Case Provent Caps

Based on historical data, we came to know of a problem faced by battery manufacturers with regards to electrolytes in the battery. We took it up as a case to help ourselves come up with a solution for the same. The case in brief is as follows.

Main Problem
  • Loss of electrolyte
  • Contamination of electrolyte
  • Damage of battery surface
  • Imminent danger to workmen
Ancillary Problem
  • 2 Types of caps used on automotive batteries
  • Filling of electrolytes in 2 stages
  • Total electrolyte spent was more than 1 fills
  • Additional packaging cost due to frequent damage of packaging
  • Additional man power cost
Problem Classification a) Splashing    b) Loss &    c) Contamination of Electrolyte
Cause Identification  

Movement of batteries and batteries fitted on moving vehicles were identified to be the cause for problems related to electrolyte splashing and lack of a filter in the vent caps for contamination and loss of electrolyte due to vaporization.



The objective was to find a solution for the main problems that should also help in overcoming the ancillary problems as well.


Solution Identification  

Since the problems were emanating from the openings on battery lids for electrolyte replenishment, we had to innovate on the next generation vent caps.


Solution Formulation  

To cater to two distinct requirements, we needed to identify 2 distinct filter materials – one a low cost one and the other for high end use.



A lot of literature was scanned. A few materials were identified and shortlisted. Thorough investigation of these materials was done and Ceramic and PP were chosen to develop the filter medium. The low cost ceramic filter though low on performance suited the price sensitive segment and the high end PP filter fitted the bills for high end use such as in automotive batteries.


Testing & Field Trial


Tests for battery movements were done by strapping the batteries on vibrators. Batteries were also subjected to handling at angles below 45 . Loss of electrolyte could be contained by as less as 30% and as much as 70% (under test conditions). Field trials were done on a variety of vehicle – from passenger vehicles on city roads to large vehicles on rough terrains. Some foreign particles were found on the neck of the battery lid openings – mainly due to environment in which the batteries were handled and party due to rubber gaskets. New rubber gaskets from synthetic rubber helped reduce the problem to a considerable extent.




As expected, PP filters were found to be more efficient than their ceramic counterparts. The Splash Proof ceramic filters were found to me more efficient than the conventional caps.




The feedback is overwhelmingly encouraging. The filter fitted Anti Splash Vent Caps are generating not only domestic interest and demand but international as well.