ZA200601893B

ZA200601893B - Electrical wire and method of fabricating the electrical wire

Info

Publication number: ZA200601893B
Application number: ZA200601893A
Authority: ZA
Inventors: Robert J Sexton; Martin Fred Lane; Charles Alexander Garris Iii
Original assignee: Newire Inc
Priority date: 2003-09-05
Filing date: 2006-03-06
Publication date: 2007-06-27
Also published as: CN1868095B; CN1868095A

Description

ELECTRICAL WIRE AND METHOD

OF FABRICATING THE ELECTRICAL WIRE

CROSS REFERENCE TO RELATED APPLICATIONS

“This Application claims priority from U. S_ Provisional Application No. 60/ 500,350,

PROTE-CTIVE LAYERED AC ELECTRICAL WIRE, which was filed on September 5, 200=3, assignec to the present assignee, and is incorporated herein by reference.

BACKGROUND OF "THE INVENTION

Field of the Invention ~The present invention generally relates to an electrical wire and method of fabricating the wire, ard more particularly, an electrical wire whi ch includes at least one Electrifiable conductor (e.g., having a purpose of carrying an electrical current, e.g., an alternating current (AC) or direct current (DC) power supply, or a communication signal such as a voice or data transmission signal), and a return conductor (e.g., first and second return conductors) which at least substantially entraps the Electrifiable conductor.

Description of te Related Art

The earliest forms of wiring homes (1920s -1950s) utilized wire insulated with shelleac permeanted cloth wrap. Asphalted cloth wrap was used for insulation in the 1950s-1970s.

Aluminum electrical wiring was installed in homes in the mid 1960s through the mid 1970s.

Wire, as we know it today with two insulated inner conductors (e.g., hot/neutral or

Electrifiable/return conductors) and a non-insulateed ground conductor (e.g., grounding conductor), all within a thermoplastic outer insulator, has been used since the mid-1950s.

Figures 1A-1B illustrate examples of sucka conventional electrical wire. As illustrated in

Figure 1A, one conventional electrical wire 50 in«cludes an Electrifiable (e.g., hot) conductor 55 surrounded by a first insulation layer 60, a return (e.g. neutral) conductor 65 surrounded bya second insulation layer 70. A third insulation layer 75 surrounds the insulated conductors 53, 65.

As illustrated in Figure 1B, another conventional electrical wire 100 includes an

Electrifiable (e.g., hot) conductor 105 surrounded] by a first insulation layer 110, a return conductor 115 surrounded by a second insulation layer 120, and a grounding conductor 125. A third insulation layer 130 surrounds all of the coraductors 105, 115 and 125.

Many millions of homes today are facing end-of-life scenarios regarding their older wiring and run significant risk of fire damage ancl casualties. According to the National Science and Technology Council November 2000 report, "[wlire systems may become unreliable or fail altogether, due to poor design, use of defective pnaterials, improper installation, or other causes.

The risk of failure increases as wire systems age, due to cumulative effects of environmental stresses (e.g. heat, cold, moisture, or vibration), i nadvertent damage during maintenance, and the wear and tear of constant use. The aging of a wir-e system can result in loss of critical function in equipment powered by the system... can jeopardize public health and safety and lead to catastrophic equipment failure or to smoke and Sire.” The Consumer Products Safety 70 Commission estimates that SO million homes in ~the United States have reached or are about to reach the “end-of-life” of their electrical wiring system.

Furthermore, wire insulation and/or condtuctors can deteriorate due to radiation, high temperature, steam, chafing, mishanciling, corrosion, mechanical loading, and vibration. Reports issued by the Consumer Products Safety Commission (CPSC) show that in 19+97 home wire systems caused over 40,000 fires that resulted in 250 deaths and over $670 mi_1lion of property damage. Further study by the CPSC based on 40,300 electrical circuit fires shmowed that 36% were due to installed wiring and 16%@ were due to cord/plugs. Along with the =usual wire system failures due to age and environmental stresses, aluminum wire systems were " prone to degradation and dangerous overheating".

Regarding modern wire systeams and technology, the National Institute= of Standards and

Technology (NIST) and Building and Fire Research Laboratory (BFRL) acknowledge, "[wlires | and cables made with fluorocarbons have excellent flammability, but are very expensive. Flame- retarded polyvinyl chloride (PVC) cables also have excellent flammability ana physical properties... However, the chloride content of (all) PVC cables is a concern fox potential formation of dioxin during incineration."

As illustrated in Figures 1A-1 B, conventional electrical wire which is commonly used in homes and offices today consist of solid, round wires individually insulated w=ith PVC (except for the ground wire) with an outer PVC j acket surrounding the inner wires. Fires are increasingly being caused by overheated wires, insulation breakdown, and penetrations. Tle open spaces afforded by conventional in-wall or ira-ceiling wiring offer plenty of oxygen fo-r fire ignition and expansion associated with electrical fires.

Moreover, such conventional electrical wire poses an electric shock hazzard and therefore, causes safety concerns. That is, such conventional electrical wire is often acciedentally penetrated by objects such as nails, screws, drill ‘bits, etc. which often results in the serious injury or death.

Thus, such conventional electrical wire has a high potential for serious injury when penetrated by any of the aforementioned electrically conductive objects.

Other key examples of convemtional wiring systems being inadequate in the changing- marketplace include: (a) the proliferation of solid wall (and ceiling) construction techniques; and (b) the proliferation of new technologies and devices being installed in new and especially existing home and office environments that require wire interfaces and many are designed for surface mounting of thesse devices.

New materials such as foam lock forms for poured concrete walls, removable form poured concrete walls, fabricated alteemative materials to wood and recycled materials formed into solid wall (and ceiling) panels a ll represent better long-term characteristics and advantages over current “hollow” exterior and interior wall (and ceiling)construction techniques. These solid material construction techniques require some type of invasive channeling done on-site.

This channeling has many drawbacks, safety concerns and costs associated. It also typically places the wiring closer to the finish ed surface where future invasions as previously described may cause shock or potential arch faults and fire potential. On a global scale the construction issues have existed for many years bpased on differences in construction techniques.

In addition, the advent of adwances in audio, video and computer/internet applications have drastically changed the paradigem of home and office devices. Surround-sound home theater and multi-media conference room amudio systems, flat-panel plasma and liquid crystal display (LCD) televisions, networked homes and offices, new applications of lighting, air quality and control systems have put tremendous strains and in many cases compromises on wiring systers.

The requirement for alternating current (AC) or direct current (DC) electric=al power interfaces and the associated wiring has created problems for the installer and the uses.

SUMMARY OF THE INVENTION

In view of the forego ing, and other problems, disadvantages, and drsawbacks of conventional methods, an exemplary aspect of the embodiments of the pres-ent invention provides an electrical wire amd method of fabricating the electrical which neway provide a safe and convenient electrical wire which is easily fabricated.

The inventors have determined that a new wiring system that is inhe=rently safe and is designed to address the curresnt and future needs of devices and technologie. s and how they are installed and used may be the only solution to the next long-term and in mazny cases short-term : wiring crises.

The exemplary aspects of the present invention include an electrical wire which includes at least one electrifiable conductor, and first and second return conductors (e=.g., at least one return conductor) which are respectively formed on opposing sides of the at least one electrifiable conductor, such that the at least one electrifiable conductor is at least substantially entrapped by the first and second return comductors. By “substantially entrapped” it is me=ant that a object penetrating an outer surface o-f the electrical wire is substantially prevented contacting the

Electrifiable conductor withowat contacting the return conductor.

Further, the electrical ~wire may be surface-mountable and may be saffely used for practically any voltage application (e.g., 0V to 240V or higher).

The wire may further include first and second insulating layers which are formed between the at least one electrifiable conductor and the first and second return conductors, respectively. Further, the at least one eJectrifiable conductor and the first and second returm conductors may include substantially fl at conductive layers having a stacked arrangement. The wire may also include an outer insulatirig layer (e.g., third and fourth insulating layers) formed on. the first and second return conductors.

In addition, a distance between the at least one electrifiable conductor and each of the first and second return conductors (e.g., a th-ickness of an insulating layer between these conductors) is no greater than about 0.030 inches. For example, in one exemplary embodiment, this distance is no more than about 0.005 inches. Futrther, the first and second return conductors may comtact each other along a longitudinal edge (e. g., at the edge of the width) of the electrical wire, sumch that the electrifiable conductor is completely entrapped (e.g., completely surrounded) by the first and second return conductors.

