Patent Publication Number: US-9887529-B2

Title: Spliced shielded wire cable

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a divisional application of U.S. patent application Ser. No. 14/274,857, filed May 12, 2014, the entire disclosure of which is hereby incorporated herein by reference. 
    
    
     TECHNICAL FIELD OF THE INVENTION 
     The invention generally relates to a method for splicing shielded wire cables and the spliced wire cables produced by this method. 
     BACKGROUND OF THE INVENTION 
     Shielded wire cables typically include an insulated core conductor and a separate insulated shield conductor surrounding the core conductor insulation. The shield conductor may consist of a braided wire mesh, metal foil, or metalized film. The cables typically have a second insulation layer covering the shield conductor. Shielded wire cables have been long used for communications systems, such as in cable television transmission lines. Shielded wire cables are also finding use in high voltage applications in electric and hybrid electric vehicles. When shielded wire cables are spliced together, there is usually a need to electrically connect the shield conductors of the spliced cables as well as the core conductor, in order to maintain electrical continuity of the shield conductors. Interconnecting the shield conductors may be complicated because the shield conductors must be cut back from the spliced ends of the cable in order to join the core conductors. Interconnecting the shield conductors may be further complicated in a one-to-many splicing configuration, sometimes referred to as a Y-splice. 
     A prior art method splicing shielded wire cables involved joining the center conductors of the cables using a crimping connection, covering the crimped joint with an insulator, such as heat shrinkable tubing and then covering the exposed shield conductors and insulated joint with a flux coated solder impregnated conductive sleeve within a section of heat shrinkable tubing. Such a solder impregnated conductive sleeve within a section of heat shrinkable tubing is available from TE Connectivity Corporation of Menlo Park Calif. (formerly Tyco Corporation) under the brand name SolderShield. 
     The subject matter discussed in the background section should not be assumed to be prior art merely as a result of its mention in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also be inventions. 
     BRIEF SUMMARY OF THE INVENTION 
     In accordance with a first embodiment and second embodiment of this invention, a wire harness assembly is provided. The wire harness assembly includes a first shielded wire cable having a first core conductor at least partially axially surrounded by a first shield conductor which is at least partially axially surrounded by a first insulative jacket, a second shielded wire cable having a second core conductor at least partially axially surrounded by a second shield conductor which is at least partially axially surrounded by a second insulative jacket, and a third shielded wire cable having a third core conductor at least partially axially surrounded by a third shield conductor which is at least partially axially surrounded by a third insulative jacket, wherein the first, second and third core conductors form a directly joined portion and the first, second, and third shield conductors are physically separated one from another. The wire harness assembly also includes a conductive sleeve defining a longitudinal axis and a first axial passage enclosing a portion of the first, second, and third shield conductors and defining a first contact attached to the first shield conductor, a second contact attached to the second shield conductor, and a third contact attached to the third shield conductor, wherein the first, second, and third insulative jackets are separated one from another and wherein enclosed portions of the of the first, second, and third shield conductors are substantially parallel to the longitudinal axis. The wire cable assembly further includes an outer insulator sealably engaging the first, second, and third insulative jackets and enclosing the conductive sleeve. 
     The wire harness assembly may include an inner insulator disposed within the first axial passage and defining a second axial passage enclosing the joined portion of the first, second, and third core conductors. The inner insulator and the sleeve may have a generally elliptical cross section. A portion of the second axial passage may be narrowed such that only a single shielded cable may be disposed within the portion of the second axial passage. The sleeve may define a crimping wing configured to form the first contact and the sleeve may define a U-shaped slot configured to form the second and third contact. The first, second, and third contact may each define a hole configured to allow the injection of solder paste into the interior of the first, second, and third contacts. The wire harness assembly may further include a plurality of ferrules attached to each of the first, second, and third shield conductors, wherein the first, second and third contacts are attached to at least one of the plurality of ferrules. At least one ferrule in the plurality of ferrules may be formed of solder. 
     The first, second, and third contact may be attached to the first, second, and third outer conductor respectively by a plurality of ferrules. The sleeve may include a first sleeve portion configured to be joined to a second sleeve portion and the inner insulator may include a first inner insulator portion configured to be joined to a second inner insulator portion. 
     A method of splicing shielded wire cables in accordance with the first or second embodiment of this invention is provided. The method includes the steps of providing a first shielded wire cable having a first core conductor at least partially axially surrounded by a first shield conductor which is at least partially axially surrounded by a first insulative jacket, providing a second shielded wire cable having a second core conductor at least partially axially surrounded by a second shield conductor which is at least partially axially surrounded by a second insulative jacket, providing a third shielded wire cable having a third core conductor at least partially axially surrounded by a third shield conductor which is at least partially axially surrounded by a third insulative jacket, providing a shield defining a longitudinal axis, a first axial passage, and a first, second, and third contact, said shield formed of a conductive material, and providing an inner insulator defining a second axial passage, said inner insulator formed of a dielectric material. The method also includes the steps of joining the first core conductor to the second core conductor and the third core conductor, disposing the joined first, second, and third core conductors within the second axial passage, disposing the inner insulator and the first, second, and third shield conductors within the first axial passage, wherein the portions of the of the first, second, and third shield conductors disposed within the inner insulator are substantially parallel to the longitudinal axis, and separating the first, second, and third insulative jackets one from another. The method further includes the steps of attaching the first contact to the first shield conductor, the second contact to the second shield conductor, and the third contact to the third shield conductor, thereby providing a conductive path between the first, second, and third shield conductors, providing an outer insulator formed of a nonconductive material, disposing the shield within the outer insulator, and sealably engaging the outer insulator to the first, second, and third insulative jackets, thereby enclosing the shield within the outer insulator. The joined first, second, and third core conductors may be slideably disposed within the second axial passage and the first, second, and third shield conductors may be slidably disposed within the first axial passage. 
     Where the first, second, and third contact each define a hole, the method may include the steps of injecting solder paste into the interior of the first, second, and third contacts through the holes defined therein and heating the solder paste until it reflows, thereby soldering the first, second, and third contacts to the first, second, and third shield conductors respectively. The method may optionally include the steps of providing a first, second, and third ferrule; attaching the first, second, and third ferrule to the first, second, and third shield conductors respectively, crimping the first, second, and third ferrule to the first, second, and third contacts respectively, thereby attaching the first, second, and third contacts to the first, second, and third shield conductors respectively. 
     Where the sleeve includes a first sleeve portion and a second sleeve portion, the method may additionally include the step of joining the first sleeve portion to the second sleeve portion, thereby disposing the joined first, second, and third core conductors within the second axial passage. 
     Where the inner insulator includes a first inner insulator portion and a second inner insulator portion, the method may further include the step of joining the first inner insulator portion to the second inner insulator portion, thereby disposing the inner insulator and the first, second, and third shield conductors within the first axial passage. 
     Where the outer insulator further includes an end cap configured to sealably engage the outer insulator and at least one shielded wire cable, the method may also include the steps of sealably engaging the end cap with the at least one shielded wire cable and sealably engaging the end cap with the outer insulator, thereby enclosing the shield within the outer insulator. 
