Connection Systems Training

Wire Harness Sealing Technology

CTIS # 29951 Prepared By John Yurtin Updated 1-20-2005
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Excellence
Performance Goal: Do it right the first time, every time Method: Innovation and continuous improvement

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..

Wire Harness Sealing Methods

Overview
Harness - Sealing

Splash Water Sealing Injection Moulding Loose Piece Grommets (Rubber EPDM) Shrinking Grommets Bulkhead Connectors Coverings (tubes, tapes, etc.)
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Longitudinal / Bundle Sealing Cold Pasticine Hot Melt PUR Foaming Capillary Action Prevention SLS Process

Methods For Bundle Sealing

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. - Overmoulding B2. - Hot Melt + Shrinking Procedure (Rayblock LMX) C. PUR Foaming
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Longitudinal / Bundle Sealing

A. Cold Plasticine (Butylene rubber) A1. - Manual Assembly (Terostat) Pros: - low price
- no capital expenditure - simple method - usable for rework

Cons: - no reliable process

- depends on operator - maybe sealing

Longitudinal / Bundle Sealing

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

Pros:
- very low capital expenditure
- in comparison to Method A1: easier Handling

Cons:
- Process Reliability - costly Handling

Longitudinal / Bundle Sealing

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

Pros: - very low capital expenditure

- in comparison to Method A1: easier Handling

Cons:
Process Reliability - costly Handling

Longitudinal / Bundle Sealing

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

B. Hot Melt B1. - Overmoulding
Pros:
- Controlled Process - Easy Handling - High Capital Expenditure (~40Thd DM per Machine plus Mould)

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

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Longitudinal / Bundle Sealing

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

Pros:
- see A2.2

Cons: - see A2.2

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Longitudinal / Bundle Sealing

C. PUR Foaming
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)

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Capillary Action Preventer

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Doors-Off Connections

13 way sealed Door connection

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

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

Grommet/connector retainer
Provides positive, one-handed installation of the grommet to the sheetmetal

Pre-staged MBS
Protects blades during shipment and vehicle assembly plant processing and handling

Positive Lever Lock Out

Assures that the lever is in the proper position at the time of assembly

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Doors-Off Connections
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 inline connection system Also allows the same connector to be used in a different door application by simply changing the grommet/connector retainer geometry

Connector
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Grommet/Connector Retainer

Doors-Off Connections

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

designed to enable improvements in vehicle assembly plant

Custom

process
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Doors-Off Connections

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Doors-Off Connections
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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Doors-Off Connections
Double Click on Photo to Activate Video Clip

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Fuel Tank Pass-Through

Sealed Mating Connector

Male Terminals

Compression Gasket

Metal Plate

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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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Toyota 635N Dash Grommet

Validated to Toyota TSC1156G and passed all the tests. Completed December 2003. Build will start at the end of Jan. 2004 in Japan.

Extended tube with 15mm

Revised opening

Larger core out for tooling 2001 TOYOTA RAV 4 FOD Grommet

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Toyota 635N Dash Grommet

A

30mm B 44mm B Section A-A

Core out for tooling 63.5mm A

Section B-B

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Toyota 635N Dash Grommet

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.

Cable The rib inside the tube helps cables being centered. Thinner portion of the tube provides space between cables and the grommet.

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SLS Grommet
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

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SLS Grommet Process

Click picture below to activate video

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