special conductors for cable extrusion

The Quality Connection

Special conductorsfor cable extrusion

Competence with Tradition

LEONI is one of the small number of manufacturers that can

be counted as market leader for the production of highly

developed electrical conductors.

LEONI’s 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 tech-

nology. Today LEONI offers a comprehensive range of wires,

stranded conductors, ropes and braids for both the cable indus-

try and electrical component market.

www.leoni-special-conductors.com2 The Quality Connection

Edition: March 2008

Subject to change and error.

The Quality Connection Page

Competence with Tradition 2

Contents 3Quality and Environmental Management 4LEONI – The Global Player 5

ConductorsCopper and Copper alloys 6

Surface FinishesTables of weights for platings 8

Electroplating options 10

Packaging 11

Product Range Wires 12Single Wires 13Single Wires to DIN Standard 14Single Wires to AWG Standard 15Braiding Wires 16

Product Range Stranded Conductors 17Bunched Conductors 18Highly Flexible Stranded Conductors and Ropes 19Concentric Stranded Conductors 20Semiconcentric Stranded Conductors 24LEONI Smooth-Bunch 25

LEONI news LEONI Histral® 26

LEONI keeps you up-to-date 27

www.leoni-special-conductors.com 3The Quality Connection

Quality and Environmental Management

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 company’s interests.

We can advise customers on the most environmentally responsible

use and disposal of our products.

LEONI – Quality Management

LEONI Draht has a universal quality management system covering all of

our worldwide manufacturing locations – ensuring that all of our prod-

ucts 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 indus-

try and high speed data transmission technology.

In LEONI Draht’s 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 – Quality from start to finish.

One of LEONI’s most important success

factors is the globally consistent high

quality of its products.

www.leoni-special-conductors.com4 The Quality Connection

LEONI Draht GmbH

Treuchtlinger Strasse 20

91781 Weissenburg

Germany

Phone +49 9141-918-240

Fax +49 9141-918-101

[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 (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


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

LEONI – The Global Player

LEONI Wire Inc.

301 Griffith Road

Chicopee, MA 01022

USA

Phone +1 413-593-6618

Fax +1 413-593-6639


LEONI Draht GmbH

Windorfer Strasse 1

93444 Bad Koetzting

Germany

Phone +49 9941-404-0

Fax +49 9941-404-40

[email protected]

Proximity 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 don´t hesitate

to make use of our strong distribution network.

www.leoni-special-conductors.com 5www.leoni-special-conductors.com The Quality Connection

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

Copper and Copper Alloys

Conductors

6The standard of purity is achieved when the electrical

conductivity in annealed condition is 58.58 m/Ωmm2 in

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

are available.

66Hydrogen resistance is tested and measured according to

international technical specifications. If individual custo-

mers have particular requirements these must be stipu-

lated at the time of order.

International Annealed Copper Standard = IACS

Electirical conductivity of copper = min. 58 m/Ωmm2 = 100 % IACS

Symbol International specification

Materialnumber

Composition Density Meltingpoint

% IACS min.

Comments

in %-by-weight g/m3 in °C

Electrolytic copper

Cu-ETP1

(E-Cu)

EN 13602 CW 003 A Cu ≥99.906

Oxygen

max. 0.040

8.9 1083 101 Electrolytic tough pitch copper with an electrical conductiv-

ity in annealed condition of ≥58.58 m/Ωmm2 at 20 °C (101 %

IACS).

Oxygen-free copper

Cu-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/Ωmm2 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 solder-

ing (brazing), and for use in the fields of vacuum technology and

electronics.

Cu-OF1

(Cu OFE)

EN 13602 CW 008 A Cu 99.99 8.9 1083 101 5 ppm oxygen

www.leoni-special-conductors.com6

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

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

(oxygen free copper) where specific requirements dictate, e.g. resi-

stance 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).

Symbol International specification

Materialnumber

Composition Density Meltingpoint

% IACS min.

Comments

in %-by-weight

g/m3 in °C

Copper alloys

Histral – – 8.9 1090 80 A high strength copper alloy, as an alternative to other cadmium-

containing copper alloys. With an electrical conductivity of 80 % IACS

CI203 – – 8.9 1084 80 A high strength copper alloy, as an alternative to other cadmium-

containing copper alloys. With an electrical conductivity of 80 % IACS

CuSn 94/6 BS EN 12166 CW452K 94 8.9 1100 20 Copper tin resistance alloy

with an electrical resistance of 0.11 m/Ωmm2

CuSn 98/2 UNS No.

