Automotive - DSG

Transcription

Automotive - DSG

DSG-Canusa
Automotive Protection Products
Company
Customer-specific solutions make us a strong development partner to our customers.
DSG-Canusa
Since 1999 DSG-Canusa has been
part of the Canadian giant ShawCor
Ltd., a globally active energy services
provider with over 5,000 employees
in over 20 countries. Since then DSGCanu
sa has recorded continuous
growth. The steady increase in profits
results not least from a comprehensive
network of international clients who
continually demand more new products
from DSG-Canusa. DSG-Canusa today
serves clients from the automotive, mili
tary, space and aviation industries as
well as from the communi
cations and
electrical industries.
Our expanding product portfolio includes thin-, medium-and thick-walled
heat-shrink tubing made of polyolefins,
fluoropolymers, elastomers and PVC,
with or without adhesive coating. We
also produce sealing systems, e.g.
for longitudinal watertight sealing of
cable harnesses, and marking systems, e.g. for cabinets and braided
cable sleeves for encasing and protecting wires, cables, pipes, hoses and
foam to prevent mechanical damage.
Our energy-provider program consists of partition casings, end caps,
creepage-current–proof hoses, lowand medium-voltage connection sleeves, terminals and repair sleeves. A
wide range of proprietary processing
and shrink equipment, as well as
equipment tooled precisely to the requirements of the customer, round off
our portfolio.
DSG-Canusa is a world leader in the
development and manufacture of highquality, technologically advanced heatshrink products. The secret formulae
of our materials and the crosslinking
technologies make it possible to offer
you unique products with exceptional
properties that provide cost-effective,
proven solutions across a wide range
of automotive applications. Unique
products coupled with outstanding
technical support, worldwide sales and
service network and dedicated customer orientation for our international
customers make us an indispensable
partner.
3
1930 ShawCor evolves from a general construction
company established by Francis E. Shaw in south-western
Ontario.
1950 Shaw Pipe Protection Limited, a specialized
pipecoating company, is formed and introduces “Yellow
Jacket” polyethylene coating.
1960 Pipecoating plants are established in Regina,
Edmonton, Montreal, Calgary and Vancouver; first international expansion occurs in Australia.
1969 Shaw Pipe Industries Ltd. is incorporated in
1968 and converts to a public company on June 27,
1969; common shares are listed on the Toronto Stock
Exchange.
1970 Shaw Pipe Protection expands into the United
States, participates in several international projects and
introduces fusion bonded epoxy (FBE) coatings.
1980 Corporate name change to Shaw Industries Ltd.
from Shaw Pipe Industries Ltd. reflects diverse nature of the
growing business.
1987 Company enters oil country tubular markets
with the acquisition of Guardian Inspection Services Ltd.
1991 Shaw Pipeline Services is formed to commercialize internally developed ultrasonic pipeline girth weld
inspection technology.
1996 Shaw Industries enters joint venture with Dresser
Industries to form Bredero Shaw, the world’s largest pipecoating business.
4
© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
Company
1998 Canusa-EMI acquires German based DSG
group of companies, expands presence in global heat
shrink markets and adopts DSG-Canusa name worldwide.
2000 Shaw Pipeline Services acquires radiographic
inspection assets and business of Edwards Pipeline Services to strengthen operations in the United States.
2001 Corporate name changed to ShawCor Ltd.
2002 ShawCor acquires the 50% of Joint Venture
with Dresser Industries that it did not already own, making
Bredero Shaw the world’s largest pipecoating company
now fully owned by ShawCor.
2003 ShawCor is awarded contract to provide pipecoating for the Ormen Lange Pipeline Project, which, at
1,200 km in length, is the world’s longest subsea pipeline.
2005 ShawCor‘s total consolidated revenue reaches
a new record and exceeds $1.0 billion for the first time.
2006 ShawCor achieves record revenue and net
income from continuing operations and aquires a 50%
interest in Bredero Shaw Revestimentos de Tubos Ltda. in
Brazil.
2007 Virginia Shaw becomes Chair of ShawCor Ltd.
on February 7
2008 ShawCor acquires Flexpipe Systems Inc., a
leading manufacturer of flexible composite pipe used for
oil and gas gathering systems, water transportation, CO2
injection and other corrosive applications.
5
Radiation cross-linkage - the enhancement process
It takes a cross-linkage process – the interlinking of threads – to provide fishermen with their nets. In the case of plastics, cross-linkage is a chemical process
during the course of which individual
plastic molecules are chemically interlinked. In an ideal scenario, all the molecules are integrated into this network.
The chemical process concerned can be
triggered via exposure to radiation in
the case of many plastics. In this way,
thermoplastics, for example, are converted into materials having elastomer properties in certain temperature ranges.
Radiation cross-linkage enhances the key characteristics of insulation materials:
Dimensional stability under exposure to heat
Thermal pressure resistance
Higher operating temperature
Resistance to temperature peaks
Higher mechanical resistance
Tensile strength
Alternating bending capacity
Abrasion (conditional)
Higher resistance to chemicals
Stress cracking resistance
Oil resistance
Hydrolysis
Enhanced elastic properties
Improved aging resistance
The key characteristics of cross-linked
tubing are its expansion and recovery
qualities that are sustained over a long
period of time even under thermal and
mechanical stress. The key feature of
these irradiated polymers is their ability
to shrink to a predefined size. As such,
halogen-free, flame-retardant polyolefins
and thermoplastic elastomers (TPE), for
example, can be cross-linked via radiation
6
Automotive
Automotive Protection Products
Contents
Page
Introduction
08 - 10
Pipes & Hoses
11 - 25
Brake Pipes
14 - 17
Air Conditioning Pipes
18 - 19
High Pressure Rubber Hoses / Pipes
20 - 21
Hose Bundling
22 - 23
Cooling Water Hoses
24 - 25
Wire Harnesses – Protection / Sealing Systems
26 - 66
Splices / End Splices
28 - 30
Cable Bundles
31 - 52
Half-Shell Sealing System
53 - 56
Insulating and Protecting Caps
57 - 63
Autoseal – Automatic Sealing System
64 - 66
High Temperature Applications
67 - 74
Braided Sleeves
75 - 78
Design
Seat Belt Locks / Car Aerials
79
7
Automotive Introduction
DSG-Canusa supplies solutions for the
electrical and mechanical insulation of
components and wires with the main
emphasis on the sensitive area “Automotive”. We offer the right product for
every application. Our braided sleeves
and heat shrink tubes protect wires and
sensitive components against mechanical, thermal and chemical damage.
And we also offer products tailored to
the specific needs of our customers.
As one of the leading manufacturers of
heat shrink products, we offer specialised materials for unique requirements.
Our offering includes products made of
polyolefin, fluoropolymer, elastomer and
PVC compounds. Individual tubes can
be thinwalled, medium-walled or heavywalled, depending on the application,
and can be with or without adhesive.
Our product range is rounded out by
our shrink appliances and accessories.
8
Automotive
Start!
With DSG-CANUSA in pole position From 0 to 30: 30% optimisation potential in product development
That much time saving, cost reduction
and quality enhancement can be achieved with successful project management
between manufacturers and suppliers in
the automotive industry, according to a
recent study conducted by Fraunhofer
Institute. We would be pleased to investigate this potential together with you.
To this end, we, as your partner, would
take on the responsibility for entire development modules.
in 120 Seconds
That’s how long it takes for a pit
stop to get to know us.
As one of the world’s leading manufacturers of heat shrink products and
processes, we have for many decades
been a reliable partner to our customers
for all aspects of sealing, insulating and
protecting. In addition to our well-known
heat shrink tubings made of polyolefin,
fluoropolymer, elastomer and PVC, our
current standard range of products also
includes innovative, non-shrink sealing
systems used for the purpose of longitudinal water blocking of wire harnesses.
DSG-Canusa
> 1.000 items
and
The comprehensive product range we offer to meet your needs
We develop customised automotive
solutions at three sites:
» Meckenheim (Germany)
» Toronto (Canada)
» Suzhou (PROC)
Our standard range of products encompasses in excess of 1,000 different products and are available at short notice.
International, innovative
absolutely reliable
We then produce these solutions in
Meckenheim (Germany), Toronto
(Canada) or Suzhou (PROC)
We guarantee the “Made in Germany”
high quality standard for all our production sites.
Our quality guarantees you a
place on the winners’ podium.
We meet the following standards:
DIN EN ISO 9001_2008
ISO-TS 16949_2009
DIN EN ISO 14001: 2005
on 600 m2
The cornerstone of our activities:
the Application engineering and
Development centre
That is where our engineers develop
innovative concepts together with you,
thereby generating pioneering products.
As such, the decades of experience as
an automotive industry supplier are testimony to our reputation as a competency
centre for “sealing solutions for automotive electrical systems” and “hose &
pipe protection”. That is why we do our
best to ensure that pit stops, if needed
at all, are dealt with as quickly as possible and that the time intervals between
them get longer and longer.
9
8x
That’s how often you can find us
in Europe.
Our Sales and Customer Service teams
are there to provide you with advice
and support. And you don’t have to
look hard to find us:
A competent DSG-Canusa contact is
always close at hand.
Hauptsitz
Head office
DSG-Canusa GmbH
Heidestraße 5
53340 Meckenheim
Germany
Tel.: +49 2225 8892-0
Fax: +49 2225 8892-44
www.dsgcanusa.com
20 dB(A)
That’s how quiet a meeting is
with us.
Admittedly, Formula 1 makes a lot of
noise. We however work for you quietly, in the background. Challenge us and
test our development competencies. We
look forward to a personal discussion
with you.
Ensuring that quiet concepts generate
products that make a really loud noise
in the market...
10
Automotive
Automotive
Pipes & Hoses
DSG-Canusa is a pioneer in the development and manufacture of innovative
products.
Our standard product range includes
heat shrink tubing for protecting pipes
and hoses against damage due to stone
chippings, abrasion and corrosion in
the engine compartment, underbody
area, passenger compartment or boot.
Pipes for air conditioning, brakes, fuel
and oil, gas springs, belt buckles and
restraint systems are just some of the
typical components whose safe and
secure operation is assured, among
others, by the application of heat shrink
tubing.
11
Brake Pipes
DERAY®-IAKT NS
DERAY®-HBKT
DERAY®-IBKT
DERAY®-HBNS
DERAY®-INS
Hose Bundling
DERAY®-DKI
Cooling Water Hoses
DERAY®-KWS
12
Automotive
High Pressure Rubber
Brake Pipes
Hoses / Pipes
DERAY®-IAKT NS
DERAY®-HBKT
DERAY®-IBKT
DERAY®-HBNS
DERAY®-INS
This product range of adhesive-lined
heat shrink tubing, available both in
black and clear, is an ideal solution for
avoiding corrosion and for protecting
parts from damage caused by stones
and chippings. The tough outer jacket
also prevents damage to the parts during installation, fastening or clamp
fixing as well as during maintenance.
