Stranded Conductors and Braids

The Best Solution For Your Application

The Quality Connection

Contents

The Quality Connection 4 Competence with Tradition 5 Product range LEONI Wire 6 LEONI Quality Management 7 LEONI The Global Player 8 Advantages of our products Current rating 9 Table of current rating Conductors 10 Copper and copper alloys Surface finishes 11 Surface finishes 12 Table of weights for platings Packaging 14 Packaging
Edition: April 2006 We reserve the right to make technical alterations. by LEONI Draht GmbH 2006

Product range 15 Product range The LEONI group 30 The high-flex wire specialists 31 The LEONI product range

The Quality Connection

Product range

page 15

Single wires

16 Single wires to DIN standard

Copper flexibles

17 Round, stranded copper flexibles 18 Ropes with integral strain members 19 Round, stranded copper flexibles with overall braid 20 Round, braided copper flexibles 21 Square braids, highly flexible 22 Rectangular braided conductors, extra flexible 23 24 25 26 Flat cables woven Braided copper tapes, flat rolled, flexible Braided copper tapes, flat rolled Braided copper tapes, flat rolled, super flexible

Braided conductors

Tapes woven / braided

Cable screening products

27 Shielding braids (tubular) 28 Knitted copper fabrics 29 Assemblies / finishing

Ready made assemblies

The Quality Connection

Competence with Tradition

LEONI is a global leader in its area of expertise the manufacture of highly engineered electrical conductors. LEONIs roots in wire drawing can be traced back to the Middle Ages. Since the beginning of the 20 th century we have been innovators in electro plating, stranding and multi-wire technology. Today LEONI offers a comprehensive range of wires, stranded conductors, ropes and braids for both the cable industry and electrical component market.

In acknowledgement

The Quality Connection

Product range LEONI Wire

Single wires, tin, silver, gold and nickel plated made of copper and copper based alloys Bunched and stranded conductors for the cable industry Highly flexible copper strands, ropes and braids Tinsel conductors and braided tubes Copper alloy wires (resistance wires) Metallic gold and silver threads; bouillon

of tradition and quality

The Quality Connection

LEONI Quality Management

LEONI Quality Management LEONI Draht has a universal quality management system covering all of our worldwide manufacturing locations ensuring that all of our products and services comply with uniform quality standards. High speed multi-wire drawing places very stringent demands on raw materials and machine process stability. LEONI conductors satisfy the highest quality and reliability requirements consistent with aircraft and aerospace technology, specialist applications in the automotive industry and high speed data transmission technology. In LEONI Drahts quality philosophy Customer satisfaction Delivery reliability Process stability Continuous improvement all play a key role. Guidelines, arising from this philosophy, become the benchmark for all internal operations, from marketing to product and process development, from manufacturing up to final delivery of our products to our customers. LEONI Quality from start to finish. LEONI Environmental Management LEONI believes in combining economic success with ecological and environmental responsibility. We acknowledge our responsibility to protect the world we live in and its natural resources to strike the right balance between environmental needs and the companys interests. We can advise customers on the most environmentally responsible use and disposal of our products.

LEONI The Global Player

The Quality Connection

A worldwide presence for our customers

Wire manufacturing sites in Germany, England, China and the USA:

LEONI Draht GmbH Weissenburg, Germany LEONI Wire Inc. Chicopee MA, USA LEONI Wire (Changzhou) Ltd. Changzhou, P.R. China

The Quality Connection

Advantages of our products

It is profitable to use LEONI products as the quality related offers advantages in both processing and production. Many years of experience in in-house wire drawing up to the final product simply pay off. This is attributed last but not least to the constant improvement of our processes and activities in order to ensure and increase our customer satisfaction.

These advantages count: No splicing of cut ends Faultless surface quality ensures the fully automatic processing The special LEONI performance: Production of constructions to foreign standards and of constructions to suit customer's requirements.

LEONI The Quality Connection

Table of current rating

Current rating

The following table will help you to select the correct conductor cross-section as a function of the current rating.

Since several influencing factors generally apply, the values specified must be considered only as non-binding guideline values.
Nom. crosssection mm2 Max. permitted current rating approx. A Nom. crosssection mm2 Max. permitted current rating approx. A

0.10 0.14 0.20 0.25 0.35 0.50 0.75 1 1.50 2.50 4 5.25 6 8 10 16

5 6 7 9 10 12.5 15 18 21 30 40 44 55 70 85 120

25 35 50 70 95 120 150 185 240 300 400 500 625 800 1000

150 195 250 300 360 420 480 570 670 780 950 1100 1300 1500 1800

Measured at 35 C room temperature

and max. permitted conductor temperature of 70 C

Conductors

Copper and copper alloys

Our main raw material is copper (Cu). In our wire manufacturing we primarily use Cu-ETP 1 for all standard applications and Cu-OF 1 (oxygen free copper) where specific requirements dictate, e.g. resistance to hydrogen as in ISO 2626.