     Another method of splicing shielded wire cables in accordance with a third embodiment of this invention is provided. The method includes the steps of providing a first, second, and third shielded wire cable each having a core conductor at least partially axially surrounded by a shield conductor which is at least partially axially surrounded by an insulative jacket, providing a flexible insulation layer, providing a flexible conductive layer, and providing a section of dual wall heat shrink tubing. The method also includes the steps of wrapping a first portion of the flexible insulation layer about the joined first, second, and third core conductors, wrapping the flexible conductive layer about the first, second, and third shield conductors, and disposing the flexible conductive layer and portions of the first, second, and third insulative jacket within the section of dual wall heat shrink tubing. 
     This method may further include the steps of wrapping a second portion of the flexible insulative layer about the first portion of the flexible insulative layer, wrapping a third portion of the flexible insulative layer about a portion of the insulative layer of the first shielded wire cable and a first portion of the flexible conductive layer, wrapping a fourth portion of the flexible insulative layer about a portion of the insulative layer of the second and third shielded wire cables and a second portion of the flexible conductive layer, providing a first and second ferrule, wrapping the first ferrule about the insulative layer of the second shielded wire cable, and wrapping the second ferrule about the insulative layer of the third shielded wire cable adjacent the first ferrule. The first and second ferrule may be disposed within the section of dual wall heat shrink tubing. 
     The first portion of the flexible insulative layer may be formed of a cloth tape. The second, third, and fourth portions of the flexible insulative layers may be formed of a section of heat shrink tubing. The fourth portion of the flexible insulative layer may have a larger diameter than the third portion of the flexible insulative layer prior to shrinking. The first and second ferrules may also be formed of a section of heat shrink tubing. 
     In accordance with the third embodiment of this invention, a wire harness assembly having a splice of at least three shielded wire cables is provided. The wiring harness includes a first shielded wire cable having a first core conductor at least partially axially surrounded by a first shield conductor which is at least partially axially surrounded by a first insulative jacket; a first, second, and third shielded wire cable each having a core conductor at least partially axially surrounded by a shield conductor which is at least partially axially surrounded by an insulative jacket, wherein the first core conductor is electrically and mechanically coupled to the second core conductor and the third core conductor. The wire harness assembly further includes a first flexible insulation layer wrapped about the joined first, second, and third core conductors, a flexible conductive layer wrapped about the first, second, and third shield conductors, and a section of dual wall heat shrink tubing in which the third and fourth flexible insulative layers and portions of the first, second, and third insulative jacket are disposed. The flexible conductive layer does not include solder. 
     The wire harness assembly may further include a second flexible insulative layer wrapped about the first insulative layer, a third flexible insulative layer wrapped about a portion of the insulative layer of the first shielded wire cable and a first portion of the flexible conductive layer, a fourth flexible insulative layer wrapped about a portion of the insulative layer of the second and third shielded wire cables and a second portion of the flexible conductive layer, a first ferrule wrapped about the insulative layer of the second shielded wire cable, and a second ferrule wrapped about the insulative layer of the third shielded wire cable and adjacent the first ferrule, wherein the first and second ferrules are also disposed within the section of dual wall heat shrink tubing. 
     The first insulative layer may be formed of a cloth tape and the flexible conductive layer is formed of braided strands. 
     Further features and advantages of the invention will appear more clearly on a reading of the following detailed description of the preferred embodiment of the invention, which is given by way of non-limiting example only and with reference to the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING 
       The present invention will now be described, by way of example with reference to the accompanying drawings, in which: 
         FIG. 1  is a schematic diagram of a prior art electrical load connection scheme; 
         FIG. 2  is a schematic diagram of an electrical load connection scheme in accordance with a first and second embodiment; 
         FIG. 3  is an illustration of a wire harness assembly having a core conductor splice connection in accordance with the first embodiment; 
         FIG. 4  is a perspective view of a wire harness assembly having an inner insulator pre-loaded on a shielded wire cable in accordance with the first embodiment; 
         FIG. 5  is a perspective view of a wire harness assembly having the inner insulator enclosing the core conductor splice connection in accordance with the first embodiment; 
         FIG. 6  is semi-transparent perspective view of the inner insulator of the wire harness assembly of  FIG. 5  enclosing the core conductor splice connection in accordance with the first embodiment; 
         FIG. 7  is a cut-away view of the inner insulator of the wire harness assembly of  FIG. 6  enclosing the core conductor splice connection in accordance with the first embodiment; 
         FIG. 8  is a perspective view of a wire harness assembly having a shield pre-loaded on the shielded wire cable in accordance with the first embodiment; 
         FIG. 9  is a perspective view of the shield the wire harness assembly of  FIG. 8  enclosing the inner insulator in accordance with the first embodiment; 
         FIG. 10  is a cut-away view of the shield of the wire harness assembly of  FIG. 9  enclosing the inner insulator in accordance with the first embodiment; 
         FIG. 11A  is a perspective view of crimping a contact of the wire harness assembly of  FIG. 10  to a shield conductor in accordance with the first embodiment; 
         FIG. 11B  is a close up top view of the crimped contact of the wire harness assembly of  FIG. 11A  in accordance with the first embodiment; 
         FIG. 12  is a top view of an outer insulator enclosing the shield of the wire harness assembly of  FIG. 10   in  accordance with the first embodiment; 
         FIG. 13  is a top view of the wire harness assembly in accordance with the first embodiment; 
         FIG. 14  is an exploded perspective view of a wiring harness assembly in accordance with a second embodiment; 
         FIG. 15  is perspective view of an inner insulator of the wiring harness assembly of  FIG. 14  in accordance with the second embodiment; 
         FIG. 16  is a perspective view of an assembly of the inner insulators of the wiring harness assembly of  FIG. 14  in accordance with the second embodiment; 
         FIG. 17  is a perspective view of an assembly of inner insulators of the wiring harness assembly of  FIG. 14  disposed within a portion of a sleeve in accordance with the second embodiment; 
         FIG. 18  is a perspective view of an assembly of inner insulators of the wiring harness assembly of  FIG. 14  enclosed within a sleeve in accordance with the second embodiment; 
         FIG. 19  is a perspective view of an assembly of fastening devices to contacts defined by the sleeve of the wiring harness assembly of  FIG. 14  in accordance with the second embodiment; 
         FIG. 20  is perspective view of a sleeve of the wiring harness assembly of  FIG. 14  in accordance with the second embodiment; 
         FIG. 21  is a perspective view of an assembly of a shield assembly within an outer insulator of the wiring harness assembly of  FIG. 14  in accordance with the second embodiment; 
         FIG. 22  is a perspective view of an assembly of end caps to shielded wire cables of the wiring harness assembly of  FIG. 14  in accordance with the second embodiment; 