In addition, additional protectiom may be provided by working (e.g., treating) the longitudinal edges of the insulating layers, return conductors and/or grounding conductors. For example, the first and second return conductors may be treated by at least one method of mechanical, thermal or chemical treatm ent to form a protective longitudinal edge of the electrical wire, the protective edge inhibiting a foxeign object from penetrating the electrical wire and contacting the Electrifiable conductor without contacting one of the first and second return conductors.

Similarly, the first and second imsulating layers may contact each other along a longitudinal edge of the electrical wire. Further, the first and second insulating layers may be treated by at least one method of mechamical, thermal or chemical treatment to form a protective longitudinal edge of the electrical wire, the protective edge inhibiting a Foreign object from penetrating the electrical wire and contacting the Electrifiable conductor. .

Another aspec-t of the present invention includes an electrical wir—e including at least one electrifiable conductor, first and second insulating layers formed on oppeosing sides of the at least one electrifiable conductor, first and second return conductors formed orn the first and second insulating layers, resp ectively, such that the at least one electrifiable con_ductor is at least substantially entrappe d by the first and second return conductors, third a-nd fourth insulating layers formed on the first and second return conductors, respectively, fir=st and second grounding conductors formed on. the third and fourth insulating layers, respectively, and fifth and sixth insulating layers form ed on the first and second grounding conductors, reespectively.

Further, the at least one Electrifiable conductor may include a plurality of Electrifiable conductors, formed in. a plurality of horizontal segments across a width Of the wire and a plurality of vertical segments across a thickness of the wire. In addition, at least ne segment in the plurality of horizontal segments of the Electrifiable conductors may be wmsed to transmit a communication signal (e.g, a voice communication signal and/or a data communication signal) and at least one segme=nt in the plurality of horizontal segments of the El .ectrifiable conductors may be used to supply~ AC or DC electrical power.

Further, a capacitance formed between the at least one Electrifiatole conductor and the first and second return conductors may be given as C= 1.5 *W oL +g/d, vwhere W is the width of the return and electrifi able conductors, L is the length of the return and e. lectrifiable conductors, & is the dielectric constant for the insulating layers (e.g., dielectric betweerm the return and electrifiable conductors, and d is the distance “between each of the return and electrifiable conductors.

In addition, the first and second grounding conductors may inhibit power transmission signals and load-generated electrical noise frosm being generated in the electrical wire. Further, the first and second return conductors and the= first and second grounding conductors may” be (e.g., substantially) thermally conductive for Clissipating heat from the at least one Electri-fiable conductor. Specifically, the first and second return conductors and the first and second grounding conductors may have (e.g., each may have) a Tate of heat dissipation which is greater thar a rate of heat dissipation for a round conductor, for a given cross-sectional area.

An important advantage of an exempl ary embodiment of the present invention, is that substantially flat conductors may have a large=r surface area than a round conductor {e.g., fora : given conductor cross-sectional area). The increased surface area provides a much greater heat transfer rate. Since the cross-sectional geometry may not substantially vary with respect to longitudinal direction, the pertinent variable i s the perimeter along the edge of any given conductor and how it varies when the total creoss-sectional area is maintained constant.

The substantially flat conductors can, therefore, carry a greater amount of electricity for a given cross-sectional area (e.g., of the conductor) if the resulting steady-state temperature is kept constant and if surrounding environment is kept constant. Alternatively, the steady-state temperature would be lower on substantially Slat conductors (versus round conductors) if” the 90 current flow is maintained constant and all other factors remain the same

Further, it may be preferable for the wire to have a thickness ratio of about 1 or m_ore.

That is, the first and second return conductors may each have a thickness Tg, and the firs€ and second grounding conductors each have a thickness Ty, and the Electrifiable conductor has a thickness Ty, such that a ratio, R, of thuicknesses R = (Tg + Tw)/Tw is about 1.00 or more (8. it may be preferable that R is maximized).

Another aspect of the present irxvention includes an electrical wire including at leasst one electrifiable conductor, a first insulating layer formed around the at least one electrifiable conductor, a return conductor formed around (e.g., at least substantially around) the first insulating layer, such that the at least ome electrifiable conductor is at least substantially entrapped by the return conductor, and a second insulating layer formed around the return conductor. The wire may further inclucle a grounding conductor formed around the second” insulating layer, and a third insulating ! ayer formed around the grounding conductor.

This aspect of the wire may include, for example, a wire having conductors e.g» electrifiable conductor, return conductor and grounding conductor) having one of substantizlly curvilinear-shaped cross-sectional geometries and substantially rectilinear cross-sectional geometries, and may be formed in substantially parallel planes. For example, the electrical wire may have a circular or oval cross-sectiom. That is, the electrifiable conductor, the return conductor and the grounding conductor may include substantially circular-shaped conductors (e.g., having a circular cross-section) which are arranged with a parallel longitudinal axes (e=-g., coaxial), or the electrifiable conductor, the return conductor and the grounding conductor maay include substantially oval-shaped conductors (e.g., in the same spatial arrangement).

Another aspect of the present invention includes a method of fabricating an electricall wire, which includes forming at least one electrifiable conductor, and forming first and secorad return conductors on opposing sides of the at least one electrifiable conductor, such that the at least one electrifiable conductor is at leasst substantially entrapped by the return conductors.

Another aspect of the present invention includes an electrical current delivery system including the electrical wire. In addition, another aspect of the present invention is an electrical signal transmission system including the electrical wire. i

With its unique and novel features, the present invention provides an electrical wire and method of fabricating the electrical wire which provides an electrical wire and method of fabricating the electrical which may provide a safe and convenient electrical wire which is easily fabricated. ' )

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing, and other objects, easpects, and advantages will be better understood from the following detailed description of the exemplary embodiments of the invention with reference to the drawings, in which:

Figures 1A-1B illustrate conventional electrical wires 50 and 100;

Figures 2A-2F illustrate various aspects of an electrical wire 200 according to the exemplary embodiments of the present inv-ention;

Figures 3A-3W illustrate various peossible conductor configurations in the electrical wire 200 according to the exemplary embodiments of the present invention;

Figures 4A-4C illustrate an aspect Of the electrical wire 200 having a hot zone 295 according to the exemplary embodiments oof the present invention therein;

Figures 5 illustrates another aspect «f the electrical wire 200 according to the exemplary embodiments of the present invention therein;

Figure 6 illustrates a possible termination configu_rations for the electrical wire 200 according to the exemplary embodiments of the present irvention therein;

Figure 7 illustrates an electrical wire that can Be considered as forming a series

Of capacitors with an equivalent capacitive circuit ac cording to the exemplary embodiments of the present invention.

Figures 8-10 provide schematic illustrations of a typical two plate capacitor, four plate <apacitor and three plate capacitor, respectively, according to the exemplary aspects of the

Present invention; and

Figures 11-12 illustrate how capacitively coupled current may be canceled in the e=lectrical wire, according the exemplary aspects of the pressent invention;

Figure 13 provides a schematic diagram of an exen-aplary configuration for detecting ground loop continuity using the electrical wire, according to the exemplary aspects of the pmresent invention;

Figure 14 provides a conceptual illustration for prowiding split ground signaling, ac=cording to the exemplary aspects of the present invention

Figure 15 illustrates a method 1500 of fabricating ar electrical wire according to the ex emplary aspects of the present invention; and

Figures 16-17 provide exemplary configurations of the electrical wire 200 according to the= exemplary aspects of the present invention.

DETAILED DESCRIPTION OF EXEMPLARY

EMBODIMENTS OF THE IN VENTION

Referring now to the drawings, and more particularly to Figures 2A-1 7, the present 11

AMENDED SHEET imvention includes an electrical wire 200 andl a method 1500 of fabricating the electricall wire.

Mas illustrated in Figure 2A, an the exemplary embodiment of present invention is directed to an eBectrical wire 200 including at least one electrifiable conductor 210, and first and secon d return conductors 22 1 which are respectively formed on opposing sides of the at least ones ele=ctrifiable conductor 2 10, such that the at le=ast one electrifiable conductor is at least substantially entrapped by the first and second return conductors 221. The wire 200 may also include a first insulating layers 215 and second insulating layers 225.