In addition to copper we process a number of copper alloys for special applications. Typical alloys include CuSn (copper/tin), CuNi (copper/ nickel), CuAg (copper/silver) and LEONI Histral.

Excerpt from EN 1977 Copper and copper alloys Copper drawing stock (wire rod)
Symbol Material number Composition in %-by-weight Density g/m3 Melting point % IACS min. Comments

Electrolytic copper Cu-ETP1 CW 003 A (E-Cu)

Cu 99.90 Oxygen max. 0.040

8.9

1083 C

101

Electrolytic tough pitch copper with an electrical conductivity in annealed condition of 58.58 m/mm2 at 20 C (101 % IACS).

Oxygen-free copper Cu-OF1 CW 007 A (OF-Cu)

Cu 99.95

8.9

1083 C

101

Oxygen free copper is purer containing less impurities and trace elements which evaporate in a vacuum and has an electrical conductivity in the annealed condition of 58.58 m/mm2 at 20 C (101 % IACS). It is suitable for semi-finished products that require resistance to hydrogen as in ISO 2626 , ultrasonic welding and hard soldering (brazing), and for use in the fields of vacuum technology and electronics.

International Annealed Copper Standard = IACS Electirical conductivity of copper = min. 58 m/mm2 = 100 % IACS
The standard of purity is achieved when the electrical conductivity in annealed condition is 58.58 m/mm2 in the case of Cu-ETP1. Details of sampling and test methods are available. Hydrogen resistance is tested and measured according to international technical specifications. If individual customers have particular requirements these must be stipulated at the time of order.

10

Surface finishes

Surface finishes

Electroplating options For plated copper/wires we use tin, silver or nickel as metal, depending on what is required from the conductor. tin solderability effective protection against corrosion
good

silver
high temperature resistance high conductivity (Skin-effect, important

for HF-applications)

nickel corrosion and temperature resistance barries of diffusion

high

DIN EN 13602 Requirements of the tin-plating

Type Min. unalloyed tin plating thickness m Purity of the tin layer Bonding of tin layer

A B C
The tin plating thickness is determined by supplier.

0.3 0.6 not specified

max. 1.0 g copper per m2 wire surface

No cracks and interruptions

LEONI wires and stranded conductors are available bare and with a range of surface finishes manufactured to industry, national and international standards as well as to individual customer specifications.

11

Surface finishes

Tables of weights for platings

at a specific weight (kg/dm3) of 7.28 Sn (= tin), 8.9 Ni (= nickel), 10.5 Ag (= silver).

Metric Wires Layer thickness 1 m

Wire- mm Tin Sn g/kg Nickel Ni g/kg Silver Ag g/kg

0.050 0.063 0.070 0.071 0.080 0.090 0.100 0.112 0.120 0.125 0.130 0.140 0.150 0.160 0.180 0.200 0.220 0.224 0.250 0.260 0.280 0.300 0.315 0.320 0.355 0.370 0.400 0.410 0.430 0.450 0.500 0.520 0.560 0.600 0.630 0.640 0.680 0.710 0.750 0.800 0.850 0.900 0.950 1.000 1.060 1.120 1.180 1.250 1.320 1.400 1.500 1.600 1.700 1.800
12

65.4 51.9 46.7 46.1 40.9 36.4 32.7 29.2 27.3 26.2 25.2 23.4 21.8 20.4 18.2 16.4 14.9 14.6 13.1 12.6 11.7 10.9 10.4 10.2 9.2 8.8 8.2 8.0 7.6 7.3 6.5 6.3 5.8 5.4 5.2 5.1 4.8 4.6 4.4 4.1 3.8 3.6 3.5 3.3 3.1 2.9 2.8 2.6 2.5 2.3 2.2 2.0 1.9 1.8

80.0 63.5 57.1 56.3 50.0 44.4 40.0 35.7 33.3 32.0 30.8 28.6 26.7 25.0 22.2 20.0 18.2 17.9 16.0 15.4 14.3 13.3 12.7 12.5 11.3 10.8 10.0 9.8 9.3 8.9 8.0 7.7 7.1 6.7 6.3 6.2 5.9 5.6 5.3 5.0 4.7 4.5 4.2 4.0 3.8 3.6 3.4 3.2 3.0 2.9 2.7 2.5 2.4 2.2

94.4 74.9 67.4 66.5 59.0 52.4 47.2 42.1 39.3 37.8 36.3 33.7 31.5 29.5 26.2 23.6 21.5 21.1 18.9 18.1 16.9 15.7 15.0 14.8 13.3 12.8 11.8 11.5 11.0 10.5 9.4 9.1 8.4 7.9 7.5 7.4 6.9 6.7 6.3 5.9 5.6 5.3 5.0 4.7 4.4 4.2 4.0 3.8 3.6 3.4 3.2 3.0 2.8 2.6

