Fully Insulated Connection Technology for Reliable Contact Protection
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 Variants at a Glance
Flex
Cap
Cap High
Cap Seal
Deep Low
Deep Smart
Angled
Curved
Key Benefits of the Lugsulation
Cost efficiency
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.
On-Site Assembly
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.
Flame retardant
Lugsulation can be supplied in UL94 V0-rated flame-retardant material on request – making it suitable for safety-critical applications with strict fire protection standards.
Corrosion-Resistant Electrical Contacts
Full insulation reliably seals out moisture, preventing oxidation, terminal degradation, and power losses – even under demanding environmental conditions.
Touch protection
low maintenance
Once installed, the connection remains permanently protected.
Lugsulation significantly reduces maintenance effort and extends the service life of electrical systems.
Lugsulation variants in detail
Lugsulation in Practice
The components of lugsulation
Find Out More About Lugsulation
Frequently Encountered Issues
Leakage current, short circuits, contact corrosion – there can be many troubles caused by insufficient insulated contacts. We have got the solutions!
Real-World Use Cases
Insufficient insulation of live contacts is a common and cross-industry issue. Subsequent risks are performance fail up to complete system collapse.
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
For Flex and Cap: Special HSYS cable lug
For Smart: Deep cable lug, also stackable for flat contacts
Screw (optional)
Flex: Insulation screw (standard)
Cap: ISK (Allen) screw
Smart: Torx screw
Interested in learning more about our Lugsulation system?
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.