         FIG. 23  is a perspective view of an assembly of the end caps to the outer insulator of the wiring harness assembly of  FIG. 14  in accordance with the second embodiment; 
         FIG. 24  is a perspective view of the outer insulator of the wiring harness assembly connected to another outer insulator of another wiring harness assembly in accordance with the second embodiment; and 
         FIG. 25A  is a side view of two wiring harness assemblies disposed within a wiring conduit in accordance with the second embodiment; 
         FIG. 25B  is an end view of two wiring harness assemblies disposed within a wiring conduit in accordance with the second embodiment; 
         FIG. 26A  is a perspective view of the shield the wire harness assembly of  FIG. 9  having four shielded wire cables in accordance with the first embodiment; 
         FIG. 26B  is a cut-away view of the shield the wire harness assembly of  FIG. 26A  in accordance with the first embodiment; 
         FIG. 26C  is a cross section view of the shield the wire harness assembly of  FIG. 26A  in accordance with the first embodiment; 
         FIG. 27A  is a flow chart of a method of splicing shielded wire cables in accordance with the first and second embodiment; 
         FIG. 27B  is a continuation of the flow chart of  FIG. 27A  in accordance with the first and second embodiment; 
         FIG. 28  is a flow chart of a method of splicing shielded wire cables in accordance with a third embodiment; 
         FIG. 29  is a top view of a wire harness assembly having a first flexible insulative layer wrapped about the spliced shielded wire cable of  FIG. 3  in accordance with the third embodiment; 
         FIG. 30  is a top view of a wire harness assembly having a second flexible insulative layer insulator wrapped about the first flexible insulative layer of  FIG. 29  in accordance with the third embodiment; 
         FIG. 31  is a top view of a wire harness assembly having a first and second ferrule insulator wrapped about the outer insulative jackets of two of the shielded wire cables of  FIG. 30  in accordance with the third embodiment; 
         FIG. 32  is a top view of a wire harness assembly having a flexible conductive layer wrapped about the exposed shield conductors of the shielded wire cables of  FIG. 31  in accordance with the third embodiment; 
         FIG. 33  is a top view of a wire harness assembly having a third flexible insulation layer wrapped about a portion of the flexible conductive layer of  FIG. 32  in accordance with the third embodiment; 
         FIG. 34  is a top view of a wire harness assembly having a fourth flexible insulation layer wrapped about a portion of the flexible conductive layer and the third flexible insulation layer of  FIG. 33  in accordance with the third embodiment; and 
         FIG. 35  is a top view of a wire harness assembly having a section of dual wall heat shrink tubing wrapped about the third and fourth flexible insulation layer and the first and second ferrules of  FIG. 34  in accordance with the third embodiment. 
         FIG. 36  is a cross section view of the wire harness assembly of  FIG. 35  in accordance with the third embodiment. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Described herein are devices and a methods for splicing two or more shielded wire cables. The devices and methods may be used to splice shielded wire cables with a single core conductor or multiple core connectors. The devices and methods described herein may be used to splice together two shield wire cables, for example to repair a cut cable. The devices and methods described herein may also be used to splice one shielded wire cable to two or more shielded wire cables to form a Y-splice. The devices and methods described herein may be used for splicing a variety of shielded wire cables types, for example shielded wire cables for communication transmissions, such as RG-59 cable, or high voltage shielded wire cables designed for electrical or hybrid electrical vehicles. 
       FIG. 1  illustrates a prior art scheme for connecting electrical loads  1  to a battery pack  2 , such as in an electric vehicle. Each electrical load  1  requires a pair of high voltage shielded wire cables (positive  3  and negative  4  polarity) running from the battery pack  2  to the electrical load  1  and a separate fuse  5  protecting each of the circuits. 
       FIG. 2  illustrates a non-limiting example of a scheme for connecting electrical loads  11  to a battery pack  12 , such as in an electric vehicle by splicing together a pair of positive cables  13  and a pair of negative cables  14  using the devices and methods presented herein. The inventors discovered that several circuits may be combined and share a single fuse  15 , for example because the electrical loads  11  are not used concurrently. The electrical loads  11  may also be connected to a controller  22  that enables the electrical loads  11  to operate one at a time so that they are not used concurrently or the controller may monitor the current used by each of the electrical loads  11  and control each of the electrical loads  11  so that the total current used by the electrical loads  11  is less than the current rating required to blow, or open, the fuse  15 . The inventors realized that a pair of high voltage shielded wire cables  13 ,  14  to these electrical loads  1  could be spliced together as shown in  FIG. 2  with a shielded cable splice device  20 , hereinafter device  20 , that connects the core conductors  17  of the shielded wire cables  13 ,  14  while maintaining isolation and continuity of the shield conductors (not shown) of the shielded wire cables  13 ,  14 , thereby reducing the length of shielded wire cable  13 ,  14  required to interconnect the electrical loads  11  to the battery pack  12 , thus reducing shielded wire cable  13 ,  14  cost, weight, packaging space, and wire routing complexity for the wiring harness. Because multiple electrical loads  11  can share a single fuse  15 , The number of fused circuits in the battery pack  12  could also be reduced; further reducing cost and complexity of the battery pack  12  by reducing the number of fuses  15  and cable connectors  16  compared with the prior art scheme of  FIG. 1 . 
       FIG. 3  illustrates a non-limiting example of three high voltage shielded wire cables a first shielded cable  110 , a second shielded cable  112 , and a third shielded cable  114  that have been spliced together. A core conductor  116 ,  118 ,  120  of each of the shielded cables  110 ,  112 ,  114  has been joined by a sonic welding process to form a connection  122 . Portions of the outer insulation layers  124 ,  126 ,  128 , shield conductors  130 ,  132 ,  134 , and inner insulation layers  136 ,  138 ,  140  have been removed from the core conductors  116 ,  118 ,  120  prior forming the connection  122 . Alternatively, other processes well known to those skilled in the art, such as soldering or crimping the conductors within a conductive sleeve may be used to form the connection  122 . An additional portion of each of the shield conductors  130 ,  132 ,  134  may be removed or cut way to provide adequate voltage creepage distance  142  to prevent a leakage current between the core conductors  116 ,  118 ,  120  and the shield conductors  130 ,  132 ,  134 , thereby exposing the inner insulation layers  136 ,  138 ,  140  of the shielded cables  110 ,  112 ,  114 . Additionally, conductive ferrules  144 ,  146 ,  148  may be mechanically and electrically attached to the shield conductors  130 ,  132 ,  134  to provide a more durable electrical connection to the shield conductors  130 ,  132 ,  134 . The ferrules may be a closed or barrel-type ferrule that is attached to the shield conductors by crimping or soldering prior to forming the connection  122  or the ferrules may be an open or clip-type ferrule that can be attached to the shield conductors by crimping after forming the connection  122 . The ferrules may be formed of a solder material that is heated, for example by induction heating, until the ferrules reflow and join the contacts to the shield conductors. The ferrules may comprise an inner ferrule that is disposed between the shield conductor and the inner insulation layer and an outer ferrule that is disposed over the shield conductor. Materials and methods used to attach the conductive ferrules  144 ,  146 ,  148  to the shield conductors  130 ,  132 ,  134  are well known to those skilled in the art. 