Moreover, the heat shrink tubing does
not separate from the pipes even when
being bent.
DERAY®-HBNS is a polyolefin heat
shrink tubing that was developed specifically for adhering to aluminium pipes
even when the pipes are being bent.
High abrasive protection at extreme
temperatures is the main characteristic of DERAY®-INS. This tubing offers
outstanding adhesive qualities and
shrinks quickly in order to avoid
damage occurring to the part during the
shrinkage process. The tough material
used for DERAY®-INS reduces vibration
and noise. The continuous operating
temperature of DERAY®-INS lies
between -55°C and 135°C.
DERAY®-HBNS offers optimum protection against corrosion, protects parts
against damage from stones and
chippings and insulates against noise
and vibration. Its continuous operating
temperature lies between -55°C and
135°C.
The continuous operating temperature
of this product range lies between
-55°C and 110°C.
Also available as a particularly ab
rasion-resistant option: Deray®-HBKT.
DERAY®-IAKT
Cooling and heating
Hose Bundling
Water Hoses
DERAY®-DKI
DERAY®-KWS/KWS-R
DERAY®-DKI is a dual-chamber poly
olefin heat shrink tubing that was developed specifically for bundling pipes
and hoses. DERAY®-DKI guarantees
excellent abrasive protection and redu
ces noise and vibration. Moreover
DERAY®-DKI bundles pipes and hoses
at temperatures of up to 135°C. The
continuous operating temperature of
DERAY®-DKI is between -55°C and
135°C.
DERAY®-KWS is a polyolefin heat
shrink (> 2:1) tubing with excellent abrasive resistance. With interior fluting
it is available as KWS-R. It shrinks
without bubbles and wrinkles on pipes
and hoses with extreme radii. A characteristic feature is its smooth finish.
In the shrinking process, it adapts completely to suit the form of the pipes and
hoses concerned, even in the case of
parts with extreme folds and bends. The
continuous operating temperature of
DERAY®-KWS lies between -55°C and
135°C.
13
Brake Pipes
DERAY®-IAKT NS
DERAY®-HBKT
DERAY®-IBKT
Brake Pipes
In motor vehicles, brake pipes in the engine compartment and underbody area
are exposed to numerous environmental influences. Primarily, they are to be
protected against mechanical damage
such as that caused by stones, abrasion
and corrosion.
For some users, the main requirement
is the provision of protection against
damage to the pipes when being fitted.
Specially modified heat shrink tubing
based on cross-linked polyolefins meets
such needs perfectly.
Advantages
Characteristics
Good abrasive resistance
Surface can be printed via hot
seal, inkjet and offset processes
Flammability complies with FMVSS
302 (combustion rate max. 101.6
mm/min)
Continuous operating temperature:
IAKT NS -55°C to +110°C*
IBKT, HBKT: -55°C to +105°C
* outer jacket
Processing
Fast shrinkage on to part requiring
protection
No detachment of heat shrink
tubing when being bent, particularly
in the fold/bend area
No detachment of tubing under
operating temperatures
Processing occurs in shrink tunnels that
are supplied as standard in the form of
two options:
DERAY®-HST 35 100
DERAY®-HST 40 170
These tunnels allow simultaneous processing of several tubes.
The surface of the part to be protected
must be free of grease and oil prior to
the shrink cover being applied. Attention must be given, moreover, to ensure
that the shrink covering process commences at one end in order to prevent
inclusion of air.
We would be pleased to advise you
on the selection of the best shrink
appliance for your specific purpose at
any time. Descriptions of the individual
shrink appliances and of the work they
perform are included in our equipment documentation that we would be
pleased to supply you with on request.
The operating instructions include information on safety matters relevant to the
operation of our shrink appliances. It is
also possible to customise shrink tunnels
or equipment to suit your specific needs
and wishes.
Abrasive protection even under
extreme temperatures
14
Automotive
DERAY®-IAKT NS
Material
Mechanical properties
Thermal properties
Chemical properties
Technical Data
Current Values
Jacket Material
Polyolefin, modified, free of
lead and cadmium
Adhesive
PE/EVA-Basis
Surface
matt
Colour
black or transparent
Specific gravity
1,0 g/cm3 max.
Shrink ratio
≥ 2:1
Longitudinal shrinkage
10 % max.
ASTM-D 2671
Tensile strength
18 MPa
IEC 60684-2
Elongation
550 %
IEC 60684-2
Secant modulus
175 MPa max.
ASTM-D 882
Thermal ageing
(168 h at +150° C)
IEC 811-1-2
Tensile strength
14 MPa
Elongation
450 %
Test Methods
ASTM-D 792, A-I
Cold bend test
does not break at -55° C
ASTM-D 2671 Meth. C
Combustion behaviour
passed
FMVSS 302
Shrink temperature
+95° C to +240° C
Storage temperature
+40° C max.
Continuous operating
temperature
-55° C to +110° C
IEC 216
Water absorption
0,10 %
VDE 0473
* outer jacket
15
DERAY®-IBKT
Material
Thermal properties
Chemical properties
Technical Data
Current Values
Jacket Material
lead and cadmium
Adhesive
PE/EVA-Basis
Surface
semi glossy
Specific gravity
0,95 g/cm3 max.
Shrink ratio
≥ 2:1
10 % max.
ASTM-D 2671
Tensile strength
17 MPa
IEC 60684-2
Elongation
500 %
IEC 60684-2
Secant modulus
100 MPa max.
ASTM-D 882
Thermal ageing
(168 h at +160°C)
IEC 811-1-2
Tensile strength
14 MPa
Elongation
400 %
© ShawCor Ltd. ASTM-D 792, A-I
Cold bend test
does not break at -55°C
ASTM-D 2671 Meth. C
passed
FMVSS 302
Shrink temperature
+95°C to +200°C
Storage temperature
+40°C max.
temperature
-55°C to +105°C
IEC 216
Resistance against chemicals good
Water absorption
16
Test Methods
0,40 %
VDE 0473
All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
Automotive
DERAY®-HBKT
Material
Thermal properties
Chemical properties
Technical Data
Current Values
Jacket Material
lead and cadmium
Adhesive
PE/EVA-Basis
Surface
matt, smooth
Specific gravity
1,0 g/cm3 max.
Shrink ratio
≥ 2:1
10 % max.
ASTM-D 2671
Tensile strength
18 MPa
IEC 60684-2
Elongation
400 %
IEC 60684-2
Secant modulus
175 MPa max.
ASTM-D 882
Thermal ageing
(168 h at +160°C)
IEC 811-1-2
Tensile strength
15 MPa
Elongation
320 %
Test Methods
ASTM-D 792, A-I
Cold bend test
ASTM-D 2671 Meth. C
passed
FMVSS 302
Shrink temperature
+95°C to +200°C
Storage temperature
+40°C max.
temperature
-55°C to +105°C
IEC 216
Water absorption
0,40 %
VDE 0473
17
DERAY®-HB NS
In the engine compartment of motor vehicles, aluminium pipes of air conditioners are exposed to numerous environmental influences. Primarily, they are to
be protected against mechanical damage, corrosion and the diffusion effect of
mineral greases and oils.
Specially modified heat shrink tubing
Advantages
protection
Good adhesion to the aluminium
pipe, even without additional
adhesive lining
No detachment of heat shrink
tubing from the aluminium pipes
when being bent, particularly in
the fold/bend area
Corrosion protection
18
© ShawCor Ltd. In its specific area of application,
DERAY®-HBNS performs impressively
thanks to its outstanding
Characteristics
-55°C to +135°C
mm/min)
Processing
two options:
inclusion of air.
on the selection of the best shrink
appliance for your specific purpose at
perform are included in our equipment
documentation that we would be pleased to supply you with on request.
and wishes.
DERAY®-HST 35 100
DERAY®-HST 40 170
Automotive
DERAY®-HB NS
Dimensions
Expanded
Recovered
Internal diameter (min.)
D (mm)
Internal diameter (max.)
L (mm)
Wall Thickness
(nom.) W (mm)
15,0
6,0
1,0
HB NS 15-6/1,0 sw
19,0
6,0
1,0
HB NS 19-6/1,0 sw
27,0
12,7
0,8
HB NS 27-12,7/0,8 sw
Technical Data
Current Values
Jacket Material
PE, modified, free of lead
and cadmium
Surface
semi glossy
Specific gravity
1,0 g/cm3 max.
Shrink ratio
≥ 2:1
- 6 % max.
ASTM-D 2671
Tensile strength
20 MPa
IEC 60684-2
Elongation
580 %
IEC 60684-2
Secant modulus
170 MPa max.
ASTM-D 882
Thermal ageing
(168 h at +150°C)
IEC 811-1-2
Material
Thermal properties
Chemical properties
Product
Tensile strength
19 MPa
Elongation
507 %
Test Methods
ASTM-D 792, A-I
Cold bend test
ASTM-D 2671 Meth. C
passed
FMVSS 302
Shrink temperature
+110°C to +200°C
Storage temperature
+40°C max.
temperature
-55°C to +135°C
IEC 216
Corrosive action
non-corrosive
ASTM-D 2671 Meth. A
Water absorption
0,01 %
VDE 0473
19
DERAY®-INS
In the engine compartment of motor
vehicles, high pressure rubber hoses /
pipes are used as a connecting sleeve
between pressure and vacuum lines
of air conditioners. They connect, for
example, aluminium air conditioning
pipes with each other or air conditioning pipes and fittings.
In its specific area of application,
DERAY®-INS performs impressively
High pressure rubber hoses / pipes are
exposed to numerous environmental
influences. Primarily, they are to be protected against mechanical damage.
-55°C to +135°C
Our DERAY®-INS heat shrink tubing
Advantages
protection without damage caused
by heat
Good adhesion to the high pressure rubber hose / pipe
20
© ShawCor Ltd. Characteristics
Flammability complies with
UL 224 C
Surface can be printed via hot seal
and offset processes
Processing
two options:
DERAY®-HST 35 100
inclusion of air.
on the selection of the best shrink appliance for your specific purpose at
and wishes.
DERAY®-HST 40 170
Automotive
DERAY®-INS
Material
Thermal properties
Chemical properties
Technical Data
Current Values
Jacket Material
lead and cadmium
Surface
semi glossy
Specific gravity
1,3 g/cm3
Shrink ratio
≥ 2:1
10 % max.
