Note: Descriptions are shown in the official language in which they were submitted.
wo 94/16884 PCT/u~4looSss
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Ei9Ld f ~
This invention relates to a system for delivering a se~ material,
a tape, an article for providing protec~n ae~inct moisture and a method
of protecting a wire bundle from moisture.
of~1~
lD
In autos, light trucks, airplanes, boats, and telephone systems,
many wire bundles traverse from a co,..~ ..rnt, such as the p~ss~nEer
~"'l'~' k~ent of a vehicle, to ~l~lotect~l areas, such as under the hood.
A rubber ~lo.. et typically seals the outside of the wire bundle to the
s sheet metal. Under the ~lo~ et, the wire bundle must be sealed in
order to ~.evt:~t water from wicking along the wires into the r~Cse~er
~nr~rtment. Until now, no effective and e~on~ math~i to ~eal the
wire bundle has been found.
The ~llto-7notive industry has ~tt~mpted a nt~mher cf solutions to
this problem. The most comm~n 5~ttçmpt is mastic and tape. Mastic pads
are pushed into the wire bundle and then .~nA~ed in an attempt to seal
each wire. A tight vvrap is then applied. When done properly, this
met~o~l can seal a wire bundle effectively, but it is messy and can flow at
zj elevated t ~ ~es. Its prims3ry drawback is that it is ~ eLuely craft
sensitive and permits no quality control for the seal. Additionally, the
seal often deteriorates over time under flexing and vibration.
A se~on~l attempt at solving this problem for sm~ller wire bundles
is a drip loop formed before the blllkhe~-l penetration. The drip loop takes
up considerable space and can be formed only on small bundles.
Often, the location of the wire bundle will be moved to a protected
area to ~ievellt water from spl~shing directly on the bundle. This
3; location is usually not optimal from a routing perspective.
WO 94116884 PCTtUS94100SSS
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Alternatively, a sealed connector csn be used instead of penetrating
the bulkhead with the wire bundle. This method is particularly
eYpensive.
sAn additional alternative includes a two-piece plastic box in the
form of a hardshell ~,lo.~....et The bottom piece is used to fix in place an
engineering pl-s-s~c comb. The individual wires are fed through the comb
during h-s-ma,ss ~semhly. The top of the box is then snapped in place and
the box, with h~mess, is transported to a water cooled nest." Hot melt
D r lh9sive iS injected into the box. This method is cllmbersome and bulky,
but provides a re~on~y e~liYe seal and is relatively inexpensive.
Articles snd/or compositions sre known that may be used as a
æ,e~l~nt and void-filler to protect a substrate in a corrosive, moist and
B adverse ~,~vi~O~ ant These articles andlor cQm~o~itions include simple
tape ~ s as well as heat l~Ye~able materials. One e~mrle is
disclosed in U.S. Patent No. 3,086,242 by Cook, ~ ne~ to the ~csignee of
the present invention, which is completely hereby incorporated by
reference for all purposes. Other articles andlor compositions that are
advantageously employed under a~ v~;ate conditions are oils, greases
and adhesives.
Gels have also been used as se~lin~ m~mbers in compression, such
as described in U.S. Patent Application No. 07/762,~33 filed on January 14,
:~; 1992 entitled "Sealing MPmher and Methods of ~.'; e~ling" by Collins et al
wbich is a ~..l ;.-,,gl ;~n-in-part of U.S. Patent Application No. 07l584,320
filed on Sept~mber 18, 1990, assigned to the s-ssi~nee of the present
inv~n~iQn, and which is completely hereby inco~ ated by reference for
all ~ oses. A layer of en~rsulant or gel is sandwiched between two
3~ constraining layers of closed cell fo~m The entire memher is disposed
within a hollow member for applying the compressive force. This
co. ~ ess*e force must be applied subsequent to positioning the member
for sealing.