Surface finishes

AWG-wires, plating thicknesses according to ASTM The table is a tool to calculate the weight and plating thickness for tin, nickel and silver. Nb. tin plated wires will not have a plating thickness of 1 m, as stated, but will be manufactured in accordance with EN 13602. Example 1: How many grammes of silver do you require for a wire with a diameter of 0.18 mm, if the plating thickness is to be 1.5 m? 0.18 mm with 1 m = 26.2 g; 0.18 mm with 1.5 m = 26.2 x 1.5 = 39.3 g = ~ 40 g of silver for 1 kg copper wire
AWG No. of wire 25 microinches 0.635 m Tin Sn g/kg 50 microinches 1.27 m Nickel Ni g/kg 40 microinches 1.016 m Silver Ag g/kg Silver thickness pore-free quality g/kg

mm

Example 2: Which plating thickness will be achieved if you use 39.3 g silver per kg for a 0.18 mm wire? 39.3 : 26.2 = 1.5 m

50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13

0.025 0.028 0.032 0.036 0.040 0.045 0.051 0.056 0.064 0.071 0.079 0.089 0.102 0.114 0.127 0.142 0.160 0.180 0.203 0.226 0.254 0.287 0.320 0.361 0.404 0.455 0.511 0.574 0.643 0.724 0.813 0.912 1.024 1.151 1.290 1.450 1.628 1.829

83.1 74.2 65.9 58.3 52.0 46.5 40.7 37.1 32.4 29.2 26.3 23.3 20.4 18.2 16.4 14.6 13.0 11.5 10.2 9.2 8.2 7.2 6.5 5.8 5.1 4.6 4.1 3.6 3.2 2.9 2.6 2.3 2.0 1.8 1.6 1.4 1.3 1.1

203.2 181.4 161.3 142.7 127.3 113.6 99.6 90.7 79.4 71.5 64.3 57.1 49.8 44.6 40.0 35.8 31.8 28.2 25.0 22.5 20.0 17.7 15.9 14.1 12.6 11.2 9.9 8.9 7.9 7.0 6.2 5.6 5.0 4.4 3.9 3.5 3.1 2.8

191.8 171.3 152.2 134.7 120.2 107.3 94.0 85.6 74.9 67.5 60.7 53.9 47.0 42.1 37.8 33.8 30.0 26.6 23.6 21.2 18.9 16.7 15.0 13.3 11.9 10.5 9.4 8.4 7.5 6.6 5.9 5.3 4.7 4.2 3.7 3.3 2.9 2.6

61 50 40 30 25

20

12.5

AWG = American Wire Gauge

13

Packaging

Packaging

The chart depicts the most common reel sizes. Special types are available upon request. d1
Type of flange

d3
of bore

l2
Traverse

l1
Overall Width

d2
of barrel Capacity max. (based on stranded conductors)

mm

mm

mm

approx. kg

Plastic reels K 125 K 160 K 200 K 250 K 355 K 400 Wooden reels H 400 H 600 H 800 H 1000

125 160 200 250 355 400 400 600 800 1000

16 22 22 22 36 32.7 36 50 81 80

100 128 160 160 160 205 200 280 400 560

125 160 200 200 200 243 250 340 550 700

80 100 125 160 224 250 200 280 400 500

3 6 12 20 35 70 70 250 500 1000

l1 l2

The main dimensions of a reel are: d1 Flange diameter d3 Bore diameter

d3 d2 d1

Additionally useful are: l2 Traverse l1 Overall Width d2 Barrel diameter

14

Product range

Single wires Copper flexibles Braided conductors Tapes, woven / braided Cable screening products Ready made assemblies

Product range

15

Single wires

Single wires to DIN standard

DIN dimensions for single copper wires in accordance with DIN 46 431 Round Copper Wires for Electrical Purposes, Exactly Drawn (These Standards apply only to plain wires as the parameters change as a result of the extrusion process and the associated wire elongation.)