       FIGS. 4 through 15  illustrate a non-limiting example of a process of forming a shielded cable assembly  150  having both the core conductors  116 ,  118 ,  120  and the shield conductors  130 ,  132 ,  134  of three shielded wire cables  110 ,  112 ,  114  spliced together according to a first embodiment. The embodiment illustrated here is configured to splice three shielded wire cables  110 ,  112 ,  114  together in a Y-splice configuration. However, alternative embodiments may be envisioned that are configured to splice just two shielded wire cables or splice more than three shielded wire cables. 
     As illustrated in  FIG. 4 , the wire cable assembly  150  includes an inner insulator  152  formed of dielectric material. The dielectric material may be a polymer material, such as glass-filled polyamide (commonly known by the trade name NYLON) or polybutylene terephthalate (PBT). The inner insulator  152  may be formed using an injection molding process or other plastic forming processes well known to those skilled in the art. The inner insulator  152  is designed to enclose the exposed portion of the connection  122  and a portion of the exposed inner insulation layers  136 ,  138 ,  140  of the shielded cables  110 ,  112 ,  114 . 
     The inner insulator  152  defines an axial passage  154 , hereafter referred to as a channel  154  that is designed to accommodate the connection  122  and the joined shielded wire cables  110 ,  112 ,  114 . As shown in  FIGS. 5 and 6 , the inner insulator  152  may then be slid over the single shielded cable  110  along the longitudinal axis A in the direction  156  over the connection  122 , leaving the shield conductors  130 ,  132 ,  134  exposed. 
     As shown in  FIG. 7 , the channel  154  of the inner insulator  152  may define shoulders  158  to provide a positive stop against the two joined core conductors  118 ,  120  and ensure proper positioning of the inner insulator  152  relative to the connection  122  and the exposed shield conductors  130 ,  132 ,  134 . The inner insulator  152  may be designed with a symmetrical shape so that the shoulders  158  contact the two joined core conductors  118 ,  120  regardless of the orientation of the inner insulator  152  when the inner insulator  152  is placed on the single shielded wire cable  110 . 
     As shown in  FIG. 8 , the wire cable assembly  150  further includes a sleeve  160  formed of conductive material that defines an axial passage  161 , hereafter referred to as a cavity  161  along a longitudinal axis A. The conductive material used to form the sleeve  160  is preferably a copper alloy, such as 425 brass and may be tin coated for corrosion resistance. As shown in  FIG. 9 , the sleeve  160  may be slid along the longitudinal axis A in the direction  156  over the inner insulator  152 , disposing the inner insulator within the cavity  161 . The sleeve  160  defines contacts  162 ,  164 ,  166  that are designed to be crimped into mechanical and electrical contact with the shield conductors  130 ,  132 ,  134 . The sleeve  160  may define a generally elliptical cross section. As used herein, generally elliptical cross section means that the circumferential shape of the sleeve varies by no more than ±10% from that of an elliptical cross section. 
     As shown in  FIG. 10 , the sleeve  160  may define lock features  168  that hold the sleeve  160  in proper position over the inner insulator  152 . The lock features  168  may define a pair of ramp structures  170  wherein one of the ramp structures  170  is designed to deflect as the sleeve  160  slides along the longitudinal axis A over the lock in the direction  156  and then snap back into place, thereby capturing the inner insulator  152  between the lock features  168 . Alternatively, the sleeve may be slid along the longitudinal axis in the direction opposite of direction  156 . The sleeve  160  may be designed with a symmetrical shape so that the lock features  168  secure the sleeve  160  to the inner insulator  152  regardless of the orientation when the sleeve  160  is placed on the single shielded wire cable  110 . Other locking features well known to those skilled in the art may alternately be utilized to secure the sleeve  160  in place over the inner insulator  152 . The shoulders  158  of the inner insulator  152  and the lock features  168  of the sleeve  160  cooperate to locate the exposed shield conductors  130 ,  132 ,  134  or ferrules relative to the contacts  162 ,  164 ,  166 . This provides the benefit of more consistent connections between the contacts and the shield conductors in the manufacturing process. 
     As illustrated in  FIG. 11 , the contacts  162 ,  164 ,  166  are crimped to the shield conductors  130 ,  132 ,  134  or ferrules attached to the shield conductors  130 ,  132 ,  134 , by applying a mechanical force to provide a mechanical and electrical connection between the sleeve  160  and the shield conductors  130 ,  132 ,  134  and provide electrical continuity between all of the shield conductors  130 ,  132 ,  134 . According to the illustrated example, the sleeve defines a plurality of U-shaped slots  172  forming bands  174 ,  176 ,  178 ,  180  that are configured to deform when crimped to secure the sleeve to the shield conductors or ferrules. The bands  178 ,  180  forming contacts  164 ,  166  are crimped by applying force to the central portion of the bands so that central portion of the bands push the shielded wire cables  112 ,  114  apart and ensuring that the insulating layers of shielded cables are separated, that is are not in physical contact with one another. The portions of the first, second, and third shield conductors that are enclosed within the shield are substantially parallel to the longitudinal axis A. This provides a splice connection that is basically in-line which may be easier to package within a location with limited space, such as within an automobile. As used herein, substantially parallel means±10° of absolutely parallel. In an alternative embodiment, the sleeve  160  may define conventional crimping wings that connect to the shield conductors or ferrules by wrapping about them and crimping. The crimping wings are configured to separate the insulating layers of the shielded cables. In another alternative embodiment, the contacts  162 ,  164 ,  166  may be electrically and mechanically connected to the shield conductors  130 ,  132 ,  134  by soldering or other processes well known to those skilled in the art rather than crimping. 
     As illustrated in  FIG. 12 , an outer insulator  182  formed on a dielectric material may be placed over the sleeve  160 . The outer insulator  182  may be formed of a thermoplastic heat shrink tubing. Suitable compositions and sources of heat shrink tubing are well known to those skilled in the art. The outer insulator  182  may also be preloaded onto the blunt cut single shielded wire cable  110  prior to forming the connection  122 . The heat shrink tubing may then be heated using methods well known to those skilled in the art to sealably engage the outer insulation layers  124 ,  126 ,  128  of at least one of the shielded wire cables  110 ,  112 ,  114  and enclose the sleeve  160  as shown in  FIG. 13 . As used herein, sealably engaged means that the outer insulator  182  will resist contaminants, such as dust, dirt, or fluids, from entering between the outer insulation layers  124 ,  126 ,  128  and the outer insulator  182 . It does not mean that it provides a hermetic seal. Alternatively, the outer insulator  182  may comprise or may consist of a conformal coating  184 , such as a silicone-based material, applied over the sleeve  160  and shielded wire cables  110 ,  112 ,  114 . The inventors have discovered that separation of the insulating layers of the shielded cables by the sleeve provides the benefit of improved sealing between the outer insulator and the shielded cables. Without subscribing to any particular theory of operation, the outer insulator or the sealant within the outer insulator is able to contact the entire circumference of the outer insulation layers  126 ,  128 , thus avoiding any gaps or voids that may be created if the outer insulation layers  126 ,  128  were not separated or were touching. 
