Abstract:
An apparatus, method, and system for sealing around an aperture in an enclosure; the aperture through which a plurality of wires, wire harness, or other objects, must pass. Injection of sealant into an assembly secured to the enclosure and about the wires, wire harness, or other objects ensures the components housed in the enclosure may be sealed against adverse effects while not limiting useful connection of the wires contained within the assembly to the enclosed components.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]    This application claims priority under 35 U.S.C. §119 to provisional U.S. application Ser. No. 61/218,302, filed Jun. 18, 2009, hereby incorporated by reference in its entirety. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]    The present invention generally relates to sealing around an aperture in an enclosure through which wires, or other objects, pass such that components within the enclosure may be shielded against adverse effects. 
         [0003]    It is well known that enclosures housing electrical components sensitive to environmental effects (e.g., sunlight, humidity) are generally sealed such that the components receive minimum exposure to said effects. One such method well known in the art is utilization of sealing ribs on the enclosure frame coupled with a complementary gasket (typically foamed in place) on one half of the enclosure frame such that when two halves of an enclosure are secured together (e.g., bolted, clamped), a seal is produced and the electrical components housed therein are protected from adverse environmental effects. However, as is also well known in the art, it is common for the components housed in an enclosure to be connected to one or more wires which must pass through an aperture in the enclosure and travel to some other location (e.g., another enclosure, another electrical component). Therefore, benefits gained from sealing the halves of the enclosure may be lost or compromised due to the aperture where the wires or other objects pass through the enclosure, unless there are means or methods for sealing the aperture itself. 
         [0004]      FIG. 1A  illustrates an example of half of a two-piece clamshell enclosure  100  which houses electrical components (indicated diagrammatically at reference no.  500 ) sensitive to environmental effects. Enclosure  100  includes a sealing rib  101  to aid in sealing; a gasket, generally complementary to sealing rib  101 , is located on the other half of the clamshell (not illustrated).  FIG. 1D  gives a perspective view of the enclosure illustrated in  FIG. 1A  when the two-piece clamshell halves are assembled. As may be seen from  FIG. 1A , each electrical component  500  may be connected to wires  400  which are guided by a wire retainer (an example of which is shown at reference no.  200 ) through an aperture  105  (see  FIG. 1D ) in enclosure  100 ; retainer  200  is secured at aperture  105  to enclosure  100  by bolts  201 . 
         [0005]    To address the insufficient sealing of enclosure  100 , in the current state of the art a grommet (an example of which is shown at reference no.  300 ) is sometimes utilized such that a bare end  401  of each wire  400  is pulled through a hole  202  in retainer  200  (front and back views shown in isolation in  FIG. 1B  (i) and (ii)), through an aligned corresponding hole  302  in grommet  300  (shown in isolation in  FIG. 1C ), and into enclosure  100 . Grommet  300  generally comprises a polymeric material (e.g., rubber, silicone) with holes  302  sized slightly smaller in diameter than that of wire  400  such that pulling of wire  400  through grommet  300  ensures a seal. As such, wire end  401  pulled into enclosure  100  is generally insulated but without a terminal, and thus, creates an insufficient means of connection to components  500 . Once pulled through grommet  300  terminals (e.g., ring tongue, lugs)—shown diagrammatically on the right ends of wires  400 —are attached manually (e.g., crimped, soldered) to end  401  of wire  400  in the enclosure, which is time-consuming and may be cost-prohibitive. Further, operator error is a concern; for example, terminals may be soldered to end  401  of wires  400  but if the heat from soldering is not regulated, components  500  may be damaged. 