Diameter Nominal value d mm Tolerance mm Min. value mm Max. value mm Nominal cross-section mm2 Weight approx. kg/km DC resistance at 20 C /m nom. value Yield approx. km/kg

0.05 0.063 0.071 0.08 0.09 0.1 0.112 0.125 0.14 0.16 0.18 0.2 0.224 0.25 0.28 0.315 0.355 0.4 0.45 0.5 0.56 0.63 0.71 0.75 0.8 0.85 0.9 0.95 1 1.06 1.12 1.18 1.25 1.32 1.4 1.5 1.6 1.7 1.8

0.003

0.005

0.007

0.009

0.012

0.016

0.020 0.025

0.047 0.060 0.068 0.077 0.087 0.097 0.107 0.120 0.135 0.155 0.175 0.195 0.219 0.243 0.273 0.308 0.348 0.391 0.441 0.491 0.551 0.621 0.698 0.738 0.788 0.838 0.888 0.938 0.988 1.044 1.104 1.164 1.234 1.304 1.384 1.480 1.580 1.680 1.775

0.053 0.066 0.074 0.083 0.093 0.103 0.117 0.130 0.145 0.165 0.185 0.205 0.229 0.257 0.287 0.322 0.362 0.409 0.459 0.509 0.569 0.639 0.722 0.762 0.812 0.862 0.912 0.962 1.012 1.076 1.136 1.196 1.266 1.336 1.416 1.520 1.620 1.720 1.825

0.00196 0.00312 0.00396 0.00503 0.00636 0.00785 0.00985 0.01227 0.01539 0.02011 0.02545 0.03142 0.03941 0.04909 0.06158 0.07793 0.09898 0.1257 0.1590 0.1964 0.2463 0.3117 0.3959 0.4418 0.5027 0.5675 0.6362 0.7088 0.7854 0.8825 0.9852 1.094 1.227 1.368 1.539 1.767 2.011 2.270 2.545

0.0175 0.0278 0.0353 0.0447 0.0566 0.0699 0.0878 0.109 0.137 0.179 0.226 0.280 0.351 0.437 0.548 0.694 0.882 1.12 1.42 1.75 2.19 2.78 3.53 3.93 4.47 5.05 5.66 6.31 6.99 7.86 8.78 9.75 10.90 12.20 13.70 15.70 17.90 20.20 22.60

8.80 5.53 4.35 3.43 2.71 2.196 1.750 1.402 1.120 0.8573 0.6774 0.5487 0.4375 0.3512 0.2799 0.2213 0.1743 0.1372 0.1084 0.0878 0.0700 0.0553 0.04354 0.03902 0.03429 0.03038 0.02710 0.02432 0.02195 0.01954 0.01750 0.01577 0.01405 0.01260 0.01120 0.00976 0.00858 0.00760 0.00677

57.10 36.00 28.30 22.40 17.67 14.31 11.39 9.17 7.30 5.59 4.42 3.57 2.85 2.29 1.825 1.441 1.134 0.893 0.704 0.571 0.457 0.36 0.283 0.254 0.224 0.198 0.177 0.158 0.143 0.127 0.114 0.103 0.0917 0.082 0.073 0.0637 0.0559 0.0495 0.0442

16

Calculated with a conductivity of 58 m 2 at 20 C. mm The maximum resistance value in the case of a diameter using the full acceptable negative m deviation range must be suitable for a conductivity of at least 57.5 mm2 at 20 C.

Round, stranded copper flexibles

Copper flexibles

Round, stranded copper flexibles similar to DIN 46438

Besides special flexibility these types distinguish themselves through no splicing of cut ends for further standard processing.

Material E-Cu/OF-Cu and alloys, plain, tinned, nickel-plated or silver-plated. Packaging On spools and drums in accordance with the table on page 14.

Special versions Highly twist-free and with a compact cutting surface. A special surface finish permits various welding methods.

Direction of stranding

Reversed lay or SZ stranding S left hand lay Z right hand lay

E-Cu, OF-Cu: plain, tinned, nickel-plated, silver-plated

Nominal cross-section mm2 of wire mm No. of wires Tol. 2 % Overall- approx. mm Weight 12 % approx. kg/km Nominal cross-section mm2 of wire mm No. of wires Tol. 2 % Overall- approx. mm Weight 12 % approx. kg/km

0.06 0.1 0.14 0.2 0.25 0.35 0.5 0.75 1 1.5 2 2.5 3 4 5.25 6 8 10 12 16

0.05 0.004

0.071 0.004

30 51 72 105 130 180 266 392 525 385 525 651 798 1036 1372 1575 2058 2562 3108 4116

0.3 0.4 0.5 0.6 0.7 0.85 1 1.25 1.5 1.75 2.1 2.4 2.6 3 3.5 3.7 4.2 4.7 5.2 6.0

0.6 1 1.4 2 2.5 3.5 5 7.5 10 15 20 25 30 40 53 60 80 100 120 160

25 35 50 70 95 120 150 185 240 300 400 500 600

0.1 0.004

3234 4508 6468 8967 12201 15435 19110 23580 30600 38200 51000 63700 76430

7.6 9.0 10.7 12.7 14.8 18.0 20.0 21.0 24.9 26.0 30.0 33.0 36.5

250 350 500 700 950 1200 1500 1850 2400 3000 4000 5000 6000

17

Copper flexibles

Ropes with integral strain members

E-Cu round, stranded copper flexible with integral strain members for high tensile strength

Material E-Cu, plain, tinned, nickel-plated, silver-plated, brass-plated (Cement wire) or genuine gold-plated. Packaging On spools in accordance with the table on 14.

