Special conductors
for cable extrusion
The Quality Connection
2
The Quality Connection
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 technology. Today LEONI offers a comprehensive range of wires,
stranded conductors, ropes and braids for both the cable industry and electrical component market.
www.leoni-special-conductors.com
The Quality Connection
www.leoni-special-conductors.com
The Quality Connection
Competence with Tradition
Contents
Quality and Environmental Management
LEONI – The Global Player
Page
2
3
4
5
Conductors
Copper and Copper alloys
6
Surface Finishes
Tables of weights for platings
Electroplating options
8
10
Packaging
11
Product Range Wires
12
13
14
15
16
Single Wires
Single Wires to DIN Standard
Single Wires to AWG Standard
Braiding Wires
Product Range Stranded Conductors
Bunched Conductors
Highly Flexible Stranded Conductors and Ropes
Concentric Stranded Conductors
Semiconcentric Stranded Conductors
LEONI Smooth-Bunch
17
18
19
20
24
25
LEONI news
LEONI Histral®
LEONI keeps you up-to-date
Edition: March 2008
Subject to change and error.
26
27
3
4
The Quality Connection
www.leoni-special-conductors.com
Quality and Environmental Management
One of LEONI’s most important success
factors is the globally consistent high
quality of its products.
LEONI – Quality Management
LEONI Draht has a universal quality management system covering all of
our worldwide manufacturing locations – ensuring that all of our products and services comply with uniform quality standards.
High speed multi-wire drawing places very stringent demands on raw
materials and machine process stability. LEONI conductors satisfy the
highest quality and reliability requirements consistent with aircraft and
aerospace technology, specialist applications in the automotive industry and high speed data transmission technology.
In LEONI 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.
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.
The Quality Connection
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5
LEONI – The Global Player
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.
Wire manufacturing sites in China, England, Germany and the US
LEONI Draht GmbH
Treuchtlinger Strasse 20
91781 Weissenburg
Germany
Phone +49 9141-918-240
Fax
+49 9141-918-101
special-conductors@leoni.com
LEONI Draht GmbH
Windorfer Strasse 1
93444 Bad Koetzting
Germany
Phone +49 9941-404-0
Fax
+49 9941-404-40
special-conductors@leoni.com
LEONI Wire (Changzhou) Ltd.
No. 209 Huashan Road
National Hi-Tech District
Changzhou 213022
Jiangsu, P.R. China
Phone +86 519-510-3456
Fax
+86 519-510-4313
E-mail
LEONI Temco Ltd.
Whimsey Industrial Estate
Cinderford, Glos. GL14 3HZ
England, UK
Phone +44 1594-820-100
Fax
+44 1594-823-691
E-mail general@leonitemco.com
LEONI Wire Inc.
301 Griffith Road
Chicopee, MA 01022
USA
Phone +1 413-593-6618
Fax
+1 413-593-6639
E-mail info@leoniwire.com
Conductors
6
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Copper and Copper Alloys
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.
In addition to copper we process a number of copper alloys for
special applications. Typical alloys include CuSn (copper/tin),
CuNi (copper/nickel), CuAg (copper/silver), LEONI Histral®,
Copper Clad Aluminium (CCA) and Copper Clad Steel (CCS).
Excerpt from EN 1977 “Copper and copper alloys – Copper drawing stock (wire rod)”
Symbol
International
specification
Material
number
Composition
Density
Melting
point
% IACS
min.
Comments
in %-by-weight
g/m3
in °C
CW 003 A
Cu ≥99.90 6
Oxygen
max. 0.040
8.9
1083
101
Electrolytic tough pitch copper with an electrical conductivity in annealed condition of ≥58.58 m/Ωmm2 at 20 °C (101 %
IACS).
Electrolytic copper
Cu-ETP1
(E-Cu)
EN 13602
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 soldering (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
6 The 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.
International Annealed Copper Standard = IACS
Electirical conductivity of copper = min. 58 m/Ωmm2 = 100 % IACS
66 Hydrogen resistance is tested and measured according to
international technical specifications. If individual customers have particular requirements these must be stipulated at the time of order.
Conductors
www.leoni-special-conductors.com
Symbol
International
specification
Material
number
Composition
Density
Melting
point
in %-byweight
g/m3
in °C
% IACS
min.