         [0006]    An alternative approach commonly used in the current state of the art to addressing the insufficient sealing at the aperture in an enclosure (e.g., such as enclosure  100  where wires  400  enter), as well as the insufficient connection between wire ends and components (see, e.g., reference nos.  401  and  500 , respectively), is via use of a bisected apparatus (not shown) in which wires are laid and sealed. In this alternative approach, sealant is generally beaded across the wires laid in the apparatus, the halves of the apparatus are fastened, and the apparatus/wire assembly is generally fed through a retainer such as retainer  200  and through an aperture in the enclosure. While this alternative approach allows for the use of wires terminated on both ends, thus ensuring sufficient connection to components housed in the enclosure, there are drawbacks. For example, unless the apparatus completely covers the aperture in the enclosure, the enclosure is not properly sealed. Even if the apparatus completely covers the aperture in the enclosure the apparatus must be secured to the enclosure to ensure positioning, at which point the holes produced by securing the apparatus to the enclosure must be sealed. Further, beading of the sealant across the wires does not ensure uniform flow of sealant (e.g., sealant may leak out of the apparatus or air pockets may form from incomplete sealant flow). Thus, this alternative approach may also be cost-prohibitive, time-consuming, and subject to operator error. 
       SUMMARY OF THE INVENTION  
       [0007]    Methods of sealing a plurality of wires or other objects, including those that may be terminated on both ends, in an envisioned assembly that interfaces with an enclosure, are discussed. One typical application may be electrical enclosures housing environmentally sensitive components with wire connections that must pass through the enclosure. However, any sealed chamber with an aperture through which an object (or plurality of objects) must pass, particularly objects that may be economically or otherwise preferable to the application, including if said objects were enabled with terminals or other connections prior to sealing, would likewise benefit from aspects of the invention described herein. 
         [0008]    It is therefore a principle object, feature, advantage, or aspect of the present invention to improve over and/or solve deficiencies in the state of the art. 
         [0009]    Other objects, features, advantages, or aspects of the present invention may include an apparatus, method, or system for sealingly interfacing one or more wires or other objects through an aperture in and to the interior of an enclosure which:
       a. can be efficiently and effectively used to interface one or more wires or other objects from outside to inside an enclosure, even if terminals or terminations on one or both ends of the wires or other objects, larger in outside diameter than the wires or other objects, are attached to one or both ends;   b. is very flexible in application, including:
           a. the same structure for any number of wires or other objects, if any, while still providing a seal at the aperture into the enclosure; and   b. the same structure for setting lengths of each wire or other object either outside or inside the enclosure;   
           c. provides an integrated approach to sealing at the aperture to the enclosure, including providing a system and method that can address varying sealing and interfacing needs in an integrated manner;   d. can be used in a variety of applications;   e. can be used with a variable number of objects passing from outside the enclosure to the inside;   f. promotes accuracy, integrity, and uniformity of sealing from application to application; and   g. is quick, economical, and robust.       
 
         [0019]    These and other objects, features, advantages, or aspects of the present invention will become more apparent with reference to the accompanying specification. 
         [0020]    A method, apparatus, and system according to one aspect of the invention comprises a multiple-component assembly with a plurality of channels, receivers, or similar structures to align wiring (or other objects) of a desired length and also provide a flow path or paths for sealant or other injectable substance. Wires or other objects (one or more) are placed in one component of the assembly, the multiple components of the assembly are fastened, and the assembly itself is secured to an enclosure. In one aspect of the invention, when injected into the assembly, the flow of sealant or other injectable substance through channels or other pre-designed paths is such that the wires are sealed in place, the components of the assembly are sealed together, and the assembly itself is sealed to the enclosure, with improved uniformity over current art practices. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0021]    From time-to-time in this description reference will be taken to the drawings which are identified by Figure number and are summarized below. 
           [0022]      FIG. 1A  illustrates a plan view of one half of a clam-shell-type electrical enclosure interfaced with a wire retainer (shown in cross-section) via grommet according to one general method of the prior art. 
           [0023]      FIG. 1B  (i) and (ii) illustrate isolated, enlarged perspective front and back views, respectively, of the wire retainer in  FIG. 1A . 
           [0024]      FIG. 1C  illustrates an isolated, enlarged perspective view of the grommet in  FIG. 1A . 
           [0025]      FIG. 1D  is a perspective view of an assembled clam-shell type enclosure, showing an aperture through which wires or other objects pass from outside to inside the enclosure. 
