Cable-to-Cable Splicing
SolderShield Shielded and Coaxial Cable Splices
Product Facts
Flux-coated, solderimpregnated copper shield
braid encased in a
transparent heat-shrinkable
insulation sleeve provides a
controlled soldering
process, encapsulation,
inspectability, strain relief,
and insulation
■ One-piece design provides
easy installation and lower
installed cost
■ Circumferential (360°)
shielding results in EMI
protection and shield
continuity equal to or better
than the original cable
■ Conductor splices are made
using MiniSeal crimp
products, which are
recognized by MIL-S-81824
and MIL-W-5088
■
Applications
Product Selection Process
Used for splicing a wide
range of cables, including
coaxial and multiconductor
cables.
For splicing multiconductor
cables refer to Table A.
SolderShield devices can
be used to repair or splice
shielded or coaxial cables.
These products consist of
a MiniSeal crimp splice
plus a flux-coated, solderimpregnated copper shield
encased in a heat-shrinkable
sealing sleeve, for splicing
the shields. SolderShield
kits terminate single- or
multiple-conductor cables,
eliminate EMI problems at
the splice, and provide
strain relief for the cable.
For splicing coaxial cables
refer to Table B.
Installation
For proper installation of
these devices, the correct
heating tool and reflector
attachment must be used.
Any one of the following
TE heating tools is recommended:
■
HL1910E/HL2010E
■
IR-1759 MiniRay
■
CV-1981
Refer to TE installation
procedure RCPS-150-02
(D-150 series) and
RPIP-699-00 (B-202 series)
for detailed instructions and
recommended reflector
attachment.
You will find ordering information for most of these
tools in Section 10.
Specifications/Approvals
Series
Military
US: M81824 (conductor splice only)
UK: RAF AP 1130-2008-1
D-150
Available in:
Americas
Europe
Asia Pacific
TE
RT-1404
■
■
■
8-66
Catalog 1654025
Revised 5-12
www.te.com
Dimensions are shown for
reference purposes only.
Specifications subject
to change.
Dimensions are in millimeters
unless otherwise specified.
USA: +1 (800) 522-6752
Canada: +1 (905) 475-6222
Mexico/C. Am.: +52 (0) 55-1106-0800
Latin/S. Am.: +54 (0) 11-4733-2200
Germany: +49 (0) 6251-133-1999
UK: +44 (0) 800-267666
France: +33 (0) 1-3420-8686
Netherlands: +31 (0) 73-6246-999
China: +86 (0) 400-820-6015
Cable-to-Cable Splicing
SolderShield Shielded and Coaxial Cable Splices (Continued)
Crimp Splice
SolderShield Splice
Table A. Multiconductor
Cable Splices
L1
Each SolderShield part
consists of a SolderShield
splice and one or more
conductor splices. Refer to
information below for
description and numbers of
conductor splices.
L3
L2
I.D.
SolderShield Product Dimensions
Dimensions
Part No.
Tin Plated
Nickel Plated
L1
Max.
L2
Nom.
L3
Min.
ID
Min.
D-150-0168
D-150-0228
D-150-0169
D-150-0229
D-150-0170
D-150-0230
D-150-0174
D-150-0231
D-150-0175
D-150-0232
D-150-0176
D-150-0233
D-150-0177
D-150-0234
D-150-0178
D-150-0235
D-150-0179
D-150-0236
D-150-0180
D-150-0237
D-150-0181
D-150-0238
80.50
[3.17]
80.50
[3.17]
80.50
[3.17]
10.60
[4.17]
10.60
[4.17]
10.60
[4.17]
10.60
[4.17]
10.60
[4.17]
10.60
[4.17]
10.60
[4.17]
10.60
[4.17]
50.00
[1.97]
50.00
[1.97]
50.00
[1.97]
75.00
[2.95]
75.00
[2.95]
75.00
[2.95]
75.00
[2.95]
75.00
[2.95]
75.00
[2.95]
75.00
[2.95]
75.00
[2.95]
10.20
[.400]
10.20
[.400]
10.20
[.400]
10.20
[.400]
10.20
[.400]
10.20
[.400]
10.20
[.400]
10.20
[.400]
10.20
[.400]
10.20
[.400]
10.20
[.400]
3.00
[.118]
4.00
[.157]
5.00
[.197]
4.00
[.157]
5.00
[.197]
6.00
[.236]
9.00
[.356]
4.00
[.157 ]
5.00
[.197]
6.00
[.236]
9.00
[.353]
Conductor Splice
Size Range
CMA [mm2]
Min.–Max.
304–1510
[0.15–0.75]
779–2680
[0.39–1.34]
1900–6755
[0.95–3.37]
304–1510
[0.15–0.75]
779–2680
[0.39–1.34]
1900–6755
[0.95–3.37]
304–1510
[0.15–0.75]
304–1510
[0.15–0.75]
779–2680
[0.39–1.34]
1900–6755
[0.95–3.37]
1900–6755
[0.95–3.37]
Color
Code
Quantity
Per Kit
Red
1
Blue
1
Yellow
1
Red
2
Blue
2
Yellow
2
Yellow
2
Red
4
Red
4
Blue
4
Yellow
4
Note: The SolderShield splice kits listed in this table are for 1:1 cable splices. The kits can be used on cables with tin-, silver-, and nickel-plated copper conductors. All the kits have environmental-sealing capability. The cable temperature rating must be 125°C minimum.
To find the splice kit part number for your application:
1. Determine the number of conductors in the cable to be spliced.
2. Determine the gauge of each conductor or the maximum jacket OD.
3. Determine the conductor plating.
4. Select the appropriate part number from the table above.
8
Electrical Interconnect Products
8-67
Catalog 1654025
Revised 5-12
www.te.com
Dimensions are shown for
reference purposes only.
