Copper Solutions
Wire Solutions for Component Production
The Quality Connection
2
The Quality Connection
Copper Solutions –
from single wires to fully
assembled components.
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.
The optimum servicecapability and reliability of the various components 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 individual 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
■■
Issue: April 2011 © LEONI Draht GmbH
The 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.
Customer-specific logistics concepts
We reserve the right to make technical modifications;
typographical errors and mistakes excepted.
www.leoni-copper-solutions.com
3
The Quality Connection
Content
The Quality Connection
page
n The LEONI Group Cable expertise for the most
varied industrial markets
n Copper Solutions
4
5
We never lose sight of your solution
Copper Solutions
Copper Solutions
Product range
Product information
page
n Product range9
n Packaging
The most common reel sizes
n Single wires to DIN standard10
at a glance
DIN dimensions for single copper
n Copper
wires in accordance with DIN 46 431
at a glance
n Copper Solutions – Worldwide 6
n Cell and string connectors
Our presence at a worldwide level
benefits you at local level.
n Round, stranded copper flexibles 12
for photovoltaic modules
n LEONI – The Quality Connection 7
n Ropes with integral strain
Quality and environmental
management
members 11
13
flexibles with overall braid
14
n Flat cables woven, flexible
15
n Round, braided copper flexibles 16
n Square braids, highly flexible
17
n Rectangular braided conductors,
extra flexible
18
n Braided copper tapes flat rolled,
flexible
19
n Braided copper tapes flexible
20
n Braided copper tapes super
flexible
20
n Braided copper tapes,
moulded with straight edges
21
n Shielding braids (tubular)
expandable and flexible
22
n Knitted copper fabrics, fine-wire 23
n Assemblies / finishing24
page
27
28
Properties and uses
n Surface properties n Round, stranded copper
www.leoni-copper-solutions.com
29
n Tables of weights for platings 30
n Table of current rating 31
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.
Our group of companies employs more than 56,000 people in
Your markets – our strength
34 countries. Corporate vision, highest quality and innovative
As diverse as our product and service range are the markets
power have made us one of the leading cable manufacturers in
and sectors LEONI is supplying. We focus our activities on
Europe. LEONI develops and produces technically sophisticated
customers in the fields of Automotive & Commercial Vehicles,
products ranging from wire and optical fibers to cables
Industry & Healthcare, Communication & Infrastructure, Electrical
through to complete cable systems and also offers the related
Appliances and Conductors & Copper Solutions.
services. Moreover, the product portfolio comprises strands,
standardised cables, hybrid cables, glass fiber as well as special
We are one of the leading European suppliers in the Conductors
cables, cable harnesses, wiring systems components and
& Copper Solutions market, which at LEONI also covers the
fully assembled systems for applications in various industrial
manufacturing of wires for the areas of “Special Conductors” and
markets.
“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
Products and services portfolio at a glance
Service
Cable systems / Wiring Systems
Cable harnesses
Copper cables
Wires & strands
Sensors
Hybrid cables
Optical fibers
Relay and safety systems
Optical cables
Development / Engineering
4
Connectors
LEONI‘s core markets
Automotive
&
Commercial Vehicles
Industry
&
Healthcare
Communication
&
Infrastructure
Electrical
Appliances
Conductors
&
Copper Solutions
www.leoni-copper-solutions.com
The Quality Connection
Copper Solutions
We never lose sight of your solution.
Traditional expertise
Business Unit Copper Solutions
Our roots in drawing wires can be traced back to the Middle
The Business Unit Copper Solutions enables us to offer our
Ages. LEONI laid the foundations for a successful business with
customers a broad range of wires and stands, as well as highly
the production of gold and silver wires and the finest metal
flexible wire products.
threads, known as Lyonese Wares. In the 1920s the first wire
and strands were produced for electrical engineering, then a
Our extensive expertise in applications means that our
rapidly growing area of industry.
products are to be found not just in one specific sector.
That’s because LEONI products prove to be the ideal solution
These days, LEONI is regarded as one of the world’s leading
wherever electricity is carried or needs to be grounded and
suppliers in the Conductors & Copper Solutions market,
the conductor is subjected to high mechanical stresses due
producing highly sophisticated conductors and strands for
to permanent movement and vibration – in electric motors,
cable technology and for special applications in the area of
circuit-breakers and safety switches, relays and thyristors, as
electrical technology and electronics. It is a leader in terms of
well as in welding plants, control cabinets, cars, aircraft, ships
the international presence of the business and the quality of
and wind power stations.
the products and production technology. LEONI has also played
a lasting role in influencing technologies such as multi-wire
Although the main focus of our work is in the areas of electrical
drawing, galvanic finishing of wires or machining into precisely
engineering and electronics, we have still remained faithful to
shaped strands.
