Wiring Harness News Jul-Aug 2022

• Jack Dennehy Retires
• Help Overcoming COVID ’ s Disruptions - Part 2
• Top 10 Tips : Successful Manufacturers Get Things Done
• Hybrid Connectors - More Than the Sum of Their Parts
• Recent Changes to DoD ’ s CMMC Cybersecurity Framework
• Thermosleeve USA Announces Move to Central US Location
• The Battery Show and Electric & Hybrid Vehicle Technology Expo
• Box Builds to Brave the Elements : Understanding Enclosure NEMA Ratings
July August 2022

Company Profile : InSource

By Joe Tito Wiring Harness News ___________________________

It ’ s not uncommon for a contract manufacturer to take an indirect journey to harness production . It ’ s a big part of what makes these Company Profiles so interesting . It ’ s also why I was excited to have a chat with Larry Manz , Director of Sales & Marketing at InSource . We first met Larry at the WHMA Conference back in February . The In- Source booth was next to ours at the event and we inevitably struck up a conversation with Larry and his cousin Fred Manz from Marketing and Sales at the company . We later caught up with them at the exhibitor party at the recent EWPT Expo in Milwaukee . What were they doing exhibiting at these events ? Well , that ’ s an interesting story in itself , and we ’ ll get to that later .

To learn the whole story , Larry took us back to the early 1990 ’ s when

Electronics have made products faster , safer , and more reliable . They have become so prevalent that they ’ re practically a commodity in the same way aluminum and steel are . As this trend continues , manufacturers need solutions that address the leak paths that occur his father Ken , InSource founder , was a key engineer at a manufacturer of components and peripherals for the HVAC industry . “ He held several patents there and was instrumental in the freon recycling and recovery industry ,” Larry described . “ Prior to that , they didn ’ t know they needed to care about freon emissions .”

Around that period , the EPA came out with with an SAE standard to deal with the problem . Ken sat on that committee and played a key role in drafting the regulation that launched R-134a , which did not have the ozone depleting properties of R-12 and R-22 refrigerants . Within his company , he helped develop the first equipment that would recycle the R-12 and R-22 refrigerants , capturing the ozone depleting elements of the gases .
The company flourished in this new industry , but as a union shop , the labor costs were quite high . As competitors jumped in , they feared losing business to Mexico or China . Ken saw
InSource boasts many innovations in their harness operation . Will Manz , Tony Manz , Fred Manz , and Nick Flint show BraiderBot at EWPT ‘ 22 .

Sealing Electronics With Vacuum Impregnation

Vacuum sealed assembly . naturally during manufacturing these components .
However , the connection is not commonly made that vacuum impregnation is just as effective for electronic assemblies , including wiring and plastics . All engineers know that plastic components must be protected before assembly to ensure optimum effectiveness . Still , when it comes time to prepare their parts for shipping to the customer , most turn to more familiar , but less effective methods like O-rings , epoxy , silicone or topcoats .
Yet , this lack of information could affect the quality of parts and ultimately lead to a failing or poorly performing product in the field . Whether you ’ re a design engineer for a vendor or an installation engineer for an OEM , your reputation as an individual and a company relies on your knowledge of the latest techniques in avoiding field failures . Only then can you deliver a quality product to the customer that can be relied upon every time .
Vacuum impregnation is a process that was developed in the 1940s to seal die cast aluminum porosity . Over time , the process has evolved to seal other materials in addition to aluminum .
This piece is a guide that will help you understand how vacuum impregnation seals electronics and the benefits of vacuum impregnation . The Vacuum Impregnation Process
Generally , the process occurs in the following four steps :
Step 1 : The part is placed in an impregnation chamber , where a deep vacuum is created to evacuate air from the leak path .
an opportunity to become a contract manufacturer supplying the company , thus keeping good jobs in Ohio . In fact , that was the inspiration for the name of his new company , InSource .
He began in 1997 with a 2,520 ft .² facility making one product , a refrigerant identifier . The briefcase sized unit had a substantial amount of wiring and InSource actually bought the wires from a local supplier . “ Then , in 1998 , we purchased a wiring harness company in central Ohio that served the forestry equipment industry and began to make our own wires for the product ,” Larry said . “ We had new products that came in , and by the end of 1998 , we were building harnesses as a contract manufacturer .”
It was at this time that they added another 9,000 ft .² of manufacturing space . The company ’ s growing engineering department also added Embedded C software capabilities as they started production of leak detectors and vacuum gauges .
In order to bring in new business , Ken hired a family friend as a sales consultant . “ This was before everybody was using the internet , and he would go to the library and sit down with The Thomas Registry looking at the target markets and regions we had identified . He made cold calls and asked for an appointment ,” Larry chronicled . “ Sometimes he would get them , sometimes he wouldn ’ t — it was a different world then .”
In the early 2000 ’ s , the company
_____________ Continued on page 21
Step 2 : The evacuated leak path is filled with sealant by covering the part with the sealant while under vacuum . When the vacuum is released , positive pressure is applied while the part is still covered .
Step 3 : The part is moved to a wash / rinse station . Here , the residual sealant is washed from the part ’ s internal passages , taps , pockets , and features where the sealant is undesirable .
Step 4 : The part is moved to a cure station . Here , the impregnated sealant is polymerized in the leak path .
Why Electronics Need to be Sealed
A leak path is any gap or void between materials in an electronic component . These gaps or voids happen during manufacturing when different materials contract at different rates due to their natural properties . These voids may not
_____________ Continued on page 14