           [0026]      FIG. 2A  is similar to  FIG. 1A  illustrating an electrical enclosure of the type of  FIG. 1A  but with a plurality of wires interfaced with the enclosure by an exemplary embodiment assembly (assembled and in cross-section) according to the present invention. 
           [0027]      FIG. 2B  illustrates a detailed enlarged, exploded perspective view of the multiple components of the assembly of  FIG. 2A . 
           [0028]      FIG. 2C  illustrates a bottom view of the assembly of  FIG. 2A  when assembled and secured to an enclosure (not illustrated). 
           [0029]      FIG. 2D  illustrates a section view of the assembly illustrated in  FIG. 2C  taken along line  2 D- 2 D of  FIG. 2C . 
           [0030]      FIG. 2E  is an enlargement of the cross-section of the assembly from  FIG. 2A , illustrating in more detail flow channels for sealant to and through various parts of the assembly, including diagrammatical use of arrows to illustrate such flow. 
           [0031]      FIG. 3A  (i) illustrates in perspective view the assembly of  FIG. 2A , when assembled and operatively mounted in an aperture of an enclosure.  FIG. 3A  (ii) diagrammatically illustrates the flow of sealant, when injected through the assembly, according to one exemplary embodiment. 
           [0032]      FIG. 3B  (i) is the same as  FIG. 3A  (i), but  FIG. 3B  (ii) diagrammatically illustrates the flow of sealant through the assembly, when assembled, according to an alternate exemplary embodiment. 
           [0033]      FIG. 4  illustrates in enlarged perspective view one possible design of an accessory component to partially plug mold cavities in the assembly illustrated in  FIGS. 2A-2E ,  3 A, and  3 B. 
       
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS  
       [0034]    To further understanding of the present invention, specific exemplary embodiments according to the present invention will be described in detail. Aspects according to the present invention envision methods of producing a seal around an aperture in an enclosure through which a plurality of wires or other objects must pass. The resulting system is such that ease of installation and sealant flow uniformity is improved over current state of the art practices, as well as reduction of cost, time-consumption, and operator error. It is of note, however, that the exemplary embodiments described herein are by way of example and not by way of limitation. 
         [0035]    Frequent mention will be made in this description to the drawings. Reference numbers will be used to indicate certain parts in the drawings. The same reference numbers will be used to indicate the same or similar parts throughout the drawings (for example,  100  to denote an enclosure). 
         [0036]    As has been stated, aspects of the invention described herein envision methods of injecting sealant into channels in an envisioned assembly such that wires or other objects laid in the channels may be sealed in place, the components of the assembly may be sealed together, and the apparatus itself may be sealed to an enclosure. There are a variety of methods available for injecting sealant or other injectable material into an assembly or onto a surface. For example, a chamber may be attached to a nozzle such that, when the chamber is compressed by hand, sealant or other injectable material is injected from the chamber through the nozzle; this method is well known in the field of art crafting (e.g., white glue). Alternatively, a similar chamber with attached nozzle may be compressed mechanically to inject sealant; this method is well known in the field of seam repair (e.g., caulking). The exemplary embodiments described herein utilize the latter method of injecting sealant; however, any method of injecting sealant or injectable substance into an assembly may be utilized without departing from aspects of the invention. It is also of note that the exemplary embodiments described herein utilize commercially available self-curing liquid sealant (i.e., sealant that does not require application of heat, pressure, etc.); however, any sealant or injectable substance or material which may be injected into an assembly, and cure by some means such that an effective seal as may be needed or defined by a particular application exists, may be utilized without departing from aspects of the invention. 