7
Comments
Copper alloys
Histral
–
–
8.9
1090
80
A high strength copper alloy, as an alternative to other cadmiumcontaining copper alloys. With an electrical conductivity of 80 % IACS
CI203
–
–
8.9
1084
80
A high strength copper alloy, as an alternative to other cadmiumcontaining copper alloys. With an electrical conductivity of 80 % IACS
CW452K
94
8.9
1100
20
Copper tin resistance alloy
with an electrical resistance of 0.11 m/Ωmm2
UNS No.
C50700
98
8.9
1100
34.5
Copper tin resistance alloy
with an electrical resistance of 0.04 m/Ωmm2
CuSn 94/6
BS EN 12166
CuSn 98/2
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
with an electrical resistivity of 0.10 m/Ωmm2
CuNi 90/10
DIN 17471
2,0811
90
8.9
1100
11.5
Copper nickel resistance alloy to DIN 17471
with an electrical resistivity of 0.15 m/Ωmm2
UNS No.
C70900
85
8.9
1100
8.6
Copper nickel resistance alloy
with an electrical resistivity of 0.20 m/Ωmm2
CuNi 85/15
CuNi 75/25
DIN 17471
2,0881
75
8.9
1150
5.75
Copper nickel resistance alloy to DIN 17471
with an electrical resistivity of 0.30 m/Ωmm2
CuNi 55/45
DIN 17471
2,0842
55
8.9
1280
3.5
Copper nickel resistance alloy to DIN 17471
with an electrical resistivity of 0.49 m/Ωmm2
in %-Cu-bydiameter
g/m3
Other material
Cu Clad
Aluminium 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
7.9
40
Composite material with Cu cladding around a steel core
and having electrical conductivity of 40 % IACS
10
Surface Finishes
8
www.leoni-special-conductors.com
Tables of weights for platings
at 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.
mm
0.050
0.064
0.070
0.080
0.090
0.100
0.114
0.120
0.127
0.130
0.140
0.150
0.160
0.180
0.200
0.220
0.226
0.250
0.254
0.260
0.280
0.300
0.320
0.360
0.400
0.450
0.500
0.600
0.650
0.700
0.750
0.800
0.850
0.900
0.950
1.000
1.150
1.250
1.300
1.400
1.450
1.500
1.600
1.700
1.800
44
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
Tin Sn
Nickel Ni
Silver Ag
g/kg
g/kg
g/kg
65.4
51.1
46.7
40.9
36.3
32.7
28.7
27.3
25.7
25.2
23.4
21.8
20.4
18.2
16.4
14.9
14.5
13.1
12.9
12.6
11.7
10.9
10.2
9.1
8.2
7.3
6.5
5.5
5.0
4.7
4.4
4.1
3.8
3.6
3.4
3.3
2.8
2.6
2.5
2.3
2.3
2.2
2.0
1.9
1.8
80.0
62.5
57.1
50.0
44.4
40.0
35.1
33.3
31.5
30.8
28.6
26.7
25.0
22.2
20.0
18.2
17.7
16.0
15.7
15.4
14.3
13.3
12.5
11.1
10.0
8.9
8.0
6.7
6.2
5.7
5.3
5.0
4.7
4.4
4.2
4.0
3.5
3.2
3.1
2.9
2.8
2.7
2.5
2.4
2.2
94.4
73.8
67.4
59.0
52.4
47.2
41.4
39.3
37.2
36.3
33.7
31.5
29.5
26.2
23.6
21.5
20.9
18.9
18.6
18.2
16.9
15.7
14.8
13.1
11.8
10.5
9.4
7.9
7.3
6.7
6.3
5.9
5.6
5.2
5.0
4.7
4.1
3.8
3.6
3.4
3.3
3.1
3.0
2.8
2.6
Surface Finishes
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9
AWG-wires, plating thicknesses according to ASTM
The table is a tool to calculate the
weight and plating thickness for tin,
nickel and silver.
Please not, that tin plated wires will not have
a plating thickness of 1 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
AWG No.
