FORM 2
THE PATENT ACT 1970
(39 OF 1970)
&
THE PATENTS RULES, 2003
PROVISIONAL/SPECIFICATION
( See section 10 and rule 13 )
TTLE OF THE INVENTION
"MANUFACTURING OF WAX FREE CONTINUOUS CAST COPPER WIRE ROD

APPLICANTS)
(a) Name:
MIS. STERLITE INDUSTRIES (I) LTD
(b) Nationality:
INDIAN NATIONAL
(c) Address:
COPPER DIVISION, 1/1/2 VILLAGE CHINCHPADA , SILVASSA

PREAMBLF TO THE DESCRIPTION
PROVISIONAL
The following specification describes the invention.

COMPLETE
The following specification
particularly describes the invention and the manrtr in which it is to be performed

DESCRIPTION (Description shall start from next page )

PAGE 1-6

Title - Manufacturing of Wax Free continuous cast copper wire rod
FIELD OF INVENTION :-
Invention is related with manufacturing of wax free copper wire rod by continuous casting
AND IS DRAWBACK
Continuous cast copper wire rods are used for Wire drawing , Strips manufacturing and other electrical purposes as a raw material. Wire rods are made from various methods, one them is Continuous casting & rolling process. Copper being very reactive to atmosphere get Oxidized. For preventing this Oxidation Casted rods are coated with fine film of wax for preventing it from getting Oxidised. Waxed Copper wires are not preferred in copper processing by customer in CONFORM technology of copper Processingmachines.
REGARD TO THE PRIOR ART.
As per paper
CONFORM™ TECHNOLOGY FOR COST EFFECTIVE MANUFACTURE OF COPPER STRIP DrJ. R. DAWSON BWE Ltd,
UK Feedstock Cleaning System
The copper wire rod ( Feed stock ), when it enters the Conform machine, must be free from oxide, oil, grease and any other contaminants. In some cases, in-line copper wire rod ( Feed stock) cleaning must be used, especially when the copper wire rod has been wax-coated to prevent oxidation. The copper wire rod ( Feed stock ) cleaning system used with BWE Conform machines is either the BWE Par orbital system or an ultrasonic system.
Copper strip manufactured by the Conform process is used in electrical products such as magnets, transformers and motors, where dimensional , surface finish and electrical

properties are of great importance. The electrical properties meet the requirements of all standards for such products and are generally better than rolled products. There is no porosity or local variation in dimensions. Surface finish is excellent. The strip is ready for enameling or polymer insulation without any further treatment. The strip is produced in the fully annealed condition. Here the problems are observed that the due to wax coating of the wire the quality of the strips are not satisfactory .
Process of manufacturing the continuous casted copper wire rod is described as below.
Tundish :-Metal received by the gas fired furnace is collected into the Tundish Before casting, metal should be clean from any foreign particles & Metal temperature should be maintained at the desired temperature in the range of Tundish. (1110 - 1135 )° Tundish is also provided with the Flow control pin, which controls the flow of the metal into the copper mould
Casting Machine :- Casting is said to be the heart of this process. System. The well-established two wheel casting process is utilized. Casting system uses trapezoidal grooved wheel and a steel belt which forms a end less mould cavity to produce a continuous cast bar.
Bar Preparation unit (BPU ) :- Bar preparation Unit is used to shave the cast bar and guide to enter into the Roughing mill.
Roughing mill :- Number of stands-one stand of Two roll each. Cast bar area Reduction is around 34%.
Intermediate mill :- Sterlite has Continuous Properzi technology for the rolling of hot cast bar. Sterlite Properzi mill contains 11 (eleven) stands Where 2 rolls in one stand i.e. two rolls configuration and 3 rolls in one stand i.e. three rolls configuration First three stands rolling profile is circular rest eight stands have alternate triangular and circle profile. Three configurations rolls the bar from three sides at 1200 angle. The portion, which gets rolled in the stand, is known as tangent and the unrolled portion is called witness. No of stands 08. First two stands of two roll each and next six stands of three roll each.
Finishing Mill :- Gives the final shape of rod and Accurate dimensions. No of stands 02.
Pickling & Quenching :- Both processes basically uses IPA on to the rod to act as a deoxidizer. The purpose of the quenching & Pickling is to reduce the surface oxide and dust formed . Here rod getting cooled to around 80 degree centigrade

Air dryer :- When the rod comes out of the quenching solution its temperature remains about 60C. This rod passes through air drier for moisture removal
Defectomat :- Instruments is operated on eddy current principle. It is being used to identify the ferrous inclusion in the rod as well as any physical damages to the rod.
Waxing :- Rod then coated with the water-soluble wax to avoid any tarnishing of the coils due to the atmosphere during the storage periods, it is studied that too low wax coated on the rods reduces the self-life of the coil. Therefore correct % age of wax in the solution is maintained in the desired range to avoid any tarnishing of the coils. Desired range for the wax is 2.5 to 3.5 %.
Pinch roll:- It is used to pull the rod and send to the lop forming section.
Loop forming :- This is used for making the coil in the orbital form .
Coiler :- The rod is getting coiled into the coiler for different weights After the coiling coils are pressed in compactor and sent for strapping and packing.
OBJECT OF lNVENTION
Making Copper wire rods suitable for processing in CONFORM machines hence Customer Satisfaction & Enhance the Quality .
THE INVENTION
Research carried out for problem of oxide layer & scratch mark on strips after drawing Rod size 12.45 mm, 11.42mm & 8.00mm . as per our invention we have stopped use of wax application and started only water application . This wax free rod are used in CONFORM machines with desired results.
BRIEF ■DESCRIPTION & REFERENCE OF THE ACCOMPANYING DRAWINGS
Nil
EXAMPLES
With popular used of new technology ( CONFORM ) for copper processing at our customers end / Copper market ; suitability of existing V\/ax rod was not giving desired result in terms of surface finish and Operation efficiency 0f CONFORM machines due to reduced Die life in CONFORM machines.

^


We claim,
1. A method of manufacturing of wax free Continuous cast copper wire rod
2. According to claim 1 there is 12.45 mm Continuous cast copper wire rod
3. According to claim 1 there is 11.42 mm Continuous cast copper wire rod
4. According to claim 1 there is 8.00 mm Continuous cast copper wire rod
5. According to Claim 1, Claim 2, Claim 3 & Claim 4 these wax free copper wire rod is used in conform technology machine.
Date
30th DayofJanuary,2009 Signature

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