C50700

98 8.9 1100 34.5 Copper tin resistance alloy

with an electrical resistance of 0.04 m/Ωmm2

CuNi 98/2 DIN 17471 2,0802 98 8.9 1090 34.5 Copper nickel resistance alloy to DIN 17471

with an electrical resistivity of 0.05 m/Ωmm2

CuNi 95/5 DIN 17471 2,0807 95 8.9 1095 18 Copper nickel resistance alloy to DIN 17471




CuNi 85/15 UNS No.

C70900

85 8.9 1100 8.6 Copper nickel resistance alloy






in %-Cu-by-diameter

g/m3

Other material

Cu Clad

Alumin-

ium 15 %

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)

Cu Clad

Steel 30%

ASTM 452 Class 30 6.5 7.9 30 Composite material with Cu cladding around a steel core

and having electrical conductivity of 30 % IACS

Cu Clad

Steel 40%

ASTM 452 Class 40 10 7.9 40 Composite material with Cu cladding around a steel core

and having electrical conductivity of 40 % IACS

www.leoni-special-conductors.com 7Conductors

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 µm

Ø of wire AWG No. Tin Sn Nickel Ni Silver Ag

mm g/kg g/kg g/kg

0.050 44 65.4 80.0 94.40.064 42 51.1 62.5 73.80.070 41 46.7 57.1 67.40.080 40 40.9 50.0 59.00.090 39 36.3 44.4 52.40.100 38 32.7 40.0 47.20.114 37 28.7 35.1 41.40.120 27.3 33.3 39.30.127 36 25.7 31.5 37.20.130 25.2 30.8 36.30.140 35 23.4 28.6 33.70.150 21.8 26.7 31.50.160 34 20.4 25.0 29.50.180 33 18.2 22.2 26.20.200 32 16.4 20.0 23.60.220 14.9 18.2 21.50.226 31 14.5 17.7 20.90.250 13.1 16.0 18.90.254 30 12.9 15.7 18.60.260 12.6 15.4 18.20.280 11.7 14.3 16.90.300 29 10.9 13.3 15.70.320 28 10.2 12.5 14.80.360 27 9.1 11.1 13.10.400 26 8.2 10.0 11.80.450 25 7.3 8.9 10.50.500 24 6.5 8.0 9.40.600 23 5.5 6.7 7.90.650 22 5.0 6.2 7.30.700 21 4.7 5.7 6.70.750 4.4 5.3 6.30.800 20 4.1 5.0 5.90.850 3.8 4.7 5.60.900 19 3.6 4.4 5.20.950 3.4 4.2 5.01.000 18 3.3 4.0 4.71.150 17 2.8 3.5 4.11.250 2.6 3.2 3.81.300 16 2.5 3.1 3.61.400 2.3 2.9 3.41.450 15 2.3 2.8 3.31.500 2.2 2.7 3.11.600 14 2.0 2.5 3.01.700 1.9 2.4 2.81.800 13 1.8 2.2 2.6

