MXPA97009664A - Flat wire for multiple purposes mounted on a superfi - Google Patents

Abstract

A flat wire, mounted on a flexible, multi-purpose surface, is described. The flat wire has a plurality of elongated flat conductors, spaced apart in a generally parallel relationship. Each of the flat conductors comprises a plurality of layers of copper. An adhesive material separates the flat conductors and the adhesive material, with the adhesive material that joins the insulation layer. A height of the cross section of the flat conductors and the insulation layer, such that the multi-purpose wire will be combined with the surface when it is painted or after wallpaper is applied

Description

FLAT WIRE FOR MULTIPLE PURPOSES MOUNTED ON A SURFACE DESCRIPTION BACKGROUND OF THE INVENTION FIELD OF THE INVENTION The present invention relates generally to flat wiring, and more particularly, to a thin, combinable flat wire mounted on a surface for use in a variety of wiring applications.

DESCRIPTION OF THE RELATED TECHNIQUE The current wiring and rewiring techniques and procedures present many limitations to the user in existing commercial or residential applications. The selection is to add, change or move any of many wiring applications-electric, telephone, antenna / CATV, speakers, and low-voltage wiring, as well as REF: 26261 as the plugs, switches, and associated connections - it is expensive or annoying or both. Temporary or removable methods such as extension wires, long wires of the telephone and antenna / CATV, the external wire of the loudspeakers, and the low voltage wire are problematic and difficult to hide or mix in a room. Permanent installations typically require either a professional install them inside a wall if the user wants a hidden installation, or the use of some kind of unattractive and inflexible conduit. Both methods tend to be expensive. In view of the above, there is a need for a hidden, location-specific, easy-to-install, low-cost, non-disruptive, permanent system for wiring and re-wiring applications on walls and ceilings. There is also a need for the plugs, switches, and associated connections that could provide an interconnection between such a new wiring system and conventional wiring.

BRIEF DESCRIPTION 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 limitations and disadvantages of the related art. By way of example and not as limitation, the present invention can be used in a wide variety of applications, including: standard electrical wiring, telephone wiring, loudspeaker wiring, low voltage wiring such as security systems, under-surface lighting, and wired TV wire. In addition, the present invention includes several outlets, switches, and unique connectors that provide the interconnection between the existing conventional round wiring and the flat wires of the present invention. In order to achieve these and other advantages and in accordance with the purpose of the invention, as it is widely incorporated and described, the invention provides a wire mounted on a flexible, multi-purpose surface, 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 is bonded to the insulation layer; and wherein a cross-sectional height of the flat conductors and the insulation layer is such that the multipurpose wire will be combined with the surface when applied or after the wallpaper is applied. The copper layers are generally of the order of approximately .002 inches in thickness, but may vary from approximately 0.0004 to 0.020 inches. The number and thickness of the copper layers can 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 may be composed of materials selected from 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 (eg, 3M 9500PC), liquid adhesive, or a combination of the two. In another aspect, the invention provides a flexible, multi-purpose surface mounted wire comprising a single flat conductor together with the adhesive material and the insulation layers as described above. It should 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 above or other objects, aspects and advantages will be better understood from the following detailed description of the preferred embodiment of the invention, with reference to the drawings, in which; Figure 1 is an exploded cross-sectional side view of a 3-wire flat conductor for use in standard electrical wiring applications; Figure 2 is an exploded cross-sectional side view of a 5-wire flat conductor for use in applications requiring two circuits; Figure 3 is an exploded cross-sectional side view of a 2-wire flat conductor for use in loudspeaker systems; Figure 4 is an exploded cross-sectional side view of a 6-wire flat conductor for use in telephone applications; Figure 5 is an exploded cross-sectional side view of a 2-wire flat conductor for CATV applications; Figure 6 is an exploded cross-sectional side view of a 2 wire flat conductor for use in low voltage applications; Figure 7 is a side view of the perspective configuration of the plug-in and independent outlets connected via a flat wire; Figure 8A is an exploded, perspective view of the components of the output assembly of the present invention; Figure 8B is an exploded, perspective, alternating view of the components of the wiring assembly of the present invention; Figure 8C is a perspective view of the underside of a fully configured output assembly of the present invention; Figure 9A is a perspective view of the flat wire for interconnecting the connector of the outlet frame according to the present invention; Figures 9B, 9C, and 9D provide top, side, and bottom views, respectively, of the flat wire for interconnecting the connector of the outlet frame in Figure 9A; Figure 9E is a bottom side perspective view of the flat wire for the plug frame connector of Figure 9A, illustrating the elongated slots and the vertical contacts; Figure 10A is a perspective view of the flat wire to the conventional wire connector according to the present invention; Figure 10B, 10C, and 10D provide top, side, and bottom views, respectively, of the flat wire to the conventional wire connector in Figure 10A; Figure HA is a three-dimensional perspective view of a three-contact sliding socket receptacle system, in accordance with the present invention; Figures 11B and 11C are front and side perspective views, respectively, of a switch mounted on one side; Figure 12A is a perspective view of the flat wire mounted on the surface connected to a ceiling fan; Figure 12B is a perspective view of the mode of the switch wired discreetly in accordance with the present invention; Figure 13 is a diagrammatic representation of a configuration of a flat / loudspeaker wire system; Figure 14 is a diagrammatic representation of a configuration of a flat wire / telephone jack system; Figure 15 is a diagrammatic representation of a configuration of a flat wire / CATV system; Figure 16 is a diagrammatic representation of a configuration of a flat wire / recessed light system; Figure 17 is a diagrammatic representation of a configuration of a flat wire / DC power system; Figure 18 is a diagrammatic representation of a GFI detection circuit for 4 receptacles and 3 terminals without a switchable input socket; Figure 19 is a diagrammatic representation of a GFI detection circuit for 8 receptacles without a switchable input plug; and Figure 20 is a diagrammatic representation of a GFI detection circuit for 8 receptacles without a switchable input plug; DETAILED DESCRIPTION OF THE MODALITIES OF THE INVENTION In general, as stated above, the present invention may be used or adapted to exercise a wide variety of applications including; standard electrical wiring; telephone wiring; wiring of loudspeakers; low voltage wiring applications such as intercom and security systems; lighting under the surface; and wired TV wire. In addition, the present invention includes several unique outlets and switches that interconnect with existing conventional round wiring. In addition, the present invention also utilizes tape, cutting tools, and unique switches to implement a particular system mode. Each of the individual components will be discussed in greater detail, followed by a description of the applications to which the present invention is directed. Each of the individual wire modalities shares a common basic 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.

