Insulated Wire Connector Terminal

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Insulated Wire Connector Terminal Overview

An insulated wire connector terminal — commonly called a butt connector, splice connector, or in-line connector — is a single-use or multi-use terminal that joins two or more conductors end-to-end inside a fully insulated barrel. The barrel provides both the mechanical crimp joint and complete electrical insulation, making the finished splice safe to handle and suitable for installation in confined spaces without additional insulation tape.

Fenglan supplies insulated wire connectors in standard PVC barrel, heat-shrink lined waterproof, and lever-actuated reusable variants, covering wire sizes from 0.5 mm² to 35 mm². Colour-coded sleeves in red, blue, and yellow allow wire-size identification at a glance, conforming to UL and IEC colour standards.

Specification

Connector Type	Insulated butt splice (crimp or lever-lock)
Wire Range	0.5 mm² – 35 mm² (AWG 20 – AWG 2)
Contact Material	Electrolytic copper, tin-plated
Insulation Material	PVC (standard); heat-shrink polyolefin (waterproof); PA nylon (lever type)
Rated Voltage	600 V AC/DC
Rated Current	Up to 100 A (35 mm² butt connector)
Operating Temperature	–40 °C to +105 °C (PVC); –40 °C to +125 °C (heat-shrink / nylon)
Colour Coding	Red (0.5–1.5 mm²), Blue (1.5–2.5 mm²), Yellow (4–6 mm²)
Waterproof Option	Heat-shrink lined with hot-melt adhesive; IP67 rated after shrinking
Standards	UL 486C, CE, RoHS
MOQ	100 pcs; 50 pcs sample

Application

Automotive and truck harness repair — in-line splice of cut or damaged harness wires without access to the connector plug or junction box
Marine wiring — heat-shrink waterproof versions seal cable joints in bilge and deck wiring against salt-water immersion
Building and residential electrical — extending circuit cables in junction boxes, loft insulation, and behind-wall installations
Solar PV string wiring — field-joining of panel extension cables on rooftops where soldering is impractical
Appliance and white-goods service — splicing lead wires to replacement heating elements, motors, and pumps during field repair
LED strip and low-voltage lighting — quick-join connections for RGB and single-colour LED power leads without soldering
Alarm, CCTV, and access control systems — clean, insulated mid-cable joins for power and signal wiring inside conduit and cable management

Advantage

Fully insulated from crimp to crimp — the barrel covers the entire joint; no bare metal is exposed after crimping, eliminating the need for insulation tape in most indoor applications
IP67 waterproof option — heat-shrink lined connectors with hot-melt adhesive form a watertight seal on both wire entries when heated, rated IP67 for submersion up to 1 m — ideal for automotive underbody and marine applications
Lever-lock reusable variant — no-crimp lever connectors allow the wire to be inserted and clamped without tools, and released and re-used repeatedly, saving time during prototyping, testing, and frequent reconfiguration
Both wire ends accessible from outside — unlike a wire nut, the straight barrel keeps both wires in line, allowing the finished splice to pass through conduit knockout holes and cable clips without snagging
UL 486C listed — third-party verified for pull-out force, voltage withstand, and temperature rise, satisfying North American electrical code requirements without additional testing
Wide size range in one product family — red, blue, and yellow colour codes and a continuous wire range from 0.5 mm² to 35 mm² allow a single supplier and single crimper to cover all wiring gauges on a job

Payment & Shipping

We accept T/T (bank transfer), L/C at sight, PayPal (samples), and Western Union. A 30% deposit is required to confirm production, with the balance paid before shipment.

Standard lead time is 7–15 business days for regular orders; prototype samples ship within 3–5 days. We ship worldwide via DHL, FedEx, UPS, sea freight (FCL/LCL), and air freight. FOB Changzhou and CIF terms are both available. All goods are packed in export-standard cartons with foam padding or wooden crates for heavy items. A commercial invoice, packing list, and COA are provided with every shipment. For large OEM orders, customized packaging and private-label options are available upon request.

Q: Can I join wires of different sizes in one insulated connector?
A: Most butt connectors are designed for one wire size range per barrel. Joining wires of very different cross-sections (e.g. 1.5 mm² to 6 mm²) in a single barrel produces an uneven crimp — one wire will be over-crimped while the other is under-crimped. For mixed-size splices, use a reducing butt connector rated for both sizes, or join through a terminal block which allows different wire sizes on each side.

Q: How do I activate the heat-shrink waterproof connectors?
A: After crimping both wire ends, apply heat uniformly along the barrel using a heat gun at 120–150 °C until the outer sleeve shrinks tightly and the hot-melt adhesive flows out of both ends, indicating a complete seal. Do not use a naked flame — uneven heat concentration chars the sleeve and prevents proper adhesive flow, resulting in a non-waterproof joint.

Q: Are insulated wire connectors reusable?
A: Standard crimp-type butt connectors are single-use — once crimped, the barrel is permanently deformed and cannot be re-used without cutting the wire and re-stripping. Our lever-lock wire connector variant is fully reusable: the lever releases the wire clamp for removal and re-insertion without tools, making it ideal for temporary connections, test rigs, and frequently reconfigured panels.

Q: What is the minimum strip length required for butt connectors?
A: Strip length should equal the depth of the barrel from the wire entry to the centre stop — typically 8–12 mm depending on connector size. The stripped wire should reach the centre stop and be visible through the inspection window (if present) to confirm full insertion before crimping. Under-stripped wire leaves an air gap in the crimp zone, significantly reducing pull-out strength.

Changzhou Fenglan New Materials Co., Ltd.

ABOUT US

Quality is Our Core Competitiveness

Changzhou Fenglan New Materials Co., Ltd.

Founded in 2010, As China Insulated Wire Connector Terminal Manufacturers and Insulated Wire Connector Terminal Company. we are dedicated to manufacturing precision parts for automotive, industrial, and electrical applications. Backed by advanced manufacturing and R&D, we provide high-quality products and trusted solutions to our clients. We provide a wide selection of components to meet diverse industry needs: Electric Shafts: Drive shafts, coil motor shafts, servo motor shafts, water pump motor shafts, industrial motor shafts, and magnetic levitation motor shafts. Hardware: Precision parts for medical equipment, water heater coils, plumbing fittings, and various gas springs. Our commitment is to support our customers with reliable performance and long-term value.

We look forward to working with you

With a strong R&D team, we are ready to take on challenges and bring creative ideas to the market.

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