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DSG-CanusaAutomotive 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 DSG-Canu 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 in-cludes thin-, medium-and thick-walled heat-shrink tubing made of poly olefins,
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 sys-tems, e.g. for cabinets and braided cable sleeves for encasing and protec-ting wires, cables, pipes, hoses and foam to prevent mechanical damage. Our energy-provider program con-sists of partition casings, end caps, creepage-current–proof hoses, low- and medium-voltage connection slee-ves, terminals and repair sleeves. A wide range of proprietary processing and shrink equipment, as well as equipment tooled precisely to the re-quirements of the customer, round off our portfolio.
DSG-Canusa is a world leader in the development and manufacture of high-quality, technologically advanced heat-shrink 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 custo-mer orientation for our international customers make us an indispensable partner.
3
4 © ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
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 interna-tional 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 commer-cialize 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 pipe-coating business.
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 Servi-ces 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 pipe-coating 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
6 7© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
It takes a cross-linkage process – the in-terlinking of threads – to provide fisher-men with their nets. In the case of plas-tics, cross-linkage is a chemical process during the course of which individual plastic molecules are chemically inter-linked. In an ideal scenario, all the mo-lecules 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 conver-ted into materials having elastomer pro-perties in certain temperature ranges.
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 radi-ation
Radiation cross-linkage - the enhancement process
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
6 7© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
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
Automotive Protection Products
8 9© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
Automotive Introduction
DSG-Canusa supplies solutions for the electrical and mechanical insulation of components and wires with the main emphasis on the sensitive area “Auto-motive”. We offer the right product for every application. Our braided sleeves and heat shrink tubes protect wires and sensitive components against mecha-nical, 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 specia-lised materials for unique requirements.
Our offering includes products made of polyolefin, fluoropolymer, elastomer and PVC compounds. Individual tubes can be thinwalled, medium-walled or heavy-walled, depending on the application, and can be with or without adhesive. Our product range is rounded out by our shrink appliances and accessories.
8 9© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
Start! DSG-Canusa > 1.000 items
With DSG-CANUSA in pole posi-tion From 0 to 30: 30% optimi-sation potential in product deve-lopment
That much time saving, cost reduction and quality enhancement can be achie-ved 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 inves-tigate this potential together with you. To this end, we, as your partner, would take on the responsibility for entire de-velopment 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 manu-facturers 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 longitu-dinal water blocking of wire harnesses.
International, innovative and absolutely reliable
We develop customised automotive solutions at three sites:
» Meckenheim (Germany) » Toronto (Canada) » Suzhou (PROC)
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 pro-duction sites.
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 testi-mony to our reputation as a competency centre for “sealing solutions for auto-motive 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 possi-ble and that the time intervals between them get longer and longer.
The comprehensive product ran-ge we offer to meet your needs
Our standard range of products encom-passes in excess of 1,000 different pro-ducts and are available at short notice.
Our quality guarantees you a place on the winners’ podium.
We meet the following standards:DIN EN ISO 9001_2008ISO-TS 16949_2009DIN EN ISO 14001: 2005
10 11© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
8 x
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.
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 quiet-ly, 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...
DSG-Canusa GmbH
Heidestraße 5
53340 Meckenheim
Germany
Tel.: +49 2225 8892-0
Fax: +49 2225 8892-44
www.dsgcanusa.com
HauptsitzHead office
10 11© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
AutomotivePipes & Hoses
DSG-Canusa is a pioneer in the deve-lopment 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.
12 13© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-IAKT NS
DERAY®-HBKT
DERAY®-IBKT
Brake Pipes
DERAY®-HBNS
Air Conditioning Pipes
DERAY®-INS
High Pressure Rubber Hoses / Pipes
DERAY®-DKI
Hose Bundling
DERAY®-KWS
Cooling Water Hoses
12 13© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
Brake Pipes Air Conditioning Pipes High Pressure Rubber
Hoses / Pipes
DERAY®-IAKT NS DERAY®-HBKTDERAY®-IBKT
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 du-ring 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.
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
DERAY®-HBNS
DERAY®-HBNS is a polyolefin heat shrink tubing that was developed speci-fically for adhering to aluminium pipes even when the pipes are being bent.
DERAY®-HBNS offers optimum protec-tion 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.
Hose Bundling
DERAY®-DKI
DERAY®-DKI is a dual-chamber poly-olefin heat shrink tubing that was de-veloped 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®-INS
High abrasive protection at extreme temperatures is the main characteris-tic 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.
Cooling and heating
Water Hoses
DERAY®-KWS/KWS-R
DERAY®-KWS is a polyolefin heat shrink (> 2:1) tubing with excellent ab-rasive resistance. With interior fluting it is available as KWS-R. It shrinks without bubbles and wrinkles on pipes and hoses with extreme radii. A cha-racteristic feature is its smooth finish. In the shrinking process, it adapts com-pletely 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.
14 15© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
Brake Pipes
In motor vehicles, brake pipes in the en-gine compartment and underbody area are exposed to numerous environmen-tal 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
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
Abrasive protection even under extreme temperatures
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
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 pro-cessing 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. Atten-tion must be given, moreover, to ensure that the shrink covering process com-mences 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 equip-ment documentation that we would be pleased to supply you with on request.
The operating instructions include infor-mation 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.
DERAY®-IAKT NS
DERAY®-HBKT
DERAY®-IBKT
Brake Pipes
14 15© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-IAKT NS
Technical Data Current Values Test Methods
Material Jacket Material Polyolefin, modified, free of lead and cadmium
Adhesive PE/EVA-BasisSurface mattColour black or transparentSpecific gravity 1,0 g/cm3 max. ASTM-D 792, A-IShrink ratio ≥ 2:1Longitudinal shrinkage 10 % max. ASTM-D 2671
Mechanical properties Tensile strength 18 MPa IEC 60684-2Elongation 550 % IEC 60684-2Secant modulus 175 MPa max. ASTM-D 882
Thermal properties Thermal ageing (168 h at +150° C) IEC 811-1-2 Tensile strength 14 MPa Elongation 450 %Cold bend test does not break at -55° C ASTM-D 2671 Meth. CCombustion behaviour passed FMVSS 302Shrink temperature +95° C to +240° CStorage temperature +40° C max.Continuous operating temperature
-55° C to +110° C IEC 216
Chemical properties Water absorption 0,10 % VDE 0473* outer jacket
16 17© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-IBKT
Technical Data Current Values Test Methods
Material Jacket Material Polyolefin, modified, free of lead and cadmium
Adhesive PE/EVA-BasisSurface semi glossy Specific gravity 0,95 g/cm3 max. ASTM-D 792, A-I Shrink ratio ≥ 2:1 Longitudinal shrinkage 10 % max. ASTM-D 2671
Mechanical properties Tensile strength 17 MPa IEC 60684-2Elongation 500 % IEC 60684-2 Secant modulus 100 MPa max. ASTM-D 882
Thermal properties Thermal ageing (168 h at +160°C) IEC 811-1-2 Tensile strength 14 MPa Elongation 400 %
Cold bend test does not break at -55°C ASTM-D 2671 Meth. CCombustion behaviour passed FMVSS 302Shrink temperature +95°C to +200°C Storage temperature +40°C max. Continuous operating temperature
-55°C to +105°C IEC 216
Chemical properties Resistance against chemicals good Water absorption 0,40 % VDE 0473
16 17© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-HBKT
Technical Data Current Values Test Methods
Material Jacket Material Polyolefin, modified, free of lead and cadmium
Adhesive PE/EVA-BasisSurface matt, smooth Specific gravity 1,0 g/cm3 max. ASTM-D 792, A-I Shrink ratio ≥ 2:1 Longitudinal shrinkage 10 % max. ASTM-D 2671
Mechanical properties Tensile strength 18 MPa IEC 60684-2Elongation 400 % IEC 60684-2Secant modulus 175 MPa max. ASTM-D 882
Thermal properties Thermal ageing (168 h at +160°C) IEC 811-1-2 Tensile strength 15 MPa Elongation 320 %Cold bend test does not break at -55°C ASTM-D 2671 Meth. C Combustion behaviour passed FMVSS 302Shrink temperature +95°C to +200°C Storage temperature +40°C max. Continuous operating temperature
-55°C to +105°C IEC 216
Chemical properties Resistance against chemicals good Water absorption 0,40 % VDE 0473
18 19© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
Air Conditioning Pipes
In the engine compartment of motor ve-hicles, aluminium pipes of air conditio-ners are exposed to numerous environ-mental influences. Primarily, they are to be protected against mechanical dama-ge, corrosion and the diffusion effect of mineral greases and oils.
