Cable Lug Stop Support Prevents Insulation Overlap
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Solution Overview
Problem
Conventional cable lugs face the issue where an insulating sleeve, when pushed over the receiving section, often covers part of the contact section, impeding proper electrical connection due to its larger initial diameter, which only shrinks to fit after expansion elements are removed or heated, leading to incomplete contact.
Innovation Solution
A cable lug design featuring a stop support that extends beyond the outer radius of the receiving section, preventing the insulating sleeve from sliding over the contact section, ensuring the sleeve only covers the receiving section and leaves the contact section free, thereby maintaining full surface contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulating sleeve with a larger initial diameter is pushed over the receiving section, then the receiving section is insulated, but the insulating sleeve covers part of the contact section, impeding proper electrical connection
Solution Approach 1:
The cable lug is divided into functionally distinct segments: the receiving section for conductor insertion, the contact section for electrical connection, and the stop support with a stop that defines the boundary between these sections. This segmentation allows the insulating sleeve to be pushed only onto the receiving section without covering the contact section, ensuring both reliable electrical connection and ease of assembly.
Solution Approach 2:
The stop support acts as an intermediary element between the receiving section and the contact section. It provides a physical stop that prevents the insulating sleeve from sliding over the contact section, thereby mediating the interaction between the insulation requirement and the electrical connection requirement.
2Ease of operation
If the insulating sleeve is pushed over the receiving section without a stop, then assembly is simple, but the sleeve slides over the contact section causing incomplete contact
Solution Approach 1:
The stop is preliminarily positioned on the cable lug before the insulating sleeve is pushed on. This preliminary positioning ensures that when the insulating sleeve is assembled, it automatically stops at the correct position and cannot slide over the contact section, thereby maintaining both assembly simplicity and manufacturing precision.
Solution Approach 2:
The stop structure enables the insulating sleeve to self-limit its own movement during assembly. The sleeve pushes against the stop and naturally stops at the correct position without requiring external intervention or precise positioning, achieving both simple assembly and precise coverage.
3Reliability
If a stop support is added to prevent the insulating sleeve from covering the contact section, then electrical connection is ensured, but the cable lug structure becomes more complex
Solution Approach 1:
The stop support is merged with the cable lug body as an integrated component rather than a separate part. This combining approach ensures reliable electrical connection by preventing the insulating sleeve from covering the contact section, while avoiding the complexity of additional separate components and assembly steps.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design ensures that the insulating sleeve is limited in its sliding range by the stop support, preventing partial coverage of the contact section and ensuring complete electrical contact, even during assembly and insulation of the cable lug.
Implementation Method 1
an insulating sleeve with an inner diameter that is too large is arranged around this receiving section and fixed there by reducing the inner diameter
Implementation Method 2
a stop support which forms a stop facing the first end of the receiving section adjoining the contact section and extends beyond the outer radius of the receiving portion
Data Source
Figure 1~4
Figure 5~6
AI summary
The cable lug has an insulation sleeve (6) comprising accommodating section e.g. crimp sleeve and ferrule, for fastening a stripped electrical conductor (3) of a cable with a contact section (5) i.e. eyelet. A flat limit stop carrier (8) is fastened at the contact section and forms a stop (7). The stop extends in an angle of 70 to 110 degrees to a longitudinal axis of the accommodating section. The carrier and contact- and accommodating sections are integrally formed. The carrier is arranged in a common plane with the contact section. The sleeve with an end is arranged against the stop. An independent claim is also included for a method for fastening a cable lug at an electrical conductor.