Special versions Round, braided conductors Flat conductors the construction is matched to the required dimensions Insulated versions these unit-type stranded conductors are also available with transparent insulation for particular applications.

E-Cu: plain, tinned, nickel-plated, silver-plated, gold-plated or with brass plating

Nominal cross-section mm2 of wire mm No. of wires 2 % Overall- approx. mm Weight approx. kg/km Tensile strength N

2.5 4

0.071 0.10 0.20 0.071 0.10 0.20 0.071 0.10 0.20

644 318 78 1044 504 126 1566 756 192

2.4 2.4 2.4 3 3 3 3.7 3.7 3.7

23 23 23 38 38 38 56 56 56

1525 1525 1525 1840 1840 1840 2260 2260 2260

18

Round, stranded copper flexibles with overall braid

Round, stranded copper flexibles with overall braid, highly flexible similar to DIN 46440

Copper flexibles

Material E-Cu/OF-Cu and alloys, plain, tinned, nickel-plated or siver-plated. Packaging On spools in accordance with the table on page 14.

Special benefits Owing to technical production reasons, the effective cross-section is greater than the nominal cross-section, in particular on the thicker cross-sections. In special cases, it is possible to achieve a reduction in diameter and weight while simultaneously observing the nominal cross-section by implementing construction modifications.

E-Cu, OF-Cu: plain, tinned, nickel-plated, silver-plated

Nominal cross-section Effective cross-sectional area mm2 Round stranded copper flexible of wire mm No. of wires tol. 2 % Overall braiding of wire mm No. of wires tol. 2 % approx. mm approx. kg/km of straded conductor Weight 12 %

mm2

0.35 0.5 0.75 1 1.5 2.5 3.75 4 6 8 10 12 16 25 35 50 70 95 120

0.35 0.51 0.77 1.02 1.53 3.08 3.91 4.60 6.99 8.90 11.20 12.00 17.80 26.90 37.30 53.60 73.30 98.70 124

0.05 0.004

0.071 0.004

0.10 0.004

51 130 266 266 525 651 798 1036 1575 2058 2562 2562 4116 3234 4508 6468 8967 12201 15435

0.10 0.004

32 32 32 64 64 64 96 64 96 96 128 240 192 192 240 360 360 360 360

0.8 1.1 1.4 1.5 1.9 2.9 3.0 3.4 4.1 4.7 5.2 5.2 6.5 8.2 9.6 11.4 13.4 16.4 18.4

3.5 5.1 7.7 10.2 15.3 30.8 39.1 46 69.9 89 112 120 178 269 373 536 733 987 1240
19

Copper flexibles

Round, braided copper flexibles

Round, braided copper flexibles

Absolute freedom from twist and compact, cutting surface with very high dimensional accuracy permit easy, fully automatic further processing.

Material E-Cu/OF-Cu and alloys, plain, tinned, nickel-plated or siver-plated. Packaging On spools in accordance with the table on page 14.

Range of production The adjacent tables show the standard range. The specified crosssectional areas can also be produced using other wire diameters.

E-Cu, OF-Cu: plain, tinned, nickel-plated, silver-plated

Nominal cross-section mm2 of wire Construction No. of wires 2 % Overall- Weight 12 % approx. kg/km

mm

approx. mm

0.047 0.094 0.14 0.20 0.25 0.35 0.50 0.75 1 1.5 1.5 2 2.5 3 4 5 6 8 10 12 16 20 25
20

0.05 0.004

0.071 0.004

0.10 0.004

8x3 8x6 8x9 8 x 13 8 x 16 8 x 23 8 x 32 8 x 48 8 x 64 8 x 49 12 x 33 12 x 44 12 x 54 12 x 65 12 x 86 12 x 108 12 x 130 12 x 174 12 x 217 12 x 260 12 x 170 12 x 213 12 x 266

0.33 0.47 0.57 0.70 0.80 0.95 1.10 1.35 1.55 1.90 1.90 2.20 2.40 2.70 3.10 3.50 3.80 4.40 4.90 5.40 6.10 6.90 7.70

0.47 0.94 1.40 2 2.50 3.50 5 7.50 10 15 15 20 25 30 40 50 60 80 100 120 160 200 250

Square braids, highly flexible

Braided conductors

Square braids, highly flexible Greater flexibility when compared to round braids. With fully automatic further processing the predefined form makes exact positioning possible. This results in continuously high accuracy in welding points.

