braided cable specification

8/2/2019 Braided Cable Specification

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Stranded Conductors and Braids

The Best Solution For Your Application


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The Quality Connection

4 Competence with Tradition

5 Product range LEONI Wire

6 LEONI Quality Management7 LEONI The Global Player

8 Advantages o our products

Current rating

9 Table o current rating

Conductors

10 Copper and copper alloys

Surface finishes

11 Surace nishes

12 Table o weights or platings

Packaging

14 Packaging

Product range

15 Produc t range

The LEONI group

30 The high-fex wire specialists31 The LEONI product range

Edition: April 2006

We reserve the right to make technical alterations.

by LEONI Draht GmbH 2006

The Quality

Connection Contents


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page 15

Product range

The Quality

Connection

Single wires

Copper flexibles

Braided conductors

Tapes

woven / braided

Cable screening products

Ready made assemblies

16 Single wires to DIN standard

17 Round, stranded copper lexibles18 Ropes with integral strain members

19 Round, stranded copper lexibles

with overall braid

20 Round, braided copper lexibles

21 Square braids, highly lexible

22 Rectangular braided conductors,

extra lexible

23 Flat cables woven

24 Braided copper tapes, lat rolled, lexible

25 Braided copper tapes, lat rolled

26 Braided copper tapes, lat rolled, super lexible

27 Shielding braids (tubular)

28 Knitted copper abrics

29 Assemblies / inishing


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4

LEONI is a global leader in its area o expertise the manuacture

o highly engineered electrical conductors.

LEONIs roots in wire drawing can be traced back to the Middle

Ages. Since the beginning o the 20 th century we have been innova-

tors in electro plating, stranding and multi-wire technology. Today

LEONI oers a comprehensive range o wires, stranded conductors,

ropes and braids or both the cable industry and electrical compo-

nent market.

Competence with TraditionThe QualityConnection

In acknowledgement


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Single wires, tin, silver,

gold and nickel platedmade of copper and

copper based alloys

Bunched and strandedconductors for the

cable industry

Highly flexible copperstrands, ropes and braids

Tinsel conductors

and braided tubes

Copper alloy wires(resistance wires)

Metallic gold and silverthreads; bouillon

Product range

LEONI Wire

The Quality

Connection

5

o tradition and quality


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The Quality

Connection LEONI Quality Management

6

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 o our products.

LEONI Quality Management

LEONI Draht has a universal quality management system covering all

o our worldwide manuacturing locations ensuring that all o our

products and services comply with uniorm quality standards.

High speed multi-wire drawing places very stringent demands on raw

materials and machine process stability. LEONI conductors satisy the

highest quality and reliability requirements consistent with aircrat and

aerospace technology, specialist applications in the automotive indus-try 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 rom this philosophy, become the benchmark or all

internal operations, rom marketing to product and process develop-

ment, rom manuacturing up to inal delivery o our products to our

customers.

LEONI Quality from start to finish.


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LEONI Draht GmbH

Weissenburg, Germany

LEONI Wire Inc.

Chicopee MA, USA

LEONI Wire (Changzhou) Ltd.

Changzhou, P.R. China

7

Wire manufacturing sites in Germany,

England, China and the USA:

A worldwide presence or our customers

The Quality

ConnectionLEONI The Global Player


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8

These advantages count:

No splicing o cut ends

Faultless surace quality ensures the ully automatic

processing

The special LEONI performance:

Production of constructions to foreign standards

and of constructions to suit customer's requirements.

Advantages o our productsThe QualityConnection

LEONI The Quality Connection

It is protable to use LEONI products as the quality related oers

advantages in both processing and production. Many years o

experience in in-house wire drawing up to the nal product simply

pay o. This is attributed last but not least to the constant improve-

ment o our processes and activities in order to ensure and increase

our customer satisaction.


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Current rating

The following table will help you to select the correct

conductor cross-section as a function of the current rating.

Since several inluencing actors generally apply, the values speciied

must be considered only as non-binding guideline values.

Nom. cross-

section

Max. permitted

current rating

mm2 approx. A

0.10 5

0.14 6

0.20 7

0.25 9

0.35 10

0.50 12.5

0.75 15

1 181.50 21

2.50 30

4 40

5.25 44

6 55

8 70

10 85

16 120

Table o current rating

Nom. cross-

section

Max. permitted

current rating

mm2 approx. A

25 150

35 195

50 250

70 300

95 360

120 420

150 480

185 570240 670

300 780

400 950

500 1100

625 1300

800 1500

1000 1800

Measured at 35 C room temperature

and max. permitted conductor tem-

perature o 70 C


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Our main raw material is copper (Cu). In our wire manuacturing we

primarily use Cu-ETP 1or all standard applications and Cu-OF 1

(oxygen ree copper) where speciic requirements dictate, e.g. resi-

stance to hydrogen as in ISO 2626.