ASTM-D 2671
Tensile strength
16 MPa
IEC 60684-2
Elongation
500 %
IEC 60684-2
Secant modulus
100 MPa max.
ASTM-D 882
Thermal ageing
(168 h at +158°C)
UL 224
Tensile strength
14 MPa
Elongation
400%
Test Methods
ASTM-D 792, A-I
Cold bend test
ASTM-D 2671 Meth. C
selfextinguishing
UL 224
Shrink temperature
+100°C to +200°C
temperature
-55°C to +135°C
Storage temperature
+40°C max.
Corrosive action
non-corrosive
ASTM-D 2671 Meth. A
Water absorption
0,40%
VDE 0473
21
Hose Bundling
DERAY®-DKI
Hose Bundling
In brake pipe, fuel line and cooling hose
systems of motor vehicles, bundling of
the pipes and hoses is required in order
to save space and achieve a specific
alignment of these parts. Moreover,
the pipes and hoses require protection
against vibration.
In its specific area of application,
DERAY®-DKI performs impressively
Characteristics
DERAY®-DKI, a specially modified double-chamber heat shrink tubing based
on cross-linked polyolefins, meets such
needs perfectly.
Halogen-free
Advantages
mm/min)
Fast shrinkage on the parts to be
bundled / protected
Good adhesion to the object
Abrasive protection under operating and extreme temperatures
Fixing of pipes, hoses or components in the required place
22
© ShawCor Ltd. Good abrasive resistance
on the selection of the best shrink appliance for your specific purpose at
documentation that we would be pleased to supply you with on request. The
operating instructions include information on safety matters relevant to the operation of our shrink appliances.
-55°C to +135°C
Processing
Processing is done using special appliances that were specifically designed
for hose bundling applications.
Automotive
DERAY®-DKI
Material
Thermal properties
Chemical properties
Technical Data
Current Values
Jacket Material
lead and cadmium
Surface
smooth
Specific gravity
1,10 g/cm3
Shrink ratio
≥ 2:1
Tensile strength
16 MPa
IEC 60684-2
Elongation
450 %
IEC 60684-2
Secant modulus
300 MPa max.
ASTM-D 882
Thermal ageing
(168 h at 150°C)
IEC 811-1-2
Tensile strength
14 MPa
Elongation
400 %
Test Methods
ASTM-D 792, A-I
Cold bend test
ASTM-D 2671 Meth. C
passed
FMVSS 302
Shrink temperature
+140°C to +200°C
Storage temperature
+40°C max.
temperature
-55°C to +135°C
IEC 216
Water absorption
0,30 %
VDE 0473
23
Cooling Water Hoses
DERAY®-KWS und KWS-R
Cooling Water Hoses
In the cooling systems of motor vehicle
engines, cooling water hoses and manifolds are exposed to the abrasive influence of surrounding components, e.g.
pipes and cables made of metal or plastic, Bowden cables and cable bundles.
A range of protective needs thus have
to be met. Fast shrinking and softer
materials only achieved inadequate to
poor results using comparable testing
methods.
DERAY®-KWS, a specially modified
heat shrink tubing based on cross-linked
polyolefins, meets all the needs of cooling water hoses perfectly. With interior
fluting it is available as DERAY®-KWS-R.
The specific area of application and
the conditions under which further processing is conducted mean that cooling
water hoses and manifolds have a special requirement profile. DERAY®-KWS
offers the following
Advantages
protection
No weld connection with the
surface of the part
24
© ShawCor Ltd. No deformation of cooling water
manifold during shrink process
Simultaneous contour adaptation
without bubbles forming
Bubble- and wrinkle-free shrink
covering of manifold parts with
extreme radii
In their specific area of application,
DERAY®-KWS and KWS-R perform impressively thanks to their outstanding.
Characteristics
Halogen-free
Processing
two options:
DERAY®-HST 35 100
DERAY®-HST 40 170
These tunnels allow simultaneous processing of several tubes. The surface of
the part to be protected must be free of
grease and oil prior to the shrink cover
being applied. Attention must be given,
moreover, to ensure that the shrink covering process commences at one end
in order to prevent inclusion of air. We
would be pleased to advise you on the
selection of the best shrink appliance
for your specific purpose at any time.
Flammability complies with JIS D
1201 1973 (classification: slow
burning, combustion rate max. 50
mm/min)
-35°C to +135°C
Automotive
DERAY®-KWS/KWS-R
Material
Thermal properties
Chemical properties
Technical Data
Current Values
Test Methods
Jacket Material
lead and cadmium
Surface
matt
Specific gravity
1,25 g/cm3
Shrink ratio
≥ 3:1
Tensile strength
15 MPa
IEC 60684-2
Elongation
420 %
IEC 60684-2
Secant modulus
150 MPa max.
ASTM-D 882
Thermal ageing
no cracks or breaks
(3000 h at 135°C)
Cold bend test
ASTM-D 2671 Meth C
passed
FMVSS 302
Shrink temperature
+120°C to +200°C
Storage temperature
+40°C max.
temperature
-55°C to +135°C
IEC 216
Corrosive action
non-corrosive
ASTM-D 2671 Meth. A
ASTM-D 792, A-I
Water absorption
0,15 %
VDE 0473
25
Automotive – Protecting Wiring Harnesses
In addition to the standard range of
heat shrink tubing products, DSG-Canusa provides solutions that are designed
specifically to meet the demanding requirements of automotive wiring harnesses. We supply tailor-made top quality
products for insulating ground connectors or splices or for longitudinal water
blocking of wiring harnesses.
Sealing of
26
© ShawCor Ltd. Cable bundles
End splices
Parallel splices
Connectors
Automotive
Splices
End splices
DERAY®-SPLICEMELT
DERAY®-SPLICEMELT-CAP
Crimped or ultrasonically welded parallel and end splices often require longitudinal water blockage and a high
resistance to thermal, chemical and
mechanical influences. Specifically for
automotive applications, we have developed sealing systems that successfully master these challenges. DERAY®Splicemelt, a specially modified heat
shrink tubing with a thermoplastic interior adhesive, meets these demanding
requirements even under adverse conditions. During the shrink process, the
hot-melt adhesive flows into all the cavities in the area to be sealed. The result
is a corrosion-proof, watertight seal.
Thanks to its fast and easy installation,
the two-in-one heat shrink tubing is also
well-suited for assembly line production
purposes.
Beside using DERAY®-Splicemelt, longitudinal water blockage of end splices
can easily be achieved by means of the
DERAY®-Splicemelt Cap. Available in 4
standard sizes and 2 standard colors
(black and clear), this product offers
reliable and low-cost sealing.
DERAY®-Splicemelt is a first-class highly
flexible splice sealing system that satisfies most automotive applications.
DERAY®-SPLICEMELT and SPLICEMELT-CAP
27
Sealing
DERAY®-SPLICEMELT
DERAY®-SPLICEMELT-CAP
Parallel- and End splices
Commonly, one of the most important
requirements of crimped end and parallel splices is longitudinal water blockage. At the same time, high resistance
to thermal, chemical and mechanical
stress is required. Numerous sealing
applications, especially in the automotive sector, have to meet these challenges. The environmental conditions vary
and hence the needs to be met by the
sealing solution.
DERAY®-SPLICEMELT, a heat shrink tubing made of radiation cross-linked modified PE with a thermoplastic interior
adhesive lining, meets all these requirements perfectly.
During the shrink process, the tubing
recovers such that the area to be sealed
is completely filled with hot-melt adhesive. Thanks to its fast and easy installation, the two-in-one heat shrink tubing
is also well-suited for series production
purposes.
Advantages
Easy processing
seal, offset and inkjet processes
protection
Resistant to temperatures up to
125°C
Low thermal stress of the part to be
covered during processing
No detachment under operating
temperatures
Watertight
Good adhesion to different types
of insulation materials, e.g. PVC,
VPE, PP-EPDM
Good resistance to aggressive
media and fuels
mm/min)
Processing
In general, DERAY®-SPLICEMELT can
be used with every type of shrink appliance. We recommend using one of the
following from our product line:
DERAY®-SpliceMan IR
DERAY®-DockMan Junior
Endsplice
DERAY®-FST
on the selection of the best shrink app
liance for your specific purpose at any
time. Descriptions of the individual
and wishes.
The jacket material of the black
version is self-extinguishing
28
Automotive
DERAY®-SPLICEMELT black
Material
Thermal properties
Chemical properties
Technical Data
Current Values
Jacket Material
lead and cadmium
Adhesive
Polyamid-basis
Surface
smooth
Specific gravity
1,25 g/cm3 max.
Shrink ratio
to 4:1
-10 % max.
ASTM-D 2671
Tensile strength
17 MPa
IEC 60684-2
Elongation
500 %
IEC 60684-2
Thermal ageing
(168 h at +160°C)
IEC 811-1-2
Tensile strength
12 MPa
Elongation
320 %
Test Methods
ASTM-D 792, A-I
Cold bend test
ASTM-D 2671 Meth. C
Jacket selfextinguishing
FMVSS 302
Shrink temperature
+150°C to +200°C
Storage temperature
+50°C max.
temperature
-40°C to +125°C
IEC 216
Compatibility with copper
non-corrosive
ASTM-D 2671 Meth. B
Electrical properties
Water absorption
0,50%
VDE 0473
Dielectric strength
18 kV/mm
VDE 0303 Part 2
Specific volume resistance
10
14
Ω x cm
VDE 0303 Part 3
29
DERAY®-SPLICEMELT clear
Material
Thermal properties
Chemical properties
Technical Data
Current Values
Jacket Material
lead and cadmium
Adhesive
Polyamid-basis
Surface
matt, smooth
Specific gravity
1,0 g/cm3 max.
Shrink ratio
to 4:1
-10 % max.
ASTM-D 2671
Tensile strength
15 MPa
IEC 60684-2
Elongation
400 %
IEC 60684-2
Thermal ageing
(168 h at +160°C)
IEC 811-1-2
Tensile strength
14 MPa
Elongation
400 %
Test Methods
ASTM-D 792, A-I
Cold bend test
ASTM-D 2671 Meth. C
passed
FMVSS 302
Shrink temperature
+125°C to +200°C
Storage temperature
+50°C max.
temperature
-40°C to +125°C
IEC 216
non-corrosive
ASTM-D 2671 Meth. B
30
© ShawCor Ltd. Water absorption
0,60 %
VDE 0473
Dielectric strength
20 kV/mm
VDE 0303 Part 2
10
14
Ω x cm
VDE 0303 Part 3
Automotive
Small Cable Bundles
DERAY®-PRESSMELT
DERAY®-PRESSMELT sealing system
DERAY®-PRESSMELT, is a special sealing
system comprising a heat shrink tubing
made of radiation cross-linked modified
PE, with an interior adhesive lining and
a clip-on profile consisting of a thermoplastic adhesive, which meets the protection needs of small cable bundles.