Specially modified heat shrink tubing based on cross-linked polyolefins meets such needs perfectly.
Advantages
Fast shrinkage on to part requiring 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
Abrasive protection even under extreme temperatures
Corrosion protection
In its specific area of application, DERAY®-HBNS performs impressively thanks to its outstanding
Characteristics
Continuous operating temperature: -55°C to +135°C
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)
Processing
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 pro-cessing 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. Atten-tion must be given, moreover, to ensure that the shrink covering process com-mences 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 ple-ased to supply you with on request.
The operating instructions include infor-mation 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.
DERAY®-HB NS
Air Conditioning Pipes
18 19© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-HB NS
Expanded Recovered Product
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 sw19,0 6,0 1,0 HB NS 19-6/1,0 sw27,0 12,7 0,8 HB NS 27-12,7/0,8 sw
Technical Data Current Values Test Methods
Material Jacket Material PE, modified, free of lead and cadmium
Surface semi glossy Specific gravity 1,0 g/cm3 max. ASTM-D 792, A-I Shrink ratio ≥ 2:1 Longitudinal shrinkage - 6 % max. ASTM-D 2671
Mechanical properties Tensile strength 20 MPa IEC 60684-2 Elongation 580 % IEC 60684-2Secant modulus 170 MPa max. ASTM-D 882
Thermal properties Thermal ageing (168 h at +150°C) IEC 811-1-2 Tensile strength 19 MPa Elongation 507 %Cold bend test does not break at -55°C ASTM-D 2671 Meth. CCombustion behaviour passed FMVSS 302 Shrink temperature +110°C to +200°C Storage temperature +40°C max. Continuous operating temperature
-55°C to +135°C IEC 216
Chemical properties Corrosive action non-corrosive ASTM-D 2671 Meth. AResistance against chemicals good Water absorption 0,01 % VDE 0473
Dimensions
20 21© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
High Pressure Rubber Hoses / Pipes
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 conditio-ning pipes and fittings.
High pressure rubber hoses / pipes are exposed to numerous environmental influences. Primarily, they are to be pro-tected against mechanical damage.
Our DERAY®-INS heat shrink tubing based on cross-linked polyolefins meets such needs perfectly.
Advantages
Fast shrinkage on to part requiring protection without damage caused by heat
Good adhesion to the high pressu-re rubber hose / pipe
Abrasive protection even under extreme temperatures
In its specific area of application, DERAY®-INS performs impressively thanks to its outstanding
Characteristics
Flammability complies with UL 224 C
Continuous operating temperature: -55°C to +135°C
Surface can be printed via hot seal and offset processes
Processing
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 pro-cessing 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. Atten-tion must be given, moreover, to ensure that the shrink covering process com-mences at one end in order to prevent inclusion of air.
We would be pleased to advise you on the selection of the best shrink ap-pliance 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 ple-ased to supply you with on request.
The operating instructions include infor-mation 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.
DERAY®-INS
High Pressure Rubber Hoses / Pipes
20 21© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-INS
Technical Data Current Values Test Methods
Material Jacket Material Polyolefin, modified, free of lead and cadmium
Surface semi glossy Specific gravity 1,3 g/cm3 ASTM-D 792, A-I Shrink ratio ≥ 2:1 Longitudinal shrinkage 10 % max. ASTM-D 2671
Mechanical properties Tensile strength 16 MPa IEC 60684-2Elongation 500 % IEC 60684-2Secant modulus 100 MPa max. ASTM-D 882
Thermal properties Thermal ageing (168 h at +158°C) UL 224 Tensile strength 14 MPa Elongation 400%Cold bend test does not break at -55°C ASTM-D 2671 Meth. CCombustion behaviour selfextinguishing UL 224Shrink temperature +100°C to +200°C Continuous operating temperature
-55°C to +135°C
Storage temperature +40°C max.
Chemical properties Corrosive action non-corrosive ASTM-D 2671 Meth. AResistance against chemicals good Water absorption 0,40% VDE 0473
22 23© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
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.
DERAY®-DKI, a specially modified dou-ble-chamber heat shrink tubing based on cross-linked polyolefins, meets such needs perfectly.
Advantages
Fast shrinkage on the parts to be bundled / protected
Good adhesion to the object
Abrasive protection under opera-ting and extreme temperatures
Fixing of pipes, hoses or compo-nents in the required place
In its specific area of application, DERAY®-DKI performs impressively thanks to its outstanding
Characteristics
Halogen-free
Good abrasive resistance
Continuous operating temperature: -55°C to +135°C
Flammability complies with FMVSS 302 (combustion rate max. 101.6 mm/min)
Processing
Processing is done using special appli-ances that were specifically designed for hose bundling applications.
We would be pleased to advise you on the selection of the best shrink ap-pliance 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 ple-ased to supply you with on request. The operating instructions include informati-on on safety matters relevant to the ope-ration of our shrink appliances.
DERAY®-DKI
Hose Bundling
22 23© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-DKI
Technical Data Current Values Test Methods
Material Jacket Material Polyolefin, modified, free of lead and cadmium
Surface smooth Specific gravity 1,10 g/cm3 ASTM-D 792, A-I Shrink ratio ≥ 2:1
Mechanical properties Tensile strength 16 MPa IEC 60684-2Elongation 450 % IEC 60684-2Secant modulus 300 MPa max. ASTM-D 882
Thermal properties Thermal ageing (168 h at 150°C) IEC 811-1-2 Tensile strength 14 MPa Elongation 400 %Cold bend test does not break at -55°C ASTM-D 2671 Meth. CCombustion behaviour passed FMVSS 302 Shrink temperature +140°C to +200°CStorage temperature +40°C max. Continuous operating temperature
-55°C to +135°C IEC 216
Chemical properties Resistance against chemicals good Water absorption 0,30 % VDE 0473
24 25© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
Cooling Water Hoses
In the cooling systems of motor vehicle engines, cooling water hoses and mani-folds are exposed to the abrasive influ-ence of surrounding components, e.g. pipes and cables made of metal or plas-tic, 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 coo-ling water hoses perfectly. With interior fluting it is available as DERAY®-KWS-R.
The specific area of application and the conditions under which further pro-cessing is conducted mean that cooling water hoses and manifolds have a spe-cial requirement profile. DERAY®-KWS offers the following
Advantages
Fast shrinkage on to part requiring protection
No weld connection with the surface of the part
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 im-pressively thanks to their outstanding.
Characteristics
Halogen-free
Good abrasive resistance
Surface can be printed via hot seal, inkjet and offset processes
Flammability complies with JIS D 1201 1973 (classification: slow burning, combustion rate max. 50 mm/min)
Continuous operating temperature: -35°C to +135°C
Processing
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 pro-cessing 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 co-vering 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.
DERAY®-KWS und KWS-R
Cooling Water Hoses
24 25© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-KWS/KWS-R
Technical Data Current Values Test Methods
Material Jacket Material Polyolefin, modified, free of lead and cadmium
Surface matt Specific gravity 1,25 g/cm3 ASTM-D 792, A-I Shrink ratio ≥ 3:1
Mechanical properties Tensile strength 15 MPa IEC 60684-2Elongation 420 % IEC 60684-2Secant modulus 150 MPa max. ASTM-D 882
Thermal properties Thermal ageing no cracks or breaks (3000 h at 135°C) Cold bend test does not break at -55°C ASTM-D 2671 Meth CCombustion behaviour passed FMVSS 302 Shrink temperature +120°C to +200°CStorage temperature +40°C max. Continuous operating temperature
-55°C to +135°C IEC 216
Chemical properties Corrosive action non-corrosive ASTM-D 2671 Meth. AResistance against chemicals good Water absorption 0,15 % VDE 0473
26 27© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
Automotive – Protecting Wiring Harnesses
In addition to the standard range of heat shrink tubing products, DSG-Canu-sa provides solutions that are designed specifically to meet the demanding re-quirements of automotive wiring harnes-ses. We supply tailor-made top quality products for insulating ground connec-tors or splices or for longitudinal water blocking of wiring harnesses.