The standard o purity is achieved when the electrical

conductivity in annealed condition is 58.58 m/mm2 in

the case o Cu-ETP1. Details o sampling and test methods

are available.

Hydrogen resistance is tested and measured according to

international technical speciications. I individual custo-

mers have particular requirements these must be stipu-

lated at the time o order.

Copper and copper alloysConductors

Excerpt from EN 1977 Copper and copper alloys Copper drawing stock (wire rod)

International Annealed Copper Standard = IACS

Electirical conductivity of copper = min. 58 m/mm2 = 100 % IACS

Symbol Materialnumber

Composition Density Meltingpoint

% IACSmin.

Comments

in %-by-weight g/m3

Electrolytic copper

Cu-ETP1

(E-Cu)

CW 003 A Cu99.90

Oxygen

max. 0.040

8.9 1083 C 101 Electrolytic tough pitch copper with an electrical

conductivity in annealed condition o58.58

m/mm2 at 20 C (101 % IACS).

Oxygen-free copper

Cu-OF1

(OF-Cu)

CW 007 A Cu 99.95 8.9 1083 C 101 Oxygen ree copper is purer containing less impu-

rities and trace elements which evaporate in a

vacuum and has an electrical conductivity in the

annealed condition o58.58 m/mm2 at 20 C

(101 % IACS).

It is suitable or semi-inished products that

require resistance to hydrogen as in ISO 2626 ,

ultrasonic welding and hard soldering (brazing),

and or use in the ields o vacuum technology and

electronics.

In addition to copper we process a number o copper alloys or special

applications. Typical alloys include CuSn (copper/tin), CuNi (copper/

nickel), CuAg (copper/silver)and LEONI Histral.

10


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Surace inishes

Electroplating options For plated copper/wires we use tin, silver or nickel as metal, depending on what is required rom the conductor.

tin silver nickelgood solderability

eective protection against corrosion

high temperature resistance

high conductivity (Skin-eect, important

or HF-applications)

high corrosion and temperature

resistance

barries o diusion

Surace inishes

11

LEONI wires and stranded conductors are available bare and with a range o surace inishes

manuactured to industry, national and international standards as well as to individual customer speciications.

DIN EN 13602 Requirements of the tin-pl ating

Type Min. unalloyed

tin plating thickness

Purity

of the tin layer

Bonding of tin layer

mA 0.3

max. 1.0 g copper

per m2 wire suraceNo cracks and interruptionsB 0.6

C not speciied

The tin plating thickness is determined by supplier.


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12

Tables o weights or platingsSurace inishesat a speciic weight (kg/dm3) o 7.28 Sn (= tin), 8.9 Ni (= nickel), 10.5 Ag (= silver).

Metric Wires Layer thickness 1 m

Wire- Tin Sn Nickel Ni Silver Ag

mm g/kg g/kg g/kg

0.050 65.4 80.0 94.40.063 51.9 63.5 74.90.070 46.7 57.1 67.40.071 46.1 56.3 66.50.080 40.9 50.0 59.00.090 36.4 44.4 52.40.100 32.7 40.0 47.20.112 29.2 35.7 42.10.120 27.3 33.3 39.30.125 26.2 32.0 37.80.130 25.2 30.8 36.30.140 23.4 28.6 33.70.150 21.8 26.7 31.50.160 20.4 25.0 29.50.180 18.2 22.2 26.20.200 16.4 20.0 23.60.220 14.9 18.2 21.50.224 14.6 17.9 21.10.250 13.1 16.0 18.9