It should be noted that unless otherwise noted, any of the layers (e.g., conductors, inswilating layers, etc.) in the present invention and discussed herein may be formed of a pRurality of layers. Thus, for example, insulating layer 215 should be construed as at least one insulating laye=r 215, an electrifiable conductor should be construed to mean at least one (e.g. a plurality of) elec-trifiable conductors, and so on,

The electrical wire may be used for a basically unlimited range of voltage applications (e.g. 0V 10240 V and higher). For example, the wire may include a Class 1 or Class 2 capability and other low voltage/current capabilities, and may be used for commercially available utiliaty voltages such as 120V AC and 240V AC, and may be used for other applications other than

Class 1or Class 2, or these commercially availab le voltages,

As illustrated in Figure 2B, the electrical wire 200 may have a longitudinal (e.g, length~wise) direction, L, and a transverse (e.g., widthwise) direction, W. These directions maay also bes referred to as a horizontal dimension of thes wire. The wire may further be considered ag having athickness (e.g., a total thickness of all of the stacked layers) which may be referred tow as a vertical dimension. 12

AMENGED SHEET

The wire 200 may also include terminal peortions (e.g., terminations) (e.g., not illustrated in Figure 2B) formed at the ends of the wire 200 —in the longitudinal direction. For example, onee end (e.g., terminal portion) of the wire 200 may be connected to a source module (e.g., power source, voice/data transmission source, etc.) and the other end (e.g., terminal portion) may be connected to a destination module (e.g., switch, omutlet, electronic device, etc.). It should be notexd that the present invention does not necessarily include any particular form termination (e.g., current source, earth ground, etc.) but may include= a longitudinal portion of wire formed betwee two termination points.

As further illustrated, the first and second return conductors 221 are formed such that the 1O at least one electrifiable conductor is at least substantially entrapped (e.g., enveloped, surrounded, encased) by the first and second returns conductors. By “substantially entrapped” it is meant that for all practical purposes, the electrifialole conductor 210 cannot be contacted with a foreign object (e.g., a nail, screw, staple, etc.) without first touching the one of the return conductors 221. The term “substantially entrapped’™ does not necessarily mean that the return conductors 22] completely surround the electrifiabl e conductor (although such a design is possible). Instead, it means that any distance betweeen the return conductors and the electrifiable conductor (e.g., the thickness of an insulating layer Exetween the electrifiable conductor and a return conductor) is so small (e.g., about 0.030” or less) that such a foreign object cannot reasonably go between the return conductors and the electrifiable conductor without touching the return conductors.

For example, as illustrated in Figure 2B, the electrical wire 200 may be formed of layers (e.g., substantially flat layers) having a stacked configuration. At least some of these layers (e.g. 13

AMENDED SHEET return conductor 221, insulating layers 215, 225) may be brought together (e.g. . , mated together by crimped, bonded, etc.) along time longitudinal edges, T, of the wire 200.

It is important to note that there may remain a distance, S, between the return conductor layers 221. That is, the electrifiable conductor 210 does not have to be completely entrapped by the return conductors 221. The iraventors have determined that so long as any distance between the return conductors and the electrifiable conductor (e.g, the thickness of an —insulating layer between the electrifiable conductor and a return conductor) is sufficiently smamll (e.g., about 0.030” or less) an object cannot 1ikely penetrate the wire 200 and contact the Electrifiable conductor 210 without first contacting the return conductor 221.

Further, the electrifiable conductor is at least “substantially entrapped™> along the longitudinal portion of the wire. That is, at the terminal portions of the wire 2200, the electrifiable conductor may be exposed and n_ot entrapped, for connection to a device (e.g, a source or . destination module).

Tt should also be noted that the term “Electrifiable” is intended to mean having a capability (e.g., purpose) of connecting to a source or electrical current and caamying (e.g, delivering) an electrical current or electrical signal (e.g., an AC or DC power - supply or an electrical communication signal such as a voice or data transmission signal). An Electrifiable : conductor may be referred to as the “non-return conductor”. An Electrifiable conductor may also be referred to as a “hot conductor”. Further, the term “return” is intended to mean having a purpose of returning an electrical current (e.g., not having a purpose of deliveering an electrical current or electrical power supply to a load). A return conductor may also be= referred to as a grounded conductor or a neutral. conductor.

Specifically, an “electrifiable” > conductor may be considered any conductor within the “hot zone” as defined herein. The elescirifiable conductor (e.g. a conductor in the hot zone) may be the “hot” conductor in operation taut not necessarily. For example, with regards to a 3-wvay switch, the electrifiable conductor (€-g., 8 conductor in the “hot zone”) may in one condition, act asa hot conductor, but in another comdition act as a ground conductor.

In addition, the term “ground ing” is intended to mean having a capability or purpose of connecting to “earth ground”. A gro-unding conductor may also be referred to as simply a “ground conductor”. The grounding: conductor is not intended to have any return current ©n it.

Further, the term “conductor” is defi ned to mean a conductive medium which is capable oof carrying an electrical current.

Figures 2C-2D illustrate another exemplary embodiment of the present invention. In the exemplary aspect which is illustrated in Figure 2C, the electrical wire 200 includes at least one . first conductor 210 which is Electrifiiable, at least one return conductor 221 and at least ore grounding conductor 222.

In this aspect, the wire 200 nay also include a first insulating layer 215, a second : insulating layer 225, and a third insualating layer 230. As illustrated in Figures 2C, the first insulation layer 215 may be formed between the at least one Electrifiable conductor 210 and the at least one return conductor 221, th-e second insulation layer 225 may be formed between the at least one return conductor 221 and t'he at least one grounding conductor 222, and the third 70 insulation layer 230 may be formed on the at least one grounding conductor 222.

Figure 2D illustrates an expl oded view of an exemplary aspect of the electrical wi re 200.

As illustrated in Figure 2D, the concluctors of the electrical wire 200 may have a stacked arrangement. The electrical wire 200 may also include =an adhesive 290 for bonding adjacent insulation layvers and conductors in the electrical wire.

It shosuld be noted that the drawings are intendec to be illustrative. In the actual electrical wire of the p-resent invention, there may be no visible spacings (e.g., the white areas in Figure 2D) between. the conductors, insulation, and adhesives ecomponents, each of which is describe d further belovev.

Figures 2E-2F illustrate additional exemplary aspects of the electrical wire 200. For example, in tthe exemplary aspect of Figure 2E, the con_ductors 210, 221, 222 may include substantially~ circular-shaped conductors (e.g., coaxiallse/ arranged). In the aspect of Figure 2F the conductors 210, 221, 222 may include substantially ovaal-shaped conductors.

In ge=neral, the electrical wire of the present inveention (e.g., protective layered wire) provides an -alternative which can be applied in a variefity of ways and in a variety of locations and represents a paradigm shift for all other electrical wire systems. The electrical wire may incluade protective lanyered wire which can have conductors with a parallel longitudinal axis (e.g., conductors Inaving a curvilinear cross-section), or the vevire may be substantially stacked in nastwre, such that eacch conductor has a substantially parallel pleane (e.g., parallel axis). However, the conductor cross-section is not necessarily coincidental (e.g., concentric) or coaxial.

For example, in one aspect, an inner (hot) conductor is surrounded or bounded by an insulator, theen an intermediate (neutral) conductor, a se=cond insulator, then an outer (groundi ng) conductor, aand an outer insulator.

The «exemplary embodiments of the electrical waire can have cross-sectional shapes ranging frormn a substantially curvilinear geometry such _ circles (e.g., concentric circles), ovals.

ellipses, or flat (e.g, linear or rectilinear) layers. The concentric format (e.gg., Figure 2E) (e.2-» major and minor axzes approximately equal) is symmetric with an innermosst conductor (e.g, hot/Electrifiable) having relatively small surface area. The oval or ellipsoied format (e.g., Figure 2F) (e.g., major ancl minor axis unequal) supports a relatively flat innermosst conductor. The flat format (e.g., Figures 2B-2D) (major axis = 1, minor axis = 0) supports all lat conductors and insulators (e.g., mualti-planar flat conductor wire).