Sealing of
Cable bundles End splices Parallel splices Connectors
26 27© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
Splices End splices
DERAY®-SPLICEMELT
Crimped or ultrasonically welded par-allel and end splices often require lon-gitudinal water blockage and a high resistance to thermal, chemical and mechanical influences. Specifically for automotive applications, we have de-veloped sealing systems that success-fully master these challenges. DERAY®-Splicemelt, a specially modified heat shrink tubing with a thermoplastic inte-rior adhesive, meets these demanding requirements even under adverse con-ditions. During the shrink process, the hot-melt adhesive flows into all the cavi-ties 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.
DERAY®-Splicemelt is a first-class highly flexible splice sealing system that satis-fies most automotive applications.
DERAY®-SPLICEMELT-CAP
Beside using DERAY®-Splicemelt, longi-tudinal 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 and SPLICEMELT-CAP
28 29© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
Parallel- and End splices
Commonly, one of the most important requirements of crimped end and paral-lel splices is longitudinal water blocka-ge. At the same time, high resistance to thermal, chemical and mechanical stress is required. Numerous sealing applications, especially in the automo-tive sector, have to meet these challen-ges. The environmental conditions vary and hence the needs to be met by the sealing solution.
DERAY®-SPLICEMELT, a heat shrink tu-bing made of radiation cross-linked mo-dified PE with a thermoplastic interior adhesive lining, meets all these require-ments perfectly.
During the shrink process, the tubing recovers such that the area to be sealed is completely filled with hot-melt adhesi-ve. Thanks to its fast and easy installa-tion, the two-in-one heat shrink tubing is also well-suited for series production purposes.
Advantages
Easy processing
Surface can be printed via hot seal, offset and inkjet processes
Fast shrinkage on to part requiring 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
Flammability complies with FMVSS 302 (combustion rate max. 101.6 mm/min)
The jacket material of the black version is self-extinguishing
Processing
In general, DERAY®-SPLICEMELT can be used with every type of shrink appli-ance. We recommend using one of the following from our product line:
DERAY®-SpliceMan IR
DERAY®-DockMan Junior Endsplice
DERAY®-FST
We would be pleased to advise you on the selection of the best shrink app-liance 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 ple-ased to supply you with on request.
The operating instructions include infor-mation 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.
DERAY®-SPLICEMELT
DERAY®-SPLICEMELT-CAP
Sealing
28 29© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-SPLICEMELT black
Technical Data Current Values Test Methods
Material Jacket Material Polyolefin, modified, free of lead and cadmium
Adhesive Polyamid-basisSurface smoothSpecific gravity 1,25 g/cm3 max. ASTM-D 792, A-I Shrink ratio to 4:1Longitudinal shrinkage -10 % max. ASTM-D 2671
Mechanical properties Tensile strength 17 MPa IEC 60684-2Elongation 500 % IEC 60684-2
Thermal properties Thermal ageing (168 h at +160°C) IEC 811-1-2 Tensile strength 12 MPa Elongation 320 %Cold bend test does not break at -40°C ASTM-D 2671 Meth. CCombustion behaviour Jacket selfextinguishing FMVSS 302Shrink temperature +150°C to +200°C Storage temperature +50°C max.Continuous operating temperature
-40°C to +125°C IEC 216
Chemical properties Compatibility with copper non-corrosive ASTM-D 2671 Meth. BResistance against chemicals good Water absorption 0,50% VDE 0473
Electrical properties Dielectric strength 18 kV/mm VDE 0303 Part 2 Specific volume resistance 1014 Ω x cm VDE 0303 Part 3
30 31© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-SPLICEMELT clear
Technical Data Current Values Test Methods
Material Jacket Material Polyolefin, modified, free of lead and cadmium
Adhesive Polyamid-basisSurface matt, smoothSpecific gravity 1,0 g/cm3 max. ASTM-D 792, A-I Shrink ratio to 4:1Longitudinal shrinkage -10 % max. ASTM-D 2671
Mechanical properties Tensile strength 15 MPa IEC 60684-2Elongation 400 % IEC 60684-2
Thermal properties Thermal ageing (168 h at +160°C) IEC 811-1-2 Tensile strength 14 MPa Elongation 400 %Cold bend test does not break at -40°C ASTM-D 2671 Meth. CCombustion behaviour passed FMVSS 302Shrink temperature +125°C to +200°C Storage temperature +50°C max.Continuous operating temperature
-40°C to +125°C IEC 216
Chemical properties Compatibility with copper non-corrosive ASTM-D 2671 Meth. B Resistance against chemicals good Water absorption 0,60 % VDE 0473
Electrical properties Dielectric strength 20 kV/mm VDE 0303 Part 2 Specific volume resistance 1014 Ω x cm VDE 0303 Part 3
30 31© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
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 thermo-plastic adhesive, which meets the pro-tection needs of small cable bundles.
The DERAY®-PRESSMELT system is available for temperatures up to either 85°C, 105°C or 125°C. It consists of two main components
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
DERAY®-HOTMELT adhesive insert
Amber up to +85°C
Red up to +105°C
Yellow up to +125°C
The adhesive component is available in various options. Over a wide tem-perature range, both excellent sealing quality and the retention of the full func-tionality of the individual cables are guaranteed.
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 re-commend the use of:
DERAY®-COLDMELT Lite
Advantages
Easy processing
Surface can be printed via hot seal, offset and inkjet processes
Fast shrinkage on to part requiring protection
Permanently resistant to temperatu-res up to 85°C / 105°C / 125°C
Low thermal stress of the part to be sealed 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
Flammability complies with FMVSS 302 (combustion rate max. 101.6 mm/min)
The jacket material of the black option is self-extinguishing
DERAY®-PRESSMELT
Small Cable Bundles
32 33© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
Sealing system DERAY®-PRESSMELT
Preparation of the shrink process
Selection of product size: Kindly address any questions you may have concerning the adhesive insert and tubing section sizes to our Customer Develop ment department.
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 bet-ween the individual cables. At the same time, the adhesive swells, thus ensuring that the sealing area is filled completely.
Processing
We recommend using the following shrink appliances for processing DERAY®-PRESSMELT:
DERAY®-WorkMan
DERAY®-DockMan
For information about their mode of operation and the technical data please refer to our equipment documentation. The operating instructions include infor-mation on safety matters relevant to the operation of our shrink appliances.
32 33© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-IPM (PRESSMELT)
Technical Data Current Values Test Methods
Material Jacket Material Polyolefin, modified, free of lead and cadmium
Adhesive PE/PA/EVA-Basis
Surface smooth
Specific gravity 1,0 g/cm3 max. ASTM-D 792, A-I
Shrink ratio up to 6:1
Longitudinal shrinkage -20 % max. ASTM-D 2671
Mechanical properties Tensile strength 14 Mpa IEC 60684-2Elongation 550% IEC 60684-2
Thermal properties Thermal ageing (168 h at +160°C) IEC 811-1-2 Tensile strength 11 MPa Elongation 300 % min.Cold bend test does not break at -40°C ASTM-D 2671 Meth. CCombustion behaviour passed FMVSS 302Shrink temperature +100°C to +200°C Storage temperature +50°C max.
