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