The exemp lary embodiments of the electrical wire may offer differ-ing advantages regarding safety, agpplication methodology, cost, and ease of manufacture. The concentric and oval formats may Ihave exceptional safety aspects (e.g., a very low penetra—tion hazard). Whereas, the flat format has an exceptional current carrying capability due to a large surface area of each conductor and would likely trip any safety disconnect device (e.g., breakem, GFCI, etc.) in any : case of penetratiora. Further, the use of the electrical wire (e.g., protective layered wire) is : . advantageous from a number of points of view including safety, electrical interference shielding, and flammability.

Regarding the risk of electrocution, the inevitable issue centers around penetration of an electrified conductor (e.g., an electrifiable conductor) by objects such as mails, screws, drill bits, etc. Traditional im-wall and in-ceiling wiring has the potential for penetra tion by any of the aforementioned objects with a possibility of electrocution as a result.

Although the electrical wire of the present invention may be surfaece mounted (e.g.,on a wall or ceiling, or on a floor such as under a carpet) it has the distinct adv-antage over conventional wire by assuring that the penetrating object first passes throvagh at least one non-

Electrifiable cond=uctor (e.g., a return conductor and/or a grounding conductor) prior to any contact with the Electrifiable (e.g., hot/innermosst) conductor. Thus, as the penetration mostion proceeds, high currents on hot through the groumnd and neutral are generated causing a circ=uit breaker to expeditiously trip.

Specifically, with respect to this penetration dynamics solution of the electrical wisre (€.8-» stacked electrical wire), to reduce the chance for electrification of a penetrating object, cosnductor thickness of the Electrifiable conductor (e.g., mot conductor) should be low (e.g., as low ams possible) relative to the total thickness of the osuter layers (e.g., grounding conductors and return conductors). A good layer thickness ratio, R, ©f 1 .00 has been demonstrated through test. results, whereby R = (Tg+Tw)/Tu = 1.00, where Tg, Thy, and Ty are the conductor thickness of thes

Grounding, Grounded, and Electrifiable conductors, respectively, and R is the Layer Thickness

Ratio. For example, in one exemplary embod#ment, the thickness of the grounding and return conductors was 0.001”, and the thickness of tte Electrifiable conductor was 0.002, such —that the ratio R = (Tg*+Tn)/ Ta = (0.0017 + 0.0017)/0.0802” = 1.00.

Further, in the penetration dynamics off the electrical wire, the opposing Grounde dand

Grounding layers may also contribute favorab_ly to the ratio, R, resulting in a safer condition. It has been shown that the higher this ratio, R, iss, the safer the wire is during a penetration witha conductive object such as a nail.

During the short circuit, the electrical —wire may act as a voltage divider from the source to the point of penetration. The layer thickness raatio produces a ratio-metric scaling of the woltage that is applied from within to the penetrating object. Therefore, the safer condition resul#s from the lower voltage at the nail, etc.

During a penetration to increase the pr-obability of actuation and to decrease the actuation timee of a safety device (e.g., circuit breaker, circuit in-terrupter (e.g., GFCI) or other safety disconnect device), the conductor thickness of the outzer (€.g-» grounding and return conductors) layeers must be substantial enough to cause a reliable short circuit at the point of pene®tration. The short circuit must result in high currents that cause thee safety devices to trip at their feastest response time. This results in a safer condition based on time. The combination of leower voltage anc shorter time produces a significantly safer condition than either condition by itse1f.

At the point of penetration, after the safety de=vice has removed from the poweet supply, it car be assumed that all layers remain in a relatively 1 ow resistance relationship. This is due to the presence of the penetrating object and/or the insulatieon displacement damage of the warious layers. Furthermore, the flashpoint of the penetration may cause somewhat of a melded or fused area in the perimeter of the penetration. With repeate=d application of power into the damaged area, the perimeter may increase (e.g., especially if tine penetrating object has been removed) in size but sufficient resistance will be residual enough to repeat reactivations of the sa—fety device upeon being reset.

The way to avoid repeated application of povver into the damaged area could be to have a cim-cuit within an Active Safety Device (ASD) that can detect a substantially shorted return to grounding conductors prior to applying power to thes electrical wire. This feature capability is supported by the design of the electrical wire.

Therefore, the electrical wire (e.g., protective layered wire) of the present inwvention can bes considered inherently safe with a circuit breaker or fuse. In addition, the safety c.an be further inmproved when the wire is used in conjunction with_ a safety device (e.g., circuit bre=aker, circuit in-terrupter (e.g., ground fault circuit interrupter (GF CI) or other safety disconnect device).

The exenxiplary embodiments of the present invention also provide advantages with respect to other electrical safety issues, such as frayed insulation allowiing incidental contact and possible electroczution are better solved by the exemplary embodiments= of the present invention (e.g., protective layered electrical wire) in that it may include three laye=ts of insulation between the hot conductor and the outside world (in any direction). This is com-monly referred to as "triple- insulate" as opposed to contemporary double-insulated conventional wire.

Regardirg electrical shielding, the outer grounding layer of the electrical wire of the present invention (e.g., protective layered wire) may provide a shield vvhereby power transmission sigznals or load-generated electrical noise cannot pass through the cable to interfere with broadcast ssignals or to cause "hum" in audio equipment.

In additi-on, regarding flammability, the electrical wire of the psresent invention offers several advantages over conventional electrical wires and wiring systems. Specifically, the electrical wire oef the present invention may provide a relatively large ssurface area for dissipating heat. Thus, the outer conductor(s) (e.g., return and grounding conduct-ors) may easily conduct heataway from film insulation being heated from an external source, reducing the risk of fire caused by the hesat. Further, the rate of heat transfer may exceed the ccombustion rate, thus quenching a loc alized combustion area.

Additioral "layers of protection” can be added to the electrical wire of the present invention. For example, in addition to an electrical wire (e.g., protective layered wire) and circuit breaker configuration, a GFCI, arc fault detector, and specially developped "active safety devices” may also be included and used with the electrical wire to further reduc=e the probability of shock, electrocution or - fire.

In addition, since the Electrifiable conductor in the pressent invention may be provided between (e.g., within) the return and grounding conductors, thes return and grounding conductors and the insulation layers may provide abrasion protection for thae Electrifiable conductor. That ms, the layers formed on the electrifiable conductor (e.g., insulation layers, return conductor and grounding conductor™) may inhibit abrasion of the Electrifiable conductor such as when a wall (gor ceiling) on which thes wire is mounted is sanded with sandpaper or any other abrasive.

Further, the electrical wire of the present invention may include a flat, flexible, wire thast allows the user to br-ing electricity to any area of a wall or ceil-ing in a room. The electrical wire= may be very thin (e.g., having a total thickness of no more tham 0.050 inches) and can be mounted to the surfemce of the wall, ceiling or floor (e.g., using an adhesive), thereby eliminating the need for costly imaner wall, ceiling or floor rewiring. The wvire may also be painted or paper—ed over to match the re- st of the surface.

Each of the conductors in the electrical wire of the present invention may include one Ora plurality of conductive layers (e.g, conductive copper, alumirium or other conductive material layers) which are ea_ch about 0.0004 to about 0.020 inches thi <k, and preferably on the order off about 0.001 inches ®hick or less.

The conduct=ors may be formed of a variety of materials and have a variety of patterns, dimensions and spascings. For example, the conductors may oe formed of an electrically conductive material such as metal (e.g., copper, aluminum, si lver, other conductive materials, etc.) polysilicon, cesramic material, carbon fiber, or conductiwe ink. Further, the conductors mazay be very thin.

The conductor thickness should be consistent across i_ts length and width, thereby eliminating any resistance "hot spots". The current carrying specifications of a particular application may be accomplished in any of three ways, either individually or in combination.

First, the width of the conductors may be varied. Second, additional thin conductive layers (€.8.» copper, aluminum or other conductive material) may be stacked for each conductor. Third, the thickness of the conductor may be increased. :

For example, in one exemplary load and current application, each conductor may include about two conductive layers (e.g., copper, aluminum or -other conductive material layers). It is understood, however, that utilizing more or less layers, for each of the below disclosed embodiments, is within the scope of the invention.

