Electrical wire and method of fabricating the electrical wire

• US 7,358,437 B2
• Filed: 03/19/2007
• Issued: 04/15/2008
• Est. Priority Date: 09/05/2003
• Status: Expired due to Fees

• Current Assignee: Newire Incorporated
• Original Assignee: Newire Incorporated
• Inventors: Martin, Fred Lane, Sexton, Robert Jay, Garris, Charles Alexander III
• Primary Examiner(s): Mayo, III; William H.
• Application Number:
  US11/688,020
• Publication Number:
  US 20070184706A1
• Time in Patent Office: 393 Days
• Field of Search: 174/36, 174/110.R, 174/113.R, 174/117.F, 174/117.FF, 174/32
• US Class Current: 174/36
• CPC Class Codes: H01B 7/0216 Two layers
• CPC Class Codes: H01B 9/006 Constructional features relating to the conductors
• CPC Class Codes: H01B 9/04 Concentric cables

Abstract

An electrical wire includes at least one electrifiable conductor, and a return conductor formed around the at least one electrifiable conductor, such that the at least one electrifiable conductor is completely entrapped by the return conductor.

Claims

1. An electrical wire comprising:

at least one electrifiable conductor for delivering electrical power;

a return conductor formed around said at least one electrifiable conductor, such that said at least one electrifiable conductor is completely entrapped by said return conductor

a first insulating layer formed between said at least one electrifiable conductor and said return conductor; and

a second insulating layer formed around said return conductor.

2. The electrical wire according to claim 1, further comprising:

a grounding conductor formed around said second insulating layer; and

a third insulating layer formed around said grounding conductor.

3. The electrical wire according to claim 2, wherein said at least one electrifiable conductor, said return conductor, and said grounding conductor comprise one of substantially curvilinear-shaped cross-sectional geometries or substantially rectilinear cross-sectional geometries.

4. The electrical wire according to claim 2, wherein said at least one electrifiable conductor, said return conductor, and said grounding conductor comprise substantially oval-shaped conductors.

5. The electrical wire according to claim 2, wherein an object penetrating an outer surface of said electrical wire contacts said grounding conductor and said return conductor before contacting said at least one electrifiable conductor.

6. The electrical wire according to claim 2, wherein said grounding conductor inhibits power transmission signals and load-generated electrical noise from being emitted from said electrical wire.

7. The electrical wire according to claim 1, wherein a total thickness of said electrical wire is no more than approximately 0.050 inches.

8. The electrical wire according to claim 1, wherein an area enclosed by said return conductor forms a hot zone, said at least one electrifiable conductor being disposed within said hot zone.

9. The electrical wire according to claim 8, wherein said at least one electrifiable conductor comprises a plurality of electrifiable conductors which are formed in said hot zone.

10. The electrical wire according to claim 9, wherein at least one of the plurality of electrifiable conductors formed in said hot zone is used to transmit a communication signal;

and

wherein at least one of the plurality of electrifiable conductors formed in said hot zone is used to supply one of AC or DC electrical power.

11. The electrical wire according to claim 10, wherein said communication signal comprises one of a voice communication signal or a data communication signal.

12. The electrical wire according to claim 1, wherein a capacitance formed between said at least one electrifiable conductor and said return conductor is given as C=1.5·

W·

L·

∈

/d, where W is the width of the return and electrifiable conductors, L is the length of the return and electrifiable conductors, ∈

is the dielectric constant for the first insulating layer, and d is the distance between the return and electrifiable conductors.

13. The electrical wire according to claim 1, further comprising:

an adhesive for bonding adjacent insulation layers and conductors in said electrical wire.

14. The electrical wire according to claim 1, wherein said electrical wire comprises one of alternating current (AC) electrical wire or direct current (DC) electrical wire for supplying an electrical current having potential of greater than 0V.

15. The electrical wire according to claim 1, wherein said electrical wire comprises one of 120V AC electrical wire or 240V AC electrical wire.

16. The electrical wire according to claim 1, wherein said electrical wire comprises surface-mountable electrical wire.

17. The electrical wire according to claim 1, wherein each of said at least one electrifiable conductors comprises a thickness which is in a range from about 0.0004 inches to about 0.020 inches.

18. An electrical wire comprising:

at least one electrifiable conductor for delivering electrical power;

a return conductor formed around said at least one electrifiable conductor, such that said at least one electrifiable conductor is completely entrapped by said return conductor;

a first insulating layer formed between said at least one electrifiable conductor and said return conductor;

a grounding conductor formed around said return conductor;

a second insulating layer formed between said return conductor and said grounding conductor; and

a third insulating layer formed on said grounding conductor.

19. The electrical wire according to claim 18, wherein said electrical wire comprises one of 120V AC electrical wire or 240V AC electrical wire.

20. The electrical wire according to claim 18, wherein a total thickness of said electrical wire is no more than approximately 0.050 inches.