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.
www.leoni-copper-solutions.com
5
6
The Quality Connection
Copper Solutions – Worldwide
Our presence at a global level benefits you at local level.
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.
LEONI Wire Inc.
Chicopee MA, USA
LEONI Draht GmbH
Weissenburg, Germany
LEONI Felisi S.r.l.
Codogno, Italy
LEONI Wire (Changzhou) Ltd.
Changzhou, P.R. China
Production of highly flexible wire products for electrical engineering applications
Production of the finest wire products for textile and decorative applications
You will find further information at www.leoni-felisi.com
www.leoni-copper-solutions.com
The Quality Connection
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.
Top quality
Green Technology
A global harmonised and ISO 9001:2008 and ISO/TS 16949
Business success and ecological responsibility are no contradiction
certified quality management system enable us to ensure that
in terms for us. As a company operating globally, we acknowledge
our products and services meet uniform quality standards.
that we share responsibility for safeguarding the natural essentials
of life. It is our aim to strike a balance between environmental
By using the latest production techniques, such as multi-
concerns and the interests of our Company. Environmental
wire drawing and advanced production systems and process
protection consequently is a mandatory element of our business
equipment, our products attain a high degree of quality and
activity. We advise our customers on environmentally friendly ways
reliability. Whether use in the industrial or textile sectors,
to handle and dispose of our products.
our wire solutions always meet the stringent standards of
our customers. This is proven by our unique reference list of
We ensure, with our DIN EN ISO 14001-certified environmental
internationally leading businesses.
management system, that our environmental policy is applied
in the entire group effectively.
www.leoni-copper-solutions.com
7
8
Copper Solutions Product range
www.leoni-copper-solutions.com
9
Product range
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.
page
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 flexibles
with 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
Braided copper tapes flexible
Braided copper tapes super flexible
19
Basic material for groundstraps and connectors of all kinds
Braided copper tapes,
moulded with straight edges
20
20
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-wire
For 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
www.leoni-copper-solutions.com
10
Product range
Single wires to DIN standard
DIN dimensions for single copper wires in acc. with DIN 46 431
m
Round Copper Wires for Electrical Purposes, Exactly Drawn.
✖Calculated
(These Standards apply only to plain wires as the parameters
The maximum resistance value in the case of a diameter using
change as a result of the extrusion process and the associ-
the full acceptable negative deviation range must be suitable
ated wire elongation.)
for a conductivity of at least. 57.5
with a conductivity of 58 Ω · mm2 at 20 °C.
m
Ω · mm2 .
Diameter
Nominal value
d
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
0.047
0.060
0.068
0.077
0.087
0.097
0.107
0.120
0.135
0.155
0.175
0.195
0.219
0.243
0.273
0.308
0.348
0.391
0.441
0.491
0.551
0.621
0.698
0.738
0.788
0.838
0.888
0.938
0.988
1.044
1.104
1.164
1.234
1.304
1.384
1.480
1.580
1.680
1.775
0.053
0.066
0.074
0.083
0.093
0.103
0.117
0.130
0.145
0.165
0.185
0.205
0.229
0.257
0.287
0.322
0.362
0.409
0.459
0.509
0.569
0.639
0.722
0.762
0.812
0.862
0.912
0.962
1.012
1.076
1.136
1.196
1.266
1.336
1.416
1.520
1.620
1.720
1.825
0.0175
0.0278
0.0353
0.0447
0.0566
0.0699
0.0878
0.109
0.137
0.179
0.226
0.280
0.351
0.437
0.548
0.694
0.882
1.12
1.42
1.75
2.19
2.78
3.53
3.93
4.47
5.05
5.66
6.31
6.99
7.86
8.78
9.75
10.90
12.20
13.70
15.70
17.90
20.20
22.60
8.80
5.53
4.35
3.43
2.71
2.196
1.750
1.402
1.120
0.8573
0.6774
0.5487
0.4375
0.3512
0.2799
0.2213
0.1743
0.1372
0.1084
0.0878
0.0700
0.0553
0.04354
0.03902
0.03429
0.03038
0.02710
0.02432
0.02195
0.01954
0.01750
0.01577
0.01405
0.01260
0.01120
0.00976
0.00858
0.00760
0.00677
0.05
0.063
0.071
0.08
0.09
0.1
0.112
0.125
0.14
0.16
0.18
0.2
0.224
0.25
0.28
0.315
0.355
0.4
0.45
0.5
0.56
0.63
0.71
0.75
0.8
0.85
0.9
0.95
1
1.06
1.12
1.18
1.25
1.32
1.4
1.5
1.6
1.7
1.8
± 0.003
± 0.005
± 0.007
± 0.009
± 0.012
± 0.016
± 0.020
± 0.025
0.00196
0.00312
0.00396
0.00503
0.00636
0.00785
0.00985
0.01227
0.01539
0.02011
0.02545
0.03142
0.03941
0.04909
0.06158
0.07793
0.09898
0.1257
0.1590
0.1964
0.2463
0.3117
0.3959
0.4418
0.5027
0.5675
0.6362
0.7088
0.7854
0.8825
0.9852
1.094
1.227
1.368
1.539
1.767
2.011
2.270
2.545
57.10
36.00
28.30
22.40
17.67
14.31
11.39
9.17
7.30
5.59
4.42
3.57
2.85
2.29
1.825
1.441
1.134
0.893
0.704
0.571
0.457
0.36
0.283
0.254
0.224
0.198
0.177
0.158
0.143
0.127
0.114
0.103
0.0917
0.082
0.073
0.0637
0.0559
0.0495
0.0442
www.leoni-copper-solutions.com
Product range
Cell and string connectors for photovoltaic modules
100 % 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.