Continuous operating temperature
-40°C to +105°C IEC 216
Chemical properties Corrosive action non-corrosive ASTM-D 2671 Meth. ACompatibility with copper non-corrosive ASTM-D 2671 Meth. BResistance against chemicals good Water absorption 0,10 % VDE 0473
Electrical properties Dielectric strength 20 kV/mm VDE 0303 Part 2 Specific volume resistance 1014 Ω x cm VDE 0303 Part 3
34 35© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-IAKT black (PRESSMELT)
Technical Data Current Values Test Methods
Material Jacket Material Polyolefin, modified, free of lead and cadmium
Adhesive PE/EVA-BasisSurface matt, smoothSpecific gravity 1,25 g/cm3 max. ASTM-D 792, A-I Shrink ratio 3:1
4:1Longitudinal shrinkage -15 % max. (3:1) ASTM-D 2671
-18 % max. (4:1) ASTM-D 2671
Mechanical properties Tensile strength 15 MPa IEC 60684-2Elongation 400 % IEC 60684-2Secant modulus 175 MPa max. ASTM-D 882
Thermal properties Thermal ageing (168 h at +150°C) IEC 811-1-2 Tensile strength 14 MPa Elongation 320 %Cold bend test does not break at -55°C ASTM-D 2671 Meth. C Flammability Jacket selfextinguishing ASTM-D876Shrink temperature +100°C to +200°CStorage temperature +40°C max.Continuous operating temperature
-55°C to +110°C IEC 216
Chemical properties Water absorption 0,15 % VDE 0473
34 35© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-IAKT clear (PRESSMELT)
Technical Data Current Values Test Methods
Material Jacket Material Polyolefin, modified, free of lead and cadmium
Adhesive PE/EVA-BasisSurface matt, smoothSpecific gravity 1,00 g/cm3 max. ASTM-D 792, A-I Shrink ratio 3:1
4:1Longitudinal shrinkage -15 % max. (3:1) ASTM-D 2671
-18 % max. (4:1) ASTM-D 2671
Mechanical properties Tensile strength 19 MPa IEC 60684-2Elongation 500 % IEC 60684-2Secant modulus 175 MPa max. ASTM-D 882
Thermal properties Thermal ageing (168 h at +150°C) IEC 811-1-2 Tensile strength 12 MPa Elongation 450 %Cold bend test does not break at -55°C ASTM-D 2671 Meth. C Flammability passed FMVSS 302 Shrink temperature +100°C to +200°CStorage temperature +40°C max.Continuous operating temperature
-55°C to +110°C IEC 216
Chemical properties Water absorption 0,17 % VDE 0473
36 37© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-IHKT black (PRESSMELT)
Technical Data Current Values Test Methods
Material Material Polyolefin, modified, free of lead and cadmium
Adhesive Polyamid-basis
Surface matt, smooth
Specific gravity 1,25 g/cm3 max. ASTM-D 792, A-I Shrink ratio 4:1
Longitudinal shrinkage -18 % max. ASTM-D 2671
Mechanical properties Tensile strength 17 MPa IEC 60684-2Elongation 600 % IEC 60684-2
Thermal properties Thermal ageing (168 h at +160°C) IEC 811-1-2 Tensile strength 11 MPa Elongation 400 %Cold bend test does not break at -55°C ASTM-D 2671 Meth. C Flammability Jacket selfextinguishing ASTM-D 876Shrink temperature +100°C to +200°C
Storage temperature +50°C max.
Continuous operating temperature
-55°C to +125°C IEC 216
Chemical properties Corrosive action non-corrosive ASTM-D 2671 Meth. A Resistance against chemicals very good
Water absorption 0,10 % VDE 0473
36 37© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-IHKT clear (PRESSMELT)
Technical Data Current Values Test Methods
Material Jacket Material Polyolefin, modified, free of lead and cadmium
Adhesive Polyamid-basis
Surface matt, smooth
Specific gravity 1,00 g/cm3 max. ASTM-D 792, A-I Shrink ratio 4:1
Longitudinal shrinkage -18 % max. ASTM-D 2671
Mechanical properties Tensile strength 19 MPa IEC 60684-2Elongation 500 % IEC 60684-2
Thermal properties Thermal ageing (168 h at +160°C) IEC 811-1-2 Tensile strength 16 MPa Elongation 450 %Cold bend test does not break at -55°C ASTM-D 2671 Meth. C Flammability passed FMVSS 302Shrink temperature +100°C to +200°C
Storage temperature +50°C max.
Continuous operating temperature
-55°C to +125°C IEC 216
Chemical properties Corrosive action non-corrosive ASTM-D 2671 Meth. A Resistance against chemicals very good
Water absorption 0,10 % VDE 0473
38 39© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-Adhesive Insert-System
Technical Data Current Values Test Methods
DERAY®-Adhesive Insert 85°C-System
DERAY®-Adhesive Insert 105°C-System
DERAY®-Adhesive Insert 125°C-System
Material Material modified EVA, free of lead and cadmium
modified PA-Hotmelt, free of lead and cadmium
modified PA-Hotmelt, free of lead and cadmium
Surface smooth smooth smoothSpecific gravity 0,97 g/cm3 max. 0,98 g/cm3 max. 0,96 g/cm3 max. ASTM-D 792, A-I
Thermal properties
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 opera-ting 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
Chemical properties
Water absorption 0,5 % max. 0,5 % max. 0,5 % max. DIN 53495
38 39© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-DUOMELT Sealing system
DERAY®-DUOMELT is an enhanced form of the DERAY®-Pressmelt system. The DERAY®-Duomelt system is particu-larly suitable for sealing small and me-dium-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.
The adhesive strips are lined with a strip of butyl rubber to ensure that the adhe-sive is evenly distributed throughout the bundle and to assist with the installati-on. DERAY®-Duomelt can be processed by a number of standard shrink appli-ances. Over a wide temperature range, both excellent sealing quality and the retention of the full functionality of the individual cables are guaranteed.
The self-adhesive strips allow proces-sing in a pre-assembly line.
The DERAY®-DUOMELT-System system is available for temperatures up to either 110°C or 125°C.
It consists of two main components:
1. Hot-Melt Adhesive Strip
Resistant to temperatures up to 110°C: modified copolymer, colour: amber
Resistant to temperatures up to 125°C: modified polyamide, colour: red
Both systems feature a butyl rubber lining.
Standard types:
(width/thickness) 10/1.1 10/1.5 15/1.5 15/1.8
2. Heat Shrink Tubing
Colour: clear and black
Resistant to temperatures up to 110°C: DERAY®-IAKT
Resistant to temperatures up to 125°C: DERAY®-IHKT
Advantages
Easy processing
Fast shrinkage on to part requiring protection
Permanently resistant to tempera-tures up to 110°C / 125°C
Low thermal stress of the part to be covered during processing
No detachment under operating temperatures
Watertight
Good adhesion to the common types of plug housing materials as well as PVC, VPE, PP-EPDM
DERAY®-DUOMELT
Medium-Sized Cable Bundles
40 41© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
Sealing system DERAY®-DUOMELT
Further advantages
Good resistance to aggressive media and fuels
Flammability pursuant to FMVSS 302 (combustion rate max. 101.6 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 tu-bing section sizes to our Customer- Oriented Development department.
Preparation of the area to be 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.
The other half of the DERAY®-DUOMELT-strip is then folded over the embedded cables and pressed in place. In so do-ing, 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
We recommend using the following shrink appliances for 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. The operating instructions include infor-mation on safety matters relevant to the operation of our shrink appliances.
40 41© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-Adhesive Strip 85°C-System
Technical Data Current Values Test Methods
Material Material modified copolymere,free of lead and cadmium
Specific gravity 0,97 g/cm3 max. ASTM-D 792, A-ISurface smooth
Thermal properties Cold bend test -40°C ASTM-D 2671 Meth. CStorage temperature +30°C max.Continuous operating temperature
-40°C to +85°C
Softening point ca. +90°CCombustion behaviour passed FMVSS 302
Chemical properties Water absorption 0,5 % max. DIN 53495
Sealing Compound – Butyl Rubber
Technical Data Current Values Test Methods
Material Material synthetic rubber-basis, free of lead and cadmium
Specific gravity 1,4 g/ cm3 max. ASTM-D 792, A-IColour black
Thermal properties Cold bend test -40°C ASTM-D 2671 Meth. CStorage temperature +30°C max.Continuous operating temperature
-40°C to +85°C/+105°C
Chemical properties Water absorption 0,5 % max.
