copper solutions - leoni
TRANSCRIPT
The Quality Connection
Copper SolutionsWire Solutions for Component Production
Copper Solutions – from single wires to fully assembled components.
The optimum servicecapability and reliability of the various compon-
ents determine the quality of the product as a whole.
A solution from LEONI minimises downtimes and increases your
operating hours because our products are developed and produced
with your specific market requirements in mind. Building on
decades of experience in drawing, stranding and braiding and in the
treatment of the finest copper wire surfaces, we only process top
quality materials using innovative technology.
Maybe you can’t find the product you’re looking for or have indivi-
dual requirements? – Just give us a call. We’ll find a solution for you!
Everything from a single source:
from wire drawing to the finished product
Tailor-made dimensions Application-specific coatings No fraying at cut ends A perfect, smooth surface and absolutely consistent
outside diameter Customer-specific logistics concepts
Issue: April 2011 © LEONI Draht GmbHThe contents of this catalogue are protected by copyright. They may only be used for private purposes. Any reproduction, presentation or transmission of the contents for commercial purposes is prohibited without the agreement of the copyright holder and is only permitted following prior approval. All rights reserved.
We reserve the right to make technical modifications; typographical errors and mistakes excepted.
The Quality Connection
You can be sure that we will always have the right wire for your application; we guarantee that our products will offer maximum functionality and longevity, even under the most difficult conditions.
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Content
The Quality Connection
The Quality Connection
Copper Solutions
Product range
Copper Solutions
Product information
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page
The LEONI Group 4
Cable expertise for the most
varied industrial markets
Copper Solutions 5
We never lose sight of your solution
Copper Solutions – Worldwide 6
Our presence at a worldwide level
benefits you at local level.
LEONI – The Quality Connection 7
Quality and environmental
management
page
Packaging 27
The most common reel sizes
at a glance
Copper 28
Properties and uses
Surface properties 29
Tables of weights for platings 30
Table of current rating 31
page
Product range 9
at a glance
Single wires to DIN standard 10
DIN dimensions for single copper
wires in accordance with DIN 46 431
Cell and string connectors
for photovoltaic modules 11
Round, stranded copper flexibles 12
Ropes with integral strain
members 13
Round, stranded copper
flexibles with overall braid 14
Flat cables woven, flexible 15
Round, braided copper flexibles 16
Square braids, highly flexible 17
Rectangular braided conductors,
extra flexible 18
Braided copper tapes flat rolled,
flexible 19
Braided copper tapes flexible 20
Braided copper tapes super
flexible 20
Braided copper tapes,
moulded with straight edges 21
Shielding braids (tubular)
expandable and flexible 22
Knitted copper fabrics, fine-wire 23
Assemblies / finishing 24
Automotive&
Commercial Vehicles
Communication &
Infrastructure
Industry &
HealthcareElectrical
Appliances
LEONI‘s core markets
Products and services portfolio at a glance
Conductors &
Copper Solutions
Service
Optical cablesHybrid cablesCopper cables
Cable systems / Wiring Systems
Relay and safety systemsSensorsCable harnesses
ConnectorsOptical fibersWires & strands
Dev
elop
men
t / E
ngin
eerin
g
The Quality Connection
The LEONI Group Cable expertise for the most varied industrial markets.
LEONI is a leading supplier of cables and systems as well as related services for the automotive industry and various other industrial sectors.
Your markets – our strength
As diverse as our product and service range are the markets
and sectors LEONI is supplying. We focus our activities on
customers in the fields of Automotive & Commercial Vehicles,
Industry & Healthcare, Communication & Infrastructure, Electrical
Appliances and Conductors & Copper Solutions.
We are one of the leading European suppliers in the Conductors
& Copper Solutions market, which at LEONI also covers the
manufacturing of wires for the areas of “Special Conductors” and
“Copper Solutions”. Customers of our Copper Solutions business
unit benefit worldwide from innovative as well as reliable and
long-lasting products of high quality. LEONI – we create the best
connection for your future. further information at www.leoni.com
Our group of companies employs more than 56,000 people in
34 countries. Corporate vision, highest quality and innovative
power have made us one of the leading cable manufacturers in
Europe. LEONI develops and produces technically sophisticated
products ranging from wire and optical fibers to cables
through to complete cable systems and also offers the related
services. Moreover, the product portfolio comprises strands,
standardised cables, hybrid cables, glass fiber as well as special
cables, cable harnesses, wiring systems components and
fully assembled systems for applications in various industrial
markets.
