R

FLEXIBAR
For Battery Cable

www.rolycab.com

ABOUT US:
Rolycab Industries, a Cable manufacturing company, is an ISI, CE certified company and was established in the Year 2006. Our
Cable Manufacturing unit is located at Daman (U.T), with ISO certification. We have also established a new manufacturing unit of
Rigid PVC ducts and channel at Vasai. Our companies aim is to research, develop & innovate products which help in less consumption of energy and is helpful to its concerning industries.
With this aim we introduce our new product ROLYCAB FLEXIBAR.

ROLYCAB FLEXIBAR
ROLYCAB FLEXIBARS are formed with multiple layers of thin copper strips, insulated with high resistance, self-extinguishing PVC compound and with special features like impervious to water, oil, grease, petrol, diesel etc. In this Flexibar holes are
punched directly through the copper laminates and are connected. The advantage of this product is that, there is elimination of end
lugs, which eventually reduces the process and labour cost.
Rolycab flexibar allows twisting and bending as well.

REPLACEMENT OF BATTERY CABLES USED IN AUTOMOBILE INDUSTRIES:

In automobile industries, till the date we used round battery cables. Main requirement of battery cables in automobile
industries is high Amperes while igniting the Engine. According to ampere requirement Cables size selected. Voltage is very low 12V,
24V and 60V.
Ampere flow in round cables is very high at outer surface (skin) of conductor. It gradually decreases towards centre of
Conductor and becomes zero at center. In technical language its called skin effect of ampicity.
This means if we remove some part of center conductor in round cable which are not useful for carrying ampere, then also
ampere capacity will remain same. With this idea to reduce wastage of material and increase efficiency we introduce our new
product as Rolycab flexibar with multiple layer of copper laminates, which give more skin of copper to carry high Ampere.
In Automobile industries Weight of each component used is also one of the important factor as reduction in weight effect to
mileage of vehicle. With replacement of Round Cable to Rolycab flexibar we can achieve reduction in weight as well.

SKIN EFFECT
Comparison of the penetration depth between
ROUND COPPER CABLE & ROLYCAB FLEXIBAR
36%
Smalle

1 X ROLYCAB FLEXIBAR
3 X 20 X 1
60 SQMM

1 X 95 SQMM COPPER CABLES

95 SQMM

323 A at 40 C

260 A at 40 C

FEATURES:
Rolycab flexibar consist of copper laminates covered with high quality durable polymers.
Internal copper laminates are insulated in such a way that it helps to give flexibility in bending and twisting.
To get optimum connectivity, terminal can be created by direct punch on copper laminates.
It reduces cost of labour and eliminates cost of Lugs.
It is ground breaking alternative to high ampere round cables.
It occupies less space than round cables.
Its easy to use as the product is flexible and easy to bend.
It can be easily customized as per sample of battery cable harness.
It is also available in Red for +Ve and Black for Ve.

FLEXIBAR SIZES & AMPLICITY TABLE

FLEXIBAR SIZES & AMPLICITY TABLE

NXAXB

PART CODE

AMP @
40C

N
A

70
90
125
150
225
300
330

BSM2105
BSM3105
BSM3135
BSM2158
BSM2201
BSM3201
BSM4201

2 X 10 X 0.50MM
3 X 10 X 0.50MM
3 X 13 X 0.50MM
2 X 15.50 X 0.80MM
2 X 20 X 1.00MM
3 X 20 X 1.00MM
4 X 20 X 1.00MM

72
95
150
191
246
323
345

ROUND
CABLE
SIZE
16
25
35
50
70
95
120

AMP @
40C
70
88
110
145
215
260
305

TECHNICAL CHARACTERISTICS:
CONDUCTOR :

INSULATION:
High grade polymer
Colour : Black
Thickness : 2mm average ( 0.20mm)
Shore Hardness: A 75-85
ROHS Compliance
Electrical Strength : > 20 Kv/mm
Flammability : UL 94 VO
Tensile Strength: > 9N/mm
Elongation: > 250%
Dielectric rigidity: 20 Kv/mm

Copper strip Electrolytic grade (> 99.9% Cu)

Surface : uncoated bare
Tensile : > 200N/mm
Extensibility : > 20% (minimum)
Lamination thinkness : 0.5mm to 1.00mm

INDUSTRIES

Head Office: 301/302, Square One Bldg, Gulmohar Road no. 1, JVPD Scheme, Vile Parle (West), Mumbai 400049.
Tel: +91 22 2701425/28 Website: www.rolycab.com Email : bkd@rolycab.com