A method for manufacturing a branched wire harness 1 includes a connection step of bundling and connecting core wires 11 of a plurality of electric wires 10 including the core wires 11; a waterproof material attachment step of attaching, to the plurality of electric wires 10, a spring-shaped waterproof material 20 constituted by a material that is softened or melted through heating; a covering step of covering, with a waterproof covering 14, the plurality of electric wires 10 to which the spring-shaped waterproof material 20 is attached; and a heating step of softening or melting the spring-shaped waterproof material 20 through heating, and filling in a gap between the waterproof covering 14 and the electric wires 10, or a gap between the adjacent electric wires 10.

A gel filled electrical connector is disclosed and claimed. The connector has a base configured to house a gel fill insulating material and a plurality of 10-gauge or larger diameter wires; the base comprising a plurality of wire receptacles to receive a plurality of wires in a cavity in the base; a top cover sized to be securely and removably attached to the base, wherein the top cover comprises a plurality of wire connectors to strip insulation from the plurality of wire and to electrically connect the plurality of wires; and a gel deposited into the cavity to provide moisture resistance to the plurality of wires and plurality of wire connectors.

A gel filled electrical connector is disclosed and claimed. The connector has a base configured to house a gel fill insulating material and a plurality of 10-gauge or larger diameter wires; the base comprising a plurality of wire receptacles to receive a plurality of wires in a cavity in the base; a top cover sized to be securely and removably attached to the base, wherein the top cover comprises a plurality of wire connectors to strip insulation from the plurality of wire and to electrically connect the plurality of wires; and a gel deposited into the cavity to provide moisture resistance to the plurality of wires and plurality of wire connectors.

A metallic cable includes, in order from an inner side thereof, a plurality of coated conduction wires, a press winding tape, a laminated tape, and an outer jacket. The outer jacket is provided on an outer circumference of the laminated tape and such that it covers the outer circumference of the laminated tape. The outer jacket is made of polyethylene having a density greater than or equal to that of medium-density polyethylene (MDPE) (≥930 kg/m.sup.3), and more preferably made of high-density polyethylene (≥942 kg/m.sup.3). If polyethylene having a density that is equal to or greater than that of MDPE is used to form the outer jacket, the temperature that is appropriate for extruding MDPE approaches a bonding temperature range of the resin layer of the laminated tape. The resin layer and the metal layer can be bonded and joined together at an overlapped part, tightly enclosing a cable core.

A metallic cable includes, in order from an inner side thereof, a plurality of coated conduction wires, a press winding tape, a laminated tape, and an outer jacket. The outer jacket is provided on an outer circumference of the laminated tape and such that it covers the outer circumference of the laminated tape. The outer jacket is made of polyethylene having a density greater than or equal to that of medium-density polyethylene (MDPE) (≥930 kg/m.sup.3), and more preferably made of high-density polyethylene (≥942 kg/m.sup.3). If polyethylene having a density that is equal to or greater than that of MDPE is used to form the outer jacket, the temperature that is appropriate for extruding MDPE approaches a bonding temperature range of the resin layer of the laminated tape. The resin layer and the metal layer can be bonded and joined together at an overlapped part, tightly enclosing a cable core.

A filling composition comprises (A) a mineral oil having a kinematic viscosity from 80 cSt to 100 cSt at 40° C.; (B) a styrene-ethylene/propylene diblock copolymer; and (C1) a propylene/ethylene copolymer having a weight average molecular weight (M.sub.w) from 5,000 to 200,000 or (C2) an ethylene/propylene copolymer having a weight average molecular weight (M.sub.w) from 5,000 to 200,000. The filling composition is used as a filling composition in a buffer tube.

A gas blocking cable includes cabled wires, where each wire includes cabled conductors having interstitial areas there between. An insulation material circumferentially surrounds the cabled conductors and a conductor filling material is positioned within the interstitial areas between conductors. A shield circumferentially surrounds the cabled wires so that a cable is formed with areas between the wires. A wire filling material is positioned within the areas between the wires. Each of the conductor filling material and wire filling material is inert, non-flammable and able to withstand a temperature of at least approximately 200° C.

A gas blocking cable includes cabled wires, where each wire includes cabled conductors having interstitial areas there between. An insulation material circumferentially surrounds the cabled conductors and a conductor filling material is positioned within the interstitial areas between conductors. A shield circumferentially surrounds the cabled wires so that a cable is formed with areas between the wires. A wire filling material is positioned within the areas between the wires. Each of the conductor filling material and wire filling material is inert, non-flammable and able to withstand a temperature of at least approximately 200° C.

A structure for creating a sealed wire bundle includes a first adhesive material in the form of a circular or semi-circular shape. The first adhesive material has a first outer wall with first spoke arms extending inward from the first outer wall. The first adhesive material has a first viscosity. First wire receiving spaces are provided between the first spoke arms. Wires are positioned in the first wire receiving spaces. As heat is applied to the adhesive structure, the adhesive structure flows to fill voids between the plurality of wires to thereby seal the wires.

A structure for creating a sealed wire bundle includes a first adhesive material in the form of a circular or semi-circular shape. The first adhesive material has a first outer wall with first spoke arms extending inward from the first outer wall. The first adhesive material has a first viscosity. First wire receiving spaces are provided between the first spoke arms. Wires are positioned in the first wire receiving spaces. As heat is applied to the adhesive structure, the adhesive structure flows to fill voids between the plurality of wires to thereby seal the wires.