www.leoni-special-conductors.com8 Surface Finishes

AWG-wires, plating thicknesses according to ASTM

AWG No. Ø of wire 25 microinches0.635 µm

Tin Sn

50 microinches1.27 µmNickel Ni

40 microinches1.016 µmSilver Ag

Silver thickness pore-free quality

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

50 0.025 83.1 203.2 191.849 0.028 74.2 181.4 171.348 0.032 65.9 161.3 152.247 0.036 58.3 142.7 134.746 0.040 52.0 127.3 120.245 0.045 46.5 113.6 107.344 0.051 40.7 99.6 94.043 0.056 37.1 90.7 85.642 0.064 32.4 79.4 74.941 0.071 29.2 71.5 67.540 0.079 26.3 64.3 60.7 6139 0.089 23.3 57.1 53.938 0.102 20.4 49.8 47.0 5037 0.114 18.2 44.6 42.136 0.127 16.4 40.0 37.8 4035 0.142 14.6 35.8 33.834 0.160 13.0 31.8 30.0 3033 0.180 11.5 28.2 26.632 0.203 10.2 25.0 23.6 2531 0.226 9.2 22.5 21.230 0.254 8.2 20.0 18.929 0.287 7.2 17.7 16.7 2028 0.320 6.5 15.9 15.027 0.361 5.8 14.1 13.326 0.404 5.1 12.6 11.925 0.455 4.6 11.2 10.524 0.511 4.1 9.9 9.423 0.574 3.6 8.9 8.422 0.643 3.2 7.9 7.521 0.724 2.9 7.0 6.620 0.813 2.6 6.2 5.9 12.519 0.912 2.3 5.6 5.318 1.024 2.0 5.0 4.717 1.151 1.8 4.4 4.216 1.290 1.6 3.9 3.715 1.450 1.4 3.5 3.314 1.628 1.3 3.1 2.913 1.829 1.1 2.8 2.6

AWG = American Wire Gauge ASTM = American Society for Testing and Materials

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 µm, as stated, but will

be manufactured in accordance with EN

13602.

Samples for thin platings < 2 µ

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 µm?

0.18 mm with 1 µm = 26.2 g;

0.18 mm with 1.5 µm = 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

if you use 39.3 g silver per kg for a 0.18 mm

Ø wire?

39.3 : 26.2 = 1.5 µm

www.leoni-special-conductors.com 9Surface Finishes

Electroplating options

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.

gold-plated enamelled

corrosion resistance

high bondability

chemical resistance

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 Temperature range max. 200 °C Temperature range max. 250 °C

Copper plain and tin plated with single

wire Ø ≤ 0.38 mm

Copper clad steel (e.g. STAKU)

with single wire Ø ≤ 0.38 mm

Silver plated copper

Silver plated copper clad steel

Silver plated copper alloys

Nickel plated copper

Nickel plated copper clad aluminium

(CCA)

Nickel plated copper clad steel (CCS)

Nickel plated high strength alloys

Nickel plated steel composites

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

tin silver nickel

good solderability

effective protection against corrosion

high temperature resistance (up to 200 °C)

high conductivity (Skin-effect, important

for HF-applications)

high corrosion and temperature

resistance (up to 250 °C)

Barriers of diffusion

Surface Finishes www.leoni-special-conductors.com10

Packaging

Packaging

d3 d1d2

l2

l1

d1 d3 l2 l1 d2

Type Ø of flange

Ø of bore

Tra-verse

Overall Width

Ø of barrel

Capa-city

mm mm mmapprox.

kg

Plastic reels

DIN 80 80 16 64 80 50 0.7

DIN 100 100 16 80 100 63 1.4

DIN 125 125 16 100 125 80 3.5

DIN 160 160 22 128 160 100 8

DIN 200 200 22 160 200 125 13

DIN 250/36 250 36 160 200 160 22

DIN 400 400 127 250 330 250 80

DIN 500 500 36 180 250 315 103

DIN 560 560 127 350 450 315 200

DIN 630 630 127 350 450 390 200

K 1600 160 22 128 160 100 8

K 2500 250 22 160 200 160 20

K 2506 250 127 160 200 160 25

K 2534 250 127 160 200 160 25

K 3550 355 36 160 200 224 40

K 4007 400 32.7 205 243 250 70

K 5600 555 127 280 355 355 180

K 5606 560 127 380 480 315 250

K 6307 630 127 380 430 320 350

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.

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

Additionally useful are:l2 Traversel1 Overall Width d2 Barrel diameter

d1 d3 l2 l1 d2

Type Ø of flange

Ø of bore

Tra-verse

Overall Width

Ø of barrel

Capa-city

mm mm mmapprox.

kg

Pay off pack

(POP)

O/All Diameter

508 mm

O/All Height

150 mm

35

Steel reels

B 4006 400 127 250 280 224 115

B 5600 560 127 355 395 315 280

B 6300 630 127 400 475 355 400

Sheet metal reels

B 6305 630 127 435 475 355 400

Wooden reels

G 0800 800 81 400 550 400 750

G 1000 1000 80 560 700 500 1000

Plastic braider bobbins

FSP75

K0751

75 10 50 100 24 1.5

FSP80/

K0804

80 10 80 100 23 2.0

WSN01/16 cc

K0660

66 16 69 80 34 1.0

WSN02/24 cc

K0661

66 16 104 116 34 1.6

www.leoni-special-conductors.com 11

Product Range Wires

Single Wires

Single Wires to DIN Standard

Single Wires to AWG Standard

Multi Wires

Braiding Wires

www.leoni-special-conductors.com12 Wires

We manufacture copper wires in line with international

standards and individual customer specifications.

