Elastomer Overmolded Terminal Lug Locking Unit
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Solution Overview
Problem
Existing connection systems for electrically connecting cables to device connectors face challenges in achieving reliable sealing against liquids and efficient installation, particularly due to the lack of clear installation signals and low shape stability of elastomer materials, which complicates automated installation.
Innovation Solution
A connection system featuring a terminal lug with an elastomer overmold and a locking unit that includes a cap element for elastic deformation, allowing for secure sealing and fixation using a screwed connection, enabling rapid, efficient, and automated installation with defined torque parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If elastomer cover caps are pressed onto the device connector to achieve sealing, then sealing effect is improved, but shape stability deteriorates making automated installation difficult
Solution Approach 1:
The patent changes the material parameter from pure elastomer to a composite of thermoplastic and elastomer (TPE/TPV). This hybrid material maintains the sealing capability of elastomer while adding the shape stability and toolability of thermoplastic, enabling automated installation with defined torque parameters
Solution Approach 2:
The fixation element uses a composite material combining thermoplastic and elastomer properties. This allows the material to exhibit both the elastic deformation needed for sealing and the structural stability required for automated, tool-based installation with monitored tightening torque
2Reliability
If elastomer material is used for cover caps, then sealing effect is improved, but installation complexity increases due to low shape stability
Solution Approach 1:
The material parameters are changed by combining thermoplastic and elastomer characteristics. This allows the fixation element to be installed using standard tooling with defined torque parameters, reducing installation complexity while maintaining sealing effectiveness
3Strength
If screwed connection is used for fixation, then mechanical stability is improved, but installation time increases compared to simple pressing
Solution Approach 1:
The fixation element is pre-configured with integrated sealing geometry and thread structure. The thermoplastic-elastomer composite allows for pre-forming the sealing surfaces, enabling rapid screwed installation with defined torque parameters without requiring separate sealing operations
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
The system provides a reliable seal against liquids and contaminants while allowing for rapid, efficient, and monitored installation, enhancing mechanical stability and ease of use through defined installation parameters.
Implementation Method 1
the cap element is set up for pressing against the wall in the fixed state and elastically deforming this wall, at least in certain sections, so as to achieve a seal between the wall and the cap element
Data Source
AI summary
A connection system for electrically connecting a cable to a device connector includes a terminal lug having a connecting section having an opening for engaging the terminal lug into a connected state with the device connector. A fixation element fixes the terminal lug in place, in the connected state, on the device connector, with shape fit and/or with force fit, to produce a fixed state. The terminal lug has an elastomer overmolded onto it, at least in the region of its connecting section, that forms a holder having a wall. The fixation element forms a section of a locking unit arranged within the holder in the fixed state, at least in certain sections, that includes a cap element for covering the fixation element, at least in certain sections. The cap element presses against and elastically deforms the wall in the fixed state, at least in certain sections.