Automotive

OVERVIEW

Linking mechanics, electrics and materials with motion

Covering all mechanical, electrical and material requirements, Prysmian Group is a leader in material development, production technologies and logistics for the automotive industry.

Draka Prestolite Automotive was born from the merge between Prysmian and General Cable and offers to its customers the widest cable and assemblies portfolio for the global automotive industry.

The automotive industry keeps on growing at a very high pace in the field of electric and connected autonomous cars. Draka Prestolite Automotive is capable of meeting the increasingly challenging requirements of its customers through a range of customized cables and assemblies for the newest generation of vehicles.

With coverage of all mechanical, electrical and chemical requirements for cars, trucks and buses, Prysmian Group is a leading name in the field of material development, production technology and logistics for the automotive industry.

With the power of our cable catalog, we are valued partners for some of the world's leading companies in the automotive industry. In order to meet the very varied requirements of our customers, we have built up an excellent portfolio of tailor-made products. It is not without reason that Prysmian Group enjoys a reputation as a specialist for challenging applications.

With a total of around 900 employees, we have branches in this sector in Asia, Europe, North Africa and Central and South America.

Innovation and sustainability

Draka Prestolite Automotive field numerous patents, and our materials research and cable-design teams are well-known and valued partners of OEMs, systems suppliers and harness makers in full compliance with the latest environmental standards and requirements.

Draka Prestolite Automotive modern logistic concepts provide the very best solutions for customers, and ensure timely delivery of products from dedicated factories that combine competitive prices with first-class quality. All our factories are IATF 16949 approved.

Your partner

We have never lost sight of what our core business is: meeting the needs of customers. As a result, we have always been able to grow and change with their demand. And we're still doing that now and we're going to continue with it.

AUTOMOTIVE

Philosophy

FOCUS ON

Electric vehicles

High Voltage cables for hybrid and electric cars.

High Voltage (600 V) cables for connections between the converter, inverter, generator and battery in hybrid cars, Fuel Cell Vehicles (FCVs) and all-Electrical Vehicles (EVs).

Our high performance and reliable High Voltage cables meet strained power requirements and ensure stable properties and easy installation especially in complex harnesses.

 
applications

APPLICATIONS
Ideal for all types of electric and hybrid vehicles, among others:

  • electric vehicles (EV)

  • battery electric vehicles (BEV)

  • plugin hybrid vehicles (PHV)

  • plugin hybrid electric vehicles (PHEV)

benefits

BENEFITS

  • superior environmental properties/recyclability

  • reliable electrical performance

  • flexibility and lightweight, easy handling and installation, heat and cold resistance, flame resistance

  • superior chemical and abrasion resistance

  • superior durability in harsh environments

 
properties

PROPERTIES

  • silicone, EPDM and halogen-free XLPE insulation materials available

  • standard temperature range -40°C up to +200°C

  • high flexibility

products

PRODUCT RANGE

  • unscreened high voltage cables

  • screened high voltage cables

  • multi/core unscreened high voltage cables

FOCUS ON

Connected and autonomous cars

Cables for the widest range of data communication systems in the automotive industry.

Our Data Cables ensure fast, safe and multimedia communication not only inside a vehicle, but also V2V /Vehicle to Vehicle), V21 (Vehicle to Vehicle), etc.

 
applications

APPLICATIONS

  • communication

  • entertainment

  • safety

benefits

BENEFITS

  • superior environmental properties/recyclability

  • super-fast and stable transmission properties

  • flexible, heat resistant, flame resistant

  • outstanding EMC protection and resistance to interferences

 
properties

PROPERTIES

  • solid/foam dielectrics

  • standard temperature range -40°C up to +150°C

  • high mechanical strength

products

PRODUCT RANGE

  • FlexRay Cables

  • CAN Bus Cables

  • Ethernet Cables up to 1GBit

  • LVDS Cables

More over the industry

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Single core cables up to temperature class A 85 °C (T1 / acc. ISO6722-1 and SAE J 1128) in 80 °C (according to JASO D 611)

Single-core cables of temperature class up to 85°C and 80°C /3000h are mostly PVC insulated. Cables are available with thick, reduced or ultra-thin wall thickness, with symmetrical, asymmetrical, fine and compressed wire guide.
Cables in this temperature class are used in areas with low thermal stress, such as car doors and trunk lids.

 

Single core cables up to temperature class B 105 °C (T2)

Single-core cables of temperature class up to 105°C/3000h are normally PVC insulated. Cables are available with thick, reduced or ultra-thin wall thickness, with symmetrical, asymmetrical, fine and compressed wire guide. Cross sections 0.22mm² and 0.35mm² in symmetrical wire guides are also intended for use in IDC technology.

