en special conductors

Special conductors for cable extrusion

The Quality Connection

2


www.leoni-special-conductors.com

Competence with TraditionLEONI is one of the small number of manufacturers that can be counted as market leader for the production of highly developed electrical conductors. LEONIs roots in wire drawing can be traced back to the Middle Ages. Since the beginning of the 20th 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.



3

The Quality ConnectionCompetence with Tradition Contents Quality and Environmental Management LEONI The Global Player

Page

2 3 4 5

ConductorsCopper and Copper alloys

6

Surface FinishesTables of weights for platings Electroplating options

8 10 11

Packaging

Product Range WiresSingle Wires Single Wires to DIN Standard Single Wires to AWG Standard Braiding Wires

12 13 14 15 16

Product Range Stranded ConductorsBunched Conductors Highly Flexible Stranded Conductors and Ropes Concentric Stranded Conductors Semiconcentric Stranded Conductors LEONI Smooth-Bunch

17 18 19 20 24 25

LEONI newsLEONI Histral LEONI keeps you up-to-date

26 27

Edition: March 2008 Subject to change and error.

4



Quality and Environmental ManagementOne of LEONIs most important success factors is the globally consistent high quality of its products.

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 Process stability Delivery reliability Fault prevention all play a key role. Process control is the key. Computer-aided monitoring and control of manufacturing processes, continuous improvement, preventative maintenance, ongoing investment in the best manufacturing equiment and employee training are all part of LEONI formula for qualitiy.

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 Quality from start to finish.



5

LEONI The Global PlayerProximity to the customer is a key element of our corporate philosophy. This is the reason why you will find LEONI close to you wherever you are. Please dont hesitate to make use of our strong distribution network.

Wire manufacturing sites in China, England, Germany and the US

LEONI Draht GmbH Treuchtlinger Strasse 20 91781 Weissenburg Germany Phone +49 9141-918-240 Fax +49 9141-918-101 [email protected]

LEONI Draht GmbH Windorfer Strasse 1 93444 Bad Koetzting Germany Phone +49 9941-404-0 Fax +49 9941-404-40 [email protected]

LEONI Wire (Changzhou) Ltd. No. 209 Huashan Road National Hi-Tech District Changzhou 213022 Jiangsu, P.R. China Phone +86 519-510-3456 Fax +86 519-510-4313 E-mail [email protected]

LEONI Temco Ltd. Whimsey Industrial Estate Cinderford, Glos. GL14 3HZ England, UK Phone +44 1594-820-100 Fax +44 1594-823-691 E-mail [email protected]

LEONI Wire Inc. 301 Griffith Road Chicopee, MA 01022 USA Phone +1 413-593-6618 Fax +1 413-593-6639 E-mail [email protected]

6

Conductors


Copper and Copper AlloysOur 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), LEONI Histral, Copper Clad Aluminium (CCA) and Copper Clad Steel (CCS).

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

Electrolytic copperCu-ETP1 (E-Cu) EN 13602 CW 003 A Cu 99.90 6 Oxygen max. 0.040 8.9 1083 101 Electrolytic tough pitch copper with an electrical conductivity in annealed condition of 58.58 m/mm2 at 20 C (101 % IACS).

Oxygen-free copperCu-OF1 (OF-Cu) EN 13602 CW 007 A Cu 99.95 8.9 1083 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 66, ultrasonic welding and hard soldering (brazing), and for use in the fields of vacuum technology and electronics. 5 ppm oxygen66Hydrogen 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.

Cu-OF1 (Cu OFE)

EN 13602

CW 008 A

Cu 99.99

8.9

1083

101

6 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.

International Annealed Copper Standard = IACS Electirical conductivity of copper = min. 58 m/mm2 = 100 % IACS


Conductors

7

Symbol

International specification

Material number

Composition in %-byweight

Density

Melting point in C

% IACS min.

