Exposed electrical contacts often lead to corrosion and performance losses across various industries.
Our Lugsulation technology provides full insulation of the terminal, eliminating leakage currents and shielding the connection from environmental stress. Installation is quick and simple – and once in place, the system remains completely maintenance-free.
Unlike conventional caps that only cover the contact, Lugsulation provides full electrical insulation.
This all-around protection makes corrosion and creepage currents a thing of the past – and reliably eliminates the risk of short circuits.
Lugsulation helps lower your total cost of ownership by combining quick installation, maintenance-free operation, and long- lasting insulation performance. It reduces system failures and eliminates the need for expensive repairs – making it a smart investment for sustainable efficiency.
Lugsulation is tool-free and can be applied directly during cable assembly. Its fast installation process reduces production time, making it suitable for both field installations and series manufacturing.
Lugsulation can be supplied in UL94 Vo-rated flame-retardant material on request – making it suitable for safety-critical applications with strict fire protection standards.
No penetration of aggressive media such as dirt, moisture or acid is possible, so the contacts remain corrosion-free.
The lugsulation is certified according to protection class IP64. With further measurements, a protection class of up to IP68 is possible.
The sealing system of the lugsulation prevents the penetration of aggressive media and reduces the maintenance effort.
Lugsulation Flex, with its sealing sleeve, insulation screw, and HSYS cable lug, ensures a fully insulated connection—and reliably protects the electrical contact from accidental contact, moisture ingress, and corrosion.
For many Lugsulation variants where a standardized insulation screw with a plastic head cannot be used for sealing, an ISK (hex socket / Allen) screw can be used instead. After tightening, a cap securely and permanently seals the screw opening.
Lugsulation Cap High is a variant of the Cap. With a hex socket screw (ISK), optimized sealing geometry, and a copper ring, it provides reliable protection up to IP64 and is suitable for applications with special spatial or geometric requirements.
Lugsulation Cap Seal is a variant of the Cap. With a hex socket screw (ISK), lower sealing geometry, and a copper ring, it provides reliable protection up to IP64 and prevents connection areas from being partially exposed. This avoids conductive or open areas that could otherwise be susceptible to creepage currents or corrosion.
Lugsulation Deep features a special deep cable-lug design with sealing tailored to the connection, ensuring durable, corrosion-free contacts with low overall costs and easy maintenance. It is designed for flat conductors where the contact surface does not protrude.
Lugsulation Deep Smart fully insulates flat contacts and, thanks to its stackable design, enables serial or parallel bolted connections without additional components. With integrated sealing, Torx insulation screws, and robust special rubber (also V0 per UL94), it provides reliable protection and is ideal for lithium-ion batteries and compact electrical systems.
Lugsulation Angled provides full insulation and protection where space is limited. With 90°, 45°, or other cable exit angles, it enables precise cable routing, can be installed quickly, and is also suitable for lithium-ion batteries, complex systems, and especially for front-end terminals.
Lugsulation Curved provides complete insulation and reliable protection over the contact in electrical systems. Thanks to its curved cable exit, it enables flexible installation, optimal use of space, and is ideal for batteries, inverters, converters, compact machines, and complex systems.
The lugsulation is a set consisting of a sealing sleeve, a specially manufactured cable lug, and an insulation screw.
Sealing sleeve
Provides reliable protection against moisture, dirt, vibrations, and corrosion—even under extreme operating conditions.
Special cable lug
Screw (optional)
Leakage current, short circuits, contact corrosion – there can be many troubles caused by insufficient insulated contacts. We have got the solutions!
Insufficient insulation of live contacts is a common and cross-industry issue. It causes risk of performance fail up to complete system collapse.
We always think one step ahead. Reach out to discover how our solutions can support your battery and terminal applications.
As your reliable partner in connection technology, we’re here to help – contact us today.
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