Wires

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:

nSingle wire

Reel weight range from 8 to 200 kg.

Range of single wire diameters: 0.05 mm–2.7 mm

nMulti wire

The reel weight ranges from 25 to 500 kg.


nBraiding wire

The reel weight ranges from 0.5 to 3 kg.


Common constructions: 2–16 wires

For wire specifications please refer to the tables

on the following pages.

www.leoni-special-conductors.com 13Wires

6Calculated with a conductivity of 58 at 20 °C.

The maximum resistance value in the case of a diameter using the full acceptable negative

deviation range must be suitable for a conductivity of at least 57.5 at 20 °C.

DIN dimensions for single copper wires in accordance with DIN 46 431

”Round Copper Wires for Electrical Purposes, Exactly Drawn” (these

Standards apply only to plain wires as the parameters change as a

result of the extrusion process and the associated wire elongation).

Single Wires to DIN Standard

Diameter

Nominal valued

Tolerance Min. value Max. value Nominal cross-section

Weight DC resistance at 20 °C 6

Yield

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

0.05

± 0.003

0.047 0.053 0.00196 0.0175 8.80 57.100.063 0.060 0.066 0.00312 0.0278 5.53 36.000.071 0.068 0.074 0.00396 0.0353 4.35 28.300.08 0.077 0.083 0.00503 0.0447 3.43 22.400.09 0.087 0.093 0.00636 0.0566 2.71 17.670.1 0.097 0.103 0.00785 0.0699 2.196 14.310.112

± 0.005

0.107 0.117 0.00985 0.0878 1.750 11.390.125 0.120 0.130 0.01227 0.109 1.402 9.170.14 0.135 0.145 0.01539 0.137 1.120 7.300.16 0.155 0.165 0.02011 0.179 0.8573 5.590.18 0.175 0.185 0.02545 0.226 0.6774 4.420.2 0.195 0.205 0.03142 0.280 0.5487 3.570.224 0.219 0.229 0.03941 0.351 0.4375 2.850.25

± 0.007

0.243 0.257 0.04909 0.437 0.3512 2.290.28 0.273 0.287 0.06158 0.548 0.2799 1.8250.315 0.308 0.322 0.07793 0.694 0.2213 1.4410.355 0.348 0.362 0.09898 0.882 0.1743 1.1340.4

± 0.009

0.391 0.409 0.1257 1.12 0.1372 0.8930.45 0.441 0.459 0.1590 1.42 0.1084 0.7040.5 0.491 0.509 0.1964 1.75 0.0878 0.5710.56 0.551 0.569 0.2463 2.19 0.0700 0.4570.63 0.621 0.639 0.3117 2.78 0.0553 0.360.71

± 0.012

0.698 0.722 0.3959 3.53 0.04354 0.2830.75 0.738 0.762 0.4418 3.93 0.03902 0.2540.8 0.788 0.812 0.5027 4.47 0.03429 0.2240.85 0.838 0.862 0.5675 5.05 0.03038 0.1980.9 0.888 0.912 0.6362 5.66 0.02710 0.1770.95 0.938 0.962 0.7088 6.31 0.02432 0.1581 0.988 1.012 0.7854 6.99 0.02195 0.1431.06

± 0.016

1.044 1.076 0.8825 7.86 0.01954 0.1271.12 1.104 1.136 0.9852 8.78 0.01750 0.1141.18 1.164 1.196 1.094 9.75 0.01577 0.1031.25 1.234 1.266 1.227 10.90 0.01405 0.09171.32 1.304 1.336 1.368 12.20 0.01260 0.0821.4 1.384 1.416 1.539 13.70 0.01120 0.0731.5

± 0.0201.480 1.520 1.767 15.70 0.00976 0.0637

1.6 1.580 1.620 2.011 17.90 0.00858 0.05591.7 1.680 1.720 2.270 20.20 0.00760 0.04951.8 ± 0.025 1.775 1.825 2.545 22.60 0.00677 0.0442


mΩ · mm2

mΩ · mm2

The 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”.

