Electrical wire and method of fabricating the electrical wire

• US 8,044,298 B2
• Filed: 05/05/2010
• Issued: 10/25/2011
• Est. Priority Date: 09/05/2003
• Status: Expired due to Fees

• Current Assignee: Newire Incorporated
• Original Assignee: Newire Incorporated
• Inventors: Garris, Charles Alexander, Martin, Fred Lane, Sexton, Robert Jay
• Primary Examiner(s): Mayo, III; William H.
• Application Number:
  US12/774,162
• Publication Number:
  US 20100212934A1
• Time in Patent Office: 538 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 a first conductor, a second conductor, and a third conductor. The first conductor is formed as an electrifiable conductor for delivering electrical power. The second and third conductors are respectively formed on opposing sides of the first conductor, such that the first conductor is at least substantially entrapped by the second and third conductors. A distance between the first conductor and each of the second and third conductors is no greater than approximately 0.030 inches.

Claims

1. An electrical wire, comprising:

a first conductor formed as an electrifiable conductor for delivering electrical power; and

second and third conductors which are respectively formed on opposing sides of the first conductor, such that the first conductor is at least substantially entrapped by the second and third conductors,

wherein a distance between the first conductor and each of the second and third conductors is no greater than approximately 0.030 inches.

2. The electrical wire of claim 1, wherein each of the second and third conductors comprises one of (i) a return conductor or (ii) a grounding conductor.

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

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

a first insulating layer formed between the first conductor and the second conductor; and

a second insulating layer formed between the first conductor and the third conductor.

5. The electrical wire of claim 1, wherein the first conductor, the second conductor, and the third conductor comprise substantially flat conductive layers having a stacked arrangement.

6. The electrical wire of claim 1, wherein the second conductor and the third conductor contact each other along a longitudinal edge of the electrical wire, such that the first conductor is completely entrapped by the second conductor and the third conductor.

7. The electrical wire of claim 1, wherein the second conductor and the third conductor are treated by at least one of a mechanical, chemical, or thermal treatment to form a protective longitudinal edge of the electrical wire, the protective edge inhibiting a foreign object from penetrating the electrical wire and contacting the first conductor without contacting one of the second and third conductors.

8. An electrical wire, comprising:

a first conductor formed as an electrifiable conductor for delivering electrical power;

first and second insulating layers respectively formed on opposing sides of the first conductor;

second and third conductors respectively formed on the first and second insulating layers opposite the first conductor, wherein the first conductor is at least substantially entrapped by the second and third conductors;

third and fourth insulating layers respectively formed on the second and third conductors opposite the first and second insulating layers; and

fourth and fifth conductors respectively formed on the third and fourth insulating layers opposite the second and third conductors,

wherein the electrical wire comprises a flexible electrical wire.

9. The electrical wire of claim 8, wherein each of the second, third, fourth, and fifth conductors comprises one of (i) a return conductor or (ii) a grounding conductor.

10. The electrical wire of claim 8, further comprising:

fifth and sixth insulating layers respectively formed on the fourth and fifth conductors opposite the third and fourth insulating layers.

11. The electrical wire of claim 8, wherein the first conductor comprises a thickness which is in a range from approximately 0.0004 inches to approximately 0.020 inches.

12. The electrical wire of claim 8, wherein the electrical wire comprises one of 120V AC electrical wire or 240V AC electrical wire.

13. The electrical wire of claim 8, wherein a distance between the first conductor and each of the second and third conductors is no greater than approximately 0.030 inches.

14. The electrical wire of claim 8, wherein a total thickness of the electrical wire is no more than approximately 0.050 inches.

15. The electrical wire of claim 8, wherein an area between the second and third conductors forms a hot zone, the first conductor being disposed within the hot zone.

16. The electrical wire of claim 15, wherein the first conductor comprises a plurality of electrifiable conductors which are formed in the hot zone.

17. The electrical wire of claim 8, further comprising:

an adhesive for bonding adjacent insulating layers and conductors in the electrical wire.

18. The electrical wire of claim 8, wherein an object penetrating an outer surface of the electrical wire contacts one of the fourth and fifth conductors and one of the second and third conductors before contacting the first conductor.

19. The electrical wire of claim 8, wherein the electrical wire comprises surface-mountable electrical wire.

20. A method of fabricating an electrical wire, the method comprising:

forming a first conductor as an electrifiable conductor for delivering electrical power; and

forming second and third conductors on opposing sides of the first conductor, such that the first conductor is at least substantially entrapped by the second and third conductors,

wherein a distance between the first conductor and each of the second and third conductors is no greater than approximately 0.030 inches.