       FIGS. 14 through 25B  illustrate a non-limiting example of a process of forming a shielded cable assembly  150  having both the core conductors  116 ,  118 ,  120  and the shield conductors  130 ,  132 ,  134  of three shielded wire cables  110 ,  112 ,  114  spliced together according to a second embodiment. The embodiment illustrated here is configured to splice three shielded wire cables  110 ,  112 ,  114  together in a Y-splice configuration. However, alternative embodiments may be envisioned that are configured to splice just two shielded wire cables together or splice more than three shielded wire cables together. 
       FIG. 14  illustrates another non-limiting example of a wire cable assembly  250 . The reference numbers in this embodiment for identical elements are the same as the previously described embodiment and the reference numbers of similar elements are 100 higher. The embodiment illustrated here is configured to splice three shielded wire cables  110 ,  112 ,  114  together by connecting the core conductor  116 ,  118 ,  120  of each of the shielded cables  110 ,  112 ,  114  to form a connection  122  as shown in  FIG. 3  and described in paragraph 0042 supra. However, this embodiment may be used to splice four shielded wire cables together and other embodiments may be envisioned that are configured to splice just two shielded wire cables together or splice more than four shielded wire cables together. 
     The shielded cable assembly  250  includes a first inner insulator  252 A formed of dielectric material and a second inner insulator  252 B formed of a dielectric material. The dielectric material may be a polymer material, such as glass filed NYLON or PBT. The first inner insulator  252 A and the second inner insulator  252 B may be formed of the same dielectric material or they may be formed of different dielectric materials. The first inner insulator  252 A and the second inner insulator  252 B may be formed using an injection molding process or other plastic forming processes well known to those skilled in the art. 
     The first inner insulator  252 A is designed to be joined to the second inner insulator  252 B and when the first inner insulator  252 A and the second inner insulator  252 B are joined, they enclose the connection  122  and a portion of the exposed inner insulation layers  136 ,  138 ,  140  each of the shielded wire cables  110 ,  112 ,  114 . 
     As shown in  FIG. 15 , the first inner insulator  252 A and the second inner insulator  252 B may define a pair of interconnected channels  254 A,  254 B to secure the joined shielded wire cables  110 ,  112 ,  114  within the first inner insulator  252 A and the second inner insulator  252 B. The first inner insulator  252 A and the second inner insulator  252 B may also include a set of mating tapered posts  253  and indentations  255  in order to facilitate alignment of the first inner insulator  252 A and the second inner insulator  252 B when they are assembled around the shielded wire cables  110 ,  112 ,  114 . The first inner insulator  252 A and the second inner insulator  252 B may be designed with a hermaphroditic shape so that a single inner insulator  252  may be used for both the first inner insulator  252 A and the second inner insulator  252 B. In the example shown here, the joined inner insulator  252  may have an unused portion of the channel  254 A. 
     As illustrated in  FIG. 18 , the wire cable assembly  250  further includes a sleeve  260  formed of conductive material that defines a longitudinal axis A. The conductive material used to form the sleeve  260  is preferably a copper alloy, such as 425 brass and may be tin coated for corrosion resistance. The sleeve  260  defines contacts  262 ,  264 ,  266  that are designed to be in mechanical and electrical contact with the shield conductors  130 ,  132 ,  134  of the shielded wire cables  110 ,  112 ,  114 . The contacts  262 ,  264 ,  266  protrude from the sleeve  260  and form an arcuate shape configured to conform to the shield conductors  130 ,  132 ,  134  or ferrules. As illustrated in  FIG. 19 , the contacts  262 ,  264 ,  266  may be secured to the shield conductors  130 ,  132 ,  134  by a separate fastening device  284 , such as a band or sleeve that may be crimped around the contacts  262 ,  264 ,  266 . 
     Alternatively, as shown in  FIG. 20 , the contacts  262 ,  264 ,  266  may define crimp wings  286  that have an arcuate shape prior to being crimped around the shield conductors  130 ,  132 ,  134  of each of the shielded wire cables  110 ,  112 ,  114 . The contacts  262 ,  264 ,  266  are designed to contact the shield conductors  130 ,  132 ,  134  to provide an electrical connection between the shield conductors  130 ,  132 ,  134  of each of the shielded wire cables  110 ,  112 ,  114 . The contacts  262 ,  264 ,  266  may also be designed to mechanically secure the shielded wire cables  110 ,  112 ,  114  to the sleeve  260  and provide strain relief to the joined core conductor  116 ,  118 ,  120  of the cables. 
     Returning to  FIG. 18 , the sleeve  260  is designed to enclose the first inner insulator  252  and to define cable portals for each of the shielded wire cables  110 ,  112 ,  114  to exit the sleeve  260 . The sleeve  260  may be made up of a first sleeve  260 A that defines a set of contacts  262 A,  264 A,  266 A and a second sleeve  260 B that defines another set of contacts  262 B,  264 B,  266 B. The first sleeve  260 A is configured to enclose the inner insulator when mated with the second sleeve  260 B. Features may be included in the joining surfaces of the first sleeve  260 A and the second sleeve  260 B to reduce electrical resistance. Alternatively, the first sleeve  260 A and the second sleeve  260 B may be secured together using conductive threaded fasteners. The first sleeve  260 A and the second sleeve  260 B may be designed with a hermaphroditic shape so that a single part may be used for both the first sleeve  260 A and the second sleeve  260 B. In the example shown here, there may be an unused portal and contact. The contacts  164 ,  166  push the shielded wire cables  112 ,  114  apart and ensuring that the insulating layers of shielded cables are separated, that is are not in physical contact with one another. The portions of the first, second, and third shield conductors that are enclosed within the shield are substantially parallel to the longitudinal axis. This provides a splice connection that is basically in-line which may be easier to package within a location with limited space, such as within an automobile. 
     As illustrated in  FIG. 21 , the wire cable assembly  250  may further include an outer insulator  282  formed of a nonconductive material and defining a cavity  261  that is configured to partially enclose the sleeve  260 . The wire cable assembly  250  also includes a first end cap  288  that is designed to sealably engage one of the shielded wire cables  110  and sealably engage the outer insulator  282  and a second end cap  290  that is designed to sealably engage the other two shielded wire cables  112 ,  114 . The end caps and outer insulator  282  are designed to provide environmental protection to the spliced cables by keeping contaminants such as dust, dirt, water, and other fluids away from the joined core conductors, joined inner insulator, and sleeve  260 . The outer insulator  282  and end caps may be formed of a polymer material, such as NYLON or PBT. The end caps may also include a sealing element  292  formed of compliant material, such as silicone rubber. The inventors have discovered that separation of the insulating layers of the shielded cables by the sleeve provides the benefit of improved sealing between the sealing element  292  and the shielded cables. Without subscribing to any particular theory of operation, the sealing element  292  is able to contact the entire circumference of the outer insulation layers  126 ,  128 , thus avoiding any gaps or voids that may be created if the outer insulation layers  126 ,  128  were not separated or were touching. 