Single Wires to AWG Standard

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

Diameter Cross-section

AWG Weight Yield

Size mils mm mm2 cmils sq. inch approx. kg/km approx. km/kg

13 72.0 1.829 2.625 5180 0.00407 23.40 0.042814 64.1 1.628 2.082 4110 0.00323 18.50 0.05415 57.1 1.450 1.652 3260 0.00256 14.70 0.068116 50.8 1.290 1.307 2580 0.00203 11.60 0.08617 45.3 1.151 1.039 2050 0.00161 9.24 0.10818 40.3 1.024 0.821 1620 0.00128 7.32 0.13719 35.9 0.912 0.654 1290 0.00101 5.81 0.17220 32.0 0.813 0.517 1020 0.000804 4.61 0.21721 28.5 0.724 0.411 812 0.000638 3.66 0.27322 25.3 0.643 0.324 640 0.000503 2.88 0.34723 22.6 0.574 0.259 511 0.000401 2.30 0.43524 20.1 0.510 0.205 404 0.000317 1.82 0.54925 17.9 0.455 0.162 320 0.000252 1.44 0.69326 15.9 0.404 0.128 253 0.000199 1.14 0.87827 14.2 0.361 0.102 202 0.000158 0.908 1.1028 12.6 0.320 0.0806 159 0.000125 0.715 1.4029 11.3 0.287 0.0648 128 0.0001 0.575 1.7430 10.0 0.254 0.0507 100 0.0000785 0.450 2.2231 8.9 0.226 0.0401 79.20 0.0000622 0.357 2.8032 8.0 0.203 0.0324 64.00 0.0000503 0.288 3.4733 7.1 0.180 0.0255 50.40 0.0000396 0.227 4.4034 6.3 0.160 0.0201 39.70 0.0000312 0.179 5.5935 5.6 0.142 0.0159 31.40 0.0000246 0.141 7.0836 5.0 0.127 0.0127 25.00 0.0000196 0.113 8.8837 4.5 0.114 0.0102 20.20 0.0000159 0.0912 11.0038 4.0 0.102 0.0081 16.00 0.0000126 0.0721 13.9039 3.5 0.089 0.0062 12.20 0.00000962 0.0552 18.1040 3.1 0.079 0.0049 9.61 0.00000755 0.0433 23.1041 2.8 0.071 0.0040 7.84 0.00000616 0.0353 28.3042 2.5 0.064 0.0032 6.25 0.00000491 0.0282 35.5043 2.2 0.056 0.0025 4.84 0.0000038 0.0218 45.9044 2.0 0.051 0.0021 4.00 0.00000314 0.0180 55.5045 1.8 0.045 0.0016 3.10 0.00000243 0.0140 71.7046 1.6 0.040 0.0013 2.46 0.00000194 0.0111 90.1047 1.4 0.036 0.00099 1.96 0.00000154 0.00883 113.0048 1.2 0.032 0.00078 1.54 0.00000121 0.00693 144.0049 1.1 0.028 0.00062 1.23 0.000000968 0.00556 180.0050 0.99 0.025 0.00050 0.98 0.00000077 0.00440 228.89

www.leoni-special-conductors.com 15Wires

Braiding wires for cable screening.

Braiding Wires

Production programme

In order to better reflect customer requirements LEONI has extended

its multi wire product range to include pre-wound braid bobbins.

LEONI‘s long known multi wire competency, high quality wires with

very narrow diameter and elongation tolerances, means that custo-

mers can expect to manufacture excellent braids. The braiding wires

are available across the full range of LEONI‘s wire products including

alloys.

Construction

LEONI‘s range of braid bobbins fits all modern braiding machines.

