What are Inline Splice Connectors?

By AJ Born | July 12, 2022

Meet the Connector: Inline Splice Connectors 

Inline splice connectors are used to connect two physical cables or to split an existing cable into two separate entities while maintaining signal continuity between them. Inline splices are designed to provide a quick and efficient solution to customer wiring requirements.  Single and dual wire splices meet MIL-T-81714 requirements and are highly resistant to temperature and fluids.

Uses range from repairing a single damaged wire, to modifying an analog circuit with components including fuses, resistors, diodes, capacitors, and inductors in order to adapt replacement systems. Splices provide a way to incorporate system modifications into a wire bundle, while avoiding changes in panels or circuit boards.

The inline splice connector can be used for multiple functions and applications. Typical applications include power distribution on aircraft, military ground vehicles, and seaborne systems in harsh environments. It is also used in lighting applications, wire extension applications, and through connections with limited space. It is a more secure replacement for the butt splice/crimp splice type of wire connection. The popularity of inline connectors has increased as space becomes more limited and, as a result, the ability to make safe, reliable connections is compromised.

WAGO’s new 221 Series Inline Splicing Connector

WAGO’s new 221 Series Inline Splicing Connector connects all conductor types at once. This connector condenses the advantages of the 221 Series into a slim design. Optional adapters provide completely modular mounting. Users get the flexibility of having five fixed-position poles in one adapter.

“We have taken all of our familiar 221 Series LEVER-NUTS technology and put it into a slim inline design,” said Nick Holzman, product manager-electrical splicing connectors, WAGO. “Simply lift the levers, insert your 11 mm stripped conductor ranging from 12-20 AWG, and push the levers down for a secure, reliable connection.” WAGO offers mounting carriers to build multipole units ranging from 1 to 5 times in one carrier, Holzman added. “You also have the ability to connect together the carriers for a complete modular experience.”

Amphenol PCD Inline splices

Amphenol PCD Inline splices are designed to provide a quick and efficient solution to customer wiring requirements. Single and dual wire splices meet MIL-T-81714 requirements and are highly resistant to temperature and fluids.

 

Phoenix Contact’s QUICKON IDC watertight inline cable splices

The small circular form factor of Phoenix Contact’s QUICKON IDC watertight inline cable splices fits round cables to establish permanent shielded connections and ensure reliable data communication.

For networking applications, newer splice connectors eliminate the trade-offs of other solutions, such as pluggable RJ45 connectors, M12 connectors, and patch panels, which require additional parts and labor. An inline splice connector, like Phoenix Contact’s IDC technology, has only a single part and does not require wire stripping or special tools. This makes it useful for field installations and faster to install than other connector solutions. 

TE Connectivity AMP's CoolSplice connectors

TE Connectivity AMP’s CoolSplice connectors, supplied by Digi-Key Electronics, combine reliability with ease of termination. CoolSplice is suitable for splicing 22 AWG to 18 AWG (0.34 mm² to 0.75 mm²) solid and stranded wire. A common pair of pliers is used to push-button terminate insulated wires into an insulation displacement crimp contact. A reliable connection is provided and visually confirmed through the clear sidewall.

Design Notes 

Wire types Inline splice connectors are available to accommodate solid or stranded wires.

Markets, Sectors, and Applications

Lighting applications, wire extension applications, traffic monitoring and surveillance, security and alarm systems, audio speaker connections, railway and public transit, and through connections with limited space.

Suppliers

WAGO, Phoenix Contact, DigiKey Electronics, TE Connectivity, Amphenol PCD

Related products:

Butt splice/crimp splice wire connectors

Like this article? Check out our other Meet the Connector, Harsh Environment, and our Military/Aerospace Industry Page, and our 2022 Article Archive

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AJ Born
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