42 43© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-IAKT black (DUOMELT)
Technical Data Current Values Test Methods
Material Jacket Material Polyolefin, modified, free of lead and cadmium
Adhesive PE/EVA-BasisSurface matt, smoothSpecific gravity 1,25 g/cm3 max. ASTM-D 792, A-I Shrink ratio 3:1
4:1Longitudinal shrinkage -15 % max. (3:1) ASTM-D 2671
-18 % max. (4:1) ASTM-D 2671
Mechanical properties Tensile strength 15 MPa IEC 60684-2Elongation 400 % IEC 60684-2Secant modulus 175 MPa max. ASTM-D 882
Thermal properties Thermal ageing (168 h at +150°C) IEC 811-1-2 Tensile strength 14 MPa Elongation 320 %Cold bend test does not break at -55°C ASTM-D 2671 Meth. C Flammability Jacket selfextinguishing ASTM-D876Shrink temperature +100°C to +200°CStorage temperature +40°C max.Continuous operating temperature
-55°C to +110°C IEC 216
Chemical properties Water absorption 0,15 % VDE 0473
42 43© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-IAKT clear (DUOMELT)
Technical Data Current Values Test Methods
Material Jacket Material Polyolefin, modified, free of lead and cadmium
Surface matt, smoothSpecific gravity 1,00 g/cm3 max. ASTM-D 792, A-I Shrink ratio 3:1
4:1Longitudinal shrinkage -15 % max. (3:1) ASTM-D 2671
-18 % max. (4:1) ASTM-D 2671
Mechanical properties Tensile strength 19 MPa IEC 60684-2Elongation 500 % IEC 60684-2Secant modulus 175 MPa max. ASTM-D 882
Thermal properties Thermal ageing (168 h at +150°C) IEC 811-1-2 Tensile strength 12 MPa Elongation 450 %Cold bend test does not break at -55°C ASTM-D 2671 Meth. C Flammability passed FMVSS 302 Shrink temperature +100°C to +200°CStorage temperature +40°C max.Continuous operating temperature
-55°C to +85°C IEC 216
Chemical properties Water absorption 0,17 % VDE 0473
44 45© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-Adhesive Strip 105°C-System
Technical Data Current Values Test Methods
Material Material modified copolymere,free of lead and cadmium
Specific gravity 0,98 g/cm3 max. ASTM-D 792, A-ISurface smooth
Thermal properties Cold bend test -40°C ASTM-D 2671 Meth. CStorage temperature +30°C max.Continuous operating temperature
-40°C to +105°C
Softening point ca. +130°C
Combustion behaviour passed FMVSS 302
Chemical properties Water absorption 0,5 % max. DIN 53495
Sealing Compound – Butyl Rubber
Technical Data Current Values Test Methods
Material Material synthetic rubber-basis, free of lead and cadmium
Specific gravity 1,4 g/ cm3 max. ASTM-D 792, A-IColour black
Thermal properties Cold bend test -40°C ASTM-D 2671 Meth. CStorage temperature +30°C max.Continuous operating temperature
-40°C to +85°C/+105°C
Chemical properties Water absorption 0,5 % max.
44 45© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-IHKT black (DUOMELT)
Technical Data Current Values Test Methods
Material Jacket Material Polyolefin, modified, free of lead and cadmium
Adhesive Polyamid-basis
Surface matt, smooth
Specific gravity 1,25 g/cm3 max. ASTM-D 792, A-I Shrink ratio 4:1
Longitudinal shrinkage -18 % max. ASTM-D 2671
Mechanical properties Tensile strength 17 MPa IEC 60684-2Elongation 600 % IEC 60684-2
Thermal properties Thermal ageing (168 h at +160°C) IEC 811-1-2 Tensile strength 11 MPa Elongation 400 %Cold bend test does not break at -55°C ASTM-D 2671 Meth. C Combustion behaviour Jacket selfextinguishing ASTM-D 876Shrink temperature +100°C to +200°C
Storage temperature +50°C max.
Continuous operating temperature
-55°C to +125°C IEC 216
Chemical properties Corrosive action non-corrosive ASTM-D 2671 Meth. A Resistance against chemicals very good
Water absorption 0,10 % VDE 0473
46 47© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-IHKT clear (DUOMELT)
Technical Data Current Values Test Methods
Material Jacket Material Polyolefin, modified, free of lead and cadmium
Adhesive Polyamid-basis
Surface matt, smooth
Specific gravity 1,00 g/cm3 max. ASTM-D 792, A-I Shrink ratio 4:1
Longitudinal shrinkage -18 % max. ASTM-D 2671
Mechanical properties Tensile strength 19 MPa IEC 60684-2Elongation 500 % IEC 60684-2
Thermal properties Thermal ageing (168 h at +160°C) IEC 811-1-2 Tensile strength 16 MPa Elongation 450 %Cold bend test does not break at -55°C ASTM-D 2671 Meth. C Combustion behaviour passed FMVSS 302Shrink temperature 100°C to 200°C
Storage temperature +50°C max.
Continuous operating temperature
-55°C to +125°C IEC 216
Chemical properties Corrosive action non-corrosive ASTM-D 2671 Meth. A Resistance against chemicals very good
Water absorption 0,10 % VDE 0473
46 47© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-COLDMELT sealing system
DERAY®-COLDMELT I is a system used to create a “cold” longitudinal water blocking for cable bundles incorpora-ting more than 20 individual cables. For applications with fewer than 20 in-dividual cables we recommend the use of DERAY®-COLDMELT Lite. Many insu-lation materials are highly heat-sensitive when undergoing processing. Lengthy exposure to heat when using conventi-onal sealing systems can cause dama-ge 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, 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 sig-nificantly less thermal energy for sealing purposes. The exposure to heat is con-siderably 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.
Over a wide temperature range, both excellent sealing quality and the reten-tion of the full functionality of the indi-vidual cables are guaranteed. The self-adhesive strips allow processing in a pre-assembly line.
Advantages
Easy processing
Fast shrinkage on to part requiring protection
Permanently resistant to temperatu-res up to 85°C / 105°C / 125°C
Very low thermal stress of the part to be sealed during processing
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
Good resistance to aggressive media and fuels
Flammability pursuant to FMVSS 302 (combustion rate max. 101.6 mm/min) is complied with by all components.
The DERAY®-COLDMELT-System is avai-la ble for the following temperatures:
resistant to temperatures up to +85°C
resistant to temperatures up to +105°C
resistant to temperatures up to +125°C (COLDMELT HT)
DERAY®-COLDMELT I
DERAY®-COLDMELT Lite
Large Cable Bundles
48 49© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-COLDMELT I sealing system
The DERAY®-COLDMELT-SYSTEM con-sists 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
Preparation of the area to be sealed
First, the upper release paper of the bu-tyl rubber strip is removed. The individu-al 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.
