1 Wire Harness Sealing Technology CTIS # 29951 Prepared By John Yurtin Updated 1-20-2005 Connection Systems Training

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Wire Harness Sealing Technology

CTIS # 29951

Prepared By John Yurtin

Updated 1-20-2005

Connection Systems Training

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Having a good technical understanding of the products and the technology behind them will help in choosing the right product for the application

This training help you understand harness sealing, and the products and technologies available so you can make better harness sealing decisions..

Excellence

Performance Goal: Do it right the first time, every time

Method: Innovation and continuous improvement

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Wire Harness Sealing Methods

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Harness - SealingHarness - Sealing

Splash Water Sealing•Injection Moulding•Loose Piece Grommets (Rubber EPDM)•Shrinking Grommets•Bulkhead Connectors•Coverings (tubes, tapes, etc.)

Splash Water Sealing•Injection Moulding•Loose Piece Grommets (Rubber EPDM)•Shrinking Grommets•Bulkhead Connectors•Coverings (tubes, tapes, etc.)

Longitudinal / Bundle Sealing•Cold Pasticine•Hot Melt•PUR Foaming•Capillary Action Prevention•SLS Process

Longitudinal / Bundle Sealing•Cold Pasticine•Hot Melt•PUR Foaming•Capillary Action Prevention•SLS Process

Overview

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A. Cold Plasticine (Butylene rubber)

A1. - Manual Assembly (Terostat)A2. - With Auxiliary Devices A2.1 Tyton A2.2 Cold Melt 1

A2.3 Cold Melt 2

B. Hot Melt

B1. - OvermouldingB2. - Hot Melt + Shrinking Procedure (Rayblock LMX)

C. PUR Foaming

Methods For Bundle Sealing

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Pro´s:- low price- no capital expenditure- simple method

- usable for rework

Con´s:- no reliable process- depends on operator

- „maybe sealing“

A. Cold Plasticine (Butylene rubber)A1. - Manual Assembly (Terostat)

Longitudinal / Bundle Sealing

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Pro´s:- very low capital expenditure- in comparison to Method A1:

easier Handling Con´s:

- Process Reliability - costly Handling

A. Cold Plasticine (Butylene rubber)

A2. - With Auxiliary Devices A2.1 Tyton


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Pro´s:- very low capital expenditure- in comparison to Method A1:

easier Handling Con´s:

Process Reliability - costly Handling

A. Cold Plasticine (Butylene rubber)A2. - With Auxiliary Devices A2.2 Cold Melt 1


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Pro´s:

- Grommet assembeled on harness- very low capital expenditure- in comparison to Method A1: easier Handling

Con´s:

- high material price depends on design- Process Reliability

- costly Handling

A. Cold Plasticine (Butylene rubber)A2. - With Auxiliary Devices A2.3 Cold Melt 2


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Pro´s:

- Controlled Process - Easy Handling

- High Capital Expenditure (~40Thd DM per Machine plus Mould)

Con´s:

- only for small wire bundles (less than 10 wires)

B. Hot MeltB1. - Overmoulding


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Pro´s:- see A2.2

Con´s:

- see A2.2

B. Hot Melt B2. - Hot Melt + Shrinking Procedure (Rayblock LMX)


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Pro´s:

- Combination of 2 Operations (Sealing + Grommet) in one Process Step

- Noise Reduction- Reduction of Manual Worktime- Reliability

Con´s:

- High Capital expenditure (~160thd DM per machine w/o Tools)

C. PUR Foaming


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Capillary Action Preventer

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13 way sealed Door connection

• Advantages:• New locking system with spring• One hand mounting• For left or right doors• Easy assembly and dis-assembly

Doors-Off Connections

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Grommet/connector retainerProvides positive, one-handed installationof the grommet to the sheetmetal

Pre-staged MBSProtects blades during shipmentand vehicle assembly plant processing and handling

Positive Lever Lock Out

Assures that the lever is in the properposition at the time of assembly

Doors-off connections provide an easy means of connecting body wiring to door wiring, especially if the doors are assembled off-line

– The system incorporates many patented Delphi design features– Lever Lock mechanical assist means that high circuit count connections

can be mated with the fingers


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Connector Grommet/Connector Retainer

Design Versatility Systems are designed to have the connector snap into the

grommet/connector retainer– Allows the connector to be used elsewhere in the vehicle as part of an in-

line connection system– Also allows the same connector to be used in a different door application

by simply changing the grommet/connector retainer geometry


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Connection system combines best in class features for mechanical assist sealing, and contact technology

Unique design provides tight contact packaging for optimum use of space

Custom designed to enable improvements in vehicle assembly plant process


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• Custom designed to enable vehicle assembly plant process improvements

• Connection system technology combines best in class feature for mechanical assist, sealing, and contact technology

• Mechanical assist feature is contained within the protective door grommet, optimizing the space required


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Double Click on Photo to Activate Video Clip


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Compression Gasket

Male Terminals

Sealed Mating Connector

Metal Plate

Fuel Tank Pass-Through

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Grommets

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Multi-Piece Grommets

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Grommets

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Door Grommets

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Validated to Toyota TSC1156G and passed all the tests. Completed December 2003.

Build will start at the end of Jan. 2004 in Japan.

2001 TOYOTA RAV 4 FOD Grommet

Revised opening

Larger core out for tooling

Extended tube with 15mm

Toyota 635N Dash Grommet

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44mm

30mm

A

A

BB Section A-A

Section B-B

Core out for tooling

63.5mm


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Additional Changes» Harness branch location in the grommet is critical. The Branch must be centered during the dispensing of the polyurethane.

» Polyurethane sealant and grommet (EPDM) are NOT chemically bonded. Gaps between grommet and sealant might be a leak pass.

»The rib inside the tube helps cables being centered.

»Thinner portion of the tube provides space between cables and the grommet.

Cable


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Objectives

» To examine whether the revised grommet could accept ‘One-shot’ application without overflow.

To examine the revised opening could accept one-shot application.

To examine if upper level of sealants could reach here.

Primary Sealing

SLS Grommet

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Click picture below to activate video

SLS Grommet Process

Documents

1 Wire Harness Sealing Technology CTIS # 29951 Prepared By John Yurtin Updated 1-20-2005 Connection Systems Training