Customized Solder Sleeve Wire Splices
Customized Solder Sleeve Wire Splices
Application
Our Solder Sleeve Wire Splices feature an all-in-one design that integrates a pre-fluxed solder preform, heat-shrink insulation, and environmental sealing rings into a single, easy-to-install unit. This design eliminates the need for soldering irons, allowing for simultaneous soldering, insulating, and sealing with just a heat gun. The transparent sleeve permits immediate visual verification of the solder joint quality. By streamlining the workflow, this solution significantly reduces installation time and guarantees process consistency across automotive, rail transit, and high-precision industrial wiring harnesses.
Series Overview
• SW125B Series: Polyolefin outer sleeve, 125°C (257°F), environmental solder ring features a slim profile; larger sizes are equipped with dual or triple solder rings. Solder ring melts at 138°C.
• SW125C Series: Polyolefin outer sleeve, 125°C (257°F), 138°C solder melt.
• SW150F Series: PVDF outer sleeve, 150°C (302°F), immersion sealing, 183°C solder melt, featuring a Thermochromic Temperature Indicator.
• SW150AP Series: PVDF outer sleeve, 150°C (302°F) without adhesive lining. Solder ring melts at 183°C.
Features and Benefits
• Three series tailored to distinct temperature and sealing demands.
• Clear sleeve for hassle-free placement and visual quality control.
• Encapsulated Protection: Heat-shrink sealing provides robust insulation, mechanical reinforcement, and superior corrosion resistance in one step.
• Field-Proven Reliability: Trusted performance across automotive, rail transit, and high-precision industrial equipment worldwide.
Color
White, Red, Blue, Yellow, Green, Purple, Orange, Clear
Notes
•Custom sizes and colors are available upon request. Technical specifications are subject to change without prior notice. Minimum order quantities (MOQ) may differ from standard packaging quantities.
•If you need a solder-sleeve splice that comes with an integrated shield (drain) wire, choose our "SS" Series.
•For complete material specifications, please contact us to request the data sheet.
•When different wire gauges are required on the two ends of the splice, opt for the "CA" Series.
Product Specifications
| Table A. Product Options | |||
| Product Series | Minimum Wire Temperature Rating | Maximum Operating Temperature | Intended Application Environment |
| SW125B | 85℃ [185℉] | 125℃ [257℉] | Splashproof |
| SW125C | 85℃ [185℉] | 125℃ [257℉] | Splashproof |
| SW150AP | 125℃ [257℉] | 150℃ [302℉] | Splashproof |
| SW150F | 125℃ [257℉] | 150℃ [302℉] | Immersion sealed |
Note: Cadmium-free option is available for operating temperature of 125℃[257℉]. Available in 150°C high-temperature versions. Choose between SW150B (Lead-free) or SW150C (Leaded) series based on your environmental requirements. Please contact the DINGYUAN for details.
| Table B. Fine Wire Splices | |||
| Part No. | Inside Diameter | ||
| As Supplied* | Fully Recovered** | Length*** | |
| SW150AP-71 | 0.9[0.035] | 0.6[0.025] | 4.7[0.185] |
| SW150AP-213 | 0.9[0.035] | 0.6[0.025] | 4.2[0.165] |
| SW150AP-214 | 0.6[0.035] | 0.3[0.013] | 6.3[0.0250] |
| SW150AP-217 | 1.0[0.040] | 0.6[0.025] | 9.1[0.360] |
| SW150AP-40 | 0.6[0.025] | 0.5[0.021] | 5.1[0.200] |
Note: Micro SolderSleeve terminations are used for splicing wires smaller than 26 awg[0.15m²].