To facilitate the reference, the basic structure will be discussed in detail with reference to the first wire mode. It is understood that this basic structure concept applies to all wire modalities. Modifications to the basic structure will be discussed where appropriate. Similar reference numbers will be used where possible to refer to similar parts throughout the drawings.

Wire Modalities Alternating Current Electric Wire (C?) Referring now to the drawings, and more particularly to Figure 1, an exploded cross-sectional side view of a standard 110 VAC 3-wire wire mode, according to the present invention, is shown. The exploded cross section view is for illustration and discussion purposes only. The actual 3-conductor mode, there would be no visible spaces (ie, the hollow areas in Figure 1) between the conductors, insulation, and adhesive components, each of which is described further below.

Generally, the electric wire 10 is a flat, flexible wire, which allows the user to carry electricity to any area of a wall or ceiling in a room. The electric wire 10 is mounted on the surface of the wall or ceiling, thereby eliminating the need to join the expensive internal wiring of the wall or ceiling. The wire can be painted or papered to match the rest of the surface. The electric wire 10 comprises a plurality of conductors 11, multilayer, and parallel spaced and elongated. As illustrated in Figure 1, a typical 3-wire 110-VAC mode would include an AC ground conductor, an AC neutral conductor, and an AC power conductor. An internal adhesive material 13 separates flat conductors 11 as well as provides an outer flat conductor sealing edge as illustrated in Figure 1. Adhesive material 13 and conductors 11 are surrounded by a thin layer of insulating material 15. In addition, an outer adhesive layer 17 is applied to the back of the flat wire to join the electrical wiring to the desired surface. Each of the conductors 11 is comprised of one or a plurality of layers made with a copper material that is from about 0.0004 to about 0.020 inches in thickness, and preferably in the order of about 0.002 inches in thickness. Shown in Figure 1, 3 layers of copper HA, 11B, and 11C, for example. The thickness of the conductive layer should be consistent throughout its length and width, thereby eliminating any "hot spots" of strength. The specifications of the current and / or transport signal of a particular application can be achieved in any of three ways, either individually or in combination. First, the width "wc" of conductors 11 may vary. Second, extra thin copper layers can be stacked for each conductor 11. Third, the thickness "t" of the conductor 11 can be increased. For most charging and current applications, each conductor will generally be composed of approximately 2-5 layers of copper. It is understood, however, that the use of more or less layers, for each of the embodiments described below, is within the scope of this invention. For example, a five-layer copper conductor, where each copper layer is approximately 0.002 inches thick, will be in the order of 0.012 inches in thickness including insulation. Even at this thickness, however, the flat wire has an extremely thin cross section that is virtually undetectable on a surface once it has been painted or papered. The insulation layer 15 will now be described in greater detail. The insulation is achieved with a minimum thickness to prevent driving only under ideal conditions. The primary purpose of the insulation layer 15 is to assist in the optical occlusion of the presence of the wire when applied to a surface, so that a pleasing appearance could be achieved with the installation. The insulation layer 15 also orientates the copper conductive layers. In addition, the insulation material can be used alone, or in combination with the internal adhesive 13, to separate the groups of conductive layers and maintain a safe dielectric distance between conductors of different purposes (e.g. AC or AC power). As shown in Figure 1, the insulation layer 15 at the edges of the multilayer flat wire 10 may be, but need not be, used to facilitate optical occlusion. The insulating material can be selected from the group consisting of, for example, polyester films (for example, Dupont Mylar), urethane films or Teflon films. It is understood that the additional insulation materials are considered to be within the scope of this invention, and can be used while the insulation is conformable, paintable, and surface-friendly. The insulation should also be compatible with the UV-tolerant bonding compounds, and have thermal expansion and contraction characteristics, similar to those of the conductors and the surface to which they adhere. Other desirable properties are that the insulation will resist tensile forces applied in the manufacturing process, will not retract or relax under storage conditions, and that they will be removable when their use is complete. Any abrasion, rupture, cut, puncture, or any other damage to the insulation - which would result in unsafe exposure to electrical damage - will be made safe using electronic means of fault detection that will disconnect the user's harmful currents, in a time frame They will avoid permanent damage. These electronic failure detection means, or Ground Fault Interrupter (GFI) circuit, is discussed in more detail later in the specification. Returning to Figure 1, the internal adhesive material 13 should be able to be attached to the insulation layer 15. For example, adhesive tape (e.g., 3M 9500PC), liquid adhesive, or a combination of the two, can be used as a internal adhesive The internal adhesive material 13 will also function to separate the groups of conductive layers and maintain a safe electrical distance between the conductors of different purposes. In addition, the adhesive 13 can level the spaces in the various components within the wire, to assist in its ability to visually disappear on a surface. The thickness of the internal adhesive material 13 closely approximates the height of the cross section "t" of the conductors 11., especially where the internal adhesive separates the conductors 11. As shown in Figure 1, the internal adhesive 13 can be tapered at the ends of the flat wire 10, to facilitate optical occlusion. An end adhesive layer 17 is provided to join the wire to the desired surface. The outer adhesive layer 17 may be, for example, a two-sided tape, with one side fixed to the back of the flat wire 10 and the other side in the wall or surface. Alternatively, a chemical adhesive may be applied separately, and may consist of any of the adhesives with good bonding qualities, and both the insulation layer 15 and the desired surface to which the flat wire 10 adheres. A finished 3-conductor flat wire 10 has, for example, three copper layers 0.002 inches thick, remaining approximately 0.007 to 0.010 inches at the height of the "t" cross section. For a nominal 15 amp wire, the entire width "W" of the 3-wire flat wire 10 is in the order of approximately 2.0-2.5 inches. The width "c" of each conductor is approximately 0.4-0.6 inches, and the space between the "ws" conductors is approximately 0.2-0.3 inches. To ensure easily identifiable, proper and safe connections, the "wc" width of the AC ground conductor could be increased slightly, compared to the AC and neutral 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 compared to the other conductors. Similar dimensions would be useful for other applications, however, it is understood that several dimensions may vary considerably, within the practice of this invention. The flat wire 10 provides a simple, low-cost alternative to expensive re-wiring jobs, to supply electricity to specific places in walls and ceilings, for use in fans, ceiling lighting, or wall or artistic lighting.

