FORM -2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
PROVISIONAL
Specification
(See Section 10 and rule 13)
ELECTRICAL CABLES


FINOLEX CABLES LIMTIED
an Indian Company of 26-27, Mumbia-Pune Road, Pimpri, Pune 411 018, Maharashtra. India

THE FOLLOWING SPECIFICATION DESCRIBES THE INVENTION


Field of Invention:
This invention relates to the field of electrical cables.
Background of the Invention:
Presently solid copper is used to manufacture the conductor in use of automobile/ battery cables. These cables are heavy and expensive.
The automobile / battery cable requires a light weight for reducing the total weight of the vehicle for optimizing on fuel efficiency. Also the battery cables with heavy cross section (above 25sq. mm) find application in connection of battery banks used in powering of mobile tower, telephone exchanges, etc.
Thus there is a need for lighter and cheaper cables without compromising their performance.
Objects of the Invention:
It is an object of the invention to provide a light weight electrical cable.
Another object of this invention is to provide a cable which is economical.
Yet another object of this invention is to provide a cable with improved performance characteristics.
Brief Description of the Drawings:
Fig 1 of accompanying drawings illustrates the cross section of a copper clad aluminum conductor in accordance with this invention.

Detailed Description of the Invention:
In accordance with this invention, the conductor is made from copper clad aluminum. The copper clad aluminum wire is made of bimetallic material with cladding concentrically covering inside it an aluminum core. The copper tape is wrapped around on solid aluminum wire and scam welded followed by compression through various dies to bond mctallurgically at the interface through an essentially cold solid process which help optimizing properties of both aluminum and copper. Generally as a rule the auto / battery cable with pure copper can be switched to a copper clad aluminum cable two gauge numbers larger and obtain similar resistance and current carrying capacity with approximately 40% weight reduction. This is applied to entire range of cable sizes typically ranging form 0.5mm2 to 240mm2. the copper clad aluminum with normal 10% copper by volume used in this application has nominal thickness of copper cladding of 2.5% of conductivity of 65% IACS (International Annealed Copper Standard). The density of 10% CCA wire is 3.32gms/ cm3 corresponds to 37% that of copper. This ensures the cost savings for replacement of pure copper.
The pure copper has a resistivity of 0.17Ohms/mm2 perter (100%. IACS) which corresponds to density of 8.89 gms/ cm .
The final CCA wire used for bunching is cold drawn by using thicker wire of CA with the same copper percent, typically 2.5% nominal on wire drawings machine. The final drawn fine wire has the same uniform copper content as that of feed wore. The wire is annealed before use for higher flexibility before handling.

The CCA wires are bunched together with the construction depending on the cross sectional area. The bunched conductor thus form on a bunching machine is then insulated with special grade PVC compound which is oil, petrol, diesel, resistant.
The design of automobile / battery cables with copper clad aluminum conductor instead of solid copper in accordance with this invention has the following advantages:
1. Copper clad aluminum conductor is lighter than solid copper reducing the overall weight of the cable. This reduces the harness weight in the car which in turn improves engine and car performance.
2. The combining of bimetallic properties of providing copper on the surface to maintain the same performance (solid copper) with marginal increase in cross sectional area. The new cable design offers lower price due to savings in use of aluminum (a cheaper conductor) in the inner core of the conductor.
3. The bimetallic CCA product is cheaper than using solid copper as a conductor but more expensive than using only aluminum as a conductor. Aluminum gets easily oxidized when exposed to atmosphere creating a barrier at the termination points of the car battery for proper flow of the current. Hence instead of using copper conductor, the bimetallic conductor which is exposed to atmosphere while retaining the inner core of aluminum for saving in cost and making it light in weight.
During the use, the galvanic corrosion on CCA conductor can occur due to presence of moisture at the point of termination and due to exposure to the

atmosphere. This can lead to degradation in the performance if no proper care is taken. This can be avoided by using the sealed connectors and / or using heat shrinkable tubings to cover the exposed portion. This procedure ensures longer and trouble free life in network operation.
The conductor is made of fine wires drawn uniformly of CCA conductor bunched together with the construction depending on the cross section and flexibility. The bunched conductor is then insulated with special grade oil, diesel, petrol resistance PVC compound. They are with different colours as per the requirement of the customers.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the invention. These and other changes in the preferred embodiment as well as other embodiments of the invention will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation.
Dated this 24th day of October, 2008.
Mohan Dewan
of R. K. Dewan & Co.
Applicants' Patent Attorney