Systems and methods for sealing electrical terminals

Abstract

A sealing device and method for sealing an electrical terminal. The sealing device includes a heat shrink tubing having an inner wall. A first sealant / adhesive is configured to cooperate with the heat shrink tubing. The first sealant / adhesive has a first sealant / adhesive first surface and an opposite-facing second sealant / adhesive surface. The second sealant / adhesive second surface is adhered to the inner wall of the heat shrink tubing. A second sealant / adhesive is configured to cooperate with a free end of an electrical conductor that electrically engages the electrical terminal. The second sealant / adhesive has a second sealant / adhesive first surface and an opposite-facing second sealant / adhesive surface. The first surface of the second sealant / adhesive is provided in engagement with the electrical conductor. The second surface of the second sealant / adhesive is provided in engagement with and adhesion to the first surface of the first sealant / adhesive.

Description

[Technical Field]

[0001] The present invention relates to a sealing device and method for sealing electrical and mechanical terminations between electrical conductors and electrical terminals, and more particularly to a sealing device and method that allows sealants / adhesives of different viscosities to be applied to the terminal area to provide a proper seal. [Background technology]

[0002] Ring terminals are typically used to attach electrical wires to studs or posts (such as those found on vehicle and other batteries) and are manufactured in a variety of types and sizes. Ring terminals typically include a ring portion and a wire attachment / connection portion to which the wire is connected by welding or other means. Non-insulated ring terminals can be crimped or soldered and may be finished with heat shrink tubing to insulate and protect the connection formed between the wire and the wire attachment portion of the terminal. Heat shrink tubing (HST) is a shrinkable plastic tube commonly used to insulate electrical wires. HST provides abrasion resistance and environmental sealing protection for stranded and solid conductors, splices, joints, and terminals used in a variety of electrical applications. HST can also be used to repair damaged insulation on electrical wires, bundle wires, and install cable entry seals. As mentioned above, HST can be a single-layer system or a multi-layer system, and a multi-layer system includes at least one heat-shrinkable layer and at least one layer of a sealant system. Heat-shrink tubing is typically made from fluoropolymers or polyolefins that shrink radially when heated. The process by which HST shrinks is referred to as the "recovering" of the HST, and the predetermined temperature at which the HST begins to recover is referred to as the "recovery temperature." When the HST recovers, or shrinks, it exerts an inward force on the item it encloses, which is referred to as the "hoop stress" of the HST. More specifically, hoop stress (also known as cylinder stress) is the force exerted circumferentially (perpendicular to both the axis and radius of the object) on all particles in the tube or cylinder wall in both directions. The degree of hoop stress is determined by specific HST characteristics, such as the type of substrate, wall thickness, degree of crosslinking, and degree of expansion. Hoop stress is also affected by process parameters, such as the recovery temperature and degree of recovery.

[0003] Ring terminals currently used in passenger car and commercial vehicle electrical systems include single-wire and multi-wire configurations. Multi-wire configurations present significant challenges with regard to sealing the terminal-wire interface area of ​​the terminal. Previously, external sealant systems, including the use of heat-shrink tubing and adhesive / sealant layers, were used to create a watertight seal between and around the wires attached to the terminal. However, existing sealant systems cannot easily and reliably seal the multiple wires (e.g., six or more wires) included in multi-wire configurations. The first problematic condition relates to the wicking of water (if present in the operating environment). Water can penetrate from the ring portion of the terminal to the wire attachment portion of the terminal, then onto the attached wire, and through the welded or crimped interface from one end of the wire to the other. Water can also penetrate between the wires and into the terminal. The second problem relates to the flow or seepage of excess adhesive or sealant into the ring portion of the ring terminal. Adhesive present in the ring portion can prevent the metal-to-metal contact necessary for effective electrical contact.

[0004] Current industrial approaches to overcome the limitations of sealing systems involving the use of external adhesives and heat shrink tubing involve multi-component, multi-step processes that are labor-intensive and expensive. Therefore, there is a continuing need for a sealing system for use with ring terminals that meets all functional requirements in a simple, reliable, and cost-effective manner. Summary of the Invention

[0005] The following provides a summary of certain exemplary embodiments of the invention. This summary is not an extensive overview and is not intended to identify key or critical aspects or elements of the invention or to delineate its scope.

