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Coroplast experience and innovation from one single provider Coroplast is a traditional, family-owned company that has built its reputation on flexibility, innovative strength and reliability since 1928. Production facilities in Germany, Poland, Tunisia and China, plus over twenty repres entative offices and service centres all over the world, demonstrate our global presence and guarantee optimum customer service. Over recent years, Coroplast has successfully expanded its Wire & Cable divisions operations in the automotive market segment. It has developed modern insulation and sheathing materials that are in line with customer requirements and have contributed to the successful extension of the wire & cable product portfolio. Today, Coroplast is provider of a comprehensive range of modern wires and cables. The new Coroflex TT3 automotive wires for continuous use at operating temperatures of up to 125 C confirm Coroplasts first mover status in the development of forward-looking product technology. This new generation of automotive wires are suitable for vehicles with hybrid power trains and for fuel cell wiring applications. The new Coroflex TT3 wires are a thermoplastic alternative to cross-linked wires because they render energy-intensive cross-linking unnecessary. Sustained energy savings are not the only ecological advantage of this new generation of wires. The Coroflex TT3 wires are lighter than other wires in the temperature class of up to 125 C. Coroflex TT3 wires already support efforts to reduce the weight of vehicle wiring systems and therefore cut back on fuel consumption and reduce CO2 emissions. All Coroflex TT3 insulating materials are recyclable.

Our forward-looking insulation and sheathing materials are suitable for applications in extreme operating temperatures ranges from 40 C to +250 C. The automotive industry has diverse system requirements for cables and wires in addition to pure temperature loads. Above all, the vehicle wires and cables have to be safe and efficient in terms of design, processing and installation. This brochure provides you with an initial overview of the Coroplast Automotive Wires and Cables product portfolio. Our R&D and delivery scope go far beyond the content of this brochure. Please contact us to discuss any queries or specific requirements and we will be happy to advise you on customised solutions. Coroplast your innovative development supplier

Quality philosophy The Coroplast product portfolio and production programme offer comprehensive depth and range. They extend from the compounding of insulation materials to system responsibility for entire components such as vehicle wheelhouse wiring. This depth of added value means that the quality assurance team not only has to ensure the quality of individual products, but also maximum quality levels throughout the entire production and process chain at all production sites. Our quality philosophy supports the following principles: Our customers needs have utmost priority Our processing times have to be much shorter than those of our competitors Our products and services must always be of first-rate quality Coroplast is a development company and a solution provider a technical innovator with attractive prices Keeping investments at a high level, irrespective of economic trends Coroplast always has been and always will be a pioneer in the use of environmentally-friendly raw materials Our employees are our companys most valuable asset, and we always promote their further training and motivation Coroplast is a brand that stands for reliability, consistency and continuous improvement Coroplast obtains annual ISO/TS 16949 certification. The current certificate is published on our website at www.coroplast.de.

Quality management system DQS-certified according to ISO/TS 16949

Motor Management

Driving Distance Control

Gearbox Management

Global Positio n System

Audio/V ideo System

Lightin g System

Battery Management

Brake Control Airbag/ Sidebag Park Distanc e Control

Body Control

Coroplast A development supplier with a complete product range

Contents

Page

PVC-insulated automotive wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 PVC-insulated automotive wires, twisted cores. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 PA-/TPE-insulated automotive wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 PVC- and PUR-sheathed cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Coroflex TT3 automotive wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12, 13 Sheathed cables, shielded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 PUR-sheathed cables for ABS application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Silicone-insulated automotive wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Silicone-insulated battery and generator cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 High voltage cables for hybrid and electric vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18, 19 ETFE- and FEP-insulated automotive wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 High temperature sheathed cables for engine compartment and gear box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Sheathed cables for infotainment application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22, 23 High frequency filter cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24, 25 Aluminium cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 High-Speed data transmission in vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Nomenclature for automotive wires and cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Insulation and sheath materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Packaging units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30, 31

PVC-insulated automotive wires

Application: Passenger and engine compartment Design of electrical distribution system and wiring harness Operating temperature range according to ISO 6722 40 C to +105 C/3000 h 40 C to +125 C/3240 h

PVC automotive wires with reduced insulation wall thickness (40 C to +105 C/3000 h)
Designation Cross-section Conductor design Type A 7 x max. 0.21 mm 7 x max. 0.26 mm 19 x max. 0.19 mm 19 x max. 0.23 mm 19 x max. 0.26 mm 19 x max. 0.32 mm 19 x max. 0.41 mm
2 2

Type B 12 x max. 0.21 mm 16 x max. 0.21 mm 24 x max. 0.21 mm 32 x max. 0.21 mm 30 x max. 0.26 mm 50 x max. 0.26 mm 56 x max. 0.31 mm 84 x max. 0.31 mm 80 x max. 0.41 mm 126 x max. 0.41 mm

Insulation Outer wall thickness diameter [mm] [mm] 1.2 ( 0.1) 1.3 ( 0.1) 1.4 ( 0.2) 1.6 ( 0.2) 1.9 ( 0.2) 2.1 ( 0.2) 2.4 ( 0.2) 3.0 ( 0.3) 3.7 ( 0.3) 4.3 ( 0.3) 6.0 ( 0.4) 7.9 ( 0.4)

Conductor resistance bare [Ohm/km] max. 84.4 max. 54.4 max. 54.4 max. 37.1 max. 24.7 max. 18.5 max. 12.7 max. 7.6 max. 4.71 max. 3.14 max. 1.82 max. 1.16 tinned [Ohm/km] max. 86.5 max. 55.5 max. 55.5 max. 38.2 max. 25.4 max. 19.1 max. 13.0 max. 7.82 max. 4.85 max. 3.23 max. 1.85 max. 1.18

