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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
of wire No. of wires
Tol. 2 %
Overall- Weight
12 %
mm2 mm approx. mm approx. kg/km
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
E-Cu, OF-Cu: plain, tinned, nickel-plated, silver-plated
Round, stranded copper flexibles with overall braid,
highly flexible
similar to DIN 46440
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 %
of wire No. of wires
tol. 2 %
of wire No. of wires
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
E-Cu, OF-Cu: plain, tinned, nickel-plated, silver-plated
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 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 %
mm2 mm approx. mm approx. kg/km
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
On spools in accordance with the table on page 14.
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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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 %
mm2 mm approx. mm approx. kg/km
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
E-Cu, OF-Cu: plain, tinned, nickel-plated, silver-plated
raided conductors
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Flat cables woven
Flat cables woven flexible
similar to DIN 46443
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
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Nominal
cross-
section
Dimensions
width 5 %
x
thickness
Construction of wire Weight
mm2 mm mm approx. kg/km
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
similar to DIN 46444
Braided copper tapes, lat rolled, lexibleTapeswoven / braided
E-Cu, OF-Cu: plain, tinned, nickel-plated, silver-plated
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
mm2 mm mm approx. kg/km
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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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
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 de sign modi-
ications.
All types are available in non-rolled orm as multiple tubes and or
screening.
Nominal
cross-
section
Dimensions
width
+5 % /25 %
x thickness
Constr uc tion of wire
0.006
Weight
12 %
mm2 mm mm approx. kg/km
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.
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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
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.
Nominalcross-
section
Dimensionswidth 5 %
x thickness
Construction of wire Weight 12 %
mm2 mm mm approx. kg/km
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
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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
On spools in accordance with the table on page 14
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
E-Cu, OF-Cu: plain, tinned, nickel-plated, silver-plated
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
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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.
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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
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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
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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
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LEONI Draht GmbH Treuchtlinger Strasse 20
91781 Weissenburg
Germany
Phone +49 (0)9141-918-109
Fax +49 (0)9141-918-100E-mail [email protected]