[0006] One embodiment relates to a sealing device for sealing an electrical terminal. The sealing device includes a heat shrink tube having an inner wall. A first sealant / adhesive is configured to cooperate with the heat shrink tube. The first sealant / adhesive has a first sealant / adhesive first surface and a second sealant / adhesive second surface facing the opposite side. The second sealant / adhesive second surface is bonded to the inner wall of the heat shrink tube. The first sealant / adhesive has a first viscosity. The second sealant / adhesive is configured to cooperate with a free end of an electrical conductor in electrical engagement with the electrical terminal. The second sealant / adhesive has a second sealant / adhesive first surface and a second sealant / adhesive second surface facing the opposite side. The first surface of the second sealant / adhesive is provided in engagement with the electrical conductor. A second surface of the second sealant / adhesive is provided in engagement with and adhesion to the first surface of the first sealant / adhesive, the second sealant / adhesive having a second viscosity that is lower than the viscosity of the first sealant / adhesive.

[0007] One embodiment relates to a sealing device for use with a cover for sealing a conductor of an electrical terminal, the cover having an inner wall. The sealing device includes a first sealant / adhesive and a second sealant / adhesive. The first sealant / adhesive is configured to cooperate with the cover. The first sealant / adhesive has a first sealant / adhesive surface and an opposite-facing second sealant / adhesive surface. The second sealant / adhesive surface is adhered to the inner wall of the cover. The first sealant / adhesive has a first viscosity. The second sealant / adhesive is configured to cooperate with a free end of the conductor that electrically engages the electrical terminal. The second sealant / adhesive has a first sealant / adhesive surface and an opposite-facing second sealant / adhesive surface. The first sealant / adhesive surface is provided to engage with the conductor. The second sealant / adhesive surface is provided to engage and adhere to the first sealant / adhesive surface. The second sealant / adhesive has a second viscosity that is lower than the first sealant / adhesive. Upon application of heat, the first sealant / adhesive conforms to the interior wall of the cover. Upon application of further heat, the second sealant / adhesive and the first sealant / adhesive melt and flow across the free ends of the conductors, filling any voids that exist between the conductors.

[0008] One embodiment relates to a method of sealing an electrical conductor to an electrical terminal, the method including fabricating a sealing device having a first sealant / adhesive and a second sealant / adhesive, and adhering the first sealant / adhesive to an inner wall of heat shrink tubing, the first sealant / adhesive having a first sealant / adhesive surface facing the first sealant / adhesive and an opposite facing second sealant / adhesive surface, the first sealant / adhesive having a first viscosity, and the second sealant / adhesive having a second sealant / adhesive surface facing the second sealant / adhesive and an opposite facing first sealant / adhesive surface, the first surface of the second sealant / adhesive adhering to the second surface of the first sealant / adhesive, and the second sealant / adhesive having a second viscosity that is lower than the first viscosity of the first sealant / adhesive.

[0009]

[0013] Additional features and aspects of the present invention will become apparent to those skilled in the art upon reading and understanding the following detailed description of the illustrative embodiments. As will be appreciated by those skilled in the art, additional embodiments of the present invention are possible without departing from the scope and spirit of the present invention. Accordingly, the drawings and associated description should be regarded as illustrative in nature and not restrictive. [Brief explanation of the drawings]

[0010] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate one or more exemplary embodiments of the invention and, together with the general description above and the detailed description below, serve to explain the principles of the invention:

[0011] [Figure 1] FIG. 1 is a perspective view of an exemplary sealing device for sealing an electrical terminal according to the present invention, showing a heat shrink tube provided with a layer of sealant / adhesive. [Figure 2] FIG. 2 is a cross-sectional perspective view of the device of FIG. 1, showing the heat shrink tubing component of the device prior to recovery. [Figure 3] FIG. 3 is a top view of the layered sealant / adhesive of FIG. [Figure 4] FIG. 4 is a bottom view of the layered sealant / adhesive of FIG. [Figure 5] FIG. 5 is a side view of the layered sealant / adhesive of FIG. [Figure 6] FIG. 6 is a schematic side view of a ring-type electrical terminal including a plurality of wires attached to a wire attachment portion, shown after the sealing device of FIG. 1 has recovered from a heating source, illustrating the distribution of adhesive between the wires. DETAILED DESCRIPTION OF THE INVENTION