3jOne additional such article for protection of a substrate is described
in U.S. Patent No. 4,866,905 by Uken, assigned to the ~ssi~nee of the
present invention, which is completely hereby incorporated by reference
for all purposes. This article includes a flexi~le matrix which is
WO g4JlC884 PCrlUS94100S5S
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impregnated with gel. ~Ypose~l surfaces are covered by a release paper
which is removed before the article is applied. This provides an effective
seal. How~ver, the tacky surface of the impreEn~ gel sticks to itself
and the hands of the operator, res~lltin~ in messy application.
5 -
roft~ li5m
JllYt~po~ition of a layer of se~linE material and a layer of open cell
material provides an improved arrangement for se~ling wire bundles.
Application of tension to the layered article when wrapped around a
h-lr~le of wires causes the ~n~pslll~nt to move through the layer of open
cell m~teri~l~ providing a tacky surface. The terms se~linE material and
Pnc~pfiulant refer to the layer of material fo~ a tacky surface and are
used interchangeably hereinafter. A ~ssive force results from this
s ~pplic~tion of tension combined with a compressive force caused 6y
contact with the wire bundle. This arrangement provides an i~ oved
seal for wire blm~lles; hu-.e~le~, ûne surface of the article rem~ins tacky to
the touch. F~ ~ore, the article must be wrapped about a surface to
enable the se~qlin~ material to move through the layer of open cell
material.
The present inven~ion is directed to a se~linE ma~n~ which allows
simple and econQmical applic~tiQn- The se~ m~n~ of the present
invention provides a non-tacky surface to the touch? is rese~l~ble,
rell~e~l~le, and can be easily h~nAlç-l All of the desired se~lin~ attributes
of previous enc~rs~ nt~ seals are ach-ieved~ with improved results.
.,
A layer of se~lin~ material is disposed between two layers of open
cell m~teri~l In its relaxed state, the se~linE ~sspmhly provides a non-
tacky surface. Upon application of a force, preferably including a
substantially perpendicular component of compression and a
substantially longitudinal component of tension, the layer of sealing
material moves through the layers of open cell material, resulting in a
tacky, easily handleable surface having sufficient volume of sealing
material to penetrate through the open cell layer and thereby provide the
desired sealing effect.
WO 94116884 PCr~US94/00555
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The open cell material can be any stretrhsble material. It is
~.efe.ably an open cell foam, but can a7so be any fabric or material
having interstices in an open cell arrangement. For ~Y~-n~,le, any lattice
structure which can be elongated, whereby an al,l,rop.;ate force would
5 allow the fie~line material to move through the illte- ~,ices to the outer
edge to provide a tacky surface at application would be acceptable.
The se~lin~ material is also preferably formed of a stretchable,
P1n~t~l~7e material. The open cell layers are ~-ere.ably stretrh~b1e to an
~ ent greater than the extent of stretching of the layer of sealing
material. The t~i~kneSs of the se~1ing material is ~.efelably between
about one and two times the thickness of each layer of open cell material.
More ~.ere.~bly, the se~1in~ material is about two times the thickness of
each layer of open cell material.
,5
Upon release of the force, the se~ F material reenters the
interstices of the open cell layers, returning to its original location
therebelwe~l.. The article thus returns to its relatively non-tacky, easily
handleable fo~ In this way, the device of the present invention can be
resealed or reused.
The se~ling material is pr~efelably a silicone based gel, although
various pol~u-etllane or thermoplastic based gel materials can also be
used. The sea1in~ material may also be a layer of material impregnated
:~ with gel.
In the ~lefe--ed embo~iment, the sealin~ me~nc is in the form of a
tape, the int~n~led app1ir~tion of which is to provide protection against
~-oisl--.e wicking about a substrate. The t)~i~n~ss of the layer of se?1inE
3~ material is sufficient to fill gaps s~loul.ding the substrate. Ho~evel, the
present invention may be used for any se~lin~ application.