DERAY®-HOTMELT adhesive insert
The DERAY®-PRESSMELT system is
available for temperatures up to either
85°C, 105°C or 125°C. It consists of
two main components
The adhesive component is available
in various options. Over a wide temperature range, both excellent sealing
quality and the retention of the full functionality of the individual cables are
guaranteed.
Heat shrink tubing
Cross-linked, adhesive-lined polyolefin.
Depending on the application, the follo
wing types of heat shrink tubing can be
used:
DERAY®-IPM
DERAY®-IAKT
DERAY®-IHKT
Advantages
Amber up to +85°C
Easy processing
Red up to +105°C
seal, offset and inkjet processes
Yellow up to +125°C
Customer-specific solutions are our
strength. Our engineers and experts
will find the optimum combination of
components for your application while
our experienced sales team would be
pleased to advise you at all times and
present the right solution for your needs
in a personal discussion.
For highly heat-sensitive applications
involving small cable bundles, we recommend the use of:
DERAY®-COLDMELT Lite
protection
Permanently resistant to temperatures up to 85°C / 105°C / 125°C
sealed during processing
temperatures
Watertight
Good adhesion to different types
of insulation materials, e.g. PVC,
VPE, PP-EPDM
media and fuels
mm/min)
The jacket material of the black
option is self-extinguishing
31
Sealing system DERAY®-PRESSMELT
Preparation of the shrink process
Processing
Selection of product size: Kindly
address any questions you may have
concerning the adhesive insert and
tubing section sizes to our Customer
Development department.
We recommend using the following
shrink appliances for processing
DERAY®-PRESSMELT:
DERAY®-WorkMan
DERAY®-DockMan
Preparation of the area to be
sealed
In the area to be sealed, the profile
is clipped or pushed on to individual
cables of the cable bundle. Then the
heat shrink tubing section is applied.
During the shrink process, the shrinking
tube section presses the adhesive between the individual cables. At the same
time, the adhesive swells, thus ensuring
that the sealing area is filled completely.
32
© ShawCor Ltd. For information about their mode of
operation and the technical data please
refer to our equipment documentation.
operation of our shrink appliances.
Automotive
DERAY®-IPM (PRESSMELT)
Material
Thermal properties
Chemical properties
Technical Data
Current Values
Jacket Material
lead and cadmium
Adhesive
PE/PA/EVA-Basis
Surface
smooth
Specific gravity
1,0 g/cm3 max.
Shrink ratio
up to 6:1
-20 % max.
ASTM-D 2671
Tensile strength
14 Mpa
IEC 60684-2
Elongation
550%
IEC 60684-2
Thermal ageing
(168 h at +160°C)
IEC 811-1-2
Tensile strength
11 MPa
Elongation
300 % min.
Test Methods
ASTM-D 792, A-I
Cold bend test
ASTM-D 2671 Meth. C
passed
FMVSS 302
Shrink temperature
+100°C to +200°C
Storage temperature
+50°C max.
temperature
-40°C to +105°C
IEC 216
Corrosive action
non-corrosive
ASTM-D 2671 Meth. A
non-corrosive
ASTM-D 2671 Meth. B
Water absorption
0,10 %
VDE 0473
Dielectric strength
20 kV/mm
VDE 0303 Part 2
10
14
Ω x cm
VDE 0303 Part 3
33
DERAY®-IAKT black (PRESSMELT)
Material
Technical Data
Current Values
Jacket Material
lead and cadmium
Adhesive
PE/EVA-Basis
Surface
matt, smooth
Specific gravity
1,25 g/cm3 max.
Shrink ratio
3:1
Test Methods
ASTM-D 792, A-I
4:1
Thermal properties
Chemical properties
34
© ShawCor Ltd. -15 % max. (3:1)
ASTM-D 2671
-18 % max. (4:1)
ASTM-D 2671
Tensile strength
15 MPa
IEC 60684-2
Elongation
400 %
IEC 60684-2
Secant modulus
175 MPa max.
ASTM-D 882
Thermal ageing
(168 h at +150°C)
IEC 811-1-2
Tensile strength
14 MPa
Elongation
320 %
Cold bend test
ASTM-D 2671 Meth. C
Flammability
ASTM-D876
Shrink temperature
+100°C to +200°C
Storage temperature
+40°C max.
temperature
-55°C to +110°C
IEC 216
Water absorption
0,15 %
VDE 0473
Automotive
DERAY®-IAKT clear (PRESSMELT)
Material
Technical Data
Current Values
Jacket Material
lead and cadmium
Adhesive
PE/EVA-Basis
Surface
matt, smooth
Specific gravity
1,00 g/cm3 max.
Shrink ratio
3:1
Test Methods
ASTM-D 792, A-I
4:1
Thermal properties
Chemical properties
-15 % max. (3:1)
ASTM-D 2671
-18 % max. (4:1)
ASTM-D 2671
Tensile strength
19 MPa
IEC 60684-2
Elongation
500 %
IEC 60684-2
Secant modulus
175 MPa max.
ASTM-D 882
Thermal ageing
(168 h at +150°C)
IEC 811-1-2
Tensile strength
12 MPa
Elongation
450 %
Cold bend test
ASTM-D 2671 Meth. C
Flammability
passed
FMVSS 302
Shrink temperature
+100°C to +200°C
Storage temperature
+40°C max.
temperature
-55°C to +110°C
IEC 216
Water absorption
0,17 %
VDE 0473
35
DERAY®-IHKT black (PRESSMELT)
Material
Thermal properties
Chemical properties
Technical Data
Current Values
Material
lead and cadmium
Adhesive
Polyamid-basis
Surface
matt, smooth
Specific gravity
1,25 g/cm3 max.
Shrink ratio
4:1
-18 % max.
ASTM-D 2671
Tensile strength
17 MPa
IEC 60684-2
Elongation
600 %
IEC 60684-2
Thermal ageing
(168 h at +160°C)
IEC 811-1-2
Tensile strength
11 MPa
Elongation
400 %
Test Methods
ASTM-D 792, A-I
Cold bend test
ASTM-D 2671 Meth. C
Flammability
ASTM-D 876
Shrink temperature
+100°C to +200°C
Storage temperature
+50°C max.
temperature
-55°C to +125°C
IEC 216
Corrosive action
non-corrosive
ASTM-D 2671 Meth. A
Resistance against chemicals very good
Water absorption
36
© ShawCor Ltd. 0,10 %
VDE 0473
Automotive
DERAY®-IHKT clear (PRESSMELT)
Material
Thermal properties
Chemical properties
Technical Data
Current Values
Jacket Material
lead and cadmium
Adhesive
Polyamid-basis
Surface
matt, smooth
Specific gravity
1,00 g/cm3 max.
Shrink ratio
4:1
-18 % max.
ASTM-D 2671
Tensile strength
19 MPa
IEC 60684-2
Elongation
500 %
IEC 60684-2
Thermal ageing
(168 h at +160°C)
IEC 811-1-2
Tensile strength
16 MPa
Elongation
450 %
Test Methods
ASTM-D 792, A-I
Cold bend test
ASTM-D 2671 Meth. C
Flammability
passed
FMVSS 302
Shrink temperature
+100°C to +200°C
Storage temperature
+50°C max.
temperature
-55°C to +125°C
IEC 216
Corrosive action
non-corrosive
ASTM-D 2671 Meth. A
Water absorption
0,10 %
VDE 0473
37
DERAY®-Adhesive Insert-System
Technical Data
Material
Thermal
properties
Chemical
properties
38
Current Values
Test Methods
DERAY®Adhesive Insert
85°C-System
105°C-System
Material
modified EVA,
free of lead and
cadmium
modified PA-Hotmelt, modified PA-Hotmelt,
free of lead and
free of lead and
cadmium
cadmium
Surface
smooth
smooth
Specific gravity
0,97 g/cm max.
0,98 g/cm max.
0,96 g/cm3 max.
ASTM-D 792, A-I
Cold bend test
does not break at
-40°C
does not break at
-40°C
does not break at
-40°C
ASTM-D 2671
Meth. C
Storage
temperature
+30°C max.
+30°C max.
+30°C max.
Continuous operating temperature
-40°C to +85°C
-40°C to +105°C
-40°C to +125°C
Softening point
ca. +90°C
ca. +130°C
ca. +130°C
Water absorption
0,5 % max.
0,5 % max.
0,5 % max.
© ShawCor Ltd. 3
125°C-System
smooth
3
DIN 53495
Automotive
Medium-Sized Cable Bundles
DERAY®-DUOMELT
DERAY®-DUOMELT Sealing system
DERAY®-DUOMELT is an enhanced
form of the DERAY®-Pressmelt system.
The DERAY®-Duomelt system is particularly suitable for sealing small and medium-sized cable bundles. It combines
DERAY®-Duomelt adhesive strips and
a heat shrink tubing made of radiation
cross-linked modified PE, for example
DERAY®-IAKT or DERAY®-IHKT.
It consists of two main components:
Advantages
1. Hot-Melt Adhesive Strip
Easy processing
Resistant to temperatures up to 110°C:
modified copolymer, colour: amber
protection
modified polyamide, colour: red
Permanently resistant to tempera
tures up to 110°C / 125°C
The adhesive strips are lined with a strip
of butyl rubber to ensure that the adhesive is evenly distributed throughout the
bundle and to assist with the installation. DERAY®-Duomelt can be processed
by a number of standard shrink appliances. Over a wide temperature range,
both excellent sealing quality and the
retention of the full functionality of the
individual cables are guaranteed.
Both systems feature a butyl rubber
lining.
covered during processing
Standard types:
temperatures
The self-adhesive strips allow processing in a pre-assembly line.
2. Heat Shrink Tubing
The DERAY®-DUOMELT-System system
is available for temperatures up to
either 110°C or 125°C.
(width/thickness)
10/1.1
10/1.5
15/1.5
15/1.8
Watertight
Good adhesion to the common
types of plug housing materials as
well as PVC, VPE, PP-EPDM
Colour: clear and black
DERAY®-IAKT
DERAY®-IHKT
39
Sealing system DERAY®-DUOMELT
Further advantages
media and fuels
Flammability pursuant to FMVSS
mm/min) is complied with by both
the hot-melt adhesive strip and the
adhesive lining of the heat shrink
tubing. The jacket material of the
black option is self-extinguishing.