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Traditional expertise
Our roots in drawing wires can be traced back to the Middle
Ages. LEONI laid the foundations for a successful business with
the production of gold and silver wires and the finest metal
threads, known as Lyonese Wares. In the 1920s the first wire
and strands were produced for electrical engineering, then a
rapidly growing area of industry.
These days, LEONI is regarded as one of the world’s leading
suppliers in the Conductors & Copper Solutions market,
producing highly sophisticated conductors and strands for
cable technology and for special applications in the area of
electrical technology and electronics. It is a leader in terms of
the international presence of the business and the quality of
the products and production technology. LEONI has also played
a lasting role in influencing technologies such as multi-wire
drawing, galvanic finishing of wires or machining into precisely
shaped strands.
Business Unit Copper Solutions
The Business Unit Copper Solutions enables us to offer our
customers a broad range of wires and stands, as well as highly
flexible wire products.
Our extensive expertise in applications means that our
products are to be found not just in one specific sector.
That’s because LEONI products prove to be the ideal solution
wherever electricity is carried or needs to be grounded and
the conductor is subjected to high mechanical stresses due
to permanent movement and vibration – in electric motors,
circuit-breakers and safety switches, relays and thyristors, as
well as in welding plants, control cabinets, cars, aircraft, ships
and wind power stations.
Although the main focus of our work is in the areas of electrical
engineering and electronics, we have still remained faithful to
our tradition of manufacturing Lyonese Wares. That’s because
things have developed significantly here too. In addition to the
classic application areas, such as church vestments and altar
cloths, these days our finest wire products can also be found in
national costumes, uniforms, flags and decorative fabrics.
Copper SolutionsWe never lose sight of your solution.
The Quality Connection
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LEONI can be found not just at our production locations in Germany, Italy, the USA and China, but also worldwide, enabling our customers to access a broad, international network.
Copper Solutions – WorldwideOur presence at a global level benefits you at local level.
LEONI Draht GmbH Weissenburg, Germany
LEONI Felisi S.r.l.Codogno, Italy
Production of highly flexible wire products for electrical engineering applications
Production of the finest wire products for textile and decorative applicationsYou will find further information at www.leoni-felisi.com
LEONI Wire Inc.Chicopee MA, USA
LEONI Wire (Changzhou) Ltd.Changzhou, P.R. China
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6 The Quality Connection
The Quality Connection
Green Technology
Business success and ecological responsibility are no contradiction
in terms for us. As a company operating globally, we acknowledge
that we share responsibility for safeguarding the natural essentials
of life. It is our aim to strike a balance between environmental
concerns and the interests of our Company. Environmental
protection consequently is a mandatory element of our business
activity. We advise our customers on environmentally friendly ways
to handle and dispose of our products.
We ensure, with our DIN EN ISO 14001-certified environmental
management system, that our environmental policy is applied
in the entire group effectively.
Top quality
A global harmonised and ISO 9001:2008 and ISO/TS 16949
certified quality management system enable us to ensure that
our products and services meet uniform quality standards.
By using the latest production techniques, such as multi-
wire drawing and advanced production systems and process
equipment, our products attain a high degree of quality and
reliability. Whether use in the industrial or textile sectors,
our wire solutions always meet the stringent standards of
our customers. This is proven by our unique reference list of
internationally leading businesses.
LEONI – The Quality Connection Quality and Environmental Management
The high standard of LEONI quality management and active environmental protection support the company’s strategy of acting as a partner to its customers with a worldwide presence.