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
ASTM = American Society for Testing and Materials
10
Surface Finishes
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Electroplating
options
Electroplating options – For plated copper/wires we use tin, silver or nickel, depending on what is required from the conductor.
tin
solderability
effective protection against corrosion
good
silver
high temperature resistance (up to 200 °C)
high conductivity (Skin-effect, important
for HF-applications)
gold-plated
corrosion resistance
high bondability
chemical resistance
nickel
corrosion and temperature
resistance (up to 250 °C)
Barriers of diffusion
high
enamelled
protection and insulation for ultra-fine
wires
Temperature Ratings of conductor materials
CSA-C22.2 No. 210.2 states the following temperature ratings of conductor materials:
Temperature range max. 150 °C
plain and tin plated with single
wire Ø ≤ 0.38 mm
Copper clad steel (e.g. STAKU)
with single wire Ø ≤ 0.38 mm
Copper
Temperature range max. 200 °C
plated copper
Silver plated copper clad steel
Silver plated copper alloys
Silver
Temperature range max. 250 °C
plated copper
Nickel plated copper clad aluminium
(CCA)
Nickel plated copper clad steel (CCS)
Nickel plated high strength alloys
Nickel plated steel composites
Nickel
LEONI wires and concentric stranded conductors are available bare and with a range of surface finishes
manufactured to industry, national and international standards as well as to individual customer specifications.
Packaging
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11
Packaging
Type
d1
d3
l2
l1
d2
Ø of
flange
Ø of
bore
Traverse
Overall
Width
Ø of
barrel
Capacity
mm
mm
mm
approx.
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
K 2500
K 2506
K 2534
K 3550
K 4007
K 5600
K 5606
K 6307
160
250
250
250
355
400
555
560
630
22
22
127
127
36
32.7
127
127
127
128
160
160
160
160
205
280
380
380
160
200
200
200
200
243
355
480
430
100
160
160
160
224
250
355
315
320
8
20
25
25
40
70
180
250
350
Type
d1
d3
l2
l1
d2
Ø of
flange
Ø of
bore
Traverse
Overall
Width
Ø of
barrel
Capacity
mm
mm
mm
approx.
kg
Pay off pack
O/All Diameter
(POP)
508 mm
Steel reels
B 4006
400
127
250
B 5600
560
127
355
B 6300
630
127
400
Sheet metal reels
B 6305
630
127
435
Wooden reels
G 0800
800
81
400
G 1000
1000
80
560
Plastic braider bobbins
FSP75
75
10
50
K0751
FSP80/
80
10
80
K0804
WSN01/16 cc 66
16
69
K0660
WSN02/24 cc 66
16
104
K0661
O/All Height
150 mm
35
280
395
475
224
315
355
115
280
400
475
355
400
550
700
400
500
750
1000
100
24
1.5
100
23
2.0
80
34
1.0
116
34
1.6
The chart depicts the most common reel sizes.
Special types are available upon request.
Note: The net weights given for DIN reels are nominal capacities.
l1
l2
The main dimensions of a reel:
d1 ➔ Flange diameter
d3 ➔ Bore diameter
d3 d2 d1
Additionally useful are:
l2 ➔ Traverse
l1 ➔ Overall Width
d2 ➔ Barrel diameter
12
Wires
Product Range Wires
Single Wires
Single Wires to DIN Standard
Single Wires to AWG Standard
Multi Wires
Braiding Wires
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Wires
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Wires
We manufacture copper wires in line with international
standards and individual customer specifications.
Product Range
In addition to CU-ETP1 and CU-OF1 in bare, tin plated, nickel plated,
silver plated or gold plated finish, we also process high strength copper
alloys.
Delivery
Wires can be supplied as:
n
n
n
Single wire
Reel weight range from 8 to 200 kg.
Range of single wire diameters: 0.05 mm–2.7 mm
Multi wire
The reel weight ranges from 25 to 500 kg.
Range of single wire diameters: 0.05 mm–0.52 mm
Braiding wire
The reel weight ranges from 0.5 to 3 kg.
Range of single wire diameters: 0.05 mm–0.52 mm
Common constructions: 2–16 wires
For wire specifications please refer to the tables
on the following pages.
13
Wires
14
www.leoni-special-conductors.com
Single Wires
to DIN Standard
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).