*Minimum. Wire insulation must be smaller than this
**Maximum.Wire insulation and combined conductor diameters must be greater than this
***Nominal Wire strip length must be approximately one-half of this
| Table C. CMA of Typical AWG Conductors | |||||||||
| AWG | 28 | 26 | 24 | 22 | 20 | 18 | 16 | 14 | 12 |
| CMA | 177 | 304 | 475 | 754 | 1216 | 1900 | 2426 | 3831 | 5874 |
| mm² | 0.09 | 0.15 | 0.23 | 0.38 | 0.62 | 0.96 | 1.23 | 1.44 | 2.97 |
| Table D. Product Characteristics | |
| Material | |
| Insulation (SW150A, SW150AP) | Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride |
| Insulation (SW125B) | Radiation-crosslinked, heat-shrinkable polyolefin |
| Solder (SW150A, SW150AP) | Solder: Sn63 Pb37 |
| Solder (SW125B) | Solder: Sn42Bi58 |
| Solder (SW125C) | Solder: Sn50 Pb32 Cd18 |
| Meltable inserts(SW125B, SW150A) | Meltable thermoplastic |
| Typical Performance | |
| Voltage drop | 2.0mv |
| Tensile strength | Exceeds strength of conductor |
| Dielectric strength | 2.0kv |
| Temperature rating(SW125B) | -55℃to +125℃ [-67℉to 257℉] |
| Temperature rating(SW150A, SW150AP) | -55℃to +150℃ [-67℉ to 302℉] |
| Insulation resistance | 1000 MΩ |
| Table E. SW125B Series | ||||||||||
| Part No. | Color Code | Product Dimensions | Wire Dimensions | Selection Guide | Solder Ring Qty | |||||
| L Max. | d Min. | B Min. | B Max. | Total mm2 | Total CMA | |||||
| Min | Max | Min | Max | |||||||
| SW125B-G1 | Clear | 26.0 [1.025] | 1.7 [0.065] | 0.4 [0.015] | 1.7 [0.065] | 0.3 | 0.8 | 450 | 1500 | 1 |
| SW125B-G2 | Red | 42.0 [1.655] | 2.7 [0.105] | 1.3 [0.050] | 2.7 [0.105] | 0.8 | 2 | 1250 | 3500 | 2 |
| SW125B-G3 | Blue | 4.5 [0.180] | 1.8 [0.070] | 4.5 [0.180] | 2 | 4 | 2500 | 7200 | 2 | |
| SW125B-G4 | Yellow | 6.0 [0.235] | 2.8 [0.110] | 6.0 [0.235] | 4 | 6 | 6100 | 19000 | 2 | |
| SW125B-G5 | Grey | 7.0 [0.275] | 3.2 [0.125] | 7.0 [0.275] | 6 | 10 | 12000 | 25000 | 2 | |
| Table F. SW125B Series | |||||||||
| Part No. | Color Code | Product Dimensions | Wire Dimensions | Selection Guide | |||||
| L Max. | d Min. | B Min. | B Max. | Total mm2 | Total CMA | ||||
| Min | Max | Min | Max | ||||||
| SW125C-G1 | Clear | 26.0 [1.025] | 1.7 [0.065] | 0.4 [0.015] | 1.7 [0.065] | 0.3 | 0.8 | 450 | 1500 |
| SW125C-G2 | Red | 42.0 [1.655] | 2.7 [0.105] | 1.3 [0.050] | 2.7 [0.105] | 0.8 | 2 | 1250 | 3500 |
| SW125C-G3 | Blue | 4.5 [0.180] | 1.8 [0.070] | 4.5 [0.180] | 2 | 4 | 2500 | 7200 | |
| SW125C-G4 | Yellow | 6.0 [0.235] | 2.8 [0.110] | 6.0 [0.235] | 4 | 6 | 6100 | 19000 | |
| SW125C-G5 | Grey | 7.0 [0.275] | 3.2 [0.125] | 7.0 [0.275] | 6 | 10 | 12000 | 25000 | |
| Table G. SW150AP Series | ||||
| Part No. | Color Code | Sleeve Dimensions | Solder Ring Dimensions | |
| L | d Min. | I.D. Min. | ||
| SW150AP-28 | Blue | 18.54±1.27 [0.73±0.05] | 1.52 [0.060] | 1.27 [0.050] |
| SW150AP-35 | Blue | 26.67±2.54 [1.05±0.10] | 1.91 [0.075] | 1.78 [0.070] |
| SW150AP-40 | Blue | 5.08±0.51 [0.20±0.02] | 0.63 [0.025] | 0.53 [0.021] |
| SW150AP-41 | Blue | Max: 27.6 [1.090] | 3.2 [1.090] | 2.7 [0.105] |
| SW150AP-71 | Blue | 4.57±0.51 [0.18±0.02] | 0.89 [0.035] | 0.84 [0.033] |
| SW150AP-83 | Blue | 54.10±2.54 [2.13±0.10] | 8.76 [0.345] | / |
| SW150AP-101 | Blue | 36.80±2.54 [1.45±0.10] | 4.32 [0.17] | / |
| SW150AP-181 | Blue | 38.10±1.30 [1.50±0.05] | 4.45 [0.175] | / |
| SW150AP-213 | Blue | 4.20±0.50 [0.165±0.02] | 0.9 [0.035] | / |
| SW150AP-214 | Clear | 6.40±0.80 [0.25±0.03] | 0.53 [0.021] | 0.66 [0.026] |
| Table H. SW150F Series | ||||||
| Part No. | CMA Range | Sleeve Dimensions | Solder Ring Dimensions | Wire Dimensions | ||
| L Max. | d Min. | I.D. Min. | B Max. | B Min. | ||
| SW150F-01 | 350 - 2000 | 29.7 [1.170] | 1.9 [0.075] | 2.4 [0.095] | 1.9 [0.075] | 0.5 [0.020] |
| SW150F-02 | 2000 - 4000 | 30.15 [1.187] | 2.8 [0.110] | 3.15 [0.125] | 2.8 [0.110] | 0.8 [0.030] |
| SW150F-03 | 4000 - 10000 | 29.6 [1.165] | 4.6 [0.180] | 5.1 [0.200] | 4.57 [0.180] | 1.3 [0.050] |
| SW150F-04 | 10000 - 13000 | 30 [1.180] | 7.11 [0.280] | 7.62 [0.300] | 7.11 [0.280] | 2 [0.080] |
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