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 re-moved 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 instal-lation 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
We recommend using the following shrink appliances for 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
48 49© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-COLDMELT I 85°C-System
Technical Data Current Values Test Methods
Material Jacket Material modified Polyolefin, free of lead, cadmium halogen and FCKW
Surface smoothSpecific gravity 1,4 g/cm3 max. ASTM-D 792, A-I Shrink ratio ≥ 3:1
Mechanical properties Tensile strength 11 MPa IEC 60684-2Elongation 400 % IEC 60684-2Secant modulus 40 MPa max. ASTM-D 882
Thermal properties Thermal ageing no tearing or cracking IEC 811-1-2 Cold bend test does not break at -35°C ASTM-D 2671 Meth. C Flammability 40 mm/minute FMVSS 302 Shrink temperature > +250°CStorage temperature +40 °C max.Continuous operating temperature
-35°C to +85°C IEC 216
Chemical properties Corrosive action non-corrosive ASTM-D 2671 Meth. A Compatibility with copper non-corrosive ASTM-D 2671 Meth. BWater absorption 0,40% VDE 0473
50 51© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-COLDMELT I 105°C-System
Technical Data Current Values Test Methods
Material Jacket Material modified Polyolefin, free of lead, cadmium halogen and FCKW
Surface smoothSpecific gravity 1,4 g/cm3 max. ASTM-D 792, A-I Shrink ratio ≥ 3:1
Mechanical properties Tensile strength 11 MPa IEC 60684-2Elongation 400 % IEC 60684-2Secant modulus 40 MPa max. ASTM-D 882
Thermal properties Thermal ageing no tearing or cracking IEC 811-1-2 Cold bend test does not break at -35°C ASTM-D 2671 Meth. C Flammability 40 mm/minute FMVSS 302 Shrink temperature > +250°CStorage temperature +40 °C max.Continuous operating temperature
-35°C to +105°C IEC 216
Chemical properties Corrosive action non-corrosive ASTM-D 2671 Meth. A Compatibility with copper non-corrosive ASTM-D 2671 Meth. BWater absorption 0,40% VDE 0473
50 51© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-COLDMELT I HT 125°C-System
Technical Data Current Values Test Methods
Material Jacket Material modified Polyolefin, free of lead, cadmium halogen and FCKW
Surface smoothSpecific gravity 1,45 g/cm3 max. ASTM-D 792, A-I Shrink ratio ≥ 3:1
Mechanical properties Tensile strength 14 MPa IEC 60684-2Elongation 410 % IEC 60684-2Secant modulus 40 MPa max. ASTM-D 882
Thermal properties Thermal ageing no tearing or cracking IEC 811-1-2 Cold bend test does not break at -35°C ASTM-D 2671 Meth. C Flammability 40 mm/minute FMVSS 302 Shrink temperature >250°CStorage temperature +40 °C max.Continuous operating temperature
-35°C to +125°C IEC 216
Chemical properties Corrosive action non-corrosive ASTM-D 2671 Meth. A Compatibility with copper non-corrosive ASTM-D 2671 Meth. BWater absorption 0,40% VDE 0473
52 53© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
Sealing Compound – Butyl Rubber
Technical Data Current Values Test Methods
Material Material synthetic rubber-basis, free of lead and cadmium
Specific gravity 1,4 g/cm3 max. ASTM-D 792, A-IColour black
Thermal properties Cold bend test -40°C ASTM-D 2671 Meth. CStorage temperature +40°C max.Continuous operating temperature
-35°C to +85°C/+105°C
Chemical properties Water absorption 0,5 % max.
DERAY®-COLDMELT I
52 53© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
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 blo-cking in the wire harness and at the ve-hicle 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 possib-le 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 insu-lation materials are highly heat-sensitive when undergoing processing. Lengthy exposure to heat when using conventi-onal sealing systems can cause dama-ge 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®-COLDMELT-system on the basis of butyl rubber is used.
This grommet consists of two half-shells that are composed of a sealing com-pound 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.
Advantages
Longitudinal water blocking and gas-proofness
Easy processing; threading of wire harnesses not necessary
DERAY®-COLDMELT II
Half-Shell Sealing System
54 55© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
Custom designed grommet DERAY®-COLDMELT II
Further advantages
Automation friendly
Good resistance to aggressive media and fuel
No thermal stressing of object
DERAY®-COLDMELT II is processed using the DERAY®-COLDMELT-Pro cessor.
DERAY®-COLDMELT II
54 55© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-COLDMELT II
Technical Data Current Values Test Methods
Material Material TPESpec. Volume 0,95 g/cm3 DIN 53 479 Shore hardness 65 Shore A DIN 53 505 Tensile strength 4,5/10 N/mm2 DIN 53 504 Elongation 445 % DIN 53 504
Mechanical properties Tensile strength 14 MPa IEC 60684-2Elongation 410 % IEC 60684-2Secant modulus 40 MPa max. ASTM-D 882
Thermal properties 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
24 % 38 % 44 %
DIN 53 517
56 57© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-COLDMELT II
Technical Data Current Values Test Methods
Material Material heat stabilized Polypropylen, liability modified
Fiberglas content 30 % DIN 53 479Specific gravity 1,13 g/cm3
Breakdown voltage DIN 53 455Ultimate Elongation 84 MPa DIN 53 455Strength-E-Modul 2 % DIN 53 457Charpy impact strength 6000 MPa DIN 53 453
Charpy- Notched impact strength
28 kJ/m2 DIN 53 4538 kJ/m2 DIN 53 456
Brinell hardness (H358/30) 110 MPa
Thermal properties 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
56 57© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
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 dia-meter 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
DERAY®-BIOK
DERAY®-HIOK
DERAY®-IOK
Insulating and Protecting Caps
58 59© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
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.
DERAY®-IOK insulating caps insulating caps are resistant to chemicals and fuels.
DERAY®-IOK insulating caps are resis-tant to temperatures up to 85°C and self-extinguishing.
Cross-sections from 0,7 mm² to 16 mm²
Continuous operating temperature: -35°C to +85°C
Processing
The cap size is to be selected to suit the diameter of the end splice to be insula-ted. The length of the cap is to be selec-ted such that the stripped part of the end splice is given sufficient cover.
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 post-assembly use on transfer lines.
DERAY®-IOK offers the following:
Advantages
Ensures 100% electrical insulation
Good resistance to aggressive media and fuel
Permanently resistant to tempera-tures up to 85°C
No detachment under operating 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
58 59© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-IOK Insulating Cap
Technical Data Current Values Test Methods
Material 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 breaksContinuous operating temperature
-35°C to +85°C: no cracks or breaks
Flammability ca. 45 mm/minute MVSS-302
Chemical properties Compatibility with copper non-corrosive ASTM-D 2671, Meth. B
Internal diameter Length Wall Thickness Colour Product
D (mm) L (mm) s (mm)3,0 30 0,75 green IOK 3,0 x 304,0 35 1,0 grey IOK 4,0 x 355,0 30 1,0 blue IOK 5,0 x 306,0 35 1,2 grey IOK 6,0 x 358,0 35 1,2 grey IOK 8,0 x 359,5 30 1,25 yellow IOK 9,5 x 3510,0 40 1,3 grey IOK 10,0 x 4012,0 35 1,25 red IOK 12,0 x 3514,0 35 2,0 black IOK 14,0 x 35
Various sizes and colours available on request.
Ordering information
60 61© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-HIOK Insulating Cap
The DERAY®-HIOK cap differs from the DERAY®-IOK cap by way of the inden-tation cut in the cap interior that enables crimp splices to be firmly located. The translucent nature of the non-shrinking insu lating cap facilitates positioning.
The soft PVC ensures reliable electri-cal 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®-HIOK insulating caps are resis-tant to chemicals and fuels and provide good adhesion properties due to their specific design.
DERAY®-HIOK insulating caps are resis-tant to temperatures up to 85°C.
Continuous operating temperature: -35°C to +85°C
Processing
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 insula-ting 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
Good resistance to aggressive media and fuel
Good adhesion to various types of splices thanks to the specifically designed indentation cut
No detachment under operating temperatures
Translucent material allows optimum positioning
Permanently resistant to tempera-tures up to 85°C
60 61© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
Technical Data Current Values Test Methods
Material 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 breaksContinuous operating temperature
-35°C to +85°C: no cracks or breaks
Flammability ca. 45 mm/Min. MVSS-302
Chemical properties Compatibility with copper non-corrosive ASTM-D 2671, Meth. B
Internal diameter Length Wall Thickness Colour Product
D (mm) L (mm) s (mm)3,0 35 1,0 grey-transp. HIOK 3,0 x 353,7 35 1,0 yellow-transp. HIOK 3,7 x 354,5 35 1,0 green-transp. HIOK 4,5 x 355,0 35 1,0 blue-transp. HIOK 5,0 x 356,0 35 1,0 black-transp. HIOK 6,0 x 356,5 35 1,0 green-transp. HIOK 6,5 x 357,5 35 1,25 yellow-transp. HIOK 7,5 x 358,0 35 1,25 blue-transp. HIOK 8,0 x 359,5 35 2,0 transp. HIOK 9,5 x 3511,0 35 2,0 white-transp. HIOK 11,0 x 35
Ordering information
DERAY®-HIOK Insulating Cap
62 63© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
Insulating Cap DERAY®-BIOK
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 elec-tronic components. The cap can be in-stalled 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.
