TE Connectivity Single Wire Seal & Cavity Plug Solutions

TE Connectivity's (TE) Single Wire Seal (SWS) and Cavity Plug Solutions include various wire sizes and connector cavities designed for automotive connector systems. These solutions effectively prevent contaminants from entering the connectors, enabling safe and reliable connections. Suitable applications for the SWS and Cavity Plug Solutions from TE include safety systems, powertrain systems, driver information, chassis systems, and entertainment. Cavity plugs feature a silicon rubber material with a ShA hardness of 50 to 60 and provide a high level of seal retention in the cavity.

SWSs are generally made of liquid silicon rubber for high mechanical resistance, and offer three different interfaces that use a multi-lip configuration, creating layers of redundant sealing: seal-to-wire, seal-to-contact, and seal-to-cavity.

Seal-to-Wire

This SWS is automatically placed on the wire where the outer diameter is within the defined range. The wire size is linked to the hole dimension and is smaller in diameter to achieve the required geometric interference for sealing. Seal geometry with two to three lips is used to provide point-distributed sealing pressure against the cable.

Seal-to-Contact

The seal is crimped onto the contact, and the crimp quality is fundamental for a proper seal-to-contact interface. The outer diameter of the "crimping zone", the length of the neck where the terminal crimp hugs the silicone, and the presence or absence of a collar are vital parameters to ensure the contact barrels close and retain the SWS without cutting the surface.

Seal-to-Cavity

Sealed contacts are inserted into the cavity. The difference between the seal's outer diameter and the cavity diameter results in radial compression of the rubber element and a consequent sealing pressure at the interface. This design increases closure pressure at the wire interface, tightening the fit towards the cable.

Features

Broad, complete portfolio providing a one-stop shop solution for automotive applications
Increased performance, safety, and longevity of your electrical connection field
IP67 waterproof protection
Cavity compatible with some competitor terminal systems
Global manufacturing footprint and integrated supply chain
Harness automation ready
48V architecture enabled

Cavity Plugs
- Silicon rubber material selection with a ShA hardness ranging between 50 to 60
- High-level seal retention into cavity
SWS
- Lip configuration creates multiple layers of redundant sealing
- Silicon rubber offers a high mechanical resistance in numerous operating temperatures
- Material hardness specified at 50 to 60 Shore A durometer
- Lubrication for wire passage through the seal to reduce damage when inserted into the cavity

Applications

Harsh Environment Automotive
- High vibration
- Elevated temperatures and high current capabilities
- Wire-to-wire, wire-to-board, and wire-to-device
- Powertrain systems
- Safety systems
- Door-to-body
- Driver information
- Convenience and entertainment
- Chassis systems