PRODUCTAND METHOD FORWIRE SEAL

This invention relates to a product and method for performing a wire seal.

Wire splices are commonly used in electrical harnesses in the automotive industry. The invention is of particular benefit in such applications, although it is applicable in other situations in which it is needed to seal splices in a production environment.

Dimensionally recoverable tubing is often used to protect spliced wires within electrical harnesses in the automotive industry. One of the most common splice configurations is an "in-line splice". In an in-line splice each wire to be spliced has its electrically insulative covering removed e.g. at one end, or at one or more other locations to expose bare electrically conductive wire. The wires to be joined are then arranged as required with all of the exposed bare wires essentially parallel and overlapping each other. Some other kinds of splice do not involve removal of an insulative covering.

The typically but not necessarily bare wires are then crimped, welded, soldered or otherwise joined together to form a splice "nugget". Subsequently, the nugget and the adjacent exposed conductors must be protected and sealed from the external environment. A preferred means for protecting the nugget and sealing out moisture and other contaminants is to encase the nugget in a dimensionally recoverable tubing which has a sealant/adhesive interior layer ("liner"), thereby forming a wire seal. Typically, heat is applied to cause the sealant/adhesive liner to flow, while simultaneously causing the tubing to heat-recover (shrink) about the nugget. The tubing shrinks around the exposed wires and the adhesive/sealant flows within the tubing to cover and seal the exposed wires. The adhesive/sealant also flows along the wires to contact and cover a portion of the unstripped, electrically insulative wire covering. This provides a seal over the entire length of the exposed wires and the splice nugget, up to and including the beginning of the insulative wire covering, and thus prevents water from entering the splice and/or

from flowing along the conductors inside the wire insulation. Wire butt splices and wire splices to ring terminals or other termination devices can also be sealed and protected in this way.

In addition connectors may be sealed against water ingress and bundles of wires blocked using adhesive inserts in combination with heat shrink tubing.

The complexity of vehicle harnesses, and the number of wire splices incorporated in the harnesses, are increasing due to the growing number of electrical functions on modern vehicles. As a result, vehicle manufacturers are using an increasing number of splice sealing products to ensure electrical integrity and guarantee reliability. In order to maximise productivity and minimise cost, it is therefore a requirement of any automotive splice sealing product that the time taken to create a seal should be a minimum.

A variety of heat-shrinkable splice seal sleeves are commercially available. An example of these is dual- wall heat-shrinkable splice seal sleeve Raychem RBK- ILS- 125 (trademark), available from Tyco Electronics. This splice seal comprises a tubular construction having an outer cross-linked polymer heat-shrinkable sleeve in combination with an inner heat-flowable adhesive/sealant liner.

When heated, the tubing shrinks and the adhesive/sealant layer melts and flows. Such products are well known in a range of different materials and sizes, and are used in various industries for environmental sealing of cable and wire splices. The products are installed by sliding the sleeve and liner over the area to be sealed and heating using a heat gun, flame, infrared, or other heat source to shrink the tubing. The minimum time taken to achieve a sealed splice depends on a number of factors including the number and size of the component wires that make up the splice, the size of the tube, the recovery temperature of the tube, the melting temperature of the adhesive liner, the viscosity of the liner at the recovery temperature, the hoop stress of the tubing at the recovery temperature, the

temperature of the copper nugget, the type of heating device employed and its thermal characteristics.

The invention as set out herein includes within its scope all such splices, harnesses, seals and blocks as may be formed using dimensionally recoverable tubing having a liner that may be caused to flow on heating. Thus the invention includes, in addition to the aforementioned structures, structures such as ring terminal seals, stub splice seals, various kinds of connector seal and various kinds of bundling block.

For convenience herein all such structures are referred to as "splices" and, as the context requires, "splice seals", although in practice some of the structures to which the invention relates may not require actual splicing together of conductors or other filaments.

A problem with known heat-shrinkable splice seal sleeves, especially in high- volume production of wiring harnesses to be installed into cars and other vehicles, is that they have either generally been of the rapid installation type, or high temperature rating, but it has not been possible to achieve both in the same product due to conflicting requirements for the flow characteristics of the adhesive.