Material
Special benefits
Core material
Cu-ETP1 and Cu-OF1
Dimensions
Coating solder
SnPbAg 62/36/2
SnAg 96.5/3.5
SnPb 60/40
Sn 99.9
Coating thickness 5–40 µm
Thickness: 0.08–0.50 mm | Width: 1.2–5.0 mm
Tensile strength
Rm >200 N/mm2 (or according to specification)
Yield strength
Rp 0.2 <80 N/mm2 possible
Elongation
>25 % (or according to specification)
other coatings are available on request
Packaging
Green Technology
Flat wire, rolled, with subsequent immersion tinning, absolutely
environmentally friendly without using flux or chemical
substances.
www.leoni-copper-solutions.com
K160, K200, K250, K355, USP4 (K1510), HKV160 (K1602), 10 S,
Disc (K0372).
Other sizes upon request.
11
12
Product range
Round, stranded copper flexibles
Besides special flexibility these types distinguish themselves through
no fraying of cut ends for further standard processing.
Material
Direction of stranding
E-Cu/OF-Cu and alloys, plain, tinned, nickel-plated or silver-
Reversed lay or SZ stranding
plated.
S ➔ left hand lay
Z ➔ right hand lay
Special versions
Highly twist-free and with a compact cutting surface.
A special surface finish permits various welding methods.
Nominal
crosssection
Ø of wire
mm2
mm
0.06
0.1
0.14
0.2
0.25
0.35
0.5
0.75
1
1.5
2
2.5
3
4
5.25
6
8
10
12
16
0.05
± 0.002
0.071
± 0.002
No. of wires
tol. ± 2 %
30
51
72
105
130
180
266
392
525
385
525
651
798
1036
1372
1575
2058
2562
3108
4116
Overall-Ø
Weight
±12 %
Nominal
crosssection
Ø of wire
approx. mm
approx.
kg/km
mm2
mm
0.3
0.4
0.5
0.6
0.7
0.85
1
1.25
1.5
1.75
2.1
2.4
2.6
3
3.5
3.7
4.2
4.7
5.2
6.0
0.6
1
1.4
2
2.5
3.5
5
7.5
10
15
20
25
30
40
53
60
80
100
120
160
25
35
50
70
95
120
150
185
240
300
400
500
600
0.1
± 0.003
No. of wires
tol. ± 2 %
3234
4508
6468
8967
12201
15435
19110
23580
30600
38200
51000
63700
76430
Overall-Ø
Weight
±12 %
approx. mm
approx.
kg/km
7.6
9.0
10.7
12.7
14.8
18.0
20.0
21.0
24.9
26.0
30.0
33.0
36.5
250
350
500
700
950
1200
1500
1850
2400
3000
4000
5000
6000
www.leoni-copper-solutions.com
Product range
Ropes with integral strain members
E-Cu round, stranded copper flexible
with integral strain members for high tensile strength.
Material
Special versions
E-Cu, plain, tinned, nickel-plated, silver-plated, brass-plated
■■
Round, braided conductors
(Cement wire) or genuine gold-plated.
■■
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
mm2
2.5
4
6
www.leoni-copper-solutions.com
No. of wires
±2 %
mm
0.071
0.10
0.20
0.071
0.10
0.20
0.071
0.10
0.20
644
318
78
1044
504
126
1566
756
192
Overall-Ø
Weight
approx. mm
approx. kg/km
2.4
2.4
2.4
3
3
3
3.7
3.7
3.7
23
23
23
38
38
38
56
56
56
Tensile strength
N
1525
1525
1525
1840
1840
1840
2260
2260
2260
13
14
Product range
Round, stranded copper flexibles
with overall braid
Material
Special benefits
E-Cu/OF-Cu and alloys, plain, tinned, nickel-plated or siver-
Owing to technical production reasons, the effective cross-
plated.