Preparation of the shrink process
Selection of product size: Kindly
address any questions you may have
concerning the adhesive strip and tubing section sizes to our CustomerOriented Development department.
sealed
The DERAY®-DUOMELT-Strip is laid out
on a covered surface and then the upper
release paper is removed. The individual
cables of the wire harness are spread
out beside each other and embedded in
the butyl rubber compound using about
half the length of the strip.
40
© ShawCor Ltd. The other half of the DERAY®-DUOMELTstrip is then folded over the embedded
cables and pressed in place. In so doing, attention must be given to ensure
that both ends of the strip overlap.
The heat shrink tubing section that had
already been applied at the start of the
installation process is then pushed over
the “parcels” of cables prepared as
above and positioned centrally.
Processing
DERAY®-DUO-MELT:
DERAY®-WorkMan
DERAY®-DockMan
For information about their mode of
operation and the technical data please
refer to our equipment documentation.
operation of our shrink appliances.
Automotive
DERAY®-Adhesive Strip 85°C-System
Material
Thermal properties
Chemical properties
Technical Data
Current Values
Test Methods
Material
modified copolymere,free of
lead and cadmium
Specific gravity
0,97 g/cm3 max.
Surface
smooth
Cold bend test
-40°C
Storage temperature
+30°C max.
temperature
-40°C to +85°C
Softening point
ca. +90°C
passed
FMVSS 302
Water absorption
0,5 % max.
DIN 53495
ASTM-D 792, A-I
ASTM-D 2671 Meth. C
Sealing Compound – Butyl Rubber
Material
Thermal properties
Chemical properties
Technical Data
Current Values
Material
synthetic rubber-basis, free
of lead and cadmium
Specific gravity
1,4 g/ cm3 max.
Colour
black
Cold bend test
-40°C
Storage temperature
+30°C max.
temperature
-40°C to +85°C/+105°C
Water absorption
0,5 % max.
Test Methods
ASTM-D 792, A-I
ASTM-D 2671 Meth. C
41
DERAY®-IAKT black (DUOMELT)
Material
Technical Data
Current Values
Jacket Material
lead and cadmium
Adhesive
PE/EVA-Basis
Surface
matt, smooth
Specific gravity
1,25 g/cm3 max.
Shrink ratio
3:1
Test Methods
ASTM-D 792, A-I
4:1
Thermal properties
Chemical properties
42
© ShawCor Ltd. -15 % max. (3:1)
ASTM-D 2671
-18 % max. (4:1)
ASTM-D 2671
Tensile strength
15 MPa
IEC 60684-2
Elongation
400 %
IEC 60684-2
Secant modulus
175 MPa max.
ASTM-D 882
Thermal ageing
(168 h at +150°C)
IEC 811-1-2
Tensile strength
14 MPa
Elongation
320 %
Cold bend test
ASTM-D 2671 Meth. C
Flammability
ASTM-D876
Shrink temperature
+100°C to +200°C
Storage temperature
+40°C max.
temperature
-55°C to +110°C
IEC 216
Water absorption
0,15 %
VDE 0473
Automotive
DERAY®-IAKT clear (DUOMELT)
Material
Technical Data
Current Values
Jacket Material
lead and cadmium
Surface
matt, smooth
Specific gravity
1,00 g/cm3 max.
Shrink ratio
3:1
Test Methods
ASTM-D 792, A-I
4:1
Thermal properties
Chemical properties
-15 % max. (3:1)
ASTM-D 2671
-18 % max. (4:1)
ASTM-D 2671
Tensile strength
19 MPa
IEC 60684-2
Elongation
500 %
IEC 60684-2
Secant modulus
175 MPa max.
ASTM-D 882
Thermal ageing
(168 h at +150°C)
IEC 811-1-2
Tensile strength
12 MPa
Elongation
450 %
Cold bend test
ASTM-D 2671 Meth. C
Flammability
passed
FMVSS 302
Shrink temperature
+100°C to +200°C
Storage temperature
+40°C max.
temperature
-55°C to +85°C
IEC 216
Water absorption
0,17 %
VDE 0473
43
DERAY®-Adhesive Strip 105°C-System
Material
Thermal properties
Chemical properties
Technical Data
Current Values
Test Methods
Material
modified copolymere,free of
lead and cadmium
Specific gravity
0,98 g/cm3 max.
Surface
smooth
Cold bend test
-40°C
Storage temperature
+30°C max.
temperature
-40°C to +105°C
Softening point
ca. +130°C
passed
FMVSS 302
Water absorption
0,5 % max.
DIN 53495
ASTM-D 792, A-I
ASTM-D 2671 Meth. C
Material
Thermal properties
Chemical properties
44
© ShawCor Ltd. Technical Data
Current Values
Material
of lead and cadmium
Specific gravity
1,4 g/ cm3 max.
Colour
black
Cold bend test
-40°C
Storage temperature
+30°C max.
temperature
-40°C to +85°C/+105°C
Water absorption
0,5 % max.
Test Methods
ASTM-D 792, A-I
ASTM-D 2671 Meth. C
Automotive
DERAY®-IHKT black (DUOMELT)
Material
Thermal properties
Chemical properties
Technical Data
Current Values
Jacket Material
lead and cadmium
Adhesive
Polyamid-basis
Surface
matt, smooth
Specific gravity
1,25 g/cm3 max.
Shrink ratio
4:1
-18 % max.
ASTM-D 2671
Tensile strength
17 MPa
IEC 60684-2
Elongation
600 %
IEC 60684-2
Thermal ageing
(168 h at +160°C)
IEC 811-1-2
Tensile strength
11 MPa
Elongation
400 %
Test Methods
ASTM-D 792, A-I
Cold bend test
ASTM-D 2671 Meth. C
ASTM-D 876
Shrink temperature
+100°C to +200°C
Storage temperature
+50°C max.
temperature
-55°C to +125°C
IEC 216
Corrosive action
non-corrosive
ASTM-D 2671 Meth. A
Water absorption
0,10 %
VDE 0473
45
DERAY®-IHKT clear (DUOMELT)
Material
Thermal properties
Chemical properties
Technical Data
Current Values
Jacket Material
lead and cadmium
Adhesive
Polyamid-basis
Surface
matt, smooth
Specific gravity
1,00 g/cm3 max.
Shrink ratio
4:1
-18 % max.
ASTM-D 2671
Tensile strength
19 MPa
IEC 60684-2
Elongation
500 %
IEC 60684-2
Thermal ageing
(168 h at +160°C)
IEC 811-1-2
Tensile strength
16 MPa
Elongation
450 %
Test Methods
ASTM-D 792, A-I
Cold bend test
ASTM-D 2671 Meth. C
passed
FMVSS 302
Shrink temperature
100°C to 200°C
Storage temperature
+50°C max.
temperature
-55°C to +125°C
IEC 216
Corrosive action
non-corrosive
ASTM-D 2671 Meth. A
Water absorption
46
© ShawCor Ltd. 0,10 %
VDE 0473
Automotive
Large Cable Bundles
DERAY®-COLDMELT I
DERAY®-COLDMELT Lite
DERAY®-COLDMELT sealing system
DERAY®-COLDMELT I is a system used
to create a “cold” longitudinal water
blocking for cable bundles incorporating more than 20 individual cables.
For applications with fewer than 20 individual cables we recommend the use
of DERAY®-COLDMELT Lite. Many insulation materials are highly heat-sensitive
when undergoing processing. Lengthy
exposure to heat when using conventional sealing systems can cause damage notably to the cable insulation of
very thin wires located directly beneath
the heat shrink tubing. A new type of
sealing system is thus required.
Over a wide temperature range, both
excellent sealing quality and the retention of the full functionality of the individual cables are guaranteed. The selfadhesive strips allow processing in a
pre-assembly line.
DERAY®-COLDMELT, a special sealing
system comprising a heat shrink tubing
made of radiation cross-linked modified
PE and a sealing component made of
butyl rubber, meets the protection needs
of large cable bundles.
A special sealing system, no longer
based on hot-melt adhesive, needs significantly less thermal energy for sealing
purposes. The exposure to heat is considerably reduced (max. approx. 60°C)
such that cable insulation damage and
resultant short circuits are avoided. A
further benefit of the Coldmelt sealing
system is a reduction in the processing
time required.
Advantages
media and fuels
Flammability pursuant to FMVSS
mm/min) is complied with by all
components.
Easy processing
The DERAY®-COLDMELT-System is avai
lable for the following temperatures:
protection
resistant to temperatures up to
+85°C
Permanently resistant to temperatures up to 85°C / 105°C / 125°C
+105°C
Very low thermal stress of the part
to be sealed during processing
+125°C (COLDMELT HT)
Short process times and hence low
overall cost
Watertight
Good adhesion to the common
types of plug housing materials as
well as different types of insulation
materials such as PVC, VPE,
PP-EPDM
47
DERAY®-COLDMELT I sealing system
The DERAY®-Coldmelt-system consists of two main components:
1. Butyl rubber strip with peel
able release paper strip on both
sides
Width: 19 mm
Thickness: 1,5 mm
Standard lengths: 50 and 70 mm
To suit special requirements, custom
lengths are also available.
2.
DERAY®-CS
heat shrink tubing
Cross-linked polyolefin
Colour: black
sealed
First, the upper release paper of the butyl rubber strip is removed. The individual cables of the cable bundle are spread
out beside each other and embedded in
the butyl rubber compound using about
half the length of the strip. The other half
of the DERAY®-Coldmelt I strip is then
folded over the embedded cables and
pressed in place. In so doing, attention
must be given to ensure that both ends
of the strip overlap.
48
© ShawCor Ltd. This process is repeated as many times
as needed to embed all cables in butyl
rubber strips. The individual “parcels”
of cables are laid on top of each other.
Then the remaining release paper is removed and the individual “parcels” are
combined to form a “block”. The heat
shrink tubing section that had already
been applied at the start of the installation process is then pushed over the
“parcels” of cables prepared as above,
positioned centrally and shrunk on.
Depending on the application, DERAY®Coldmelt I may also be used without
heat shrink tubing selection.
Processing
DERAY®-Cold-melT I:
DERAY®-SealMan 53/70
for board applications
DERAY®-SealMan 53/70
for bench applications
Continuous operating temperature using
DERAY®-COLDMELT HT: +125°C
Automotive
DERAY®-Coldmelt I 85°C-System
Material
Thermal properties
Chemical properties
Technical Data
Current Values
Test Methods
Jacket Material
modified Polyolefin, free of
lead, cadmium halogen and
FCKW
Surface
smooth
Specific gravity
1,4 g/cm3 max.