DERAY®-BIOK insulating caps are resis-tant to temperatures up to 85°C.
Processing
The cap size is to be selected to suit the diameter of the end splice to be insula-ted. The length of the cap is to be selec-ted 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
Good resistance to aggressive media and fuel
Permanently resistant to temperatu-res up to 85°C
Good adhesion to various types of insulation materials such as PVC, VPE, PP-EPDM
No detachment under operating temperatures
Translucent material allows opti-mum positioning
Halogen-free
Complies with FMVSS 302
Combines the advantages of DERAY®-IOK and DERAY®-HIOK
62 63© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
Technical Data Current Values Test Methods
Material Jacket Material Polyolefin, modified, free of lead, cadmium, halogen and FCKW
Adhesive layer modified butyl rubberShore Hardness D ca. 42 DIN 53 505 Thermal ageing 3.000 h at +85°C:
no cracks or breaksContinuous operating temperature
-35°C to +85°C: no cracks or breaks
Flammability ca. 45 mm/minute
Chemical properties Compatibility with copper non-corrosive ASTM-D 2671, Meth. B
Internal diameter Length Colour suitable for Product
D (mm) L (mm) cross section range*3,0 42 transp. 1,4 - 2,5 mm2 BIOK 3,0 x 423,5 42 yellow-transp. 2,5 - 2,9 mm2 BIOK 3,5 x 424,0 42 blue-transp. 2,9 - 3,6 mm2 BIOK 4,0 x 425,0 42 green-transp. 3,6 - 4,1 mm2 BIOK 5,0 x 425,5 42 yellow-transp. 4,1 - 4,5 mm2 BIOK 5,5 x 426,0 42 blue-transp. 4,5 - 5,3 mm2 BIOK 6,0 x 427,0 42 transp. 5,3 - 6,5 mm2 BIOK 7,0 x 429,5 45 green-transp. 6,5 - 7,5 mm2 BIOK 9,5 x 4512 45 transp. On demand BIOK 12 x 45
Ordering information
DERAY®-BIOK 85°C System
* Ultrasonic welded end connectors, values serve as a proposal
64 65© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
Automatic sealing DERAY®-AUTOSEAL
Automatic sealing
This type of sealing consists of a super-absorbent polymer – integrated in cel-lulose or a similar material – which is able to absorb up to 300 times its own weight in water, depending on its con-centration 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 ab-sorption of water, the superabsorbent polymer for water blockage and perma-nent water absorption.
If temperatures rise, the water absorbed will evaporate.
Fully automatic processing in the pre- assembly stage, integrated into and synchronised with the cutting and con-tacting processes – and to a large extent in a time-neutral manner. Cycle time < 1 second, for adaptation to all common cutting machines such as Ko-max.
Advantages
The system works at any time, again and again.
If temperatures rise, the water absorbed will evaporate.
No need to manually fit a sealing medium
Locational advantage due to low-cost production
No assembly time needed due to fully automatic processing
New automatic sealing solution for automotive electrical systems
DERAY®-AUTOSEAL
Wire
Contact with water
Free swelling of the superabsorber
Sealing on demand
64 65© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
Automatic sealing DERAY®-AUTOSEAL
Processing
The processing module AutosealMan 40 uses DERAY®-AUTOSEAL roll material for fully automatic processing in a pre-assem bly line. Processing takes place in an environment of controlled constant air humidity allowing an almost dust-free 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 sec-tion to be sealed (one complete wrap).
For specific questions regarding appli-cation, please contact our team of ex-perts. 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.
66 67© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
Automatic sealing DERAY®-AUTOSEAL
DERAY®-AutosealMan 40
Processing Module DERAY®-AutosealMan 40
66 67© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
High Temperature Applications
DSG-Canusa provides special materi-als for demanding applications. These products, made of materials ranging from elastomers to fluoropolymers, of-fer increased protection against extre-me temperatures and harsh operating environments.
They include diesel resistant products like DERAY® -VA 25 and high tempera-ture products likeDERAY®-VT 220.
68 69© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
High Temperature Applications
DERAY® VA 25
Diesel resistant elastomeric heat shrink tubing, suited for protecting compo-nents in high temperature Automotive Applications
Flexible
Flame retardant
High abrasion and cut resistance
Long-term resistance to diesel, hydraulic fluids and chemicals
Continuous Operating Temperature: -75°C to 150°C
Shrink Temperature: 180°C
Thinwall variant DERAY® VA 25 TW
DERAY® VT 220
Thin Wall Crosslinked Viton®** fluoro-elastomer heat shrink tubing, ideal for protecting electronic components in high temperature systems.
Very flexible
Flame retardant
Highly abrasion resistant
High withstand to corrosive fluids in extreme temperatures
Continuous Operating Temperature: -55°C to 220°C
Shrink Temperature: 175°C
68 69© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
Technical Data Current Values Test Methods
Material Jacket Material Elastomer, modified, free of lead and cadmium
Surface satin, mattSpecific gravity 1.5 g/cm3 max. ASTM-D 792, A-IShrink ratio 2:1Longitudinal shrinkage 15 % max. ASTM-D 2671
Mechanical Properties Tensile strength 18 MPa IEC 60684-2Elongation 490 % IEC 60684-2Secant modulus 30 MPa max. ASTM-D 882
Thermal Properties Thermal ageing (168 h at 160°C) IEC 60684-2Tensile strength 12 MPa Elongation 200 %
Thermal shock (4 h at 200°C) IEC 811-1-2Tensile strength 11 MPa Elongation 290 %
Cold bend test does not break at -75°C ASTM-D 2671 Meth. CCombustion behaviour selfextinguishing UL 224Shrink temperature +130°C to +250°CStorage temperature +50°C max.Continous operating temperature
-75°C to +150°C IEC 216
Chemical Properties Corrosive action non-corrosive ASTM-D 2671 Meth. ACompatibility with copper non-corrosive ASTM-D 2671 Meth. BResistance against chemicals goodWater absorption 1,10 % max. VDE 0473
Electrical Properties Dielectric strength 15 kV/mm VDE 0303 Part 2Spec. volume resistivity 1012 Ω x cm VDE 0303 Part 3
Printability Hot stamp printing very goodInk jet printing goodOffset printing good
DERAY®-VA 25
70 71© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-VA 25 TW
Technical Data Current Values Test Methods
Material Jacket Material Elastomer, modified, free of lead and cadmium
Surface satin, mattSpecific gravity 1,5 g/cm3 max. ASTM-D 792, A-IShrink ratio 2:1Longitudinal shrinkage 15 % max. ASTM-D 2671
Mechanical Properties Tensile strength 18 MPa IEC 60684-2Elongation 490 % IEC 60684-2Secant modulus 30 MPa max. ASTM-D 882
Thermal Properties Thermal ageing (168 h at 160 °C) IEC 811-1-2Tensile strength 12 MPaElongation 200 %
Thermal shock (4 h at 200 °C) IEC 811-1-2Tensile strength 11 MPaElongation 290%
Cold bend test does not break at -75°C ASTM-D 2671 Meth. CCombustion behaviour selfextinguishing UL 224Shrink temperature +130°C at +250°CStorage temperature +50°C max.Continous operating temperature
-75°C to +150°C IEC 216
Chemical Properties Corrosive action non-corrosive ASTM-D 2671 Meth. ACompatibility with copper non-corrosive ASTM-D 2671 Meth. BResistance against chemicals goodWater absorption 1,10 % VDE 0473
Electrical Properties Dielectric strength 15 kV/mm VDE 0303 Part 2Spec. volume resistivity 1012 Ω x cm VDE 0303 Part 3
Printability Hot stamp printing very goodInk jet printing goodOffset printing good
70 71© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-VT 220
Technical Data Current Values Test Methods
Material Jacket Material Elastomer, modified, free of lead and cadmium
Surface satin, mattSpecific gravity 1,9 g/cm3 max. ASTM-D 792, A-IShrink ratio 2:1Longitudinal shrinkage 10 % max. ASTM-D 2671
Mechanical Properties Tensile strength 18 MPa IEC 60684-2Elongation 520 % IEC 60684-2Secant modulus 70 MPa max. ASTM-D 882
Thermal Properties Thermal ageing (168 h at 250 °C) IEC 811-1-2Tensile strength 14 MPaElongation 220 %
Thermal shock (4 h at 300 °C) IEC 811-1-2Tensile strength 17 MPaElongation 250%
Cold bend test does not break at -55°C ASTM-D 2671 Meth. CCombustion behaviour selfextinguishing UL 224Shrink temperature +175°C to +220°CStorage temperature +50°C max.Continous operating temperature
-55°C to +220°C IEC 216
Chemical Properties Corrosive action non-corrosive ASTM-D 2671 Meth. ACompatibility with copper non-corrosive ASTM-D 2671 Meth. BResistance against chemicals very goodWater absorption 0,20 % VDE 0473
Electrical Properties Dielectric strength 16 kV/mm VDE 0303 Part 2Spec. volume resistivity 1013 Ω x cm VDE 0303 Part 3
Printability Hot stamp printing very goodInk jet printing goodOffset printing good
72 73© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
High Temperature Applications
DERAY® KYF 190
Flexible thin wall Kynar®* heat shrink tubing, with extreme chemical resis-tance, ideal for protecting components in a wide range of harsh conditions.