The insulating layers in the electrical wire may t»e formed of a variety of materials. For example, the insulating layers may include a polymeric mmaterial (e.g., polypropylene film, polyester film, polyethylene film, etc.). Further, the insvalating layers may have a thickness, for example, in a range of 0.00025 to 0.030 inches.

The insulation layers formed between the conductors may also orient the conductive layers. In addition, the insulation material may be used alone, or in combination with the internal adhesive, to separate the conductors and maintain a safe distance between conductors of different purposes (e.g., grounding vs return or Electrifiable (e.g.,. hot). Further, the electrical wire may have tapered edges (e.g., tapered in a transverse width direction) to facilitate the optical occlusion (e.g., when mounted on a ceiling or wall). For example, the layers (e.g., conductor layers and/or insulation layers) may have different widths to facilitate such a tapered edge.

It is understood that additional insulative materieamls are considered to be within the scope of this invention and maybe used so long as the insulation is compliant, paintable, and bondable to surfaces, The insulation should also be compatible with concealing (e.g., 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 applie=d in the faBorication process, not retract or relax under storage conditions, and be removable whe=n its use is completed. Any abrasion, cracking, cutting, pdercing, or any other insulation damage (e.g., darnage that would render an unsafe exposure to bodily harm or damage, or physical or construction damage, such as to a structure) will be mace safe using electronic means of failumre detectiorn that will disconnect potentially harmful or darnaging currents from the user in a time frame that will prevent permanent harm.

Further, adhesive material 290 (e.g., Figure 2D") should be able to bond to the insulatieon layers an=d the conductors. For example, adhesive tape, Riquid adhesive, thermal adhesive, pressure—sensitive adhesive or UV sensitive adhesive or a combination of any such adhesives or adhering methods, may be used as an internal adhesive. The internal adhesive material may al=so function to separate the conductive layer groups and ma intain a safe dielectric distance between conductomrs of different purposes.

An external adhesive layer may also be formed on the outermost insulating layer of thes electrical wire, for adhering the wire to a desired surface. The external adhesive layer could be=, for examgple, two-sided tape, with one side being fixed teo the back of the wire and the other to the wall (or ceiling) or surface. Alternatively, a chemical adhesive may be applied separately, and may conszist of any of the adhesives with good bonding qualities to both the insulation layer an_d the desire=d surface to which the wire is adhered. Insulati ng layers may also be joined by mechanical deformations and thermal fusing withou t the addition of any adhesive.

Referring again to the drawings, Figures 3A- 3W illustrate cross-sectional views of possible configurations of the electrical wire 200 according the exemplary aspects of the present invention (for simplicity, the insulating layers are not identified in Figures 3A-3W).

For example, the wires of F igures 3A and 3M are similar to the wires of Figures 2B and 2C, respectively. As shown in Figures 3B, 3E and 3NJ, the conductors may have a staggered arrangement and may include non-uniform widths (e_ g., in a transverse direction).

As illustrated in Figure 3C, the conductors (e. 28, hot conductor 210) may be folded over onthemselves Further, as illustrated in Figure 3D, another conductor (e.g., return conductor 221) may be folded over a folded conducto-r (e.g., Electrifiable conductor 2 10).

As illustrated in Figure 3F, the conductors macy be treated (e.g., thermally , chemically or mechanically) or bonded by some manner on a side. For example, in Figure 3F, an upper conductor 222 is joined (e.g., by stitching, seam weldi_ng, chemical bonding, or other mechanical means) to a lower conductor 222. This may be used to provide a more protective barrier along the longitudinal edges of the electrical wire, making it more difficult for an object to penetrate the electrical wire and contact the electrifiable conduct or from such longitudinal edge.

Figure 3G-31 illustrates a wire in which a conduactor 210 has a round shape, whereas conductors 221 and 222 are wave-shaped or substantial ly flat. Further, F igures 3J-3L illustrate a wire in which the conductors may each be bent such that they are formed in more than one plane.

For example, in Figure 3J, the conductor 221 has a bent: configuration for substantially surrounding the conductors 210.

Figures 30 and 3S illustrate a wire in which a cawnductor 210 has a substantially oblong 24

AMENCEDS SHEET

(e.g., oval) shape, whereas the other conductors 221, 222 may be substantially-flat or be=nt. In

Figures 3P-3R, and 3T, some of the conductors may be substantially-flat and other of thae conductors may be formed around (e.g., partially around) the flat conductor. . Further, a=s illustrated in Figures 3U-3W, the conductors (e.g., conductors 210 in Figure 3U) may toe bent around each other in an interlocking manner.

Figures 4A-4C illustrate another exxemplary aspect of the electrical wire accorcling to the present invention. These drawings describ e the “hot zone” which is an important concept introduced by the present invention. Specifically, the “hot zone” may be considered a=s a zone which is at least “substantially entrapped” by a return conductor. As illustrated in Figure 4A, the hot zone may include layer segments arrarnged in any horizontal and vertical format, d.epending upon the application(s) of the electrical wire.

For example, Figure 4A illustrates a cross-sectional view of a general case for= a conductor orientation. It should be noted that the insulating layers (and adhesive) are= not shown in Figures 4A-4C for simplification.

As shown in Figure 4A, the electrical wire 200 may include grounding conductors 222 and return conductors 221 formed on opposing sides of (e.g., above and beneath) the hot zone 295. Moreover, in the hot zone 295 is included “M” vertical segments, and “N’* hor zontal segments of Electrifiable conductors. More specifically, the hot zone 295 may include segment (1,1) 296, through segment (1,M) 297, ard segment (N,1) 298 through segment (M,IN) 299. It should be noted that M and N are not particularly limited.

In addition, an application of the wire according to the exemplary aspects of the present invention may include transmission of electrical communication signals such as voiece and data transmission signals, For example, the wire may be useed as part of power line carrier (PLC) communication system in which the wire (e.g., a portion: of the wire) is used to provide AC electrical power, and is also used (e.g., a portion of the wire is used) as a network medium to transmit voice and/or data communication signals. Thuss, the wire may be used to provide high speed network access points wherever there is an AC ele=ctrical outlet.

Specifically, the wire may transmit electrical communication si gnals during the time proximity of zero-crossing of an AC power supply. In acldition, there can be many different types (e.g., formats) of communication signals transmitte=d by the wire including RS485, HDTV", etC., according to the present invention.

For example, as illustrated in Figure 4A, the electrical wire 200 may also include a portion 450 which may be reserved for an electrical signa_l (e.g., a communications signal) in addition to an electrical power being supplied elsewhere by the “hot zone". For example, the -conductors in this reserved portion 450 may include pattemrned conductors such as those describe.d in McCurdy, et al., U. S. Pat. No. 6.688.912 (NON—-UNIFORM TRANSMISSION LINE

AND METHOD OF FABRICATING THE SAME) which was filed on May 28. 2002 and pub lished on December 4, 2003 which is commonly assigned with the present Application and is incorporated by reference herein. Further, the wire 200 may include a plurality of su_ch portions 450 which may each be «dedicated to carrying the same or different types (e.g., formmats) of communication signals.

It should be noted that the electrical wire accordingz to the exemplary aspects of the present invention may be used for transmitting communica_tion signals independently of any e=lectrical current. That is, the Electrifiable conductors may~ be dedicated entirely to ¢ ommunication signals or entirely to an electrical power sugpply. 26

AMENDED SHEET

For 3-vevay switching of lights there may be a nee=d for two conductors in the hot zone that a will alternately~ be switched from return to electrified (e~g. neutral to hot). Figure 4B illustrates two possible ermbodiments to accomplish this with the present invention.

For exa_xuple, the first embodiment (on the left) i ncludes return conductors 221 and grounding wire=s 222. In addition, this embodiment includes two Electrifiable conductors 21 0 which are subs®antially co-planar in the hot zone 295. T he second embodiment (on the right™) is similar to the fi: rst embodiment, except that the Electrificable conductors have a stacked arrangement.

Tt should be noted that the first embodiment prov-ides an electrical wire with a smallest thickness (e.g., “thinner), whereas the second embodiment provides a electrical wire having a smaller width (e=.g., narrower). As noted above, the exemplary embodiments of the electrical wire may be use=d for a basically unlimited range of volta_ge applications (e.g., 0V t0 240 V ard higher). For exzample, the wire can be used to supply 2-p hase power such as standard 240V MC.