[0012] The description of illustrative embodiments consistent with the principles of the present invention is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In describing the embodiments of the invention disclosed herein, any reference to direction or orientation is intended merely for convenience of description and is not intended to limit the scope of the invention. Relative terms such as "lower," "upper," "horizontal," "vertical," "above," "below," "up," "down," "top," and "bottom," as well as derivatives thereof (e.g., "horizontally," "downwardly," "upwardly," etc.), should be construed as referring to the orientation shown in the drawings being described or discussed. These relative terms are for convenience of description only and do not require that the device be constructed or operated in a particular orientation, unless expressly indicated as such. Terms such as "mounted," "affixed," "connected," "coupled," "interconnected," and the like, unless expressly stated otherwise, refer to a fixed or attached relationship of structures to one another, directly or indirectly through intervening structures, as well as a movable or fixed attachment or relationship. Furthermore, the features and benefits of the present invention are described by reference to preferred embodiments. Therefore, the present invention should not be limited to the preferred embodiments, which illustrate some possible, non-limiting combinations of features that may exist alone or in combination with other features; the scope of the present invention is defined by the appended claims.

[0013] Exemplary embodiments of the present invention will now be described with reference to the drawings. Reference numerals will be used throughout the detailed description to refer to various elements and structures. Although the following detailed description contains many details for purposes of illustration, those skilled in the art will appreciate that many variations and modifications to the following details are within the scope of the present invention. Accordingly, the following embodiments of the present invention will be described without loss of generality to, and without imposing limitations on, the claimed invention.

[0014] Referring to the figures, FIG. 1 provides a diagram of an electrical terminal 10 compatible with the systems, methods, and devices of the present invention. The electrical terminal shown in FIG. 1 is a ring-type terminal. However, the systems, methods, and devices of the present invention are compatible with many other types of electrical terminals, such as spade terminals, hook terminals, flag terminals, push-on terminals, etc. Referring to FIG. 1, the electrical terminal 10 includes a terminal mounting portion 12 and a wire mounting portion 14. The terminal mounting portion 12 is configured to connect to a complementary terminal, such as a stud or post, of an electrical device, such as a battery. The wire mounting portion 14 is configured to connect to one or more electrical wires, such as a plurality of wires 16, and may be connected by welding, soldering, crimping, or other suitable attachment methods.

[0015] 1-5, an exemplary embodiment of an electrical terminal sealing device 20 of the present invention is shown. The device 20 includes a portion of shrink tubing 22, a first strip of a first sealant / adhesive 24 (e.g., a planar member, strip, or other profile), a second strip of a second sealant / adhesive 26 (e.g., a planar member, strip, or other profile), a third strip of a third sealant / adhesive 28 (e.g., a planar member, strip, or other profile), and a fourth strip of a fourth sealant / adhesive 30 (e.g., a planar member, strip, or other profile). The first sealant / adhesive 24, the second sealant / adhesive 26, the third sealant / adhesive 28, and the fourth sealant / adhesive 30 are disposed on the shrink tubing 22 before the shrink tubing 22 is disposed on the terminal 10. In various exemplary embodiments, the first sealant / adhesive 24, the second sealant / adhesive 26, the third sealant / adhesive 28, and the fourth sealant / adhesive 30 may be co-extruded.

[0016] The shrink tubing 22 can be a single-layer or multi-layer tubing. The shrink tubing 22 is a polymeric component that shrinks when heat is applied. Such shrink tubing includes, but is not limited to, heat shrink tubing or tape. The term sealant / adhesive includes, but is not limited to, sealants and adhesives that are viscoelastic materials capable of flowing under appropriate stimuli, such as temperature and / or pressure. Examples of such materials include hot melt adhesives and butyl mastics.

[0017] A first strip of a first sealant / adhesive 24 is disposed within the shrink tubing 22. The first sealant / adhesive 24 is a high viscosity sealant / adhesive. In one exemplary embodiment, the high viscosity sealant / adhesive has a viscosity greater than 20 Pa·s at an installation temperature that correlates to a specified or rated temperature. However, the viscosity of the first sealant / adhesive 24 may vary. The first sealant / adhesive 24 has a first sealant / adhesive first surface 40 and an opposite facing first sealant / adhesive second surface 42. The first sealant / adhesive second surface 42 is adhered to the inner wall 34 of the heat shrink tubing 22.