0.260 12.6 15.4 18.10.280 11.7 14.3 16.90.300 10.9 13.3 15.7

0.315 10.4 12.7 15.00.320 10.2 12.5 14.80.355 9.2 11.3 13.30.370 8.8 10.8 12.80.400 8.2 10.0 11.80.410 8.0 9.8 11.50.430 7.6 9.3 11.00.450 7.3 8.9 10.50.500 6.5 8.0 9.40.520 6.3 7.7 9.10.560 5.8 7.1 8.40.600 5.4 6.7 7.90.630 5.2 6.3 7.50.640 5.1 6.2 7.40.680 4.8 5.9 6.90.710 4.6 5.6 6.70.750 4.4 5.3 6.30.800 4.1 5.0 5.90.850 3.8 4.7 5.60.900 3.6 4.5 5.30.950 3.5 4.2 5.01.000 3.3 4.0 4.71.060 3.1 3.8 4.41.120 2.9 3.6 4.21.180 2.8 3.4 4.01.250 2.6 3.2 3.81.320 2.5 3.0 3.61.400 2.3 2.9 3.41.500 2.2 2.7 3.2

1.600 2.0 2.5 3.01.700 1.9 2.4 2.81.800 1.8 2.2 2.6


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13

Surace inishes

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 o 1 m, as stated, but will be

manuactured in accordance with EN 13602.

Example 1:

How many grammes o silver do you require

or a wire with a diameter o 0.18 mm, i 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

Example 2:

Which plating thickness will be achieved

i you use 39.3 g silver per kg or a 0.18 mm

wire?

39.3 : 26.2 = 1.5 m

AWG-wires, plating thicknesses according to ASTM

AWG No. of wire 25 microinches

0.635 mTin Sn

50 microinches

1.27 mNickel Ni

40 microinches

1.016 mSilver Ag

Silver thickness

pore-free quality

mm g/kg g/kg g/kg g/kg

50 0.025 83.1 203.2 191.8

49 0.028 74.2 181.4 171.3

48 0.032 65.9 161.3 152.2

47 0.036 58.3 142.7 134.7

46 0.040 52.0 127.3 120.2

45 0.045 46.5 113.6 107.3

44 0.051 40.7 99.6 94.0

43 0.056 37.1 90.7 85.6

42 0.064 32.4 79.4 74.9

41 0.071 29.2 71.5 67.5

40 0.079 26.3 64.3 60.7 61

39 0.089 23.3 57.1 53.9

38 0.102 20.4 49.8 47.0 50

37 0.114 18.2 44.6 42.1

36 0.127 16.4 40.0 37.8 40

35 0.142 14.6 35.8 33.8

34 0.160 13.0 31.8 30.0 30

33 0.180 11.5 28.2 26.6

32 0.203 10.2 25.0 23.6 25

31 0.226 9.2 22.5 21.2

30 0.254 8.2 20.0 18.9

29 0.287 7.2 17.7 16.7 20

28 0.320 6.5 15.9 15.027 0.361 5.8 14.1 13.3

26 0.404 5.1 12.6 11.9

25 0.455 4.6 11.2 10.5

24 0.511 4.1 9.9 9.4

23 0.574 3.6 8.9 8.4

22 0.643 3.2 7.9 7.5

21 0.724 2.9 7.0 6.6

20 0.813 2.6 6.2 5.9 12.5

19 0.912 2.3 5.6 5.3

18 1.024 2.0 5.0 4.7

17 1.151 1.8 4.4 4.2

16 1.290 1.6 3.9 3.7

15 1.450 1.4 3.5 3.314 1.628 1.3 3.1 2.9

13 1.829 1.1 2.8 2.6

AWG = American Wire Gauge


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PackagingPackaging

14

d1 d3 l2 l1 d2

Type of flange of bore Traverse Overall Width of barrel Capacity max.

(based on stranded

conductors)

mm mm mm approx. kg

Plastic reels

K 125 125 16 100 125 80 3

K 160 160 22 128 160 100 6

K 200 200 22 160 200 125 12

K 250 250 22 160 200 160 20

K 355 355 36 160 200 224 35

K 400 400 32.7 205 243 250 70

Wooden reels

H 400 400 36 200 250 200 70

H 600 600 50 280 340 280 250

H 800 800 81 400 550 400 500

H 1000 1000 80 560 700 500 1000

The chart depicts the most common reel sizes. Speci al

types are available upon request.

The main dimensions of a reel are:

d1 Flange diameter

d3 Bore diameter

Additionally useful are:

l2 Traverse

l1 Overall Widthd2 Barrel diameter

d3 d1d2

l2

l1


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Product range

Product range

Single wires

Copper fexibles

Braided conductors

Tapes, woven / braided

Cable screening products

Ready made assemblies

15


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16

DIN dimensions or single copper wires in accordance with

DIN 46 431 Round Copper Wires or Electrical Purposes, Exactly

Drawn

(These Standards apply only to plain wires as the parameters change

as a result o the extrusion process and the associated wire elongation.)