In Figure 2, a cross-sectional, side, electrical view of a 5-wire 110 VAC wire of the present invention, having 5 copper conductors 11, of multiple layers, separated in a parallel manner, is shown. . This 5-conductor wire mode includes all the characteristics of the 3-conductor wire mode described above, with the addition of two conductors 11, to accommodate a second circuit. Like or similar parts are identified by the same reference numbers. The 5-wire 110 VAC wire is used where two circuits are desired in a flat wire, such as a wire carrying a light and a fan, or where a switched plug is used. In this mode, the five conductors consist of two neutral AC conductors, two AC power conductors, and a single AC ground conductor. The number and thickness of the copper layers, the width "w" and the thickness "t" of the conductors 11, and the space between the "ws" conductors are generally of the same dimensions as for the 3-conductor wire of 110 VAC The total width "W" of the finished flat wire 20 is in the order of approximately 3.5-4.25 inches. The conductors of the flat wire of the present invention can be used to construct a 220 VAC wire mode, as shown in general with reference to Figure 1. A flat wire, 3 conductor 220 VAC, terminated, having, for example, four layers of copper approximately 0.002 inches thick, would be approximately 0.012 inches in cross section height "t". The total width "W" would be in the order of approximately 3.0-3.5 inches. The "wc" width of the neutral and power conductors is approximately 0.4-0.6 inches, while the "c" width of the conductors to ground is approximately 0.2-0.4 inches. The space between the "3" conductors is approximately 0.4-0.6 inches. As with the 3-wire 110 VAC electric wire, the difference in the width of the conductor to ground in the 220 VAC 3-wire electric wire is to facilitate the proper connection of the wires to the connectors.

Loudspeaker Wire As with the previous embodiments, the loudspeaker wire 30 of the present invention, illustrated in Figure 3, is a flat, thin, flexible wire, which allows the user to place the loudspeakers in any area of a wall or ceiling in a room. The loudspeaker wire 30 may be used, for example, with stereo or mono audio components, or to wire external loudspeakers for improved television or sound systems, such as "ambient sound". The loudspeaker wire 30 can be mounted to a surface of a wall or ceiling, thereby eliminating the need for an internal re-wiring of the wall or ceiling. The wire can also be used or papered to match the rest of the surface. With reference to Figure 3, the thin loudspeaker wire 30 is comprised of a pair of multilayer copper conductors 11. The conductive capacity of the loudspeaker wire 30 is preferably equivalent to a 10 gauge braided wire. Each of the conductors 11 would generally have two or three layers of copper, the foregoing is shown by the copper layers Ia and llb in Figure 3. The copper layers are from about 0.0004 to about 0.020 inches thick, and so preferable in the order of approximately 0.002 inches in thickness. It is understood that, depending on the particular application, more or less layers of copper can be used. The pair of conductors 11 is separated by a suitable adhesive material 13, and both are surrounded by an insulating layer 15, as discussed above. Isolation and similar adhesives may be used as previously described in the above. Due to this application, the wire of the loudspeaker 30 can also include a cover material 18, which surrounds the conductors 11, to reduce the output signal and the transverse interference. The cover material 18 can be one or a plurality of layers of any suitable metal or semi-metallic cover material, for example aluminum or metallized polyester films. The finished loudspeaker wire 30 is approximately 0.008 inches in cross section height "t", with three layers of copper, with a total width "W" of approximately 2.5-3.9 inches. The width "wc" of each conductor is approximately 0.6-0.8 inches, and the space between the "s" conductors is approximately 0.2-0.3 inches. As shown in Figure 3, the edges of the wire 30 can be tapered to facilitate optical occlusion. An outer adhesive layer 17, similar, as previously described, is also provided for attaching the wire of the loudspeaker 30 to the appropriate surface.

Telephone Wire In Figure 4, an illustrative example of a telephone wire mode 40, according to the present invention, is shown. In this embodiment, six multilayer copper conductors 11 are provided, separated by an adhesive material 13, and surrounded by an insulating layer 15. A six conductor wire facilitates the use of private branch exchange switching (PBX) ), thus providing a private telecommunications exchange that includes access to a public telecommunications exchange. The conductors 11 are functionally equivalent to the standard 22-gauge telephone wire. Telephone wires and conductors of two, four, and eight multiple layers can also be used. In addition, the eight conductor mode approximates four pairs of twisted wires (for example twisted pair roof wire (UTP)), which may be suitable for transporting data. Each of the conductors 11 would generally have two or three layers of copper, the foregoing is shown by copper layers Ia and llb, in Figure 4. The copper layers are from about 0.0004 to about 0.020 inches in thickness, and preferably of the order of about 0.002 inches in thickness. It is understood that, depending on the particular application, more or less layers of copper can be used. The finished telephone wire 40, with three layers of copper, is approximately 0.008 inches in height in the "t" cross section, with "W" total width of approximately 1.5-3.5 inches, depending on the number of conductors 11 used. The width "c" of each conductor is approximately 0.2-0.4 inches, and the space between the "ws" conductors is approximately 0.125-0.25 inches. As shown in Figure 4, the edges of the wire 40 can be tapered to facilitate optical occlusion. An outer adhesive layer 17 as previously described is also provided to join the telephone wire 40 to the appropriate surface.