[0018] The first sealant / adhesive 24 is configured to have a melting point lower than the melting points of the other sealants / adhesives 26, 28, and 30. This allows the first sealant / adhesive 24 to be ultrasonically welded to the shrink tubing 22 without prematurely melting or flowing the other sealants / adhesives 26, 28, and 30. For example, the melting temperature of the first sealant / adhesive 24 may be in the range of 105° C. to 120° C., while the melting temperatures of the other sealants / adhesives 26, 28, and 30 may be in the range of 110° C. to 130° C. The lower melting point of the first sealant / adhesive 24 allows the first sealant / adhesive 24 to better adhere to the shrink tubing 22 and the other sealants / adhesives 26, 28, and 30 during assembly of the device 20.

[0019] In the illustrated exemplary embodiment, the first sealant / adhesive 24 has a thickness between 0.25 mm and 1.0 mm. The width of the first sealant / adhesive is equal to or greater than the widths of the second sealant / adhesive 26, the third sealant / adhesive 28, and / or the fourth sealant / adhesive 30. The first viscosity of the first sealant / adhesive 24 is greater than 20 Pa·s at the installation temperature. The first sealant / adhesive 24 is a crosslinkable sealant / adhesive.

[0020] A second strip of second sealant / adhesive 26 is disposed within shrink tubing 22 adjacent or proximate edge 32 of shrink tubing 22. Second sealant / adhesive 26 is a low-viscosity sealant / adhesive. The viscosity of second sealant / adhesive 26 is lower than that of first sealant / adhesive 24. In one exemplary embodiment, as previously described, a low-viscosity sealant / adhesive has a viscosity of less than 20 Pa·s at an installation temperature that correlates to a specified or rated temperature. Second sealant / adhesive 26 has a second sealant / adhesive first surface 44 and an opposite-facing second sealant / adhesive surface 46. Second sealant / adhesive second surface 46 engages and adheres to first sealant / adhesive first surface 40. Second sealant / adhesive first surface 44 faces wire or conductor 16. In the illustrated exemplary embodiment, the first surface 44 of the second sealant / adhesive has a rounded portion 45 adjacent its end, however, the first surface 44 of the second sealant / adhesive may have other configurations.

[0021] A third strip of third sealant / adhesive 28 is disposed within shrink tubing 22. The strip of third sealant / adhesive 28 is spaced from edge 32 and is adjacent to or spaced from the strip of second sealant / adhesive 26. The spacing or distance between the strip of second sealant / adhesive 26 and the strip of third sealant / adhesive 28 depends on, but is not limited to, the structure, size, and application of the terminal. For example, the spacing or distance between the strip of second sealant / adhesive 26 and the strip of third sealant / adhesive 28 may range from 0 mm to 10 mm. Third sealant / adhesive 28 is a high-viscosity sealant / adhesive. In one exemplary embodiment, as described above, the high-viscosity sealant / adhesive 28 has a viscosity greater than 20 Pa s at an installation temperature that correlates to a specified or rated temperature. Third sealant / adhesive 28 has a third sealant / adhesive first surface 48 and a third sealant / adhesive second surface 50 facing the opposite side. The second surface 50 of the third sealant / adhesive is provided in engagement with and adhesion to the first surface 40 of the first sealant / adhesive. The first surface 48 of the third sealant / adhesive faces the wire or conductor 16. In the exemplary embodiment shown, the first surface 48 of the third sealant / adhesive has a rounded shape. However, the first surface 48 of the third sealant / adhesive may have other configurations.