Single wires to DIN standardSingle wires

Diameter

Nominal valued

Tolerance Min. value Max. value Nominalcross-section

Weight DC resistanceat 20 C

Yield

mm mm mm mm mm2 approx. kg/km /m nom. value approx. km/kg

0.05

0.003

0.047 0.053 0.00196 0.0175 8.80 57.10

0.063 0.060 0.066 0.00312 0.0278 5.53 36.00

0.071 0.068 0.074 0.00396 0.0353 4.35 28.30

0.08 0.077 0.083 0.00503 0.0447 3.43 22.40

0.09 0.087 0.093 0.00636 0.0566 2.71 17.67

0.1 0.097 0.103 0.00785 0.0699 2.196 14.31

0.112

0.005

0.107 0.117 0.00985 0.0878 1.750 11.39

0.125 0.120 0.130 0.01227 0.109 1.402 9.17

0.14 0.135 0.145 0.01539 0.137 1.120 7.30

0.16 0.155 0.165 0.02011 0.179 0.8573 5.59

0.18 0.175 0.185 0.02545 0.226 0.6774 4.420.2 0.195 0.205 0.03142 0.280 0.5487 3.57

0.224 0.219 0.229 0.03941 0.351 0.4375 2.85

0.25

0.007

0.243 0.257 0.04909 0.437 0.3512 2.29

0.28 0.273 0.287 0.06158 0.548 0.2799 1.825

0.315 0.308 0.322 0.07793 0.694 0.2213 1.441

0.355 0.348 0.362 0.09898 0.882 0.1743 1.134

0.4

0.009

0.391 0.409 0.1257 1.12 0.1372 0.893

0.45 0.441 0.459 0.1590 1.42 0.1084 0.704

0.5 0.491 0.509 0.1964 1.75 0.0878 0.571

0.56 0.551 0.569 0.2463 2.19 0.0700 0.457

0.63 0.621 0.639 0.3117 2.78 0.0553 0.36

0.71

0.012

0.698 0.722 0.3959 3.53 0.04354 0.283

0.75 0.738 0.762 0.4418 3.93 0.03902 0.254

0.8 0.788 0.812 0.5027 4.47 0.03429 0.2240.85 0.838 0.862 0.5675 5.05 0.03038 0.198

0.9 0.888 0.912 0.6362 5.66 0.02710 0.177

0.95 0.938 0.962 0.7088 6.31 0.02432 0.158

1 0.988 1.012 0.7854 6.99 0.02195 0.143

1.06

0.016

1.044 1.076 0.8825 7.86 0.01954 0.127

1.12 1.104 1.136 0.9852 8.78 0.01750 0.114

1.18 1.164 1.196 1.094 9.75 0.01577 0.103

1.25 1.234 1.266 1.227 10.90 0.01405 0.0917

1.32 1.304 1.336 1.368 12.20 0.01260 0.082

1.4 1.384 1.416 1.539 13.70 0.01120 0.073

1.5

0.020

1.480 1.520 1.767 15.70 0.00976 0.0637

1.6 1.580 1.620 2.011 17.90 0.00858 0.0559

1.7 1.680 1.720 2.270 20.20 0.00760 0.0495

1.8 0.025 1.775 1.825 2.545 22.60 0.00677 0.0442

Calculated with a conductivity o 58 at 20 C.

The maximum resistance value in the case o a diameter using the ull acceptable negative

deviation range must be suitable or a conductivity o at least 57.5 at 20 C.

m mm2

m mm2


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17

Round, stranded copper lexibles Copper lexibles

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

Round, stranded copper flexibles

similar to DIN 46438

Besides special lexibility these types distinguish themselves through

no splicing o cut ends or urther 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 t able on page 14.