Material E-Cu/OF-Cu and alloys, plain, tinned, nickel-plated or silver-plated. Packaging On spools in accordance with the table on page 14.

E-Cu, OF-Cu: plain, tinned

Nominal cross-section mm2 Construction No. of wires 2 % of wire Edge length Weight 12 % approx. kg/km

mm

mm

0.5 1 1.5 1.5 2 2 2.5 2.5 3 3 4 4 5 5 6 6 8 8 10 10 12 12 16 25 35 40 50

8 x 32 8 x 64 8 x 96 8 x 49 8 x 128 8 x 65 8 x 160 8 x 81 8 x 192 8 x 97 8 x 256 8 x 130 8 x 320 8 x 162 8 x 384 8 x 195 8 x 512 8 x 260 8 x 640 8 x 324 8 x 768 8 x 390 8 x 255 8 x 400 8 x 560 8 x 640 8 x 800

0.05 0.05 0.05 0.071 0.05 0.071 0.05 0.071 0.05 0.071 0.05 0.071 0.05 0.071 0.05 0.071 0.05 0.071 0.05 0.071 0.05 0.071 0.10 0.10 0.10 0.10 0.10

1.0 1.4 1.75 1.75 2.0 2.0 2.2 2.2 2.5 2.5 2.8 2.8 3.2 3.2 3.5 3.5 4.1 4.1 4.6 4.6 5.0 5.0 5.8 7.2 8.5 9.0 10.2

5 10 15 15 20 20 25 25 30 30 40 40 50 50 60 60 80 80 100 100 120 120 160 250 350 400 500

21

Braided conductors

Rectangular braided conductors, extra flexible

Rectangular braided conductors, extra flexible

Due to the rectangular form a significantly greater cross-section can be accommodated in the smallest of spaces as compared to round stranded conductors. This saves valuable space.

Material E-Cu/OF-Cu plain, tinned.

Special benefits Extraordinarily high flexibility is achieved in the stranded conductors through a special manufacturing process which, even with high packing density (multilayer installations), allows the tightest bending radiuses and does not degrade switching operations.
Dimensions

The braided conductor can be manufactured with a dimension ratio from 1:1.5 to 1:1.25, where the dimension is determined in agreement with the customer depending on the intended use and availability of space. E-Cu, OF-Cu: plain, tinned, nickel-plated, silver-plated Example of two possible dimensions for 50 mm2 13 x 8.5 mm or 15 x 7 mm
Weight 12 % approx. kg/km

Effective cross-section mm2

No. of wires mm

of wire

Dimensions approx. mm

16 25 35 40 50

2040 3200 4480 5120 6400

0.10 0.10 0.10 0.10 0.10

160 250 350 400 540

22

Flat cables woven

Tapes woven / braided

Flat cables woven flexible similar to DIN 46443 The special plaiting method means that the width of the flat cable remains virtually constant, even when subject to high tensile or compressive load.

Material E-Cu, plain or tinned. Packaging In coils.

Flat cables woven in accordance with DIN 46443

Dimensions Nominal cross-section mm2 Width mm mm Thickness 0.5 mm Construction of the flat cables in acc. with DIN 46443 Warp Nominal cross-section mm2 Number Weft Nominal cross-section mm2 Weight 12 % kg/km Width of the connecting rail/bus

25 25 35 35 35 35 50 50 50 50 70 70 70 95 95 120 120 150

28 38 23 28 38 47 28 38 47 57 38 47 57 47 57 57 77 77

1.6 1.6 1.6 1.6 1.6 2.5 1.6 1.6 2.5 2.5 1.6 2.5 2.5 2.5 2.5 2.5 2.5 2.5

3 2 5 4 3 2 6 4 3 2.5 6 5 4 6.5 5.5 7 5 6.5

1.5 1 6.0 4 1.5 1 6 4 2.5 1.5 8 6 4 8 6 10 6 10

16 24 6 9 22 34 8 12 20 32 9 12 18 12 16 12 20 15

1 0.75 1.5 1.5 1 0.75 1.5 1.5 1.5 1 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5

325 340 430 430 445 470 565 600 675 645 835 860 900 1105 1135 1365 1430 1715

30 40 25 30 40 50 30 40 50 60 40 50 60 50 60 60 80 80
23

Dimensions can be varied.

Tapes woven / braided

Braided copper tapes, flat rolled, flexible

Braided copper tapes, flat rolled, flexible similar to DIN 46444

Material E-Cu, plain, tinned, nickel-plated or silver-plated. Packaging On spools in accordance with the table on page 14 or in coils.

Special versions If required, individual dimensions can be varied slightly during the rolling process. Non standard dimensions may require design modifications. All types are available in non-rolled form as multiple tubes and for screening.

