Two-shot LSR molding and recessed rear seals combine to lock-out the contaminants of engines, pumps, breaks and other operations while reducing decades-old sealing failures.
BUSINESS CHALLENGE
For Commercial Vehicle applications such as trucks, agricultural machinery, boats and many others, the main priority is durability. Required to work long hours in harsh conditions, the reliable performance of these vehicles can make or break an operation. After daily contact with water, fuel and other contaminants, these vehicles can experience electrical system malfunctions and failures if the connector system seals are ineffective or compromised.
For decades, the same sealed connector system has been used in manufacturing. As products have become exponentially more complex electrically, two critical sealing issues have been observed:
Contaminants such as chemicals and fuel cause the chemical cross-link structure within the silicone seal material to break down. This significant weakening of the bond between the seal and the connector renders the seal completely ineffective. These weakened seals are likely to fail during insertion into a harness, and will even arrive at harness facilities already detached.
Due to the rugged nature of these applications, cables often bend near their connector entry points. These bends occur in the field, as well as during the wire harness to vehicle connection process. A bend within 2.50cm of entry into these connector systems pulls at the seal and creates leak paths, enabling the ingress of a host of contaminants.
Manufacturers of these connectors have tried additional covers and attachments to try and solve these problems, but have just created more issues in the process. These covers are ultrasonically spot-welded, which results in brittle joints, cover and connector failure, and significant costs to the customer.
Commercial Vehicle applications will only continue to rapidly increase in electrical sophistication, thus increasing the number of sealed connections that the overall performance will rely upon. A sealed connector system that can eliminate critical failures, and keep systems running much more reliably is desirable.
SOLUTION
The ML-XT™ Sealed Connection System from Molex has completely redefined seal reliability with multiple breakthrough innovations. Two-shot LSR (liquid silicone rubber) molding eliminates the seal-bonding issues seen in traditional connector systems. Creating a covalent bond between the seal and the connector body, this two-shot LSR technique permanently connects the two components at a molecular level, combining two components into one connector. This makes concerns over seal positioning and movement a thing of the past.
HCR (high-consistency rubber) recessed rear seals completely resist movement during cable routing. Protected by a rigid back cover, the seal allows flexible cable movement, and its recessed, fixed nature significantly reduces the leak-paths found in traditional designs.
A wedgelock terminal position assurance accessory locks the terminals in position, creating a reliable electrical contact. Further features such as an enhanced locking latch and latched back covers deliver unparalleled mating and housing reliability.
Solutions such as two-shot LSR molding and HCR rear seals deliver full IP68, IP69K and SAE J2030 compliance. With unique offerings such as a complete 18-circuit connector system, field-proven XRC™ terminals, colour coded housings and custom options, the ML-XT™ Sealed Connector System delivers reliability improvements to any design.
Delivered fully assembled and leak tested, Molex’s ML-XT™ Sealed Connector System offers superior reliability for critical vehicle-wiring applications in harsh environments.
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