Single core cables up to temperature class C 125 °C (T3)

Heat-resistant single-core cables of temperature class up to 125°C/3000h are normally made of cross-linked polyethylene (2X – T125), cross-linked polyolefin copolymer (42X) or polypropylene (9Y). Special PVC with thin wall thickness is also possible.

These heat-resistant single-core cables are mainly used in the engine compartment at moderate temperature ranges up to 125°C/3000h and with good resistance to mechanical stress at high temperatures. In view of future environmental requirements, a halogen-free, flame-retardant insulation material (21X HFFR) is also available. Where greater flexibility is required, especially on larger cross-sections, polyolefin copolymer (42X) as an insulating material is an excellent choice. XLPE insulated materials, with their excellent electrical properties over the total temperature range, are suitable for data and sensor lines.

 

Single core cables up to temperature class D 150 °C (T4)

Heat-resistant single-core cables of temperature class up to 150°C/3000h are normally made of cross-linked polyethylene (2X – T150).
Single-core cables in this temperature class are intended for use in the engine compartment, at operating temperatures up to 150°C/3000h and with good resistance to pressure at high temperatures.
In view of future environmental requirements, a halogen-free, flame-retardant insulation material (91X HFFR) is also available.

XLPE insulated materials, with their excellent electrical properties over the total temperature range, are suitable for data lines.

Single-core cables up to temperature class F 175 °C (T7), class G 200 °C (T6) and class H 250 °C (T7)

Heat-resistant single-core cables 175°C/3000h (temperature class F / T5) are insulated with ethylene-tetrafluoroethylene copolymer (7Y / ETFE). These cables offer excellent mechanical properties and chemical resistance and are therefore mainly used in harsh environments.

Suitable for insulation up to 200°C/3000h (temperature class G / T6) are silicone (2G / SIR) and fluoridated ethylene-propylene (6Y / FEP). Fluoridated ethylene-propylene (6Y/FEP) provides good mechanical properties and chemical resistance. Silicone (2G / SIR) instead, in addition to very good thermal stability, also offers excellent flexibility. Single-core cables up to a maximum of 250°C/3000h (PTFE) (temperature class H / T8) are insulated with polytetrafluoroethylene (5Y / PTFE) and perfluoro-alkoxyalkanes (51Y / PFA).

This product is mainly intended for seat heaters and exhaust aftertreatment systems.

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Multi-core sheathed cables for operating temperatures up to 105°C/3000h usually consist of single PVC cores and a PVC or polyurethane sheath (11Y / TPE-U). The single cores usually have a reduced wall thickness and symmetrical, asymmetric or fine wire guides.

For operating temperatures up to 125°C/3000h, the single cores are mainly made of cross-linked polyethylene (2X – T125) or polypropylene (9Y). A suitable sheathing material in this temperature class is polyurethane (11Y / TPE-U) due to its good flexibility and abrasion resistance.

In the temperature class up to 150°C/3000h, ethylene-tetrafluoroethylene copolymer (7Y / ETFE) or cross-linked polyethylene (2X – T150) single cores and a sheath of across-linked polyester (33X) or cross-linked polyethylene (2X – T150) are a good combination. These multi-core cables are used for sensor applications.

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The shielding of shielded multi-core cables is usually conceived as ground wire with aluminum-coated foil. This shielding, which is sufficient in many cases, is electrically effective and easy to process when making wiring harnesses. Shielding with braided copper wires or with a spiral screen increases the effectiveness of shielding for pulses in lower frequency ranges.

The wires are mainly used in temperature classes T2 (105°C/3000 h), T3 (125°C/3000 h) and T4 (150°C/3000 h).

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ABS sensor cables for bodywork applications, up to temperature class B (105°C/3000h). The insulation of the core and the shielding are made of PVC.
Shielded ABS sensor cables that are fully EMC compliant are also available.

For applications in the wheels, high-performance cables with rubber core and PUR shielding are available. These materials offer better mechanical and thermal properties and have been specially developed for applications with high varying bending cycles.

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Resistance cables are specifically chosen because of their resistance range and copper alloy wire cross-section.

Resistance cables are typically coated with insulating shields with ultra-thin wall thickness and materials that can withstand high temperatures.
As a material with optimal thermal and chemical resistance, PTFE insulation is very suitable. PTFE cables are also very flexible and resistant to all kinds of chemicals.

Another application is to reduce the voltage in the electrical system and thereby extend the life of front and rear lighting.
In this case, the resistance wires act as a shunt to achieve the required voltage reduction over the entire wire length. This extends the life of the lamps and reduces the number of defects due to high peak currents.

The voltage drop of the wires results in heat loss; with its excellent heat stability and heat pressure, XPE is therefore ideal as an insulating material. Cross-linked XPE is resistant to high temperatures and also offers good mechanical properties.