     As best illustrated in  FIG. 23 , the outer insulator  282  may include a male attachment feature  294  and a female attachment feature  296  that are designed to interconnect multiple outer insulators  282  as shown in  FIG. 24 . These attachment features  294 ,  296  may simplify assembly of the wiring harnesses by maintaining a spatial relationship between the outer insulators and provide a more robust wiring harness assembly because there is less likely to be vibrational contact between outer insulators that may degrade the outer insulators  282  over time. 
     As illustrated in  FIG. 25 , multiple wire cable assemblies  250  may be positioned in a staggered arrangement so that the wire cable assemblies  250  may be enclosed with a wiring conduit  298 . Staggering the wire cable assemblies  250  may offer the benefit of a smaller conduit and therefore require less packaging space for the resulting wiring harness. 
     Alternative embodiments may be envisioned by combining various features of the two embodiments illustrated in  FIGS. 4-25 . For example, the inner insulator  152  and the sleeve  160  may comprise two separate portions, similar to the inner insulator  252  and sleeve  260 . As another example, the sleeve  160  may define contacts that protrude from the sleeve that are attached to the shield conductors or ferrules by a separate fastening device, such as a band or sleeve that may be crimped around the contacts, similarly to the sleeve  260 . 
       FIG. 26  illustrates a non-limiting method  300  of splicing shielded wire cables together. The method  300  includes the following steps. 
     STEP  310 , PROVIDE A FIRST, SECOND, AND THIRD SHIELDED WIRE CABLE, includes providing a first shielded wire cable having a first core conductor at least partially axially surrounded by a first shield conductor which is at least partially axially surrounded by a first insulative jacket, providing a second shielded wire cable having a second core conductor at least partially axially surrounded by a second shield conductor which is at least partially axially surrounded by a second insulative jacket, and providing a third shielded wire cable having a third core conductor at least partially axially surrounded by a third shield conductor which is at least partially axially surrounded by a third insulative jacket as shown in  FIG. 3 . 
     STEP  312 , PROVIDE A SHIELD DEFINING A LONGITUDINAL AXIS, A FIRST AXIAL PASSAGE, AND A FIRST, SECOND, AND THIRD CONTACT, includes providing a shield that defines a longitudinal axis, a first axial passage, a first contact, a second contact, and a third contact. The shield is formed of a conductive material. The shield may be formed of one piece as shown in  FIG. 9  or multiple pieces as shown in  FIG. 14 . 
     STEP  314 , PROVIDE AN INNER INSULATOR DEFINING A SECOND AXIAL PASSAGE includes providing an inner insulator defining a second axial passage. The inner insulator is formed of a dielectric material. The inner insulator may be formed of one piece as shown in  FIG. 5  or multiple pieces as shown in  FIG. 14 . 
     STEP  316 , JOIN THE FIRST CENTER CONDUCTOR TO THE SECOND CENTER CONDUCTOR AND THE THIRD CENTER CONDUCTOR, includes joining the first core conductor to the second core conductor and to the third core conductor to form a mechanical and electrical connection between the core conductors as shown in  FIG. 3 . The core conductors may be joined by sonic welding, soldering, or other methods of joining wires known to those skilled in the art. The inner insulator and the ferrules may be preloaded onto the shielded cables prior to joining the core conductors. 
     STEP  318 , DISPOSE THE JOINED FIRST, SECOND, AND THIRD CORE CONDUCTORS WITHIN THE SECOND AXIAL PASSAGE, includes disposing the connection including the joined first, second, and third core conductors within the second axial passage, or channel, of the inner insulator as shown in  FIGS. 6 and 15 . The joined first, second, and third core conductors may be slideably disposed within the second axial passage as shown in  FIG. 6 . 
     STEP  320 , DISPOSE THE INNER INSULATOR AND THE FIRST, SECOND, AND THIRD SHIELD CONDUCTORS WITHIN THE FIRST AXIAL PASSAGE, includes disposing the inner insulator and the first, second, and third shield conductors within the first axial passage as shown in  FIGS. 8-9 and 17-18 . The portions of the first, second, and third shield conductors that are disposed within the inner insulator are substantially parallel to the longitudinal axis. The inner insulator and the first, second, and third shield conductors may be slidably disposed within the first axial passage as shown in  FIGS. 8-9 . 
     STEP  322 , SEPARATE THE FIRST, SECOND, AND THIRD INSULATIVE JACKETS ONE FROM ANOTHER, includes separating the first, second, and third insulative jackets one from another. This may be accomplished by the connection of the first, second, and third shield conductors to the contacts as shown in  FIGS. 11 and 19 . 
     STEP  324 , ATTACH THE FIRST CONTACT TO THE FIRST SHIELD CONDUCTOR, THE SECOND CONTACT TO THE SECOND SHIELD CONDUCTOR, AND THE THIRD CONTACT TO THE THIRD SHIELD CONDUCTOR, includes attaching the first contact to the first shield conductor, the second contact to the second shield conductor, and the third contact to the third shield conductor, thereby providing a conductive path between the first, second, and third shield conductors. The contacts may be attached to the shield conductors by crimping wings, ferrules, soldering, or other methods known to those skilled in the art. 
     STEP  326 , DISPOSE THE SHIELD WITHIN THE OUTER INSULATOR, includes disposing the shield within the outer insulator as illustrated in  FIGS. 12 and 21-22 . 
     STEP  328 , SEALABLY ENGAGE THE OUTER INSULATOR TO THE FIRST, SECOND, AND THIRD INSULATIVE JACKETS, includes sealably engaging the outer insulator to the first, second, and third insulative jackets, thereby enclosing the shield within the outer insulator as illustrated in  FIGS. 13 and 22-23 . 
     Method  300  may further include the following optional steps. 
     Prior to step  324 , method  300  may include STEP  330 , PROVIDE A FIRST, SECOND, AND THIRD FERRULE, which includes providing a first, second, and third ferrule. 
     Following step  330 , method  300  may include STEP  332 , ATTACH THE FIRST, SECOND, AND THIRD FERRULE TO THE FIRST, SECOND, AND THIRD SHIELD CONDUCTORS RESPECTIVELY, which includes attaching the first, second, and third ferrule to the first, second, and third shield conductors respectively. 
     Following step  330 , method  300  may include STEP  334 , CRIMP THE FIRST, SECOND, AND THIRD FERRULE TO THE FIRST, SECOND, AND THIRD CONTACTS RESPECTIVELY, which includes crimping the first, second, and third ferrule to the first, second, and third contacts respectively, thereby attaching the first, second, and third contacts to the first, second, and third shield conductors respectively. 
     Prior to step  324 , method  300  may include STEP  336 , INJECT SOLDER PASTE INTO THE INTERIOR OF THE FIRST, SECOND, AND THIRD CONTACTS THROUGH THE HOLES DEFINED THEREIN, which includes injecting solder paste into the interior of the first, second, and third contacts through holes defined by the first, second, and third contacts. 