E-Cu, OF-Cu: plain, tinned, nickel-plated, silver-plated

Nominal crosssection mm2 Dimensions width 5 % x thickness mm Construction of wire Weight Nominal crosssection mm2 Dimensions width 5 % x thickness mm Construction of wire Weight

mm

approx. kg/km

mm

approx. kg/km

0.09 0.16 0.25 0.5 0.75 1 1.5 2 2.5 3 4 6 8 10

1 x 0.2 1.2 x 0.2 1.6 x 0.2 2.5 x 0.4 2.7 x 0.5 3.2 x 0.7 4 x 0.8 5 x 0.8 5.8 x 0.8 7.5 x 0.9 8.2 x 1 10 x 1.3 12.3 x 1.5 14 x 1.5

16 x 3 16 x 5 16 x 8 16 x 16 16 x 24 16 x 32 16 x 25 16 x 33 24 x 27 24 x 33 24 x 43 24 x 66 24 x 88 24 x 109

0.05 0.004

0.071 0.004

0.9 1.6 2.5 5.0 7.5 10 15 20 25 30 40 60 80 100

16 25 35 50 70 95 120 140 150 168 185 240 250 300 400

17.5 x 2 22 x 2.5 30 x 2.5 33 x 3.2 45 x 3.5 50 x 4 60 x 4 60 x 4.5 65 x 5 70 x 5 75 x 5 80 x 6.5 80 x 7 90 x 7 100 x 8.5

24 x 85 24 x 135 36 x 124 48 x 133 48 x 186 48 x 253 48 x 319 48 x 372 48 x 399 48 x 446 48 x 491 48 x 637 48 x 664 48 x 797 48 x 1062

0.1 0.004

160 250 350 500 700 950 1200 1400 1500 1680 1850 2400 2500 3000 4000

24

max. 25 % below nominal value.

Braided copper tapes, flat rolled

Tapes woven / braided

Braided copper tapes (braided copper tubes), flat rolled similar to DIN 72333, Part 3

Material E-Cu, plain, tinned. Packaging On spools in accordance with the table on page 14 or in coils.

Special versions If required, individual dimensions can be varied slightly during the rolling process. Non standard dimensions may require design modifications. All types are available in non-rolled form as multiple tubes and for screening.

E-Cu, OF-Cu: plain, tinned

Nominal crosssection mm2 Dimensions width +5 % /25 % x thickness mm Construction of wire 0.006 Weight 12 %

mm

approx. kg/km

14 14 16 16 21 21 25 25 35 35 50 50 70 70

18 x 1.5 18 x 1.5 20 x 1.6 20 x 1.6 22 x 2 22 x 2 22 x 2.5 22 x 2.5 25 x 3 25 x 3 33 x 3.2 33 x 3.2 35 x 4.5 35 x 4.5

36 x 20 36 x 12 36 x 22 36 x 14 36 x 29 36 x 19 36 x 35 36 x 22 36 x 48 36 x 31 48 x 52 48 x 33 48 x 73 48 x 46

0.16 0.2 0.16 0.2 0.16 0.2 0.16 0.2 0.16 0.2 0.16 0.2 0.16 0.2

140 140 160 160 210 210 250 250 350 350 500 500 700 700
25

max. 25 % below nominal value.

Tapes woven / braided

Braided copper tapes, flat rolled, super flexible

Braided copper tapes (braided copper tubes), flat rolled, super-flexible

Material E-Cu, plain, tinned, nickel-plated or silver-plated. Packaging On spools in accordance with the table on page 14 or in coils.

Special versions If required, individual dimensions can be varied slightly during the rolling process. Non standard dimensions may require design modifications. All types are available in non-rolled form as multiple tubes and for screening.

E-Cu: plain, tinned, nickel-plated, silver-plated

Nominal crosssection mm2 Dimensions width 5 % x thickness mm Construction of wire Weight 12 % approx. kg/km

mm

4 6 8 10 14 16 21 25 35 42 50 70
26

7 x 1.2 10 x 1.3 12 x 1.4 13 x 1.7 15 x 2 16 x 2 19 x 2.4 24 x 2.3 29 x 2.6 35 x 2.6 36 x 3 40 x 3.8

24 x 86 24 x 128 24 x 171 24 x 213 24 x 298 24 x 341 24 x 450 36 x 355 36 x 497 48 x 447 48 x 532 48 x 745

0.05 0.004

40 60 80 100 140 160 210 250 350 420 500 700

Dimensions can be varied.

Shielding braids (tubular)

Cable screening products

Shielding braids (tubular) expandable and flexible

The expandability and coverage can be determined precisely by changing the braiding angle.

Material E-Cu, plain, tinned Packaging On spools in accordance with the table on page 14 or in coils.