The present invention is also directed to a method of protect;n~ a
wire bundle from moisture c-, ~pl;sing:
3j
(a) providing a section of tape, wherein the tape comprises at least
one layer of ç~r~psulant disposed between at least two layers of open cell
material;
WO 94/1C884 PClrUS94~00555
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~b) selecting two individual wires of the wire bundle;
(c) ~inchin{~ the end of the tape between the wires;
(d) w-~ the tape around bothwires;
(e) applging a force to the tape such that the encapsulant
s penetrates through the open cell layers, thereby providing a moisture seal
around the wires;
(f) selecting an additional wire from the bundle;
(g) w.~ .;.~ a layer of tape around the ~sA~litionslly selected wire;
(h) ço..~ to apply a force to the tape;
(i) selecting ~,cltlitiQn-s-l wires from the bundle and repeating steps
(f) through (h) until all wires from the b~ln~lle are wrapped.
As described above, the force applied is most preferably a
substantially perpendicular component of compression and also
s preferably inCln~es a suhst~nti-slly longitudinal comrQnçnt of tension.
How~:ver, the lo~git~ insl co-~ ~o,~ent of te~C;on is not eq~ ed in the
e~tinvention. The se~ior oftape ..~ o~d the protected wire
b~n~lle is s~lffi~ nt to ensure enough çnc~rsulant on the outside of the
wire bundle to seal a~in~t mni~t~lre.
:D
In one form of the particularly preferred embodiment of the
illV~ ;or, a wrap of vinyl tape may be ~lie~ to the protec~l wire bundle
to msin~sin it sealed with ~nce~rs~ s-nt and to lJ-e~ t the novel s~sling
tape from unwlal ~illg. Additionally or alternatively, a compressive force
aj may be ~pplie~l over the sealed wire bundle to msints~in the wire bundle in
its sealed c~n~lition~
The wires may be positioned in an optimal arrangement so as to
ellt wicking thereon.
:D
Other features and advantages of the present invention vvill appear
from the following description in which the preferred embodiment has
been set forth in detail in conjunction with the -~ccv~ .A~.ying drawings.
WO 94/lC884 PCTlUSg4/00555
21 ~ 1 8 0
~fnf~on;~f~
Fig. 1 is a cross sectional view of the preferred embodiment of a
seAling delivery system constructed in accordance with the present
5 inv~n~ion
Fig. 2 is a cross sectional view of the invention of Fig. 1 upon
application of force.
o Figs. 3A - 3C are srhemA~ic cross sectional views of the i~ elll ion in
its preferred application.
s Referring now to the Figures, Figs. 1 and 2 illustrate a se~li~
delivery system 2 including a center, seAline material layer or
en< ApslllAnt 4 sandwiched bel~ eell retic~llAte layers of open cell material
6, 8. Upon Ap~ At;on of a force, I,lefe~sbly a compressive force, to
se~lin~ delivery system 2, the se~linF material moves through reticulate
layers 6, B in the direction of arrow 12. ~eA~ e material 4 moves throu~h
retic~lste layers 6, 8 to the outer edges 14, 16 of the open cell mater
thereby wetting the tape and providing a tacky surface for seAling, as ~n
at ~f~leuce numeral 20 in Fig. 2.
2j In the l,lafelled emho~lim~nt seAline delivery system 2 is in the
form of a double reticulate tape having a triple layer construction.
Reticulate layers 6, 8 and se~lin~ material 4 are, together, stretched in
the direction of arrow 10. Each reticulate layer is stretchable, or
elongAtshle, to an extent at least equal to but } lefe~ably greater than the
3D extent of stret~hinE of the seslin~ material layer 4. When compressed,
reticulate layers 6, 8 allow seslin~ material 4 to penetrate the open
structure of the reticulate layers and, thereby provides the wetting and
tack properties of previous gel applications. The relative thicknesses of
reticulate layers 6, 8 and se~slin~ material 4 is sufficient to fill gaps
su~fo~ in~ the surface to be sealed. The open cell layers 6, 8 stretch
elastically with se~ling material 4 to allow the tape to be smoothly applied
to an uneven surface and thereby conform to the uneven surface.
