Our top 5 tips

for the right choice of battery terminals

Do you frequently have problems with battery terminals in your day-to-day work?

Do you want to know what makes different types of terminals for battery connections so special and what you need to consider when buying battery terminals?

Here are our top 5 tips for the right selection of battery terminals

1. Type selection

Depending on the connection type, the areas of application also differ.

2. Surface coating

The coating of a battery terminal reveals a lot about its quality.

3. Screw fitting

Tin-plated or galvanized - that' s what counts.

4. Manufacturing process

The manufacturing process is a crucial factor depending on the area of application.

5. Climate & Environment

Sustainability, durability & quality.

1. Type selection

Depending on the type of connection, we distinguish the following battery terminals:

1

battery terminals to screw
2

solder battery terminals
3

crimp battery terminals
4

band terminals
5

special molded parts

Choosing correctly saves money.

The type of connection has a decisive influence on the current flow and resistance! With the correct selection power losses and heat generation can be minimized, which can prevent a system failure or even a fire.

An example: During each charging and discharging process of electrical storage systems, the components heat up. A screw terminal, for example, can never be tightened in such a way that no cavities are created when the components expand (see picture on the right).

As a result, the terminal "breathes" when it heats up. In addition to a gradual loosening of the battery terminal, atmospheric oxygen and moisture will also be drawn into the cavities. This point is particularly sensitive if battery acid or other aggressive media diffuse into the cavity. In this case, battery terminals can become porous and break (see picture).

The consequences are power losses and overheating. For this reason, we have a wide range of different battery terminals for different applications, as they all have their special advantages.

Just ask us, we will be pleased to help you!

contact

2. Surface coating

The surface makes the difference.

Many battery terminals on the market are not coated in the first place and have bare brass as a surface. This is problematic because brass tends to corrode quickly. This results in higher contact resistances and a reduction in performance.

Our battery terminals, on the other hand, have a tin-plated surface. Tin is a softer metal and fits into the gaps in the surface of a battery terminal.

When screwed into place, the tin begins to flow and ensures fewer gaps there as well. In addition, there is significantly less corrosion, which, when combined with the natural properties of tin described above, results in significantly less resistance and a noticeable increase in performance compared to the non-tinned terminals.

Rough surface

Surface coating: none

Smooth surface

Surface coating: tin plated

3. Screw fitting

A comparison.

Also to be considered is the coating of the screw, which makes contact with the battery terminal. To ensure a safe connection, the screw should not rust after a short time.

This corrosion effect is often caused by acids, alkalis, spray or salt water. The risk of corrosion is significantly higher with a galvanized screw than with a tinned screw (see picture comparison).

In addition to our special tinning method, we have developed other processes that reduce corrosion. Please do not hesitate to contact us.

Not tin-plated

Corrosion on a non-tinned screw connection

Tinned

Corrosion on a tinned screw connection

4. Manufacturing process

Quality over quantity.

Brittle fracture on a cast iron terminal

Attempt of breakage on a pressed terminal

What should also be taken into account when buying a battery terminal is the type of manufacture and thus the area of application. Depending on the application and requirements, it makes sense to use battery terminals made using different manufacturing processes.

A cast terminal, for example, is manufactured using the permanent mold or sand casting process.
It has a low material input weight and is therefore less expensive, but due to the manufacturing process it has a fragile microstructure. Under heavy mechanical loads or vibration, the weak structure can quickly lead to fracture.

We also recommend not using a cast terminal in applications where bending and torsion may occur. The cast terminal is cheap to produce, but it is only suitable for applications where there are no high continuous stresses or high safety requirements.
In addition to cast terminals, there are also terminals made of solid material, which are often milled. The material costs are very high in this case. In addition, the material is very hard so that it can be machined.

The edges are sharp and there are no radii in the form of soft transitions. Therefore, such terminals are susceptible to notch effects, which in turn can lead to breakage. Terminals made of solid material are not suitable for crimped connection technology in particular, as a forming process takes place during crimping, which contradicts the material hardness of the terminal.

The pressed terminal, on the other hand, is forged in the hot forming process. A pressed terminal has a higher material input weight and is adapted to forming and subsequent machining. They are therefore particularly suitable for mechanical and dynamic influences such as vibration, torsion or bending.

Due to the manufacturing process, the components are void-free and have a viscoplastic microstructure, which makes them particularly suitable for crimping.

A pressed terminal will always be more expensive than other battery terminals because of the way it is manufactured, but it offers many advantages and can be used universally for any application. For example, in the case of high continuous stress and safety requirements, we recommend the use of pressed terminals only. We say, better buy right once instead of buying cheap twice.

5. Climatic and environmental influences

Although high-quality battery terminals are initially more expensive to procure, they are more sustainable and less expensive in the long term. Due to ever-increasing energy demand and rising safety requirements, the correct selection of contact elements is of weighty importance.