Comments

g/m3

Copper alloysHistral CI203 CuSn 94/6 CuSn 98/2 CuNi 98/2 CuNi 95/5 CuNi 90/10 CuNi 85/15 CuNi 75/25 CuNi 55/45 DIN 17471 DIN 17471 DIN 17471 DIN 17471 DIN 17471 BS EN 12166 CW452K UNS No. C50700 2,0802 2,0807 2,0811 UNS No. C70900 2,0881 2,0842 94 98 98 95 90 85 75 55 8.9 8.9 8.9 8.9 8.9 8.9 8.9 8.9 8.9 8.9 1090 1084 1100 1100 1090 1095 1100 1100 1150 1280 80 80 20 34.5 34.5 18 11.5 8.6 5.75 3.5 A high strength copper alloy, as an alternative to other cadmiumcontaining copper alloys. With an electrical conductivity of 80 % IACS A high strength copper alloy, as an alternative to other cadmiumcontaining copper alloys. With an electrical conductivity of 80 % IACS Copper tin resistance alloy with an electrical resistance of 0.11 m/mm2 Copper tin resistance alloy with an electrical resistance of 0.04 m/mm2 Copper nickel resistance alloy to DIN 17471 with an electrical resistivity of 0.05 m/mm2 Copper nickel resistance alloy to DIN 17471 with an electrical resistivity of 0.10 m/mm2 Copper nickel resistance alloy to DIN 17471 with an electrical resistivity of 0.15 m/mm2 Copper nickel resistance alloy with an electrical resistivity of 0.20 m/mm2 Copper nickel resistance alloy to DIN 17471 with an electrical resistivity of 0.30 m/mm2 Copper nickel resistance alloy to DIN 17471 with an electrical resistivity of 0.49 m/mm2

in %-Cu-bydiameter

g/m3

Other materialCu Clad Aluminium 15 % Cu Clad Steel 30% Cu Clad Steel 40% ASTM B566 Class 15 4 3.6 65.7 Composite material with Cu cladding around an alumium core, resulting in much lighter material (41 % compared to Cu) Composite material with Cu cladding around a steel core and having electrical conductivity of 30 % IACS Composite material with Cu cladding around a steel core and having electrical conductivity of 40 % IACS

ASTM 452 ASTM 452

Class 30 Class 40

6.5 10

7.9 7.9

30 40

8

Surface Finishes


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

AWG-wires plating thickness 1 m of wire mm AWG No. Tin Sn g/kg Nickel Ni g/kg Silver Ag g/kg

0.050 0.064 0.070 0.080 0.090 0.100 0.114 0.120 0.127 0.130 0.140 0.150 0.160 0.180 0.200 0.220 0.226 0.250 0.254 0.260 0.280 0.300 0.320 0.360 0.400 0.450 0.500 0.600 0.650 0.700 0.750 0.800 0.850 0.900 0.950 1.000 1.150 1.250 1.300 1.400 1.450 1.500 1.600 1.700 1.800

44 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

65.4 51.1 46.7 40.9 36.3 32.7 28.7 27.3 25.7 25.2 23.4 21.8 20.4 18.2 16.4 14.9 14.5 13.1 12.9 12.6 11.7 10.9 10.2 9.1 8.2 7.3 6.5 5.5 5.0 4.7 4.4 4.1 3.8 3.6 3.4 3.3 2.8 2.6 2.5 2.3 2.3 2.2 2.0 1.9 1.8

80.0 62.5 57.1 50.0 44.4 40.0 35.1 33.3 31.5 30.8 28.6 26.7 25.0 22.2 20.0 18.2 17.7 16.0 15.7 15.4 14.3 13.3 12.5 11.1 10.0 8.9 8.0 6.7 6.2 5.7 5.3 5.0 4.7 4.4 4.2 4.0 3.5 3.2 3.1 2.9 2.8 2.7 2.5 2.4 2.2

94.4 73.8 67.4 59.0 52.4 47.2 41.4 39.3 37.2 36.3 33.7 31.5 29.5 26.2 23.6 21.5 20.9 18.9 18.6 18.2 16.9 15.7 14.8 13.1 11.8 10.5 9.4 7.9 7.3 6.7 6.3 5.9 5.6 5.2 5.0 4.7 4.1 3.8 3.6 3.4 3.3 3.1 3.0 2.8 2.6


Surface Finishes

9

AWG-wires, plating thicknesses according to ASTM The table is a tool to calculate the weight and plating thickness for tin, nickel and silver. Please not, that tin plated wires will not have a plating thickness of 1 m, as stated, but will be manufactured in accordance with EN 13602. Samples for thin platings < 2 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 wireAWG 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

