Teardrop shape slug for cable assembly

Abstract

A remote control cable assembly (10) includes a conduit (12) with a core element (24) slidably supported in the conduit (12). Slugs (30, 32) are die cast on each end of the core element (24) for connection to various controlling and controlled devices to transmit tensile forces therebetween. At least one slug (32) is formed with a teardrop shape having a spherically rounded head (34) and a frustum tail (36). The end (28) of the core element (24) is embedded within the slug (32). The twisted strands of the core element (24) are fanned over a segment (50) and embedded within the slug (32) to improve adhesion. During the die casting formation process, a sprue (52) injects molten zinc into a die cavity (44) near a truncated tip (38) of the frustum tail (36). The sprue (52) location and angle (I) decreases the possibility of unwanted core element (24) movement during the pressurized injection of molten zinc thereby improving cable assembly tolerances. Also, the sprue (52) location improves adhesion between the core element (24) and the zinc by immediately conducting the flow of molten zinc into the fanned and untwisted segment (50) of cable strands.

Dependencies are inferred from the claim text.