Nominal

cross-section

of wire No. of wires

Tol. 2 %

Overall- Weight

12 %

mm2 mm approx. mm approx. kg/km

0.06

0.05

0.004

30 0.3 0.6

0.1 51 0.4 1

0.14 72 0.5 1.4

0.2 105 0.6 2

0.25 130 0.7 2.5

0.35 180 0.85 3.5

0.5 266 1 5

0.75 392 1.25 7.5

1 525 1.5 10

1.5

0.071 0.004

385 1.75 15

2 525 2.1 20

2.5 651 2.4 25

3 798 2.6 30

4 1036 3 40

5.25 1372 3.5 53

6 1575 3.7 60

8 2058 4.2 80

10 2562 4.7 100

12 3108 5.2 120

16 4116 6.0 160

Nominal

cross-section


Tol. 2 %

Overall- Weight

12 %


25

0.1 0.004

3234 7.6 250

35 4508 9.0 350

50 6468 10.7 500

70 8967 12.7 700

95 12201 14.8 950

120 15435 18.0 1200

150 19110 20.0 1500

185 23580 21.0 1850

240 30600 24.9 2400

300 38200 26.0 3000

400 51000 30.0 4000

500 63700 33.0 5000

600 76430 36.5 6000

Reversed lay or SZ stranding

S let hand lay

Z right hand lay

Special versions

Highly twist-ree and with a compact cutting surace.

A special surace inish permits various welding methods.

Direction of stranding


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18

E-Cu round, stranded copper flexible

with integral strain members for high tensile strength

Ropes with integral strain membersCopper lexibles

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

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 or particular applications.

Nominal cross-section of wire No. of wires

2 %

Overall- Weight Tensile strength

mm2 mm approx. mm approx. kg/km N

2.5

0.071 644 2.4 23 1525

0.10 318 2.4 23 1525

0.20 78 2.4 23 1525

4

0.071 1044 3 38 1840

0.10 504 3 38 1840

0.20 126 3 38 1840

6 0.071 1566 3.7 56 22600.10 756 3.7 56 2260

0.20 192 3.7 56 2260


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19

Round, stranded copper lexibleswith overall braid

Copper lexibles


Round, stranded copper flexibles with overall braid,

highly flexible


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 eective 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 modiications.

Nominal

cross-section

Effective

cross-sectional

area

Round stranded copper flexible Overall braiding of straded

conductor

Weight

12 %


tol. 2 %


tol. 2 %

mm2 mm2 mm mm approx. mm approx. kg/km

0.35 0.35

0.05 0.004

51

0.10 0.004

32 0.8 3.5

0.5 0.51 130 32 1.1 5.1

0.75 0.77 266 32 1.4 7.7

1 1.02 266 64 1.5 10.21.5 1.53 525 64 1.9 15.3

2.5 3.08

0.071 0.004

651 64 2.9 30.8

3.75 3.91 798 96 3.0 39.1

4 4.60 1036 64 3.4 46

6 6.99 1575 96 4.1 69.9

8 8.90 2058 96 4.7 89

10 11.20 2562 128 5.2 112

12 12.00 2562 240 5.2 120

16 17.80 4116 192 6.5 178

25 26.90

0.10 0.004

3234 192 8.2 269

35 37.30 4508 240 9.6 373

50 53.60 6468 360 11.4 536

70 73.30 8967 360 13.4 73395 98.70 12201 360 16.4 987

120 124 15435 360 18.4 1240


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20

Round, braided copper flexibles

Absolute reedom rom twist and compact, cutting surace with

very high dimensional accuracy permit easy, ully automatic urther

processing.

Round, braided copper lexiblesCopper lexibles


Material

E-Cu/OF-Cu and alloys, plain, tinned, nickel-plated or siver-plated.

Packaging


Range of production

The adjacent tables show the standard range. The speciied cross-

sectional areas can also be produced using other wire diameters.

Nominal

cross-section

of wire Constru ction

No. of wires

2 %

Overall- Weight

12 %


0.047

0.05 0.004

8 x 3 0.33 0.47

0.094 8 x 6 0.47 0.94

0.14 8 x 9 0.57 1.40

0.20 8 x 13 0.70 2

0.25 8 x 16 0.80 2.50

0.35 8 x 23 0.95 3.50

0.50 8 x 32 1.10 5

0.75 8 x 48 1.35 7.50

1 8 x 64 1.55 10

1.5 0.071 0.004

8 x 49 1.90 15

1.5 12 x 33 1.90 15

2 12 x 44 2.20 20

2.5 12 x 54 2.40 25

3 12 x 65 2.70 30

4 12 x 86 3.10 40

5 12 x 108 3.50 50

6 12 x 130 3.80 60

8 12 x 174 4.40 80

10 12 x 217 4.90 100

12 12 x 260 5.40 120

160.10

0.004

12 x 170 6.10 160

20 12 x 213 6.90 200

25 12 x 266 7.70 250


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21

Square braids, highly lexible Braided conductors

Square braids, highly flexible

Greater lexibility when compared to round braids. With ully

automatic urther processing the predeined orm makes exact

positioning possible. This results in continuously high accurac y in

welding points.