[0022] The strip of fourth sealant / adhesive 30 is disposed within shrink tubing 22. The strip of fourth sealant / adhesive 30 is spaced from edge 32 and is adjacent to or spaced from the strip of third sealant / adhesive 28. The spacing or distance between the strip of fourth sealant / adhesive 30 and the strip of third sealant / adhesive 28 depends on, but is not limited to, the structure, size, and application of the terminal. For example, the spacing or distance between the strip of fourth sealant / adhesive 30 and the strip of third sealant / adhesive 28 may range from 0 mm to 10 mm. The fourth sealant / adhesive 30 is a low-viscosity sealant / adhesive. In one exemplary embodiment, the low-viscosity sealant / adhesive 30 has a viscosity of less than 20 Pa·s at an installation temperature that correlates to the specified or rated temperature, as described above. The fourth sealant / adhesive 30 has a first fourth sealant / adhesive surface 52 and a second fourth sealant / adhesive surface 54 facing the opposite side. The second surface 54 of the fourth sealant / adhesive is provided in engagement with and adhesion to the first surface 40 of the first sealant / adhesive. The first surface 52 of the fourth sealant / adhesive faces the wire or conductor 16. In the exemplary embodiment shown, the first surface 52 of the fourth sealant / adhesive has rounded portions 53 proximate its ends. However, the first surface 52 of the fourth sealant / adhesive may have other configurations.

[0023] In the illustrated embodiment, the strip of fourth sealant / adhesive 30 is the same as or similar to the strip of second sealant / adhesive 26. However, the strip of fourth sealant / adhesive 30 and the strip of second sealant / adhesive 26 may be made of different materials and may have different viscosities. In the illustrated embodiment, the strip of first sealant / adhesive 24 is the same as or similar to the strip of third sealant / adhesive 28. However, the strip of first sealant / adhesive 24 and the strip of third sealant / adhesive 28 may be made of different materials and may have different viscosities.

[0024] The third sealant / adhesive 28 strip has flow behavior that allows it to conform to the surface of the wire attachment portion or the surface of multiple wires without significantly bleeding out of the desired area. This is achieved by using a sealant / adhesive in the third sealant / adhesive 28 strip that has a high intrinsic viscosity or that can achieve high viscosity through methods such as crosslinking (where crosslinking increases viscosity at a rate greater than the ooze-out rate). The third sealant / adhesive 28 strip forms a barrier, preventing the fourth sealant / adhesive 30 from leaching out. The fourth sealant / adhesive 30 strip has a low initial viscosity that allows it to efficiently displace air within the substrate being sealed. The fourth sealant / adhesive 30 strip forms a strong seal. The third sealant / adhesive 28 strip has a higher viscosity than the fourth sealant / adhesive 30 strip prior to installation.

[0025] The strip of second sealant / adhesive 26 is sized to interact with the wire at the weld area of ​​the terminal where the wire is mechanically and electrically attached to the terminal. Placing the second sealant / adhesive 26 adjacent to the free end of the wire and allowing it to interact allows the second sealant / adhesive 26 to flow and properly seal the free end of the wire.

[0026] Upon application of heat (e.g., 30 seconds or other time in an infrared oven) after installation of shrink tubing 22 over the electrical terminal, second sealant / adhesive 26 melts and flows over and adjacent the free end of the wire. The interaction of second sealant / adhesive 26 with the wire in the weld area provides a strong seal to the free end of the wire.

[0027] Because the second sealant / adhesive 26 is a small, controlled strip, the adhesive flow of the second sealant / adhesive 26 is controlled and constrained to an open geometry, such as the free end of a wire. Furthermore, the controlled flow allows the second sealant / adhesive 26 to encapsulate the sharp free end of an individual wire. While in some cases, a small amount of the second sealant / adhesive 26 may migrate to the terminal attachment portion of the terminal, the amount is not significant with respect to the functionality of the electrical terminal.

[0028] Additionally, the strip of third sealant / adhesive 28 melts and flows over the surface of the wire attachment portion or plurality of wires to form a barrier. The strip of fourth sealant / adhesive 30 melts and flows over the plurality of wires to fill any voids that may be present. The shrink tubing 22 shrinks to encapsulate the plurality of electrical wires and the wire attachment portion of the electrical terminal, thereby substantially sealing the molten sealants / adhesives 24, 26, 28, 30 within the shrink tubing 22. During the heating process, the strip of first sealant / adhesive 24 and the third sealant / adhesive 28 effectively restrict the flow of fourth sealant / adhesive 30 in the direction of the terminal attachment portion of the terminal, thereby reducing or preventing problematic contamination of the terminal attachment portion.

