Overmolded Cable Lug Anchoring for Moisture-Resistant Contacts
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Solution Overview
Problem
Existing cable lugs face challenges in maintaining a stable and secure housing, especially under mechanical loads and in corrosive environments, which can lead to moisture penetration and instability during connection to electrical systems.
Innovation Solution
A contact element with a cable lug featuring a flat annular contact part and multiple smaller recesses around a central fastening recess, encapsulated in an electrically insulating casing made of thermoplastic polyurethane, providing secure anchoring and protection from moisture through overmolding, allowing for a low-resistance electrical connection and enhanced mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cable lug is securely embedded in the housing through overmolding, then the mechanical stability and protection against moisture penetration is improved, but the manufacturing complexity increases due to the additional overmolding process
Solution Approach 1:
The cable lug and housing are combined into a single integrated component through overmolding, where the housing material is molded directly onto the cable lug. This merging of components eliminates the need for separate assembly steps and creates a unified structure that provides both mechanical stability and moisture protection.
Solution Approach 2:
The solution uses composite construction by combining the metallic cable lug with a plastic housing material through overmolding. This creates a hybrid component that leverages the advantages of both materials: the electrical conductivity and mechanical strength of metal, combined with the insulating and protective properties of plastic.
2Stability of the object's composition
If multiple recesses are added to the contact part for enhanced anchoring, then the mechanical stability is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The recesses are pre-formed on the cable lug before the overmolding process begins. This preliminary action allows the housing material to flow into and anchor at these predetermined locations during molding, ensuring precise positioning without requiring additional post-processing steps or complex tooling.
Solution Approach 2:
The recesses are strategically positioned at specific locations on the contact part where enhanced anchoring is needed. This local modification approach concentrates the structural reinforcement exactly where mechanical stresses are applied during connection, rather than uniformly strengthening the entire component.
3Ease of operation
If the contact part is designed with a flat annular shape and multiple recesses, then the ease of operation for passing fastening elements is improved, but the structural strength may be reduced
Solution Approach 1:
The contact part is segmented into a flat annular structure with multiple recesses distributed around the central fastening opening. This segmentation creates multiple anchoring points that collectively distribute and bear mechanical loads, preventing stress concentration at any single point while maintaining ease of fastening element passage.
Solution Approach 2:
The recesses are positioned in the radial direction around the central fastening recess, utilizing the circumferential dimension of the annular structure. This dimensional arrangement allows fastening elements to pass through the center while the surrounding recesses provide lateral anchoring, effectively separating the functions of fastening and structural reinforcement.
Data Source
Figure 1a
Figure 1b
Figure 2a
AI summary
The invention relates to a cable lug (10, 10', 10", 10"') comprising a connection region (9, 9", 9"') for connecting the cable lug (10, 10', 10", 10'") to a cable (4), and comprising a contact part (11) for an electrical interconnection of a connection part (40) of an electrical system (42), in particular an electrical system of a motor vehicle, the contact part (11) having a fastening cut-out (12), through which a fastening element (46) can be passed in order to fasten the cable lug (10, 10', 10", 10'") to a connection part (40), and said contact part (11) having one or more additional cut-outs (13). The invention also relates to the use of the cable lug (10, 10', 10", 10'"), to a contact element (2) comprising a cable lug (10, 10', 10", 10'") of this type, and to a method for producing said element.