Rapid installation type splice seal sleeves generally comprise an adhesive with relatively low viscosity at the installation temperature. This rapid installation characteristic makes them commercially attractive, especially in high-throughput environments. However, the adhesive in such splice seal sleeves typically flows excessively in service at the rated temperature, which renders it unsuitable for high temperature environments. Alternatively, high-temperature resistant splice seal sleeves tend to be manufactured with an adhesive which has relatively high viscosity at the service temperature, rendering them suitable for use in high temperature environments, but which adhesive slows down the rate of product installation, thereby undesirably slowing the production process. In particular,

although the manufacturing process is only slowed by a few seconds with high- temperature rated splice seal sleeves, compared to rapid installation ones, when production is carried out on a large scale, as it is in the automotive industry, the extra delay results in a significant cost penalty.

Once installed, the splice seals must meet certain specification requirements which are designed to reflect the use environment. In the automotive industry these specifications include sustained sealing during immersion in fuel, temperature cycling and high temperature flow withstand, to reflect the engine compartment environment. To meet these requirements and sustain a seal the installed adhesive must be resistant to flow at relatively high temperatures. Two of the key requirements for an automotive splice seal are rapid installation and, once installed, minimal adhesive flow in a vertical position at 150°C. The technical solutions to these requirements are in direct conflict — low adhesive viscosity for rapid installation, and yet high viscosity for flow inhibition once installed.

It is known from EP-A-376461 to provide hot-melt adhesives comprising ethylene vinyl acetate (EVA) copolymers, which copolymers additionally comprise 1% to 15% fumed silica. The hot melt adhesives are typically used may be used to provide glue sticks which may be used in hot-melt guns. The resultant glue sticks are said in use to be less prone to stringing, and to provide a sag-resistant melt.

US-A-3983070 describes adhesives which are said to be particularly useful in bonding polymeric materials used in encapsulation and termination of insulated electrical conductors. The adhesive comprises a polar copolymer of an α olefin and an inorganic silicon-containing compound. The adhesives used in the context of this document are said to be particularly useful for providing the internal coatings of heat-shrinkable sleeves and end caps for cable joints and termination, especially in telephone cables, and preferably have a melt flow index less than 5. The use of the silica-containing adhesive is said to increase the strength of the bonds obtained between cross-linked polyethylene and the lead sheaths of cables, as well as to provide a high peel strength at temperatures as high as 7O ⁰ C.

Telephone cables however typically have dimensions which are substantially greater than those contemplated by the splice seal sleeves of the present invention.

From the description, the silicon-containing compound in this document is a chemically treated silica filler, for example Aerosil R972. The resultant adhesive is said to provide a high bond strength when e.g. bonding a polymeric material to another polymeric material, or to another substrate, and also to provide desirable electrical characteristics, and may particularly be used where heat-recoverable materials are used to effect the encapsulation or termination.

In a first aspect of the invention there is provided a heat-shrinkable tubular article for sealing a wire splice comprising (i) a heat-shrinkable jacket material, and (ii) a thixotropic heat-flowable inner adhesive layer, the tubular article having at least one of a maximum internal diameter no more than 15mm or a maximum length no more than 100mm. In some instances, the tubular article may have both of these maximum dimensions.

The thixotropic heat fiowable adhesive comprises an adhesive which contains an additive which provides the adhesive with thixotropic properties. Conveniently the additive is silica; surprisingly in the context of US 3,983,070 we have found that untreated silicas work well and may be preferred.

The adhesive used in the invention can be any adhesive, provided it is a hot melt, adhesive that has good filler compatibility. It is highly preferable that the adhesive has a Melt Flow Index greater than 5, as determined by ASTM D 1238 (modified). Conveniently, the thixotropic adhesive (Le. incorporating the thixotropic additive) has a Melt Flow Index greater than 10, preferably greater then 20, preferably greater than 50, and in some embodiments preferably greater than 100 or even greater than 500. Conveniently the adhesive is an ethylene vinyl acetate (EVA) copolymer adhesive. Preferred EVA copolymer adhesives have a vinyl acetate content of 15% to 40% w/w; particularly EVA copolymer preferred adhesives have a vinyl acetate content of 25% to 28% w.w.

