ZH-WWS-436
Solder Sleeve Wire Splice
Solder sleeve wire splices combine solder, heat shrink insulation, and sealing support into a compact connection solution for wire harness assemblies. They are commonly used where quick, reliable, and insulated wire-to-wire splicing is required.
Product Benefits
- Dual Material Design: Modified fluoropolymer insulation + tin/nickel-plated copper crimp barrels.
- Compact & Lightweight: Easy to install in confined spaces (e.g., aircraft wiring).
- Electrical Safety: Dielectric strength 2.5 kV, insulation resistance 5000MΩ.
- Multi-Cable Compatibility: Supports 2-cable splicing (max.) per sleeve.
Description
The ZH-WWS-D436 series Wire-to-Wire Splice Connectors is a high-reliability wire-to-wire splicing solution designed for aerospace, defense, and industrial applications. It combines tinned/nickel-plated copper crimp terminals with transparent heat-shrinkable sealing sleeves, ensuring secure connections with excellent insulation, flame retardancy, and resistance to solvents and corrosion. Ideal for environments demanding durability and electrical performance.TubeBoot manufactures wire-to-wire splice connectors in China, with factory direct pricing and MOQ from 50 pieces. Products meet or exceed MIL-SPEC M81824 standards.
Key Features:
- Military & Aerospace Certified: Complies with SAE AS 81824/1 standards.
- High Conductivity: Tin/nickel-plated copper crimp barrels minimize voltage drop (6.9 mV at 4.5 A).
- Robust Sealing: Heat-shrinkable transparent sleeves with meltable thermoplastic sealant for waterproof and corrosion-resistant protection.
- Wide Temperature Range: Operates from -55°C to +150°C.
- Color-Coded Sizes: Red/Blue/Yellow markings for easy identification of cable ranges (0.15–3.37 mm² / AWG 26–12).
- Superior Mechanical Strength: Tensile strength exceeds conductor strength, ensuring long-term reliability.
Size:
Applications ：
Automotive & Racing Harness Repair
Aerospace & Military Wiring
Marine & Industrial Equipment
FAQ:
Q1: What is a solder sleeve wire splice?
A solder sleeve wire splice is a heat-activated, all-in-one wire joining solution that combines a pre-loaded solder ring, a dual-wall heat shrink tube, and a hot-melt adhesive lining into a single component. When heat is applied, the solder melts and flows around the conductor to form a reliable electrical connection, while the outer heat shrink sleeve contracts and the inner adhesive creates an environmentally sealed insulation layer — all in one step, with no soldering iron required.
This makes solder sleeve wire splices the preferred choice for aerospace, automotive, and military harness technicians who need fast, repeatable, and inspection-friendly wire repairs or extensions in the field.
Q2: What wire sizes does it support?
TubeBoot solder sleeve wire splices are available across a full AWG range to cover most harness applications:
| Size | AWG Range | Wire Cross Section |
|---|---|---|
| Red (Small) | 26–22 AWG | 0.14 – 0.34 mm² |
| Blue (Medium) | 22–18 AWG | 0.34 – 0.75 mm² |
| Yellow (Large) | 18–14 AWG | 0.75 – 2.5 mm² |
| Green (XL) | 12–10 AWG | 4.0 – 6.0 mm² |
Custom AWG configurations and solder alloy specifications (e.g., Sn42Bi58 low-temp solder) are available for OEM orders. Contact us for a sample kit.
Q3: Is it suitable for sealed harness applications?
Yes. TubeBoot solder sleeve splices are engineered for sealed and environmentally protected harness applications. The dual-wall construction features an outer polyolefin heat shrink layer and an inner ring of hot-melt adhesive. When activated, the adhesive flows around the wire insulation to create a 360° moisture-tight seal that resists water ingress, vibration, and fuel/fluid exposure.
Our solder sleeve splices are commonly used in:
- Automotive sealed harnesses (engine bay, underbody, door modules)
- Marine wiring (bilge, outboard motor, navigation systems)
- Aerospace and military cable repair (meets or exceeds MIL-DTL-23053 environmental requirements)
- EV battery pack wiring (high-humidity, thermal cycling environments)
For full IP67/IP68-rated harness builds, pair with TubeBoot heat shrink boots for connector backshell sealing.
Q4: Do you offer shielded solder sleeve options?
Yes. In addition to standard wire-to-wire solder sleeve splices, TubeBoot offers shielded solder sleeve terminators designed for coaxial cables, shielded twisted pairs, and EMI-sensitive harnesses. These feature:
- A tinned copper braid ring (or foil contact band) that bonds to the cable’s outer shield during reflow
- A standard solder ring for the center conductor connection
- Dual-wall heat shrink with adhesive for full environmental sealing
- Compatible with MIL-SPEC M83519/1 and M83519/2 shield terminator formats
Shielded solder sleeves are widely used in avionics wiring, CAN bus harnesses, sensor cables, and military communication systems where continuous shield integrity is critical. Available in standard and custom braid coverage options. Request a spec sheet or sample below.