       A. Exemplary Method and Apparatus Embodiment 1  
       [0037]    As is illustrated in  FIGS. 2A and 3A , an electrical enclosure  100  houses components  500  (e.g., electrical or electronic devices) which are connected to wires  400  which are, in turn, fed out an aperture  105  in the side of enclosure  100  (for reference,  FIG. 1D  illustrates in isolation an enclosure  100  with its aperture  105 ). A three-part assembly  600  (see also  FIGS. 2A-2E ) aligns wires  400  and, when secured to the enclosure  100  via bolts  201  and injected with sealant  603 , seals wires  400  within assembly  600 , seals the components of assembly  600  together, and seals assembly  600  to enclosure  100 . One of the benefits of the design of assembly  600  is such that wires  400  (or other objects) may be laid and sealed with a desired length in enclosure  100  and a desired length outside enclosure  100 . For example, assume three wires are to be placed in assembly  600  and connected to components  500  within enclosure  100 ; in this example, the first wire is 6″ long, the second wire is 12″ long, and the third wire is 18″ long. A user may lay each wire in their respective positions within assembly  600  such that when sealed, exactly 3″ of each wire extends outwardly from enclosure  100  (leaving 3″, 9″, and 15″, respectively, extending through assembly  600  into aperture  105 ). Alternatively, exactly 3″ of each wire could extend into enclosure  100  via aperture  105 . This is useful because, for example, often there is limited room in an enclosure for wiring, wiring lengths must be equal to maintain a balanced load, or wiring length must be exact to determine electrical losses. 
         [0038]      FIG. 2B  illustrates an exploded perspective top view of assembly  600  in which two outer molds  609 , when brought together, enclose or clamp an inner mold  601  and are secured by bolt(s)  201  (or other fastener or fastening method) at connection points  602 ; keys  604  on both sides of inner mold  601  mate with key holes, slots, or receivers  605  on the two outer molds  609  to ensure alignment of the three components ( 609 ,  601 ,  609 ). When fully assembled, a plurality of wires  400  may be secured in mold cavities  607  (here two rows of twelve wire-holding cavities  607  per row) of assembly  600 ; as illustrated in  FIG. 2B , twenty-four mold cavities  607  are produced when assembly  600  is fully assembled, though this is by way of example and not by way of limitation. When pieces  609 ,  601 , and  609  are assembled, mold cavities  607  form an increase in diameter at the center of the longitudinal axis of the cavity (reference no.  611 ) to provide a series of channels through which sealant  603  may flow from one sprue  606  to another while concurrently sealing wires  400  in place. Further, the flow of sealant  603  through assembly  600  concurrently fills a series of channels surrounding each connection point  602  such that the components ( 609 ,  601 ,  609 ) of assembly  600  are connected and sealed together. 
         [0039]      FIG. 2C  illustrates a bottom view of assembly  600  when assembled and secured to the enclosure (not illustrated) at connection points  608  with bolts  201  (see  FIGS. 2A and 2B ). As may be seen from  FIGS. 2C-2D , injection of sealant  603  through the sprue (see reference no.  606 ) and down channel  613  creates a seal at and extending from an exposed rectangular bottom channel  614  that surrounds connection points  608  (i.e., forms a rectangular perimeter around all six connection points  608 ), thus ensuring a more complete seal against enclosure  100  than in current art practices. Current art grommet design  300  ( FIGS. 1A-1C ) typically limits the number and positioning of apertures through which bolts or other hardware may be used to secure grommet  300  to enclosure  100  which limits the flexibility of the sealing method. Further, if bolts or other hardware used to secure grommet  300  to enclosure  100  are not sized compliantly with the apertures in the grommet  300  the enclosure  100  may be insufficiently sealed. In the present exemplary embodiment sealant  603  bonds to the adjacent exterior surface of enclosure  100  around aperture  105  and creates a perimeter seal around connection points  608 , thus allowing any number of connection points  608  and size of bolt (or other hardware) to be utilized, provided connection points  608  are positioned within the perimeter of sealant  603 . 
         [0040]      FIG. 2E , in combination with the  FIGS. 2A-D , is intended to further illustrate how one injection of sealant into sprue  606  may not only move sealant to and around each wire  400  at each enlarged portion  611  of each side-by-side cavity  607  (each portion  611  is in fluid communication and allows flow of sealant between opposite sprues  606 A and  606 B even with wires in cavities  607 ), but in this embodiment, through other channels to connection points or bores  602  and to bottom exposed rectangular channel  614 . This flow of sealant through different paths will be described with reference to the diagrammatic arrows  630 - 639  in  FIG. 2E , which are intended to depict the flow of sealant  603  in the embodiment where sealant  603  is injected into one sprue  606 . 
