Automotive

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.

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.

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).

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.

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.

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.

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.

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.