Leoni elocab chose DuPont Hytrel thermoplastic polyester elastomer for the jacketing of high-voltage spiral jumper cables which carry electric power between carriages of high-speed trains such as the German ICE or the Spanish Velaro. Leoni, a manufacturer of tailor-made special cables and specialist for mobile highflex connections, picked this thermoplastic elastomer because it met the application's demanding multiple requirements. These include flex-fatigue resistance, flexibility at low temperatures, resistance to chemicals, to UV exposure and to impact; it also had to be a good electrical insulator, and to have good processing characteristics that permit cost-effective manufacturing.
Cable jacketing for high-voltage cables from the roof of one carriage to the next must withstand a demanding combination of extreme stresses. Operating voltage at contact points is 25kV. While a train is moving, the cables are exposed to permanent vibration and have to dynamically compensate distance differences between carriages, which can be as much as 1000mm on extreme track sections. Very good hydrolysis resistance is required, as well as good recovery at temperatures between -30°C and +80°C. The cables must stand up to ice, snow and hail as well as exposure to UV radiation, ozone and cleaning agents.
The jumper cables protected by Hytrel daily demonstrate their suitability for use under extremely tough conditions in high-speed use. On the Madrid-Valladolid stretch and in German high-speed rail traffic the ICE and Velaro trains on which they are used reach speeds up to 350km/h in all weathers.
Leoni elocab manufactures the stranded copper conductor at its factory at Georgensgmünd, near Nürnberg, Germany, and extrudes the jacketing of Hytrel at the same location. The complete cable is then formed into a spiral and sections are completed with terminal plates. Together with the plates one carriage-to-carriage system for the ICE weighs about 16kg.

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