FLRY 0.22 mm2 FLRY 0.35 mm2 FLRY 0.5 mm2 FLRY 0.75 mm2 FLRY 1.0 mm2 FLRY 1.5 mm FLRY 4.0 mm
2

min. 0.20 min. 0.20 min. 0.20 min. 0.22 min. 0.24 min. 0.24 min. 0.24 min. 0.28 min. 0.32 min. 0.32 min. 0.48 min. 0.52

FLRY 2.5 mm2

2

FLRY 6.0 mm2 FLRY 10.0 mm FLRY 16.0 mm

Battery and generator cables, PVC-insulated (40 C to +105 C/3000 h)

Designation Cross-section Conductor design (exemplary) Type f (fine wires) FLY 16 mm2 FLY 25 mm FLY 35 mm FLY 70 mm
2 2

Insulation Outer wall thickness diameter [mm] min. 0.80 min. 1.05 [mm] max. 8.3 max. 10.4 max. 11.6 max. 13.5 max. 15.5 max. 18.0

Conductor resistance bare [Ohm/km] max. 1.160 max. 0.743 max. 0.527 max. 0.368 max. 0.259 max. 0.196 tinned [Ohm/km] max. 1.180 max. 0.757 max. 0.538 max. 0.375 max. 0.264 max. 0.200

Type ff (fine wires) 448 x max. 0.21 mm 783 x max. 0.21 mm

126 x max. 0.41 mm 196 x max. 0.41 mm 276 x max. 0.41 mm 396 x max. 0.41 mm 360 x max. 0.51 mm 457 x max. 0.51 mm

1107 x max. 0.21 mm min. 1.05 1592 x max. 0.21 mm min. 1.20 1427 x max. 0.26 mm min. 1.20 1936 x max. 0.26 mm min. 1.30

FLY 50 mm2
2

FLY 95 mm2

PVC-insulated automotive wires, twisted cores

Application: Passenger and engine compartment Design of electrical distribution system and wiring harness Operating temperature range according to ISO 6722 40 C to +105 C/3000 h 40 C to +125 C/3240 h

PVC automotive wires with reduced insulation wall thickness (40 C to +105 C/3000 h)
Selection table twisted cores, e.g. 2 to 6 twisted cores Designation Cross-section FLRY 0.22 mm2 FLRY 0.35 mm2 FLRY 0.5 mm2 FLRY 0.75 mm2 FLRY 1.0 mm2 FLRY 1.5 mm FLRY 4.0 mm
2

Type A

Conductor design Type B 12 x max. 0.21 mm 16 x max. 0.21 mm 24 x max. 0.21 mm 32 x max. 0.21 mm 30 x max. 0.26 mm 50 x max. 0.26 mm 56 x max. 0.31 mm 84 x max. 0.31 mm

2-wires [mm] ca. 2.3 ca. 2.5 ca. 2.7 ca. 3.0 ca. 3.6 ca. 4.0 ca. 4.6 ca. 5.8 ca. 7.2 ca. 8.3

Diameter above the strand 3-wires 4-wires 5-wires [mm] ca. 2.5 ca. 2.7 ca. 2.9 ca. 3.2 ca. 3.9 ca. 4.3 ca. 5.0 ca. 6.3 ca. 7.8 ca. 9.0 [mm] ca. 2.8 ca. 3.0 ca. 3.3 ca. 3.6 ca. 4.3 ca. 4.8 ca. 5.5 ca. 7.0 ca. 8.7 ca. 10.0 [mm] ca. 3.1 ca. 3.4 ca. 3.6 ca. 4.1 ca. 4.9 ca. 5.4 ca. 6.2 ca. 7.8 ca. 9.7 ca. 11.2

6-wires [mm] ca. 3.5 ca. 3.8 ca. 4.1 ca. 4.5 ca. 5.4 ca. 6.0 ca. 6.9 ca. 8.7 ca. 10.8 ca. 12.5

7 x max. 0.21 mm 7 x max. 0.26 mm 19 x max. 0.19 mm 19 x max. 0.23 mm 19 x max. 0.26 mm 19 x max. 0.32 mm 19 x max. 0.41 mm

FLRY 2.5 mm2

2

FLRY 6.0 mm2

The table provides design examples with calculated diameter above the strand. Bunch strand products are always according to the customer requirements. Strand lay lengths are specified according to application. Please contact us for details.

PA-/TPE-insulated automotive wires

Application: Passenger and engine compartment Fuel tank gauge unit Door and tailgate wiring Operating temperature range according to ISO 6722 40 C to +100 C/3000 h (FLR4Y) 40 C to +125 C/3000 h (FLR31Y)

PA-automotive wires with reduced insulation wall thickness (40 C to +100 C/3000 h)
Designation Cross-section Type A FLR4Y 0.22 mm2 FLR4Y 0.35 mm2 FLR4Y 0.5 mm2 FLR4Y 0.75 mm FLR4Y 1.0 mm2 FLR4Y 1.5 mm FLR4Y 4.0 mm
2 2

Conductor design Type B

Insulation wall thickness [mm]

Outer diameter

Conductor resistance bare [Ohm/km] max. 84.4 max. 54.4 max. 54.4 max. 37.1 max. 24.7 max. 18.5 max. 12.7 max. 7.6 max. 4.71 max. 3.14 tinned [Ohm/km] max. 86.5 max. 55.5 max. 55.5 max. 38.2 max. 25.4 max. 19.1 max. 13.0 max. 7.82 max. 4.85 max. 3.23

[mm] 1.2 ( 0.1) 1.3 ( 0.1) 1.4 ( 0.2) 1.6 ( 0.2) 1.9 ( 0.2) 2.1 ( 0.2) 2.4 ( 0.2) 3.0 ( 0.3) 3.7 ( 0.3) 4.3 ( 0.3)

7 x max. 0.21 mm 7 x max. 0.26 mm 19 x max. 0.19 mm 19 x max. 0.23 mm 19 x max. 0.26 mm 19 x max. 0.32 mm 19 x max. 0.41 mm