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 crosssection by implementing construction modifications.
Nominal crosssection
Effective
cross-sectional
area
mm2
mm2
0.35
0.5
0.75
1
1.5
2.5
3.75
4
6
8
10
12
16
25
35
50
70
95
120
0.35
0.51
0.77
1.02
1.53
3.08
3.91
4.6
6.99
8.9
11.2
12.0
17.8
26.9
37.3
53.6
73.3
98.7
124
Round stranded copper flexible
Ø of wire
No. of wires
tol. ± 2 %
mm
0.05
± 0.002
0.071
± 0.002
0.10
± 0.003
Overall braiding
Ø of wire
0.10
± 0.003
Weight
± 12 %
approx. mm
approx. kg/km
No. of wires
tol. ± 2 %
mm
51
130
266
266
525
651
798
1036
1575
2058
2562
2562
4116
3234
4508
6468
8967
12201
15435
Ø of straded
conductor
32
32
32
64
64
64
96
64
96
96
128
240
192
192
240
360
360
360
360
0.8
1.1
1.4
1.5
1.9
2.9
3.0
3.4
4.1
4.7
5.2
5.2
6.5
8.2
9.6
11.4
13.4
16.4
18.4
3.5
5.1
7.7
10.2
15.3
30.8
39.1
46
69.9
89
112
120
178
269
373
536
733
987
1240
www.leoni-copper-solutions.com
Product range
Flat cables woven, flexible
(for special applications)
Material
E-Cu, plain or tinned.
Packaging
In coils.
Dimensions
Nominal
crosssection
Width
mm2
25
25
35
35
35
35
50
50
50
50
70
70
70
95
95
120
120
150
Construction of the flat cables in acc. with DIN
46443
±
Thickness
± 0.5
mm
mm
mm
mm2
28
38
23
28
38
47
28
38
47
57
38
47
57
47
57
57
77
77
1.6
1.6
1.6
1.6
1.6
2.5
1.6
1.6
2.5
2.5
1.6
2.5
2.5
2.5
2.5
2.5
2.5
2.5
3
2
5
4
3
2
6
4
3
2.5
6
5
4
6.5
5.5
7
5
6.5
1.5
1
6.0
4
1.5
1
6
4
2.5
1.5
8
6
4
8
6
10
6
10
The table shows possible product variants
www.leoni-copper-solutions.com
Warp
Nominal
cross-section
Weft
Number
16
24
6
9
22
34
8
12
20
32
9
12
18
12
16
12
20
15
Nominal
cross-section
mm2
1
0.75
1.5
1.5
1
0.75
1.5
1.5
1.5
1
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
Weight
± 12 %
Width of the
connecting
rail/bus
kg/km
325
340
430
430
445
470
565
600
675
645
835
860
900
1105
1135
1365
1430
1715
30
40
25
30
40
50
30
40
50
60
40
50
60
50
60
60
80
80
15
16
Product range
Round, braided copper flexibles
Absolute free from twist and compact, cutting surface with very high dimensional accuracy
permit easy, fully automatic further processing.
Material
Range of production
E-Cu/OF-Cu and alloys, plain, tinned, nickel-plated or siver-
The adjacent tables show the standard range. On request we
plated.
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
crosssection
Ø of wire
mm2
mm
0.047
0.094
0.14
0.20
0.25
0.35
0.50
0.75
1
0.05
± 0.002
Construction
No. of wires
±2 %
8x3
8x6
8x9
8 x 13
8 x 16
8 x 23
8 x 32
8 x 48
8 x 64
Overall-Ø
Weight
± 12 %
Nominal
crosssection
Ø of wire
approx. mm
approx.
kg/km
mm2
mm
0.33
0.47
0.57
0.70
0.80
0.95
1.10
1.35
1.55
0.47
0.94
1.40
2
2.50
3.50
5
7.50
10
1.5
1.5
2
2.5
3
4
5
6
8
10
12
16
20
25
0.071
± 0.002
0.10
± 0.003
Construction
No. of wires
±2 %
8 x 49
12 x 33
12 x 44
12 x 54
12 x 65
12 x 86
12 x 108
12 x 130
12 x 174
12 x 217
12 x 260
12 x 170
12 x 213
12 x 266
Overall-Ø
Weight
± 12 %
approx. mm
approx.
kg/km
1.90
1.90
2.20
2.40
2.70
3.10
3.50
3.80
4.40
4.90
5.40
6.10
6.90
7.70
15
15
20
25
30
40
50
60
80
100
120
160
200
250
www.leoni-copper-solutions.com
Product range
Square braids, highly flexible
Greater 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.