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Copper Solutions Product range
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Single wires to DIN standard DIN dimensions for single copper wires in accordance with DIN 46 431 10
Cell and string connectors for photovoltaic modules
100 % all around tinned flat wire, burr-free 11
Round, stranded copper flexibles Good cutting properties for conventional processing methods 12
Ropes with integral strain members E-Cu round rope with textile reinforcement as an integral strain member for strain relief 13
Round, stranded copper flexibleswith overall braid
Braided strands 14
Flat cables woven, flexible The bandwidth remains almost unchanged despite changes in traction or crushing stress 15
Round, braided copper flexibles Absolute freedom from twisting and compact cut end with extremely high precision 16
Square braids, highly flexible The form permits precise positioning during fully automatic processing 17
Rectangular braided conductors, extra flexible
A much larger cross-section can be accommodated in a very small space 18
Braided copper tapes flat rolled, flexible
Basic material for groundstraps and connectors of all kinds
19
Braided copper tapes flexible 20
Braided copper tapes super flexible 20
Braided copper tapes, moulded with straight edges
21
Shielding braids (tubular) expandable and flexible
The expandability of the braid and the solidity can be altered by changing the angle of the braid
22
Knitted copper fabrics, fine-wireFor repair work as cable shielding, where the density of the shielding or the solidity can be determined by the wrapping
23
Assemblies / finishing Connection-ready, pressure-welded copper strands and ribbons 24
LEONI always offers the top product for your industrial application:Optimum production procedures and stable processes ensure a consistently high quality standard: No fraying of cut ends Faultless surface quality Absolutely consistent outside diameter.
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9Product range
Diameter
Nominal valued
Tolerance min. value max. value Nominal cross-section
Weight DC resistance at 20 °C
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
Calculated 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 .
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 associ-
ated wire elongation.)
Single wires to DIN standardDIN dimensions for single copper wires in acc. with DIN 46 431
mΩ · mm2
mΩ · mm2
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Single wires to DIN standardDIN dimensions for single copper wires in acc. with DIN 46 431
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Cell and string connectors for photovoltaic modules100 % all around tinned flat wire, burr-free with excellent properties and maximum precision.
Due to its homogeneous tin surface, it can be perfectly utilized in all-automatic soldering processes.
Product range
Material
Core material
Coating solder
Cu-ETP1 and Cu-OF1
SnPbAg 62/36/2 SnAg 96.5/3.5 SnPb 60/40 Sn 99.9 other coatings are available on request
Green Technology
Flat wire, rolled, with subsequent immersion tinning, absolutely
environmentally friendly without using flux or chemical
substances.
Special benefits
Dimensions
Coating thickness
Tensile strength
Yield strength
Elongation
Thickness: 0.08–0.50 mm | Width: 1.2–5.0 mm
5–40 µm
Rm >200 N/mm2 (or according to specification)
Rp 0.2 <80 N/mm2 possible
>25 % (or according to specification)
Packaging
K160, K200, K250, K355, USP4 (K1510), HKV160 (K1602), 10 S,
Disc (K0372).
Other sizes upon request.
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Material
E-Cu/OF-Cu and alloys, plain, tinned, nickel-plated or silver-
plated.
Special versions
Highly twist-free and with a compact cutting surface.
A special surface finish permits various welding methods.
Direction of stranding
Reversed lay or SZ stranding
S left hand lay
Z right hand lay
Nominal cross-
section
Ø of wire No. of wirestol. ± 2 %
Overall-Ø Weight ±12 %
mm2 mm approx. mm approx. kg/km
0.06
0.05± 0.002
30 0.3 0.60.1 51 0.4 10.14 72 0.5 1.40.2 105 0.6 20.25 130 0.7 2.50.35 180 0.85 3.50.5 266 1 50.75 392 1.25 7.51 525 1.5 101.5
0.071± 0.002
385 1.75 152 525 2.1 202.5 651 2.4 253 798 2.6 304 1036 3 405.25 1372 3.5 536 1575 3.7 608 2058 4.2 80
10 2562 4.7 10012 3108 5.2 12016 4116 6.0 160
Nominal cross-
section
Ø of wire No. of wirestol. ± 2 %
Overall-Ø Weight ±12 %
mm2 mm approx. mm approx. kg/km
25
0.1± 0.003
3234 7.6 25035 4508 9.0 35050 6468 10.7 50070 8967 12.7 70095 12201 14.8 950
120 15435 18.0 1200150 19110 20.0 1500185 23580 21.0 1850240 30600 24.9 2400300 38200 26.0 3000400 51000 30.0 4000500 63700 33.0 5000600 76430 36.5 6000
Product range
Round, stranded copper flexiblesBesides special flexibility these types distinguish themselves through
no fraying of cut ends for further standard processing.
Material
E-Cu, plain, tinned, nickel-plated, silver-plated, brass-plated
(Cement wire) or genuine gold-plated.
Special versions
Round, braided conductors Flat conductors:
the construction is matched to the required dimensions Insulated versions:
these unit-type stranded conductors are also available
with transparent insulation for particular applications.
