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Wire Harness SealingTechnology
CTIS # 29951Prepared By John Yurtin
Updated 1-20-2005
Connection Systems Training
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Having a good technical understanding of the products andthe technology behind them will help in choosing the rightproduct for the application
This training help you understand harness sealing, and theproducts and technologies available so you can make betterharness sealing decisions..
Excellence
Performance Goal: Do itright the first time everytime
Method: Innovation andcontinuous improvement
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Wire Harness Sealing Methods
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Harness - Sealing
Splash WaterSealingInjection MouldingLoose Piece Grommets
(Rubber EPDM)
Shrinking GrommetsBulkhead ConnectorsCoverings
(tubes, tapes, etc.)
Longitudinal / BundleSealingCold PasticineHot MeltPUR FoamingCapillary Action
PreventionSLS 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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Pros:
- low price- no capital expenditure- simple method- usable for rework
Cons:- no reliable process- depends on operator- maybe sealing
A. Cold Plasticine (Butylene rubber) A1. - Manual Assembly (Terostat)
Longitudinal / Bundle Sealing
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Pros:- very low capital expenditure- in comparison to Method A1:
easier Handling Cons:
- Process Reliability
- costly Handling
A. Cold Plasticine (Butylene rubber) A2. - With Auxiliary Devices
A2.1 Tyton
Longitudinal / Bundle Sealing
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Pros:- very low capital expenditure- in comparison to Method A1:
easier Handling
Cons: Process Reliability
- costly Handling
A. Cold Plasticine (Butylene rubber)
A2. - With Auxiliary Devices A2.2 Cold Melt 1
Longitudinal / Bundle Sealing
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Pros:- Grommet assembeled on
harness- very low capital expenditure- in comparison to Method A1: easier Handling
Cons:- high material price depends
on design- Process Reliability- costly Handling
A. Cold Plasticine (Butylene rubber) A2. - With Auxiliary Devices A2.3 Cold Melt 2
Longitudinal / Bundle Sealing
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Pros:- Controlled Process- Easy Handling- High Capital Expenditure
(~40Thd DM per Machineplus Mould)
Cons:- only for small wire bundles
(less than 10 wires)
B. Hot Melt B1. - Overmoulding
Longitudinal / Bundle Sealing
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Pros: - see A2.2
Cons: - see A2.2
B. Hot Melt B2. - Hot Melt + Shrinking Procedure (Rayblock LMX)
Longitudinal / Bundle Sealing
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Pros:- Combination of 2 Operations
(Sealing + Grommet) in one Process Step- Noise Reduction
- Reduction of Manual Worktime- Reliability
Cons:- High Capital expenditure(~160thd DM per machine w/o Tools)
C. PUR Foaming
Longitudinal / Bundle Sealing
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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 plantprocessing and handling
Positive Lever Lock Out Assures that the lever is in the proper
position at the time of assembly
Doors-off connections provide an easy means of connecting bodywiring 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
Doors-Off Connections
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Connector Grommet/ConnectorRetainer
Design VersatilitySystems are designed to have the connector snap into thegrommet/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
Doors-Off Connections
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Connection system combines best in class features for mechanical assistsealing, and contact technology
Unique design provides tight contact packaging foroptimum use of space
Custom designed to enable improvements in vehicle assembly plant process
Doors-Off Connections
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Doors-Off Connections
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Custom designed to enable vehicle assemblyplant process improvements
Connection system technology combines bestin class feature for mechanical assist, sealing,and contact technology
Mechanical assist feature is contained withinthe protective door grommet, optimizing thespace required
Doors-Off Connections
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Double Click on Photo to Activate Video Clip
Doors-Off Connections
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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
Revisedopening
Largercore outfor tooling
Extended tubewith 15mm
Toyota 635N Dash Grommet
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44mm
30mm
A
A
BB Section A-A
Section B-B
Core outfortooling
63.5mm
Toyota 635N Dash Grommet
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Additional Changes Harness branch location in the grommet is critical. The Branch must be centered during thedispensing of the polyurethane.
Polyurethane sealant and grommet (EPDM) are NOT chemically bonded. Gaps betweengrommet and sealant might be a leak pass.
The rib inside the tube helps cables beingcentered.
Thinner portion of the tube provides spacebetween cables and the grommet.
Cable
Toyota 635N Dash Grommet
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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 sealantscould reach here.
Primary Sealing
SLS Grommet
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Click picture below to activate video
SLS Grommet Process