U.S. patent number RE42,085 [Application Number 11/008,750] was granted by the patent office on 2011-02-01 for flat surface-mounted multi-purpose wire.
This patent grant is currently assigned to Newire, Inc.. Invention is credited to Robert J. Sexton.
United States Patent |
RE42,085 |
Sexton |
February 1, 2011 |
Flat surface-mounted multi-purpose wire
Abstract
A multi-purpose wire includes at least one elongated conductor
having a width of at least 0.125 inches. The conductor includes at
least one conductive layer having a thickness no greater than about
0.0200 inches. The wire also includes a bonding material between
each conductor, and an insulation layer surrounding the conductor
and bonding material.
Inventors: |
Sexton; Robert J.
(Hendersonville, TN) |
Assignee: |
Newire, Inc. (Knoxville,
TN)
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Family
ID: |
25477890 |
Appl.
No.: |
11/008,750 |
Filed: |
December 10, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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08942305 |
Oct 1, 1997 |
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Reissue of: |
09783576 |
Feb 14, 2001 |
06492595 |
Dec 10, 2002 |
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Current U.S.
Class: |
174/117F;
174/117FF; 174/117A |
Current CPC
Class: |
H01B
7/0823 (20130101); H02G 3/26 (20130101); H01R
25/16 (20130101); H01R 12/594 (20130101); H02G
5/005 (20130101); H02G 3/10 (20130101); H01B
7/0018 (20130101); H02G 3/0431 (20130101) |
Current International
Class: |
H01B
7/08 (20060101) |
Field of
Search: |
;174/117F,117FF,117A
;439/652 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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0116505 |
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EP |
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1028980 |
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2252197 |
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Jul 1992 |
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GB |
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60-82883 |
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Dec 1986 |
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JP |
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61-65649 |
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JP |
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62-99147 |
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Jan 1989 |
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62-166487 |
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63-47080 |
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03-27608 |
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Nov 1992 |
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03-63168 |
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Mar 1993 |
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JP |
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87/06760 |
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Nov 1987 |
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WO |
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Other References
Withers, R.S. et al., "Superconductive Analog Signal Processing
Devices," Proceedings of the IEEE, IEEE, New York, US, vol. 77, No.
8, Aug. 1, 1989, pp. 1247-1262. cited by other .
Skalare, A. et al., "Slot Line Components for Millimeter Wave and
Sub-Millimeter Wave Integrated Circuits," Proceedings of the
European Microwave Conference. Folkets Hus, Sweden, Sep. 12-16,
1988, Tunbridge Wells, Microwave Exhibitions, GB, vol. Conf. 18,
pp. 665-668. cited by other .
Declaration of Robert J. Sexton pursuant to 37 C.F.R. Section 1.132
dated Jan. 25, 2008. cited by other .
"Stealth Speaker Wire," Home Mechanix, A Times Mirror Magazine,
Oct. 1994, p. 12. cited by other .
Taperwire Advertisement, Systems: Contractor News, Fall 1994. cited
by other .
"Wired Up," Professional Security Installer, Nov. 1995, pp. 10-11.
cited by other .
Advance Wire Solutions Web Site, available at
http://www.advancewiresolutions.com/index.htm, accessed on Jun. 2,
2006. cited by other .
List of Taperwire Wire Models and Invoice Listings, Sep. 2001.
cited by other .
Tape-R Wire, Taperwire Description and Installation Instructions,
Date Unknown. cited by other .
Taperwire Price Schedules, Date Unknown. cited by other.
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Primary Examiner: Nguyen; Chau N
Attorney, Agent or Firm: Sutherland Asbill & Brennan
LLP
Parent Case Text
This application is a continuation of application Ser. No.
08/942,305 filed Oct 1, 1997 now abandoned.
Claims
Having thus described my invention, what I claim as new and desire
to secure by Letters Patent is as follows:
1. A surface mountable, flexible, multi-purpose wiring comprising:
a plurality of flat, elongated conductors, each conductor having a
width of 0.125 inches or more and comprising at least one
conductive layer having a cross sectional height in the range of
.Iadd.about .Iaddend.0.0004 to .Iadd.about .Iaddend.0.0200 inches;
a bonding material adjacent each said flat, elongated conductor;
and an insulation layer .Iadd.selected from the group consisting of
urethane, polyethylene and a fluoropolymer, said insulating layer
.Iaddend.surrounding said plurality of flat, elongated conductors
and said bonding material, said bonding material being bonded to
said insulation layer, wherein a combined cross-sectional height of
said plurality of flat, elongated conductors, bonding material and
insulation layer is less than .Iadd.about .Iaddend.0.050 inches,
wherein said plurality of flat, elongated conductors are separated
by a distance in a range of .Iadd.about .Iaddend.0.125 and
.Iadd.about .Iaddend.0.6 .[.inches..]. .Iadd.inches, and wherein
the wiring may be folded back upon itself at any angle to
accommodate angle changes on the surface of a wall or ceiling.
.Iaddend.
2. The multi-purpose wiring of claim 1, wherein opposite side edges
of said insulation layer are tapered to allow said wiring to blend
in with a surface to which said wiring is mounted.
3. The multi-purpose wiring of claim 2, wherein said wiring bears
or accepts an adhesive tape, liquid or spray on either side of said
wiring to adhere said wiring to a surface.
4. The multi-purpose wiring of claim 1, wherein said at least one
conductive layer comprises at least one conductive metal layer.
5. A multi-purpose wire, comprising: a plurality of elongated
conductors, each conductor having a width of 0.125 inches or more
and comprising at least one conductive layer having a thickness in
a range of .Iadd.about .Iaddend.0.0004 to .Iadd.about
.Iaddend.0.0200 inches; a bonding material adjacent each said
elongated conductor; and an insulation layer .Iadd.selected from
the group consisting of urethane, polyethylene and a fluoropolymer,
said insulation layer .Iaddend.surrounding said plurality of
elongated conductors and said bonding material, wherein a thickness
of said wire is no greater than .Iadd.about .Iaddend.0.050 inches,
and wherein said plurality of elongated conductors are separated by
a distance in a range of .Iadd.about .Iaddend.0.125 and .Iadd.about
.Iaddend.0.6 .[.inches..]. .Iadd.inches, and wherein the
multi-purpose wire may be folded back upon itself at any angle to
accommodate angle changes on the surface of a wall or ceiling.
.Iaddend.
6. The multi-purpose wire of claim 5, wherein said plurality of
elongated conductors comprises a plurality of conductors spaced
apart in a generally parallel, coplanar relationship.
7. The wire according to claim 5, wherein each elongated conductor
in said plurality of elongated conductors has a width in a range of
about 0.125 to about 1.5 inches.