Nominal cross-section Ø of wire No. of wires± 2 %
Overall-Ø Weight Tensile strength
mm2 mm approx. mm approx. kg/km N
2.50.071 644 2.4 23 15250.10 318 2.4 23 15250.20 78 2.4 23 1525
40.071 1044 3 38 18400.10 504 3 38 18400.20 126 3 38 1840
60.071 1566 3.7 56 22600.10 756 3.7 56 22600.20 192 3.7 56 2260
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Ropes with integral strain membersE-Cu round, stranded copper flexible
with integral strain members for high tensile strength.
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Material
E-Cu/OF-Cu and alloys, plain, tinned, nickel-plated or siver-
plated.
Special benefits
Owing to technical production reasons, the effective cross-
section is greater than the nominal cross-section, in particular
on the thicker cross-sections.
In special cases, it is possible to achieve a reduction in diameter
and weight while simultaneously observing the nominal cross-
section by implementing construction modifications.
Nominal cross-section
Effective cross-sectional
area
Round stranded copper flexible Overall braiding Ø of straded conductor
Weight± 12 %
Ø of wire No. of wirestol. ± 2 %
Ø of wire No. of wirestol. ± 2 %
mm2 mm2 mm mm approx. mm approx. kg/km
0.35 0.35
0.05± 0.002
51
0.10± 0.003
32 0.8 3.50.5 0.51 130 32 1.1 5.10.75 0.77 266 32 1.4 7.71 1.02 266 64 1.5 10.21.5 1.53 525 64 1.9 15.32.5 3.08
0.071± 0.002
651 64 2.9 30.83.75 3.91 798 96 3.0 39.14 4.6 1036 64 3.4 466 6.99 1575 96 4.1 69.98 8.9 2058 96 4.7 89
10 11.2 2562 128 5.2 11212 12.0 2562 240 5.2 12016 17.8 4116 192 6.5 17825 26.9
0.10± 0.003
3234 192 8.2 26935 37.3 4508 240 9.6 37350 53.6 6468 360 11.4 53670 73.3 8967 360 13.4 73395 98.7 12201 360 16.4 987
120 124 15435 360 18.4 1240
Product range
Round, stranded copper flexibleswith overall braid
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Material
E-Cu, plain or tinned.
Packaging
In coils.
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-sectionNumber Nominal
cross-sectionmm2 mm mm mm mm2 mm2 kg/km
25 28 1.6 3 1.5 16 1 325 3025 38 1.6 2 1 24 0.75 340 4035 23 1.6 5 6.0 6 1.5 430 2535 28 1.6 4 4 9 1.5 430 3035 38 1.6 3 1.5 22 1 445 4035 47 2.5 2 1 34 0.75 470 5050 28 1.6 6 6 8 1.5 565 3050 38 1.6 4 4 12 1.5 600 4050 47 2.5 3 2.5 20 1.5 675 5050 57 2.5 2.5 1.5 32 1 645 6070 38 1.6 6 8 9 1.5 835 4070 47 2.5 5 6 12 1.5 860 5070 57 2.5 4 4 18 1.5 900 6095 47 2.5 6.5 8 12 1.5 1105 5095 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 80150 77 2.5 6.5 10 15 1.5 1715 80
The table shows possible product variants
Product range
Flat cables woven, flexible(for special applications)
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16 Product range
Material
E-Cu/OF-Cu and alloys, plain, tinned, nickel-plated or siver-
plated.
Range of production
The adjacent tables show the standard range. On request we
can also supply all listed cross-sections with other wire
diameters.
Special versions
A version with a high nickel content (27 % Ni) was developed
specially for the aviation industry. Product variants available on
request.