Material
E-Cu/OF-Cu and alloys, plain, tinned, nickel-plated or silverplated.
Nominal
crosssection
Construction
No. of wires
±2 %
Ø of wire
Edge
length
Weight
± 12 %
Nominal
crosssection
mm
mm
approx.
kg/km
mm2
0.05
0.05
0.05
0.071
0.05
0.071
0.05
0.071
0.05
0.071
0.05
0.071
0.05
0.071
1.0
1.4
1.75
1.75
2.0
2.0
2.2
2.2
2.5
2.5
2.8
2.8
3.2
3.2
5
10
15
15
20
20
25
25
30
30
40
40
50
50
mm2
0.5
1
1.5
1.5
2
2
2.5
2.5
3
3
4
4
5
5
8 x 32
8 x 64
8 x 96
8 x 49
8 x 128
8 x 65
8 x 160
8 x 81
8 x 192
8 x 97
8 x 256
8 x 130
8 x 320
8 x 162
www.leoni-copper-solutions.com
6
6
8
8
10
10
12
12
16
25
35
40
50
Construction
No. of wires
±2 %
8 x 384
8 x 195
8 x 512
8 x 260
8 x 640
8 x 324
8 x 768
8 x 390
8 x 255
8 x 400
8 x 560
8 x 640
8 x 800
Ø of wire
Edge
length
Weight
± 12 %
mm
mm
approx.
kg/km
0.05
0.071
0.05
0.071
0.05
0.071
0.05
0.071
0.10
0.10
0.10
0.10
0.10
3.5
3.5
4.1
4.1
4.6
4.6
5.0
5.0
5.8
7.2
8.5
9.0
10.2
60
60
80
80
100
100
120
120
160
250
350
400
500
17
18
Product range
Rectangular braided conductors, extra flexible
The rectangular shape enables maximum space-saving: in comparison with round
strands, a much larger cross-section can be accommodated in a very small space.
Material
 Dimensions
E-Cu/OF-Cu plain, tinned.
The braided conductor can be manufactured with a dimension
ratio from 1 : 1.5 to 1 : 2.5, where the dimension is determined in
Special benefits
agreement with the customer depending on the intended use
Extraordinarily high flexibility is achieved in the stranded
and availability of space.
conductors through a special manufacturing process which,
even with high packing density (multilayer installations), allows
Example of two possible dimensions:
the tightest bending radiuses and does not degrade switching
for 50 mm2 ➔ 13 x 8.5 mm or
operations.
Nominal
crosssection
No. of wires
mm2
mm
16
25
35
40
50
2040
3200
4480
5120
6400
Ø of wire
0.10
0.10
0.10
0.10
0.10
Dimensions
Weight
± 12 %
approx. mm
approx.
kg/km

15 x 7 mm
160
250
350
400
540
www.leoni-copper-solutions.com
Product range
Braided copper tapes flat rolled, flexible
(Basic material for grounding strapes and connectors of all kinds)
Material
Special versions
E-Cu, plain, tinned, nickel-plated or silver-plated.
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.
Nominal
crosssection
Dimensions
width ± 5 %
x
thickness 
mm2
mm
0.09
0.16
0.25
0.5
0.75
1
1.5
2
2.5
3
4
6
8
10
1 x 0.2
1.2 x 0.2
1.6 x 0.2
2.5 x 0.4
2.7 x 0.5
3.2 x 0.6
4 x 0.8
5 x 0.8
5.8 x 0.8
7.5 x 0.9
8.2 x 1
10 x 1.3
10.5 x 1.7
12 x 1.8
Construction
16 x 3
16 x 5
16 x 8
16 x 16
16 x 24
16 x 32
16 x 25
16 x 33
24 x 27
24 x 33
24 x 43
24 x 66
24 x 88
24 x 109
Ø of wire
Weight
Nominal
crosssection
Dimensions
width ± 5 %
x
thickness 
mm
approx.
kg/km
mm2
mm
0.05
± 0.002
0.071
± 0.002
0.9
1.6
2.5
5.0
7.5
10
15
20
25
30
40
60
80
100
16
25
35
50
70
95
120
140
150
168
185
240
250
300
400
15 x 2.3
19 x 2.9
29 x 2.6
33 x 2.8
45 x 2.9
50 x 3.2
60 x 3.5
60 x 4.0
60 x 4.5
70 x 4.5
75 x 4.6
80 x 5.3
80 x 5.6
90 x 6.0
100 x 7.5
Construction
24 x 85
24 x 135
36 x 124
48 x 133
48 x 186
48 x 253
48 x 319
48 x 372
48 x 399
48 x 446
48 x 491
48 x 637
48 x 664
48 x 797
48 x 1062
 max. 25 % below nominal value
www.leoni-copper-solutions.com
Ø of wire
Weight
mm
approx.
