Electrical wire and method of fabricating the electrical wire

• US 7,737,359 B2
• Filed: 10/31/2007
• Issued: 06/15/2010
• 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
• Primary Examiner(s): Mayo, III; William H
• Application Number:
  US11/932,757
• Publication Number:
  US 20080047727A1
• Time in Patent Office: 958 Days
• Field of Search: 174/36, 174/110.R, 174/113.R, 174/117.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
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing

Abstract

An electrical wire includes at least one electrifiable conductor for delivering electrical power, a first insulating layer formed on one side of the electrifiable conductor, a second insulating layer formed on the opposite side of the electrifiable conductors, a first return conductor formed on the first insulating layer opposite the at least one electrifiable conductor, and a second return conductor formed on the second insulating layer opposite the at least one electrifiable conductor. The at least one electrifiable conductor is at least substantially entrapped by the first and second return conductors such that the distance between said at least one electrifiable conductor and each of said first and second return conductors is no greater than approximately 0.030 inches. At least one of the first insulating layer or the second insulating layer comprises a plurality of insulating layers.

Claims

1. An electrical wire, comprising:

at least one electrifiable conductor for delivering electrical power;

a first insulating layer formed on one side of the electrifiable conductor;

a second insulating layer formed on the opposite side of the electrifiable conductors;

a first return conductor formed on the first insulating layer opposite the at least one electrifiable conductor; and

a second return conductor formed on the second insulating layer opposite the at least one electrifiable conductor,

wherein the at least one electrifiable conductor is at least substantially entrapped by the first and second return conductors such that the distance between said at least one electrifiable conductor and each of said first and second return conductors is no greater than approximately 0.030 inches, and

wherein at least one of the first insulating layer or the second insulating layer comprises a plurality of insulating layers.

2. The electrical wire of claim 1, wherein at least one of the first insulating layer or the second insulating layer comprises one of a flame resistant insulating layer, a liquid resistant insulating layer, or an abrasion resistant insulating layer.

3. The electrical wire of claim 1, further comprising:

a third insulating layer formed on the first return conductor opposite the first insulating layer; and

a fourth insulating layer formed on the second return conductor opposite the second insulating layer.

4. The electrical wire of claim 3, wherein at least one of the third insulating layer or the fourth insulating layer comprises a plurality of insulating layers.

5. The electrical wire of claim 3, further comprising:

a first grounding conductor formed on the third insulating layer opposite the first return conductor; and

a second grounding conductor formed on the fourth insulating layer opposite the second grounding conductor.

6. The electrical wire of claim 5, further comprising:

a fifth insulating layer formed on the first grounding conductor opposite the third insulating layer; and

a sixth insulating layer formed on the second grounding conductor opposite the fourth insulating layer.

7. The electrical wire of claim 6, wherein at least one of the fifth insulating layer or the sixth insulating layer comprises a plurality of insulating layers.

8. The electrical wire of claim 6, wherein at least one of the fifth insulating layer or the sixth insulating layer comprises a flame resistant insulating layer, a liquid resistant insulating layer, an abrasion resistant insulation layer, an anti-slip insulating layer, or a slick insulating layer.

9. The electrical wire of claim 5, further comprising an adhesive for bonding adjacent insulation layers and conductors in said electrical wire.

10. The electrical wire of claim 9, wherein the adhesive is situated in a pattern along the surface of at least one of an insulation layer or a conductor.

11. The electrical wire of claim 10, wherein the pattern of adhesive facilitates the termination of the electrical wire.

12. The electrical wire of claim 1, wherein a total thickness of the electrical wire is no more than approximately 0.050 inches.

13. The electrical wire of claim 1, wherein the electrical wire comprises one of 120V AC electrical wire or 240V AC electrical wire.

14. The electrical wire of claim 1, wherein the electrical wire comprises a flexible wire.

15. An electrical wire, comprising:

at least one electrifiable conductor for delivering electrical power;

a first insulating layer formed on one side of the electrifiable conductor;

a second insulating layer formed on the opposite side of the electrifiable conductors;

a first return conductor formed on the first insulating layer opposite the at least one electrifiable conductor;

a second return conductor formed on the second insulating layer opposite the at least one electrifiable conductor, wherein the at least one electrifiable conductor is at least substantially entrapped by the first and second return conductors,

a third insulating layer formed on the first return conductor opposite the at least one electrifiable conductor,

a fourth insulating layer formed on the second return conductor opposite the at least one electrifiable conductor,

a first grounding conductor formed on the third insulating layer opposite the first return conductor, and

a second grounding conductor formed on the fourth insulating layer opposite the second return conductor,

wherein at least one of the first insulating layer, the second insulating layer, the third insulating layer, or the fourth insulating layer comprises a plurality of insulating layers, and

wherein the electrical wire comprises a flexible electrical wire.

16. The electrical wire of claim 15, wherein at least one of the first insulating layer, the second insulating layer, the third insulating layer, or the fourth insulating layer comprises one of a flame resistant insulating layer, a liquid resistant insulating layer, or an abrasion resistant insulating layer.

17. The electrical wire of claim 15, further comprising:

a fifth insulating layer formed on the first grounding conductor opposite the third insulating layer; and

a sixth insulating layer formed on the second grounding conductor opposite the fourth insulating layer.

18. The electrical wire of claim 17, wherein at least one of the fifth insulating layer or the sixth insulating layer comprises a plurality of insulating layers.

19. The electrical wire of claim 17, wherein at least one of the fifth insulating layer or the sixth insulating layer comprises a flame resistant insulating layer, a liquid resistant insulating layer, an abrasion resistant insulation layer, an anti-slip insulating layer, or a slick insulating layer.

20. The electrical wire of claim 15, further comprising an adhesive for bonding adjacent insulation layers and conductors in said electrical wire.

21. The electrical wire of claim 20, wherein the adhesive is situated in a pattern along the surface of at least one of an insulation layer or a conductor.

22. The electrical wire of claim 21, wherein the pattern of adhesive facilitates the termination of the electrical wire.

23. The electrical wire of claim 15, wherein a distance between said at least one electrifiable conductor and each of said first and second return conductors is no greater than approximately 0.030 inches.

24. The electrical wire of claim 15, wherein a total thickness of the electrical wire is no more than approximately 0.050 inches.

25. The electrical wire of claim 15, wherein the electrical wire comprises one of 120V AC electrical wire or 240V AC electrical wire.

26. 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; and

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

wherein at least one of the first insulating layer or the second insulating layer comprises a plurality of insulating layers.

27. The electrical wire of claim 26, wherein a distance between said at least one electrifiable conductor and said return conductor is no greater than approximately 0.030 inches.

28. The electrical wire of claim 26, wherein a total thickness of the electrical wire is no more than approximately 0.050 inches.

29. The electrical wire of claim 26, wherein the electrical wire comprises one of 120V AC electrical wire or 240V AC electrical wire.