8. The wire according to claim 5, wherein each of said at least one
conductive layer has a thickness in a range of .Iadd.about
.Iaddend.0.001 to .Iadd.about .Iaddend.0.010 inches.
9. The wire according to claim 5, wherein said plurality of
elongated conductors comprises a range of 1 to 6 conductors.
10. The wire according to claim 5, wherein said at least one
conductive layer comprises a range of 1 to 5 conductive layers.
11. The wire according to claim 5, wherein said wire comprises a
flexible wire.
12. The wire according to claim 5, wherein each of said at least
one conductive layer has a uniform width and thickness.
13. The wire according to claim 5, wherein an application of said
wire may be varied by varying one of a width of each elongated
conductor in said plurality of elongated conductors, a height of
each said elongated conductor, and a number of conductive layers in
each said elongated conductor.
14. The wire according to claim 5, wherein said at least one
conductive layer comprises a range of 3 to 5 conductive layers,
each conductive layer having a thickness of about 0.002 inches, and
wherein said wire has a thickness of about 0.012 inches.
.[.15. The wire according to claim 5, wherein said insulation layer
comprises one of polyester, urethane, polyethylene and a
fluoropolymer..].
16. The wire according to claim 5, wherein said insulation layer is
flexible, paintable, and resistant to ultraviolet light and joint
compounds.
17. The wire according to claim 5, wherein said bonding material is
bonded to an inner surface of said insulation layer.
18. The wire according to claim 5, wherein said bonding material
comprises one of a thermal bonding material, adhesive tape, liquid
adhesive .[.and.]. .Iadd.or .Iaddend.a combination thereof.
19. The wire according to claim 5, wherein said bonding material
separates said plurality of elongated conductors and maintains a
safe dielectric distance between said elongated conductors.
20. The wire according to claim 5, wherein said plurality of
elongated conductors comprises 3 conductors, wherein said at least
one conductive layer comprises 3 conductive layers, each conductive
layer having a thickness of about .Iadd.about .Iaddend.0.002
inches, and wherein said thickness of said wire is in a range of
.Iadd.about .Iaddend.0.007 to .Iadd.about .Iaddend.0.050
inches.
21. The wire according to claim 5, wherein said wire has a width in
a range of .Iadd.about .Iaddend.2.0 and .Iadd.about .Iaddend.4.0
inches, wherein a thickness of said at least one conductive layer
is in a range of .Iadd.about .Iaddend.0.0004 to .Iadd.about
.Iaddend.0.0020 inches, and wherein a distance between said
plurality of elongated conductors is in a range of .Iadd.about
.Iaddend.0.2 to .Iadd.about .Iaddend.0.3 inches.
22. The wire according to claim 5, wherein said plurality of
elongated conductors comprises an alternating current (AC) ground
conductor, split or unified, an AC neutral conductor, and an AC
power conductor.
23. The wire according to claim 5, wherein said wire comprises 110
V AC wire, wherein said plurality of elongated conductors comprises
a range of 3 to 5 conductors, and wherein said at least one
conductive layer comprises a range of 1 to 5 conductive layers.
24. The wire according to claim 23, wherein said plurality of
elongated conductors comprises 2 AC neutral conductors, 2 AC power
conductors and 1 AC ground conductor, and wherein said wire
accommodates two circuits.
25. The wire according to claim 23, wherein said plurality of
elongated conductors comprises 1 AC neutral conductors, 2 AC power
conductors and 1 AC ground conductor, and wherein said wire
accommodates two circuits.
26. The wire according to claim 23, wherein said plurality of
elongated conductors comprises 1 AC neutral conductor, 1 AC power
conductor and 1 AC ground conductor, and wherein said wire
accommodates two circuits.
27. The wire according to claim 23, wherein said wire has a width
in a range of .Iadd.about .Iaddend.3.5 and .Iadd.about
.Iaddend.4.25 inches.
28. The wire according to claim 5, wherein said wire comprises 220
V AC wire, and wherein said plurality of elongated conductors
comprises: an AC neutral conductor and an AC power conductor, each
having a width in a range of .Iadd.about .Iaddend.0.4 and
.Iadd.about .Iaddend.0.6 inches; and an AC ground conductor having
a width in a range of .Iadd.about .Iaddend.0.2 and .Iadd.about
.Iaddend.0.4 inches, and wherein of said at least one conductive
layer has a thickness of about .Iadd.about .Iaddend.0.002 inches,
wherein said thickness of said wire is in a range of .Iadd.about
.Iaddend.0.012 to .Iadd.about .Iaddend.0.050 inches, wherein a
distance between said plurality of elongated conductors is in a
range of .Iadd.about .Iaddend.0.4 and .Iadd.about .Iaddend.0.6
inches, and wherein a width of said wire is in a range of
.Iadd.about .Iaddend.3.0 and .Iadd.about .Iaddend.3.5 inches.
29. The wire according to claim 5, wherein said wire comprises one
of loud speaker wire, telephone wire, cable television wire, low
voltage wire .[.and.]. .Iadd.or .Iaddend.under-surface lighting
wire.
30. The wire according to claim 5, wherein said plurality of
elongated conductors are separated by a distance in a range of
.Iadd.about .Iaddend.0.2 and .Iadd.about .Iaddend.0.3 inches.
.Iadd.31. The multi-purpose wiring of claim 1, wherein each
conductor comprises a plurality of conductive layers. .Iaddend.
.Iadd.32. The multi-purpose wiring of claim 1, wherein the wiring
is concealed on the surface of the wall or ceiling by paint or
wallpaper. .Iaddend.
.Iadd.33. The wire according to claim 5, wherein each conductor
comprises a plurality of conductive layers. .Iaddend.
.Iadd.34. A wire comprising: a plurality of conductors, each
conductor having a width of about 0.125 inches or more and
comprising at least one conductive layer having a thickness no
greater than about 0.0200 inches; a bonding material adjacent to
said plurality of conductors; and an insulation layer selected from
the group consisting of urethane, polyethylene and a fluoropolymer,
said insulation layer surrounding said plurality of conductors and
said bonding material, said bonding material being bonded to said
insulation layer, wherein said plurality of conductors are
separated by a distance in a range of about 0.125 inches and about
0.6 inches, and wherein the wire may be folded back upon itself at
any angle to accommodate angle changes on the surface of a wall or
ceiling. .Iaddend.
.Iadd.35. The wire of claim 34, wherein a total thickness of said
plurality of conductors, said bonding material and said insulation
layer is less than about 0.050 inches. .Iaddend.
.Iadd.36. The wire of claim 34, wherein said at least one
conductive layer has a thickness in a range of about 0.0004 inches
to about 0.0200 inches. .Iaddend.
.Iadd.37. The wire of claim 34, wherein a conductor in said
plurality of conductors has a width in a range of about 0.2 inches
to about 0.8 inches. .Iaddend.