kg/km
0.1
± 0.003
160
250
350
500
700
950
1200
1400
1500
1680
1850
2400
2500
3000
4000
19
20
Product range
Braided copper tapes flexible
Braided copper tapes super flexible
(Basic material for grounding strapes and connectors of all kinds)
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
crosssection
Dimensions
width ± 5 %
x thickness 
mm2
mm
14
14
16
16
21
21
25
25
35
35
50
50
70
70
18 x 1.5
18 x 1.5
19 x 1.5
19 x 1.5
22 x 1.7
22 x 1.7
22 x 2.1
22 x 2.1
25 x 2.4
25 x 2.4
33 x 2.7
33 x 2.7
35 x 3.8
35 x 3.8
Braided copper tapes super flexible
Construction
36 x 20
36 x 12
36 x 22
36 x 14
36 x 29
36 x 19
36 x 35
36 x 22
36 x 48
36 x 31
48 x 52
48 x 33
48 x 73
48 x 46
Ø of wire
± 0.003
Weight
± 12 %
Nominal
crosssection
Dimensions
width ± 5 %
x thickness 
mm
approx.
kg/km
mm2
mm
0.16
0.2
0.16
0.2
0.16
0.2
0.16
0.2
0.16
0.2
0.16
0.2
0.16
0.2
140
140
160
160
210
210
250
250
350
350
500
500
700
700
4
6
8
10
14
16
21
25
35
42
50
70
7 x 1.1
9 x 1.3
10 x 1.5
12 x 1.6
14 x 1.9
15 x 2.0
18 x 2.2
24 x 2.0
30 x 2.0
35 x 2.4
35 x 2.8
40 x 3.0
Construction
24 x 86
24 x 128
24 x 171
24 x 213
24 x 298
24 x 341
24 x 450
36 x 355
36 x 497
48 x 447
48 x 532
48 x 745
Ø of wire
Weight
± 12 %
mm
approx.
kg/km
0.05
± 0.002
40
60
80
100
140
160
210
250
350
420
500
700
 max. 25 % below nominal value.
 max. 25 % below nominal value.
www.leoni-copper-solutions.com
Product range
Braided copper tapes, moulded with straight edges
High precision and improved weldability in automated processes
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
Dimensions
width from – to
mm2
25
50
100
120
Dimensions
thickness from – to
mm
mm
1.8 – 4.0
3.5 – 6.0
4.0 – 7.5
5.0 – 8.5
20.0 – 9.0
24.0 – 13.0
42.0 – 21.0
46.0 – 23.0
Other cross-sections and dimensions available on request.
www.leoni-copper-solutions.com
21
22
Product range
Shielding braids (tubular) expandable and flexible
The expandability and coverage can be determined precisely by changing the braiding angle.
Material
Special benefits
E-Cu, plain, tinned.
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.
Coverage
approx.
approx. mm
Extended length
weight
±12 %
approx. kg/km
3
3.5
4
6
8
10
15
16
18
20
25
30
40
50
60
70
80
100
120
140
160
2.3
3.5
4.6
8.1
12.1
15.6
18.1
48.8
55.3
62
73
93
124
218
280
311
373
466
664
885
995
36.58
45.82
52.77
60.66
64.39
68.03
56.40
63.94
65.16
67.72
62.70
66.93
68.31
64.70
68.69
66.39
68.45
67.23
60.71
66.82
68.42
Effektive
cross-section
Construction
Ø of wire
Expandable
max. inner-Ø
mm2
Reel x No. of wires
mm
0.25
0.38
0.50
0.88
1.32
1.70
1.98
5.30
6.00
6.80
7.90
10.20
13.60
23.80
30.50
33.90
40.70
50.90
72.40
96.50
108.60
16 x 2
16 x 3
16 x 4
16 x 7
24 x 7
24 x 9
36 x 7
24 x 7
24 x 8
24 x 9
36 x 7
36 x 9
36 x 12
48 x 7
48 x 9
48 x 10
48 x 12
48 x 15
48 x 12
48 x 16
48 x 18
0.10
± 0.003
0.20
± 0.003
0.30
± 0.004
0.40
± 0.004
%
www.leoni-copper-solutions.com
Product range
Knitted copper fabrics, fine-wire
For repair work as cable screens.
The screen density and coverage can be determined by the winding.
Material
Versions
E-Cu, plain, tinned.
■■
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.
Packaging
In coils.
■■
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.
www.leoni-copper-solutions.com
23
24
Product range
The photographs show
some examples of ready
made assemblies.
Assemblies / finishing
Ready made rope and braid assemblies.
