow so as to crush slightly upon insertion of indicator  10  into battery cover  12 . Crushing or deflection of ribs  96 ,  98  promote effective sealing engagement of the ribs against under surface  44 . Once inserted, with head  18  forced against ribs  96 ,  98  to slightly crush ribs  96 ,  98 , the position will be maintained as seal plates  62 ,  64 ,  66  embed into the material of cover  12  along bore  94 . If a crush rib or crush ribs  96 ,  98  are used without seal plates  62 ,  64 ,  66  a snap locking feature between indicator  10  and a battery  12  can be used to secure the position of indicator  10  in battery  12 , with head  18  against the one or more crush rib  96 ,  98 . Ribs  96 ,  98  establish a barrier to the migration of contaminants or flow of fluids past lip  92 , including leakage from the battery and/or infiltration of an external fluid, including wash water.  
         [0034]     While shown and described herein for use and application in a vehicle battery, it should be understood that the present invention also can be used for other types of fluid containers requiring the installation and sealing of an indicator or insert of some type. Use for vehicle batteries is merely one advantageous application of the present invention.  
         [0035]     Variations and modifications of the foregoing are within the scope of the present invention. It is understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention. The claims are to be construed to include alternative embodiments to the extent permitted by the prior art.  
         [0036]     Various features of the invention are set forth in the following claims.