Copper Solutions - LEONI

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.


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.

www.leoni-copper-solutions.com

2

Content



Copper Solutions

Product range

Copper Solutions

Product information


3

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 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.


4

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.



5

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


6 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.


7

Copper Solutions Product range


8

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 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.


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


10 Product range

Single wires to DIN standardDIN dimensions for single copper wires in acc. with DIN 46 431


11

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.


12

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


Overall-Ø Weight ±12 %


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


13Product range

Ropes with integral strain membersE-Cu round, stranded copper flexible

with integral strain members for high tensile strength.


14

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 %



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


15

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)


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 %


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 %


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.


17

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 %


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.


18

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 %


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


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


x thickness

Construc-tion

Ø of wire Weight


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


19

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


20

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


x thickness

Construction Ø of wire± 0.003

Weight± 12 %


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


x thickness

Construc-tion

Ø of wire Weight± 12 %


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)


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


22

Material


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.


23

Material


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.


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.


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!


26 Product information

Copper Solutions Product information


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 electrical 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 specifications. 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



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.



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



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



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]


LEONI Draht GmbH

Business Unit Copper Solutions

Copper Solutions - LEONI

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