Nominal cross-
section
Ø of wire Construc-tion
No. of wires± 2 %
Overall-Ø Weight± 12 %
mm2 mm approx. mm approx. kg/km
0.047
0.05± 0.002
8 x 3 0.33 0.470.094 8 x 6 0.47 0.940.14 8 x 9 0.57 1.400.20 8 x 13 0.70 20.25 8 x 16 0.80 2.500.35 8 x 23 0.95 3.500.50 8 x 32 1.10 50.75 8 x 48 1.35 7.501 8 x 64 1.55 10
Nominal cross-
section
Ø of wire Construc-tion
No. of wires± 2 %
Overall-Ø Weight± 12 %
mm2 mm approx. mm approx. kg/km
1.5 0.071± 0.002
8 x 49 1.90 151.5 12 x 33 1.90 152 12 x 44 2.20 202.5 12 x 54 2.40 253 12 x 65 2.70 304 12 x 86 3.10 405 12 x 108 3.50 506 12 x 130 3.80 608 12 x 174 4.40 80
10 12 x 217 4.90 10012 12 x 260 5.40 12016
0.10± 0.003
12 x 170 6.10 16020 12 x 213 6.90 20025 12 x 266 7.70 250
Round, braided copper flexibles Absolute free from twist and compact, cutting surface with very high dimensional accuracy
permit easy, fully automatic further processing.
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Material
E-Cu/OF-Cu and alloys, plain, tinned, nickel-plated or silver-
plated.
Nominal cross-
section
Construc-tion
No. of wires± 2 %
Ø of wire Edge length
Weight± 12 %
mm2 mm mm approx. kg/km
0.5 8 x 32 0.05 1.0 51 8 x 64 0.05 1.4 101.5 8 x 96 0.05 1.75 151.5 8 x 49 0.071 1.75 152 8 x 128 0.05 2.0 202 8 x 65 0.071 2.0 202.5 8 x 160 0.05 2.2 252.5 8 x 81 0.071 2.2 253 8 x 192 0.05 2.5 303 8 x 97 0.071 2.5 304 8 x 256 0.05 2.8 404 8 x 130 0.071 2.8 405 8 x 320 0.05 3.2 505 8 x 162 0.071 3.2 50
Nominal cross-
section
Construc-tion
No. of wires± 2 %
Ø of wire Edge length
Weight± 12 %
mm2 mm mm approx. kg/km
6 8 x 384 0.05 3.5 606 8 x 195 0.071 3.5 608 8 x 512 0.05 4.1 808 8 x 260 0.071 4.1 80
10 8 x 640 0.05 4.6 10010 8 x 324 0.071 4.6 10012 8 x 768 0.05 5.0 12012 8 x 390 0.071 5.0 12016 8 x 255 0.10 5.8 16025 8 x 400 0.10 7.2 25035 8 x 560 0.10 8.5 35040 8 x 640 0.10 9.0 40050 8 x 800 0.10 10.2 500
Product range
Square braids, highly flexibleGreater flexibility when compared to round braids. With fully automatic further processing the
predefined form makes exact positioning possible. This results in continuously high accuracy in welding points.
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Material
E-Cu/OF-Cu plain, tinned.
Special benefits
Extraordinarily high flexibility is achieved in the stranded
conductors through a special manufacturing process which,
even with high packing density (multilayer installations), allows
the tightest bending radiuses and does not degrade switching
operations.
Dimensions
The braided conductor can be manufactured with a dimension
ratio from 1 : 1.5 to 1 : 2.5, where the dimension is determined in
agreement with the customer depending on the intended use
and availability of space.
Example of two possible dimensions:
for 50 mm2 13 x 8.5 mm or
15 x 7 mm
Nominal cross-
section
No. of wires Ø of wire Dimensions Weight± 12 %
mm2 mm approx. mm approx. kg/km
16 2040 0.10
16025 3200 0.10 25035 4480 0.10 35040 5120 0.10 40050 6400 0.10 540
Product range
Rectangular braided conductors, extra flexibleThe rectangular shape enables maximum space-saving: in comparison with round
strands, a much larger cross-section can be accommodated in a very small space.