         [0041]    Sealant enters sprue  606 B on one side of assembly  600  (arrow  630 ). Sealant advances towards the path through the side-by-side cavities  607  (arrow  634 ). This would both seal and help connect together (when the sealant cures) the two pieces  609  of assembly  600 . Also, some sealant would flow through into bottom rectangular channel  614  by the path shown in  FIG. 2E  by arrow  633  and side channel  613  (see also  FIGS. 2B and 2C ). When the bottom side of assembly  600  is fastened against the exterior of enclosure  100  at and around aperture  105 , the configuration of bottom channel  614  is designed to be outside aperture  105  and be exposed to solid surface of enclosure  100  surrounding aperture  105 . When sealant fills bottom channel  614 , it would also move out against the adjacent surface of housing  100 . When cured, it thus forms a rectangular seal around aperture  105  and around the six bolts fastening assembly  600  to housing  100  at mounting threaded blind bores  608  in the bottom of assembly  600 . This is similar to a gasket between assembly  600  and enclosure  100 , but also the sealant may assist in connection of assembly  600  to enclosure  100  by any adherent or adhesive characteristics. 
         [0042]    As further shown in  FIG. 2E , sealant would flow in the direction of arrow  634  and fill all spaces not occupied by wires  400  in cavities  607 . Note that some sealant (arrow  635 ) may flow into connection point  602 M, which is at or near the middle of cavities  607 , and may assist in sealing around any fastener extending through all aligned bores  602  from side to side of assembly  600 , as well as help connect pieces  609 ,  601 , and  609  of assembly  600 . 
         [0043]    Sealant would continue in the direction of the arrows across cavities  607  towards the other side of assembly  600 . At arrow  636 , sealant may split off into side channel  613  to fill bottom channel  614  (arrow  637 ) to further help produce the bottom seal between assembly  600  and enclosure  100 . Sealant would also move to fill opposite sprue  606 A (arrow  639 ), to complete the sealant injection through assembly  600  and seal the connection between pieces  609 ,  601 , and  609  of assembly  600 , respectively. 
         [0044]    As may be appreciated, other flow channels may be pre-designed into assembly  600 . Furthermore, alternative embodiments may just design a flow path through cavities  607  to seal wires  400  and not have flow paths into connection points  602  or not have a bottom channel  614 . But in the first exemplary embodiment all of these flow paths and features are combined. This allows an integrated system for sealing wires, but also for sealing and helping to connect pieces of assembly  600 , as well as sealing and helping to connect assembly  600  relative to enclosure  100 . 
         [0045]      FIG. 3A  (i) and (ii) illustrate the assembly from  FIGS. 2B-2D  assembled, securing a plurality of wires  400 , and secured to an enclosure  100 . Sealant is then injected into assembly  600 , the flow of which may generally be characterized by the following.
       Sealant is injected into sprue  606 B as indicated diagrammatically by the arrow entering assembly  600  in  FIG. 3A  (ii).   Sealant flows around each wire  400  via channels in mold cavities  607  (see also examples in  FIGS. 2C-2E ), thus sealing each wire in assembly  600  and sealing the components ( 609 ,  601 ,  609 ) at connection points  602 M.
           Concurrently, bottom channel  614  fills with sealant, thus sealing assembly  600  to enclosure  100 .   Concurrently, side channels  613  fill with sealant, thus sealing the components ( 609 ,  601 ,  609 ) of assembly  600  together at connection points  602  (see also examples in  FIG. 2B ).
               It is of note that bolts or other hardware used to secure the components ( 609 ,  601 ,  609 ) of assembly  600  together at connection points  602  are not illustrated in  FIG. 3A  (see  FIGS. 2A-2E  for possible examples).   
               
           When sealant has filled all channels and cavities, excess sealant flows out sprue  606 A as indicated by the arrow exiting assembly  600  in  FIG. 3A  (ii), thus giving a clear indication that the injection process is complete.       