12 x max. 0.21 mm 16 x max. 0.21 mm 24 x max. 0.21 mm 32 x max. 0.21 mm 30 x max. 0.26 mm 50 x max. 0.26 mm 56 x max. 0.31 mm 84 x max. 0.31 mm

min. 0.20 min. 0.20 min. 0.20 min. 0.22 min. 0.24 min. 0.24 min. 0.24 min. 0.28 min. 0.32 min. 0.32

FLR4Y 2.5 mm2

2

FLR4Y 6.0 mm2

TPE-insulated automotive wires (40 C to +125 C/3000 h)

Designation Cross-section Conductor design Type f (fine wires) Type ff (fine wires) 65 x max. 0.08 mm 88 x max. 0.08 mm 64 x max. 0.11 mm 96 x max. 0.11 mm 126 x max. 0.11 mm 192 x max. 0.11 mm 140 x max. 0.16 mm 216 x max. 0.16 mm 340 x max. 0.16 mm Insulation wall thickness [mm] min. 0.20 min. 0.20 min. 0.22 min. 0.24 min. 0.24 min. 0.24 min. 0.28 min. 0.32 min. 0.32 Outer diameter [mm] 1.3 ( 0.1) 1.4 ( 0.2) 1.6 ( 0.2) 1.9 ( 0.2) 2.1 ( 0.2) 2.4 ( 0.2) 3.0 ( 0.3) 3.7 ( 0.3) 4.3 ( 0.3) Conductor resistance bare [Ohm/km] max. 84.4 max. 54.4 max. 37.1 max. 24.7 max. 18.5 max. 12.7 max. 7.6 max. 4.71 max. 3.14 tinned [Ohm/km] max. 86.5 max. 55.5 max. 38.2 max. 25.4 max. 19.1 max. 13.0 max. 7.82 max. 4.85 max. 3.23

FLR31Y 0.22 mm2 32 x max. 0.11 mm FLR31Y 0.35 mm2 43 x max. 0.11 mm FLR31Y 0.5 mm FLR31Y 1.0 mm FLR31Y 2.5 mm FLR31Y 6.0 mm
2

28 x max. 0.16 mm 52 x max. 0.16 mm 82 x max. 0.16 mm 74 x max. 0.21 mm 118 x max. 0.21 mm 189 x max. 0.21 mm

FLR31Y 0.75 mm2 42 x max. 0.16 mm

2

FLR31Y 1.5 mm2

2

FLR31Y 4.0 mm2

2

10

PVC- and PUR-sheathed cables

Application: Passenger and commercial vehicles passenger and engine compartments Sensor and control cables; power supply Operating temperature range according to ISO 6722 40 C to +105 C/3000 h 40 C to +125 C/3240 h

Round sheathed cables Sheathed cables are always used for automotive applications where the cables have to satisfy particularly stringent requirements. The strand lay lengths are fixed, even if the outer sheath has a tight bending radius. Chemical and mechanical resistance are considerably enhanced by the sheath. Gas and watertight overmoulding of grommets and the like can only be achieved with round sheathed cables. The selection of suitable insulation and outer sheathing materials is oriented on your requirements. An extensive range of standard and special materials is available.

Design example: FLRYY 2 x 0.5 mm/T105

Flat sheathed cables Sheathed cables arent always round. Depending on requirements, we extrude sheathed cables in accordance with your specific requirements. Flat sheathed cables are in widespread use. The single wires run parallel to each other underneath the outer sheath. A specific distance between the wires ensures a safe contacting process. Depending on which insulation and sheathing material you choose, IDC technology is also an option. Flat designs with pre-stranded wires can also be implemented if required. We look forward to hearing your suggestions.

Design example: FLFRYY 2 x 0.5 mm2/T105

Hybrid sheathed cables Hybrid sheathed cables perform several functions. The large-diameter wires enable efficient power supply and the small-diameter wires are used for control functions and data communication. Our state-of-the-art production technology enables the integration of pre-stranded wire pairs - as electrical shields for voice circuits if required. Our experienced cable designers develop robust and assembly-friendly solutions.
Design example: FLRY11Y 12 x 1.0 mm2 + 3 x 2.5 mm2/T105

11

Coroflex TT3 insulated automotive wires

Application: Engine compartment and gearbox Development of wiring systems and wiring harnesses for engine compartment and engine wiring Operating temperature ranges according to ISO 6722 40 C to +125 C/3000 h 40 C to +125 C/3000 h 40 C to +150 C/3000 h 40 C to +150 C/3240 h

Single wires FLR9Y 0.35 mm to 6 mm

Designation Cross-section Type A 7 x max. 0.26 mm 19 x max. 0.19 mm 19 x max. 0.23 mm 19 x max. 0.26 mm 19 x max. 0.32 mm 19 x max. 0.41 mm Conductor design Type B [mm] FLR9Y 0.35 mm2 FLR9Y 0.5 mm2 FLR9Y 0.75 mm2 FLR9Y 1.0 mm2 FLR9Y 1.5 mm2 FLR9Y 2.5 mm2 FLR9Y 4.0 mm
2

Insulation Outer wall thickness diameter [mm] 1.3 ( 0.1) 1.4 ( 0.2) 1.6 ( 0.2) 1.7 ( 0.2) 1.9 ( 0.2) min. 0.24 min. 0.28 min. 0.32 2.1 ( 0.2) 2.4 ( 0.2) 3.0 ( 0.3) 3.7 ( 0.3) 4.3 ( 0.3)

Conductor resistance bare [Ohm/km] max. 52.0 max. 37.1 max. 24.7 max. 18.5 max. 12.7 max. 7.6 max. 4.7 max. 3.1 tinned [Ohm/km] max. 55.5 max. 38.2 max. 25.4 max. 19.1 max. 13.0 max. 7.82 max. 4.85 max. 3.23