Further, Figure 4C illustrates an electrical wire 2080 according to another exemplary aspect. Asshowen in Figure 4C, the electrical wire 200 m ay include a “N” plurality of horizoratal stacks 460, each stack baving “M” Electrifiable conductomrs 210.

This aspe=ct may be used, for example, for multiples branch circuits. It should be noted ®hat the horizontal segzments may share a common insulator be=tween layers and on the outside of tae grounding conduectors 222.

Referring again to the drawings, Figure 5 illustrate=s another exemplary aspect of the electrical wire 2080 of the present invention. (Note that the= wire of Figure 5 is similar to that in_

Figure 2D). As sh_own in Figure 5, the electrical wire 200 ray include 14 AWG (e.g., American

Wire Gauge) electrical wire. For example, an adhessive 290 may be included as illustr-ated.

Further, the wire 200 may include insulatings layers 215, 225 and 230 which ar«e formed of polyester and which are 0.001 inches thick, fully annealed. The wire 200 also include=s conductors 210, 221 and 222 which are formed of ¢ opper (or aluminum or other conductive

S material) CDA 102 or CDA 110, having a thickness of 0.001 inches.

As is evident from Figure 5, the widths of tae layers vary. For example, the conductor 210 has a width of 1.620 inches, whereas conductor=s 221 and 222 have a width of 1.7 50 inches.

Insulating layer 215 has a width of 2.000 inches, inssulating layer 225 has a width of 2-250 inches and insulating layer 230 has a width of 2.500 inches.

The electrical wire according to the exempleary aspects of the present inventior may include a longitudinal portion formed between two sterminal portions. Figure 6 illustr=ates possible terminations for the electrical wire 200.

The line side 610 in Figure 6 is where power originates and the load side 620 i_s where it is delivered. The line side power may typically origsinated via a common receptacle owr other source (e.g., a conventional source). Termination te=chniques (e.g., at either end of the= wire) can. include soldering, crimping, surface contact, clamping and insulation displacement.

With respect to the line side terminations, a mmale plug placed in the receptacle with a tail of power cord can be terminated within the line side= termination box 615. In this case=, the box may be mounted on the wall (or ceiling) near the ountlet receptacle. Further, the termimmation box can be a “source module” as a mechanical interface ~to an active safety device (ASD), which plugs into the outlet. In addition, the termination bo~x can reside over the outlets and pelug into an outlet (receptacle).

With respect to the load side terminations, & set of three “flying heads” or conventional wires may be provided for the user to cut-to-length and terminate as needed (&.g., sconce lights, ceiling fans, etc.). Further, a terminal strip mounteed on a small printed circuit board that is attached too the wire can provide screw terminals to the user. In addition, the load side terminatiomn (destination) box 625 can include outle=ts of its own for the user to plug.

Aneother aspect of the wire according to the exemplary aspects of the present inventiorm, is that it may provide a capacitance solution. That is, ®the capacitance resulting from the

ElectrifiabMe conductor which may be in close proximity to the return conductor, may represerata reactive current in superposition with any load current. This capacitance is charged based on the applied vol tage (e.g., AC or DC). Since the return —onductor has a low voltage relative to the

Electrifiabl_e conductor, very little charge will be acecumulated within any capacitor formed between thes return and grounding conductors.

Spe- cifically, the electrical wire (e.g., layered! FlatWire) can be considered as forming a series of cagpacitances (e.g., capacitors) with an equivalent circuit (e.g., capacitive circuit) as illustrated imn Figure 7. As shown in Figure 7, the ele=ctrical wire 200 including an Electrifiable= conductor 2: 10, grounding conductors 221 and grounmding conductors 222 may form capacitors

C1, C2A and C2B.

In this case, capacitor C1 is a parallel plate ceapacitor formed by the return conductor 2221 (e.g., neutral layer(s)) in close proximity to the Electmrifiable (e.g., inner (hot)) conductor 210.

Capacitor C22 is formed by return (e.g., neutral) condwuctor 221 and grounding conductor 222 in close proxin-aity.

With respect to the impact of the capacitors CZ1 and C2, it should be noted that capacitor

C1 (C1A/C1B) may~ cause a current to flow between the Electriffiable conductor (e.g., FlatWire hot) 210 and return conductor (e.g., FlatWire neutral) 221 via thee dielectric (and any air that pay be present with the absence of adhesive) formed therebetween. WM hus, it can be seen that any alr that remains trappeed between layers after the final fixation (e.g. concealing compound, wallpaper, paint, etc.) of the electrical wire 200 (e.g., FlatWire) may cause a dramatic reduction in capacitance due to air’s low dielectric constant (€ = 1.0). As the longitudinal (e.g., lengthwise) distance of the wires increases, a significant capacitance in the eMectrical wire 200 (e.g, AC

FlatWire) can be careated and, therefore, relatively large currentss can be produced.

Further, the= current from capacitor C1, being on the rettxm (e.g., neutral) conductor 221 and Electrifiable (e.g., hot) conductor 210, represent a balanced load current to H-N CTs (e.g5., return current flows minus hot current flow is zero) and therefore are not considered to be a problem regarding: line source GFCI false tripping. In case the capacitive current on return and

Electrifiable conduictors (e.g., neutral and hot) should become &2 problem, a “cancellation” cimcuit may be implemented to null out the current.

Further, ca_pacitor C2 (C2A/C2B) will not cause a signi” ficant current to flow between the return (e.g., neutraml) conductor 221 and Electrifiable (e.g., hot) conductor 210 (e.g., FlatWire neutral and FlatW-ire Gnd) since the voltage differential is typiecally less than 1 volt. Further, as noted above, in case the capacitive current on the return and EM ectrifiable conductors, (e.g,. neutral and hot) ewer become a problem, a “cancellation” circumit (e.g., a circuit having an inductance) may be implemented to null out the current. : Referring again to the drawings, the capacitance value of the capacitor C1A may actwally be derived from a_ parallel plate capacitor model. Figures 8-10 illustrate a typical two plate capacitor, four plate capacitor and three plate capacitor, respectively, where P idemtifies the capacitor plates, and. D identifies the dielectric between the capacitor plates.

The parallel -plate capacitance, C, (¢.g., as indicated by a capacitance meter, C meter) may be given by C = eA” d, where the dielectric constant of the dielectric, D, between the conductors is given as £ = o*Eix , where A is the area of the plate capacitor, d is the distance between plate surfaces, £0 is the d_ielectric constant (e.g., permittivity) of free space, and er is the relative permittivity of the clielectric material.

Thus, as illustrated in Figure 8, for a two plate capacitor, the area, A, of the parallel plate capacitor is given 2s A= LsW, and where L is the Length of the plate, W is the width of the plate, and as illustrated imn Figure 9, for a four plate capacitor, the area, A, is given as A=1LeWe2

Figure 10 shows the wiring/configuration of a 3-plate capacitor stack th at emulates the electrical wire 2000 (¢.g., electrical FlatWire) with shorted shields relative to each Electrifiable (e.g., inner) condumctor. It should be noted that the configuration of Figure 10 may be derived by climinating 1 plates (e.g., conductor) and 1 dielectric separator (e.g., insulating ayer) from the structure shown im Figure 9. ,

Further, ass illustrated in Figure 10, the area A of the plate capacitor is given as A=WeLsk, where the plate multiplier constant, k, is actually the number of plates (n) divided by 2. Thus, for a three plate capa_citor, the constant k = 1.5.

Therefore=, for the electrical wire (e.g., stacked electrical FlatWire) the capacitance for the capacitor formed between the Electrifiable conductor and its two adjacent retum conductors (e.g, layers), is given @asC =g(W-L*1.5 Yd, or C= 1.5 +W sL »&/d.

It should be further noted that the capacitance value calculated using the above equation tums out to be wo-xst case since the conductors (e.g., layers) are not necessarily in full contact with each other. Air spaces and gaps where no adhesive is presen-t produce larger values of “4” thus causing smaller values of capacitance. This capacitance may vary based on the percent of surface adhesion between layers and the amount of compressive force that may be applied to the outer surfaces of the electrical wire (e.g., FlatWire)

Referring again to the drawings, Figures 11-12 illustrate how capacitively coupled current may be canceled in the electrical wire according the exe=mplary aspects of the present invention. Specifically, Figure 11 illustrates the case where thes electrical wire 200 having an

Electrifiable co-nductor 210 and two return conductors 221, is terminated at an active safety device (ASD) or source module 1100.