Cable for CATV Cable TV In Figure 5, there is shown an educational example of the wire mode for CATV 50 wire television, according to the present invention. In this embodiment, a pair of conductors 11 is provided, each of which can generally have two or three layers of copper, the former being shown by copper layers Ia and llb in Figure 5. The layers of copper are from about 0.0004 to about 0.020 inches thick, and preferably, in the order of about 0.002 inches thick. It is understood that, depending on the particular application, more or less layers of copper can be used. As in the previous embodiments, the conductors 11 are separated by an adhesive material 13, and surrounded by an insulation layer 15. As shown in Figure 5, the edges of the wire 50 can be tapered to facilitate optical occlusion. An outer adhesive layer 17 similar to that previously described is also provided for attaching the wire 50 to the appropriate surface. The antenna / CATV 50 wire, finished, with three layers of copper, is approximately 0.008 inches in cross section height "t", with a total width "" of approximately 1.8-2.2 inches. The width "wc" of each conductor is approximately 0.4-0.6 inches. As shown in Figure 5, the space between the "w3" conductors is approximately 0.4-0.6 inches, which is somewhat larger than the previous modes, in order to reduce radio frequency interference and improve the quality of the transmission. The CATV wire is fixed at 300 ohms.

Low Voltage Wire Applications Figure 6 illustrates one embodiment of the low voltage wire 60, in accordance with the present invention. Such low voltage applications (direct current) would include security and intercommunication systems, and "smart home products". As illustrated in Figure 6, two DC power conductors 11 are shown. The structure of the conductors 11 is essentially the same as that of the multilayer conductors 11 described above. The internal adhesive material 13, the insulation layer 15, and the outer adhesive layer 17, would be the same in this embodiment as those previously described. Each of the conductors 11 would generally have two or three layers of copper, the last shown by the copper layers Ia, llb and 11c in Figure 6. The copper layers are from about 0.004 to about 0.020 inches in thickness, and preferably in the order of approximately 0.0002 inches in thickness. It is understood that, depending on the particular application, more or less layers of copper can be used. The finished low voltage wire 60, with three layers of copper is approximately 0.008 inches in cross section height "t", with a "W" width of a total of 1.2-1.6. The width "c" of each conductor is approximately 0.3-0.5 inches, and the space between the "wt" conductors is approximately 0.2-03 inches. As shown in Figure 6, the edges of the wire 60 can be tapered to facilitate optical occlusion. An outer fiber layer 17 similar as previously described is also provided to join the telephone wire 60 of the appropriate surface.

Wire for Elimination Under the Surface While the thin, flexible wire for under-surface illumination is similar in construction to the 3-conductor and 5-conductor 110 VAC wire modes, described above, it is unique in that the under-surface lighting wire incorporates lights Recessed 160. See Figure 16. This allows the user to install lighting under a surface of a closet, shelf, or other locations where lighting below the surface is desired. This modality will be described in greater detail in the discussions of the implementations of the conventional wire-to-wire system, later in the specification.

Outlets and Switches The present invention encompasses a family of outlets that provides connection points between the flat wires of the present invention and conventional existing electrical outlets, and conventional round wire systems. These connection sockets are of two general types with one that is directly "plug-in" to the existing conventional outlets, while the other is a unit mounted on an "independent" surface. Plugs that connect plug-ins will always provide the compatibility interconnection between standard domestic electrical wiring apparatuses, and the various embodiments of the flat wires according to the present invention. Therefore, the plug-in outlet is always at the source of the standard electric current. The independent unit is interconnected with the plug-in unit by means of several flat wire embodiments of the present invention. Figure 7 illustrates the typical configuration of the interconnection between the plug-in and independent units. Assuming that a conventional two receptacle receptacle, as fed by the conventional round wire 69 from behind the wall 66, is located behind the outlet 65. The receptacle 65 would therefore be of a directly "plug-in" variety. The socket 67 would thus be an independent outlet that is fixed to the wall without the connection of a plug. The independent outlet can therefore be placed anywhere in the room, regardless of the location of existing outlets. In the electric wire modes, for example, the conventional wire stream 69 is transferred to the separate outlet 67 via the plug-in socket 65, and the flat wire 110 VAC of the present invention. Figure 8A is an exploded perspective view of the plug-in outlet unit 65, which describes the various internal and external components of the receptacle. As shown, the receptacle 65 contains laterally mounted female receptacles 72 and 73 housed within the receptacle cover 74. Alternatively, the receptacles 72 and 73 may be noted in the front as in the considerations of the standard receptacle . The version of the laterally mounted receptacle has an advantage in that the cover of the receptacle 74 can be painted or papered to be combined with the surface. Also, the additional female receptacles 72 'and 73d can be located on another side of the receptacle cover 74, as in Figure 8B, which shows four female receptacles. The receptacle base 75 for the plug-in receptacle 65 contains openings 75a and 75b, which would be placed on the female receptacles of the conventional existing receptacle, and fixed to the surface with screws or other equivalent connecting devices. The cover of the receptacle 74 would then be placed on the base 75. The plug-in receptacle 65 also contains a flat wire connector 76 and a Ground Fault Interrupter (GFI) module 77, with its associated reset button GFI 78. The GFI 77 module (the operation of which is discussed later in the specification) contains two sets of male contacts 79 and 79 'which pass through the openings 75a and 75b to be plugged into the respective female receptacles, associated with conventional wiring systems. The GFI 77 module works to interrupt the electrical current to the load, in the event that the flat wire is punctured or broken. Figure 8C provides a perspective view of the underside of a complete plug-in receptacle assembly 65, which describes the male contacts GFU 79 and 79 'extending through the base member 75 through the openings 75a and 75b. The independent outlet 67 (see Figure 7) differs from the plug-in receptacle 65 in two respects. First, there is no need to provide a GFI 77 module and its associated reset button 78 in the independent outlet. Second, the base of the independent outlet 75 does not need openings 75a and 75b since the independent outlet does not interconnect directly with the conventional wiring system. In all other aspects, plug-in and independent outlets are the same. A single outlet base 75 can be configured with "punched" openings 75a and 75b, so that it can be used with either plug-in or stand-alone outlet assemblies. Figure 8B is an alternate perspective view of the plug-in receptacle unit 65, which describes two sets of male contacts 81 and 83, which are interconnected with the flat wire connector 76 and the GFI 77 module respectively. Note that the flat wire connector 76 and the GFI 77 module are not attached to the base member 75, but are selectively connected to the receptacle cover 74 by the male contacts 81 and 83. Also described in Figure 8B is the copper frame 84, on the underside of the cover 74. The copper frame 84 functions to provide conductive functions to the female receptacles 72, 72 ', 73, and 73', and to the two male contact sets 81 and 83. The male contacts 83 are plugged into the corresponding slots 82 in a surface of the GFI module 77, as shown in Figure 8A. The flat wire connector 76, which is common to both the independent and plug-in outlets, will now be discussed in more detail. The flat wire connector 76 provides the connection point between the flat wires of the present invention and the frame of the copper socket 84. An example of such a "flat wire to outlet frame" connector 90 is illustrated in the view in FIG. perspective of Figure 9A. While a mounting of 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, having any number of layers of copper. A plurality of flat wire receptacles 92 are provided along a surface of the connector 90 to receive each of the flat wire conductors 11. The electrical wires of 3 conductors and 5 conductors can use the same connector assembly 5 conductors 90, with the condition that the outer wire receptacles are emptied when the 3 conductor electrical wire is used. The other wire modalities would have their own interconnect switches 90. The need for multiple switches is not a problem, since the connectors can easily be changed and inserted into the receptacle cover 74, by plugging the connector into the male contacts 81 fixed in the receptacle 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 multilayer conductors 11 (see Figure 9B as well). Generally two to five slotted springs 94 are provided, to correspond to the multilayer copper conductor modes discussed above. As the perspective views are shown in Figures 9A and 9E, and the side view in Figure 9C, a plurality of elongated female slots 98, are contained in another surface of the connector 90. These elongated female slots 98, are interconnected with the corresponding male contact set 81, as shown in Figure 8B. The male contacts 81 simply slide into the slots 98 to make the connection. As more clearly seen in Figure 9E, each of the extended slots 98 contains a series of slidable contacts or brushes 98a-98d, each of which moves independently of the others, to provide a better connection and more contact surface with the male contacts 81. The sequence of the connection of the flat wire to the connector 90 is described with reference to an exemplary embodiment of 5 conductors, wherein each of the conductors has three layers of copper. First, each conductor 11 is aligned 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 deflected by screws 96, as it is shown in Figure 9D. By tightening the screws, one can ensure that both the top and the bottom of each copper layer are in contact with the slotted springs. This ensures the best contact of the driver, and also ensures that each layer of copper (and therefore each conductor) experiences the same resistance. Finally, the male contacts 81 and the extended female slots 98, are aligned and the connection is made to either the plug-in or the independent outlet. The cover of the receptacle 74 has a small cut in the edge facing the receptacles of the flat wire 92, of the connector 90, to allow the flat wires to pass through the cover of the receptacle 74 to reach the connector 90.