Material

E-Cu/OF-Cu and alloys, plain, tinned, nickel- plated or silver-plated.

Packaging


Nominal

cross-section

Construction

No. of wires

2 %

of wire Edge length Weight

12 %

mm2 mm mm approx. kg/km

0.5 8 x 32 0.05 1.0 5

1 8 x 64 0.05 1.4 10

1.5 8 x 96 0.05 1.75 15

1.5 8 x 49 0.071 1.75 15

2 8 x 128 0.05 2.0 20

2 8 x 65 0.071 2.0 20

2.5 8 x 160 0.05 2.2 25

2.5 8 x 81 0.071 2.2 25

3 8 x 192 0.05 2.5 30

3 8 x 97 0.071 2.5 30

4 8 x 256 0.05 2.8 40

4 8 x 130 0.071 2.8 40

5 8 x 320 0.05 3.2 50

5 8 x 162 0.071 3.2 50

6 8 x 384 0.05 3.5 60

6 8 x 195 0.071 3.5 60

8 8 x 512 0.05 4.1 80

8 8 x 260 0.071 4.1 80

10 8 x 640 0.05 4.6 100

10 8 x 324 0.071 4.6 100

12 8 x 768 0.05 5.0 120

12 8 x 390 0.071 5.0 120

16 8 x 255 0.10 5.8 160

25 8 x 400 0.10 7.2 250

35 8 x 560 0.10 8.5 350

40 8 x 640 0.10 9.0 400

50 8 x 800 0.10 10.2 500

E-Cu, OF-Cu: plain, tinned


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22

Rectangular braided conductors, extra flexible

Due to the rectangular orm a signiicantly greater cross-section can be

accommodated in the smallest o spaces as compared to round stranded

conductors. This saves valuable space.

Rectangular braided conductors,extra lexible

Material

E-Cu/OF-Cu plain, tinned.

Special benefits

Extraordinarily high lexibility is achieved in the stranded conduc-

tors through a special manuacturing process which, even with high

packing density (multilayer installations), allows the tightest bend-

ing radiuses and does not degrade switching operations.

Dimensions

The braided conductor can be manuactured with a dimension ratio

rom 1:1.5 to 1:1.25, where the dimension is determine d in agree-

ment with the customer depending on the intended use and avail-

ability o space.

Example of two possible dimensionsor 50 mm2 13 x 8.5 mm or

15 x 7 mmEffective

cross-section

No. of wires of wire Dimensions Weight

12 %


16 2040 0.10

160

25 3200 0.10 250

35 4480 0.10 350

40 5120 0.10 400

50 6400 0.10 540


raided conductors


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23

Flat cables woven

Flat cables woven flexible


The special plaiting method means that the width o the lat

cable remains virtually constant, even when subject to high

tensile or compressive load.

Material

E-Cu, plain or tinned.

Packaging

In coils.

Tapes

woven / braided

Dimensions can be varied.

