Practical Measures For The Protection Design Of Cable Terminals Under Temperature Difference Conditions

For cable lugs insulation protection, the industry employs multi-layered design schemes. Increasing the creepage distance is the most direct method—by lengthening the shortest path between conductors along the insulation surface, it makes it difficult for conductive water films to form a continuous discharge path. Depending on the operating voltage and pollution level, the creepage distance typically needs to be 4 to 6 millimeters or more.

The application of silicone rubber insulating boots and heat-shrink tubing provides physical isolation for wire lugs. These protective sleeves are usually made of chlorinated polyethylene or cross-linked polyolefin materials, which can both isolate condensation and improve phase-to-phase insulation. In humid salt spray environments, these protective measures are effective in extending the life of electrical lugs.

Layout optimization is also crucial. Designers should place high and low voltage terminal lugs zones separately, maintaining sufficient spacing, and install drainage holes at the bottom of junction boxes to allow occasional condensation to drain promptly. For areas prone to condensation, installing hydrophobic drying devices can actively control local humidity.