Case Study - Warranty Solution for Headlight Wire Harness
Background
If a connector short circuits, it can potentially overheat and may even cause a fire under the right conditions. In vehicles with hundreds of connectors, this poses a significant safety concern. One Automotive OEM issued a warranty after vehicle headlights began to experience thermal issues within the wiring harness. To prevent the same issue from occurring, they came to Nye in search of a grease that would prevent short circuits in their new headlight harness.
Challenge
- Can Nye provide a grease that protects connectors against common causes of connector failure?
- Can Nye provide a packaging solution that can be distributed to and applied by dealerships?
Solution
NyoGel® 760G
A silica thickened, medium viscosity, synthetic hydrocarbon grease.
- Protects against fretting corrosion & oxidation
- Provides an environmental seal against dirt & debris
- Provides lifetime lubrication for lasting connections
- Compatible with most plastics & elastomers
| Typical Properties | NyoGel® 760G | Test Methods |
|---|---|---|
| Chemistry | PAO/Silica | - |
| Temperature Range | -40 to 135 °C | - |
| Kinematic Viscosity (40 °C) | 400 cSt | ASTM D445 |
| Viscosity Index | 147.5 | ASTM D2270 |
| Water Washout (1 h, 80 °C) | 2% | ASTM D1264 |
| Salt Spray Resistance (750 h) | No Corrosion | ASTM B117-18 |
| Dielectric Breakdown Voltage | 11.2 kV | CTM |
Results
Short circuits may occur if connector terminals become corroded, worn, or oxidized. Connector grease protects connectors against common causes of failure including fretting corrosion (corrosion caused by microvibrations), oxidation, and even seals the terminal surface to protect it against dirt and debris. Nye provided the OEM with 25-gram tubes of our industry standard connector grease, NyoGel® 760G. The OEM was pleased with the results and was able to distribute the grease to dealerships around the country.
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