Nominal cross-
section
Dimensionswidth ± 5 %
x thickness
Construc-tion
Ø of wire Weight
mm2 mm mm approx. kg/km
0.09 1 x 0.2 16 x 3
0.05± 0.002
0.90.16 1.2 x 0.2 16 x 5 1.60.25 1.6 x 0.2 16 x 8 2.50.5 2.5 x 0.4 16 x 16 5.00.75 2.7 x 0.5 16 x 24 7.51 3.2 x 0.6 16 x 32 101.5 4 x 0.8 16 x 25
0.071± 0.002
152 5 x 0.8 16 x 33 202.5 5.8 x 0.8 24 x 27 253 7.5 x 0.9 24 x 33 304 8.2 x 1 24 x 43 406 10 x 1.3 24 x 66 608 10.5 x 1.7 24 x 88 80
10 12 x 1.8 24 x 109 100
Nominal cross-
section
Dimensionswidth ± 5 %
x thickness
Construc-tion
Ø of wire Weight
mm2 mm mm approx. kg/km
16 15 x 2.3 24 x 85
0.1± 0.003
16025 19 x 2.9 24 x 135 25035 29 x 2.6 36 x 124 35050 33 x 2.8 48 x 133 50070 45 x 2.9 48 x 186 70095 50 x 3.2 48 x 253 950
120 60 x 3.5 48 x 319 1200140 60 x 4.0 48 x 372 1400150 60 x 4.5 48 x 399 1500168 70 x 4.5 48 x 446 1680185 75 x 4.6 48 x 491 1850240 80 x 5.3 48 x 637 2400250 80 x 5.6 48 x 664 2500300 90 x 6.0 48 x 797 3000400 100 x 7.5 48 x 1062 4000
max. 25 % below nominal value
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Material
E-Cu, plain, tinned, nickel-plated or silver-plated.
Special versions
If required, individual dimensions can be varied slightly during
the rolling process. Non standard dimensions may require
design modifications.
All types are available in non-rolled form as multiple tubes and
for screening.
Product range
(Basic material for grounding strapes and connectors of all kinds)
Braided copper tapes flat rolled, flexible
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Material
E-Cu, plain, tinned, nickel-plated or silver-plated.
Special versions
If required, individual dimensions can be varied slightly during
the rolling process. Non standard dimensions may require
design modifications.
All types are available in non-rolled form as multiple tubes and
for screening.
Braided copper tapes flexible
Nominal cross-
section
Dimensionswidth ± 5 %
x thickness
Construction Ø of wire± 0.003
Weight± 12 %
mm2 mm mm approx. kg/km
14 18 x 1.5 36 x 20 0.16 14014 18 x 1.5 36 x 12 0.2 14016 19 x 1.5 36 x 22 0.16 16016 19 x 1.5 36 x 14 0.2 16021 22 x 1.7 36 x 29 0.16 21021 22 x 1.7 36 x 19 0.2 21025 22 x 2.1 36 x 35 0.16 25025 22 x 2.1 36 x 22 0.2 25035 25 x 2.4 36 x 48 0.16 35035 25 x 2.4 36 x 31 0.2 35050 33 x 2.7 48 x 52 0.16 50050 33 x 2.7 48 x 33 0.2 50070 35 x 3.8 48 x 73 0.16 70070 35 x 3.8 48 x 46 0.2 700
max. 25 % below nominal value.
Braided copper tapes super flexible
Nominal cross-
section
Dimensionswidth ± 5 %
x thickness
Construc-tion
Ø of wire Weight± 12 %
mm2 mm mm approx. kg/km
4 7 x 1.1 24 x 86
0.05± 0.002
406 9 x 1.3 24 x 128 608 10 x 1.5 24 x 171 80
10 12 x 1.6 24 x 213 10014 14 x 1.9 24 x 298 14016 15 x 2.0 24 x 341 16021 18 x 2.2 24 x 450 21025 24 x 2.0 36 x 355 25035 30 x 2.0 36 x 497 35042 35 x 2.4 48 x 447 42050 35 x 2.8 48 x 532 50070 40 x 3.0 48 x 745 700
max. 25 % below nominal value.
Product range
Braided copper tapes flexible Braided copper tapes super flexible (Basic material for grounding strapes and connectors of all kinds)
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21
Material
E-Cu, plain, tinned.
Special benefits
A special production process enables narrower tolerances to
be achieved. Variable widths and thicknesses possible with the
same cross-section – this enables different cross-sections to be
combined with ease (modular system).
Cross-section Dimensionswidth from – to
Dimensionsthickness from – to
mm2 mm mm
25 1.8 – 4.0 20.0 – 9.050 3.5 – 6.0 24.0 – 13.0
100 4.0 – 7.5 42.0 – 21.0120 5.0 – 8.5 46.0 – 23.0
Other cross-sections and dimensions available on request.
Product range
Braided copper tapes, moulded with straight edgesHigh precision and improved weldability in automated processes
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22
Material
E-Cu, plain, tinned.