ASTM = American Society for Testing and Materials

10

Surface Finishes


Electroplating options

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

silver high temperature resistance (up to 200 C) high conductivity (Skin-effect, important

for HF-applications)

nickel corrosion and temperature resistance (up to 250 C) Barriers of diffusion high

gold-plated corrosion resistance high bondability chemical resistance

enamelled protection and insulation for ultra-fine wires

Temperature Ratings of conductor materials CSA-C22.2 No. 210.2 states the following temperature ratings of conductor materials: Temperature range max. 150 C plain and tin plated with single wire 0.38 mm Copper clad steel (e.g. STAKU) with single wire 0.38 mm Copper

Temperature range max. 200 C plated copper Silver plated copper clad steel Silver plated copper alloys Silver

Temperature range max. 250 C plated copper Nickel plated copper clad aluminium (CCA) Nickel plated copper clad steel (CCS) Nickel plated high strength alloys Nickel plated steel composites Nickel

LEONI wires and concentric 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.


Packaging

11

Packaging

d1Type of flange mm

d3 of bore mm

l2Traverse

l1Overall Width

d2 of barrel mm Capacity approx. kg Type

d1 of flange mm

d3 of bore mm

l2Traverse

l1Overall Width

d2 of barrel mm Capacity approx. kg

Plastic reels DIN 80 DIN 100 DIN 125 DIN 160 DIN 200 DIN 250/36 DIN 400 DIN 500 DIN 560 DIN 630 K 1600 K 2500 K 2506 K 2534 K 3550 K 4007 K 5600 K 5606 K 6307 80 100 125 160 200 250 400 500 560 630 160 250 250 250 355 400 555 560 630 16 16 16 22 22 36 127 36 127 127 22 22 127 127 36 32.7 127 127 127 64 80 100 128 160 160 250 180 350 350 128 160 160 160 160 205 280 380 380 80 100 125 160 200 200 330 250 450 450 160 200 200 200 200 243 355 480 430 50 63 80 100 125 160 250 315 315 390 100 160 160 160 224 250 355 315 320 0.7 1.4 3.5 8 13 22 80 103 200 200 8 20 25 25 40 70 180 250 350

Pay off pack O/All Diameter (POP) 508 mm Steel reels B 4006 400 127 250 B 5600 560 127 355 B 6300 630 127 400 Sheet metal reels B 6305 630 127 435 Wooden reels G 0800 800 81 400 G 1000 1000 80 560 Plastic braider bobbins FSP75 75 10 50 K0751 FSP80/ 80 10 80 K0804 WSN01/16 cc 66 16 69 K0660 WSN02/24 cc 66 16 104 K0661

O/All Height 150 mm 280 395 475 475 550 700 100 100 80 116 224 315 355 355 400 500 24 23 34 34

35

115 280 400 400 750 1000 1.5 2.0 1.0 1.6

The chart depicts the most common reel sizes. Special types are available upon request. Note: The net weights given for DIN reels are nominal capacities.l1 l2

The main dimensions of a reel: d1 Flange diameter d3 Bore diameter Additionally useful are: l2 Traverse l1 Overall Width d2 Barrel diameter

d3 d2 d1

12

Wires


Product Range Wires

Single Wires Single Wires to DIN Standard Single Wires to AWG Standard Multi Wires Braiding Wires


Wires

13

Wires

We manufacture copper wires in line with international standards and individual customer specifications.

Product Range In addition to CU-ETP1 and CU-OF1 in bare, tin plated, nickel plated, silver plated or gold plated finish, we also process high strength copper alloys.

Delivery Wires can be supplied as:n

Single wire Reel weight range from 8 to 200 kg. Range of single wire diameters: 0.05 mm2.7 mm Multi wire The reel weight ranges from 25 to 500 kg. Range of single wire diameters: 0.05 mm0.52 mm Braiding wire The reel weight ranges from 0.5 to 3 kg. Range of single wire diameters: 0.05 mm0.52 mm Common constructions: 216 wires

n

n

For wire specifications please refer to the tables on the following pages.

14

Wires


Single Wires to DIN StandardDIN 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 6 /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 0.0256

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 2.545m

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

Calculated with a conductivity of 58 mm2 at 20 C. 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.