     Following step  336 , method  300  may include STEP  338 , HEAT THE SOLDER PASTE UNTIL IT REFLOWS, which includes heating the solder paste until it reflows, thereby soldering the first, second, and third contacts to the first, second, and third shield conductors respectively. 
     Prior to step  320 , method  300  may include STEP  340 , JOIN A FIRST SLEEVE PORTION TO A SECOND SLEEVE PORTION, which includes joining the first sleeve portion to the second sleeve portion, thereby disposing the joined first, second, and third core conductors within the second axial passage, wherein the sleeve includes a first sleeve portion and a second sleeve portion. 
     Prior to step  318 , method  300  may include STEP  342 , JOIN A FIRST INNER INSULATOR PORTION TO A SECOND INNER INSULATOR PORTION, which includes joining the first inner insulator portion to the second inner insulator portion, thereby disposing the inner insulator and the first, second, and third shield conductors within the first axial passage, wherein the inner insulator includes a first inner insulator portion and a second inner insulator portion. 
     Following step  326 , method  300  may include STEP  344 , SEALABLY ENGAGE AN END CAP WITH AT LEAST ONE SHIELDED WIRE CABLE, which includes joining sealably engaging the end cap with the at least one shielded wire cable, wherein the outer insulator further includes an end cap configured to sealably engage the outer insulator and at least one shielded wire cable. 
     Following step  344 , method  300  may include STEP  346 , SEALABLY ENGAGE THE END CAP WITH THE OUTER INSULATOR, which includes engaging the end cap with the outer insulator, thereby enclosing the shield within the outer insulator. 
       FIG. 28  illustrates another non-limiting method  400  of splicing shielded wire cables together. The method  400  includes the following steps. 
     STEP  410 , PROVIDE A FIRST, SECOND, AND THIRD SHIELDED WIRE CABLE, FLEXIBLE INSULATION LAYER, FLEXIBLE CONDUCTIVE LAYER, AND DUAL WALL HEAT SHRINK TUBING, includes providing a first shielded wire cable  110  having a first core conductor  116  at least partially axially surrounded by a first inner insulation layer  136  which is at least partially axially surrounded by a first shield conductor  130  which is at least partially axially surrounded by a first insulative jacket  124 , providing a second shielded wire cable  112  having a second core conductor  118  at least partially axially surrounded by a second inner insulation layer  138  which is at least partially axially surrounded by a second shield conductor  132  which is at least partially axially surrounded by a second insulative jacket  126 , and providing a third shielded wire cable  116  having a third core conductor  120  at least partially axially surrounded by a third inner insulation layer  140  which is at least partially axially surrounded by a third shield conductor  134  which is at least partially axially surrounded by a third insulative jacket  128  as shown in  FIG. 3 . Step  410  also includes providing a flexible dielectric insulation layer that may be formed of a flexible dielectric material such as heat shrinkable plastic tubing made of a heat shrinkable plastic (e.g. polyolefin), cloth tape, or plastic tape. The flexible insulation layer provided may be divided into sections of varied length and/or the flexible insulation layer may comprise various types of insulation such as those described above and applied to various portions of the wire harness assembly. Step  410  further includes providing a flexible conductive layer  518  that may be formed of a sleeve of braided wire strands (e.g. tin plated copper wire strands), a metallic foil (e.g. copper or aluminum foil), or a metallized plastic film (e.g. aluminized MYLAR film). The flexible conductive layer  518  is not impregnated with solder and does not include solder. 
     STEP  412 , REMOVE A POTION OF THE OUTER INSULATIVE JACKETS AND THE INNER INSULATION LAYERS FROM THE A FIRST, SECOND, AND THIRD SHIELDED WIRE CABLE, includes removing a portion of the outer insulative jackets  124 ,  126 ,  128  of the first, second, and third shield wire cables  112 ,  114 ,  116  to expose the shield conductors  130 ,  132 ,  134  and removing a portion of the shield conductors  130 ,  132 ,  134  and the inner insulation layers  136 ,  138 ,  140  to expose the core conductors  116 ,  118 ,  120  as shown in  FIG. 3 . 
     STEP  414 , JOIN THE FIRST CORE CONDUCTOR TO THE SECOND CORE CONDUCTOR AND THE THIRD CORE CONDUCTOR, includes joining the first core conductor  116  to the second core conductor  118  and to the third core conductor  120  to form a mechanical and electrical connection  122  between the core conductors  116 ,  118 ,  120  as shown in  FIG. 3 . The core conductors  116 ,  118 ,  120  may be joined by sonic welding, soldering, or other methods of joining wires known to those skilled in the art. 
     STEP  416 , WRAP A FIRST FLEXIBLE INSULATION LAYER ABOUT THE EXPOSED JOINED PORTION OF THE FIRST, SECOND, AND THIRD CORE CONDUCTORS, is an optional step that includes wrapping a first flexible insulation layer  510  about the joined portion  122  and the exposed portions of the core conductors  116 ,  118 ,  120  so as to completely cover and enclose the exposed portions of the core conductors  116 ,  118 ,  120  while leaving the shield conductors  130 ,  132 ,  134  exposed as shown in  FIG. 29 . The first flexible insulation layer  510  may be formed of a flexible dielectric material such as heat shrinkable plastic tubing, cloth tape, or plastic tape. 
     STEP  418 , WRAP A SECOND FLEXIBLE INSULATION LAYER OVER THE FIRST FLEXIBLE INSULATION LAYER, includes wrapping a second flexible insulation layer  512  over the first flexible insulation layer  510  while still leaving the shield conductors  130 ,  132 ,  134  exposed as shown in  FIG. 30 . The second flexible insulation layer  512  may be a section of heat shrinkable plastic tubing that is placed over the first flexible insulation layer  510  and heated until it is in compressive contact with and encloses the first flexible insulation layer  510 . The second flexible insulation layer  512  may protect the first flexible insulation layer  510  from moisture that could degrade the insulative properties of the first flexible insulation layer  510 . The first flexible insulative layer  510  may be an adhesive backed polyester tape to protect the second flexible insulation layer from abrasion that could be caused by edges of the joined portion  122 . The adhesive backing may simplify application of the cloth tape. 
     STEP  420 , WRAP A FIRST AND SECOND FERRULE OVER THE OUTER INSULATION LAYER OF THE SECOND AND THIRD SHIELDED WIRE CABLE, is an optional step that includes wrapping or placing first and second nonconductive ferrules  514 ,  516  over the outer insulation layers  126 ,  126  of the second and third shielded wire cables  112 ,  114  so that the first and second ferrules  514 ,  516  are proximate the exposed shield conductors  132 ,  134  of the second and third shielded wire cables  112 ,  114  and adjacent to one another as shown in  FIG. 31 . The first and second ferrules  514 ,  516  may be formed of sections of heat shrinkable plastic tubing that is placed over the second and third shielded wire cables  112 ,  114  and heated until it is in compressive contact with the outer insulation layers  126 ,  128  of the wire cables  112 ,  114 . Alternatively, the first and second ferrules  514 ,  516  may be plastic rings placed over the outer insulation layers  126 ,  128  of the second and third shielded wire cables  112 ,  114 . The first and second ferrules  514 ,  516  provide a gap between the outer insulation layers  126 ,  126  of the second and third shielded wire cables  112 ,  114 . 