.Iadd.38. The wire of claim 34, wherein each conductor comprises a
plurality of conductive layers. .Iaddend.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to flat wiring, and more
particularly, to a thin, bendable, surface-mounted flat wire for
use in a variety of wiring applications.
2. Description of the Related Art
Current wiring and re-wiring techniques and procedures present many
limitations to the user in existing commercial or residential
applications. The choices for adding, changing or moving any of the
many wiring applications--electrical, telephone, antenna/CATV, loud
speaker, and low voltage wiring, as well as the associated plugs,
switches, and connections--is expensive or obtrusive or both.
Temporary or removable methods such as extension cords, long
telephone and antenna/CATV cords, external loud speaker wire, and
low voltage wire, are cumbersome and hard to hide or blend into a
room.
Permanent installations typically require either a professional to
install in a wall if the user desires a hidden installation or the
use of some type of unattractive and inflexible conduit. Both
methods tend to be expensive.
In light of the foregoing, there exists a need for a permanent,
non-obtrusive, low-cost, easy to self-install, location specific,
hidden system for wiring and re-wiring applications on walls and
ceilings. There also exists a need for associated plugs, switches,
and connections that could provide an interface between such a new
wiring system and conventional wiring.
SUMMARY OF THE INVENTION
The present invention is directed to flat, thin, flexible,
multi-layered wires, which substantially obviate one or more of the
problems due to the limitations and disadvantages of the related
art.
By way of example and not by limitation, the present invention can
be utilized in a wide variety of applications, including: standard
electrical wiring; telephone wiring; loud speaker wiring; low
voltage wiring such as security systems; under surface lighting;
and cable TV wiring.
In addition, the present invention includes several unique outlets,
switches, and connectors that provide the interface between
existing conventional round wiring and the flat wires of the
present invention.
To achieve these and other advantages and in accordance with the
purpose of the invention, as embodied and broadly described, the
invention provides for a surface mounted, flexible, multi-purpose
wire, comprising, a plurality of flat elongated conductors spaced
apart in a generally parallel relationship, wherein each of the
plurality of flat conductors comprises a plurality of copper
layers; an adhesive material separating the plurality of flat
conductors; and an insulation layer surrounding the flat conductors
and the adhesive material, wherein the adhesive material bonds to
the insulation layer; and wherein a cross-sectional height of the
flat conductors and insulation layer is such that the multi-purpose
wire will blend in with the surface when painted or after wallpaper
is applied.
The copper layers are generally on the order of about 0.002 inches
thick, but may range from about 0.0004 to 0.020 inches. The number
and thickness of the copper layers may be adjusted to suit the
desired application. It is understood that the various dimensions
described herein may vary considerably within the practice of this
invention.
The insulation layer can be composed of materials selected form the
group consisting of polyester films (e.g., Dupont Mylar), urethane
films, or teflon films. The adhesive material can be selected from
the group consisting of adhesive tape (e.g., 3M 9500PC), liquid
adhesive, or a combination of the two.
In another aspect, the invention provides for a surface mounted,
flexible, multi-purpose wire, comprising a single flat conductor
together with the adhesive material and insulation layers as
described above.
It is to be understood that both the foregoing general description
and the following detailed description are exemplary and
explanatory and are intended to provide further explanation of the
invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, aspects and advantages will be
better understood from the following detailed description of a
preferred embodiment of the invention with reference to the
drawings, in which:
FIG. 1 is an exploded side cross-sectional view of a 3-wire flat
conductor for use in standard electrical wiring applications;
FIG. 2 is an exploded side cross-sectional view of a 5-wire flat
conductor for use in applications requiring two circuits;
FIG. 3 is an exploded side cross-sectional view of a 2-wire flat
conductor for use in loud speaker systems;
FIG. 4 is an exploded side cross-sectional view of a 6-wire flat
conductor for use in telephone applications;
FIG. 5 is an exploded side cross-sectional view of a 2-wire flat
conductor for CATV applications;
FIG. 6 is an exploded side cross-sectional view of a 2-wire flat
conductor for use in low voltage applications;
FIG. 7 is a perspective configuration view of the pluggable and
stand-alone outlets connected via a flat wire;
FIG. 8A is an exploded perspective view of the components of the
outlet assembly of the present invention;
FIG. 8B is an alternate exploded perspective view of the components
of the outlet assembly of the present invention;
FIG. 8C is a perspective view of the underside of a fully
configured outlet assembly of the present invention;
FIG. 9A is a perspective view of the flat-wire to outlet frame
connector interface in accordance with the present invention;
FIGS. 9B, 9C, and 9D provide top, side, and bottom views,
respectively, of the flat-wire to outlet frame connector interface
in FIG. 9A;
FIG. 9E is a perspective view of the underside of the flat-wire to
outlet frame connector of FIG. 9A showing the elongated slots and
wipers;
FIG. 10A is perspective view of the flat-wire to conventional-wire
connector in accordance with the present invention;
FIGS. 10B, 10C, and 10D provide top, side, and bottom views,
respectively, of the flat-wire to conventional-wire connector in
FIG. 10A;
FIG. 11A is a three dimensional perspective view of a three wiper
female plug receptacle system according to the present
invention;
FIGS. 11B and 11C are front and side perspective views,
respectively, of a side mounted switch;
FIG. 12A is a perspective view of the surfaced mounted flat wire
connected to a ceiling fan;
FIG. 12B is a perspective view of the discrete wired switch
embodiment in accordance with the present invention;
FIG. 13 is a diagrammatical representation of a flat wire/loud
speaker system configuration;
FIG. 14 is a diagrammatical representation of a flat wire/phone
jack system configuration;
FIG. 15 is a diagrammatical representation of a flat wire/CATV
system configuration;
FIG. 16 is a diagrammatical representation of a flat wire/embedded
light system configuration;
FIG. 17 is a diagrammatical representation of a flat wire/DC power
system configuration;
FIG. 18 is a diagrammatical representation of a GFI detection
circuit for 4 outlets and 3 terminals without a switchable input
plug;
FIG. 19 is a diagrammatical representation of a GFI detection
circuit for 8 outlets without a switchable input plug; and
FIG. 20 is a diagrammatical representation of a GFI detection
circuit for 8 outlets with a switchable input plug.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
In general, as stated above, the present invention can be used or
be adapted to perform in a wide variety of applications including:
standard electrical wiring; telephone wiring; loud speaker wiring;
low voltage wiring applications such as intercoms and security
systems; under surface lighting; and cable TV wiring. In addition,
the present invention includes several unique outlets and switches
that interface with existing conventional round wiring. Moreover,
the present invention also utilizes tape, stripping tools, and
unique connectors to implement a particular system embodiment. Each
of the individual components will be discussed in greater detail,
followed by a description of the applications to which the present
disclosure is directed.