12 x max. 0.21 mm 16 x max. 0.21 mm 24 x max. 0.21 mm 32 x max. 0.21 mm 30 x max. 0.26 mm 50 x max. 0.26 mm 56 x max. 0.31 mm 84 x max. 0.31 mm

min. 0.20 min. 0.22

FLR9Y 6.0 mm2

Battery and generator cables, FLR9Y 10 mm to 35 mm

Designation Cross-section Type f (fine wires) FLR9Y 10 mm2 FLR9Y 12 mm2 FLR9Y 16 mm FLR9Y 25 mm FLR9Y 35 mm
2

Conductor design Type ff (fine wires) 324 x max. 0.21 mm 385 x max. 0.21 mm 513 x max. 0.21 mm 612 x max. 0.21 mm 783 x max. 0.21 mm 895 x max. 0.21 mm 1107 x max. 0.21 mm

Outer Insulation wall thickness diameter [mm] min. 0.48 min. 0.50 min. 0.52 min. 0.52 min. 0.64 min. 0.76 min. 0.80 [mm] 5.8 ( 0.4) 6.5 ( 0.5) 7.0 ( 0.5) 7.9 ( 0.5) 8.8 ( 0.6) 9.7 ( 0.7) 10.5 ( 0.7)

Conductor resistance bare [Ohm/km] max. 1.82 max. 1.52 max. 1.16 max. 0.96 max. 0.743 max. 0.674 max. 0.527 tinned [Ohm/km] max. 1.85 max. 1.60 max. 1.18 max. 1.03 max. 0.757 max. 0.684 max. 0.538

80 x max. 0.41 mm 98 x max. 0.41 mm 126 x max. 0.41 mm 154 x max. 0.41 mm 196 x max. 0.41 mm 224 x max. 0.41 mm 276 x max. 0.41 mm

FLR9Y 20 mm2
2

FLR9Y 30 mm2
2

12

The Coroflex TT3 range consists of thermoplastic wires in temperature class T3 Coroflex TT3 wires are the better alternative to similar products in this temperature class. The excellent product features of the Coroplast compound in combination with the thermoplastic manufacturing process render additional, energy-intensive cross-linking unnecessary. There are also ecological benefits such as the recyclability of all Coroflex TT3 wires. Wires in the Coroflex TT3 product family are distinguished by their comparatively higher mechanical threshold reserves compared to other wires in temperature class 3. As a result of their low weight, these wires are gaining in popularity. Energy and weight saving opportunities round off the ecological benefits of the Coroflex TT3 product family.

The Coroflex TT3 product family Single automotive wires and twisted cores are available. The product family is rounded off by battery and generator wires plus multicore, shielded and unshielded sheathed cables.

Coroflex TT3 single wires Wires for use in wiring systems are listed in the table opposite. Copper wires can be either bare or tinned depending on contact requirements.

Coroflex TT3 stranded wires Stranded single wires for loudspeaker or data transmission applications are produced in long lengths. Custom designs are possible based on data pertaining to the number of cores, cross-sections and strand lay lengths.

Coroflex TT3 battery and generator cables Battery and generator cables with reduced insulation wall thickness up to a conductor cross-section of 35 mm are listed in the table. Coroflex TT3 high voltage cables for hybrid and fuel-cell power drives are also available by request.

Coroflex TT3 - sheathed cables Sheathed and unsheathed sensor, control and actuator cables are available. Customer-specific designs can be implemented based on data pertaining to the number of cores, nominal cross-sections, shielding variants and cable assembly requirements.

13

Sheathed cables, shielded

Application: Passenger and engine compartment Design for shielded automotive cables, Sensor and control cables, power supply Shielding measures to filter EMC-interferences

The use of either shielded or unshielded cables in vehicles depends on the electromagnetic compatibility (EMC) requirements of the system. In addition to the stranding of individual wires, which is the most common and inexpens ive method of

shielding, metal foil shields, spiral shields and braided shields are also used. The abovementioned sheathing options can also be combined for specific ap plication or vehicle installation situations.

Metal foil shield The element to be shielded is enclosed in metal foil. The electrical contact is established by way of a stranded drain wire. It can either be a separate stranded wire or a wire with a conductive coating. This enables the use of proven and inexpensive insulation crimp technology without the need for any additional heat shrinking sleeves.

Design examples: FLRYBY 2 x 0.5 mm + 0.5 mm/T105

Spiral shield Single wires made of metal (e.g. copper) are spun in a coil around the element to be shielded. Degrees of optical coverage of approx. 96% are possible. The required shield attenuation depends on the effective use of the metal and the degree of optical coverage. Spiral shields are good for highly flexible applications because of their variable design parameters.

Design example: FLRYDY 3 x 0.5 mm/T105

Braided shield The braided shield is made of multiple metal wires that are braided diagon ally together. Normally, braided shields are used to prevent high frequency interference. High frequency transmission cables (antenna cables) have braided shields.
Design example: FLRYCY 3 x 0.5 mm/T105

Optical coverage of approximately 85% is reflected in very efficient shield attenuation.

14

PUR-sheathed cables for ABS application

Application: Wheelhouse wiring ABS, brake lining indicator, dynamic chassis control, headlamp levelling Operating temperature range according to ISO 6722 40 C to +125 C/3000 h 40 C to +150 C/3240 h

ABS sensor cables In the product group ABS cables, requirements of the highest order are fulfilled for connecting the ABS sensor of the wheel to the electronic control box. The wiring in the wheelhouse requires a safe signal transmission during all vibrations and motions of the chassis and the steering wheel. Environmental influences, e.g. stone chipping or low temperature, require a total quality from the cable during the life span of the vehicle. These cables are manufactured in fully-automated production processes as a result of the widespread use of ABS systems in vehicles. Our cable surfaces are designed to satisfy the customers specific requirements and these customised surfaces make process-safe and low-tolerance overmoulding of grommets etc. possible.
Design example: FLR31Y11Y 2 x 0.5 mm/T125

ABS sensor and brake lining indicator Vehicles servicing intervals are continuously extended to save costs. An additional safety feature is a brake lining indicator in the vehicles cockpit. For this purpose, the two core ABS sensor cable requires two additional wires for the indicator. The whole range of requirements on the ABS cable is met by this four core, ABS and break lining indicator cable. The use of modern insulation and sheathing material guarantees compliance with the total demands on the cable and also on future applications.

