[Al Skierkiewicz]

There are two consistent failures that I have seen over the years. A quick inspection of the case will usually show some evidence of being dropped. This is easy to pick out if it occurs on a corner. When a battery is dropped the internal plates of the battery can shift within the cell. With the use of absorbed glass mat, I believe this might lead to a shorted cell. Once the cell shorts, significant heat builds up withing the cell causing the leaking acid and bubbles you experienced. I also have a theory that in the event of a either a failure for a normal charger, or the use of a high current charger, the plates will deform under the high current and also cause an internal short. To achieve a zero volt output, the battery would have to electrically open. This can occur if the connector plates between cells should break or melt open or the terminals become dislodged internal to the battery. The battery is manufactured with round terminals. Depending on the external terminal type ordered (there are several), the terminal is placed down on the round terminal internal to the battery and then it is flow soldered. To finish, a red or black epoxy is then added to seal the top of the battery. It is possible to break the solder joint (usually by lifting by the cables) and still not find any movement in the terminal.