Each of the individual wire embodiments share a basic common
structure. However, depending on the particular application,
various modifications can be made to the basic structure and the
dimensions of the structural components to achieve the desired
purpose.
For ease of reference, the basic structure will be discussed in
detail with reference to the first wire embodiment. It is
understood that this basic structural concept applies to all the
wire embodiments. Modifications to the basic structure will be
discussed where appropriate. Like reference numbers will be used
where possible to refer to similar parts throughout the
drawings.
Wire Embodiments
Alternating Current (AC) Electrical Wire
Referring now to the drawings, and more particularly to FIG. 1,
there is shown an exploded side cross-sectional view of a standard
110 VAC 3-conductor wire embodiment in accordance with the present
invention. The exploded cross-sectional view is for illustrative
and discussion purposes only. In the actual 3-conductor embodiment,
there would be no visible spacings (i.e., the white areas in FIG.
1) between the conductors, insulation, and adhesives components,
each of which is described further below.
Generally, the electrical wire 10 is a flat, flexible, wire that
allows the user to bring electricity to any area of a wall or
ceiling in a room. The electrical wire 10 is mounted to the surface
of the wall or ceiling, thereby eliminating the need for costly
inner wall or ceiling rewiring. The wire may be painted or papered
over to match the rest of the surface.
The electrical wire 10 comprises a plurality of elongated and
parallel spaced multi-layer conductors 11. As shown in FIG. 1, a
typical 110 VAC 3-wire embodiment would include an AC ground
conductor, an AC neutral conductor, and an AC power conductor.
An internal adhesive material 13 separates the flat conductors 11
as well as providing edge sealing of the outer flat conductors as
shown in FIG. 1. The adhesive material 13 and conductors 11 are
surrounded by a thin layer of insulation material 15. In addition,
an external adhesive layer 17 is applied to the back of the flat
wire to attach the electrical wiring to the desired surface.
Each of the conductors 11 are comprised of one or a plurality of
layers made with a copper material that is about 0.0004 to about
0.020 inches thick, and preferably on the order of about 0.002
inches thick. Three copper layers 11a, 11b, and 11c, are shown in
FIG. 1 for example. The conductor layer thickness should be
consistent across its length and width, thereby eliminating any
resistance "hot spots".
The current and or signal carrying specifications of a particular
application may be accomplished in any of three ways, either
individually or in combination. First, the width `w.sub.c` of the
conductors 11 may be varied. Second, additional thin copper layers
may be stacked for each conductor 11. Third, the thickness `t` of
the conductor 11 may be increased.
For most load and current applications, each conductor will
generally be composed of about 2-5 layers of copper. It is
understood, however, that utilizing more or less layers, for each
of the below disclosed embodiments, is within the scope of this
invention.
For example, a five copper layer conductor, where each copper layer
is about 0.002 inches thick, will be on the order of 0.012 inches
thick including insulation. Even at that thickness, however, the
flat wire presents an extremely thin cross-section that is
virtually undetectable on a surface once painted or papered
over.
The insulation layer 15 will now be described in greater detail.
Insulation is achieved with minimum thickness to prevent conduction
under ideal conditions only. The primary purpose of the insulation
layer 15 is to assist in the optical occlusion of the presence of
the wire as applied to a surface so that a pleasing appearance can
be achieved upon installation.
The insulation layer 15 also orients the copper conductive layers.
In addition, the insulation material may be used alone, or in
combination with the internal adhesive 13, to separate the
conductive layer groups and maintain a safe dielectric distance
between conductors of different purposes (e.g., AC ground vs AC
neutral or AC power conductors).
As shown in FIG. 1, the insulation layer 15 at the edges of the
multi-layered flat wire 10 may be, but need not be, tapered to
facilitate the optical occlusion. The insulative material may be
selected from the group consisting of, for example, polyester films
(e.g., Dupont Mylar), urethane films, or teflon films.
It is understood that additional insulative materials are
considered to be within the scope of this invention and may be used
so long as the insulation is compliant, paintable, and bondable to
surfaces. The insulation should also be compatible with joint
compounds, be UV tolerant, and have similar thermal expansion and
contraction characteristics as that of the conductors and the
surface to which it is adhered.
Other desirable properties are that the insulation should withstand
tensile forces applied in the fabrication process, not retract or
relax under storage conditions, and be removable when its use is
completed.
Any abrasion, cracking, cutting, piercing, or any other insulation
damage--that would render an unsafe exposure to electrical
harm--will be made safe using electronic means of failure detection
that will disconnect harmful currents from the user in a time frame
that will prevent permanent harm. This electronic failure detection
means, or Ground Fault Interrupter (GFI) circuit, is discussed in
greater detail later in the specification.
Returning to FIG. 1, the internal adhesive material 13 must be able
to bond to the insulation layer 15. For example, adhesive tape
(e.g., 3M 9500PC), liquid adhesive, or a combination of the two,
may be used as an internal adhesive. The internal adhesive material
13 will also function to separate the conductive layer groups and
maintain a safe dielectric distance between conductors of different
purposes. In addition, the adhesive 13 can even out gaps in the
various components within the wire to aid in its ability to
visually disappear on a surface.
The thickness of the internal adhesive material 13 closely
approximates the cross-sectional height `t` of the conductors 11,
especially where the internal adhesive separates the conductors 11.
As shown in FIG. 1, the internal adhesive 13 may be tapered at the
edges of the flat wire 10 to facilitate the optical occlusion.
An external adhesive layer 17 is provided for attaching the wire to
the desired surface. The external adhesive layer 17 could be, for
example, two-sided tape, with one side being fixed to the back of
the flat wire 10 and the other to the wall or surface.
Alternatively, a chemical adhesive may be applied separately, and
may consist of any of the adhesives with good bonding qualities to
both the insulation layer 15 and the desired surface to which the
flat wire 10 is adhered.
A finished flat 3-conductor wire 10, having, for example, three
copper layers of 0.002 inch thickness, would be approximately 0.007
to 0.010 inches in cross-sectional height `t`. For a 15 amp rated
wire, the entire width `W` of the 3-conductor flat wire 10 is on
the order of about 2.0-2.5 inches. The width `w.sub.c` of each
conductor is about 0.4-0.6 inches, and the spacing between
conductors `w.sub.s` is about 0.2-0.3 inches.
To ensure readily identifiable, proper and safe connections, the
width `w.sub.c` of the AC ground conductor could be increase
slightly as compared to the AC neutral and AC power conductors. The
width of the AC ground conductor would therefore be closer to 0.6
inches, while the widths of the other two conductors would be
closer to 0.4 inches. Alternatively, the width of the AC ground
conductor could be reduced as compared to the other conductors.