 
       B. Exemplary Method and Apparatus Embodiment 2 
       [0052]    An alternative exemplary embodiment of the invention envisions an electrical enclosure  100  housing components  500  which are connected to wires  400  which are, in turn, fed out an aperture in the enclosure  100  as in  FIGS. 2A and 3B . As in Exemplary Method and Apparatus Embodiment 1, a three-part assembly  600  (see also  FIGS. 2A-2E ) aligns wires  400 —each wire  400  may be selectively placed in assembly  600  such that a desired length will extend into enclosure  100  and a desired length will extend outwardly from enclosure  100 —and, when secured to enclosure  100  via bolts  201  and injected with sealant  603 , seals wires  400  within assembly  600 , seals the components ( 609 ,  601 ,  609 ) of assembly  600  together, and seals assembly  600  to enclosure  100 . In this alternative exemplary embodiment, the device injecting sealant  603  into assembly  600  is enabled with means of measuring resistance to injection (e.g., internal pressure). 
         [0053]      FIG. 3B  illustrates assembly  600  from  FIGS. 2A-2E  assembled, securing a plurality of wires  400 , and secured to an enclosure  100 . Sealant is then injected into assembly  600 , the flow of which may generally be characterized by the following.
       Sealant is injected into both sprues  606 A and  606 B as indicated diagrammatically by the arrows entering the assembly  600  in  FIG. 3B  (ii).   Sealant flows around each wire  400  via channels in mold cavities  607 , thus sealing each wire in assembly  600  and sealing the components ( 609 ,  601 ,  609 ) at connection points  602 M.
           Concurrently, the bottom channel fills with sealant, thus sealing assembly  600  to the enclosure  100 .   Concurrently, the side channels fill with sealant, thus sealing the components ( 609 ,  601 ,  609 ) of assembly  600  together at connection points  602 .
               It is of note that bolts or other hardware used to secure the components ( 609 ,  601 ,  609 ) of assembly  600  together at connection points  602  are not illustrated in  FIG. 3B .   
               
           When sealant has filled all channels and cavities, the device injecting the sealant will register a significant increase in resistance to injection (e.g., internal pressure of assembly  600  will increase), thus giving a clear indication that the injection process is complete. Further, excess sealant may flow out of the top of mold cavities  607  where wire  400  exits assembly  600 , thus giving a clear indication that the injection process is complete.       
 
       C. Options and Alternatives  
       [0060]    The invention may take many forms and embodiments. The foregoing examples are but a few of those. To give some sense of some options and alternatives, a few examples are given below. 
         [0061]    As described in Exemplary Method and Apparatus Embodiments 1 and 2 the components ( 609 ,  601 ,  609 ) of assembly  600  are secured together by bolt(s)  201 ; assembly  600  is secured to enclosure  100  by bolt(s)  201  as well. It is of note that any method of securing the components ( 609 ,  601 ,  609 ) of assembly  600  together, as well as securing assembly  600  to an enclosure  100 , may be utilized and not depart from aspects of the invention described herein. Further, assembly  600  or enclosure  100  could have guide pins, positioning tabs, or analogous structural features to help position and center assembly  600  relative to enclosure  100  about aperture  105 . 
         [0062]    As described in Exemplary Method and Apparatus Embodiments 1 and 2 assembly  600  houses twenty-four mold cavities  607  in which wires  400  may be secured. It is of note that assembly  600  may house any number of mold cavities  607 , may secure any length of wire  400  with any desired amount of that length on either side of assembly  600 , and may secure objects other than wires, and not depart from aspects of the invention described herein. Further, a plurality of mold cavities  607  may secure wires  400  or other objects while another plurality of mold cavities  607  may be plugged or otherwise partially obstructed, and not depart from aspects of the invention described herein. For example, if assembly  600  illustrated in  FIG. 3A  secured eighteen wires  400  (instead of the twenty-four illustrated) the six empty mold cavities may be plugged by a simple component  620 , such as that illustrated in  FIG. 4 , so as not to impede the flow of sealant  603  but also to prevent sealant from leaking out of unused mold cavities. Elongated members  621  of component  620  would generally fit in cavities  607 . Upper and lower webbing  622  may sit flush on the top and bottom faces, respectively, of assembly  600  (see  FIG. 2B  for orientation reference); webbing  622  may aid a user in handling component  620  as elongated members  621  may be very small. Component  620  may be made of rubber, plastic, or other material that may be formed to assume a generally complementary shape to the space to be filled up, but does not completely fill the space as sealant may then flow around and past and finalize a seal. Component  620  may be easily inserted into position and may be used in whole or broken or separated into a lesser number of members  621 , if needed. The design of component  620  may vary as is needed for the application so long as flow of sealant  603  is not impeded. 