Highly flame retardant, UL-224 VW-1
High temperature resistance
Continuous Operating Temperature: -55°C to 190°C
Shrink Temperature: 175°C
* Kynar® is a registered trademark of ATOFINA
** Viton® is a registered trademark of du Pont de
Nemours and Co. Inc. for the raw material
DERAY® KY 175
Semi-rigid thin wall Kynar®* heat shrink tubing, ideal for electronic and automo-tive 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
Continuous Operating Temperature: -55°C to 175°C
Shrink Temperature: 175°C
72 73© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
Technical Data Current Values Test Methods
Material Jacket Material PDVF, modified, free of lead and cadmium
Surface smoothSpecific gravity 1.8 g/cm3 max. ASTM-D 792, A-IShrink ratio 2:1Longitudinal shrinkage 6 % max. ASTM-D 2671
Mechanical Properties Tensile strength 50 MPa IEC 60684-2Elongation 450 % IEC 60684-2Secant modulus 750 MPa max. ASTM-D 882
Thermal Properties Thermal ageing (168 h at 200°C) IEC 811-1-2Tensile strength 45 MPa Elongation 230 %
Thermal shock (4 h at 250°C) IEC 811-1-2Tensile strength 48 MPa Elongation 300 %
Cold bend test does not break at -55°C ASTM-D 2671 Meth. CCombustion behaviour selfextinguishing UL 224 VW-1Shrink temperature +175°C to +300°CStorage temperature +50°C max.Continous operating temperature
-55°C to +175°C IEC 216
Chemical Properties Corrosive action non-corrosive ASTM-D 2671 Meth. ACompatibility with copper non-corrosive ASTM-D 2671 Meth. BResistance against chemicals very goodResistance against mould does not promote mould
growth ISO 846
Water absorption 0,07 % max. VDE 0473
Electrical Properties Dielectric strength 31 kV/mm VDE 0303 Part 2Spec. volume resistivity 1013 Ω x cm VDE 0303 Part 3
Printability Hot stamp printing very goodInk jet printing goodOffset printing good
DERAY®-KY 175
74 75© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
DERAY®-KYF 190
Technical Data Current Values Test Methods
Material Jacket Material Fluorpolymer, modified, free of lead and cadmium
Surface smoothSpecific gravity 1,8 g/cm3 max. ASTM-D 792, A-IShrink ratio 2:1Longitudinal shrinkage 6 % max. ASTM-D 2671
Mechanical Properties Tensile strength 30 MPa IEC 60684-2Elongation 450 % IEC 60684-2Secant modulus 300 MPa max. ASTM-D 882
Thermal Properties Thermal ageing (168 h at 215°C) IEC 811-1-2Tensile strength 20 MPaElongation 300 %
Thermal shock (4 h at 275°C) IEC 811-1-2Tensile strength 20 MPaElongation 250 %
Cold bend test does not break at -55°C ASTM-D 2671 Meth. CCombustion behaviour selfextinguishing UL 224 VW-1Shrink temperature +175°C to +300°CStorage temperature +50°C max.Continous operating temperature
-55°C to +190°C IEC 216
Chemical Properties Corrosive action non-corrosive ASTM-D 2671 Meth. ACompatibility with copper non-corrosive ASTM-D 2671 Meth. BResistance against chemicals goodResistance against mould does not promote mould
growthISO 846
Water absorption 0,30 % VDE 0473
Electrical Properties Dielectric strength 33 kV/mm VDE 0303 Part 2Spec. volume resistivity 1013 Ω x cm VDE 0303 Part 3
Printability Hot stamp printing very goodInk jet printing goodOffset printing good
74 75© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
AutomotiveBraided Sleeves
In addition to its standard heat shrink tu-bing product range, DSG-Canusa also offers a range of braided sleeves which are used specifically to provide abrasi-ve protection to pipes, hoses and cables as well as wire harness assemblies in the automotive industry. The various op-tions available provide a great deal of scope for application-specific solutions.
76 77© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
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 in-dustry. 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 slee-ves, available in various material types such as e.g. polyester or polyamide, offer excellent abrasive protection over several years. Heat shrink tubing per-mits the reliable fixing of the product during the entire life cycle. Both com-ponents have been used for protecting pipes, hoses and cables in the automo-tive 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 individu-al 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 pro-ne 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.
Continuous operating temperature:
CANUFIX®-PET -50°C to +150°C *
CANUFIX®-PA -55°C to +130°C *
* braided sleeve only
CANUFIX® Braided Sleeves
76 77© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
CANUFIX® Braided Sleeves
CANUFLEX® is an all-purpose low-cost PET braided sleeve for protecting or bundling up wires, cables, pipes and hoses such as wire harnesses, media-conducting 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® brai-ded sleeves
Particularly abrasion and chemical-resistant
No formation of condensed moisture
Continuous operating temperature:
CANUFLEX®-PE HB -50°C to +150°C
Other types of sleeves, e.g. a flame-retardant option, available on request.
CANUFIX® Braided Sleeves
78 79© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
CANUROUND® Woven Sleeves
CANUROUND® is a self-closing, lami-nated, woven sleeve used for protecting wires, cables, pipes, hoses and foamed material in order to avoid mechanical damage.
Advantages
Quick and easy installation
Self-closing and easy to re-open
Can be retrofitted
Very good coverage
Abrasion and cut-resistant
Excellent abrasive resistance
Silencing effect
Attractive design
Continuous operating temperature: -50°C to +150°C
CANUROUND® Woven Sleeves
Feed through cable bundle
Apply CanuRound starting from the left CanuRound Tool
Also available in a minibox
Pull CanuRound to the right over the tool
Continue pulling CanuRound to the right
78 79© ShawCor Ltd. All specifications are subject to modification. Consult DSG-Canusa for the latest specification.
automotive
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 coor-dination of specific vehicle components.:
Seat belt locks Car aerials
This heat shrink tubing has outstan-dingly 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.
Advantages
Quick shrinking
Very flexible
Details remain visible under the aerial finish
Not only for automotive applications
Matt or glossy finish options
DERAY®-HB
DERAY®-IB
Design: Seat belt locks and car aerials
DERAY®-HB DERAY®-IB NS
DERAY®-IB NS
DERAY®-IB NS
Information
Contact
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.
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]