Electrical wire and method of fabricating the electrical wire

• US 8,481,853 B2
• Filed: 09/21/2011
• Issued: 07/09/2013
• Est. Priority Date: 09/05/2003
• Status: Expired due to Fees

• Current Assignee: Newire Incorporated
• Original Assignee: Newire Incorporated
• Inventors: Sexton, Robert Jay, Martin, Fred Lane, Garris, Charles Alexander III
• Primary Examiner(s): Mayo, III, William H
• Application Number:
  US13/238,904
• Publication Number:
  US 20120012361A1
• Time in Patent Office: 657 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 plurality of first conductors. The plurality of first conductors includes at least one electrifiable conductor for delivering electrical power and at least one signal conductor for delivering a communications signal. Second and third conductors are respectively formed on opposing sides of the plurality of first conductors, such that each of the plurality of first conductors is at least substantially entrapped by the second and third conductors. A distance between the at least one electrifiable conductor and each of the second and third conductors is no greater than approximately 0.030 inches.

Claims

1. A wire, comprising:

a plurality of first conductors comprising at least one electrifiable conductor for delivering electrical power and at least one signal conductor for delivering a communications signal; and

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

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

2. The wire of claim 1, wherein the at least one signal conductor comprises a patterned conductor.

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

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

5. The wire of claim 1, further comprising:

a first insulating layer formed between the plurality of first conductors and the second conductor; and

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

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

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

8. The 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 wire, the protective edge inhibiting a foreign object from penetrating the wire and contacting the plurality of first conductors without contacting one of the second and third conductors.

9. The wire of claim 1, further comprising:

a fourth conductor formed on an opposing side of the second conductor from the plurality of first conductors; and

a fifth conductor formed on an opposing side of the third conductor from the plurality of first conductors, wherein

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

wherein each of the fourth and fifth conductors comprises one of (i) a return conductor or (ii) a grounding conductor.

10. The wire of claim 1, wherein the at least one electrifiable conductor is configured to carry one of a 120V AC electrical signal or a 240V AC electrical signal.

11. The wire of claim 1, wherein an area between the second and third conductors forms a hot zone, the plurality of first conductors being disposed within the hot zone.

12. The wire of claim 1, wherein the wire comprises a surface-mountable wire.

13. The wire of claim 1, wherein the wire comprises a flexible wire that may be bent back upon itself at any angle.

14. A wire, comprising:

at least one first conductor, the at least one first conductor comprising at least one electrifiable conductor for delivering electrical power

second and third conductors which are respectively formed on opposing sides of the at least one first conductor, such that the at least one first conductor is at least substantially entrapped by the second and third conductors, wherein a distance between the at least one first conductor and each of the second and third conductors is no greater than approximately 0.030 inches; and

and at least one signal conductor for delivering a communications signal.

15. The wire of claim 14, wherein each of the second and third conductors comprises one of (i) a return conductor or (ii) a grounding conductor.

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

17. The wire of claim 14, wherein an area between the second and third conductors forms a hot zone, the at least one first conductor being disposed within the hot zone.

18. The wire of claim 14, wherein the at least one signal conductor is disposed within the hot zone.

19. The wire of claim 14, wherein the at least one signal conductor comprises a patterned conductor.

20. A method of fabricating a wire, the method comprising:

forming a plurality of first conductors comprising at least one electrifiable conductor for delivering electrical power and at least one signal conductor for delivering a communications signal; and

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

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