Similar dimensions would be useful for other applications, however,
it is understood that the various dimensions can vary considerably
within the practice of this invention.
The flat wire 10 provides a simple, low cost alternative to
expensive rewiring jobs for supplying electricity to specific
locations of walls and ceilings for use in fans, ceiling lighting,
or wall or art lighting.
In FIG. 2, there is shown an exploded side cross-sectional view of
a 110 VAC 5-conductor wire 20 of the present invention, having 5
parallel spaced multi-layered copper conductors 11. This
5-conductor wire embodiment includes all of the features of the
3-conductor wire embodiment disclosed above, with the addition of
two conductors 11 to accommodate a second circuit. Like or similar
parts are identified by the same reference numerals.
The 110 VAC 5-conductor wire is used where two circuits on one flat
wire are desirable, such as a wire leading to a light and a fan, or
where a switched plug is used. In this embodiment the five
conductors consist of two AC neutral conductors, two AC power
conductors, and a single AC ground conductor.
The number and thickness of the copper layers, the width `w.sub.c`
and thickness `t` of the conductors 11, and the spacing between the
conductors `w.sub.s` are generally of the same dimensions as that
of the 110 VAC 3-conductor wire. The overall width `W` of the
finished flat wire 20 is on the order of about 3.5-4.25 inches.
The flat wire conductors of the present invention may also be
utilized to construct a 220 VAC wire embodiment, generally as shown
with reference to FIG. 1. A finished flat 3-conductor 220 VAC wire,
having, for example, four copper layers of about 0.002 inch
thickness, would be approximately 0.012 inches in cross-sectional
height `t`. The entire width `W` would be on the order of about
3.0-3.5 inches. The width `w.sub.c` of the neutral and power
conductors is about 0.4-0.6 inches, while the width `w.sub.c` of
the ground conductors is about 0.2-0.4 inches. The spacing between
conductors `w.sub.s` is about 0.4-0.6 inches.
As in the 3-conductor 110 VAC electrical wire, the difference in
ground conductor width in the 3-conductor 220 VAC electrical wire
is to facilitate proper connection of the wires to the
connectors.
Loud Speaker Wire
As with the previous embodiments, the loud speaker wire 30 of the
present invention, illustrated in FIG. 3, is a flat, thin,
flexible, wire that allows the user to position loud speakers at
any area of a wall or ceiling in a room. The loud speaker wire 30
may be used, for example, with stereo or mono audio components, or
for wiring external speakers for enhanced television or sound
systems such as "surround sound".
The loud speaker wire 30 can be mounted to the surface of a wall or
ceiling, thereby eliminating the need for costly inner wall or
ceiling rewiring. The wire may also be painted or papered over to
match the rest of the surface.
Referring to FIG. 3, the thin loud speaker wire 30 is comprised of
a pair of multi-layered copper conductors 11. The conductive
capacity of the loud speaker wire 30 is preferably equivalent to 10
gauge stranded wire. Each of the conductors 11 would generally have
two or three copper layers, the former being shown by copper layers
11a and 11b in FIG. 3. The copper layers are about 0.0004 to about
0.020 inches thick, and preferably on the order of about 0.002
inches thick. It is understood that depending on the particular
application, more or less copper layers may be utilized.
The pair of conductors 11 are separated by an appropriate adhesive
material 13 and both are surrounded by an insulation layer 15 as
discussed above. Similar insulation and adhesives may be used as
previously described above.
Because of its application, the loud speaker wire 30 may also
include a shielding material 18 surrounding the conductors 11 to
reduce outside signal and cross-over interference. The shielding
material 18 may be one or a plurality of layers of any suitable
metallic or semi-metallic shielding materials, for example,
aluminum or metalized polyester films.
The finished loud speaker wire 30 is approximately 0.008 inches in
cross-sectional height `t` with three copper layers, with an
overall width `W` of about 2.5-3.0 inches. The width `w.sub.c` of
each conductor is about 0.6-0.8 inches, and the spacing between the
conductors `w.sub.s` is about 0.2-0.3 inches.
As shown in FIG. 3, the edges of the wire 30 may be tapered to
facilitate the optical occlusion. A similar external adhesive layer
17 as that previously described is also provided to attach the loud
speaker wire 30 to the appropriate surface.
Telephone Wire
An illustrative example of a telephone wire embodiment 40 according
to the present invention is shown in FIG. 4. In this embodiment,
six multi-layered copper conductors 11 are provided, separated by
adhesive material 13, and surrounded by insulation layer 15. A six
conductor wire facilitates the use of Private Branch Exchange (PBX)
switching, thereby providing a private telecommunications exchange
that includes access to a public telecommunications exchange. The
conductors 11 are functionally equivalent to standard 22 gauge
telephone wire.
Two, four, and eight multi-layered copper conductor telephone wires
may also be utilized. Moreover, the eight conductor embodiment
approximates four twisted pair wires (e.g., unshielded twisted pair
(UTP) wire), which may be suitable for carrying data.
Each of the conductors 11 would generally have two or three copper
layers, the former being shown by copper layers 11a and 11b in FIG.
4. The copper layers are about 0.0004 to about 0.020 inches thick,
and preferably on the order of about 0.002 inches thick. It is
understood that, depending on the particular application, more or
less copper layers may be utilized.
The finished telephone wire 40, with three copper layers, is
approximately 0.008 inches in cross-sectional height `t`, with an
overall width `W` of about 1.5-3.5 inches, depending on the number
of conductors 11 utilized. The width `w.sub.c` of each conductor is
about 0.2-0.4 inches, and the spacing between the conductors
`w.sub.s` is about 0.125-0.25 inches.
As shown in FIG. 4, the edges of the wire 40 may be tapered to
facilitate the optical occlusion. A similar external adhesive layer
17 as that previously described is also provided to attach the
telephone wire 40 to the appropriate surface.
Cable Television CATV Wire
An illustrative example of a cable television CATV wire embodiment
50 in accordance with the present invention is shown in FIG. 5. In
this embodiment, a pair of conductors 11 are provided, each of
which may generally have two or three copper layers, the former
being shown by copper layers 11a and 11b in FIG. 5. The copper
layers are about 0.0004 to about 0.020 inches thick, and preferably
on the order of about 0.002 inches thick. It is understood that,
depending on the particular application, more or less copper layers
may be utilized.
As in the previous embodiments, the conductors 11 are separated by
adhesive material 13, and surrounded by insulation layer 15. As
shown in FIG. 5, the edges of the wire 50 may be tapered to
facilitate the optical occlusion. A similar external adhesive layer
17 as that previously described is also provided to attach the wire
50 to the appropriate surface.