Design example: FLR31Y11Y 4 x 0.5 mm/T125

ABS cable harness Besides the production of ABS cables, Coroplast features the assembly of these cables to ABS cable harnesses. Optional functions, e.g. brake lining indicator, headlamp leveling, dynamic chassis control, tyre pressure control are a matter of course. In-house injection moulding of all the sleeves and plug contacts demonstrate that Coroplast is a qualified and innovative partner.

15

Silicone-insulated automotive wires

Application: Engine compartment and gearbox Single wires for engine and gearbox wiring Operating temperature range according to ISO 6722 40 C to +175 C/3000 h 40 C to +200 C/3000 h

Silicone-insulated automotive wires (40 C to +200 C/3000 h)

Designation Cross-section Conductor design (exemplary) Type f (fine wires) 12 x max. 0.21 mm 16 x max. 0.21 mm 24 x max. 0.21 mm 32 x max. 0.21 mm 30 x max. 0.26 mm 50 x max. 0.26 mm 56 x max. 0.31 mm 84 x max. 0.31 mm Type ff (fine wires) 43 x max. 0.11 mm 28 x max. 0.16 mm 42 x max. 0.16 mm 52 x max. 0.16 mm 82 x max. 0.16 mm 140 x max. 0.16 mm 228 x max. 0.16 mm 189 x max. 0.21 mm Insulation wall thickness [mm] nom. 0.5 nom. 0.6 nom. 0.6 nom. 0.6 nom. 0.6 nom. 0.7 nom. 0.8 nom. 0.8 Outer diameter [mm] max. 1.9 max. 2.3 max. 2.5 max. 2.7 max. 3.0 max. 3.6 max. 4.4 max. 5.0 Conductor resistance bare [Ohm/km] max. 54.4 max. 37.1 max. 24.7 max. 18.5 max. 12.7 max. 7.6 max. 4.71 max. 3.14 tinned [Ohm/km] max. 55.5 max. 38.2 max. 25.4 max. 19.1 max. 13.0 max. 7.82 max. 4.85 max. 3.23

FL2G 0.35 mm2 FL2G 0.5 mm FL2G 1.0 mm FL2G 2.5 mm FL2G 6.0 mm
2

FL2G 0.75 mm2

2

FL2G 1.5 mm2

2

FL2G 4.0 mm2

2

16

Silicone-insulated battery and generator cables

Application: Engine compartment and gear box Highly flexible even at low operating temperatures Operating temperature range according to ISO 6722 40 C to +175 C/3000 h 40 C to +200 C/3000 h

Silicone rubber is distinguished as an insulation and sheathing material by its outstanding flexibility at extremely low temperatures in combination with a long life span at extremely high temperatures. Modern, highly tear resistant special silicone compounds facilitate applications in particularly critical areas where high mechanical stresses exist without any impairment to the other temperature properties.

Silicone compounds with optimised outgassing properties demonstrate excellent mechanical properties. Cables with these low-fogging silicone types are used in places where fogging could cause interference, such as on headlamp reflectors. We offer a comprehensive range of state of the art silicone cables. Please contact us for further information.

Battery and generator cables, silicone-insulated (40 C to +200 C/3000 h)

Designation Cross-section Conductor design (exemplary) Type f (fine wires) 80 x max. 0.41 mm 126 x max. 0.41 mm 196 x max. 0.41 mm 276 x max. 0.41 mm 396 x max. 0.41 mm 360 x max. 0.51 mm 457 x max. 0.51 mm Type ff (fine wires) 324 x max. 0.21 mm 448 x max. 0.21 mm 783 x max. 0.21 mm 1107 x max. 0.21 mm 1592 x max. 0.21 mm 1427 x max. 0.26 mm 1936 x max. 0.26 mm Insulation wall thickness [mm] nom. 1.0 nom. 1.0 nom. 1.3 nom. 1.3 nom. 1.5 nom. 1.5 nom. 1.6 Outer diameter [mm] max. 6.5 max. 8.3 max. 10.4 max. 11.6 max. 13.5 max. 15.5 max. 18.0 Conductor resistance bare [Ohm/km] max. 1.160 max. 1.160 max. 0.743 max. 0.527 max. 0.368 max. 0.259 max. 0.196 tinned [Ohm/km] max. 1.180 max. 1.180 max. 0.757 max. 0.538 max. 0.375 max. 0.264 max. 0.200

FL2G 10 mm2 FL2G 16 mm FL2G 35 mm FL2G 50 mm FL2G 95 mm

2

FL2G 25 mm2
2 2

FL2G 70 mm2
2

17

High voltage cables for hybrid and electric vehicles

Application: Engine compartment and gearbox High voltage cable harnesses, high voltage batteries, power electronics, fuel cells Operating voltage according to ISO 6722 Voltage class 600 volt AC Voltage class 600 volt DC

Cables for high voltage cable harnesses New electric mild or full hybrid drivetrains in vehicles necessitate innovative high voltage cables that are specifically designed for voltage classes of 60 volt and more. These special cables are already used in conventional electric vehicles and, in future, they will also be used in fuel cell electric vehicles. They enable a continuous power supply of up to 600 volt and are designed on the basis of the internationally recognised automotive wire norm ISO 6722.
Design example: High voltage cable, unshielded FLY 25 mm/T105

Particular significance is accorded to the specific insulation resistance of the polymers in continuous operation under moist climatic conditions. The continuous operation temperature range is between temperature class T2 up to +105 C and temperature class T6 up to +200 C. The requirement of high operating temperatures is due to the fact that these cables are installed in the engine compartment and gearbox and as a result of the electrical heat generated by operational cables. The Coroflex TT3 product family is suitable for applications in temperature class T3 +125 C. Modern silicone materials are recommended for higher temperatures and due to their outstanding cost effectiveness. For generations now, silicone has proven to be a reliable insulation material for high voltage-resistant ignition cables in vehicles with petrol engines. In addition to high cable flexibility, Coroplasts modern silicone mater ials deliver far superior mechanical resistance than earlier compounds. This is evident by their improved tear resistance at thermoplastic and TPE level.