In this «case, the capacitively coupled current, CC, can “be represented as shown in Figure 11. Since the return conductor (e.g., neutral) is not sigificantlsy electrified (e.g., low AC volts) it has little impact on current coupled to the shields. The Electr fiable conductor (e.g., hot) 210 however, is highly electrified and is coupling capacitive currents into the ground conductors 22 1 (e.g., neutrals) throughout the length of the electrical wire (eg, flatwire).

Figur € 12 provides a capacitive current cancellation cliagram which illustrates how a cancellation circuit might be used to produce a net zero curr-ent on the Electrifiable conductor 210 and grownd conductors (e.g., hot and neutral conductors) regarding capacitance. As illustrated ira Figure 12, the cancellation circuit 1200 may b eincluded as part of or used in conjunction. with an active safety device 1100.

Specifically, the current, I after application of the cancellation circuit 1200 may be guven by Ii=ha + In —Ic, where In and Ix, are the current on th_e return conductors 21 , and Icis tthe oo 32 cancellation current (e.g ., provided by the cancellation circuit). For example, I may be 0mA.

Another aspect Of the electrical wire according to the exemplary embodiments of the present invention, is a tei-directional nature of the “shielding” capability of the groundingx (e.g outer; earth ground) comductors. For exaraple, as noted above, the at least one groundings layer

S inhibits power transmission signals and load-generated electrical noise from being ransferred/emitied fromm the electrical wire. In addition, the shielding provided by the grounding conductors prevents immgress of externally generated electrical noise onto either the return or

Electrifiable conductosrs, which is also a valuable feature.

Also in the interest of safety and communications regarding grounding layers, the two or more grounding cond uctors 222 (e.g., isolated (outer) grounding layers) in the electrical wire (e.g., stacked arrangement) provide an opportunity to send a communication type sign_al longitudinally to the other end of the grounding conductor 222, through a wired “jumpper” at the destination “module™" and returned longitudinally to the source. This may be used to provide, for example, a “ground loop continuity check”.

Thus, the electrical wire may provide the ability to check for continuity by an_ “Active

Safety Device” prior to electrifying the Electrifiable conductor or segments of the El-ectrifiable conductor. One practical application for this feature is for providing safety while an electrician terminates exposed. destination ends of the electrical wire.

Figure 13 provides an schematic diagram of an exemplary configuration for detecting ground loop continuity using the electrical wire. As illustrated in Figure 13, the grounding conductor 222 and opposing grounding conductor 222 may be considered as part of a closed loop between a source 1310 and destination 1320.

The wire may also accommodate additional communication tasks such as providing a transmitting current transformer (CT) and a sensing current transformer= (CT). A periodic signal, which may be (e.g., preferably) greater than AC line frequency, may be- injected onto one of the grounding conductors 222 while the opposed grounding conductor 222 is sensed for signal return viathe sensing CT.

Figure 14 provides a conceptual illustration for providing split ground signaling where the electrical wire is disposesd between a source module (e.g., current teap) 1410 and a destination module 1420, which may transmit and receive electrical signals proces-sed by transmit and receive electronics. The twe or more return conductors 222 (e.g., isolamted (outer) grounding layers in the stacked or lateral (planar) arrangement) can be further split or separated transversely to provide an opportunity to send a communication type signal longitudinally and differentially between the split conductors.

Referring again to the drawings, Figure 15 illustrates a method 1500 of fabricating an electrical wire according to the exemplary aspects of the present inven—tion. The method 1500 includes forming (1510) at least one electrifiable conductor, forming ( 1520) a pair of return conductors on opposing sid es of the at least one electrifiable conductor, such that the at least one electrifiable conductor is at least substantially entrapped by the reCum conductors.

Specifically, the coraductors in the electrical wire (¢.g., the Electrifiable, return and grounding conductors) may be formed of a substantially conductive m_edium, and may include, for example, copper, alumimum, steel, silver, gold, platinum, nickel, tin, graphite, silicon, an alloy including any of theses, conductive gas, metal, alloy metal. That is, the conductors may include any material that is able to transfer electrons regardless of effieciency in doing so. This is true as long ass the relative ability to transfer electrons in the * conductors” is substantially better than the “insu”lators”.

Furthe=r, the insulating layers may be formed of substamntially non-conductive mediums (“insulators”), and may include, for example, a material that Sis organic, inorganic, composite, metallic, carbwonic, homogeneous, heterogeneous, thermoplasstic (e.g. poly-olefin, polyester, polypropylen_e, polyvinyl chloride (PVC)), thermoset, wood, paper, anodic formation, corrosive layer, or othe=r.

The ionsulating layers can be made of any material theat is ratiometrically less (e.g. proportional Ry less) able to conduct electricity than the conductors. A distinguishing feature of the insulating layers (which determines the implied ratio), iss that their size, shape, and dielectric strength are -independent variables whose resulting dependamnt variable is the maximum design voltage, between the aforementioned “conductors”, before ssubstantial current flows through the insulating pmedium due to a break-down of its insulating properties.

The substantial current typically creates a condition that could result in catastrophic failure of thee electrical wire. The insulating layers should bee designed such that in the typical application or intended use of the electrical wire, there is nc break-down between the conductors (e.g., substaantially conductive mediums), through the insulating layers (€.g., substantially non- conductive - mediums).

The electrical wire may be formed by layering (e.g. , laminating) the conductors and insulating lsayers (e.g., substantially conductive and substartially non-conductive mediums (e.g., laminates). Further, laminates including pre-manufacturead materials facilitate bulk rolling.

Mosst electrical wires are made by wrapping flat insulators around the axis of a round wire bundle in the form of a helix. Also most individual wixzes are insulated by having a plasstic PVC sheath extruded around the round wire.

The electrical wire according " the exemplary aspects of the present invention, however, may include a rolled sheet or foil that is slit to the desi—red widths. The same is true of the insulating materi_al. Those conductors and insulators which are processed by rolling te=chniques may then coated with adhesives that allow the dissimilar materials to be bonded to onee another in a continuous fee d process. The slitting may occur before the bonding of the dissimilar materials or after, depending on the geometric configuration. F= or example, in one preferred embodiment of the present irmvention, the insulators and conductors are slit before bonding materials together.

Further, as illustrated in Figure 16, the conduectors 210, 221, 222 may be sealed or encapsulated byw insulation layers (e.g., individual insulation 1620 and/or group insul ation 1630) and adhesive 16550 may be formed between the insul_ation layers 1620, 1630. The in-sulators are bonded to the c=onductors, and overlap the transverse width of the conductors such that insulators may be bondedB to insulators. ‘The mutual bonding beetween insulator materials creat=es a much stronger and peemanent bond, further encapsulating the conductor around the entire cross- sectional periphery.

Any nuamber of insulators may exist betweemn conductors. Insulators for ind vidual conductors may end up, beside one another (back to back). Or there can exist a multi-layer : combination ofinsulators for purposes typically having to do with the connectorizemtion requirements.

In addition, as illustrated in Figure 17, mul#iple insulator groups 1710 (e.g. insulating laminates) which are formed of groups of individu_al insulators 1720 may be place] between any two conductors 210, 221,222. A layer of group insulat=ion 1730 may also be formed around the structure including the insulator groups 1710 and conductors 210, 221, 222.

When layers of conductors are separated by a l=ayer of insulating material, the possibility exists that a defect in the insulating material is present. One such defect, in the case of laminates, isan opening (e.g., a pin hole opening) in the insulatimng material. The opening prevents the intended insulation from occurring and can result in = conductive path in the area of the laminate opening. By placing two laminates or two sheets or ®wo ribbons, (whatever the name for the substantially flat insulating layers), between any twos conductors, the statistical likelihood of positioning two openings (e.g., defects) ina coincident position is substantially minimized.

The individually insulated conductors (e.g., as illustrated in Figures 16 and 17) may be ' formed by placing insulating materials in substantis=ally parallel planes with the conductors, and then bonding the insulating materials to the conductor for fixation. Conductors may be grouped together by group insulation 1630, 1730. The indi~vidually insulated conductors may be joined bey possible adhesive 1650 or alternate methods of comnjoining. This allows the present invention tos provide for an insulated wire whose adhesive or 1=yered configuration allows for the peeling and folding of individual conductors for purposes of termination.