The finished antenna/CATV wire 50, with three copper layers, is
approximately 0.008 inches in cross-sectional height `t`, with an
overall width `W` of about 1.8-2.2 inches. The width `w.sub.c` of
each conductor is about 0.4-0.6 inches. As shown in FIG. 5, the
spacing between the conductors `w.sub.s` is about 0.4-0.6 inches,
which is somewhat larger than in previous embodiments in order to
reduce radio frequency interference and improve transmission
quality. The CATV wire is rated at 300 ohms.
Low Voltage Wire Applications
FIG. 6 illustrates a low voltage wire embodiment 60 in accordance
with the present invention. Such low voltage (direct current)
applications would include intercoms, security systems, and "smart
house products". As shown in FIG. 6, two DC power conductors 11 are
shown. The structure of the conductors 11 is essentially the same
as the multi-layer conductors 11 described earlier. The internal
adhesive material 13, insulation layer 15, and external adhesive
layer 17, would be the same in this embodiment as those described
previously.
Each of the conductors 11 would generally have two or three copper
layers, the later being shown by copper layers 11a, 11b, and 11c in
FIG. 6. The copper layers are about 0.0004 to about 0.020 inches
thick, and preferably on the order of about 0.002 inches thick. It
is understood that, depending on the particular application, more
or less copper layers may be utilized.
The finished low voltage wire 60, with three copper layers, is
approximately 0.008 inches in cross-sectional height `t`, with an
overall width `W` of about 1.2-1.6 inches. The width `w.sub.c` of
each conductor is about 0.3-0.5 inches, and the spacing between the
conductors `w.sub.s` is about 0.2-0.3 inches.
As shown in FIG. 6, the edges of the wire 60 may be tapered to
facilitate the optical occlusion. A similar external adhesive layer
17 as that previously described is also provided to attach the
telephone wire 60 to the appropriate surface.
Under Surface Lighting Wire
While the thin, flexible wire for under surface lighting is similar
in construction to the 110 VAC 3-conductor and 5-conductor wire
embodiments described above, it is unique in that the under surface
lighting wire incorporates embedded lights 169. See FIG. 16. This
allows the user to install the lighting under a surface of a
cabinet, shelf, or other locations where under surface lighting is
desired. This embodiment will be described in greater detail in the
discussions of the conventional wire-to-flat wire system
implementations later in the specification.
Outlets and Connectors
The present invention encompasses a family of outlets that provide
connection points between the flat wires of the present invention
and conventional existing electrical outlets and conventional round
wire systems. These connecting outlets are of two general types,
with one being directly "pluggable" into a conventional existing
outlets, while the other is a "stand-alone" surface mounted
unit.
The pluggable connecting outlets will always provide the
compatibility interface between the standard household electric
wiring apparatus and the various embodiments of the flat wires in
accordance with the present invention. Accordingly, the pluggable
outlet is always at the source of the standard electrical current.
The stand-alone unit interfaces with the pluggable unit via the
various flat wire embodiments of the present invention.
FIG. 7 illustrates the typical configuration interface between the
pluggable and stand-alone units. Assuming that a conventional
two-female receptacle outlet, as fed by conventional round wire 69
from behind the wall 66, is located behind outlet 65. Outlet 65
would therefore be of the directly "pluggable" variety. Outlet 67
would thus be a stand-alone outlet that is affixed to the wall
without a plug attachment. The stand-alone outlet can therefore be
placed anywhere in the room, regardless of the location of the
existing outlets.
In the electrical wire embodiments, for example, current from the
conventional wire 69 is transferred to the stand-alone outlet 67
via pluggable outlet 65 and the flat 110 VAC wire 68 of the present
invention.
FIG. 8A is an exploded perspective view of the pluggable outlet
unit 65, depicting the various internal and external components of
the outlet. As shown, the outlet 65 contains side mounted female
receptacles 72 and 73 housed within an outlet cover 74.
Alternatively, the female receptacles 72 and 73 may be mounted in
the front as in standard outlet configurations. The side mounted
receptacle version has an advantage in that the outlet cover 74 may
be painted or papered to blend into the surface. Also, additional
female receptacles 72' and 73' may be located on another side of
the outlet cover 74 as in FIG. 8B, which shows four female
receptacles.
The outlet base 75 for the pluggable outlet 65 contains openings
75a and 75b that would be positioned over the female receptacles of
the conventional existing outlet, and affixed to the surface with
screws or other equivalent attachment devices. The outlet cover 74
would then be placed over the base 75.
The pluggable outlet 65 also contains a flat wire connector 76 and
a Ground Fault Interrupter (GFI) module 77 with its associated GFI
reset button 78. The GFI module 77 (the operation of which is
discussed later in the specification) contains two sets of male
contacts 79 and 79' that pass through the openings 75a and 75b to
plug into the respective female receptacles associated with
conventional wiring systems. The GFI module 77 functions to
interrupt the electric current to the load in the event the flat
wire is pierced or cracked. FIG. 8C provides a perspective view of
the underside of a completed pluggable outlet assembly 65,
depicting the GFI male contacts 79 and 79' extending through the
base member 75 through openings 75a and 75b.
The stand-alone outlet 67 (see FIG. 7) differs from the pluggable
outlet 65 in two respects. First there is no need to provide for a
GFI module 77 and its associated reset button 78 in the stand-alone
outlet. Second, the stand-alone outlet's base 75 does not need
openings 75a and 75b as the stand-alone outlet does not interface
directly with the conventional wiring system. In all other
respects, the pluggable and stand-alone outlets are the same.
A single outlet base 75 may be configured with "punch out" openings
75a and 75b so that it may be used with either the pluggable or
stand-alone outlet assemblies.
FIG. 8B is an alternate perspective view of the pluggable outlet
unit 65, depicting the two sets of male contacts 81 and 83, which
interface with the flat wire connector 76 and GFI module 77,
respectively. Note that the flat wire connector 76 and GFI module
77 are not affixed to the base member 75, but are selectively
connected to the outlet cover 74 by the male contacts 81 and
83.
Also depicted in FIG. 8B is copper frame 84 on the underside of
cover 74. The copper frame 84 functions to provide conductive
connections to female receptacles 72, 72', 73, and 73', and the two
sets of male contacts 81 and 83. The male contacts 83 plug into
corresponding slots 82 on one surface of the GFI module 77 as shown
in FIG. 8A.
The flat wire connector 76, which is common to both the stand-alone
and pluggable outlets, will now be discussed in greater detail. The
flat wire connector 76 provides the connection point between the
flat wires of the present invention and the copper outlet frame
84.
An example of such a "flat-wire to outlet frame" connector 90 is
illustrated in the perspective view of FIG. 9A. While a 5-conductor
connector assembly is shown for illustrative purposes, it is
understood that the connector can be constructed to interface with
any number of flat conductors having any number of copper
layers.