         [0063]    As described in Exemplary Method and Apparatus Embodiments 1 and 2 assembly  600  comprises two outer molds  609  and one inner mold  601  such that two rows of mold cavities  607  exist when the components ( 609 ,  601 ,  609 ) are assembled. It is of note that a plurality of combinations of outer molds  609  and inner molds  601  may be utilized for a particular application and not depart from aspects of the invention described herein. For example, if it is desirable for assembly  600  to secure a single row of mold cavities  607 , then only outer molds  609  may be used. As a further example, if it is preferable for assembly  600  to secure three rows of mold cavities  607 , then two outer molds  609  may be used in conjunction with two inner molds  601 . 
         [0064]    As described in Exemplary Method and Apparatus Embodiments 1 and 2, when assembly  600  is fully assembled, secured to enclosure  100 , and injected with sealant, a seal is formed against the outer surface of enclosure  100  about aperture  105  via bottom channel  614 . Though not required, it may be desirable to include features which help to dam sealant in channel  614  and prevent undesirable spread of sealant on the surface of enclosure  100  or into aperture  105 . One way this can be achieved is via crush ribs  610  on both sides of bottom channel  614  (see  FIGS. 2C-E ); as is well known in the art, crush ribs are very small (e.g., on the order of a millimeter or less in height and thickness) deformable extensions of material which crush down when two parts are brought together (e.g., for purposes of sealing between parts or allowing for an interference fit). Alternatively, an o-ring or other analogous device could be placed on both sides of channel  614  such that, when assembly  600  is affixed to enclosure  100 , the o-ring or analogous device would be compressed between assembly  600  and enclosure  100 , thus helping to prevent the undesired spread of sealant beyond bottom channel  614 . 
         [0065]    As described in Exemplary Method and Apparatus Embodiments 1 and 2, sealant  603  is injected into assembly  600  by a device comprising a chamber containing sealant  603  that is compressed mechanically and a nozzle to apply sealant  603 . It is of note that the device as described utilizes a nozzle shaped to match the sprue ( 606 A,  606 B), however, any nozzle shape that may be fitted to the sprue ( 606 A,  606 B) may be utilized and not depart from aspects of the invention described herein. Alternatively, the sprue ( 606 A,  606 B) shape may be altered to match a particular nozzle type if it may be beneficial to the application. Other methods to inject sealant or the like may be used. 
         [0066]    As described in Exemplary Method and Apparatus Embodiment 2 the device which injects sealant into assembly  600  is enabled with means of measuring resistance to injection. It is of note that there are several methods by which resistance to injection may be measured, and such methods may be enabled for assembly  600  as well as the device injecting sealant. For example, internal pressure of the chamber holding the sealant or internal pressure of assembly  600  may be measured (e.g., via pressure sensor or strain gage applied to said chamber or assembly  600 ) in a variety of locations (e.g., on the external body of assembly  600  or on the internal body of assembly  600  through a bored hole). As an alternative to measuring pressure, e.g., a sensor placed on assembly  600  may monitor air flow out of the mold cavities while wires are secured in place. In such alternative method, injection of the sealant may be complete when there is no longer a significant air flow out of assembly  600  as determined by measurement or calculation. Any means of measuring resistance to injecting sealant into a mold (including a user feeling a notable resistance to compression of the plunger or analogous part of the injection device) may be utilized and not depart from aspects of the invention described herein.