In addition to the flat wire connector to the outlet frame, a second type of connector is also needed to provide an interconnection between the conventional round wires and the various flat wire modalities described above. This would cover, for example, where the flat wires are connected to a wall light, fan, or an intercommunication system. An example of such connector 100 is illustrated in the perspective view of Figure 10A, which describes a connector of a 5 wire flat wire to the conventional wire. While the 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 with any number of conventional round wires. The 3-conductor, 5-conductor electrical wires can use the same 5-wire connector assembly 100, with the proviso that the outer wire receptacles are emptied when the 3-wire electrical wire is used. The other wire modes would have their own interconnect switches 100. As shown in Figure 10A, the connector 100 contains a plurality of sets of conventional screws 101, along a surface of the connector to provide an interconnection for the connections " of "standard" coiled wire, common in conventional round wiring systems (also Figure 10B). Along another surface one or more flat wire receptacles 102 are placed, to receive each of the flat wire conductors. Each of the flat wire receptacles 102 contains a plurality of slotted springs 104 (see also Figure 10D) to contact each of the layers in each of the multilayer conductors. The slotted springs 104 are slightly deflected by the screws 96, as shown in Figures 10A and 10C and operate in the same manner as described with respect to the connector 90. The connection to the flat wire receptacles by the flat wire conductors it is the same as the one discussed with respect to the connector 90. FIG. HA discloses a female receptacle of three improved cleaners 110, which can be incorporated in the plug-in receptacles 65 or stand-alone 67 of the present invention. The receptacle 110 contains molded copper guides 111 and 112 that contact the respective wiper assemblies 114 and 166. 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 sliding three-contact receptacle 110 thus provides a better connection and more contact surfaces with the copper guides 111 and 112. The other ends of the copper guides 111 and 112 extend to the copper frame 84 (see Figure 8B) . In addition, since the three sliding contacts move independently, the receptacle is better able to adapt the torque in a plug.

Switches A single set of switches 124 'is provided for use with the wire products of the present invention. The switches can be electrically wired to the existing switch, or plugged into an existing outlet, or operated by remote radio frequency (RF) energy. The switches are mainly used with the wires of 3 conductors and 5 conductors, and in the lighting modes below the surface described above. The switch mechanism can be mounted on the front side (Figures 11B and 11C) and many variations of the switch are concentrated, including: (1) electrically controlled, permanent amount of discrete wiring; (2) Capacitive touch, or controlled by membrane switch, of permanent quantity, discretely wired; (3) capacitive touch, or controlled by membrane switch, of permanent quantity, or a radio frequency (RF) emitter / receiver pair; (4) capacitive touch, or controlled by membrane switch, or held by hand or hanging on the wall, an emitter / receiver (RF) pair; or (5) capacitive touch, a set of full voltage regulator controlled by membrane switch, with indicators, held by hand or hanging on the wall, an RF emitter / receiver pair. Regardless of the particular type of switch used, however, all switches share certain common elements. Switches 124 '(see Figure 12B) do not commute the AC circuit. Instead, they send a signal, via a low voltage wire 125 (12 VDC) as shown in Figure 12B, to the corresponding plug that will switch the AC circuit. If the switch unit is wired, it is coupled by means of voltage circuits. This makes the switches not capable of being used without a compatible plug-in unit.