Wires

15

Single Wires to AWG StandardThe most popular AWG (American Wire Gauge) sizes, diameters and cross-sectional areas in accordance with ASTM B 258 Standard Nominal Diameters and Cross-Sectional AREAS OF AWG SIZES for Solid Round Wires used As Electrical Conductors.Diameter AWG Size mils mm mm2

Cross-section Weight cmils sq. inch approx. kg/km Yield approx. km/kg

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

72.0 64.1 57.1 50.8 45.3 40.3 35.9 32.0 28.5 25.3 22.6 20.1 17.9 15.9 14.2 12.6 11.3 10.0 8.9 8.0 7.1 6.3 5.6 5.0 4.5 4.0 3.5 3.1 2.8 2.5 2.2 2.0 1.8 1.6 1.4 1.2 1.1 0.99

1.829 1.628 1.450 1.290 1.151 1.024 0.912 0.813 0.724 0.643 0.574 0.510 0.455 0.404 0.361 0.320 0.287 0.254 0.226 0.203 0.180 0.160 0.142 0.127 0.114 0.102 0.089 0.079 0.071 0.064 0.056 0.051 0.045 0.040 0.036 0.032 0.028 0.025

2.625 2.082 1.652 1.307 1.039 0.821 0.654 0.517 0.411 0.324 0.259 0.205 0.162 0.128 0.102 0.0806 0.0648 0.0507 0.0401 0.0324 0.0255 0.0201 0.0159 0.0127 0.0102 0.0081 0.0062 0.0049 0.0040 0.0032 0.0025 0.0021 0.0016 0.0013 0.00099 0.00078 0.00062 0.00050

5180 4110 3260 2580 2050 1620 1290 1020 812 640 511 404 320 253 202 159 128 100 79.20 64.00 50.40 39.70 31.40 25.00 20.20 16.00 12.20 9.61 7.84 6.25 4.84 4.00 3.10 2.46 1.96 1.54 1.23 0.98

0.00407 0.00323 0.00256 0.00203 0.00161 0.00128 0.00101 0.000804 0.000638 0.000503 0.000401 0.000317 0.000252 0.000199 0.000158 0.000125 0.0001 0.0000785 0.0000622 0.0000503 0.0000396 0.0000312 0.0000246 0.0000196 0.0000159 0.0000126 0.00000962 0.00000755 0.00000616 0.00000491 0.0000038 0.00000314 0.00000243 0.00000194 0.00000154 0.00000121 0.000000968 0.00000077

23.40 18.50 14.70 11.60 9.24 7.32 5.81 4.61 3.66 2.88 2.30 1.82 1.44 1.14 0.908 0.715 0.575 0.450 0.357 0.288 0.227 0.179 0.141 0.113 0.0912 0.0721 0.0552 0.0433 0.0353 0.0282 0.0218 0.0180 0.0140 0.0111 0.00883 0.00693 0.00556 0.00440

0.0428 0.054 0.0681 0.086 0.108 0.137 0.172 0.217 0.273 0.347 0.435 0.549 0.693 0.878 1.10 1.40 1.74 2.22 2.80 3.47 4.40 5.59 7.08 8.88 11.00 13.90 18.10 23.10 28.30 35.50 45.90 55.50 71.70 90.10 113.00 144.00 180.00 228.89

Conversion factors:

mils x 0.0254 = mm cmils x 0.0005067 = mm2 sq.inch x 645.16 = mm2

mm x 39.37 = mils mm2 x 1973.55 = cmils mm2 x 0.00155 = sq.inch

16

Wires


Braiding Wires

Braiding wires for cable screening.

Production programme In order to better reflect customer requirements LEONI has extended its multi wire product range to include pre-wound braid bobbins. LEONIs long known multi wire competency, high quality wires with very narrow diameter and elongation tolerances, means that customers can expect to manufacture excellent braids. The braiding wires are available across the full range of LEONIs wire products including alloys.

