SPLICE FOR FINE ALUMINUM MAGNET WIRE

For the growing number of motor, solenoid and coil manufacturers converting to fine (0.14 - 0.32mm dia) aluminum magnet wire, this new open barrel pigtail splice offers a reliable connectivity solution at a low applied cost.

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TE Connectivity’s (TE) new fine aluminum (Al) magnet wire splice accommodates 0.14 to 0.32mm dia (35 to 28 AWG) wires. This addresses the needs of a growing number of motor and solenoid manufacturers who are switching to fine (<0.32mm) Al magnet wires to reduce product cost and weight. Prior to introduction of this splice, traditional soldering/welding processes were still being used for terminations of these wires, as existing AMPLIVAR splices could only accommodate Al wires larger than 0.32mm. This new open barrel, pigtail splice fills the gap at the lower end of the AMPLIVAR splice size range. It can accommodate up to three fine Al magnet wires plus a copper stranded lead wire (400 to 1500 CMA total). By converting to this new splice applied with an APT-5A terminating machine, customers using fine Al magnet wire can eliminate traditional soldering/welding, reducing labor and improving efficiency with our IDC crimp technology.

Benefits

Accommodates up to three fine Al magnet wires plus a copper stranded lead wire (400 to 1500 CMA total) in a single splice for efficient connectivity.
Improves production efficiency with IDC compression crimp feature that does not require pre-stripping of magnet wires. It penetrates the magnet wire insulation while simultaneously terminating wire.
Helps reduce applied cost and increase connection reliability by eliminating possible errors such as cold solder joints, weld burns and wire embrittlement that might occur during soldering/welding.
Enables higher production rates with precision formed and strip-fed splices applied with APT-5A terminating machine.
Provides a mechanically strong, superior electrical connection free of contaminants such as stripper residue and solder flux.

Quick Reference Guide

Splice For Fine Aluminum Magnet Wire

.14mm

Minimum diameter of aluminum wire for use in this splice

3+1

Handles up to 3 fine aluminum magnet wires plus a stranded copper lead wire

1500

Maximum total CMA this splice can accommodate