It is highly desirable that the adhesive is a high flow thixotropic adhesive; by this is meant that the adhesive flows under the installation conditions to block and seal the joint seal, but in subsequent use it must not flow significantly at 150 ⁰ C.

In more detail, it is highly preferable that the adhesive used in the heat shrinkable tubular article flows under shear at a temperature of less than 130 ⁰ C, preferably less than 120 ⁰ C. In such instances, the shear is provided by the heat recoverable jacket material shrinking. However, the adhesive preferably must not flow at a temperature of 150 ⁰ C.

In a further aspect of the invention, there is provided a heat shrinkable tubular article for sealing a wire splice comprising (i) a heat-shrinkable jacket material and (iϊ) a thixotropic heat flowable inner adhesive layer, the adhesive layer flowing under shear at a temperature of no less than 130 ⁰ C, but not flowing at a temperature of 15O ⁰ C.

Determination of flow in such instances may conveniently be done by determining whether the adhesive flows substantially from a sealed splice post-installation when hung vertically at the appropriate temperature (e.g. 150 ⁰ C) for 24 hours.

The additive that provides the adhesive with the thixotropic properties, making it a thioxtropic adhesive, is preferably a silica. Suitable silicas for use according to the invention accord to the adhesive thixthropic properties, and are typically high surface area silicas, e.g. fumed silicas, conveniently with a surface area greater than 100m ² /g. Other additives which confer on the adhesive thixotropic properties may also be suitable, and would typically be high surface area mineral fillers, such as for example Bentonite or Garamite. Conveniently, the additive which provides the adhesive with thoxtropic properties may present in the adhesive at a level of 1% to 15% by weight, preferably 2% to 10%, and in some embodiments 5% to 7% by weight of the adhesive.

The heat-shrinkable splice seal sleeves of the invention are particularly suitable for use when sealing wire splices, typically with a diameter of less than 12mm. As such, the unrecovered heat-shrinkable splice seal sleeve of the invention will typically have an internal diameter of less than about 20mm, preferably less than about 15mm.

Since they are only used for sealing splices made up from wires, in contrast to the cable seals and end caps described in US 3,983,070, the heat-shrinkable tubular articles according to the invention typically have a length no more than 100mm, and in certain preferred embodiments less than 80mm or less than 70mm.

According to a further aspect of the invention, there is provided a method of forming a splice seal between two or more wires including the steps of (i) heating a heat-shrinkable tubular article (e.g. sleeve) having a heat-shrinkable jacket material and a heat-flowable thixotropic inner adhesive layer, and (ii) causing the heat-shrinkable tubular article to shrink and form the splice seal.

In a further aspect of the invention there is provided a method of forming a heat- shrinkable tubular article suitable for forming a splice seal between wires, comprising the step of co-extruding a heat-shrinkable jacket material and a heat- flowable thixotropic inner adhesive layer. Preferably, the co-extruded jacket material and adhesive layer article is then cut to lengths no longer than 100mm.

The heat-shrinkable splice seal sleeves of the invention incorporating the adhesive containing the thixotropic additive have been found to confer on the splice seal sleeve, and the resultant wire splice seal not only good high temperature resistance, and thereby passing the requisite vertical drip performance tests, but also surprisingly good (i.e. rapid) installation times. The rapid installation times observed help maintain the economic benefits of known fast shrink splice seal sleeves, and are surprising in the light of the incorporation of a thixotropic additive, which might otherwise have been expected to slow down installation times.

The heat shrinkable splice seals of the invention are suitable for use in any known seal forming procedure, using known equipment for heating and forming such splice seals.

A suitable heating device for forming a splice seal according to the invention is a RBK Processor MkII, available from Tyco Electronics.

A preferred heat-shrink tubular article, suitable for use in a method according to the invention has a clear (that is substantially non- light-absorbing) jacket and black liner and is based on the high density polyethylene jacket of the Tyco

ESlOOO product in combination with an EVA based liner containing 7% fumed silica, with a surface area of 200m ² /g, and 0.5% colour masterbatch, which incorporates the equivalent of 0.0125% carbon black. The jacket and liner are co- extruded to create an effective interface for heat transfer from the liner to the jacket.