Construction LEONIs range of braid bobbins fits all modern braiding machines. Standard available diameter range: 0.05mm0.254mm Standard wire range: 412 wires per bobbin

Standard bobbin types

d1Type Flange diameter mm

d3Bore diameter mm

l2Traverse

l1Overall width

d2Barrel diameter mm Capacity (max.) ca. g

Plastic braid bobbins FSP75 / K0751 FSP80 / K0804 WSN01 / K0660 WSN02 / K0661 75 80 66 66 10 10 16 16 50 80 69 104 100 100 80 116 24 23 34 34 1500 2000 1000 1600


Stranded Conductors

17

Product Range Stranded Conductors

Bunched Conductors Highly Flexible Stranded Conductors and Ropes Concentric Stranded Conductors Semiconcentric Stranded Conductors LEONI Smooth-Bunch

18

Stranded Conductors


Bunched Conductors

This type of conductor is made up of bunched multi-wires. The wires are twisted together in a random pattern. Standard bunched conductors are widely used in the cable industry.

Construction The average diameter of a bunched conductor can be calculated using the table and the formula: D = d f (D = of bunched conductor, d = of single wire) Example: Stranded conductor 16 x 0.20 mm (= 0.50 mm2) D = 0.20 x 4.7 D = 0.94 mm

n = no. of wires f = multiplication factor (average) n 1 2 3 4 5 7 10 12 14 16 f 1.00 2.00 2.15 2.41 2.70 3.00 4.00 4.15 4.41 4.70 n 19 24 26/27 28/30 31/32/33 37 44 48 52 56 f 5.00 6.00 6.15 6.41 6.70 7.00 8.00 8.15 8.41 8.70 n 61 70 75 80 85 91 102 108 114 120 f 9.00 10.00 10.15 10.41 10.70 11.00 12.00 12.15 12.41 12.70

Typical constructions for multi-wire, fine-wire and ultrafine-wire bunched conductorsAWG Cross-section of wire in mm

44 0.05 51 x 0.05 72 x 0.05 128 x 0.05 173 x 0.05 192 x 0.05 256 x 0.05 385 x 0.05 511 x 0.05 770 x 0.05 1274 x 0.05 2016 x 0.05 3192 x 0.05

41 0.07 25 x 0.07 36 x 0.07 66 x 0.07 88 x 0.07 88 x 0.07 130 x 0.07 196 x 0.07 259 x 0.07 392 x 0.07 651 x 0.07 1036 x 0.07 1548 x 0.07 2556 x 0.07 4116 x 0.07

38 0.10 12 x 0.10 18 x 0.10 32 x 0.10 42 x 0.10 48 x 0.10 64 x 0.10 96 x 0.10 128 x 0.10 189 x 0.10 320 x 0.10 511 x 0.10 756 x 0.10 1281 x 0.10 2037 x 0.10 3213 x 0.10 4410 x 0.10 6370 x 0.10 8917 x 0.10 12348 x 0.10 15435 x 0.10 19110 x 0.10 23373 x 0.10 30870 x 0.10

36 0.127 8 x 0.127 11 x 0.127 20 x 0.127 27 x 0.127 30 x 0.127 39 x 0.127 59 x 0.127 79 x 0.127 118 x 0.127 196 x 0.127 322 x 0.127 476 x 0.127 784 x 0.127 1260 x 0.127

34 0.16 7 x 0.16 12 x 0.16 17 x 0.16 19 x 0.16 25 x 0.16 37 x 0.16 50 x 0.16 75 x 0.16 124 x 0.16 196 x 0.16 294 x 0.16 504 x 0.16 798 x 0.16

32 0.20

30 0.254

0.1 0.14 0.25 0.34 0.38 0.5 0.75 1 1.5 2.5 4 6 10 16 25 35 50 70 95 120 150 185 240

8 x 0.20 11 x 0.20 12 x 0.20 16 x 0.20 24 x 0.20 32 x 0.20 48 x 0.20 80 x 0.20 118 x 0.20 189 x 0.20 315 x 0.20

7 x 0.254 8 x 0.254 10 x 0.254 15 x 0.254 19 x 0.254 30 x 0.254 50 x 0.254 79 x 0.254


Stranded Conductors

19

Highly Flexible Stranded Conductors and RopesHighly flexible round concentric stranded conductors and ropes These products have high flexibility and are suitable for cables used in dynamic environments.

Construction The examples shown in the table below can be manufactured both as bunched conductors and as 7 way ropes. n lay length of bunched conductors 2550 times the overall diameter of the strand n lay length of 7 way conductors 816 times the overall diameter of the strand

Product Range Available with bare, silver, nickel or tin plated copper wires.

