deray®-iakt ns - DSG-Canusa

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


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


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.


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


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


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.


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


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.


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


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


automotive

DERAY®-IBKT



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


automotive

DERAY®-HBKT



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


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



automotive


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


Good adhesion to the aluminium pipe, even without additional adhesive lining

No detachment of heat shrink tubing from the aluminium pipes when being bent, particularly in the fold/bend area


Corrosion protection

In its specific area of application, DERAY®-HBNS performs impressively thanks to its outstanding

Characteristics

Continuous operating temperature: -55°C to +135°C




Processing


DERAY®-HST 35 100

DERAY®-HST 40 170



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.


DERAY®-HB NS



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


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


automotive


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


In its specific area of application, DERAY®-INS performs impressively thanks to its outstanding

Characteristics

Flammability complies with UL 224 C


Surface can be printed via hot seal and offset processes

Processing


DERAY®-HST 35 100

DERAY®-HST 40 170



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.


DERAY®-INS



automotive

DERAY®-INS



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


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


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




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


automotive

DERAY®-DKI



Surface smooth Specific gravity 1,10 g/cm3 ASTM-D 792, A-I Shrink ratio ≥ 2:1


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



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


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



Flammability complies with JIS D 1201 1973 (classification: slow burning, combustion rate max. 50 mm/min)


Processing


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


automotive

DERAY®-KWS/KWS-R



Surface matt Specific gravity 1,25 g/cm3 ASTM-D 792, A-I Shrink ratio ≥ 3:1


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


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


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


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


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


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.


DERAY®-SPLICEMELT

DERAY®-SPLICEMELT-CAP

Sealing


automotive

DERAY®-SPLICEMELT black



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


automotive

DERAY®-SPLICEMELT clear



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


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



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


Permanently resistant to temperatu-res up to 85°C / 105°C / 125°C

Low thermal stress of the part to be sealed during processing


Watertight

Good adhesion to different types of insulation materials, e.g. PVC, VPE, PP-EPDM



The jacket material of the black option is self-extinguishing

DERAY®-PRESSMELT

Small Cable Bundles


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.


automotive

DERAY®-IPM (PRESSMELT)



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



automotive

DERAY®-IAKT black (PRESSMELT)



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


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


automotive

DERAY®-IAKT clear (PRESSMELT)





-18 % max. (4:1) ASTM-D 2671


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



automotive

DERAY®-IHKT black (PRESSMELT)


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



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



-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


automotive

DERAY®-IHKT clear (PRESSMELT)








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



-55°C to +125°C IEC 216




automotive

DERAY®-Adhesive Insert-System


DERAY®-Adhesive Insert 85°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


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


Permanently resistant to tempera-tures up to 110°C / 125°C

Low thermal stress of the part to be covered during processing


Watertight

Good adhesion to the common types of plug housing materials as well as PVC, VPE, PP-EPDM

DERAY®-DUOMELT

Medium-Sized Cable Bundles


automotive

Sealing system DERAY®-DUOMELT

Further advantages


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.


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.


automotive

DERAY®-Adhesive Strip 85°C-System


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


Material Material synthetic rubber-basis, free of lead and cadmium

Specific gravity 1,4 g/ cm3 max. ASTM-D 792, A-IColour black


-40°C to +85°C/+105°C

Chemical properties Water absorption 0,5 % max.


automotive

DERAY®-IAKT black (DUOMELT)





-18 % max. (4:1) ASTM-D 2671


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



automotive

DERAY®-IAKT clear (DUOMELT)



Surface matt, smoothSpecific gravity 1,00 g/cm3 max. ASTM-D 792, A-I Shrink ratio 3:1


-18 % max. (4:1) ASTM-D 2671


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



automotive

DERAY®-Adhesive Strip 105°C-System


Material Material modified copolymere,free of lead and cadmium

Specific gravity 0,98 g/cm3 max. ASTM-D 792, A-ISurface smooth


-40°C to +105°C

Softening point ca. +130°C

Combustion behaviour passed FMVSS 302

Chemical properties Water absorption 0,5 % max. DIN 53495




Specific gravity 1,4 g/ cm3 max. ASTM-D 792, A-IColour black


-40°C to +85°C/+105°C



automotive

DERAY®-IHKT black (DUOMELT)








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



-55°C to +125°C IEC 216




automotive

DERAY®-IHKT clear (DUOMELT)








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



-55°C to +125°C IEC 216




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


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


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


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


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


automotive

DERAY®-COLDMELT I 85°C-System


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


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


automotive

DERAY®-COLDMELT I 105°C-System





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



automotive

DERAY®-COLDMELT I HT 125°C-System





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



automotive




Specific gravity 1,4 g/cm3 max. ASTM-D 792, A-IColour black


-35°C to +85°C/+105°C


DERAY®-COLDMELT I


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


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


automotive

DERAY®-COLDMELT II


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


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


automotive

DERAY®-COLDMELT II


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


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


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


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


Permanently resistant to tempera-tures up to 85°C


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


automotive

DERAY®-IOK Insulating Cap


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


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.


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 adhesion to various types of splices thanks to the specifically designed indentation cut


Translucent material allows optimum positioning

Permanently resistant to tempera-tures up to 85°C


automotive


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:



Flammability ca. 45 mm/Min. MVSS-302


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


DERAY®-HIOK Insulating Cap


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


Permanently resistant to temperatu-res up to 85°C

Good adhesion to various types of insulation materials such as PVC, VPE, PP-EPDM


Translucent material allows opti-mum positioning

Halogen-free

Complies with FMVSS 302

Combines the advantages of DERAY®-IOK and DERAY®-HIOK


automotive


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:



Flammability ca. 45 mm/minute


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


DERAY®-BIOK 85°C System

* Ultrasonic welded end connectors, values serve as a proposal


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


automotive


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.


automotive


DERAY®-AutosealMan 40

Processing Module DERAY®-AutosealMan 40


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.


automotive


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




automotive


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


automotive

DERAY®-VA 25 TW



Surface satin, mattSpecific gravity 1,5 g/cm3 max. ASTM-D 792, A-IShrink ratio 2:1Longitudinal shrinkage 15 % max. ASTM-D 2671


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




automotive

DERAY®-VT 220



Surface satin, mattSpecific gravity 1,9 g/cm3 max. ASTM-D 792, A-IShrink ratio 2:1Longitudinal shrinkage 10 % max. ASTM-D 2671


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




automotive


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



* 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




automotive


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


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



DERAY®-KY 175


automotive

DERAY®-KYF 190


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


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





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.


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



automotive


CANUFLEX® is an all-purpose low-cost PET braided sleeve for protecting or bundling up wires, cables, pipes and hoses such as wire harnesses, 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.



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


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


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]

Documents

deray®-iakt ns - DSG-Canusa