[0029] The geometry of the first sealant / adhesive 24, the second sealant / adhesive 26, the third sealant / adhesive 28, and the fourth sealant / adhesive 30 allows for controlled flow of the first sealant / adhesive 24, the second sealant / adhesive 26, the third sealant / adhesive 28, and the fourth sealant / adhesive 30. The configurations of the first sealant / adhesive 24, the second sealant / adhesive 26, the third sealant / adhesive 28, and the fourth sealant / adhesive 30 are intended to be exemplary. For example, the widths and lengths of the first sealant / adhesive 24, the second sealant / adhesive 26, the third sealant / adhesive 28, and the fourth sealant / adhesive 30 may be varied.

[0030] 1-5, the first sealant / adhesive 24, the second sealant / adhesive 26, the third sealant / adhesive 28, and the fourth sealant / adhesive 30 have a generally planar configuration. However, other cross-sectional profiles and shapes may be used. The configuration of the first sealant / adhesive 24, the second sealant / adhesive 26, the third sealant / adhesive 28, and the fourth sealant / adhesive 30 may be varied to allow different amounts of the first sealant / adhesive 24, the second sealant / adhesive 26, the third sealant / adhesive 28, and / or the fourth sealant / adhesive 30 to flow in different regions along the width of the terminal.

[0031] While the present invention has been illustrated by description of illustrative embodiments thereof and certain details have been provided for the embodiments, it is not intended to restrict the scope of the appended claims to such details or in any way limit them. Additional advantages and modifications will readily occur to those skilled in the art. Therefore, in its broader aspects, the invention is not limited to the specific details, representative devices and methods, and / or illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the general inventive concept.

Claims

1. 1. A sealing device for sealing an electrical terminal, comprising: a heat shrink tube having an inner wall; a first sealant / adhesive configured to cooperate with the heat shrink tubing; a second sealant / adhesive configured to cooperate with the free end of the electrical conductor in electrical engagement with the electrical terminal; the first sealant / adhesive having a first sealant / adhesive first surface and an opposite-facing second sealant / adhesive surface, the second surface of the first sealant / adhesive adhering to an inner wall of the heat shrink tubing, the first sealant / adhesive having a first viscosity; the second sealant / adhesive having a first surface of the second sealant / adhesive and an opposite-facing second surface of the second sealant / adhesive, the first surface of the second sealant / adhesive being provided in engagement with the electrical conductor and the second surface of the second sealant / adhesive being provided in engagement with and adhesion to the first surface of the first sealant / adhesive, the second sealant / adhesive having a second viscosity lower than that of the first sealant / adhesive; a second sealant / adhesive is disposed adjacent the edge of the heat shrink tubing; a third sealant / adhesive provided adjacent to the first sealant / adhesive, the third sealant / adhesive configured to cooperate with the electrical conductor, the third sealant / adhesive having a first surface of the third sealant / adhesive and an opposite-facing second surface of the third sealant / adhesive, the first surface of the third sealant / adhesive provided in engagement with the electrical conductor, the third sealant / adhesive having a third viscosity that is the same as or higher than the first viscosity of the first sealant / adhesive, such that when heated, the third sealant / adhesive melts and conforms to the surface of the electrical conductor without significantly flowing from predetermined areas of the electrical conductor.

2. The sealing device of claim 1 , wherein the second surface of the third sealant / adhesive is provided in engagement with and adhesion to the first surface of the first sealant / adhesive.

3. The sealing device of claim 2 , wherein the third viscosity of the third sealant / adhesive is equal to the first viscosity of the first sealant / adhesive.

4. 4. The sealing device of claim 3, wherein a fourth sealant / adhesive is provided adjacent to the third sealant / adhesive, the fourth sealant / adhesive being configured to cooperate with the electrical conductor, the fourth sealant / adhesive having a fourth sealant / adhesive first surface and an opposite facing fourth sealant / adhesive second surface, the fourth sealant / adhesive first surface being provided in engagement with the electrical conductor, and the fourth sealant / adhesive having a fourth viscosity such that, when heated, the fourth sealant / adhesive melts and flows between the free ends of the electrical conductors to fill any gaps present between the electrical conductors.

5. The sealing device of claim 4 , wherein the second surface of the fourth sealant / adhesive is provided in engagement with and adhesion to the first surface of the first sealant / adhesive.

6. The sealing device of claim 5 , wherein the fourth viscosity of the fourth sealant / adhesive is equal to the second viscosity of the second sealant / adhesive.