Along one surface of connector 90 there is provided a plurality of
flat wire receptacles 92 for receiving each of the flat wire
conductors 11. The 3-conductor and 5-conductor electrical wires may
use the same 5-conductor connector assembly 90, provided the outer
wire receptacles are depopulated when the 3-conductor electrical
wire is used. The other wire embodiments would have their own
interface connectors 90. The need for multiple connectors does not
pose a problem as the connectors can easily be swapped and inserted
in the outlet cover 74 by plugging the connector into the male
contacts 81 fixed to the outlet cover 74.
Each of the flat wire receptacles contains a plurality of slotted
springs 94 for contacting the corresponding copper layers in each
of the multi-layer conductors 11 (see FIG. 9B also). Two to five
slotted springs 94 would generally be provided to correspond to the
multi-layer copper conductor embodiments discussed above.
As shown in the perspective views in FIGS. 9A and 9E, and the side
view in FIG. 9C, a plurality of elongated female slots 98 are
contained on another surface of the connector 90. These elongated
female slots 98 interface with the corresponding set of male
contacts 81 as shown in FIG. 8B. The male contacts 81 merely slide
into slots 98 to make the connection.
As more clearly seen in FIG. 9E, each of the extended slots 98
contain a series of wipers or brushes 98a-98d, each of which moves
independently of the others, to provide a better connection and
more surface contact with the male contacts 81.
The sequence of connecting the flat wire to the connector 90 is
described with reference to an exemplary 5-conductor embodiment
where each of the conductors has three copper layers. First, each
conductor 11 is lined up with a respective flat wire receptacle 92.
Then, each copper layer for each of the conductors 11 is inserted
between the slotted springs 94. The slotted springs 94 are slightly
biased by screws 96 as shown in FIG. 9D. By tightening the screws,
one can ensure that both the top and bottom of each copper layer
are in contact with the slotted springs. This ensures the best
conductor contact, and also ensures that each copper layer (and
thus each conductor) experiences the same resistance.
Finally, the male contacts 81 and extended female slots 98 are
lined up and the connection to either the pluggable or stand-alone
outlet is made. The outlet cover 74 would have a small cutout at
the edge facing the flat wire receptacles 92 of connector 90 to
enable the flat wires to pass through the outlet cover 74 to reach
the connector 90.
In addition to the flat-wire to outlet frame connector, a second
connector type is also needed to provide an interface between
conventional round wires and the various flat wire embodiments
described above. This would occur, for example, where the flat
wires connect to a wall light, fan, or intercom system.
An example of such a connector 100 is illustrated in the
perspective view of FIG. 10A, which depicts a 5-conductor flat-wire
to conventional wire connector. While a 5-conductor connector is
shown for illustrative purposes, it is understood that the
connector can be constructed to interface with any number of flat
conductors and any number of conventional round wires. The
3-conductor and 5-conductor electrical wires may use the same
5-conductor connector assembly 100, provided the outer wire
receptacles are depopulated when the 3-conductor electrical wire is
used. The other wire embodiments would have their own interface
connectors 100.
As shown in FIG. 10A, connector 100 contains a plurality of
conventional set screws 101 along one surface of the connector to
provide an interface for the standard "wire wrap" connections
common in conventional round wiring systems (see FIG. 10B also).
Along another surface are placed one or more flat wire receptacles
102 for receiving each of the flat wire conductors. Each of the
flat wire receptacles 102 contains a plurality of slotted springs
104 (see FIG. 10D also) for contacting each of the layers in each
of the multi-layer conductors. The slotted springs 104 are slightly
biased by screws 96 as shown in FIGS. 10A and 10C and function in
the same way as that described with respect to the connector 90.
Connection to the flat-wire receptacles by the flat wire conductors
is the same as that discussed with regard to connector 90.
FIG. 11A depicts an improved three wiper female receptacle 110,
which may be incorporated into the pluggable 65 or stand-alone 67
outlets of the present invention.
Receptacle 110 contains cast copper leads 111 and 112 that contact
the respective wiper assemblies 114 and 116. Each of the wiper
assemblies contains three wipers (114a, 114b, 114c; 116a, 116b,
116c), each of which moves independently of the other two in the
respective assembly.
The three-wiper receptacle 110 thus provides a better connection
and more surface contact with the copper leads 111 and 112. The
other ends of copper leads 111 and 112 extend to the copper frame
84 (see FIG. 8B). In addition, since the three wipers move
independently, the receptacle is better able to accommodate torque
in a plug.
Switches
A unique set of switches 124' are provided for use with the wire
products of the present invention. The switches may be electrically
wired to an existing switch, or plugged into an existing outlet, or
operated by radio frequency (RF) remote power. The switches are
used mainly with the 3-conductor and 5-conductor wires, and
under-surface lighting embodiments described above.
The switch mechanism may be front or side mounted (FIGS. 11B and
11C) and many switch variations are contemplated, including: (1)
toggle controlled, permanent mount, discrete wired; (2) capacitive
touch or membrane switch controlled, permanent mount, discrete
wired; (3) capacitive touch or membrane switch controlled,
permanent mount, radio frequency (RF) sender/receiver pair; (4)
capacitive touch or membrane switch controlled, hand held or wall
hung, RF sender/receiver pair; or (5) capacitive touch or membrane
switch controlled full dimmer set with indicators, hand held or
wall hung, RF sender/receiver pair.
Regardless of the particular type of switch utilized, however, all
of the switches share certain common elements. The switches 124'
(see FIG. 12B) do not switch the AC circuit. Rather, they send a
signal, via a low voltage wire 125 (12 VDC) as shown in FIG. 12B,
to the corresponding plug that will switch the AC circuit.
If the switch unit is hardwired, it is coupled via voltage
circuits. This makes the switches incapable of being used without a
compatible plug unit.
Tools
The unique thin, flat wires of the present invention require
equally unique insulation stripping tools to facilitate attachment
to connectors and existing outlets. Each wire embodiment described
above will have its own specialized tools.
Two versions are contemplated--one directed to use by professional
electricians or installers and the other to non-professionals. The
professional stripping tool is designed to cut and strip the
insulation layer 17 off the conductors 11 in a single procedure
similar to the manner of operating a conventional stripping tool.
Considering the small thicknesses of the conductors, it is apparent
that the stripping tool be precisely milled to allow for such
precision cutting and stripping. Such precise milling may tend to
raise the cost of such a tool, making it economically feasible for
professional use only.
A second slicing tool directed to the non-professional will align
the wire in the stripper and slice adjacent and perpendicular to
the conductors, to allow the user to strip away the necessary
insulation material to get to the conductive layers. The insulation
is then peeled back and removed by scissors.
System Applications
A general illustrative system embodiment--incorporating the various
wires, outlets, switches, and connectors described above--is shown
in FIG. 12A.