Shrink ratio
≥ 3:1
Tensile strength
11 MPa
IEC 60684-2
Elongation
400 %
IEC 60684-2
Secant modulus
40 MPa max.
ASTM-D 882
Thermal ageing
no tearing or cracking
IEC 811-1-2
Cold bend test
ASTM-D 2671 Meth. C
Flammability
40 mm/minute
FMVSS 302
Shrink temperature
> +250°C
Storage temperature
+40 °C max.
temperature
-35°C to +85°C
IEC 216
Corrosive action
non-corrosive
ASTM-D 2671 Meth. A
non-corrosive
ASTM-D 2671 Meth. B
Water absorption
0,40%
VDE 0473
ASTM-D 792, A-I
49
DERAY®-Coldmelt I 105°C-System
Material
Thermal properties
Chemical properties
50
Current Values
Test Methods
Jacket Material
FCKW
Surface
smooth
Specific gravity
1,4 g/cm3 max.
Shrink ratio
≥ 3:1
Tensile strength
11 MPa
IEC 60684-2
Elongation
400 %
IEC 60684-2
Secant modulus
40 MPa max.
ASTM-D 882
Thermal ageing
IEC 811-1-2
Cold bend test
ASTM-D 2671 Meth. C
Flammability
40 mm/minute
FMVSS 302
Shrink temperature
> +250°C
Storage temperature
+40 °C max.
temperature
-35°C to +105°C
IEC 216
Corrosive action
non-corrosive
ASTM-D 2671 Meth. A
non-corrosive
ASTM-D 2671 Meth. B
Water absorption
0,40%
VDE 0473
ASTM-D 792, A-I
Automotive
DERAY®-Coldmelt I HT 125°C-System
Material
Thermal properties
Chemical properties
Technical Data
Current Values
Test Methods
Jacket Material
FCKW
Surface
smooth
Specific gravity
1,45 g/cm3 max.
Shrink ratio
≥ 3:1
Tensile strength
14 MPa
IEC 60684-2
Elongation
410 %
IEC 60684-2
Secant modulus
40 MPa max.
ASTM-D 882
Thermal ageing
IEC 811-1-2
Cold bend test
ASTM-D 2671 Meth. C
Flammability
40 mm/minute
FMVSS 302
Shrink temperature
>250°C
Storage temperature
+40 °C max.
temperature
-35°C to +125°C
IEC 216
Corrosive action
non-corrosive
ASTM-D 2671 Meth. A
non-corrosive
ASTM-D 2671 Meth. B
Water absorption
0,40%
VDE 0473
ASTM-D 792, A-I
51
DERAY®-COLDMELT I
Material
Thermal properties
Chemical properties
52
Current Values
Material
of lead and cadmium
Specific gravity
1,4 g/cm3 max.
Colour
black
Cold bend test
-40°C
Storage temperature
+40°C max.
temperature
-35°C to +85°C/+105°C
Water absorption
0,5 % max.
Test Methods
ASTM-D 792, A-I
ASTM-D 2671 Meth. C
Automotive
Half-Shell Sealing System
DERAY®-COLDMELT II
DERAY®-COLDMELT II custom grommet
DERAY®-COLDMELT II is a split half-shell
sealing system for longitudinal water
blocking of wire harnesses and pipe/
hose systems (air conditioning pipes
and cooling water hoses). The optimum
combination of longitudinal water blocking in the wire harness and at the vehicle body feed-through location in one
system. In addition to its longitudinal
water blocking capability, the half-shell
sealing system offers high resistance
to thermal, mechanical and chemical
influences, combined with user-friendly
handling and easy installation at the
body or panel feed-through location.
Due to the usage of two half-shells, there
is no need to thread the cable bundle in
place. The two half-shells can easily be
unlocked so that disassembly is possible at any time. The compact system can
be integrated into the automated wire
harness production process without
diffi
culty whatsoever. It is resistant to
aggressive media and fuel and allows
“cold” creation of longitudinal water
blocking in cable bundles. Some insulation materials are highly heat-sensitive
when undergoing processing. Lengthy
exposure to heat when using conventional sealing systems can cause damage notably to the cable insulation of
very thin wires located directly beneath
the heat shrink tubing. A new type of
sealing system is thus required.
DERAY®-COLDMELT II is based on
the proven and widely used DERAY®COLDMELT I system. In this system, a
custom designed grommet substitutes
the DERAY®-CS heat shrink tubing. As
a sealing material the proven sealing
component of the DERAY®-COLDMELTsystem on the basis of butyl rubber is
used.
Advantages
Longitudinal water blocking and
gas-proofness
Easy processing; threading of wire
harnesses not necessary
This grommet consists of two half-shells
that are composed of a sealing compound made of polyamide (PA) and a
moulded part (e.g. a socket) made of
TPE. The special contour of the moulded
part ensures optimum sealing results at
the body feed-through locations. The
system’s special advantage, however,
is that it also ensures perfect sealing
of the wires and that time-consuming
threading of the wire harness is no longer
necessary.
DERAY®-COLDMELT II is specifically
designed to provide longitudinal water
blocking in large cable bundles.
53
Custom designed grommet DERAY®-COLDMELT II
Further advantages
Automation friendly
media and fuel
No thermal stressing of object
DERAY®-Coldmelt II is processed
using the DERAY®-Coldmelt-Processor.
DERAY®-COLDMELT II
54
Automotive
DERAY®-COLDMELT II
Material
Thermal properties
Technical Data
Current Values
Material
TPE
Spec. Volume
0,95 g/cm3
Shore hardness
65 Shore A
Tensile strength
4,5/10 N/mm
DIN 53 504
Elongation
445 %
DIN 53 504
Tensile strength
14 MPa
IEC 60684-2
Elongation
410 %
IEC 60684-2
Secant modulus
40 MPa max.
ASTM-D 882
Deformation
(each direction)
(Platte 150*100*2 mm)
1,5 – 2,5 %
1,5 – 2,5 %
Pressure deformation
24 Std. 23°C
24 Std. 70°C
24 Std. 100°C
DIN 53 479
DIN 53 505
2
24 %
38 %
44 %
Test Methods
DIN 53 517
55
DERAY®-COLDMELT II
Material
Technical Data
Current Values
Material
heat stabilized Polypropylen,
liability modified
Fiberglas content
30 %
Specific gravity
1,13 g/cm
DIN 53 479
3
Breakdown voltage
Thermal properties
56
© ShawCor Ltd. Test Methods
DIN 53 455
Ultimate Elongation
84 MPa
DIN 53 455
Strength-E-Modul
2 %
DIN 53 457
Charpy impact strength
6000 MPa
DIN 53 453
CharpyNotched impact strength
28 kJ/m
DIN 53 453
8 kJ/m
DIN 53 456
Brinell hardness (H358/30)
110 MPa
VICAT Softening temp.
A/50 (10 N)
B/50 (50 N)
+162°C
+127°C
ISO 306
ISO 306
Dimensional stability temp.
HDT Af (1,80 MPa)
HDT Bf (0,45 MPa)
+144°C
+159°C
ISO 75
ISO 75
2
2
Automotive
Insulating and Protecting Caps
DERAY®-BIOK
DERAY®-HIOK
DERAY®-IOK
End splices
Non-shrinking insulating caps allow
easy and low-cost insulation of crimped
and ultrasonically welded end splices.
They can be used in all areas where it is
necessary to insulate end splices.
The cap size is selected to suit the diameter of the end splice to be insulated.
The length of the cap is selected such
that the stripped part of the end splice is
given sufficient cover.
No tools or processing appliances are
required when installing DERAY®-Caps .
The fact that the insulating cap can simply
be slotted in place means it is particularly
well-suited for pre- and post-assembly use
on transfer lines.
DSG-Canusa offers three different types
of insulating caps:
DERAY®-IOK
DERAY®-HIOK
DERAY®-BIOK
57
Insulating Cap DERAY®-IOK
DERAY®-IOK is an opaque, full-coloured
PVC insulating cap that only needs to be
pushed in place to offer reliable electrical
insulation of ultrasonically welded end
and crimp splices in wire harnesses and
electronic components.
The cap can be installed quickly as no
exposure to heat is required. All it needs
is simply to be pushed in place.
Processing
DERAY®-IOK offers the following:
The cap size is to be selected to suit the
diameter of the end splice to be insulated. The length of the cap is to be selected such that the stripped part of the end
splice is given sufficient cover.
Advantages
No tools or processing appliances are
required when installing DERAY®-IOK.
The fact that the insulating cap can
simply be slotted in place means it is
particularly well-suited for pre- and postassembly use on transfer lines.
Ensures 100% electrical insulation
media and fuel
tures up to 85°C
temperatures
Easy installation without processing
appliances; tight fit on object
thanks to optimum size selection
Various colours available on
request; therefore, particularly
suitable for colour marking
DERAY®-IOK insulating caps insulating
caps are resistant to chemicals and fuels.
DERAY®-IOK insulating caps are resistant to temperatures up to 85°C and
self-extinguishing.
Cross-sections from 0,7 mm² to 16 mm²
-35°C to +85°C
58
Automotive
DERAY®-IOK Insulating Cap
Material
Chemical properties
Technical Data
Current Values
Test Methods
Material
Soft PVC, stabilised, free of
lead and cadmium
Resistance against tearing
15 N/mm min.
DIN 53 507, Meth. A
Shore Hardness A
ca. 70
DIN 53 505
Thermal ageing
3.000 h at +90°C:
no cracks or breaks
temperature
-35°C to +85°C:
no cracks or breaks
Flammability
ca. 45 mm/minute
MVSS-302
non-corrosive
ASTM-D 2671, Meth. B
Ordering information
Internal diameter
Length
Wall Thickness
Colour
Product
D (mm)
L (mm)
s (mm)
3,0
30
0,75
green
IOK 3,0 x 30
4,0
35
1,0
grey
IOK 4,0 x 35
5,0
30
1,0
blue
IOK 5,0 x 30
6,0
35
1,2
grey
IOK 6,0 x 35
8,0
35
1,2
grey
IOK 8,0 x 35
9,5
30
1,25
yellow
IOK 9,5 x 35
10,0
40
1,3
grey
IOK 10,0 x 40
12,0
35
1,25
red
IOK 12,0 x 35
14,0
35
2,0
black
IOK 14,0 x 35
Various sizes and colours available on request.