Nominal cross-section mm2

Min. number of wires

of stranded conductor mm

Weight kg/km

Nominal cross-section mm2

Min. number of wires

of stranded conductor mm

Weight kg/km

of wire 0.05 mm 0.020 10 0.029 15 0.041 21 0.059 30 0.079 40 0.100 51 0.140 72 0.200 102 0.250 128 0.350 180 0.500 266 0.750 385 1.000 525 of wire 0.07 mm 0.081 21 0.140 36 0.250 66 0.350 90 0.500 130 0.750 195 1.000 259

0.18 0.22 0.26 0.31 0.36 0.40 0.50 0.60 0.65 0.75 0.95 1.15 1.35 0.36 0.50 0.65 0.75 0.95 1.10 1.35

0.175 0.262 0.367 0.524 0.700 0.890 1.260 1.780 2.240 3.240 4.750 7.060 9.390 0.719 1.240 2.230 3.080 4.550 6.910 9.310

1.50 392 2.50 650 4.00 1050 6.00 1575 of wire 0.1 mm 0.50 64 0.75 96 1.00 126 1.50 189 2.50 322 4.00 511 6.00 777 10.00 1281 16.00 2058 25.00 3185 35.00 4508 50.00 6370 70.00 8918 100.00 12348 120.00 15336 150.00 19110 185.00 23373 240.00 30870

1.65 2.25 2.90 3.60 0.95 1.15 1.30 1.65 2.25 2.90 3.60 4.80 6.10 7.60 9.20 10.80 12.80 15.00 16.72 18.66 20.64 23.72

14.10 23.40 37.80 56.60 4.56 6.84 9.13 13.70 23.40 37.10 56.50 94.90 153.00 236.00 334.00 472.00 661.00 879.10 1154.10 1461.20 1818.60 2473.00

20

Stranded Conductors


Concentric Stranded ConductorsIn concentric stranded conductors each single wire occupies a specific position within the formation, guaranteeing a regular construction.

Product Range / Construction The superior quality of LEONIs concentric stranded conductors is due to: n layer wound traversing allowing smooth running at high extrusion speeds n uniform net weight or reel lengths resulting in a significant reduction in waste, particularly in extrusion of multicore and ribbon cables n uniform elongation of the individual wires. n tight tolerances substantially better than ASTM requirements n higher yield m/kg by manufacturing in the negative tolerance range. This type of conductor allows cable manufacturers to either increase insulation wall thicknesses without impacting upon the overall diameter of the cable for safety purposes, or to achieve smaller overall diameters whilst maintaining standard insulation wall thicknesses thereby saving space and weight.

LEONI strands are free of high riding wires which can cause insulation problems. Concentric stranded conductors are made up as follows: 7-strand = 1 + 6 19-strand = 1 + 6 + 12 37-strand = 1 + 6 + 12 + 18 etc. More details can be found in ASTM B 354. Cable technology favours 7 or 19 strand formations especially for electronic wiring. Due to the exact position of the single wires the strands have a very even surface and a constant diameter. They are ideally suited for thin wall insulation using higher value insulation materials.

7-strand (1 + 6) Examples of concentric strand constructions

19-strand (1 + 6 + 12)

37-strand (1 + 6 + 12 + 18)


Stranded Conductors

21

LEONI produces four types of concentric strands.

Unilay

Unilay Concentric

n n n n

same lay direction same lay length manufactured in one working step nearly round construction

Direction of stranding

Unidirectional Concentric

same lay direction n different lay lengths for each working step n manufactured in two working steps n more round than unilay concentricn

Different lay lengths impact on the roundness of the strand Longer lay length = hexagonal / shorter lay length = circular

True concentric

Equilay Concentric(reversed lay stranding

n n n n

or SZ stranding)

different lay directions same lay length manufactured in two working steps very round construction different lay directions different lay lengths for each working step manufactured in two working steps very round construction

Direction of stranding

Conventional Concentric

n n

n n

Concentric stranded conductors with same lay direction are generally known as Unilay. Concentric stranded conductors with different lay directions (reversed or S/Z lay) are known as True concentric.

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

22

Stranded Conductors


Concentric Stranded ConductorsConcentric and electrical conductors Type II to ASTM B 286.

Product Range / Construction Available as plain, tin plated, silver plated and nickel plated copper wires. Alternative wire sizes are available subject to applicable minimum order quantities.