Flat cables woven in accordance with DIN 46443

Dimensions Construction of the flat cables in acc. with DIN 46443

Nominal

cross-section

Width

Thickness

0.5

Warp Weft Weight

12 %

Width of the

connecting

rail/busNominal

cross-section

Number Nominal

cross-section

mm2 mm mm mm mm2 mm2 kg/km

25 28 1.6 3 1.5 16 1 325 30

25 38 1.6 2 1 24 0.75 340 40

35 23 1.6 5 6.0 6 1.5 430 2535 28 1.6 4 4 9 1.5 430 30

35 38 1.6 3 1.5 22 1 445 40

35 47 2.5 2 1 34 0.75 470 50

50 28 1.6 6 6 8 1.5 565 30

50 38 1.6 4 4 12 1.5 600 40

50 47 2.5 3 2.5 20 1.5 675 50

50 57 2.5 2.5 1.5 32 1 645 60

70 38 1.6 6 8 9 1.5 835 40

70 47 2.5 5 6 12 1.5 860 50

70 57 2.5 4 4 18 1.5 900 60

95 47 2.5 6.5 8 12 1.5 1105 50

95 57 2.5 5.5 6 16 1.5 1135 60

120 57 2.5 7 10 12 1.5 1365 60120 77 2.5 5 6 20 1.5 1430 80

150 77 2.5 6.5 10 15 1.5 1715 80


24/32

24

Nominal

cross-

section

Dimensions

width 5 %

x

thickness

Construction of wire Weight


0.09 1 x 0.2 16 x 3

0.05 0.004

0.9

0.16 1.2 x 0.2 16 x 5 1.6

0.25 1.6 x 0.2 16 x 8 2.5

0.5 2.5 x 0.4 16 x 16 5.0

0.75 2.7 x 0.5 16 x 24 7.5

1 3.2 x 0.7 16 x 32 10

1.5 4 x 0.8 16 x 25

0.071 0.004

15

2 5 x 0.8 16 x 33 20

2.5 5.8 x 0.8 24 x 27 25

3 7.5 x 0.9 24 x 33 30

4 8.2 x 1 24 x 43 40

6 10 x 1.3 24 x 66 60

8 12.3 x 1.5 24 x 88 80

10 14 x 1.5 24 x 109 100

Braided copper tapes, flat rolled, flexible


Braided copper tapes, lat rolled, lexibleTapeswoven / braided


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

I required, individual dimensions can be varied slightly during the

rolling process. Non standard dimensions may require design modi-

ications.

All types are available in non-rolled orm as multiple tubes and or

screening.

Nominal

cross-

section

Dimensions

width 5 %

x

thickness

Construction of wire Weight


16 17.5 x 2 24 x 85

0.1 0.004

160

25 22 x 2.5 24 x 135 250

35 30 x 2.5 36 x 124 350

50 33 x 3.2 48 x 133 500

70 45 x 3.5 48 x 186 700

95 50 x 4 48 x 253 950

120 60 x 4 48 x 319 1200

140 60 x 4.5 48 x 372 1400

150 65 x 5 48 x 399 1500

168 70 x 5 48 x 446 1680

185 75 x 5 48 x 491 1850

240 80 x 6.5 48 x 637 2400

250 80 x 7 48 x 664 2500

300 90 x 7 48 x 797 3000

400 100 x 8.5 48 x 1062 4000

max. 25 % below nominal value.


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25

Braided copper tapes, lat rolled

E-Cu, OF-Cu: plain, tinned

Braided copper tapes (braided copper tubes), flat rolled

similar to DIN 72333, Part 3

Material

E-Cu, plain, tinned.

Packaging


or in coils.

Special versions


rolling process. Non standard dimensions may require de sign modi-

ications.


screening.

Nominal

cross-

section

Dimensions

width

+5 % /25 %

x thickness

Constr uc tion of wire

0.006

Weight

12 %


14 18 x 1.5 36 x 20 0.16 140

14 18 x 1.5 36 x 12 0.2 140

16 20 x 1.6 36 x 22 0.16 160

16 20 x 1.6 36 x 14 0.2 160

21 22 x 2 36 x 29 0.16 210

21 22 x 2 36 x 19 0.2 210

25 22 x 2.5 36 x 35 0.16 250

25 22 x 2.5 36 x 22 0.2 250

35 25 x 3 36 x 48 0.16 350

35 25 x 3 36 x 31 0.2 350

50 33 x 3.2 48 x 52 0.16 500

50 33 x 3.2 48 x 33 0.2 500

70 35 x 4.5 48 x 73 0.16 700

70 35 x 4.5 48 x 46 0.2 700

Tapes

woven / braided

max. 25 % below nominal value.


26/32

26

Braided copper tapes (braided copper tubes),

flat rolled, super-flexible

Braided copper tapes, lat rolled,super lexible

Material

E-Cu, plain, tinned, nickel-plated or silver-plated.

Packaging


or in coils.

Special versions


rolling process. Non standard dimensions may require design modi-

ications.


screening.

Nominalcross-

section

Dimensionswidth 5 %

x thickness

Construction of wire Weight 12 %


4 7 x 1.2 24 x 86

0.05 0.004

40

6 10 x 1.3 24 x 128 60

8 12 x 1.4 24 x 171 80

10 13 x 1.7 24 x 213 100

14 15 x 2 24 x 298 140

16 16 x 2 24 x 341 160

21 19 x 2.4 24 x 450 210

25 24 x 2.3 36 x 355 250

35 29 x 2.6 36 x 497 350

42 35 x 2.6 48 x 447 420

50 36 x 3 48 x 532 500

70 40 x 3.8 48 x 745 700

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

Dimensions can be varied.

Tapes

woven / braided


27/32

27

Shielding braids (tubular)

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


or in coils.

Comment

In case o larger cross-sections the eective cross-section is greater

than the nominal value.

