Products / Special cables

MUNFLEX® Special is a comprehensive range of special cables with a multitude of variations available.

Based on the serial range that has been introduced in detail in this catalogue, almost all imaginable variations can be supplied on request.

In addition, special variations may be developed and produced at the request of the client in order to meet the needs of specific applications or problems.

Experienced and qualified constructors are responsible for design. A modern database containing over 20,000 special products forms the constructive basis for an offer within a very short period of time.

The implementation and realisation of the constructions is carried out in accordance with the procedures and technologies of modern cable and lead production, on request, as of an order volume of 300 m.

The multitude of special products and special manufactured items cannot for obvious reasons be included in the catalogue.

The following selection is designed to introduce the range and variation options of the materials and procedures.

Conductor material and conductor construction

The conductor material is copper on principle. Only high copper qualities are used.

Fine and finest copper wires are processed either in a not insulated or tin-plated state to form copper litz. The individual wire thicknesses lie between 0.05 and 0.40 mm in diameter. In individual circumstances, solid conductors may also be processed.

The individual wires are "strangled" into litz form for standard applications. In special usage and large dimensions they are stranded individually or in bundles. The cross-section range lies between 0.14 and 25.0 mm², for flat cables it is up to 35.0 mm², for individual cores up to 50.0 mm².

The twisted length of the litz wires and bundles is precisely defined in accordance with the application.

Insulation

A wide range of materials are available for the insulation of the copper litz.

Our own mixing facilities produce PVC compounds. High-quality S-PVC, plasticizer, additives and fillers are processed according to company recipes and made into granulates that fulfil the required mechanical, thermal and chemical properties and conditions for the subsequent use, such as cold or heat proofing, oil or chemical resistances. PVC mixtures are in principle stabilised without the use of lead.

Further requirements with regard to the thermal properties, the mechanical durability, the reaction to fire and the hazard potential in the event of fire (lack of halogen), as well as minimised wall thicknesses designed to reduce diameter are all fulfilled by high-performance materials such as, TPU, TPE, TPR, PE, PP, Special compounds and mixture types in accordance with national and international norms (UL, CSA, CNOMO etc.) are just as easy to deliver as approved mixtures for applications, for example, in ex-protected or tank station operation.

Combination elements

For special applications, the integration of other elements in the core group is also possible.

Central or externally arranged carrying elements of tension relief made from organic or synthetic fibres, steel wires of various dimensions and qualities, coaxial, bus and LWL elements as well as hoses for pneumatic or fluid technical applications enables multifunctional solutions.

Stranding

The stranding of individual cores and, if required, other elements is carried out according to the specification of the application the cable is used for. The geometric structure, the arrangement of elements in layers, pairs or bundles, the selection of the core element at the centre, the twisted lengths and the direction changes of the stranded layers are decisive when it comes to the flexibility and durability of the finished product, and particularly for cables that are moved often.

For the minimisation of the adhesion of elements, on a case by case basis, powdering with finely ground mica and/or webbing of cotton fibres, fleece, textile fabrics or special sheets is possible.

Stranded bundles which contain a connected copper or steel wire shield will be protected with a impact-resistance sheet or extruded intermediate sheath made from a relevant compatible material. For hanging cables and special cables that can be wound onto drums, the stranded group may be given a stabilising, coarsely meshed support braid made from cotton or polyamide threads.

Shields and armour

Shields act to keep external electrical and electromagnetic fields from the conductors or to prevent such fields exiting from the conductor group.

Braids made from not insulated or tin-plated copper wires applied with high density to the core wire or an inner sheath do this task. Alternatively, copper wires may be wrapped around the entire surface.

Static shields are made from aluminium or copper clad polyester sheet. Particularly high shielding effects are achieved using a combination of sheets and total shielding.

Tin-plate steel wires may be applied as braids for additional mechanical protection of cable elements.

Alongside the shielding of the entire cable union, shielding of individual cores, core pairs or groups of cores is possible in accordance with the applications and the constructions arrangements.

Outer sheath

The outer layer of each special cable is the outer sheath. Like the insulation of the copper conductor, there is a wide range of materials available to choose from with very varied properties.

PVC mixtures from our own manufacturing processes offer high quality means of meeting all national and international norms. Mechanical and thermal resistances, chemical resistances and high to highest flexibility guarantee an optimum in practical use. The PVC sheath materials are, as a basic principle, stabilised without the use of lead.

For special applications, the high-performance materials such as, TPU, TPE, TPR, PE and PP, are available. These meet further requirements.

All outer sheath qualities are available in standard and special colours and with norm-conforming or client-specific prints.

Flat cables can be surface-profiled (only available for PVC and TPR) on request to reduce the adhesion tendency.