Design example: High voltage cable, shielded FL2GCB2G 25 mm -0.21/T175

Design example: High voltage cable, shielded FL2GCB2G 35 mm -0.21/T175

18

Two fundamentally different cable designs are necessary in electric vehicles.

High voltage power transmission Shielded and unshielded single wires with cross-sections of between 4.0 mm and 50 mm are available for power transmission between the high voltage battery and the power electronics and to connect the power electronics and the electric engine. Polarity reversal protection is ensured by coloured vertical smear-proof stripes on the outer sheath.

Unit power supply Multicore sheathed cables, some with additional data transmission elements, are used to supply electrical power to other units such as the air-conditioning compressor or oil pumps. All high voltage cables are visually recognisable by the signal colour orange. All cables in operating voltage class 600 volt can also have a warning text printed on the outer sheath.

Design example: High voltage cable, shielded FLR9YBC11Y 3 x 2.5 mm/T125

Design example: High voltage cable, shielded FLR7YBC2G 3 x 2.5 mm + 1 x 2 x 0.35 mm/T150

19

ETFE- and FEP-insulated automotive wires

Application: Engine compartment and gearbox Single wires for engine and gearbox wiring Operating temperature range according to ISO 6722 40 C to +175 C/3000 h for ETFE 40 C to +200 C/3000 h for FEP

Automotive wires with ultra reduced insulation wall thickness

ETFE-Insulation (7Y) for 40 C to +175 C/3000 h FEP-Insulation (6Y) for 40 C to +200 C/3000 h Designation Cross-section Conductor design Type A 7 x max. 0.21 mm 7 x max. 0.26 mm 19 x max. 0.19 mm
2

Type B 12 x max. 0.21 mm 16 x max. 0.21 mm 24 x max. 0.21 mm 32 x max. 0.21 mm 30 x max. 0.26 mm 50 x max. 0.26 mm 56 x max. 0.31 mm 84 x max. 0.31 mm

Insulation Outer wall thickness diameter [mm] [mm] 1.2 ( 0.1) 1.3 ( 0.1) 1.4 ( 0.2) 1.6 ( 0.2) 1.9 ( 0.2) 2.1 ( 0.2) 2.4 ( 0.2) 3.0 ( 0.3) 3.7 ( 0.3) 4.3 ( 0.3)

Conductor resistance bare [Ohm/km] max. 84.4 max. 54.4 max. 54.4 max. 37.1 max. 24.7 max. 18.5 max. 12.7 max. 7.6 max. 4.71 max. 3.14 tinned [Ohm/km] max. 86.5 max. 55.5 max. 55.5 max. 38.2 max. 25.4 max. 19.1 max. 13.0 max. 7.82 max. 4.85 max. 3.23

FLR6Y (7Y) 0.22 mm2 FLR6Y (7Y) 0.35 mm2 FLR6Y (7Y) 0.5 mm2 FLR6Y (7Y) 0.75 mm FLR6Y (7Y) 1.0 mm2 FLR6Y (7Y) 1.5 mm FLR6Y (7Y) 4.0 mm FLR6Y (7Y) 6.0 mm
2

min. 0.20 min. 0.20 min. 0.20 min. 0.22 min. 0.24 min. 0.24 min. 0.24 min. 0.28 min. 0.32 min. 0.32

19 x max. 0.23 mm 19 x max. 0.26 mm 19 x max. 0.32 mm 19 x max. 0.41 mm

FLR6Y (7Y) 2.5 mm2

2 2

20

High temperature sheathed cables for engine compartment and gear box
Application: Engine compartment and gearbox Control and sensor cables for engine and gearbox wiring Operating temperature range according to ISO 6722 40C to +150 C/3000 h 40C to +175 C/3000 h

High temperature sheathed cables High temperature sheathed cables are used in areas of the vehicle which expose them to continuous operating temperatures of +150 C and over. These wires are generally installed in the engine compartment, e.g. wiring harnesses installed directly on top of the engine block. Automotive applications such as crankshaft speed (rpm) sensor, knock sensor and sensor cables for high performance fuel injection engines necessitate the use of shielded control and sensor cables. The increase of modern engine controls and automatic gear transmission have driven up demand for cables. The stringent requirements of automot ive customers can only be fulfilled through the use of high performance insulation and sheathing materials in conjunction with application-oriented special cable designs.
Design example: FLU7Y2G 2 x 0.5 mm/T150

Design example: FLU7YB2G 1 x 0.5 mm + 0.5 mm/T150

Design example: FLU7YB2G 2 x 0.5 mm + 0.5 mm/T150

21

Sheathed cables for infotainment application

Application: Passenger compartment Connector cable for telematics, CD changer and car phone Operating temperature range according to ISO 6722 40 C to +105 C/3000 h 40 C to +125 C/3240 h

Special cables for on-board infotainment applications Demand for modern on-board infotainment systems is continually increas ing. Electrical signals are constantly transmitted from point to point, i.e. control, audio and video information is transported via electrically conduct ive media for modern in-vehicle sound, video, DVD, telecommunication and online connections. Customer and system-specific cable designs are necessary for these applications. Video and audio signals have to be transmitted with very low attenuation and cross-talk has to be effectively prevented. High frequency harmonics from the signal and power supply cables have to be prevented from interfering with the voice circuits. There are also customer specific requirements with respect to automated and competitively priced cable assembly which necessitate extensive cable development experience. Many alternative design and shielding methods, such as low-cost foil shields with drain wires that are coated in conductive materials or high frequency attenuating polymers for specific low-pass applications are available to our cable developers. Our extensive design experience gained in diverse customer development projects helps us to meet your requirements. Please contact us. Coroplast your development partner