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
0.00196
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
0.0175
0.0278
0.0353
0.0447
0.0566
0.0699
0.0878
0.109
0.137
0.179
0.226
0.280
0.351
0.437
0.548
0.694
0.882
1.12
1.42
1.75
2.19
2.78
3.53
3.93
4.47
5.05
5.66
6.31
6.99
7.86
8.78
9.75
10.90
12.20
13.70
15.70
17.90
20.20
22.60
8.80
5.53
4.35
3.43
2.71
2.196
1.750
1.402
1.120
0.8573
0.6774
0.5487
0.4375
0.3512
0.2799
0.2213
0.1743
0.1372
0.1084
0.0878
0.0700
0.0553
0.04354
0.03902
0.03429
0.03038
0.02710
0.02432
0.02195
0.01954
0.01750
0.01577
0.01405
0.01260
0.01120
0.00976
0.00858
0.00760
0.00677
57.10
36.00
28.30
22.40
17.67
14.31
11.39
9.17
7.30
5.59
4.42
3.57
2.85
2.29
1.825
1.441
1.134
0.893
0.704
0.571
0.457
0.36
0.283
0.254
0.224
0.198
0.177
0.158
0.143
0.127
0.114
0.103
0.0917
0.082
0.073
0.0637
0.0559
0.0495
0.0442
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
✖
m
Calculated with a conductivity of 58 Ω · mm2 at 20 °C.
The maximum resistance value in the case of a diameter using the full acceptable negative
m
deviation range must be suitable for a conductivity of at least 57.5 Ω · mm2 at 20 °C.
Wires
www.leoni-special-conductors.com
15
Single Wires
to AWG Standard
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”.
Diameter
Cross-section
AWG
cmils
Size
mils
mm
mm
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
72.0
64.1
57.1
50.8
45.3
40.3
35.9
32.0
28.5
25.3
22.6
20.1
17.9
15.9
14.2
12.6
11.3
10.0
8.9
8.0
7.1
6.3
5.6
5.0
4.5
4.0
3.5
3.1
2.8
2.5
2.2
2.0
1.8
1.6
1.4
1.2
1.1
0.99
1.829
1.628
1.450
1.290
1.151
1.024
0.912
0.813
0.724
0.643
0.574
0.510
0.455
0.404
0.361
0.320
0.287
0.254
0.226
0.203
0.180
0.160
0.142
0.127
0.114
0.102
0.089
0.079
0.071
0.064
0.056
0.051
0.045
0.040
0.036
0.032
0.028
0.025
2.625
2.082
1.652
1.307
1.039
0.821
0.654
0.517
0.411
0.324
0.259
0.205
0.162
0.128
0.102
0.0806
0.0648
0.0507
0.0401
0.0324
0.0255
0.0201
0.0159
0.0127
0.0102
0.0081
0.0062
0.0049
0.0040
0.0032
0.0025
0.0021
0.0016
0.0013
0.00099
0.00078
0.00062
0.00050
Conversion factors:
mils x 0.0254
= mm
cmils x 0.0005067 = mm2
sq.inch x 645.16
= mm2
2
5180
4110
3260
2580
2050
1620
1290
1020
812
640
511
404
320
253
202
159
128
100
79.20
64.00
50.40
39.70
31.40
25.00
20.20
16.00
12.20
9.61
7.84
6.25
4.84
4.00
3.10
2.46
1.96
1.54
1.23
0.98
mm x 39.37 = mils
mm2 x 1973.55 = cmils
mm2 x 0.00155 = sq.inch
sq. inch
0.00407
0.00323
0.00256
0.00203
0.00161
0.00128
0.00101
0.000804
0.000638
0.000503
0.000401
0.000317
0.000252
0.000199
0.000158
0.000125
0.0001
0.0000785
0.0000622
0.0000503
0.0000396
0.0000312
0.0000246
0.0000196
0.0000159
0.0000126
0.00000962
0.00000755
0.00000616
0.00000491
0.0000038
0.00000314
0.00000243
0.00000194
0.00000154
0.00000121
0.000000968
0.00000077
Weight
Yield
approx. kg/km
approx. km/kg
23.40
18.50
14.70
11.60
9.24
7.32
5.81
4.61
3.66
2.88
2.30
1.82
1.44
1.14
0.908
0.715
0.575
0.450
0.357
0.288
0.227
0.179
0.141
0.113
0.0912
0.0721
0.0552
0.0433
0.0353
0.0282
0.0218
0.0180
0.0140
0.0111
0.00883
0.00693
0.00556
0.00440
0.0428
0.054
0.0681
0.086
0.108
0.137
0.172
0.217
0.273
0.347
0.435
0.549
0.693
0.878
1.10
1.40
1.74
2.22
2.80
3.47
4.40
5.59
7.08
8.88
11.00
13.90
18.10
23.10
28.30
35.50
45.90
55.50
71.70
90.10
113.00
144.00
180.00
228.89
16
Wires
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Braiding Wires
Braiding wires for cable screening.