Standard available diameter range: 0.05mm–0.254mm

Standard wire range: 4–12 wires per bobbin

Standard bobbin types

d1 d3 l2 l1 d2

Type Flange diameter Bore diameter Traverse Overall width Barrel diameter Capacity (max.)

mm mm mm ca. g

Plastic braid bobbins

FSP75 / K0751 75 10 50 100 24 1500

FSP80 / K0804 80 10 80 100 23 2000

WSN01 / K0660 66 16 69 80 34 1000

WSN02 / K0661 66 16 104 116 34 1600


Bunched Conductors

Highly Flexible Stranded Conductors and Ropes

Concentric Stranded Conductors

Semiconcentric Stranded Conductors

LEONI Smooth-Bunch

Product Range Stranded Conductors

www.leoni-special-conductors.com 17Stranded Conductors

Construction

The average diameter of a bunched conductor can be calculated

using the table and the formula: D = d • f

(D = Ø of bunched conductor, d = Ø 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)

Typical constructions for multi-wire, fine-wire and ultrafine-wire bunched conductors

AWG 44 41 38 36 34 32 30

Cross-section Ø of wire in mm 0.05 0.07 0.10 0.127 0.16 0.20 0.254

0.1 51 x 0.05 25 x 0.07 12 x 0.10 8 x 0.1270.14 72 x 0.05 36 x 0.07 18 x 0.10 11 x 0.127 7 x 0.160.25 128 x 0.05 66 x 0.07 32 x 0.10 20 x 0.127 12 x 0.16 8 x 0.200.34 173 x 0.05 88 x 0.07 42 x 0.10 27 x 0.127 17 x 0.16 11 x 0.20 7 x 0.2540.38 192 x 0.05 88 x 0.07 48 x 0.10 30 x 0.127 19 x 0.16 12 x 0.20 8 x 0.2540.5 256 x 0.05 130 x 0.07 64 x 0.10 39 x 0.127 25 x 0.16 16 x 0.20 10 x 0.254

0.75 385 x 0.05 196 x 0.07 96 x 0.10 59 x 0.127 37 x 0.16 24 x 0.20 15 x 0.2541 511 x 0.05 259 x 0.07 128 x 0.10 79 x 0.127 50 x 0.16 32 x 0.20 19 x 0.254

1.5 770 x 0.05 392 x 0.07 189 x 0.10 118 x 0.127 75 x 0.16 48 x 0.20 30 x 0.2542.5 1274 x 0.05 651 x 0.07 320 x 0.10 196 x 0.127 124 x 0.16 80 x 0.20 50 x 0.2544 2016 x 0.05 1036 x 0.07 511 x 0.10 322 x 0.127 196 x 0.16 118 x 0.20 79 x 0.2546 3192 x 0.05 1548 x 0.07 756 x 0.10 476 x 0.127 294 x 0.16 189 x 0.20

10 2556 x 0.07 1281 x 0.10 784 x 0.127 504 x 0.16 315 x 0.2016 4116 x 0.07 2037 x 0.10 1260 x 0.127 798 x 0.1625 3213 x 0.1035 4410 x 0.1050 6370 x 0.1070 8917 x 0.1095 12348 x 0.10

120 15435 x 0.10150 19110 x 0.10185 23373 x 0.10240 30870 x 0.10

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.

n f n f n f

1 1.00 19 5.00 61 9.002 2.00 24 6.00 70 10.003 2.15 26/27 6.15 75 10.154 2.41 28/30 6.41 80 10.415 2.70 31/32/33 6.70 85 10.707 3.00 37 7.00 91 11.00

10 4.00 44 8.00 102 12.0012 4.15 48 8.15 108 12.1514 4.41 52 8.41 114 12.4116 4.70 56 8.70 120 12.70

www.leoni-special-conductors.com18 Stranded Conductors

Highly flexible round concentric stranded conductors

and ropes

These products have high flexibility and are suitable for cables

used in dynamic environments.

Highly Flexible Stranded Conductors and Ropes

Product Range

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

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

25–50 times the overall diameter of the strand

n lay length of 7 way conductors

8–16 times the overall diameter of the strand

Nominalcross-section

Min. number of wires

Ø of stranded conductor

Weight

mm2 mm kg/km

Ø of wire 0.05 mm0.020 10 0.18 0.1750.029 15 0.22 0.2620.041 21 0.26 0.3670.059 30 0.31 0.5240.079 40 0.36 0.7000.100 51 0.40 0.8900.140 72 0.50 1.2600.200 102 0.60 1.7800.250 128 0.65 2.2400.350 180 0.75 3.2400.500 266 0.95 4.7500.750 385 1.15 7.0601.000 525 1.35 9.390