7 wire strands are particularly suited to high frequency data cables.

Electrical conductors Type II in to ASTM B 286 (Examples)AWG No. Nom. cross-section mm2 Construction No. of wires x of wires of stranded conductor mm Weight kg/km Yield km/kg

7-wire conductors 32 30 28 26 24 22 20 18 30 28 26 24 22 20 18 16 14 12 14 12 10 0.034 0.06 0.09 0.14 0.23 0.35 0.56 0.90 0.072 0.093 0.16 0.24 0.38 0.62 0.96 1.23 1.95 3.09 1.87 2.97 4.53 7 x 0.079 7 x 0.102 7 x 0.127 7 x 0.160 7 x 0.203 7 x 0.254 7 x 0.320 7 x 0.404 19 x 0.071 19 x 0.079 19 x 0.102 19 x 0.127 19 x 0.160 19 x 0.203 19 x 0.254 19 x 0.287 19 x 0.361 19 x 0.455 37 x 0.25 37 x 0.32 37 x 0.40 0.28 0.33 0.41 0.51 0.63 0.78 0.99 1.27 0.35 0.43 0.56 0.68 0.84 1.06 1.32 1.50 1.85 2.36 1.71 2.18 2.75 0.315 0.524 0.813 1.290 2.080 3.250 5.160 8.220 0.07 0.854 1.44 2.23 3.53 5.68 8.93 11.36 17.86 28.57 17.4 26.3 43.6 3.175 1.908 1.230 0.775 0.481 0.308 0.194 0.122 1.531 1.171 0.694 0.448 0.283 0.176 0.112 0.088 0.056 0.035 0.057 0.038 0.023

19-wire conductors

37-wire concentric stranded conductors


Stranded Conductors

23

Concentric Stranded ConductorsConcentric stranded conductors, metric dimensions.

Metric dimensions (example)Nominal cross-section mm2 Construction no. of wires x of wire of conductor mm Weight kg/km Yield km/kg

7-wire conductors 0.028 0.055 0.093 0.12 0.18 0.22 0.34 0.50 0.88 1.14 1.42 0.04 0.15 0.33 0.48 0.60 1.34 2.04 2.39 3.09 3.88 0.30 0.47 0.75 1.00 1.50 2.00 2.50 3.00 4.00 4.50 7 x 0.071 7 x 0.10 7 x 0.13 7 x 0.15 7 x 0.18 7 x 0.20 7 x 0.25 7 x 0.30 7 x 0.40 7 x 0.455 7 x 0.51 19 x 0.05 19 x 0.10 19 x 0.15 19 x 0.18 19 x 0.20 19 x 0.30 19 x 0.37 19 x 0.40 19 x 0.455 19 x 0.51 37 x 0.102 37 x 0.127 37 x 0.160 37 x 0.180 37 x 0.226 37 x 0.250 37 x 0.287 37 x 0.320 37 x 0.370 37 x 0.404 0.21 0.30 0.39 0.45 0.54 0.60 0.75 0.90 1.20 1.37 1.53 0.25 0.50 0.75 0.90 1.00 1.50 1.85 2.00 2.28 2.55 0.69 0.88 1.12 1.26 1.58 1.75 2.01 2.24 2.59 2.83 0.247 0.504 0.852 1.130 1.585 2.020 3.150 4.540 8.060 10.130 12.727 0.3 1.35 3.03 4.35 5.38 12.20 18.52 21.28 27.78 34.48 2.6 4.2 6.6 8.4 13.3 16.2 21.4 26.6 35.6 42.5 4.049 1.984 1.174 0.885 0.631 0.495 0.317 0.220 0.124 0.099 0.079 3.001 0.74 0.33 0.230 0.186 0.082 0.054 0.047 0.036 0.029 0.385 0.239 0.152 0.119 0.075 0.062 0.047 0.038 0.029 0.024

19-wire conductors

37-wire concentric stranded conductors

37 wire strands may be used in thin wall insulation constructions. LEONI Smooth-Bunch with its extremely round construction offer an excellent alternative to traditional 37 wire strands (see page 25).

24

Stranded Conductors


Semi-concentric ConductorsThis type of conductor provides the advantages of a concentric conductor in terms of its smooth surface and roundness. Yet it is not tied to conventional concentric construction (1 + 6 + 12 + 18, etc.).

