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Delphi Aluminum Cable Systems

Delphi Aluminum Cable Systems
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ELECTRICAL/ELECTRONIC ARCHITECTURE Delphi Aluminum Cable Systems Delphi Aluminum Cable Systems include a cost-effective, lightweight wiring alternative that offers up to 45 percent mass reduction compared to traditional copper core cable. Approximately one kilogram of aluminum can replace 2 kilograms of copper, providing equal conductivity. Delphi Aluminum Cable Systems enable improved fuel economy due to mass savings and lighter, easier vehicle assembly, while reducing the susceptibility to copper commodity volatility. Aluminum cable is larger than copper cable due to the greater cross section of aluminum required, yet it achieves the same conductivity. The insulation is lighter in weight than conventional insulations, further enhancing the weight reduction potential of Delphi's aluminum cable. A range of aluminum cable sizes are available, depending on the intended application: • • Primary cable — 0.75 to 2.5 mm2 Power/battery cable — 3.0 to 120.0 mm2 Delphi aluminum cable is available for both primary cable and power/battery cable applications. Delphi Aluminum Cable Systems feature advanced materials such as halogen free ultra thin-wall insulation, which provides exceptional pinch and abrasion resistance to enable a volume reduction compared to thin-wall cable. Delphi's high strength, high conductivity aluminum alloy provides up to 45 percent higher break strength than pure aluminum cable. Delphi continues to expand its portfolio of aluminum cable related products and processes. A portfolio of aluminum-capable terminals is also available. Advanced processes include automated crimp termination technology and innovative corrosion protection solutions. Benefits • • Reduced weight lowers harness mass and helps improve vehicle fuel economy o Achieving the same conductivity, aluminum is half the weight of copper Various insulation materials are available with aluminum core o Lead-free PVC (polyvinyl chloride) o Halogen free, heavy metal free Ultra thin-wall insulation helps to offset the larger cross section required by aluminum Reduced volume enables bundle size reduction, reduces the space needed for cable, and improves packaging opportunities www.delphi.com | © Delphi. All rights reserved. | In addition to aluminum cable, Delphi also designs and manufactures aluminum-capable terminals. 1

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Delphi Aluminum Cable Systems • • • • • • • • • • • Replaces copper, which costs more than aluminum, enhancing the cost-effectiveness of wire assembly o Reduced susceptibility to commodity market fluctuations Aluminum prices are historically more stable (less variation on a percentage basis) when compared to copper prices Complies with ISO 6722-2 (International Organization for Standardization) Proven termination performance and corrosion protection In-house aluminum cable manufacturing o Proven, production ready manufacturing assembly processes, including automation Aluminum cable...

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Delphi Aluminum Cable Systems Delphi offers a complete line of wiring and cable to meet the demanding requirements for many applications, including engine compartments, interior and chassis wiring harnesses. In addition to Delphi Aluminum Cable Systems, other offerings include the following: • • • • • • 0.13 mm2 Cable Battery Cable Halogen Free Thin-Wall & Ultra Thin-Wall Cable PVC (polyvinyl chloride) Primary Cable RF (radio frequency) Cable Assemblies and Connections XLPE (cross-linked polyolefin) Primary Cable The Delphi Advantage Delphi has the benefit of a long history of cable design,...

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