Production programme
In order to better reflect customer requirements LEONI has extended
its multi wire product range to include pre-wound braid bobbins.
LEONI‘s long known multi wire competency, high quality wires with
very narrow diameter and elongation tolerances, means that customers can expect to manufacture excellent braids. The braiding wires
are available across the full range of 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
Type
d1
d3
l2
l1
d2
Flange diameter
Bore diameter
Traverse
Overall width
Barrel diameter
Capacity (max.)
mm
mm
mm
ca. g
75
80
66
66
10
10
16
16
24
23
34
34
1500
2000
1000
1600
Plastic braid bobbins
FSP75 / K0751
FSP80 / K0804
WSN01 / K0660
WSN02 / K0661
50
80
69
104
100
100
80
116
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Product Range
Stranded Conductors
Bunched Conductors
Highly Flexible Stranded Conductors and Ropes
Concentric Stranded Conductors
Semiconcentric Stranded Conductors
LEONI Smooth-Bunch
Stranded Conductors
17
Stranded Conductors
18
www.leoni-special-conductors.com
Bunched Conductors
This type of conductor is made up of bunched multi-wires.
The wires are twisted together in a random pattern.
Standard bunched conductors are widely used in the cable industry.
Construction
The average diameter of a bunched conductor can be calculated
using the table and the formula: D = d • f
(D = Ø of bunched conductor, d = Ø of single wire)
n = no. of wires
f = multiplication factor (average)
n
1
2
3
4
5
7
10
12
14
16
Example: Stranded conductor 16 x 0.20 mm (= 0.50 mm2)
D = 0.20 x 4.7
D = 0.94 mm
f
1.00
2.00
2.15
2.41
2.70
3.00
4.00
4.15
4.41
4.70
n
19
24
26/27
28/30
31/32/33
37
44
48
52
56
f
5.00
6.00
6.15
6.41
6.70
7.00
8.00
8.15
8.41
8.70
n
61
70
75
80
85
91
102
108
114
120
f
9.00
10.00
10.15
10.41
10.70
11.00
12.00
12.15
12.41
12.70
Typical constructions for multi-wire, fine-wire and ultrafine-wire bunched conductors
AWG ➔
Cross-section
0.1
0.14
0.25
0.34
0.38
0.5
0.75
1
1.5
2.5
4
6
10
16
25
35
50
70
95
120
150
185
240
Ø of wire in mm ➔
44
41
38
36
34
32
30
0.05
51 x 0.05
72 x 0.05
128 x 0.05
173 x 0.05
192 x 0.05
256 x 0.05
385 x 0.05
511 x 0.05
770 x 0.05
1274 x 0.05
2016 x 0.05
3192 x 0.05
0.07
25 x 0.07
36 x 0.07
66 x 0.07
88 x 0.07
88 x 0.07
130 x 0.07
196 x 0.07
259 x 0.07
392 x 0.07
651 x 0.07
1036 x 0.07
1548 x 0.07
2556 x 0.07
4116 x 0.07
0.10
12 x 0.10
18 x 0.10
32 x 0.10
42 x 0.10
48 x 0.10
64 x 0.10
96 x 0.10
128 x 0.10
189 x 0.10
320 x 0.10
511 x 0.10
756 x 0.10
1281 x 0.10
2037 x 0.10
3213 x 0.10
4410 x 0.10
6370 x 0.10
8917 x 0.10
12348 x 0.10
15435 x 0.10
19110 x 0.10
23373 x 0.10
30870 x 0.10
0.127
8 x 0.127
11 x 0.127
20 x 0.127
27 x 0.127
30 x 0.127
39 x 0.127
59 x 0.127
79 x 0.127
118 x 0.127
196 x 0.127
322 x 0.127
476 x 0.127
784 x 0.127
1260 x 0.127
0.16
0.20
0.254
7 x 0.16
12 x 0.16
17 x 0.16
19 x 0.16
25 x 0.16
37 x 0.16
50 x 0.16
75 x 0.16
124 x 0.16
196 x 0.16
294 x 0.16
504 x 0.16
798 x 0.16
8 x 0.20
11 x 0.20
12 x 0.20
16 x 0.20
24 x 0.20
32 x 0.20
48 x 0.20
80 x 0.20
118 x 0.20
189 x 0.20
315 x 0.20
7 x 0.254
8 x 0.254
10 x 0.254
15 x 0.254
19 x 0.254
30 x 0.254
50 x 0.254
79 x 0.254
Stranded Conductors
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19
Highly Flexible Stranded
Conductors and Ropes
Highly flexible round concentric stranded conductors
and ropes
These products have high flexibility and are suitable for cables
used in dynamic environments.