Ø of wire 0.07 mm0.081 21 0.36 0.7190.140 36 0.50 1.2400.250 66 0.65 2.2300.350 90 0.75 3.0800.500 130 0.95 4.5500.750 195 1.10 6.9101.000 259 1.35 9.310


Min. number of wires

Ø of stranded conductor

Weight

mm2 mm kg/km

1.50 392 1.65 14.102.50 650 2.25 23.404.00 1050 2.90 37.806.00 1575 3.60 56.60

Ø of wire 0.1 mm0.50 64 0.95 4.560.75 96 1.15 6.841.00 126 1.30 9.131.50 189 1.65 13.702.50 322 2.25 23.404.00 511 2.90 37.106.00 777 3.60 56.50

10.00 1281 4.80 94.9016.00 2058 6.10 153.0025.00 3185 7.60 236.0035.00 4508 9.20 334.0050.00 6370 10.80 472.0070.00 8918 12.80 661.00

100.00 12348 15.00 879.10120.00 15336 16.72 1154.10150.00 19110 18.66 1461.20185.00 23373 20.64 1818.60240.00 30870 23.72 2473.00


In concentric stranded conductors each single wire

occupies a specific position within the formation,

guaranteeing a regular construction.

Product Range / Construction

37-strand (1 + 6 + 12 + 18) 19-strand (1 + 6 + 12)7-strand (1 + 6)

Examples of concentric

strand constructions


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 elec-

tronic 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.

The superior quality of LEONI’s 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 produces four types of concentric strands.

Unilay

True concentric

Unilay Concentric n same lay direction

n same lay length

n manufactured in one working step

n nearly round construction

Unidirectional n same lay direction

Concentric n different lay lengths for each

working step

n manufactured in two working steps

n more round than unilay concentric

Direction

of stranding

Different lay lengths impact on the roundness of the strand

Longer lay length = hexagonal / shorter lay length = circular

Reversed lay or SZ stranding

S left hand lay

Z right hand lay

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.

Direction

of stranding

Equilay Concentric n different lay directions

(reversed lay stranding n same lay length

or SZ stranding) n manufactured in two working steps

n very round construction

Conventional n different lay directions

Concentric n different lay lengths for each

working step

n manufactured in two working steps

n very round construction


Concentric and electrical conductors

Type II to ASTM B 286.


Available as plain, tin plated, silver plated and nickel plated copper

wires. Alternative wire sizes are available subject to applicable mini-

mum 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

ConstructionNo. of wires x Ø of wires

Ø of strandedconductor

Weight Yield

mm2 mm kg/km km/kg

7-wire conductors

32 0.034 7 x 0.079 0.28 0.315 3.17530 0.06 7 x 0.102 0.33 0.524 1.90828 0.09 7 x 0.127 0.41 0.813 1.23026 0.14 7 x 0.160 0.51 1.290 0.77524 0.23 7 x 0.203 0.63 2.080 0.48122 0.35 7 x 0.254 0.78 3.250 0.30820 0.56 7 x 0.320 0.99 5.160 0.19418 0.90 7 x 0.404 1.27 8.220 0.122

19-wire conductors

30 0.072 19 x 0.071 0.35 0.07 1.53128 0.093 19 x 0.079 0.43 0.854 1.17126 0.16 19 x 0.102 0.56 1.44 0.69424 0.24 19 x 0.127 0.68 2.23 0.44822 0.38 19 x 0.160 0.84 3.53 0.28320 0.62 19 x 0.203 1.06 5.68 0.17618 0.96 19 x 0.254 1.32 8.93 0.11216 1.23 19 x 0.287 1.50 11.36 0.08814 1.95 19 x 0.361 1.85 17.86 0.05612 3.09 19 x 0.455 2.36 28.57 0.035

37-wire concentric stranded conductors

14 1.87 37 x 0.25 1.71 17.4 0.05712 2.97 37 x 0.32 2.18 26.3 0.03810 4.53 37 x 0.40 2.75 43.6 0.023


Concentric stranded conductors,

metric dimensions.

37 wire strands may be used in thin

wall insulation constructions.

“LEONI Smooth-Bunch” with its extremely

round construction offer an excellent alter-

native to traditional 37 wire strands (see

page 25).