Assemblies / finishing
Cross-sectional area range
In order to provide as much as help as possible with the process-
0.5 – 1000 mm2
ing and fitting of our copper flexibles and copper straps, we
have developed techniques of finishing the end in such a way
Example applications
that the flexibles and straps can be easily connected and the
■■
Special engineering
electrical contact resistance at the connection points is kept as
■■
Mechanical engineering
low as possible.
■■
Control cabinets
■■
Battery connectors
We shall be pleased to advise you about the optimum design of
■■
Current-operated earth-leakage circuit-breakers
the corresponding connection points.
■■
Earthing straps
www.leoni-copper-solutions.com
Product
Product
information
range
Copper Solutions
Maybe 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!
www.leoni-copper-solutions.com
25
26
Product information
Copper Solutions Product information
www.leoni-copper-solutions.com
Product information
Packaging
The most common reel sizes at a glance
The main dimensions of a reel are: Additionally useful are:
d1➔ Flange diameter
d3➔ Bore diameter
Type
d1
d3
Ø of flange
Ø of bore
l2
internal
mm
l1
Distance from flange
l2 ➔Traverse
l1 ➔ Overall Width
d2➔ Barrel diameter
d2
Ø of barrel
external
mm
Capacity max.
(based on stranded
conductors)
mm
approx. kg
Plastic reels
K 125
K 160
K 200
K 250
K 355
K 400
125
160
200
250
355
400
16
22
22
22
36
32.7
100
128
160
160
160
205
125
160
200
200
200
243
80
100
125
160
224
250
3
6
12
20
35
70
36
50
81
80
200
280
400
560
250
340
550
700
200
280
400
500
70
250
500
1000
Wooden reels
H 400
H 600
H 800
H 1000
400
600
800
1000
Special types are available upon request.
www.leoni-copper-solutions.com
27
28
Product information
Copper
Properties and Applications
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. resistance to hydrogen as in
ISO 2626.
Excerpt from EN 1977 “Copper and copper alloys – Copper drawing stock (wire rod)”
Symbol
Materialnumber
Composition
Density
in %-byweight
kg/dm3
Melting
point
% IACS
min.
Information on properties and applications.
1083 °C
101
Electrolytic tough pitch copper with an
Electrolytic copper
Cu-ETP1
(E-Cu)
CW 003 A
Cu ≥99.90 6
Oxygen
max. 0.040
8.9
Cu 99.95
8.9
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
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
66, ultrasonic welding and hard soldering
(brazing).
For use in the fields of vacuum technology and
electronics.
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®.
6 The standard of purity is achieved when the elec-
66 Hydrogen resistance is tested and measured
trical conductivity in annealed condition is
58.58 m/Ωmm2 in the case of Cu-ETP1. Details of
sampling and test methods are available.
according to international technical specifications. If individual customers have particular
requirements these must be stipulated at the
time of order.
International Annealed Copper Standard = IACS
Electirical conductivity of copper = min. 58 m/Ωmm2 = 100 % IACS
www.leoni-copper-solutions.com
Product information
Surface properties
Electroplating options:
For plated copper/wires we use tin, silver or nickel as metal,
depending on what is required from the conductor.
Tin
Silver
Nickel
temperature resistance (120 °C)
high temperature resistance (200 °C)
high temperature resistance
effective
high
high
protection against
corrosion
Easy
conductivity (Skin-effect, impor-
tant for HF-applications)
to solder
Easy
barries
Can
to solder
(260 °C)
corrosion resistance
of diffusion
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
max. 1.0 g copper
per m2 wire surface
no cracks and interruptions
µm
A
B
C
0.3
0.6
not specified
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.
www.leoni-copper-solutions.com
29
30
Product information
Tables of weights for platings
at a specific weight (kg/dm3) of 7.28 Sn (= tin), 8.9 Ni (= nickel), 10.5 Ag (= silver)
Metric Wires – Layer thickness 1 µm
AWG-wires, plating thicknesses according to ASTM
AWGNo.