59
DERAY®-HIOK Insulating Cap
DERAY®-HIOK insulating caps are resistant to temperatures up to 85°C.
-35°C to +85°C
Processing
The DERAY®-HIOK cap differs from the
DERAY®-IOK cap by way of the indentation cut in the cap interior that enables
crimp splices to be firmly located. The
translucent nature of the non-shrinking
insulating cap facilitates positioning.
The soft PVC ensures reliable electrical insulation of end splices in wire
harnesses and electronic components.
The cap can be installed quickly as
no exposure to heat is required. All it
needs is simply to be pushed in place.
That means: excellent conditions for
process automation.
The cap size is to be selected to suit
the size of the crimp ring. The length of
the cap is to be selected such that the
stripped part of the end splice is given
sufficient cover. No tools or processing
appliances are required when installing
DERAY®-HIOK. The fact that the insulating cap can simply be slotted in place
means it is particularly well-suited for
pre- and post-assembly use on transfer
lines. The indentation cut ensures that
the cap is firmly located on the splice.
DERAY®-HIOK offers the following:
Advantages
media and fuel
Good adhesion to various types of
splices thanks to the specifically
designed indentation cut
temperatures
Translucent material allows optimum
positioning
tures up to 85°C
DERAY®-HIOK insulating caps are resistant to chemicals and fuels and provide
good adhesion properties due to their
specific design.
60
Automotive
DERAY®-HIOK Insulating Cap
Material
Chemical properties
Technical Data
Current Values
Test Methods
Material
Soft PVC, stabilised, free of
lead and cadmium
Resistance against tearing
min. 15 N/mm
DIN 53 507, Meth. A
Shore Hardness A
ca. 60
DIN 53 505
Thermal ageing
3.000 h at +90°C:
no cracks or breaks
temperature
-35°C to +85°C:
no cracks or breaks
Flammability
ca. 45 mm/Min.
MVSS-302
non-corrosive
Internal diameter
Length
Wall Thickness
Colour
Product
D (mm)
L (mm)
s (mm)
3,0
35
1,0
grey-transp.
HIOK 3,0 x 35
3,7
35
1,0
yellow-transp.
HIOK 3,7 x 35
4,5
35
1,0
green-transp.
HIOK 4,5 x 35
5,0
35
1,0
blue-transp.
HIOK 5,0 x 35
6,0
35
1,0
black-transp.
HIOK 6,0 x 35
6,5
35
1,0
green-transp.
HIOK 6,5 x 35
7,5
35
1,25
yellow-transp.
HIOK 7,5 x 35
8,0
35
1,25
blue-transp.
HIOK 8,0 x 35
9,5
35
2,0
transp.
HIOK 9,5 x 35
11,0
35
2,0
white-transp.
HIOK 11,0 x 35
61
Insulating Cap DERAY®-BIOK
DERAY®-BIOK insulating caps are resistant to temperatures up to 85°C.
Processing
DERAY®-BIOK is a slip-on, non-shrinking,
translucent polyolefin insulating cap
with an integral butyl rubber liner which
ensures reliable electrical insulation of
end splices in wire harnesses and electronic components. The cap can be installed quickly as no exposure to heat
is required. All it needs is simply to be
pushed in place. That means: excellent
conditions for process automation.
DERAY®-BIOK insulating caps are resis
tant to chemicals and fuels and provide
good adhesion to various substrates
such as PVC, XLPE and PP-EPDM due to
their interior lining with several strips of
butyl rubber.
62
© ShawCor Ltd. The cap size is to be selected to suit the
diameter of the end splice to be insulated. The length of the cap is to be selected such that the stripped part of the end
splice is given sufficient cover. No tools
or processing appliances are required
when installing DERAY®-BIOK. The fact
that the insulating cap can simply be
slotted in place means it is particularly
well-suited for pre- and post-assembly
use on transfer lines.
DERAY®-BIOK offers the following:
Advantages
Good adhesion to the object due
to the interior lining with butyl
rubber strips
media and fuel
Permanently resistant to temperatures up to 85°C
Good adhesion to various types of
insulation materials such as PVC,
VPE, PP-EPDM
temperatures
Translucent material allows optimum positioning
Halogen-free
Complies with FMVSS 302
Combines the advantages of
DERAY®-IOK and DERAY®-HIOK
Automotive
DERAY®-BIOK 85°C System
Material
Chemical properties
Technical Data
Current Values
Test Methods
Jacket Material
lead, cadmium, halogen and
FCKW
Adhesive layer
modified butyl rubber
Shore Hardness D
ca. 42
Thermal ageing
3.000 h at +85°C:
no cracks or breaks
temperature
-35°C to +85°C:
no cracks or breaks
Flammability
ca. 45 mm/minute
non-corrosive
DIN 53 505
Internal diameter
Length
Colour
suitable for
Product
D (mm)
L (mm)
3,0
42
transp.
1,4 - 2,5 mm2
BIOK 3,0 x 42
3,5
42
yellow-transp.
2,5 - 2,9 mm
2
BIOK 3,5 x 42
4,0
42
blue-transp.
2,9 - 3,6 mm
2
BIOK 4,0 x 42
5,0
42
green-transp.
3,6 - 4,1 mm
2
BIOK 5,0 x 42
5,5
42
yellow-transp.
4,1 - 4,5 mm
2
BIOK 5,5 x 42
6,0
42
blue-transp.
4,5 - 5,3 mm
2
BIOK 6,0 x 42
7,0
42
transp.
5,3 - 6,5 mm
2
BIOK 7,0 x 42
9,5
45
green-transp.
6,5 - 7,5 mm
2
BIOK 9,5 x 45
12
45
transp.
On demand
cross section range*
BIOK 12 x 45
* Ultrasonic welded end connectors, values serve as a proposal
63
DERAY®-AUTOSEAL
New automatic sealing solution for automotive electrical systems
Automatic sealing DERAY®-AUTOSEAL
Automatic sealing
Advantages
This type of sealing consists of a superabsorbent polymer – integrated in cellulose or a similar material – which is
able to absorb up to 300 times its own
weight in water, depending on its concentration and granulation.
For the purpose of sealing automotive
electrical systems, however, such an
increase in volume is only required to
a smaller extent. What matters here is
to close the spaces occurring and block
the water instantly.
The cellulose is for the very rapid absorption of water, the superabsorbent
polymer for water blockage and permanent water absorption.
If temperatures rise, the water absorbed
will evaporate.
Sealing on demand
The system works at any time,
again and again.
If temperatures rise, the water
absorbed will evaporate.
Wire
No need to manually fit a sealing
medium
Locational advantage due to
low-cost production
No assembly time needed due to
fully automatic processing
Contact with water
Free swelling of the superabsorber
Fully automatic processing in the preassembly stage, integrated into and
synchronised with the cutting and contacting processes – and to a large
extent in a time-neutral manner. Cycle
time < 1 second, for adaptation to all
common cutting machines such as Komax.
64
Automotive
Processing
The processing module AutosealMan 40
uses DERAY®-AUTOSEAL roll material
for fully automatic processing in a preassembly line. Processing takes place in
an environment of controlled constant
air humidity allowing an almost dustfree process, continuously monitored
by a state-of-the-art camera system,
irrespective of light conditions. So,
in the pre-assembly stage, wires are
produced in appropriate lot sizes that
have automatically been provided with
DERAY®-AUTOSEAL in the future vehicle
body feed-through section.
To automatically provide all wires with
DERAY®-AUTOSEAL, an Autoseal sea
ling strip is wrapped around the section to be sealed (one complete wrap).
For specific questions regarding application, please contact our team of experts. To facilitate assembly, both ends
are firmly taped up using PVC tape or
the like. The sealing area of the grommet
will later be seated directly on the sealing
cellulose.
65
DERAY®-AutosealMan 40
Processing Module DERAY®-AutosealMan 40
66
Automotive
High Temperature
Applications
DSG-Canusa provides special materials for demanding applications. These
products, made of materials ranging
from elastomers to fluoropolymers, offer increased protection against extreme temperatures and harsh operating
environments.
They include diesel resistant products
like DERAY® -VA 25 and high temperature products like
DERAY®-VT 220.
67
DERAY® VA 25
DERAY® VT 220
Diesel resistant elastomeric heat shrink
tubing, suited for protecting components in high temperature Automotive
Applications
Thin Wall Crosslinked Viton®** fluoroelastomer heat shrink tubing, ideal for
protecting electronic components in
high temperature systems.
Flexible
Very flexible
Flame retardant
Flame retardant
High abrasion and cut resistance
Highly abrasion resistant
Long-term resistance to diesel,
hydraulic fluids and chemicals
High withstand to corrosive fluids
in extreme temperatures
Continuous Operating
Temperature: -75°C to 150°C
Shrink Temperature: 180°C
Thinwall variant
DERAY® VA 25 TW
68
Automotive
DERAY®-VA 25
Material
Mechanical Properties
Thermal Properties
Technical Data
Current Values
Jacket Material
Elastomer, modified, free of
lead and cadmium
Surface
satin, matt
Specific gravity
1.5 g/cm3 max.
Shrink ratio
2:1
15 % max.
ASTM-D 2671
Tensile strength
18 MPa
IEC 60684-2
Elongation
490 %
IEC 60684-2
Secant modulus
30 MPa max.
ASTM-D 882
Thermal ageing
(168 h at 160°C)
IEC 60684-2
Tensile strength
12 MPa
Elongation
200 %
Thermal shock
Chemical Properties
(4 h at 200°C)
Tensile strength
11 MPa
Elongation
290 %
Test Methods
ASTM-D 792, A-I
IEC 811-1-2
Cold bend test
ASTM-D 2671 Meth. C
selfextinguishing
UL 224
Shrink temperature
+130°C to +250°C
Storage temperature
+50°C max.
Continous operating
temperature
-75°C to +150°C
IEC 216
Corrosive action
non-corrosive
ASTM-D 2671 Meth. A
non-corrosive
ASTM-D 2671 Meth. B
Electrical Properties
Printability
Water absorption
1,10 % max.
VDE 0473
Dielectric strength
15 kV/mm
VDE 0303 Part 2
Spec. volume resistivity
10
Hot stamp printing
very good
Ink jet printing
good
Offset printing
good
12
Ω x cm
VDE 0303 Part 3
69
DERAY®-VA 25 TW
Material
Thermal Properties
Technical Data
Current Values
Jacket Material
lead and cadmium
Surface
satin, matt
Specific gravity
1,5 g/cm3 max.
Shrink ratio
2:1
15 % max.