Metric dimensions (example)



Construction no. of wires x Ø of wire

Ø of conductor Weight Yield

mm2 mm kg/km km/kg

7-wire conductors

0.028 7 x 0.071 0.21 0.247 4.0490.055 7 x 0.10 0.30 0.504 1.9840.093 7 x 0.13 0.39 0.852 1.1740.12 7 x 0.15 0.45 1.130 0.8850.18 7 x 0.18 0.54 1.585 0.6310.22 7 x 0.20 0.60 2.020 0.4950.34 7 x 0.25 0.75 3.150 0.3170.50 7 x 0.30 0.90 4.540 0.2200.88 7 x 0.40 1.20 8.060 0.1241.14 7 x 0.455 1.37 10.130 0.0991.42 7 x 0.51 1.53 12.727 0.079

19-wire conductors

0.04 19 x 0.05 0.25 0.3 3.0010.15 19 x 0.10 0.50 1.35 0.740.33 19 x 0.15 0.75 3.03 0.330.48 19 x 0.18 0.90 4.35 0.2300.60 19 x 0.20 1.00 5.38 0.1861.34 19 x 0.30 1.50 12.20 0.0822.04 19 x 0.37 1.85 18.52 0.0542.39 19 x 0.40 2.00 21.28 0.0473.09 19 x 0.455 2.28 27.78 0.0363.88 19 x 0.51 2.55 34.48 0.029

37-wire concentric stranded conductors

0.30 37 x 0.102 0.69 2.6 0.3850.47 37 x 0.127 0.88 4.2 0.2390.75 37 x 0.160 1.12 6.6 0.1521.00 37 x 0.180 1.26 8.4 0.1191.50 37 x 0.226 1.58 13.3 0.0752.00 37 x 0.250 1.75 16.2 0.062

2.50 37 x 0.287 2.01 21.4 0.0473.00 37 x 0.320 2.24 26.6 0.0384.00 37 x 0.370 2.59 35.6 0.0294.50 37 x 0.404 2.83 42.5 0.024


Semi-concentric Conductors

Examples of semi-concentric conductor construction

30-wire

Semi-concentric conductors are suited especially to cables

with thin-walled insulation.

This 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.

Nominal cross section Construction No. of wires x wire dia.

Conductor dia.nom.

Weight nom.

mm2 mm kg/km

0.25 21 x 0.127 0.66 2.4150.5 16 x 0.203 0.93 4.8020.75 24 x 0.203 1.13 7.3341 32 x 0.203 1.31 9.9491.5 30 x 0.254 1.59 14.4472.5 50 x 0.254 2.05 23.3574 56 x 0.30 2.56 36.4536 84 x 0.30 3.13 54.650

10 80 x 0.404 4.12 94.448

Alternatively, LEONI offers this product

range with particularly round

“LEONI Smooth-Bunch” conductor

construction (see page 25).

24-wire12-wire 16-wire

Conductor examples


Examples of

smooth bunch

constructions

24-wires16-wires 84-wires

LEONI Smooth-Bunch

Using a special manufacturing process “LEONI Smooth-

Bunch” conductors have a compact and precise round

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.

Nominal cross-section

Construction (No. of wires x Ø of wires)

Ø of conductor(Nom. value)

Weight(Nom. value)

mm2 mm kg/km

0.50 16 x 0.203 0.874 4.802

0.75 24 x 0.203 1.062 7.334

1.00 32 x 0.203 1.231 9.949

1.50 30 x 0.254 1.494 14.447

2.50 50 x 0.254 1.927 23.357

4.00 56 x 0.30 2.406 36.453

6.00 84 x 0.30 2.942 54.650

10.00 80 x 0.404 3.873 94.448

16.00 133 x 0.404 4.991 158.639

Example construction types


LEONI news

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 domes-

tic 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.

LEONI has successfully created a 100 % cadmium free

alloy. It is superior to conventional copper cadmium,

both in terms of its electrical and mechanical

properties.

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

LEONI Histral®RoHS compliant

More detailled information on LEONI Histral®

is provided in our Histral brochure which is

available for download under

www.leoni-special-conductors.com

www.leoni-special-conductors.com26

LEONI Histral® is a registered trademark of LEONI Draht GmbH.

LEONI news

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


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.

www.leoni-special-conductors.com 27

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



special conductors for cable extrusion

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