With reference to FIG. 12A, there is provided a conventional outlet
120 and conventional switch 124. A person desirous of wiring a
ceiling fan 126 in the location shown would normally have to engage
in an expensive wall and ceiling wiring job to bring electric
current to the subject fan.
By utilizing the flat wires, outlets, switches, and connectors of
the present invention, however, the task is greatly simplified as
is now described. First a pluggable outlet 65 (FIG. 8A) is plugged
into the conventional outlet 120. Next a stand-alone outlet 67 is
fastened to the wall in the desired location. Lengths of flat wire
123 (e.g., 3-conductor or 5-conductor 110 VAC) are run between the
pluggable outlet 65 and stand-alone outlet 67, and again between
stand-alone outlet 67 and the fan.
A connector 90 (not shown in FIG. 12A, but is of the type depicted
in FIG. 9A) connects the flat wires 123 to the pluggable and
stand-alone outlets 65 and 67. In addition, another connector 100
(of the type depicted in FIG. 10A) connects the conventional round
wires of the fan 126 with the flat wire 123.
The flat wire 123 is affixed to the wall surface with the adhesive
layer 17 as described above, typically double sided tape, and
either painted or papered over to obscure the wire.
As illustrated, the flexible, flat wire 123 incurs a 90 degree bend
along its width at point 127 where the ceiling and wall adjoin, as
the flat wire is adhered to a different planar surface. In addition
to bending at any angle along its width to accommodate different
planar surface joints, the flexible wire may actually be bent back
upon itself at any angle to accommodate angle changes on the same
planar surface.
Consider, for example, the second wall lighting, apparatus 126' in
FIG. 12A. The wall light 126' is connected to standard switch 124
by a flat wire 128. For aesthetic reasons, rather than put a second
stand-alone switch near the conventional switch, the flat wire is
bent at a 45 degree angle at points 129 and 129'. The flat wire is
basically folded back upon itself to achieve the 45 degree
turn.
FIGS. 13-17 are more specific diagrammatic representations of the
various system embodiment using the flat wires previously
disclosed. The systems are briefly described below.
FIG. 13 illustrates the flat wire/conventional loud speaker wire
interface. For simplicity and ease of illustration, only one
speaker 131 is illustrated with stereo 130. It is understood that
any number of speakers may be used with the flat wires of the
present invention.
As illustrated, stereo system 130 is connected to speaker 131 via
flat wires 133. The speaker 131 can be placed in any desired
location. The traditional speaker wires 136 are then connected to a
stand-alone plug on the wall. A second stand-alone plug is placed
in the desired location near the new speaker position. The flat
wires 133 are then run between the two stand-alone plugs. The
entire length of the flat wire 133 may then be painted or papered
over, thereby eliminating unsightly and cumbersome speaker
wire.
With reference to FIG. 14, there is shown a diagrammatic
representation of the application of the flat wire/conventional
phone jack interface for use in providing a connection to an
extension phone.
As illustrated, the existing phone jack or phone receptacle 141 is
connected to the extension phone jack 142 via flat wires 143. As
shown, a flat wire phone apparatus 147 is connected to the existing
phone jack 141. The extension phone jack 142 is then placed in the
desired location and connected to flat wire phone apparatus 147'.
The flat wires 143 are then connected between the flat wire phone
apparatuses 147 and 147'. The entire length of the flat wire 143
may then be painted or papered over, thereby eliminating unsightly
and cumbersome phone wire.
A diagrammatic representation of a CATV application is shown in
FIG. 15. The cable input 151 is fed into the house via the 75 ohm
coaxial cable 158. The cable 158 is then connected to 75 ohm-300
ohm conversion apparatus 157 located on the wall near the input 151
into the house. A second conversion apparatus 157 is placed near
the desired television 152 location. Flat wires 153 are then run
between the two conversion apparatuses. As above, the entire length
of the flat wire 153 may then be painted or papered over, thereby
eliminating unsightly and cumbersome CATV wire.
The under surface lighting embodiment, including flat wires 163
with embedded lights 169, is shown in FIG. 16. The switch or plug
161 is connected to the flat wire 163. The embedded lights 169, may
be, for example, double-ended RSC base 120V halogen lamp from 20 to
100 watts. The flat wires can be placed in any under surface
location where additional light is desired, such as under a cabinet
or shelf. The flat wire 163 may then be painted or papered over to
match the rest of the surface.
The flat wires of the present invention may also be used with
direct current (DC) applications. With reference to FIG. 17, a DC
source 171 is connected to a DC outlet 172, via flat wires 173. As
in the other system embodiments, wall connectors provide the
interface between the conventional DC wires 158 and flat wires
153.
Ground Fault Interruption (GFI) Circuit
Since the flat wire is nearly invisible after it is painted or
papered over, there is a possibility that at some later date, a
person could inadvertently drive a nail or picture hook through the
flat wire, or otherwise cut the wire.
In each of the systems, therefore, a ground fault interruption
(GFI) module(s) 77 (see FIGS. 8A-8C) will be provided as a safety
measure to prevent injury should accidental penetration through the
ultra thin layers of insulation occur. The term ground fault comes
from anything or any person providing a ground path other than the
normal internal ground.
The GFI circuit will monitor the current flow through the power and
neutral conductors of the AC circuits, and if more than ten
milliampere of mismatch is sensed, then both conductors will be
disconnected by a circuit breaker. The circuit breaker will be fast
enough to prevent any permanently harmful discharge.
The circuits will provide a fail safe methodology such that any
circuits will be checked before connection and rechecked after
connection. Power from the circuit will provide connection so that
a circuit failure will result in no power beyond the circuit
breaker.
As described previously, the circuit is physically located in the
"pluggable" outlet 65 (see FIGS. 8A-8C) that plugs into a
conventional wall outlet as discussed above. The GFI detection
circuit is basically a relay that is normally closed. When the
fault current to ground exceeds some predetermined value that is
less than that required to operate the overcurrent protective
device of the supply circuit, the relay opens, interrupting the
electric current to the load.
FIG. 18 illustrates a standard single circuit 180 non-switchable
two-plug system having a GFI detection circuit connected to a
4-plug, 3-terminal apparatus in accordance with the present
invention.
FIG. 19 illustrates a standard single circuit 190 non-switchable
two-plug system having a GFI detection circuit connected to an
8-plug apparatus (4 main plugs and 4 extension plugs) in accordance
with the present invention.
FIG. 20 illustrates a standard two circuit 200 switchable two-plug
system, therefore requiring two GFI detection circuits, each
connected a 4-plug apparatus (2 main plugs and 2 extension plugs)
in accordance with the present invention.
While the invention has been described in terms of the embodiments
described above, those skilled in the art will recognize that the
invention can be practiced with modification within the spirit and
scope of the appended claims.
* * * * *
References