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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
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 A2.2 Cold Melt 1
Longitudinal / Bundle Sealing
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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
Longitudinal / Bundle Sealing
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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
Longitudinal / Bundle Sealing
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Pro´s:- see A2.2
Con´s:
- see A2.2
B. Hot Melt B2. - Hot Melt + Shrinking Procedure (Rayblock LMX)
Longitudinal / Bundle Sealing
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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
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 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
Doors-Off Connections
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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
Doors-Off Connections
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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
Doors-Off Connections
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Doors-Off Connections
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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
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
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
Toyota 635N Dash Grommet
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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
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 sealants could reach here.
Primary Sealing
SLS Grommet
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Click picture below to activate video
SLS Grommet Process