     STEP  422 , WRAP A FLEXIBLE CONDUCTIVE LAYER ABOUT THE EXPOSED SHIELD CONDUCTORS OF THE FIRST, SECOND, AND THIRD SHIELDED WIRE CABLE, includes wrapping a flexible conductive layer  518  over at least a portion of the exposed shield conductors  130 ,  132 ,  134  so that it is electrical contact with all of the shield conductors  130 ,  132 ,  134  as shown in  FIG. 32 . The flexible conductive layer  518  is preferably not in contact with the outer insulation layers  124 ,  126 ,  126  of the shielded wire cables  110 ,  112 ,  114 . 
     STEP  424 , WRAP A THIRD FLEXIBLE INSULATION LAYER OVER A PORTION OF THE OUTER INSULATION LAYER OF THE FIRST SHIELDED WIRE CABLE AND A PORTION OF THE FLEXIBLE CONDUCTIVE LAYER, is an optional step that includes wrapping a third flexible insulation layer  520  over a portion of the outer insulation layer  124  of the first shielded wire cable  112  that is proximate the exposed shield conductor  130  and over a portion of the flexible conductive layer  518  as shown in  FIG. 33 . STEP  422  may include placing the third flexible insulation layer  520  which is a section of heat shrinkable plastic tubing over the outer insulation layer  124  of the first shield wire cable  112  and a portion of the flexible conductive layer  518  and heating the heat shrinkable tubing until it is in compressive contact with and encloses the outer insulation layer  124  of the first shield wire cable  112  and a portion of the flexible conductive layer  518 . The shield conductor  130  is preferably completely enclosed by the third flexible insulation layer  520 . 
     STEP  426 , WRAP A FOURTH FLEXIBLE INSULATION LAYER OVER A PORTION OF THE OUTER INSULATION LAYERS OF THE SECOND AND THIRD SHIELDED WIRE CABLES AND A PORTION OF THE FLEXIBLE CONDUCTIVE LAYER, is an optional step that includes wrapping a fourth flexible insulation layer  522  over a portion of the outer insulation layers  126 ,  128  of the second and third shielded wire cables  112 ,  114  that is proximate the exposed shield conductors  132 ,  134  and over a portion of the flexible conductive layer  518 , but not over the first and second ferrules  514 ,  516  as shown in  FIG. 34 . The fourth flexible insulation layer  522  may also be applied over a portion of the third flexible insulation layer  520  so that it overlaps the third flexible insulation layer  520 . STEP  426  may include placing the fourth flexible insulation layer  522  which is a section of heat shrinkable plastic tubing over outer insulation layers  126 ,  128  of the second and third shield wire cables  112 ,  114  and a portion of the flexible conductive layer  518  and heating the heat shrinkable tubing until it is in compressive contact with and encloses the outer insulation layers  126 ,  128  of the second and third shielded wire cable  112 ,  114  and a portion of the flexible conductive layer  518 . The fourth flexible insulation layer  522  may also overlap a portion of the third flexible insulation layer  520  so that enclosure of the flexible conductive layer  518  is assured. The section of heat shrink tubing used for the fourth flexible insulation layer  522  may have a larger diameter than the section of heat shrink tubing used for the third flexible insulation layer  520  in STEP  424  before it is heated. 
     STEP  428 , WRAP A SECTION OF DUAL WALL HEAT SHRINK TUBING OVER THE FLEXIBLE CONDUCTIVE LAYER, includes wrapping a section of dual wall heat shrink tubing  524  over at least the flexible conductive layer  518  and a portion of the outer insulation layers  124 ,  126 ,  128  of the first, second, and third shielded wire cables  110 ,  112 ,  114  as shown in  FIG. 35 . Dual wall heat shrink tubing  524  has an outer wall made of a heat shrinkable plastic such as polyolefin and an inner wall made of a thermoplastic adhesive sealant  526 . When the dual wall heat shrink tubing  524  is heated, the thermoplastic adhesive sealant  526  on the inner wall melts and adheres to the outer insulation layers  124 ,  126 ,  128  as the outer wall shrinks to conform to the shielded cables  110 ,  112 ,  114  and flexible conductive layer  518 , thus forming a sealed shielded wire cable splice  528 . A portion of the sealant  526  may extrude from the dual wall heat shrink tubing  524  as the outer wall shrinks. The dual wall heat shrink tubing  524  may also be wrapped about the third and fourth flexible insulation layers  520 ,  522  as well as the first and second ferrules  514 ,  516 , thus sealing these features within the dual wall heat shrink tubing  524  when heated. The first and second ferrules  514 ,  516  provide a gap between the outer insulation layers  126 ,  128  of the second and third shielded wire cables  112 ,  114  that is filled by the sealant  526 , blocking a possible leak path between the second and third shielded wire cables  112 ,  114 . 
     While the method  400  shown in  FIG. 28  and the sealed shielded wire cable splice  528  shown in  FIG. 35  include three shielded wire cables  110 , 112 ,  114 , other embodiments of the method  400  and the sealed shielded wire cable splice  528  may be envisioned having two shielded wire cables or more than three shielded wire cables. Ferrules may be wrapped about the outer insulation layers of each shielded wire cable that is adjacent to another shielded wire cable to provide a gap that is filled by the adhesive sealant  526  of the dual wall heat shrink tubing  524 . 
     Accordingly, a shielded wire cable splice  528  and a method of splicing a plurality of shielded wire cables  400  are provided. The method  400  provides a shielded wire cable splice  528  that is sealed from environmental contamination. The shielded wire cable splice  528  and the method  400  do not use solder to join the flexible conductive layer  518  to the shield conductors  130 ,  132 ,  134 . That allows the method  400  form the shielded wire cable splice  528  by heating the flexible insulation layers and the dual wall heat shrink tubing  524  to a lower temperature than would be required to reflow solder as required by prior art methods described in the Background of the Invention above. The lower heat used provides the advantage of reducing the likelihood of damage to the shielded wire cables  110 ,  112 ,  114  from the application of heat. When the core conductors  116 ,  118 ,  120  of the shielded wire cables  110 ,  112 ,  114  are joined using a sonic welding process, the use of solder is completely eliminated from the method  400  and the shielded wire cable splice  528 . The elimination of solder obviates the need for environmental precaution needed with the use of solder. Without subscribing to any particular theory of operation, the compressive contact of the third and fourth flexible insulation layers  520 ,  522  and/or the dual wall heat shrink tubing  524  with the flexible conductive layer  518  keeps the flexible conductive layer  518  in contact with the shield conductors  130 ,  132 ,  134 , thereby providing a reliable electrical connection between the flexible conductive layer  518  and the shield conductors  130 ,  132 ,  134 . 
     While this invention has been described in terms of the preferred embodiments thereof, it is not intended to be so limited, but rather only to the extent set forth in the claims that follow. Moreover, the use of the terms first, second, etc. does not denote any order of importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.