Construction
The examples shown in the table below can be manufactured both
as bunched conductors and as 7 way ropes.
n lay length of bunched conductors
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
Nominal
cross-section
Min. number
of wires
mm2
Ø of wire 0.05 mm
0.020
10
0.029
15
0.041
21
0.059
30
0.079
40
0.100
51
0.140
72
0.200
102
0.250
128
0.350
180
0.500
266
0.750
385
1.000
525
Ø of wire 0.07 mm
0.081
21
0.140
36
0.250
66
0.350
90
0.500
130
0.750
195
1.000
259
Product Range
Available with bare, silver, nickel or tin plated copper wires.
Ø of stranded
conductor
Weight
Nominal
cross-section
mm
kg/km
mm2
0.18
0.22
0.26
0.31
0.36
0.40
0.50
0.60
0.65
0.75
0.95
1.15
1.35
0.175
0.262
0.367
0.524
0.700
0.890
1.260
1.780
2.240
3.240
4.750
7.060
9.390
0.36
0.50
0.65
0.75
0.95
1.10
1.35
0.719
1.240
2.230
3.080
4.550
6.910
9.310
Min. number
of wires
1.50
392
2.50
650
4.00
1050
6.00
1575
Ø of wire 0.1 mm
0.50
64
0.75
96
1.00
126
1.50
189
2.50
322
4.00
511
6.00
777
10.00
1281
16.00
2058
25.00
3185
35.00
4508
50.00
6370
70.00
8918
100.00
12348
120.00
15336
150.00
19110
185.00
23373
240.00
30870
Ø of stranded
conductor
Weight
mm
kg/km
1.65
2.25
2.90
3.60
14.10
23.40
37.80
56.60
0.95
1.15
1.30
1.65
2.25
2.90
3.60
4.80
6.10
7.60
9.20
10.80
12.80
15.00
16.72
18.66
20.64
23.72
4.56
6.84
9.13
13.70
23.40
37.10
56.50
94.90
153.00
236.00
334.00
472.00
661.00
879.10
1154.10
1461.20
1818.60
2473.00
20
Stranded Conductors
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Concentric Stranded
Conductors
In concentric stranded conductors each single wire
occupies a specific position within the formation,
guaranteeing a regular construction.
Product Range / Construction
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.
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 electronic wiring. Due to the exact position of the single wires the strands
have a very even surface and a constant diameter.
They are ideally suited for thin wall insulation using higher
value insulation materials.
19-strand (1 + 6 + 12)
37-strand (1 + 6 + 12 + 18)
Stranded Conductors
www.leoni-special-conductors.com
LEONI produces four types of concentric strands.
Unilay
➔ Unilay Concentric
n
n
n
n
n
➔ Unidirectional
n
Concentric
n
n
same lay direction
same lay length
manufactured in one working step
nearly round construction
Direction
of stranding
same lay direction
different lay lengths for each
working step
manufactured in two working steps
more round than unilay concentric
Different lay lengths impact on the roundness of the strand
Longer lay length = hexagonal / shorter lay length = circular
True concentric
➔ Equilay Concentric
n
(reversed lay stranding
n
or SZ stranding)
n
n
n
➔ Conventional
n
Concentric
n
n
Concentric stranded conductors with same lay
direction are generally known as Unilay.
