Wire-to-Wire Splicing
MiniSeal High-Performance, Immersion-Resistant Crimp Splices
Product Facts
Immersion-resistant crimp
splices are on QPL for
SAE-AS-81824
MIL-Spec approval
Small size
Light weight
Insulation and strain relief
Easy installation
Applications Product Selection Process Table A provides the 5. Determine the type of
CMA of typical conduc- sealing sleeve required.
MiniSeal wire-to-wire splic- 1. Determine the type of
2
tors. (Both CMA and mm Some wire insulations will
ing products offer solutions splice required.
give the same results, so not fit in the holes of the
for hundreds of aerospace
Stub (parallel) splice:
choose either CMA or sealing sleeve inserts, so
and defense applications.
2
mm as your unit of be sure to compare the
These environment-resistant
measure for selection internal diameter of each
splices provide excellent
Butt (in-line) splice:
purposes and continue hole with the outer
reliability, long term per-
to use it for all your diameter of the wire(s)
formance, MIL-S-81824/1
selection criteria.) you intend to insert in
qualification, and a low 2. Determine which crimp
that hole. To create a
installed cost. barrel plating is required: 4. Select the color code for
reliable seal, place a
the size crimp barrel
MiniSeal crimp splices con- Tin plating,
maximum of two wires
required. Using Table B
sist of a plated copper recommended for tin
in any hole of the sealing
(page 8-23), select the
crimp barrel and a sepa- or silverplated wire
sleeve.
crimp barrelcolor-
rate, heat-shrinkable, trans-
Nickel plating,
coded red, blue, or 6. Select the part number.
parent sealing sleeve. They
recommended for
yellowfor the CMA or Turn to the MiniSeal part
can be used on a combina-
nickel-plated wire, or 2
mm you calculated. number selection tables
tion of wires, from 1:1 to
silver-plated wire in
(Tables C and D, page
10:10. MiniSeal splices are Stub splice: Select the
applications above
8-23 and 8-24) and find
one of the smallest, lightest, barrel that will accommo-
150C [302F].
the table for the type of
and most environment- date the total cross
splice (stub or butt)
3. Calculate the size of
resistant splices available. section.
required.
crimp barrel required.
They preserve the electrical
Butt splice: Select the
2
integrity of the splice by Using the appropriate
Using the CMA/mm
smallest barrel that will
preventing the penetration table, find the crimp
worksheet on the next
accommodate the
of liquids and the resulting barrel size range and
2
page, calculate the total
largest CMA/mm
chemical and galvanic the size and number of
cross section to be
required. (Refer to the
corrosion. wires for your applica-
spliced by adding the
example in the work-
tion. Then select the
circular mil area (CMA)
sheet for a more specific
part number for the type
or square millimeters
description.) If the
2 of plating required. The
2
(mm ) of each wire.
CMA/mm of the smaller
color code accompany-
side of a butt splice is
Stub splice: Add the
ing that part number
2 too small for the size
CMA or mm of all wires
should match the color
barrel required to fit the
together.
code you arrived at in
larger side, increase the
Butt splice: Calculate Table B, confirming that
2
CMA/mm either by
each side separately the part number you
doubling back one wire
(see example on the have selected is correct.
(stripping the conductor
worksheet).
twice the length you
Available in:
would ordinarily strip it
Americas
and then folding it back)
Europe
or by adding a filler wire.
Asia Pacific
8-24
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters Canada: +1 (905) 475-6222 UK: +44 (0) 800-267666
Revised 5-12 reference purposes only. unless otherwise specified. Mexico/C. Am.: +52 (0) 55-1106-0800 France: +33 (0) 1-3420-8686
Specifications subject Latin/S. Am.: +54 (0) 11-4733-2200 Netherlands: +31 (0) 73-6246-999
www.te.com to change. USA: +1 (800) 522-6752 Germany: +49 (0) 6251-133-1999 China: +86 (0) 400-820-6015Electrical Interconnect Products
Wire-to-Wire Splicing
MiniSeal High-Performance, Immersion-Resistant Crimp Splices (Continued)
Table A. CMA of Typical
Strands 7 19 19 19 19 19 19 19 37
Conductors
AWG 28 26 24 22 20 18 16 14 12
CMA 177 304 475 754 1216 1900 2426 3831 5874
2
mm 0.09 0.15 0.24 0.38 0.61 0.95 1.21 1.92 2.94
Table B. Crimp Barrel Color
CMA Range 1:1 Splice (AWG Size) Color Code
Code Selection
3041510 2620 Red
10582680 2016 Blue
23756755 1612 Yellow
2
CMA/mm Worksheet Example:
Application: A butt splice The other side, where the
with three AWG 22 wires in CMA for AWG 18 is 1900, is
one side and one AWG 18 calculated as:
wire in the other side:
CMA = 1 x 1900 = 1900
The CMA for AWG 22 wire
Using Table B to select the
in Table A is 754.
smallest crimp barrel that
Side one is therefore calcu- will easily fit 2262 CMA, the
lated as follows: blue barrel is the correct
choice.
CMA = 3 x 754 = 2262
2
Wire Number CMA mm
1
2
3
4
5
6
7
8
8
9
10 Part Number:
Total
Table C. Stub (Parallel) Splices
I.D.dimensions
Crimp Barrel
Part No.
Size Range
Side 1 Side 2
Illustration
CMA
Sealing Max. No. Sealing Max. No.
Tin Plated Nickel Plated
Min.Max.
Insert of Wires Insert of Wires
D-436-0128 D-436-0119
3041510 22
Red Red 2.16 [.085] 1.01 [.040]
D-436-58 D-436-75
10582680 22
Blue Blue
4.56 [.180] 2.28 [.090]
D-436-59 D-436-76
23756755 22
Yellow Yellow
4.56 [.180]
2.28 [.090]
D-436-60 D-436-77 10
10582680 2
2.03
Blue Blue (2 per hole)
[.080]
6.35 [.250]
D-436-61 D-436-78 10
23756755 2
2.03
Yellow Yellow (2 per hole)
[.080] 6.35 [.250]
8-25
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters Canada: +1 (905) 475-6222 UK: +44 (0) 800-267666
Revised 5-12 reference purposes only. unless otherwise specified. Mexico/C. Am.: +52 (0) 55-1106-0800 France: +33 (0) 1-3420-8686
Specifications subject Latin/S. Am.: +54 (0) 11-4733-2200 Netherlands: +31 (0) 73-6246-999
www.te.com to change. USA: +1 (800) 522-6752 Germany: +49 (0) 6251-133-1999 China: +86 (0) 400-820-6015