Special benefits
In case of larger cross-sections the effective cross-section is
greater than the nominal value. Alterations to constructions may
allow a reduction of diameter and weight while maintaining
the nominal cross-section values. This results in a change to the
expandability and solidity.
Effektive cross-section
Construction Ø of wire Expandable max. inner-Ø
Extended lengthweight±12 %
Coverageapprox.
mm2 Reel x No. of wires mm approx. mm approx. kg/km %
0.25 16 x 2
0.10± 0.003
3 2.3 36.580.38 16 x 3 3.5 3.5 45.820.50 16 x 4 4 4.6 52.770.88 16 x 7 6 8.1 60.661.32 24 x 7 8 12.1 64.391.70 24 x 9 10 15.6 68.031.98 36 x 7 15 18.1 56.405.30 24 x 7
0.20± 0.003
16 48.8 63.946.00 24 x 8 18 55.3 65.166.80 24 x 9 20 62 67.727.90 36 x 7 25 73 62.70
10.20 36 x 9 30 93 66.9313.60 36 x 12 40 124 68.3123.80 48 x 7
0.30± 0.004
50 218 64.7030.50 48 x 9 60 280 68.6933.90 48 x 10 70 311 66.3940.70 48 x 12 80 373 68.4550.90 48 x 15 100 466 67.2372.40 48 x 12
0.40± 0.004
120 664 60.7196.50 48 x 16 140 885 66.82
108.60 48 x 18 160 995 68.42
Product range
Shielding braids (tubular) expandable and flexibleThe expandability and coverage can be determined precisely by changing the braiding angle.
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23
Material
E-Cu, plain, tinned.
Packaging
In coils.
Versions
Flat knitted copper fabrics
consisting of 4, 6 or 8 wires 0.10 mm diameter up to a max.
width of 100 mm, mesh spacing approx. 5 mm.
Knitted copper fabric tubes, rolled
made of wire 0.10 mm and above up to a max. width
of 130 mm, close-mesh.
Special versions
High-strength knitted copper fabrics made of tinsel conductors
(also combined with wires) are available for special applications.
Product range
Knitted copper fabrics, fine-wireFor repair work as cable screens.
The screen density and coverage can be determined by the winding.
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24
Assemblies / finishing
In order to provide as much as help as possible with the process-
ing and fitting of our copper flexibles and copper straps, we
have developed techniques of finishing the end in such a way
that the flexibles and straps can be easily connected and the
electrical contact resistance at the connection points is kept as
low as possible.
We shall be pleased to advise you about the optimum design of
the corresponding connection points.
Cross-sectional area range
0.5 – 1000 mm2
Example applications
Special engineering Mechanical engineering Control cabinets Battery connectors Current-operated earth-leakage circuit-breakers Earthing straps
The photographs show some examples of ready made assemblies.
Product range
Assemblies / finishingReady made rope and braid assemblies.
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25Product informationProduct range
Copper SolutionsMaybe you can’t find the product you’re looking for or have individual requirements?
Just give us a call. We’ll find a solution for you!
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26 Product information
Copper Solutions Product information
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27Product information
PackagingThe most common reel sizes at a glance
d1 d3 l2 l1 d2Type Ø of flange Ø of bore Distance from flange Ø of barrel Capacity max.
internal external (based on stranded conductors)
mm mm mm approx. kg
Plastic reels
K 125 125 16 100 125 80 3K 160 160 22 128 160 100 6K 200 200 22 160 200 125 12K 250 250 22 160 200 160 20K 355 355 36 160 200 224 35K 400 400 32.7 205 243 250 70
Wooden reels
H 400 400 36 200 250 200 70H 600 600 50 280 340 280 250H 800 800 81 400 550 400 500
H 1000 1000 80 560 700 500 1000
Special 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 Width d2 Barrel diameter
The standard of purity is achieved when the elec- trical conductivity in annealed condition is 58.58 m/Ωmm2 in the case of Cu-ETP1. Details of sampling and test methods are available.
In addition to copper we process a number of copper alloys for special applications. Typical alloys include CuSn (copper/tin), CuNi (copper/nickel), CuAg (copper/silver) and LEONI Histral®.
Hydrogen resistance is tested and measured according to international technical specifica- tions. If individual customers have particular requirements these must be stipulated at the time of order.
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/Ωmm2 = 100 % IACS
Symbol Material-number
Composition Density Meltingpoint
% IACS min.