Design example: Hybrid cable for the car phone FLR31YBCY 5 x 2 x 0.14 mm + 2 x 0.35 mmT105

22

Design example: Hybrid CD changer cable FLRYY 6 x 0.22 mm + 1 x 0.35 mm + 2 x FLRYDY 0.22 mm + 2 x FLRYC 0.22 mm/T105

Design example: Hybrid CD changer cable FLRYBY 7 x 0.35 mm + 1 x 3 x 0.35 mm-BY/T105

Design example: Hybrid GPS multicoaxial cable 4 x coax 50 ohm + 1 x audio pair 2 x 0.14 mm + 1 x data transmission pair 2 x 0.09 mm/T105

23

High frequency filter cables

Applications: Passenger compartment Connecting cables for pyrotechnical seat belt retention system Operating temperature range according to ISO 6722 40 C to + 85 C/3000 h 40 C to +105 C/3240 h

High frequency filter cables High frequency noise signals interfere with the electrical system of a modern car so that an interference suppressor has to be integrated into the housing. This conventional but costly interference suppression demands very high requirements on the process ability for contacting and assembly. An innovative alternative are the Coroplast high frequency filter cables. In these cables the necessary low-pass depending upon the function is integrated into the electrical connecting cable. Due to its special design, this cable is in a position to filter the high frequency interference from the electrical system where it is not desired, e.g. pyro-technical seat belt retention system. The conductor is coated with a filter compound with magnetic properties. High frequency (HF) oscillations lead to a rapid magnetising and demagnetising of this coating. Because of non-reversible magnetising processes, some losses occur, so that the HF-energy is transformed into heat. These losses correlate to the frequency and increase with it. The figure besides shows the equivalent electric circuit of a homogeneous cable. In this circuit, the filtering property of the cable is expressed by the frequency dependent impedance Z(f).

Z (f )

Transmission (f ) [dB] 0 - 10 - 20 - 30 - 40 - 50 - 60 - 70 - 80 0 750 1500 2250 3000 Frequency [MHz]

24

A large area of utilisation for this HF filter cable is the control of the pyrotechnical seat belt retention system. Besides the described and necessary decoupling elements, depending upon the specific application, cost savings of the contacting system can also be demonstrated. Coroplast HF filter cable can be connected to a pyro-technical sensor without an additional connecting system. The figure shows some typical attenuation curves as a function of frequency up to 3000 MHz. Let us know your requirements. Our specialists will be pleased to advise you. HF filter cables work with specially developed filter compounds. Conventional conductor designs and our high-class insulation materials are continuously coated with HF filter compounds in an economical production process. Since the design parameters are in line with the agreed standards, the conventional contacting system is used without any difficulty. The filter cables are very similar to the conventional sheathed cables and hence can visually be identified only at a second glance. It is only the function filtering of the high frequency interference from the electrical system in the vehicle which differentiates them from the standard cables. Our cables are customized designs. Design examples are shown here with two core sheathed cable for the broad field of pyrotechnical applications. Depending on the attenuation requirement one or two HF filter cores are used. A shield additionally influences the attenuation behaviour and hence clearly the electromagnetic compatibility (EMC). Preference is given to shielded cables with economical foil shield in combination with conductive materials coated drain wires. Further information is available on page 14 Sheathed cables, shielded of this catalogue. Everywhere, where electronic components of the electrical system are negatively influenced by high frequency, Coroplast high frequency filter cable can help economically and efficiently. Please contact us.

Design example: HF filter cable, unshielded, with 1 filter core

Design example: HF filter cable with foil shield and 1 filter core

Design example: HF filter cable, unshielded, with 2 filter cores

25

Aluminium cables
Applications: Car body and engine compartment battery and generator wiring harnesses, actuator power supply It is only practical to use aluminium in combination with aluminium-compatible contacts.

Conductor material aluminium Aluminium cables with nominal cross-sections of approx. 10 mm and more are used in road vehicles to save weight. A direct comparison of aluminium and copper demonstrates the weight advantage of aluminium with the material-related limitation on tensile strength. The table of parameters containing information about electrical resistance shows options for direct substitution with the reference conductor material of copper. Depending on the necessary operating temperatures, aluminium cables are produced with the insulation materials of PVC via Coroflex TT3 up to mechanically modified and low-outgassing silicone compounds.

Material comparison Al Cu
Aluminium Standard: Abbreviation: Material no.: Conductivity: Tensile strength: Density: DIN EN 573-3 E-AL 99.7 1.370 35.0 Sm/mm min. 70 120 N/mm 2.7 g/cm Copper DIN EN 13602 Cu-ETP/Cu-ETP1 CW 003A/004A 58.5 Sm/mm min. 200 N/mm 8.9 g/cm

Dimensions of aluminium cable with references to copper conductors

Cross-section Aluminium 10 mm 17 mm 27 mm 42 mm 59 mm 85 mm 120 mm Copper as reference 6 mm 10 mm 16 mm 25 mm 35 mm 50 mm 70 mm Conductor design Aluminium 49 x max. 0.51 mm 84 x max. 0.51 mm 133 x max. 0.51 mm 210 x max. 0.51 mm 294 x max. 0.51 mm 420 x max. 0.51 mm 608 x max. 0.51 mm Insulation wall thickness [mm] min. 0.8 min. 0.8 min. 1.04 min. 1.04 min. 1.2 min. 1.2 min. 1.28 Outer diameter Conductor resistance Aluminium [Ohm/km] max. 3.100 max. 1.820 max. 1.160 max. 0.743 max. 0.527 max. 0.368 max. 0.259 Copper [Ohm/km] min. 2.852 min. 1.674 min. 1.067 min. 0.683 min. 0.484 min. 0.338 min. 0.238

[mm] 6.5 ( 0.6) 7.7 ( 0.7) 9.9 ( 0.8) 11.9 ( 1.0) 14.0 ( 1.0) 16.3 ( 1.2) 18.8 ( 1.4)

