Dual-Shrink™

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From protection, color identification, strain relief, to waterproofing, Zeus heat shrinks provide the best shrink-to-fit encapsulations for your components. Dual-Shrink™ is our unique bilayer heat shrink that takes advantage of differing properties of two polymers combined into a single heat shrink tubing. Dual-Shrink™ delivers superior encapsulation and protection for critical components.

Particularly valuable in automotive and aerospace applications, our Dual-Shrink™ tubings are specialized bilayer products developed to fully encapsulate components and smart parts to lock out moisture and other chemicals. These products are available in two versions: a PTFE outer / FEP inner layer, and a low temperature version with an FEP outer / EFEP inner layer. These dual-layer heat shrinks provide tight and moisture-proof bonds over wires, cables, connectors, splices, terminals, and other essential parts.

Dual-Shrink™ works like this: When heated, the outer layer shrinks tightly over inserted parts while the inner layer melts and flows into a solid or near-solid encapsulation. The result is a fit so tight that it can withstand severe stresses involving pull or vibration.

Zeus Dual-Shrink™ tubing provides all the outstanding electrical, chemical, and mechanical properties of fluoropolymers but in a bilayer form. Our PTFE / FEP Dual-Shrink™ has a continuous service temperature up to 450 °F (232 °C). The PTFE outer layer has a recovery (shrinkage) temperature between 654 °F (346 °C) and 670 °F (354 °C) and offers superior corrosion resistance.

Our Low Temperature Dual-Shrink™ has a continuous upper working temperature of up to 302 °F (150 °C), and the FEP outer layer recovers at 419 °F (215 °C). Low Temperature Dual-Shrink™ was created to provide dual layer encapsulation to heat-sensitive components which cannot tolerate the higher recovery temperatures of other heat shrinks.

Custom combinations of polymers, sizes and tolerances can be quoted upon request. Contact our team today or call toll-free in the US 1-800-526-3842 or +1-803-268-9500 internationally to find out what our Dual-Shrink™ or other products can do for you or to request samples.

Dual-Shrink™ Heat Shrink Recovery Procedures:

  1. Always assure good ventilation in the immediate work area prior to beginning the heat shrink process. Caution: Fumes may cause nausea and dizziness.
  2. PTFE / FEP Dual-Shrink™ tubing requires 650 °F ± 50 °F (343 °C ± 28 °C). Low Temperature FEP / EFEP Dual-Shrink™ requires 419 °F ± 20 °F (215 °C ± 11 °C). These are liberal and safe ranges.

    Please note:
    The heat shrink temperatures listed here are general guidelines. Actual shrink temperatures may be higher or lower depending on the design and dimensions of the heat shrink, application techniques and other factors.
  3. The mandrel or part to be covered by Dual-Shrink™ must be able tolerate the range of the heat shrink temperatures.
  4. The part being covered may act as a heat sink preventing sufficient thermal energy from being transferred to the Dual-Shrink™ before fully recovering and reflowing the inner layer. Therefore, Zeus recommends preheating large diameter mandrels and similar parts as appropriate.
  5. Dual-Shrink™ requires moderate recovery. Highly restricted radical recovery tends to induce longitudinal loss, while excessive restriction tends to induce splitting.
  6. Evenly heating and returning to room temperature on all sides provides the best results. Uneven heating or cooling tends to split the side of the outer layer that is still in the “gel” state while the other side is in the hard or crystalline state – especially upon recovery.

Note: Shrinking starts when the outer layer is brought up to the gel state during heating but completes its recovery during the cooling cycle. In its gel state, the tubing becomes clear and glassy in appearance. The inner layer will melt and flow when the temperature of reflow is reached.

Ovens are the most reliable way to recover heat shrink products due to their ability to ensure even heating and reduce the risk of overheating the material (which can lead to brittleness and cracking). However, heat guns can also be used successfully to recover heat shrink material.

  • APPLICATIONS

    Component Encapsulation – Zeus Dual-Shrink™ is a specialized double layer tubing which allows the internal layer to be melted over components and then covered by a shrinkable outer polymer layer. Through this process, the covered components are doubly sealed providing protection from moisture and other potentially harmful chemicals in their working environment.

    Electrical Connections – For connecting electrical components, whether to each other or to a terminal, Zeus Dual-Shrink™ helps hold fast the connection to insure a secure and dependable power flow while providing the necessary protection in wide-ranging operating environments.