50
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
Ø of
wire
25 microinches
0.635 µm
Tin Sn
50 microinches
1.27 µm
Nickel Ni
40 microinches
1.016 µm
Silver Ag
Silver thickness
pore-free
quality
g/kg
mm
g/kg
g/kg
g/kg
0.025
0.028
0.032
0.036
0.040
0.045
0.051
0.056
0.064
0.071
0.079
0.089
0.102
0.114
0.127
0.142
0.160
0.180
0.203
0.226
0.254
0.287
0.320
0.361
0.404
0.455
0.511
0.574
0.643
0.724
0.813
0.912
1.024
1.151
1.290
1.450
1.628
1.829
83.1
74.2
65.9
58.3
52.0
46.5
40.7
37.1
32.4
29.2
26.3
23.3
20.4
18.2
16.4
14.6
13.0
11.5
10.2
9.2
8.2
7.2
6.5
5.8
5.1
4.6
4.1
3.6
3.2
2.9
2.6
2.3
2.0
1.8
1.6
1.4
1.3
1.1
203.2
181.4
161.3
142.7
127.3
113.6
99.6
90.7
79.4
71.5
64.3
57.1
49.8
44.6
40.0
35.8
31.8
28.2
25.0
22.5
20.0
17.7
15.9
14.1
12.6
11.2
9.9
8.9
7.9
7.0
6.2
5.6
5.0
4.4
3.9
3.5
3.1
2.8
191.8
171.3
152.2
134.7
120.2
107.3
94.0
85.6
74.9
67.5
60.7
53.9
47.0
42.1
37.8
33.8
30.0
26.6
23.6
21.2
18.9
16.7
15.0
13.3
11.9
10.5
9.4
8.4
7.5
6.6
5.9
5.3
4.7
4.2
3.7
3.3
2.9
2.6
AWG = American Wire Gauge
61
50
40
30
25
20
12.5
Ø of wire
Tin Sn
Nickel Ni
Silver Ag
mm
g/kg
g/kg
g/kg
0.050
0.063
0.070
0.071
0.080
0.090
0.100
0.112
0.120
0.125
0.130
0.140
0.150
0.160
0.180
0.200
0.220
0.224
0.250
0.260
0.280
0.300
0.315
0.320
0.355
0.370
0.400
0.410
0.430
0.450
0.500
0.520
0.560
0.600
0.630
0.640
0.680
0.710
0.750
0.800
0.850
0.900
0.950
1.000
1.060
1.120
1.180
1.250
1.320
1.400
1.500
1.600
1.700
1.800
65.4
51.9
46.7
46.1
40.9
36.4
32.7
29.2
27.3
26.2
25.2
23.4
21.8
20.4
18.2
16.4
14.9
14.6
13.1
12.6
11.7
10.9
10.4
10.2
9.2
8.8
8.2
8.0
7.6
7.3
6.5
6.3
5.8
5.4
5.2
5.1
4.8
4.6
4.4
4.1
3.8
3.6
3.5
3.3
3.1
2.9
2.8
2.6
2.5
2.3
2.2
2.0
1.9
1.8
80.0
63.5
57.1
56.3
50.0
44.4
40.0
35.7
33.3
32.0
30.8
28.6
26.7
25.0
22.2
20.0
18.2
17.9
16.0
15.4
14.3
13.3
12.7
12.5
11.3
10.8
10.0
9.8
9.3
8.9
8.0
7.7
7.1
6.7
6.3
6.2
5.9
5.6
5.3
5.0
4.7
4.5
4.2
4.0
3.8
3.6
3.4
3.2
3.0
2.9
2.7
2.5
2.4
2.2
94.4
74.9
67.4
66.5
59.0
52.4
47.2
42.1
39.3
37.8
36.3
33.7
31.5
29.5
26.2
23.6
21.5
21.1
18.9
18.1
16.9
15.7
15.0
14.8
13.3
12.8
11.8
11.5
11.0
10.5
9.4
9.1
8.4
7.9
7.5
7.4
6.9
6.7
6.3
5.9
5.6
5.3
5.0
4.7
4.4
4.2
4.0
3.8
3.6
3.4
3.2
3.0
2.8
2.6
www.leoni-copper-solutions.com
Product information
Table of current rating
The table is a tool to calculate the weight and
The choice of the right conductor diameter depends on the
plating thickness for tin, nickel and silver.
current load.
Tin plated wires will not have a plating thickness
Since several influencing factors generally apply, the values
of 1 µm, as stated, but will be manufactured in
specified must be considered only as non-binding guideline
accordance with EN 13602.
values.
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
Nom. crosssection
Max. permitted current
rating
Nom. crosssection
Max. permitted current
rating
mm2
approx. A
mm2
approx. A
0.1
0.14
0.2
0.25
0.35
0.5
0.75
1
1.5
2.5
4
5.25
6
8
10
16
5
6
7
9
10
12.5
15
18
21
30
40
44
55
70
85
120
25
35
50
70
95
120
150
185
240
300
400
500
625
800
1000
150
195
250
300
360
420
480
570
670
780
950
1100
1300
1500
1800
 Measured at 35 °C room temperature and max. permitted conductor
temperature of 70 °C
www.leoni-copper-solutions.com
31
LEONI Draht GmbH
Business Unit Copper Solutions
Treuchtlinger Strasse 20
91781 Weissenburg
Germany
Phone +49 (0)9141-918-138
Fax
+49 (0)9141-918-100
E-mailcopper-solutions@leoni.com
www.leoni-copper-solutions.com