26

High-speed data transmission in vehicles

Application: Passenger compartment HSD applications such as FlexRay, UHI, USB, LVDS, GVIF, eMOST, Firewire Operating temperature ranges according to ISO 6722 40 C to +105 C/3000 h 40 C to +125 C/3000 h

High-speed data transmission in vehicles (HSD) Modern data transmission in vehicles necessitates special cables which are adapted to automotive requirements and optimised for data transmission. Standard home and office solutions have their limitations as a result of strong EMC interference affecting the vehicles electrical system. Specially modified insulation and sheathing materials guarantee high reliab ility throughout the vehicles entire lifespan. Carefully selected design parameters guarantee high interference resistance and high near-end cross-talk attenuation. The low attenuation of the cable enables larger connecting lengths in the vehicle. Impedance and mutual capacitance are in line with the corresponding systems. The vehicle-friendly development of quad cables, which have proven their efficiency over decades, reduces signal frequency differences in the individual voice circuits. Compared with the multi-twisted pair cables, quad designs more effectively meet the higher bending requirements in tailgate or lift-up arm rest applications. The assembly friendly connections of the symmetrical data cables for audio and video transmission are also suitable for your system.

Design example: LVDS cable, shielded FLR9YBCY 4 x 2 x 0.22 mm/T105

Design example: Quad cable, shielded FLR9YBCY 2 x 2 x 0.14 mm/T105

Design example: FlexRay cable, unsheathed FL9Y11Y 2 x 0.35 mm/T125

27

Insulation and sheath materials

Insulation and sheath materials

Temperature Classfication Temperature Range Long-term (3000 h) A 40 C to +85 C Short-term (240 h) to +110 C Y 2Y Y B 40 C to +100 C to +125 C 4Y 9Y 9Y 11Y C 40 C to +125 C to +150 C 13Y 31Y 91Y 7Y D 40 C to +150 C to +175 C 11Y NY E F G H 40 C to +175 C 40 C to +200 C 40 C to +225 C 40 C to +250 C to +200 C to +225 C to +250 C to +275 C 6Y 2G 6Y 2G 51Y PVC PE PVC PA PP PP TPE-U TPE-E TPE-S TPE-O ETFE TPE-U TPE FEP SiR FEP SiR PFA Polyvinyl Chloride Polyethylene Polyvinyl Chloride Polyamide Polypropylene Coroflex TT3 PUR, Thermoplastic Polyurethane Elastomer Thermoplastic Polyester Elastomer Thermoplastic Styrenic Elastomer Thermoplastic Polyolefin Elastomer Ethylentetrafluorethylene PUR, Polyurethane Thermoplastic Elastomer Tetrafluorethyleneperfluorpropylene Silicone Rubber Tetrafluorethyleneperfluorpropylene Silicone Rubber Perfluoralkoxy Material Designation

Nomenclature example: FLRY 0.75-A/T105

Automotive wire

FL

0.75 mm

-A

/T105

Reduced insulation wall thickness according to ISO 6722

Insulation material PVC

Conductor cross-section 0.75 mm

Symmetric conductor design Continuous operation temperature 105 C (3000 h) according to ISO 6722

28

Nomenclature for automotive wires and cables

According to DIN 76722

Wire type
FL: Automotive cable

Special design R: Reduced insulation wall thickness according to ISO 6722 U: Ultra reduced insulation wall thickness according to ISO 6722 S: Increased insulation wall thickness F: Flat cable Z: Multi core cable, cores separable Conductor material Al: Aluminium W: Resistance conductor CCA: Copper cladded aluminium CCS: Copper cladded steel M: Other material than copper and restistance conductor Insulation and sheat material Y: PVC, Polyvinyl Chloride nn: For further comments, please see the table Insulation and sheath materials on the right hand side Non extruded covers B: Foil shield with drain wire D: Copper - Single wire spiral cover C: Copper - Braid shield G: Glass fibre braid L: Varnish coating Conductor design and coating A: Symmetric conductor design, e.g. according to ISO 6722 B: Asymmetric conductor design, e.g. according to ISO 6722 SN: Tinned wires NI: Nickelized wires AG: Silvered wires Number of cores and cross-section of the conductors (example) 3 x 0.5: 3 cores of cross-section 0.5 mm Ohm/km: Resistance cable unit in Ohm/km Continous operating temperature (example) T125: +125 C/3000 h according to ISO 6722

29

Packaging units

Single cores and lightweight sheathed cables

Coroplast offers tailor-made packaging units depending on the type, form and weight of the cable and on the cable diameter. A number of choices are possible. Some examples of conventional and usually used units are as follows. The cable packet is normally recommended for lightweight single wires. As one way packaging, this unit occupies the least space. A real returnable packaging unit (multi-way) is the cable bundle. It is quick and easy to dismantle for the return transport and refilling. In addition to the Coroplast drum (barrel) as returnable package (multi-way), the octagonal drum is suitable to carry the same capacity as a one-way package. Both package units are available in 400 mm and 800mm height. Typical packaging units for the sheathed cables and heavy weight battery and generator cables are the plywood and plastic reels. Both units are dismountable for the return transport and can be reused. Plywood reels are available in 600 mm and 800 mm diameter whereas the plastic reels from 270 mm up to 800 mm diameter suitably meet all requirements.

STR 600 Plywood reel, 600 mm

KTG 80 Plastic reel, 800 mm

30

Sheathed cables and battery and generator cables

KP 400 Cable packet, height 400 mm

KG 400 Cable bundle, height 400 mm

AFS 800 Octagonal drum, height 800 mm

CFS 800 Coroplast drum, height 800 mm

31

Coroplast Fritz Mller GmbH & Co. KG Tapes Cables Cable Assemblies Wittener Strae 271 D-42279 Wuppertal Fon +49 (0)202.2681.228 Fax +49 (0)202.2681.360 coroplast@coroplast.de www.coroplast.de

11/08

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