Tools in The flat, thin, single wires of the present invention also require unique cutting and insulating tools to facilitate connection to the connectors and existing outlets. Each type of wire described above will have its own specialized tools. Two versions are contemplated, one directed to the use of professional electricians, or installers, and the other to non-professionals. The professional removal tool is designed to cut and remove the insulation layer 17 of the conductors 11 in a similar procedure unique to the manner of operation of a conventional cutting tool. Considering the small thickness of the conductors, it is evident that the cutting tool is engraved in a precise manner to allow such precision in the cutting and removal. Such precise engraving may tend to raise the cost of such a tool, making it available economically for professional use only. A second cutting tool directed to the non-professional, will align the wire in the cutter and cut adjacently and perpendicular to the conductors, to allow the user to remove the necessary insulation material to reach the conductive layers. The insulation is then pulled back and removed with scissors.

System Applications A general embodiment of the system, illustrative-incorporating the various wires, outlets, switches and connectors described above-is shown in Figure 12. With reference to Figure 12A, a conventional outlet 120 and a conventional switch 124. A person is provided. Desiring to wiring a ceiling fan 126 in the location shown, it would normally have to be coupled in an expensive wiring and wall wiring job, to bring electric current to the fan. Using the flat wires, outlets, switches, and connectors of the present invention, however, the task is greatly simplified as described now. First, a plug-in receptacle 65 (Figure 8A) is plugged into the conventional outlet 120. Next, an independent outlet 67 is attached to the wall at the desired location. The flat wire sections 123 (for example, 3-wire or 5-wire 110 VAC) run between the plug-in receptacle 65 and the receptacle 67, and again between the separate receptacle 67 and the fan. A connector 90 (not shown in Figure 12A, but which is of the type described in Figure 9A) connects the flat wires 123 to the plug-in and independent outlets 65 and 67. In addition, another connector 100 (of the type described in Figure 10A) ) connects the conventional round wires of the fan 126 with the flat wire 123. The flat wire 123 is fixed to the surface of the wall with the adhesive layer 17, as described above, typically two-sided tape, and either paint or paper to darken the wire. As illustrated, the flat, flexible wire 123 undergoes a 90 degree bend along its width at point 127, where the roof and the wall meet, since the flat wire adheres to a different surface flat In addition to bending at any angle along its width, to accommodate the joints of different planar surfaces, the flexible wire can actually bend over itself at any angle to accommodate changes in angle on the same planar surface. Consider, for example, the second wall lighting apparatus 126 'in Figure 12A. The wall light 126 'connects to a standard switch 124 by a flat wire 128. For aesthetic reasons, the place of placing a second independent switch near the conventional switch, the flat wire is bent at an angle of 45 degrees at the points 129 and 129 '. The flat wire basically bends to itself to achieve the 45 degree turn. Figures 13-17 are diagrammatic representations specific to the various system modalities using the flat wires previously described. The systems are briefly described later. Figure 13 illustrates the interconnection of conventional flat wire / wire. For simplicity and ease of illustration, only one speaker 131 is illustrated with the stereo 130. It is understood that any number of speakers may be used with the flat wires of the present invention. As illustrated, the stereo system 130 is connected to the speaker 131 by means of the flat wires 136. The speaker 131 can be placed in any desired location. The wires of the traditional speakers 136 are then connected to a separate plug on the wall. A second independent plug is placed in the entry location near the new position of the speaker. The flat wires 133 then run between the two independent plugs. The total length of the flat wire 133 can then be painted or papered, thereby eliminating the nasty and annoying horn wire.With reference to Figure 14, there is shown a diagrammatic representation of the application of the flat wire / conventional telephone wire interconnection, to be used to provide a connection to a telephone extension. As illustrated, the existing telephone jack or telephone jack 141 is connected to the telephone jack of the extension 142, by means of flat wires 143. As shown, a flat wire telephone apparatus 147 is connected to the existing telephone jack 141. The telephone plug of the extension 142 is then placed in the desired location and connected to the flat wire telephone apparatus 137 '. The flat wires 143 are then connected between the flat wire telephone sets 147 and 147 '. The total length of the flat wire 143 can then be painted or papered, thereby eliminating the unpleasant and annoying telephone wire. Figure 15 shows a diagram representation of the application in a CATV. The cable input 151 is fed into the house by means of a coaxial cable 158 of 75 ohm. The cable 158 is then connected to a 75 ohm-300 ohm conversion apparatus located on the wall near the 151 inlet inside the house. A second conversion apparatus 157 is placed near the desired location of the television 152. The flat wires 153 then run between the two conversion apparatuses. Previously, the total length of the flat wire 153 can then be painted or papered, thereby eliminating the unpleasant and annoying CATV wire. The mode of illumination below the surface, including the flat wires 163 with recessed lights 169, is shown in Figure 16. The plug switch 161 is connected to the flat wire 163. The recessed lights 169, may be, for example, lamps Halogen 120 volts, with RSC double end base, from 20 to 100 watts. Flat wires can be placed below any location below the surface, where additional light is desired, such as under a closet or shelf. The flat wire 163 should then be painted or papered to impinge with the rest of the surface. The flat wires of the present invention can also be used with direct current (DC) applications. With reference to Figure 17, a CD source 171 is connected to a CD outlet 172 by means of the flat wires 173. As in other embodiments of the system, the wall connectors provide interconnection between the conventional CD wires 178 and the flat wires 173.