Product range / construction Available made of bare, tin plated, nickel plated or silver plated copper wires. Cross sections can thus be tailored to the specific requirements of our customers.

Semi-concentric conductors are suited especially to cables with thin-walled insulation.

Examples of semi-concentric conductor construction 12-wire 16-wire

24-wire

30-wire

Conductor examplesNominal cross section mm2 Construction No. of wires x wire dia. Conductor dia. nom. mm Weight nom. kg/km

0.25 0.5 0.75 1 1.5 2.5 4 6 10

21 x 0.127 16 x 0.203 24 x 0.203 32 x 0.203 30 x 0.254 50 x 0.254 56 x 0.30 84 x 0.30 80 x 0.404

0.66 0.93 1.13 1.31 1.59 2.05 2.56 3.13 4.12

2.415 4.802 7.334 9.949 14.447 23.357 36.453 54.650 94.448

Alternatively, LEONI offers this product range with particularly round LEONI Smooth-Bunch conductor construction (see page 25).


Stranded Conductors

25

LEONI Smooth-BunchUsing a special manufacturing process LEONI SmoothBunch conductors have a compact and precise round construction.

Product Range / Construction Available in plain, tin plated, silver plated and nickel plated copper wire. Standard constructions are listed below. Different cross-sections can be supplied if required. LEONI Smooth-Bunch conductors are particularly suitable for thin wall extrusion using high value insulation materials. Cables made using these conductors can have the smallest possible overall diameters.

16-wires Examples of smooth bunch constructions

24-wires

84-wires

Example construction typesNominal cross-section mm2 Construction (No. of wires x of wires) of conductor (Nom. value) mm Weight (Nom. value) kg/km

0.50 0.75 1.00 1.50 2.50 4.00 6.00 10.00 16.00

16 x 0.203 24 x 0.203 32 x 0.203 30 x 0.254 50 x 0.254 56 x 0.30 84 x 0.30 80 x 0.404 133 x 0.404

0.874 1.062 1.231 1.494 1.927 2.406 2.942 3.873 4.991

4.802 7.334 9.949 14.447 23.357 36.453 54.650 94.448 158.639

26

LEONI news


LEONI HistralRoHS compliantLEONI has successfully created a 100 % cadmium free alloy. It is superior to conventional copper cadmium, both in terms of its electrical and mechanical properties.LEONI Histral is a registered trademark of LEONI Draht GmbH.

Key benefits:High tensile strength in soft condition Rm > 415 N/mm2 elongation >7 % in hard condition Rm > 700 N/mm2 High conductivity in soft condition 80 % according to ASTM B 624 in hard condition > 70 % IACS Excellent in flexlife properties Good solderability High temperature resistance retains tensile strength up to 400 C Good corrosion resistance EU Prohibits Use of Cadmium Until now copper cadmium has been used for electrical conductors which have to exhibit high mechanical strength. Since EU law has now banned the use of cadmium in any form in motor vehicles and domestic appliances, LEONI has developed its own high strength cadmium free alternative alloy, which is free of harmful substances LEONI Histral. LEONI Histral is currently available as single wire, strand, braid or tinsel using wires as fine as 0.08 mm. LEONI Histral is available in both hard and soft condition, with a bare, nickel and silver surface.

More detailled information on LEONI Histral is provided in our Histral brochure which is available for download under www.leoni-special-conductors.com


LEONI news

27

LEONI keeps you up-to-date

We offer high quality electrical conductors for cable engineering as well as for special applications in electrical engineering and in electronics. Our engineers are constantly working on ways to improve our products, extending our product range with new materials and constructions and developing innovative solutions to satisfy the many and varied needs of the cable industry. The LEONI Special Conductors business unit is the right partner for special constructions. Please feel free to contact us.

In addition we would recommend that you visit our web site www.leoni-special-conductors.com

Our newsletter will inform you either by post or e-mail about the most recent developments in the wire marketplace and in our business unit. Please register at [email protected] so that you will not miss any updates.

LEONI Draht GmbH Business Unit Special Conductors

Treuchtlinger Strasse 20 91781 Weissenburg Germany Phone +49 (0)9141-918-240 Fax +49 (0)9141-918-101 E-mail [email protected] www.leoni-special-conductors.com

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