Specifications subject
to change.
Dimensions are in millimeters
unless otherwise specified.
USA: +1 (800) 522-6752
Canada: +1 (905) 475-6222
Mexico/C. Am.: +52 (0) 55-1106-0800
Latin/S. Am.: +54 (0) 11-4733-2200
Germany: +49 (0) 6251-133-1999
UK: +44 (0) 800-267666
France: +33 (0) 1-3420-8686
Netherlands: +31 (0) 73-6246-999
China: +86 (0) 400-820-6015
Cable-to-Cable Splicing
SolderShield Shielded and Coaxial Cable Splices (Continued)
Table B. Coaxial Cable
Splices
Crimp Splice
SolderShield Splice
Each SolderShield part
consists of a SolderShield
splice and one or more
conductor splices. Refer to
information below for
description and numbers
of conductor splices.
L1
L3
L2
I.D.
RG Cable No.
Cable Description
8A, 9B, 11
13, 26, 31
115, 144, 149
165, 213, 214
216, 235, 391
393, 397
178, 196,
179, 187, 188,
316, 404, M17/138-00001,
M17/136-00001
180, 195
M17/137-00001
M17/139-00001
—
124, 140, 141
159, 302, 303
—
—
—
29, 30, 55B
58, 223
—
59, 62, 71
—
—
5012A3311
5012E1339
7518A1311
—
—
—
5028A1317
7528A1317
5030A1317
7530A1317
5024A1311
7526A1311
9527A1318
9530E1014
5020A1311
5022A1311
7522A1311
7523D1331
7524A1311
5019D3318
5021D1331
5022A1311
7523D1331
7524A1311
9524A1311
SolderShield Dimensions
L2 Min
ID Min
Conductor
Splice Qty/Kit
Part
No.
1
D-150-0214
80.50
[3.170]
50.00
[1.970]
12.00
[.472]
1
D-150-0094
80.50
[3.170]
50.00
[1.970]
3.00
[.118]
1
D-150-0095
80.50
[3.170]
50.00
[1.970]
4.00
[.157]
1
D-150-0096
80.50
[3.170 ]
50.00
[1.970]
5.00
[.236]
1
B-202-81*
56.00
[2.200]
23.00
[.900]
7.00
[.275]
1
B-202-82*
56.00
[2.200 ]
23.00
[.900]
7.00
[.275]
L1 Max
*These kits use solder to terminate the center conductors. All other kits use crimp.
All kits are for one-to-one coaxial cable splices, and all kits have environmental sealing capability. Each kit contains products to splice conductors, build up
dielectric, splice the shield, and provide insulation.
8-68
Catalog 1654025
Revised 5-12
www.te.com
Dimensions are shown for
reference purposes only.
Specifications subject
to change.
Dimensions are in millimeters
unless otherwise specified.
USA: +1 (800) 522-6752
Canada: +1 (905) 475-6222
Mexico/C. Am.: +52 (0) 55-1106-0800
Latin/S. Am.: +54 (0) 11-4733-2200
Germany: +49 (0) 6251-133-1999
UK: +44 (0) 800-267666
France: +33 (0) 1-3420-8686
Netherlands: +31 (0) 73-6246-999
China: +86 (0) 400-820-6015
Cable-to-Cable Splicing
SolderShield Shielded and Coaxial Cable Splices (Continued)
Product Characteristics
Materials
Insulation sleeve
Meltable inserts
Radiation-crosslinked polyvinylidene fluoride
Fluorocarbon-based thermoplastic
Base metal: Copper alloy C10200 per ASTM B75
Plating: Tin per MIL-T-10727 or nickel per QQ-N-290
Base metal: Tin-plated copper wire braid per ASTM B3
Solder and flux coating: Type Sn63 Pb37. Flux: ROM1 per ANSI - J - STD - 004 (RA flux)
MiniSeal crimp splice
SolderShield shield splice
Parameter
Electromechanical Performance
Dielectric strength (shield connection)
Dielectric strength (conductor connection)
Voltage drop
Insulation resistance (shield connection)
Insulation resistance (conductor connection)
Tensile strength for MiniSeal
Tensile strength for SolderShield
Temperature rating
Environmental Resistance
Salt spray
Heat aging
Temperature cycling
Altitude immersion
Test Method
Requirement
—
—
MIL-S-81824
—
—
MIL-S-81824
MIL-S-81824
No breakdown or arcing at 1000 Vac (RMS)
2.5 kV
Less than 2.0-millivolt increase
1000 megohms minimum at 500 Vdc
5000 megohms
Exceed yield strength (pounds) of wire.
75% of strength (pounds) of unspliced cable
—
MIL-STD-202 M101
750 hours at 150°C [302°F]
MIL-STD-202 M107C
Immersion at 22,860m [75,000 ft]
Corrosion resistance
—
-55°C to 150°C [-67°F to 302°F]
Meet voltage drop requirement.
Meet all electromechanical requirements.
Meet all electromechanical requirements.
Meet insulation-resistance requirement.
No evidence of corrosion after testing in accordance
with MIL-STD-202, Method 101, Test Condition A
8
Electrical Interconnect Products
8-69
Catalog 1654025
Revised 5-12
www.te.com
Dimensions are shown for
reference purposes only.
Specifications subject
to change.
Dimensions are in millimeters
unless otherwise specified.
USA: +1 (800) 522-6752
Canada: +1 (905) 475-6222
Mexico/C. Am.: +52 (0) 55-1106-0800
Latin/S. Am.: +54 (0) 11-4733-2200
Germany: +49 (0) 6251-133-1999
UK: +44 (0) 800-267666
France: +33 (0) 1-3420-8686
Netherlands: +31 (0) 73-6246-999
China: +86 (0) 400-820-6015