With its unique and novel features, the pr- esent invention provides an electrical wire and method of fabricating the electrical wire that when externally damaged, has a reduced risk of contributing to bodily harm or damage, or property (€.8., structural) damage, over conventional electrical wire.

While the invention has been described -in terms of one or more embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit= and scope of the appended claims. Specifically, one of ordinary skill in the art will undemstand that the drawings herein are meant to be illustrative, and the design of the inventive assermbly is not limited to that disclosed herein but may be modified within the spirit and scope of thes present invention.

Further, Applicant’s intent is to encoxmpass the equivalents of all claim elements, and no amemdment to any claim the present application should be construed as a disclaimer of any interest in or right to an equivalent of any element or feature of the amended claim.

Claims

CLAIMS What i s claimed is:

1. An electrical wire comprising: at least one electrifiable conductor; and first and second return conductors which are respectively form-ed on opposing sides of said ak least one electrifiable conductor, such that said at least one electrifiable conductor is at least substantially entrapped by said first and second return conductorss.

2. The electrical wire according to claim 1, further comprising: first and second insulating layers which are formed between s=aid at least one electrifiable conductor and said first and second return conductors, respectively.

3. The electrical wire according to claim 1, wherein said at least one clectrifiable conductor and s aid first and second return conductors comprise substantially flaat conductive layers having a stack-ed arrangement.

4, The electrical wire according to claim 3, wherein a distance between said at least one elect-rifiable conductor and each of said first and second return conductors is no greater than about 0.030 inches.

S. The electrical wire according to claim 1, wherein said first and second return condumctors contact each other along a longitudinal edlige of said electrical wire, such that said electrifia_ble conductor is completely entrapped by saici first and second return conductors.

6. The electrical wire according to cLaim 1, wherein said first and second return condumctors are treated by at least one of a mechanical , chemical and thermal treatment to form a protective longitudinal edge of said electrical wire, said protective edge inhibiting a foreign object fro=m penetrating said electrical wire and contacting said Electrifiable conductor without contacting one of said first and second return conductors.

7. The electrical wire according to claim 2, wherein said first and second insulating lawyers, contact each other along a longitudinal edgee of said electrical wire.

3. The electrical wire according to claim 7, wherein said first and second insulating layers are treated by at least one of a mechanical, chemical and thermal treatment to form a protective longitudinal edge of said electrical wire, said protective edge inhibiting a foreign object frorn penetrating said electrical wire and contac€ing said Electrifiable conductor.

0. The electrical wire according to claim 2, further comprising: an outer insulating layer formed on said first and second return conductors.

10. Anelectrical wire comprising: -

at least one electrifiable conductor; first and second insulating layers formed on opposing sides of said at least one electrifSiable conductor; first and second return conductors formed on said first and second insulating layers, respectzively, such that said at least one clectrifiable conductor is at least substantially entrapped by said first and second return conductors; third and fourth insulating layers formed on said first amd second return conductors, respectively; first and second grounding conductors formed on said tBhird and fourth insulating layers, respectively; and fifth and sixth insulating layers formed on said first and second grounding conductors, respectively.

11. ~The electrical wire according to claim 10, wherein said first and second return conductors are treated by at least one of a mechanical, chemical and thermem] treatment to form a protective longituclinal edge of said electrical wire, said protective edge inhibiting a foreign object from penetrat-ing said electrical wire and contacting said Electrifiable conductor without contacting one of s-aid first and second return conductors.

12. The electrical wire according to claim 10, wherein an ar-ea between said first and second return conductors forms a hot zone, said at least one electrifiables conductor being disposed within sz2id hot zone.

WO» 2005/024849 PCT/US2004/028972

13. The electrical wire according to claim 12, wherein said at least one Electrifiable corductor comprises a plurality of Electrifiable conduc-tors which are formed in said hot zone anc comprise a plurality of horizontal segments across a width of said wire and a plurality of S vertical segments across a thickness of said wire.

14. The electrical wire according to claim 13, wherein at least one segment in said plurality of horizontal segments of said Electrifiable conductors is used to transmit a communication signal, and wherein at least one segment in said plurality off horizontal segments of said Electrifiable cormductors is used to supply one of AC and DC electrical power.

15. The electrical wire according to claim 14, wheresin said communication signal comprises one= of a voice communication signal and a data commu anication signal. :

16. The electrical wire according to claim 10, wherein a capacitance formed between said at leasst one Electrifiable conductor and said first and second return conductors is givenasC=1.5 «WoL g/d, where W is the width of the return and elec trifiable conductors, L is the length of the retumrn and electrifiable conductors, € is the dielectric co-nstant for the first and second insulating layests, and d is the distance between each of the return and electrifiable conductors.

17. The electrical wire according to claim 10, further comprising:

an adhesive for bonding adjacent insulation layers and «conductors in said electrical wire.

18. The electrical wire according to claim 10, wherein an object penetrating an outer surface of said electrical wire contacts one of said first and second grounding conductors and one of said first and second return conductors, before contacting said at least one Electrifiable conductor.

19. The electrical wire according to claim 10, wherein said first and second grounding conductors inhibit power transmission signals and load-generated electrical noise from being emitted from said electrical wire.

90. The electrical wire according to claim 10, wherein said first and second return conductors and said first and second grounding conductors comprise a rate of heat dissipation which is greater than a rate of heat dissipation for an round conductor, for a given cross-sectional area.

71. The electrical wire according to claim 10, wherein said electrical wire comprises one of alternating current (AC) electrical wire and direct current (DC) electrical wire for supplying an electrical current having potential of greater than ov.

22. The electrical wire according to claim 10, wherein said electrical wire comprises surface- mountable electrical wire.

23. The electrical wire according to claim 10, wherein said first and ssecond return conductors each have a thickness Tg, and said first and second grounding conductor-s each have a thickness Ty, and said Electrifiable conductor has a thickness Ty, such that a ratio of thicknesses R=Tct+ Tn) Ty is at Least 1.00

24. An electrical wire comprising: at lea st one elecirifiable conductor; a first insulating layer formed around said at least one electrifiable conductor; a return conductor formed around said first insulating layer, sucha that said at least one electrifiable conductor is at least substantially entrapped by said retu1n conductor; and a second insulating layer formed around said return conductor.

25. The electrical wire according to claim 24, further comprising: a grounding conductor formed around said second insulating layer; and a third insulating layer formed around said grounding conductor.

26. The electrical wire according to claim 24, wherein said electrifia®ble conductor, said return conductor and said grounding conductor comprise one of substan®ially curvilinear-shaped "cross-section al geometries and substantially rectilinear cross-sectional gesometries.

27. The electrical wire according to claim 24, wherein said electrifialble conductor, said return conductor and said grounding conductor are formed in substantial ly parallel planes.

28. ‘The electrical wire according to claim 24, wherein said electrical wire comprises a substanstially flat electrical wire having a total thickness of no mmore than about 0.050 inches.

29. Whe electrical wire according to claim 24 whercin said «lectrifiable conductor, said return conductor and said grounding conductor comprise substantially oval-shaped conductors.

30. Aa method of fabricating an electrical wire, comprising: forming at least one electrifiable conductor; and foerming first and second return conductors on opposing sides of said at least ope electrifiabole conductor, such that said at least one electrifiable conductor is at least substantially entrapped by said return conductors.

31. An_ electrical current delivery system comprising the electrical wire of claim 1.

32. An electrical signal transmission system comprising the electrical wire of claim 1.

33. Aan electrical wire according to any one of claims I, 10 or 24, substantially as herein descmribed and exemplified and/or described with reference tos the accompanying drawings.

34, A method of fabricating an electrical wire according to claim 30), substantially as herein described and exemplified and/or described with reference to the accompanying drawings,

3s. Arvcelectrical current delivery system according to claim 3 8 substantially as herein described and exemplified and/or described with reference to the decompanying drawings.

36. An clectrical signal transmission system according to claim 32, substantially as herein descritoed and exemplified and/or described with reference to te accompanying drawings. mae 5 45 AMENDED SHEET