Alterations to constructions may allow a reduction o diameter and

weight while maintaining the nominal cross-section values.

Cable screening

products


Effektive

cross-section

Construction of wire Expandable

max. inner-

Extended length

weight

12 %

Coverage

approx.

mm2 mm approx. mm approx. kg/km %

0.25 16 x 2

0.10 0.004

3 2.3 36.58

0.38 16 x 3 3.5 3.5 45.82

0.50 16 x 4 4 4.6 52.77

0.88 16 x 7 6 8.1 60.66

1.32 24 x 7 8 12.1 64.39

1.70 24 x 9 10 15.6 68.03

1.98 36 x 7 15 18.1 56.40

5.30 24 x 7

0.20 0.006

16 48.8 63.94

6.00 24 x 8 18 55.3 65.16

6.80 24 x 9 20 62 67.72

7.90 36 x 7 25 73 62.70

10.20 36 x 9 30 93.0 66.93

13.60 36 x 12 40 124 68.31

23.80 48 x 7

0.30 0.008

50 218 64.70

30.50 48 x 9 60 280 68.69

33.90 48 x 10 70 311 66.39

40.70 48 x 12 80 373 68.45

50.90 48 x 15 100 466 67.23

72.40 48 x 12

0.40 0.01

120 664 60.71

96.50 48 x 16 140 885 66.82

108.60 48 x 18 160 995 68.42


28/32

28

Knitted copper fabrics, fine-wire

For repair work as cable screens.

The screen density and coverage can be determined by the winding.

Knitted copper abricsCable screeningproducts

Material

E-Cu, plain, tinned.

Packaging

In coils.

Versions

Flat knitted copper fabrics

consisting o 4, 6 or 8 wires 0.10 mm up to a max. width

o 100 mm, mesh spacing approx. 5 mm.

Knitted copper fabric tubes, rolled

made o wire 0.10 mm and above up to a max. width

o 130 mm, close-mesh.

Special versions

High-strength knitted copper abrics made o tinsel conductors

(also combined with wires) are available or special applications.


29/32

29

Assemblies / inishing

Ready made rope and braid assemblies

The photographs show some examples o 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 he lp as possible with the proce ssing

and itting o our copper lexibles and copper straps, we have devel-

oped techniques o inishing the end in such a way that the lexibles

and straps can be easily connected and the electrical contact resis-

tance at the connection points is kept as low as possible.

We shall be pleased to advise you about the optimum design o the

corresponding connection points.

Ready made

assemblies


30/32

30

The high-lex wire specialistsThe LEONI group

LEONI Draht

GmbH

LEONI Wire Inc.

USA

LEONI (Changzhou)

Wire Co., Ltd.

China

Treuchtlinger Strasse 20

91781 Weissenburg

Germany

Phone +49-9141-918-109

Fax +49-9141-918-100

E-mail [email protected]

301 Griith Road

Chicopee, MA 01022

USA

Phone +1-413-593-6618

Fax +1-413-593-6639

E-mail [email protected]

No. 209 Huashan Rd.

National Hi-Tech. Dist.,

213022 Changzhou

P.R. China

Phone +86-519-510-3456

Fax +86-519-510-4313


31/32

The LEONI groupThe LEONI product range

CableWire Wiring Systems

Single wires, tin, silver, gold and nickel

plated made o copper and copper based

alloys Bunched and stranded conductors or

the cable industry

Highly fexible copper strands, ropes

and braids

Tinsel conductors and braided tubes

Copper alloy wires (resistance wires)

Metallic gold and silver threads;

bouillon

Wiring systems or automobiles, trucks

and buses

tractors and orklits Conventional and preormed cable

harnesses

Plastic mouldings, also in oamed version

Electronic solutions or automobile

construction (part and ull multiplex)

Cable assemblies or ABS systems and

sensors

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 bers

Copper data cables

Coaxial cables

Customised special cables or robotics,

seismology, medicine, sensor systems,

audio/video, environmental engineering ...

Cord sets

Spiral cables

Cable assemblies

Special cables assembled to customer

specication

Connection cables and car kits or

mobile phones

Automotive cables or electronic drive

controls, engine management, mobile

communication Extruded fat cables

Battery, starter and generator cables

with copper and aluminium conductors


32/32

LEONI Draht GmbH Treuchtlinger Strasse 20

91781 Weissenburg

Germany

Phone +49 (0)9141-918-109

Fax +49 (0)9141-918-100E-mail [email protected]

braided cable specification

Documents