Earth Fault Interconnection Circuit (GFI) Since the flat wire is almost invisible after it has been painted or papered, there is a possibility that at a later date, a person could inadvertently place a nail or a hook painted through the flat wire, or otherwise cut the wire. At each end, therefore, an earth fault interruption module (GFI) 77, (see Figures 8A-8C) will be provided as a safety measure to prevent damage if accidental penetration occurs through the ultra-thin layers of insulation. The term fails to ground, refers to any thing or any person that provides a path to earth other than a normal internal earth. The GFI circuit will verify the flow of current through the power and neutral conductors of the circuits, and if more than ten milliamperes of difference are detected, then both conductors will be disconnected by a circuit breaker. The circuit breaker will be fast enough to permanently avoid any harmful discharge. The circuits will provide a secure methodology to failure such that any circuit will be verified before connection and re-verified after connection. The circuit power will provide connection, so the circuit failure will result in no power beyond the circuit breaker. As previously described, the circuit is typically located in the "plug-in" outlet 65 (see Figures 8A-8C) that plugs into the conventional wall outlet, as discussed above. The GFI address circuit is basically a relay that is normally closed. When the ground fault current exceeds some predetermined value, which is less than that required to operate the overcurrent protection device of the supply circuit, the relay opens, interrupting the electric current to the load. Figure 18 illustrates a non-switchable, two-socket system of a single standard circuit 180, having a GFI detection circuit connected to a 4-pin, 3-terminal apparatus in accordance with the present invention. Figure 19 illustrates a two-plug system, non-switchable, of a single standard circuit 190, having a GFI detection circuit connected to an apparatus of 8 sockets (4 main sockets and 4 extension sockets) in accordance with the present invention . Figure 20 illustrates a two-plug system, switchable, of two standard circuits 200, which therefore requires two GFI detection circuits, each connected to a 4-pin device (2 main plugs and 2 extension plugs) according to 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. It is noted that in relation to this date, the best method known by the applicant to carry out the aforementioned invention, is the conventional one for the manufacture of the objects to which it relates. Having described the invention as above, property is claimed as contained in the following:

Claims (29)

1. A wire mounted on a flexible, multipurpose surface, characterized in that it comprises: a plurality of elongated flat conductors, spaced apart in a generally parallel relationship, wherein each of the plurality of flat connectors comprises a plurality of layers of copper, and where the flat conductors have the capacity to transport high and low voltage and current; an adhesive material that separates the plurality of flat conductors; and an insulation layer surrounding the plurality of flat conductors and the adhesive material, the adhesive material is bonded to the insulation layer, wherein a cross-sectional height of the flat conductors and the insulation layer is less than about 0.040. inches, so that the multi-purpose wire will be combined with the surface when wallpaper is applied or applied.

2. The wire according to claim 1, characterized in that each of the plurality of copper layers is from about 0.0004 to about 0.020 inches thick.

3. The wire according to claim 1, characterized in that the thickness of the conductive layer is consistent throughout its length and width.

4. The wire according to claim 1, characterized in that the insulation material is selected from the group consisting of polyester films, urethane films, and Teflon films.

5. The wire according to claim 1, characterized in that the adhesive material is at least one of adhesive tape and liquid adhesive.

6. The wire according to claim 1, characterized in that the height of the cross section of the flat conductors and the insulating layer is from about 0.002 to about 0.050 inches in thickness.

7. The wire according to claim 1, characterized in that the wire is tapered at its ends, to assist in the combination of the wire with the surface.

8. The wire according to claim 1, characterized in that it also comprises a layer of adhesive fixed to the insulation layer for joining the wire to the surface.

9. The wire according to claim 1, characterized in that the flexible wire is bent at any angle to conform to the different planar surfaces.

10. The wire according to claim 1, characterized in that the flexible wire is bent at any angle to conform to the change of direction along a common planar surface.

11. A wire mounted on a flexible, multi-purpose surface, characterized in that it comprises: an elongated flat conductor having a plurality of copper layers, wherein the flat conductor has the capacity to carry high and low voltage and current; an adhesive material fixed to the conductor and an insulation layer surrounding the conductor and the adhesive material, the adhesive material is bonded to the insulation layer; wherein a cross-sectional height of the flat conductor and the insulation layer is less than about 0.040 inches, so that the multi-purpose wire will be combined with the surface when wallpapering or painting.

12. A female receptacle for use in an electrical receptacle assembly, having openings for communicating with the respective male contacts, of a conventional plug, characterized in that it comprises: a plurality of slidable contact assemblies spaced along the respective openings in the receptacle , to contact the respective male contacts of the conventional plug, each of the slidable contact assemblies has a plurality of slidable contacts, and each of the slidable contacts move independently of the other sliding contacts; and conductive guides coupled to one end of the slidable contact assemblies, and at the other end to a current source.

13. A receptacle assembly containing a base member and a receptacle cover removably secured to the base member, characterized in that it comprises: a copper frame assembly disposed in the receptacle cover; a flat wire connection assembly removably secured to the outlet cover, a first plurality of male conductor contacts fixedly secured to the copper frame assembly for respective communication with the corresponding elongated slots extending from a surface of the Flat wire connection assembly; and a plurality of female receptacle integrated with the cover of the receptacle and which are in contact with the mounting of the copper frame.

14. The outlet assembly according to claim 13, characterized in that the base member comprises a plurality of openings to match a receptacle assembly of the standard female receptacle.

15. The receptacle assembly according to claim 14, characterized in that it also includes: a ground fault interrupter module, removably secured to the receptacle cover, the ground fault interrupter module has male contacts for communication, through the openings in the base member, with respective slots in the receptacle assembly of the standard female receptacle; and a second plurality of male conductor contacts, fixedly secured to the copper frame assembly, for respective communication with the corresponding slots contained along a surface of the ground fault interrupter module.

16. A connector for the conventional wire-to-wire connection, characterized in that it comprises: a plurality of conventional screw sets along a first surface of the connector, the set of screws is in selective communication with the conventional wiring lines; and one or more flat wire receptacles along a second connector surface, for receiving the respective conductors of the flat wire, each of the flat wire receptacles contains a plurality of slotted springs to contact the copper layers. respective in each of the respective conductors.

17. The connector according to claim 16, characterized in that it includes screw means for deflecting the slotted springs.