W0 94/16884 PCrlU~4/OOS55
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Force in the direction of arrow 10 applied to se~linE delivery system
2 includes a s~hst~ntially longit~l~in~l component of t~nSion along arrow
10 and a s~htsn~ y perpentlic~ r comronant of ~p-ession as shown
by a,.o~.s 18. Upon apr~ on of the force to tape 2, se~ling material 4
5 penetrates through interstices of open cell layers 6, 8, forming tacky
surface 20 for se~lin~ Upon release of the force, se~ling material 4
reenters back through the interstices of open cell layers 6, 8, again
r~s~ ng in a relatively non-tacky, easily handleable snrf~ce, as shown in
Fig. 1. Thus, layers 6, 8 are selected to have an adhesive af~mity for
se~ling material 4 which is less than the cohesive strength of the sealing
material.
Retic~ te layers 6, 8 are preferably in the form of an open cell
foam, more particularly, a polyester urethane foam. However, it is
s wii,Li~ the scope of the l,~es~,lt invention to utilize a fabric material or
ce structure having interstices through which ~eiqling material 4 can
move or "ooze." In either latter case, the ~flhesive ~~ ,y of the fabric
ms~b~ri~l or lattice structure is less i~l,o, ~t.
a~ The ret;c~ te layers may also be a woven or n~woYe~ fabric, the
fibers of the fabric being natural or synthetic and co~npose-l of organic or
inorganic material. The fibers may be glass, metal or organic polymer
fibers. The fibers of reticulate layers 6, 8 need not themselves be
stretrh~hle, so long as the structure can be elon~ For eY~mple, a
:z; metal mesh material would be suitable for use as a reticulate layer
ac~w~i~ to the present ~ve~ on~
.~li~ m~tJ?ri~l 4 is l"efelably a gel, and more particularly an oil
eYten-le-l triblock copolymer. The most preferred gel of tbe present
3 invention is constructed of a silicone based gel. In alternate
embodiments, tbe se~ling material may be a polyurethane or
thermoplastic gel. Two such ey~mrles are oil extended Kratont~
.ellc cthylene-butylene-styrene) triblock polymers and oil extended
&pton~ (styrene-ethylene-propylene-styrene) triblock copolymers.
Preferably, se~lin~ material 4 is selected to have an ultimate
elQ~ion of at least 100%, especially at least 160% and more preferably at
least 200%. The sealing material is also selected to bave a voland
WO 94116884 PCT/US94/OOSSs
2l5l~8
hardness of between 7.5 and 40 g, especially between 10 and 20 g, and
more particularly between 10 and 15 g.
As is a~l.aleht, the wetting characteristics of gels which may be
used for the present invention differ. Thelefo~e, the choice of open cell
foam must be optimized to ~:l~it the particular gel utilized to penetrate
the interstices of the open cell structure. For e~smrle, a softer seslin~
material will be used with a rehC~ s-te material having a smaller average
cell 6ize while a harder se-s-lin~ material may be used with a reticulate
o material having a larger average cell size. Additionally, the sealing
material may be a center layer of foam impreEn-st~ with a gel.
~ e~linE material 4 is bonded, preferaWy chemically bonded,
betwccn reticlll-s-te layers 6, 8. A roll of se-s-linE material is joined with two
~s rolls of reticlll~t~l tape, thereby forming se~s-lin~ material layer 4
~ osed be~ reticulste layers 6, 8. Tension of the se~s-lin~ material
and open cell maten~l is sufficien~dy mstche~l such that tape 2 cures as
the joined rolls are ~mhled Optimally, e~ch open cell layer 6, 8 has a
~ kn~8 of 0.030 inrhes, and a ~ osi~ of 100 pores per square inch with
a~ a m~yimu_ hole ~i~met~r of 0.020 in~hes. The ~lefel,el thickness of
se~linE material 4 difers 1epen~1in~ upon the application. For uniform
PlP~nt6 to be sealed, the l.,efe~,ed tl i~ness of se~linF material layer 4
is 0.030 in~hes. Thus, the l,~afe~ed ratio of relative thirkness of layers is
1:1:1. For elemPnts to be seiqling having varying configurations, the
se~ E matenal layer ~lefe~bly has a thirkness of a~l.lo~ately 0.060
in~hes In this case, the preferred ratio of thickness of layers is 1:2:1.
