Tubular Cable Lug Web Seal for Longitudinal Moisture Blocking
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Solution Overview
Problem
Tubular cable lugs face challenges with moisture penetration between the cable and the interface, requiring complex sealing processes like soldering or hot-dip tinning.
Innovation Solution
A tubular cable lug design featuring a web that creates a longitudinal water seal between the flange element and the first tubular element, eliminating the need for complex sealing processes by using a symmetrical starting semi-finished product made from extruded material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex sealing processes like soldering or hot-dip tinning are used to prevent moisture penetration, then moisture protection is improved, but production time and costs increase
Solution Approach 1:
The cable lug is divided into two separate tubular elements (first and second tubular elements) that are pressed together. The web structure created by this segmentation forms a longitudinal water seal that prevents moisture penetration without requiring additional sealing processes like soldering or hot-dip tinning.
Solution Approach 2:
The web structure acts as an intermediary element between the two tubular elements. This web creates the water seal function, eliminating the need for separate sealing processes while maintaining moisture protection.
2Reliability
If complex sealing processes like soldering or hot-dip tinning are used to prevent moisture penetration, then moisture protection is improved, but manufacturing costs increase
Solution Approach 1:
The cable lug is divided into two separate tubular elements (first and second tubular elements) that are pressed together. The web structure created by this segmentation forms a longitudinal water seal that prevents moisture penetration without requiring additional sealing processes like soldering or hot-dip tinning.
Solution Approach 2:
The web structure acts as an intermediary element between the two tubular elements. This web creates the water seal function, eliminating the need for separate sealing processes while maintaining moisture protection.
3Ease of operation
If a symmetrical starting semi-finished product is used, then handling during manufacturing is improved, but the complexity of creating the water seal structure increases
Solution Approach 1:
The cable lug is divided into two separate tubular elements (first and second tubular elements) that are pressed together. The web structure created by this segmentation forms a longitudinal water seal that prevents moisture penetration without requiring additional sealing processes like soldering or hot-dip tinning.
Solution Approach 2:
While the starting semi-finished product is symmetrical for ease of handling, the pressing process creates an asymmetric web structure that provides the water seal function. The web has a specific geometry that is asymmetric relative to the tubular elements, enabling effective moisture protection.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Tubular cable lug (10) for connecting a cable to an interface, comprising: a web (11); a first tubular element (12) for receiving a cable; a flange element (13) with a bore (14) for connecting to an interface; wherein the web (11) is arranged between the bore (14) of the flange element (13) and the first tubular element (12) and effects a longitudinal water seal between the first tubular element (12) and the flange element (13); wherein the flange element (13) is at least partially formed as a flat-pressed second tubular element.