Design Considerations for Long-Term Splice Sealing Reliability in Harness Applications
Download Trend PaperIn modern electrical systems, splice locations often represent one of the most vulnerable points in the wire harness. Hidden within constrained spaces and exposed to moisture, fluids, temperature cycling, and vibration, unprotected splices can become a source of corrosion, electrical degradation, and system-level failures. TE Connectivity's Performance Materials splice sealing portfolio helps engineers address these challenges through proven materials science and application expertise.
Our splice sealing portfolio combines insulation, environmental sealing, strain relief, and mechanical reinforcement within a single integrated solution. Whether you're designing automotive harnesses, EV battery systems, industrial equipment, or transportation platforms, TE offers solutions engineered for long-term durability and manufacturing efficiency.
• Adhesive-Lined Heat Shrink Tubing: For environmental sealing and mechanical protection of wire splices exposed to moisture, fluids, and harsh operating environments.
• High Shrink Ratio Solutions: Accommodate multiple wire diameters while simplifying inventory management and manufacturing processes.
• Flame-Retardant Solutions: Designed to support applications requiring enhanced safety and performance.
• Sealing Sleeves and End Caps: Purpose-built solutions that provide additional environmental protection in demanding installation environments.
• Automotive-Qualified Products: Engineered to support body, chassis, battery, and high-voltage electrical architectures
• Environmental Protection: Create a durable barrier against water, road salt, humidity, oils, fuels, hydraulic fluids, and other contaminants.
• Mechanical Protection: Provide abrasion resistance, cut-through protection, and strain relief at critical transition zones.
• Thermal Durability: Maintain sealing performance across demanding temperature ranges and repeated thermal cycling.
• Manufacturing Confidence: Enable repeatable assembly through predictable recovery characteristics and visible adhesive flow.
• Inventory Optimization: High shrink ratio solutions support multiple wire sizes, helping reduce SKU complexity and inventory costs.
Protect critical splice locations throughout:
• Body harnesses
• Chassis systems
• EV battery packs
• High-voltage distribution systems
• Charging infrastructure
Electrification is increasing harness complexity, power density, and reliability expectations, making robust splice protection more critical than ever.
• Truck and bus harnesses
• Construction equipment
• Agricultural machinery
• Off-highway vehicles
Designed to withstand vibration, shock, fluid exposure, and harsh environmental conditions.
• Industrial automation
• Robotics
• Energy systems
• Harsh-environment electronics
Deliver protection where downtime and system failures are costly.