To seal a splice a sealant material must flow around and between the bare component wires of a metal nugget where the polymer insulation has been removed. In a dual wall heat-shrink product the liner must therefore be heated to the point at which the adhesive will flow under the shear generated by the shrinking jacket material, and must then be forced in to and around the nugget and insulation by the heat-shrink jacket. It is also important that the resultant seal should be able to block the ingress of water.

Preferably the jacket and liner used in such a method are co-extruded. It is also preferable that the liner is or includes a layer of adhesive material. In an alternative arrangement the inner layer (liner) may be coated onto the jacket interior.

Examples

The invention will now be further described with reference to the accompanying examples.

Example 1 An EVA adhesive comprising 92% EVA copolymer (28% vinyl acetate, MFI 500dg/min), 5% tackifier and 3% antioxidant was utilized. The adhesive has been used in quick-shrinking splice sealing products, and will typically generate a splice seal in approximately 5 seconds. However at temperatures of 120°C or higher, when the splice seal is vertically suspended, the adhesive flows and drips out of the sealed splice area, which renders it unsuitable for use in certain European applications.

Experimental

The adhesive was mixed with a small internal mixer (Brabender) with fumed silica of surface area 200m ² /g (5% & 7% addition level, see table below) and carbon black (0.0125wt%). The filler was added at 12O ⁰ C, and was mixed at 32 rpm for 15 minutes.

From each mix, 0.2 to 0.3mm thick slabs were pressed at 160 ⁰ C.

The heat-shrink jackets used were hand-prepared. Thus, a splice seal product, ESlOOO, available from Tyco Electronics, had the adhesive lining carefully removed, leaving the high density polyethylene heat-shrink jacket material. Measured sheets of adhesive prepared as described above were cut such that there was minimum overlap of adhesive when rolled and placed inside the heat-shrink jacket material. The jacket/adhesive assembly was then placed onto a 10mm PTFE mandrel, which was heated inside an infrared heating device, to melt the adhesive and consolidate the jacket and adhesive. After cooling in cold water, the dual wall product was removed from the PTFE mandrel.

The samples were used to seal splices in. an RBK Processor MkII, available from Tyco Electronics, which processor was set at 500°C. The splices prepared were 7:4 1.5mm ² , i.e. on one side of the splice were 7 x 1.5 mm ² wires, on the other side were 4 x 1.5mm ² wires.

The time taken to seal was the shortest time in which 5 consecutive samples were installed and passed a 1 bar air pressure test.

Drip performance 5 samples of each sample type were suspended vertically in an air circulating oven at the temperature shown in Tables 1 and 2. The distance moved by the adhesive was recorded as the drip performance.

Observations Examples are given in Table 1 showing the effect on installation characteristics (time to seal) and elevated temperature performance (resistance to drip) when a preferred type of particulate filler, e.g. fumed silica, is used.

Table 1

The examples given in Table 2 are by way of comparison showing the effect on installation and elevated temperature performance when an alternative type non- preferred non-thixotropic particulate filler (e.g. magnesium hydroxide) was used.

Table 2

¹ Drip performance measured on splice hung vertically in an air circulating oven. Adhesive flow measured in mm after 24 hours. N.B. maximum value measurable = 250mm.

Conclusions

Table 1 shows the effect of fumed silica on adhesive drip performance, i.e. 0 mm being no drip, and therefore best. Addition of 5% or 7% fumed silica eliminated drip at temperatures up to 150°C, but had no measurable detrimental effect on installation time.

It is thought that the adhesive with fumed silica is acting in a thixotropic manner. That is, at low shear rates the material is relatively viscous, resisting drip, whereas at higher shear rates (driven through small wire gaps by recovery of the heat- shrinkable outer jacket) the material has lower viscosity, allowing relatively easy installation.

Therefore, in this system, there is a benefit in drip performance without any apparent penalty in installation time.

If an alternate non-thixotropic particulate filler is added to the EVA adhesive, the effect is not readily observed, as shown in Table 2. In this case as the quantity of magnesium hydroxide is increased, the improvement in drip performance is modest, and could be explained by filler increasing the viscosity of the base material. In any event the drip properties at 120°C and 130 ⁰ C suggest the adhesive would be unsuitable for service at 125 ⁰ C.

With the magnesium hydroxide filler, as the quantity increases so the installation time increases; this too could be a result of increasing viscosity by filler addition.