Concentric stranded conductors with different
lay directions (reversed or S/Z lay) are known as
True concentric.
different lay directions
same lay length
manufactured in two working steps
very round construction
different lay directions
different lay lengths for each
working step
manufactured in two working steps
very round construction
Reversed lay or SZ stranding
S ➔ left hand lay
Z ➔ right hand lay
Direction
of stranding
21
Stranded Conductors
22
www.leoni-special-conductors.com
Concentric
Stranded Conductors
Concentric and electrical conductors
Type II to ASTM B 286.
Product Range / Construction
Available as plain, tin plated, silver plated and nickel plated copper
wires. Alternative wire sizes are available subject to applicable minimum order quantities.
7 wire strands are particularly suited to high frequency data
cables.
Electrical conductors Type II in to ASTM B 286 (Examples)
AWG No.
Nom.
cross-section
Construction
No. of wires x Ø of wires
Ø of stranded
conductor
Weight
Yield
mm
kg/km
km/kg
7 x 0.079
7 x 0.102
7 x 0.127
7 x 0.160
7 x 0.203
7 x 0.254
7 x 0.320
7 x 0.404
0.28
0.33
0.41
0.51
0.63
0.78
0.99
1.27
0.315
0.524
0.813
1.290
2.080
3.250
5.160
8.220
3.175
1.908
1.230
0.775
0.481
0.308
0.194
0.122
19 x 0.071
19 x 0.079
19 x 0.102
19 x 0.127
19 x 0.160
19 x 0.203
19 x 0.254
19 x 0.287
19 x 0.361
19 x 0.455
0.35
0.43
0.56
0.68
0.84
1.06
1.32
1.50
1.85
2.36
0.07
0.854
1.44
2.23
3.53
5.68
8.93
11.36
17.86
28.57
1.531
1.171
0.694
0.448
0.283
0.176
0.112
0.088
0.056
0.035
37 x 0.25
37 x 0.32
37 x 0.40
1.71
2.18
2.75
17.4
26.3
43.6
0.057
0.038
0.023
mm2
7-wire conductors
32
30
28
26
24
22
20
18
0.034
0.06
0.09
0.14
0.23
0.35
0.56
0.90
19-wire conductors
30
28
26
24
22
20
18
16
14
12
0.072
0.093
0.16
0.24
0.38
0.62
0.96
1.23
1.95
3.09
37-wire concentric stranded conductors
14
12
10
1.87
2.97
4.53
Stranded Conductors
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23
Concentric
Stranded Conductors
Concentric stranded conductors,
metric dimensions.
Metric dimensions (example)
Nominal
cross-section
Construction no.
of wires x Ø of wire
mm2
Ø of conductor
Weight
Yield
mm
kg/km
km/kg
0.21
0.30
0.39
0.45
0.54
0.60
0.75
0.90
1.20
1.37
1.53
0.247
0.504
0.852
1.130
1.585
2.020
3.150
4.540
8.060
10.130
12.727
4.049
1.984
1.174
0.885
0.631
0.495
0.317
0.220
0.124
0.099
0.079
0.25
0.50
0.75
0.90
1.00
1.50
1.85
2.00
2.28
2.55
0.3
1.35
3.03
4.35
5.38
12.20
18.52
21.28
27.78
34.48
3.001
0.74
0.33
0.230
0.186
0.082
0.054
0.047
0.036
0.029
2.6
4.2
6.6
8.4
13.3
16.2
21.4
26.6
35.6
42.5
0.385
0.239
0.152
0.119
0.075
0.062
0.047
0.038
0.029
0.024
7-wire conductors
0.028
0.055
0.093
0.12
0.18
0.22
0.34
0.50
0.88
1.14
1.42
7 x 0.071
7 x 0.10
7 x 0.13
7 x 0.15
7 x 0.18
7 x 0.20
7 x 0.25
7 x 0.30
7 x 0.40
7 x 0.455
7 x 0.51
19-wire conductors
0.04
0.15
0.33
0.48
0.60
1.34
2.04
2.39
3.09
3.88
19 x 0.05
19 x 0.10
19 x 0.15
19 x 0.18
19 x 0.20
19 x 0.30
19 x 0.37
19 x 0.40
19 x 0.455
19 x 0.51
37-wire concentric stranded conductors
0.30
0.47
0.75
1.00
1.50
2.00
2.50
3.00
4.00
4.50
37 x 0.102
37 x 0.127
37 x 0.160
37 x 0.180
37 x 0.226
37 x 0.250
37 x 0.287
37 x 0.320
37 x 0.370
37 x 0.404
0.69
0.88
1.12
1.26
1.58
1.75
2.01
2.24
2.59
2.83
37 wire strands may be used in thin
wall insulation constructions.