Comment In case of larger cross-sections the effective cross-section is greater than the nominal value. Alterations to constructions may allow a reduction of diameter and weight while maintaining the nominal cross-section values.

E-Cu, OF-Cu: plain, tinned, nickel-plated, silver-plated

Effektive cross-section mm2 Construction of wire Expandable max. inner- approx. mm Extended length weight 12 % approx. kg/km Coverage approx. %

mm

0.25 0.38 0.50 0.88 1.32 1.70 1.98 5.30 6.00 6.80 7.90 10.20 13.60 23.80 30.50 33.90 40.70 50.90 72.40 96.50 108.60

16 x 2 16 x 3 16 x 4 16 x 7 24 x 7 24 x 9 36 x 7 24 x 7 24 x 8 24 x 9 36 x 7 36 x 9 36 x 12 48 x 7 48 x 9 48 x 10 48 x 12 48 x 15 48 x 12 48 x 16 48 x 18

0.10 0.004

0.20 0.006

0.30 0.008

0.40 0.01

3 3.5 4 6 8 10 15 16 18 20 25 30 40 50 60 70 80 100 120 140 160

2.3 3.5 4.6 8.1 12.1 15.6 18.1 48.8 55.3 62 73 93.0 124 218 280 311 373 466 664 885 995

36.58 45.82 52.77 60.66 64.39 68.03 56.40 63.94 65.16 67.72 62.70 66.93 68.31 64.70 68.69 66.39 68.45 67.23 60.71 66.82 68.42
27

Cable screening products

Knitted copper fabrics

Knitted copper fabrics, fine-wire

For repair work as cable screens. The screen density and coverage can be determined by the winding.

Material E-Cu, plain, tinned. Packaging In coils.

Versions Flat knitted copper fabrics consisting of 4, 6 or 8 wires 0.10 mm up to a max. width of 100 mm, mesh spacing approx. 5 mm. Knitted copper fabric tubes, rolled made of wire 0.10 mm and above up to a max. width of 130 mm, close-mesh. Special versions High-strength knitted copper fabrics made of tinsel conductors (also combined with wires) are available for special applications.

28

Assemblies / finishing

Ready made assemblies

Ready made rope and braid assemblies

The photographs show some examples of ready made assemblies.

Cross-sectional area range 0.5 1000 mm2 Example applications Power semiconductors Thyristors Relays Battery connectors Current-operated earth-leakage circuit-breakers Earthing straps

Special benefits In order to provide as much as help as possible with the processing and fitting of our copper flexibles and copper straps, we have developed techniques of finishing the end in such a way that the flexibles and straps can be easily connected and the electrical contact resistance at the connection points is kept as low as possible. We shall be pleased to advise you about the optimum design of the corresponding connection points.

29

The LEONI group

The high-flex wire specialists

LEONI Draht GmbH

Treuchtlinger Strasse 20 91781 Weissenburg Germany Phone +49-9141-918-109 Fax +49-9141-918-100 E-mail draht@leoni.com

LEONI Wire Inc. USA

301 Griffith Road Chicopee, MA 01022 USA Phone +1-413-593-6618 Fax +1-413-593-6639 E-mail info@leoniwire.com

LEONI (Changzhou) Wire Co., Ltd. China

No. 209 Huashan Rd. National Hi-Tech. Dist., 213022 Changzhou P.R. China Phone +86-519-510-3456 Fax +86-519-510-4313

30

The LEONI product range

The LEONI group

Wire

Cable

Wiring Systems
automobiles, trucks and buses tractors and forklifts Conventional and preformed cable harnesses Plastic mouldings, also in foamed version Electronic solutions for automobile construction (part and full multiplex) Cable assemblies for ABS systems and sensors

Single wires, tin, silver, gold and nickel plated made of copper and copper based alloys Bunched and stranded conductors for the cable industry Highly flexible copper strands, ropes and braids Tinsel conductors and braided tubes Copper alloy wires (resistance wires) Metallic gold and silver threads; bouillon

Automotive wires UL and CSA approved cables Insulated power cables Earthing ropes Control cables, shielded and unshielded Insulated Hook-up wires according to DIN, VDE Fiber optic cables with glass and plastic optical fibers Copper data cables Coaxial cables Customised special cables for robotics, seismology, medicine, sensor systems, audio/video, environmental engineering ... Cord sets Spiral cables Cable assemblies Special cables assembled to customer specification Connection cables and car kits for mobile phones Automotive cables for electronic drive controls, engine management, mobile communication Extruded flat cables Battery, starter and generator cables with copper and aluminium conductors

Wiring systems for

LEONI Draht GmbH

Treuchtlinger Strasse 20 91781 Weissenburg Germany Phone +49 (0)9141-918-109 Fax +49 (0)9141-918-100 E-mail draht@leoni.com www.leoni.com