    Wire Splicing – For those times when conventional connectors or terminals are not available such as out in the field, our Dual-Shrink™ tubing can provide the necessary fix when needing to splice or join wires together. The near-solid inner melt layer of the Dual-Shrink™ tubing is strong enough to tolerate the most rigorous pulling, bending, and vibrational stresses.

  • KEY PROPERTIES

    Chemical Resistance – Dual-Shrink™ tubings provide resistance to an extremely broad spectrum of commonly encountered workplace chemicals to extend the life of your components.

    Secure Moisture-Proof Protection – Dual-Shrink™ provides a tight and moisture-proof encapsulation for covering wires, cables, connectors, splices, terminals, and other parts. This super-secure moisture proofing is accomplished when the Dual-Shrink™ is heated to recovery temperature causing the inner layer to melt and reflow over and into the covered component for a secure seal.

    Wide Working Temperature Range – PTFE / FEP Dual-Shrink™ can safely operate in temperature from -328 °F (-200 °C) to 450 °F (232 °C). FEP / EFEP Low Temperature Dual-Shrink™ has an upper working temperature of at least 302 °F (150 °C) and a lower service temperature also extending to sub-zero temperatures.

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  • PTFE/FEP Encapsulation

    Capabilities and Sizing - STANDARD WALL

    STANDARD WALL
    Item No. As Supplied ID Min. Recovered Dim. ID Will Shrink to at Least After Shrinking Total Wall Thickness-Norm.
    in. mm in. mm in. mm
    ZDS–S–036 0.0360 0.9144 N/A N/A
    ZDS–S–060 0.0600 1.5240 N/A N/A
    ZDS–S–130 0.1300 3.3020 N/A N/A
    ZDS–S–160 0.1600 4.0640 N/A N/A
    ZDS–S–190 0.1900 4.8260 0.0620 1.5748 0.0350 0.8890
    ZDS–S–250 0.2500 6.3500 0.1250 3.1750 0.0350 0.8890
    ZDS–S–350 0.3500 8.8900 0.1900 4.8260 0.0350 0.8890
    ZDS–S–450 0.4500 11.4300 0.3120 7.9248 0.0550 1.3970
    ZDS–S–700 0.7000 17.7800 0.4400 11.1760 0.0550 1.3970
    ZDS–S–950 0.9500 24.1300 0.6300 16.0020 0.0650 1.6510
  • Capabilities and Sizing - LIGHTWEIGHT WALL

    LIGHTWEIGHT WALL
    Item No. As Supplied ID Min. Recovered Dim. ID Will Shrink to at Least After Shrinking Total Wall Thickness-Norm.
    in. mm in. mm in. mm
    ZDS–L–065 0.0650 1.6510 N/A N/A
    ZDS–L–115 0.1150 2.9210 0.0450 1.1430 0.0150 0.3810
    ZDS–L–130 0.1300 3.3020 0.0600 1.5240 0.0150 0.3810
    ZDS–L–180 0.1800 4.5720 0.0650 1.6510 0.0150 0.3810
    ZDS–L–190 0.1900 4.8260 0.0700 1.7780 0.0150 0.3810
    ZDS–L–240 0.2400 6.0960 0.1500 3.8100 0.0200 0.5080
    ZDS–L–350 0.3500 8.8900 0.2100 5.3340 0.0250 0.6350
    ZDS–L–480 0.4800 12.1920 0.3150 8.0010 0.0320 0.8128
    ZDS–L–700 0.7000 17.7800 0.5000 12.7000 0.0400 1.0160
    ZDS–L–1000 1.0000 25.4000 0.7000 17.7800 0.0450 1.1430
  • FEP/EFEP Encapsulation

    Capabilities and Sizing

    Part Number

    Expanded ID Minimum

    Recovered ID Maximum

    Recovered Wall Thickness (Nominal)

    in.

    mm

    in.

    mm

    in.

    mm

    LTDS-046

    0.046

    1.168

    0.000

    0.000

    N/A

    N/A

    LTDS-082

    0.082

    2.083

    0.000

    0.000

    N/A

    N/A

    LTDS-112

    0.112

    2.845

    0.000

    0.000

    N/A

    N/A

    LTDS-163

    0.163

    4.140

    0.000

    0.000

    N/A

    N/A

    LTDS-200

    0.200

    5.080

    0.000

    0.000

    N/A

    N/A

    LTDS-250

    0.250

    6.350

    0.125

    3.175

    0.070

    1.778

    LTDS-375

    0.375

    9.525

    0.225

    5.715

    0.070

    1.905

    LTDS-413

    0.413

    10.490

    0.250

    6.350

    0.059

    1.499