“LEONI Smooth-Bunch” with its extremely
round construction offer an excellent alternative to traditional 37 wire strands (see
page 25).
24
Stranded Conductors
www.leoni-special-conductors.com
Semi-concentric
Conductors
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.
Examples of semi-concentric conductor construction
12-wire
16-wire
Semi-concentric conductors are suited especially to cables
with thin-walled insulation.
24-wire
30-wire
Conductor examples
Nominal cross section
Construction
No. of wires x wire dia.
Conductor dia.
nom.
Weight
nom.
mm
kg/km
21 x 0.127
16 x 0.203
24 x 0.203
32 x 0.203
30 x 0.254
50 x 0.254
56 x 0.30
84 x 0.30
80 x 0.404
0.66
0.93
1.13
1.31
1.59
2.05
2.56
3.13
4.12
2.415
4.802
7.334
9.949
14.447
23.357
36.453
54.650
94.448
mm2
0.25
0.5
0.75
1
1.5
2.5
4
6
10
Alternatively, LEONI offers this product
range with particularly round
“LEONI Smooth-Bunch” conductor
construction (see page 25).
Stranded Conductors
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LEONI Smooth-Bunch
Using a special manufacturing process “LEONI SmoothBunch” conductors have a compact and precise round
construction.
Product Range / Construction
Available in plain, tin plated, silver plated and nickel plated copper
wire. Standard constructions are listed below. Different cross-sections
can be supplied if required.
“LEONI Smooth-Bunch” conductors are particularly suitable for thin
wall extrusion using high value insulation materials. Cables made using
these conductors can have the smallest possible overall diameters.
16-wires
24-wires
Examples of
smooth bunch
constructions
Example construction types
Nominal
cross-section
Construction
(No. of wires x Ø of wires)
Ø of conductor
(Nom. value)
Weight
(Nom. value)
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
mm2
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
84-wires
25
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LEONI news
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LEONI Histral®
RoHS compliant
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.
LEONI Histral® is a registered trademark of LEONI Draht GmbH.
Key benefits:
High tensile strength
in soft condition Rm > 415 N/mm2
elongation >7 %
in hard condition Rm > 700 N/mm2
High conductivity
in soft condition ≥ 80 % according to ASTM B 624
in hard condition > 70 % IACS
Excellent in flexlife properties
Good solderability
High temperature resistance
retains tensile strength up to 400 °C
Good corrosion resistance
More detailled information on LEONI Histral®
is provided in our Histral brochure which is
available for download under
www.leoni-special-conductors.com
EU Prohibits Use of Cadmium
Until now copper cadmium has been used for electrical conductors
which have to exhibit high mechanical strength. Since EU law has now
banned the use of cadmium in any form in motor vehicles and domestic appliances, LEONI has developed its own high strength cadmium
free alternative alloy, which is free of harmful substances –
LEONI Histral®.
LEONI Histral® is currently available as single wire, strand, braid or tinsel
using wires as fine as 0.08 mm. LEONI Histral® is available in both hard
and soft condition, with a bare, nickel and silver surface.
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LEONI keeps you
up-to-date
We offer high quality electrical conductors for cable engineering as well
as for special applications in electrical engineering and in electronics.
Our engineers are constantly working on ways to improve our products,
extending our product range with new materials and constructions and
developing innovative solutions to satisfy the many and varied needs of
the cable industry.
The LEONI Special Conductors business unit is the right partner for special
constructions. Please feel free to contact us.
In addition we would recommend that you visit our web site
www.leoni-special-conductors.com
Our newsletter will inform you either by post or e-mail about the most
recent developments in the wire marketplace and in our business unit.
Please register at special-conductors@leoni.com so that you will not
miss any updates.
LEONI news
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
E-mail special-conductors@leoni.com
www.leoni-special-conductors.com