18. A connector for connecting the flat wire tracks to an outlet frame assembly, characterized in that it comprises: one or more flat wire receptacles along a first surface of the connector, for receiving the respective conductors of the flat wire, each of the flat wire receptacles contain a plurality of slotted springs to contact the respective copper layers in each of the respective conductors; and one or more elongated slots along a second surface for receiving the respective male conductor contacts spaced along the mounting frame of the receptacle.

19. The connector according to claim 18, characterized in that the elongated slots contain a plurality of sliding contacts that move individually, to contact the male conductive contacts.

20. The connector according to claim 18, characterized in that it includes further screw means for deflecting the slotted springs.

21. A cable mounted on a flexible, multi-purpose surface, characterized in that it comprises: 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 layers of copper, where flat conductors have the ability to carry high and low voltage and current, wherein the current carrying capacity is in the range of about several milliamperes to about 20 amps. an adhesive material that separates the plurality of flat conductors; and an insulation layer surrounding the plurality of flat conductors and the adhesive material, the adhesive material is bonded to the insulation layer; wherein a cross-sectional height of the flat conductors and of the insulation layer is less than about 0.040 inches, so that the multi-purpose wire will be consistent with the surface when wallpapering or painting.

22. The wire according to claim 1, characterized in that it comprises: three elongated flat conductors, separated approximately 0.2 - 0.3 inches in the generally parallel relation, wherein each of the flat conductors comprises three layers of copper, each of the layers of copper is 0.002 inches thick, and the width of each flat conductor is approximately 0.4 - 0.6 inches, where the height of the cross section of the flat conductors and the insulation layer is approximately 0.007 to 0.010 inches so that the multi-purpose wire will be combined with the surface when wallpaper is applied or applied, and where the multi-purpose wire has a nominal capacity of 15 amperes, and 110 VAC.

23. The wire according to claim 22, characterized in that the three elongated flat conductors comprise ground and neutral power conductors, and the width of the ground conductor is wider than the respective widths of the power and neutral conductors.

24. The wire according to claim 1, characterized in that it comprises: five elongated flat conductors, separated approximately 0.2 - 0.3 inches in the generally parallel relationship, wherein each of the conductors comprises three layers of copper, each of the copper layers is 0.002 inches thick, and the width of each flat conductor is approximately 0.4 - 0.6 inches, where the height of the cross section of the flat conductors and the insulation layer is approximately 0.007 to 0.010 inches, so that The multi-purpose wire will be combined with the surface when wallpaper is applied or applied, where the multi-purpose wire has a nominal capacity of 15 amps, 110 VAC.

25. The wire according to claim 1, characterized in that it comprises: three elongated flat conductors, separated approximately 0.4 - 0.6 inches in the generally parallel relation, wherein each of the flat conductors comprises four layers of copper, each of the layers of copper is 0.002 inches thick, and the width of each flat conductor is 0.2 - 0.6 inches, where the height of the cross section of the flat conductors and the insulation layer is approximately 0.012 inches, so that the Multi-purpose wire will be mixed with the surface when wallpaper is applied or applied, where the multi-purpose wire has a nominal capacity of 15 amps, 220 VAC.

26. A loudspeaker wire, mounted on a flexible surface, characterized in that it comprises: two elongated flat conductors, separated approximately 0.2 - 0.3 inches in a generally parallel relationship, wherein each of the flat conductors comprises three layers of copper, each of The copper layers are 0.002 inches thick, and the width of each flat conductor is approximately 0.6 - 0.8 inches; an adhesive material that separates the plurality of flat conductors; and an insulation layer surrounding the plurality of flat conductors and the adhesive material, the adhesive material is bonded to the insulation layer, wherein a cross-sectional height of the flat conductors and the insulation layer is approximately 0.008 inches , so that the multi-purpose wire will be combined with the surface when wallpaper is applied or applied, and where the wire of the speaker is equivalent to a 10-gauge braided wire.

27. A telephone wire, mounted on a flexible surface, characterized in that it comprises: a plurality of elongated flat conductors, spaced approximately 0.125 - 0.25 inches in a generally parallel relationship, wherein each of the conductors comprises three layers of copper, each of Copper layers 0.02 inches thick, and the width of each flat conductor is approximately 0.2 - 0.4 inches; an adhesive material that separates the plurality of flat conductors; and an insulation layer surrounding the plurality of flat conductors and the adhesive material, the adhesive material is bonded to the insulation layer, wherein a cross-sectional height of the flat conductors and the insulation layer is about 0.008. inches, so that the multi-purpose wire will be combined with the surface when painting or applying wallpaper, and where the telephone wire is equivalent to a 22-gauge telephone wire.

28. A cable television wire, mounted on a flexible surface, characterized in that it comprises: a plurality of elongated flat conductors, separated approximately 0.4 - 0.6 inches in a generally parallel relationship, wherein each of the flat conductors comprises three layers of copper , each of the copper layers is 0.002 inches thick, and the width of each flat conductor is approximately 0.4 - 0.6 inches; an adhesive material that separates the plurality of flat conductors; and an insulation layer surrounding the plurality of flat conductors and the adhesive material, the adhesive material is bonded to the insulation layer, wherein a cross-sectional height of the flat conductors and the insulation layer is approximately 0.008 inches , so that the multi-purpose wire will be combined with the surface when it is painted or after the wallpaper is applied, and where the cable television wire is pre-recorded at 300 ohm.

29. A low voltage wire, mounted on a flexible surface, characterized in that it comprises: a plurality of elongated flat conductors, separated approximately 0.2 - 0.3 inches in a generally parallel relationship, wherein each of the flat conductors comprises three layers of copper, each of the copper layers is 0.002 inches thick, and the width of each flat conductor is approximately 0.3 - 0.5 inches; an adhesive material that separates the plurality of flat conductors; and an insulation layer surrounding the plurality of flat conductors, and to the adhesive material, the adhesive material is bonded to the insulation layer; wherein a cross-sectional height of the flat conductors and of the insulation layer is approximately 0.008 inches, so that the multipurpose wire will be combined with the surface when it is painted or after wallpaper is applied.