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

2. 2 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

3. 3 Wire Harness Sealing Methods

4. 4 Harness - 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

5. 5 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 Methods For Bundle Sealing

6. 6 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

7. 7 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

8. 8 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

9. 9 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

10. 10 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 Melt B1. - Overmoulding Longitudinal / Bundle Sealing

11. 11 Pro´s: - see A2.2 Con´s: - see A2.2 B. Hot Melt B2. - Hot Melt + Shrinking Procedure (Rayblock LMX) Longitudinal / Bundle Sealing

12. 12 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

13. 13 Capillary Action Preventer

14. 14 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

15. 15 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 u 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

16. 16 ConnectorGrommet/Connector Retainer Design Versatility u 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

17. 17 u Connection system combines best in class features for mechanical assist sealing, and contact technology u Unique design provides tight contact packaging for optimum use of space u Custom designed to enable improvements in vehicle assembly plant process Doors-Off Connections

18. 18 Doors-Off Connections

19. 19 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

20. 20 Double Click on Photo to Activate Video Clip Doors-Off Connections

21. 21 Compression Gasket Male Terminals Sealed Mating Connector Metal Plate Fuel Tank Pass-Through

22. 22 Grommets

23. 23 Multi-Piece Grommets

24. 24 Grommets

25. 25 Door Grommets

26. 26 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

27. 27 44mm 30mm A A B B Section A-A Section B-B Core out for tooling 63.5mm Toyota 635N Dash Grommet

28. 28 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

29. 29 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

30. 30 Click picture below to activate video SLS Grommet Process