ASTM-D 2671
Tensile strength
18 MPa
IEC 60684-2
Elongation
490 %
IEC 60684-2
Secant modulus
30 MPa max.
ASTM-D 882
Thermal ageing
(168 h at 160 °C)
IEC 811-1-2
Tensile strength
12 MPa
Elongation
200 %
Thermal shock
Chemical Properties
(4 h at 200 °C)
Tensile strength
11 MPa
Elongation
290%
Test Methods
ASTM-D 792, A-I
IEC 811-1-2
Cold bend test
ASTM-D 2671 Meth. C
selfextinguishing
UL 224
Shrink temperature
+130°C at +250°C
Storage temperature
+50°C max.
Continous operating
temperature
-75°C to +150°C
IEC 216
Corrosive action
non-corrosive
ASTM-D 2671 Meth. A
non-corrosive
ASTM-D 2671 Meth. B
Printability
70
© ShawCor Ltd. Water absorption
1,10 %
VDE 0473
Dielectric strength
15 kV/mm
VDE 0303 Part 2
10
Hot stamp printing
very good
Ink jet printing
good
Offset printing
good
12
Ω x cm
VDE 0303 Part 3
Automotive
DERAY®-VT 220
Material
Thermal Properties
Technical Data
Current Values
Jacket Material
lead and cadmium
Surface
satin, matt
Specific gravity
1,9 g/cm3 max.
Shrink ratio
2:1
10 % max.
ASTM-D 2671
Tensile strength
18 MPa
IEC 60684-2
Elongation
520 %
IEC 60684-2
Secant modulus
70 MPa max.
ASTM-D 882
Thermal ageing
(168 h at 250 °C)
IEC 811-1-2
Tensile strength
14 MPa
Elongation
220 %
Thermal shock
Chemical Properties
(4 h at 300 °C)
Tensile strength
17 MPa
Elongation
250%
Test Methods
ASTM-D 792, A-I
IEC 811-1-2
Cold bend test
ASTM-D 2671 Meth. C
selfextinguishing
UL 224
Shrink temperature
+175°C to +220°C
Storage temperature
+50°C max.
Continous operating
temperature
-55°C to +220°C
IEC 216
Corrosive action
non-corrosive
ASTM-D 2671 Meth. A
non-corrosive
ASTM-D 2671 Meth. B
Printability
Water absorption
0,20 %
VDE 0473
Dielectric strength
16 kV/mm
VDE 0303 Part 2
10
Hot stamp printing
very good
Ink jet printing
good
Offset printing
good
13
Ω x cm
VDE 0303 Part 3
71
DERAY® KY 175
Semi-rigid thin wall Kynar®* heat shrink
tubing, ideal for electronic and automotive applications requiring protection
and see through inspection
Highly flame retardant
UL-224, VW-1 & CSA OFT
High withstand to abrasion and
cut-through
Excellent chemical and solvent
resistance
DERAY® KYF 190
Flexible thin wall Kynar®* heat shrink
tubing, with extreme chemical resistance, ideal for protecting components
in a wide range of harsh conditions.
Highly flame retardant, UL-224
VW-1
High temperature resistance
*Kynar® is a registered trademark of ATOFINA
**Viton® is a registered trademark of du Pont de
Nemours and Co. Inc. for the raw material
72
Automotive
DERAY®-KY 175
Material
Thermal Properties
Technical Data
Current Values
Jacket Material
PDVF, modified, free of lead
and cadmium
Surface
smooth
Specific gravity
1.8 g/cm3 max.
Shrink ratio
2:1
6 % max.
ASTM-D 2671
Tensile strength
50 MPa
IEC 60684-2
Elongation
450 %
IEC 60684-2
Secant modulus
750 MPa max.
ASTM-D 882
Thermal ageing
(168 h at 200°C)
IEC 811-1-2
Tensile strength
45 MPa
Elongation
230 %
Thermal shock
Chemical Properties
(4 h at 250°C)
Tensile strength
48 MPa
Elongation
300 %
Test Methods
ASTM-D 792, A-I
IEC 811-1-2
Cold bend test
ASTM-D 2671 Meth. C
selfextinguishing
UL 224 VW-1
Shrink temperature
+175°C to +300°C
Storage temperature
+50°C max.
Continous operating
temperature
-55°C to +175°C
IEC 216
Corrosive action
non-corrosive
ASTM-D 2671 Meth. A
non-corrosive
ASTM-D 2671 Meth. B
Printability
Resistance against mould
does not promote mould
growth
ISO 846
Water absorption
0,07 % max.
VDE 0473
Dielectric strength
31 kV/mm
VDE 0303 Part 2
1013 Ω x cm
VDE 0303 Part 3
Hot stamp printing
very good
Ink jet printing
good
Offset printing
good
73
DERAY®-KYF 190
Material
Thermal Properties
Technical Data
Current Values
Jacket Material
Fluorpolymer, modified,
free of lead and cadmium
Surface
smooth
Specific gravity
1,8 g/cm3 max.
Shrink ratio
2:1
6 % max.
ASTM-D 2671
Tensile strength
30 MPa
IEC 60684-2
Elongation
450 %
IEC 60684-2
Secant modulus
300 MPa max.
ASTM-D 882
Thermal ageing
(168 h at 215°C)
IEC 811-1-2
Tensile strength
20 MPa
Elongation
300 %
Thermal shock
Chemical Properties
(4 h at 275°C)
Tensile strength
20 MPa
Elongation
250 %
Test Methods
ASTM-D 792, A-I
IEC 811-1-2
Cold bend test
ASTM-D 2671 Meth. C
selfextinguishing
UL 224 VW-1
Shrink temperature
+175°C to +300°C
Storage temperature
+50°C max.
Continous operating
temperature
-55°C to +190°C
IEC 216
Corrosive action
non-corrosive
ASTM-D 2671 Meth. A
non-corrosive
ASTM-D 2671 Meth. B
Printability
74
© ShawCor Ltd. Resistance against mould
does not promote mould
growth
ISO 846
Water absorption
0,30 %
VDE 0473
Dielectric strength
33 kV/mm
VDE 0303 Part 2
1013 Ω x cm
VDE 0303 Part 3
Hot stamp printing
very good
Ink jet printing
good
Offset printing
good
Automotive
Automotive
Braided Sleeves
In addition to its standard heat shrink tubing product range, DSG-Canusa also
offers a range of braided sleeves which
are used specifically to provide abrasive protection to pipes, hoses and cables
as well as wire harness assemblies in
the automotive industry. The various options available provide a great deal of
scope for application-specific solutions.
75
CANUFIX® Braided Sleeves
CANUFIX® is the perfect solution for
problems in the abrasion protection of
pipes, hoses and cables as well as wire
harness assemblies in the automotive industry. In comparison with conventional
methods, such as the use of heat shrink
tubing or standard braided sleeves, the
usage of CANUFIX® is significantly less
time- and cost effective.
CANUFIX® is a combination of known
and proven components. Braided sleeves, available in various material types
such as e.g. polyester or polyamide,
offer excellent abrasive protection over
several years. Heat shrink tubing permits the reliable fixing of the product
during the entire life cycle. Both components have been used for protecting
pipes, hoses and cables in the automotive industry for decades.
Thanks to its excellent stretching capa
bility and heat shrink tube fasteners,
CANUFIX® can be pulled over objects
quickly without other aids having to be
used.
As an integrated system, CANUFIX®
saves users from having to engage in
the intensive handling of the individual parts. Installation of CANUFIX® on
pipes, hoses and cables is possible
within a matter of seconds.
At the same time, the heat shrink tube
fasteners CANUFIX® has prevent the
troublesome fraying that the ends of
the braided sleeves are otherwise prone to while facilitating the fixing of the
sleeve to the object. No adhesive tape
or plastic cable ties are needed. In
contrast to other products, CANUFIX®
permits rapid installation, notably on
moulded bends, thanks to the highly
flexible nature of its braided sleeve.
CANUFIX®-PET
-50°C to +150°C *
CANUFIX®-PA
-55°C to +130°C *
* braided sleeve only
76
Automotive
CANUFLEX® is an all-purpose low-cost
PET braided sleeve for protecting or
bundling up wires, cables, pipes and
hoses such as wire harnesses, mediaconducting and air conditioning pipes
In contrast to other products, CANU
FLEX® permits rapid installation, notably
on moulded bends, thanks to the highly
flexible nature of its braided sleeve.
Advantages
Highly stretchable
Very flexible
Lightweight, robust polyester
monofilament
Push-back effect allows easy
processing of CANUFLEX® braided sleeves
Particularly abrasion and chemicalresistant
No formation of condensed
moisture
CANUFLEX®-PE HB
-50°C to +150°C
Other types of sleeves, e.g. a flameretardant option, available on request.
77
CANUROUND® Woven Sleeves
CANUROUND® Woven Sleeves
CANUROUND® is a self-closing, laminated, woven sleeve used for protecting
wires, cables, pipes, hoses and foamed
material in order to avoid mechanical
damage.
Advantages
Feed through cable bundle
Quick and easy installation
Self-closing and easy to re-open
Can be retrofitted
Very good coverage
Apply CanuRound starting from the left
Abrasion and cut-resistant
CanuRound Tool
Excellent abrasive resistance
Silencing effect
Attractive design
Pull CanuRound to the right over
the tool
-50°C to +150°C
Also available in a minibox
Continue pulling CanuRound to
the right
78
Automotive
Design: Seat belt locks and car aerials
DERAY®-HB
DERAY®-IB
Seat belt locks and car aerials
The DERAY®-HB- and DERAY®-IB range
of products is a low-cost solution for the
mechanical protection and colour coordination of specific vehicle components.:
Seat belt locks
Car aerials
This heat shrink tubing has outstandingly good abrasive resistance and
can be colour coordinated to suit the
customer’s needs, for example to match
the design of the car interior or that of
the exterior paintwork.
DERAY®-HB
DERAY®-IB NS
Advantages
Quick shrinking
Very flexible
Details remain visible under the
aerial finish
Not only for automotive applications
DERAY®-IB NS
Matt or glossy finish options
DERAY®-IB NS
79
Information
If you have any questions concerning our shrink appliances and accessories, we will be
pleased to answer them. Please also ask for our “Application Equipment” brochure.
Contact
Europe/Middle East/Africa/Russia
DSG-Canusa GmbH
Heidestrasse 5
53340 Meckenheim
Germany
Your contacts concerning automotive products
Mrs. Vera Dahlhausen
Mr. Ralf Gülden
Phone: +49 (0) 22 25 88 92 - 0
E-Mail: [email protected]

Automotive - DSG

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