With the rapid advancement of new energy vehicles (NEVs) and intelligent connected vehicle technologies, automotive wiring harnesses—often referred to as the vehicle’s “nervous system”—are facing increasingly stringent requirements for reliability, sealing integrity, and long-term durability. As wiring architectures become more complex and electronic integration intensifies, critical areas such as connectors, branching points, and junction boxes must deliver robust protection against water ingress, dust, vibration, and electrical interference.
In this context, polyurethane (PU) foaming materials have emerged as a preferred solution across the automotive industry. Thanks to their excellent sealing performance, mechanical resilience, and formulation flexibility, PU systems are widely applied in wiring harness encapsulation and sealing processes. Responding to these evolving demands, Feilong Polyurethane Equipment has introduced a dedicated polyurethane foaming machine for automotive wiring harnesses, designed to deliver stable, precise, and repeatable sealing performance. This solution is gaining growing recognition among OEMs and Tier 1 wiring harness suppliers.
1. Equipment Architecture Optimized Specifically for Wiring Harness Applications
Unlike general-purpose foaming machines adapted for automotive use, Feilong’s wiring harness foaming system has been developed from the ground up based on the unique characteristics of harness manufacturing processes. Key technical features include:
High-Precision Metering and Mixing System
The machine adopts servo-driven dual-component metering pumps, enabling an A/B ratio control accuracy of ±1%. This ensures consistent foaming reactions and prevents defects such as incomplete curing or degraded mechanical properties caused by ratio deviations.
Modular Mold Compatibility Design
The system supports rapid mold changes for different harness connectors, branching nodes, and terminal housings. This modular approach significantly enhances production flexibility, making it well-suited for high-mix, low-to-medium volume manufacturing environments common in modern wiring harness plants.
Closed-Loop Temperature and Pressure Control
Raw material preheating, mixing head temperature, and injection pressure are all controlled via closed-loop systems. This ensures uniform foaming quality and dimensional consistency, even under fluctuating ambient temperature conditions.
Automation and Line Integration Capability
The equipment is equipped with PLC and industrial bus interfaces, allowing seamless integration into existing automated production lines. From material feeding and precise positioning to dispensing and curing, the entire process can be automated, minimizing human intervention and reducing quality risks.
2. Process Reliability That Meets Stringent Automotive Standards
Automotive wiring harness sealing components must withstand prolonged exposure to harsh operating environments, including high temperatures, oil contamination, vibration, and humidity cycling. Feilong’s polyurethane foaming equipment supports a wide range of PU formulations—such as microcellular elastomers and high-resilience foams—which have been validated in customer applications to meet key automotive requirements, including:
- Protection ratings up to IP67 / IP68
- Operating temperature range from –40°C to +125°C
- Excellent tear resistance and low compression set
- Compliance with RoHS, REACH, and other environmental regulations
These capabilities enable manufacturers to achieve stable, repeatable sealing performance across different vehicle platforms and application scenarios.
Conclusion
As vehicle electrification and intelligence continue to accelerate, the complexity and reliability challenges of wiring harness systems will only intensify. Selecting a polyurethane foaming machine that offers high precision, long-term stability, and strong application adaptability has become a critical factor in building robust sealing and protection capabilities.
With its application-driven design philosophy and continuous focus on technical refinement, Feilong Polyurethane Equipment delivers a dedicated wiring harness foaming solution that manufacturers can rely on—helping the automotive industry set new benchmarks for sealing performance and production quality.