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Multimediakabels distribueren analoge of digitale signalen in verscheidene signaalcircuits. Bijv. LVDS en audiosignalen uit een bron naar aparte lcd-schermen. De signaalcircuits kunnen apart, collectief of – naargelang van de specificatie van de bus-systemen – in combinaties afgeschermd zijn.

Asymmetrisch afgeschermde enkeldraadse kabels, voor het transport van hoge-frequentiesignalen. De meest voorkomende toepassing in auto's is als antennekabel voor mobiele telefoon-,  radio- en satellietontvangers.

 

Multimediakables

Multimediakabels distribueren analoge of digitale signalen in verscheidene signaalcircuits. Bijv. LVDS en audiosignalen uit een bron naar aparte lcd-schermen. De signaalcircuits kunnen apart, collectief of – naargelang van de specificatie van de bussystemen – in combinaties afgeschermd zijn.

De signaalcircuits zijn vaak apart gewonden (getwist paar) met verschillende twistlengtes ten opzichte van elkaar.

Voor het verkrijgen van een compacte vorm kunnen twee circuits samen weer in een 'star quad' gewonden zijn. Met deze techniek wordt bijna dezelfde interferentie verkregen als met het getwiste paar-design.

Voor hoge eisen aan omgekeerde buigcycli leveren we speciale kabeltypen. Neemt u in dit geval alstublieft rechtstreeks contact met ons op, zodat we uw toepassing kunnen bespreken.

Net als coaxiale zijn multimediakabels van materialen met uitstekende elektrische eigenschappen. Voor dit doel worden merendeels PE-, XPE- of FEP-materialen gebruikt vanwege hun voortreffelijke eigenschappen over het volle bereik van frequenties en temperaturen.

Om zeer kleine dimensies te realiseren kunnen isolatiematerialen opgeschuimd worden om de relatieve permittiviteit (diëlektrische constante) te verlagen tot een waarde van 1,5–1,7.

Ook afgeschermde typen zijn leverbaar.

 

Coaxiale kables

Asymmetrisch afgeschermde enkeldraadse kabels, voor het transport van hoge-frequentiesignalen. De meest voorkomende toepassing in auto's is als antennekabel voor mobiele telefoon-,  radio- en satellietontvangers.

Impedantie, demping, transmissieverliezen en afscherming, lenen zich voor voortreffelijke elektrische eigenschappen.

PE-, XPE- of FEP-materialen zijn erg geschikt, omdat ze stuk voor stuk voortreffelijke elektrische parameters bieden over het volle bereik van frequenties en temperaturen.

Om zeer kleine dimensies te realiseren kunnen isolatiematerialen opgeschuimd worden om de relatieve permittiviteit (diëlektrische constante) te verlagen tot een waarde van 1,5–1,7.

Coaxiale kabels met parallelle afgeschermde draden zijn gemakkelijk te verwerken. Omdat de afscherming niet gevlochten is, hoeft u niet eerst de kabelvlecht open te maken om het scherm met een connector te verbinden. Nadat de afscherming gestript is, zijn de schermdraden stevig genoeg voor bevestiging.

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The application of passenger assistance systems in modern passenger and commercial vehicles is increasing and with it the data rates in the bus systems must also increase.

In addition to standard CAN-bus cables, which must meet characteristic impedance and signal run times, the Prysmian Group catalogue offers various other data cables for Flex-Ray and Ethernet applications.

Shielded coaxial cables, for the transport of high-frequency signals, are commonly used in automotive applications as the mobile phone antenna cable or camera assistance systems.

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Stricter requirements for emission levels and fuel consumption in modern passenger cars require the total weight of the vehicles to be reduced.

In addition to lighter body parts, weight reduction of wiring harnesses is an opportunity to meet this target.

High-tensile conductor materials, such as copper magnesium (CuMg) or copper bronze (CuSn), make it possible to reduce the cross-section of single-core cables from 0.35 mm² to 0.13 mm². In addition to a smaller cross-section, lighter conductor materials are a way to reduce the overall weight of wiring harnesses.

Especially for larger cross-sections, from 2.50 mm², using aluminum instead of the standard copper conductors is a good way for weight reduction.

Currently, it is possible to achieve a weight reduction of approx. 20% by means of lower conductor cross-sections and the use of aluminium instead of copper.

As an alternative to expensive and complicated water-resistant sealed applications, Prysmian Group offers T3 (125°C/3000h) and T4 (150°C/3000h) anticapillary single-core wires. The copper strands of the conductor are sheathed by a special material, which prevents liquids from penetrating into the copper conductor. With this special conductor, the electronics and sensors at the cable ends are protected against damage.

Downloads

Automotive Catalog

23 Nov. 2015