Information on properties and applications.
in %-by-weight
kg/dm3
Electrolytic copper
Cu-ETP1(E-Cu)
CW 003 A Cu ≥99.90
Oxygenmax. 0.040
8.9 1083 °C 101 Electrolytic tough pitch copper with an
electrical conductivity in annealed condition
of ≥58.58 m/Ωmm2 at 20 °C (101 % IACS).
Oxygen-free copper
Cu-OF1(OF-Cu)
CW 007 A Cu 99.95 8.9 1083 °C 101 Oxygen free copper is purer containing less
impurities and trace elements which evaporate
in a vacuum and has an electrical conductivity
in the annealed condition of ≥58.58 m/Ωmm2 at
20 °C (101 % IACS).
It is suitable for semi-finished products that
require resistance to hydrogen as in ISO 2626 , ultrasonic welding and hard soldering
(brazing).
For use in the fields of vacuum technology and
electronics.
Our main raw material is copper (Cu). In our wire manufac-
turing we primarily use Cu-ETP 1 for all standard applica-
tions and Cu-OF 1 (oxygen free copper) where specific
requirements dictate, e.g. resistance to hydrogen as in
ISO 2626.
CopperProperties and Applications
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28 Product information
LEONI wires and stranded conductors are available bare and with a range of surface finishes manufactured to industry, national and international standards as well as to individual customer specifications.
Tin Silver Nickeltemperature resistance (120 °C)effective protection against
corrosionEasy to solder
high temperature resistance (200 °C)high conductivity (Skin-effect, impor-
tant for HF-applications)Easy to solder
high temperature resistance (260 °C)high corrosion resistance barries of diffusionCan only be soldered under certain
conditions
DIN EN 13602 “Requirements of the tin-plating”
Type Min. unalloyed tin plating thickness
Purity of the tin layer
Bonding of tin layer
µm
A 0.3max. 1.0 g copper
per m2 wire surfaceno cracks and interruptionsB 0.6
C not specified
Surface properties
Electroplating options: For plated copper/wires we use tin, silver or nickel as metal, depending on what is required from the conductor.
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29Product information
Tables of weights for platingsat a specific weight (kg/dm3) of 7.28 Sn (= tin), 8.9 Ni (= nickel), 10.5 Ag (= silver)
AWG = American Wire Gauge
Metric Wires – Layer thickness 1 µm
Ø of 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 18.90.260 12.6 15.4 18.10.280 11.7 14.3 16.90.300 10.9 13.3 15.70.315 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 3.21.600 2.0 2.5 3.01.700 1.9 2.4 2.81.800 1.8 2.2 2.6
AWG-wires, plating thicknesses according to ASTM
AWG-No.
Ø of wire
25 micro-inches
0.635 µmTin Sn
50 micro-inches
1.27 µmNickel Ni
40 micro-inches
1.016 µmSilver Ag
Silver thick-ness
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
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30 Product information
Measured at 35 °C room temperature and max. permitted conductor temperature of 70 °C
The choice of the right conductor diameter depends on the
current load.
Since several influencing factors generally apply, the values
specified must be considered only as non-binding guideline
values.
Table of current ratingTables of weights for platingsat a specific weight (kg/dm3) of 7.28 Sn (= tin), 8.9 Ni (= nickel), 10.5 Ag (= silver)
The table is a tool to calculate the weight and
plating thickness for tin, nickel and silver.
Tin plated wires will not have a plating thickness
of 1 µm, as stated, but will be manufactured in
accordance with EN 13602.
Example 1:
How many grammes of silver do you require for a
wire with a diameter of 0.18 mm, if the plating
thickness is to be 1.5 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
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31Product information
Nom. cross-section
Max. permit-ted current
rating
mm2 approx. A
0.1 50.14 60.2 70.25 90.35 100.5 12.50.75 151 181.5 212.5 304 405.25 446 558 70
10 8516 120
Nom. cross-section
Max. permit-ted current
rating
mm2 approx. A
25 15035 19550 25070 30095 360
120 420150 480185 570240 670300 780400 950500 1100625 1300800 1500
1000 1800
Treuchtlinger Strasse 20
91781 Weissenburg
Germany
Phone +49 (0)9141-918-138
Fax +49 (0)9141-918-100
E-mail [email protected]
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LEONI Draht GmbH
Business Unit Copper Solutions