The relative thirknesses of reticulate layers 6, 8 and se~linE material 4
1et--...;..e the ne~sP~ry forces to adequately move through the interstices
of reticulate layers 6, 8 and provide a se~lir~ effect.
Reticulate tape 2 may be employed in any sealing application. A
force applied to the tape, including a substantially perpendicular
co~npQnPnt of cG~-ession 18, causes se~linE material or encapsulant 4
to move through the interstices of open cell layers 6, 8, to outer edges 14,
16 of the tape, thereby providing a tacky, se~lin~ surface 20. In the
preferred embodiment, the force also includes a substantially
longitudinal component of tension, e~æin~ movement of the sealing
m:~ef i:~l through the open cell layers.
W09411C884 2151~8o PCTJUS94/005ss
Upon removal of force 10, tape 2 returns to its original
configuration shown in Fig 1. ~e~lin~ material 4 reenters back through
the interstioes of open cell foam layers 6, 8, again resulting in a relatively
non-tacky, easily handleable surface.
In the most preferred application, double reticulate tape 2 is used to
protect a wire bundle from moisture. A piece of reticulate tape is
provided. To seal a bllndle of 10 to 15 wires, a piece of tape a~ tely
6 inches is necess~ . Referring to Fig. 3, two individual wires, 24, 26 are
pulled from the bundle (not shown). The end of the reticulate tape is
pinched be~w~ll the wires, 8S shown at lefelc~ce numeral 22. The tape
is then wrapped around both ~nres, as seen in Fig. 3A. Light ten~ion is
A~plieA in the direction of arrow 10, ~llci~E Pnc~ps~ nt 4 to penetrate
re~ te layers 6, 8, providing a tacl~y surface at 20 and providing a
mo;ct~re seal a,ouIld wires 24, 26. Colllylessive force 18, as shown in
Eig. 2, results from the application of force in the direction of arrow 10. A
third wire 28 is selected and pulled from the bundle and placed adjacent
outer edge 16 opposite wires 24, 26. The force in the direction of arrow 10
is m~...tci.~e~ Additional wires, such as wire 30 shown in Fig. 3C, are
selecte-l from the bundle and the above steps rep~te-l until all wires from
the bundle are wrapped. As the wrapped and sealed bundle grows,
multiple wires can be added simultaneously, so long as they are
sey~ated by 180 degrees. Once all wires from the bundle are wrapped,
an ~d~ Qn~l turn is made around the wrapped wire bundle to ensure
sl7ffi^ient sealine material on the outside of the bundle to adequately seal,
and thereby protect the bundle from moisture.
With large wire bundles, it may be necessary to position the wires
in an optimal al,a~ent so as to l,levent wicking thereon.
If desired, a member, such as a grommet, for applying a
co~lessive force over the sealed wire bundle maintains the wire bundle
sealed with enc~rsulant. Additionally or alternatively, a wrap of vinyl
tape is applied to the bundle to l,revel~t reticulate tape 2 from unwrapping.
Although the preferred embo~liment is directed to sealing material
sandwiched between two layers of open cell material, it is within the
wos4n6ss4 215l~8o PcTlusg4~s~
-1~
scope of the present invention to provide a se~ling material disposed
~1jr cent a single layer of open cell material. The se~linE delivery system
of the present invention can be employed to address a variety of sealing
app1ic~tionc. Vari~tionc and mo~lific~tion~ can be made to the preferred
5 Pmbo~limPnt without de~a~ g from the scope of the present invention,
wbich is l;mit~ only ~y the following ~l~im~.