7. The sealing device of claim 6 , wherein the second sealant / adhesive, the third sealant / adhesive, and the fourth sealant / adhesive form a planar member.

8. The sealing device of claim 1 , wherein the heat shrink tubing, the first sealant / adhesive, and the second sealant / adhesive are assembled prior to placing the sealing device over the electrical terminal.

9. The encapsulation device of claim 1 , wherein the first sealant / adhesive has a thickness between 0.25 mm and 1.0 mm.

10. 10. The sealing device of claim 1, wherein the first sealant / adhesive has a width equal to or greater than the second sealant / adhesive.

11. The sealing device of claim 1 , wherein the first viscosity of the first sealant / adhesive is greater than 20 Pa·s at the installation temperature.

12. 10. The sealing device of claim 1, wherein the second viscosity of the second sealant / adhesive is less than 20 Pa-s at the installation temperature.

13. The sealed device of claim 1 , wherein the first sealant / adhesive is a crosslinkable sealant / adhesive.

14. The encapsulation device of claim 1 , wherein the first sealant / adhesive has a melting point that is lower than the melting point of the second sealant / adhesive.

15. 1. A sealing device for use with a cover to seal an electrical conductor of an electrical terminal, comprising: The cover has an inner wall; The sealing device is a first sealant / adhesive configured to cooperate with the cover; a second sealant / adhesive configured to cooperate with the free end of the electrical conductor in electrical engagement with the electrical terminal; the first sealant / adhesive has a first sealant / adhesive first surface and an opposite-facing second sealant / adhesive surface, the second surface of the first sealant / adhesive adhering to the interior wall of the cover, the first sealant / adhesive having a first viscosity; the second sealant / adhesive having a first surface of the second sealant / adhesive and an opposite-facing second surface of the second sealant / adhesive, the first surface of the second sealant / adhesive being provided in engagement with the electrical conductor and the second surface of the second sealant / adhesive being provided in engagement with and adhesion to the first surface of the first sealant / adhesive, the second sealant / adhesive having a second viscosity that is lower than the viscosity of the first sealant / adhesive; Upon heating, the first sealant / adhesive conforms to the interior wall of the cover; Upon further heating, the second sealant / adhesive and the first sealant / adhesive melt and flow between the free ends of the conductors, filling any voids that exist between the conductors; a second sealant / adhesive disposed adjacent the edge of the cover; A sealing device comprising a third sealant / adhesive provided adjacent to the first sealant / adhesive, the third sealant / adhesive having a third viscosity higher than the first viscosity of the first sealant / adhesive, such that when heated, the third sealant / adhesive melts and is capable of conforming to the surface of the wire without significantly flowing from a predetermined area of ​​the wire.

16. 1. A method of sealing an electrical conductor to an electrical terminal, comprising: creating a sealed device having a first sealant / adhesive, a second sealant / adhesive, and a third sealant / adhesive adjacent to the first sealant / adhesive; adhering a first sealant / adhesive to an inner wall of the heat shrink tubing; the first sealant / adhesive having a first sealant / adhesive surface and an opposite-facing second sealant / adhesive surface, the first sealant / adhesive having a first viscosity; the second sealant / adhesive having a second sealant / adhesive surface and an opposite-facing second sealant / adhesive surface, the first surface of the second sealant / adhesive being adhered to the second surface of the first sealant / adhesive, the second sealant / adhesive having a second viscosity that is lower than the first viscosity of the first sealant / adhesive; a second sealant / adhesive is disposed adjacent the edge of the heat shrink tubing; The third sealant / adhesive has a third viscosity that is higher than the first viscosity of the first sealant / adhesive, such that when heated, the third sealant / adhesive melts and is capable of conforming to the surface of the wire without significantly flowing from predetermined areas of the wire.

17. 17. The method of claim 16, wherein bonding the first sealant / adhesive to the inner wall of the heat shrink tubing is accomplished by ultrasonic welding.

18. 17. The method of claim 16, further comprising placing heat shrink tubing over the electrical conductors and electrical terminals with the sealing device disposed thereon.

19. 17. The method of claim 16, further comprising applying heat to the heat shrink tubing to melt the second sealant / adhesive and cause it to flow between the free ends of the conductors, filling any voids present between the conductors, and shrinking the heat shrink tubing.

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