HK1067230B - Female receptacle for use in electrical outlet assembly - Google Patents

Abstract

A flat, surface mounted, flexible, multi-purpose wire is disclosed. The flat wire (10) has a plurality of flat elongated conductors (11) spaced apart in a generally parallel relationship. Each of the flat conductors comprises a plurality of copper layers (11a, 11b, 11c). An adhesive material (13) separates the flat conductors and an insulation layer (15) surrounds the flat conductors and the adhesive material, with the adhesive material bonding to the insulation layer. A cross-sectional height of the flat conductors and insulation layer is such that the multi-purpose wire will blend in with the surface when painted or after wallpaper is applied.

Description

Socket for use in an electrical outlet assembly

The present application is a divisional application of chinese patent application 96194442.0.

Technical Field

The present invention relates to planar wiring, and more particularly to a thin, flexible, surface-mounted flat wire for use in various types of wiring.

Background

Current wiring and rewiring techniques and operations impose many limitations on users of today's business or residential sectors. Many wiring applications, such as any additions, changes, and removal of power, telephone, antenna/cable television (CATV), and low voltage wiring, as well as associated plugs, switches, and connections, are costly or obtrusive, or both.

Temporary or removable methods are cumbersome indoors and difficult to hide or blend into one place. Such as extension wires, long telephone lines and antenna/CATV lines, external speaker lines, and low voltage lines.

If the user wishes to install concealed, permanent installation typically requires a professional to install in the wall, or use some sort of unsightly inflexible conduit. Both methods are costly.

In view of the above, there is a need for a fixed, unobtrusive, low cost, easy to self-install, well-defined, concealed system for wiring and re-wiring on walls and ceilings, and for mating plugs, switches and connections that can interface between such new and conventional wiring systems.

Disclosure of Invention

The present invention is directed to a flat, thin, flexible, multi-layer wire that substantially obviates one or more of the problems due to limitations and disadvantages of the related art.

By way of non-limiting example, it will be seen that the present invention may be used in a wide variety of applications, including: standard power wiring, speaker wiring, telephone wiring, low voltage wiring, such as security systems, subsurface lighting, and cable television wiring.

In addition, the present invention includes several unique output switches and connectors that interface between the existing conventional round and flat wires of the present invention. To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described, the present invention provides a receptacle for use in an electrical outlet assembly, the receptacle having an opening communicating with a corresponding male contact of a plug and comprising: a plurality of brush assemblies spaced along said opening in said receptacle for contacting said respective male contacts of a plug, each said brush assembly having a plurality of brushes, each said brush being movable independently of one another; and one end of the conductive lead is coupled with the electric brush component, and the other end of the conductive lead is coupled with a power supply.

The thickness of the copper sheet layers is typically about 0.002 inches, but can be in the range of 0.0004 to 0.020 inches, and the number and thickness of the copper sheet layers can be adjusted to suit their intended use. It is contemplated that the dimensions described herein may vary considerably in the practice of the invention.

The insulating layer may be selected from polyester films (e.g., Dupont Mylar), urethane films, and polytetrafluoroethylene films. The adhesive material may be selected from tape (e.g., 3M 9500PC) and liquid adhesive or a combination of both.

In another aspect of the present invention, a surface mount bendable utility wire is provided that includes a single flat conductor and an adhesive material and an insulating material as described above.

It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.

Drawings

The foregoing and other objects and advantages will be apparent from the following detailed description of a preferred embodiment of the invention, taken in conjunction with the accompanying drawings. In the drawings:

FIG. 1 is a side cross-sectional view of a 3-wire flat conductor used in standard electrical wiring;

FIG. 2 is an exploded side cross-sectional view of a 5-wire flat conductor for use in a circuit requiring two loops;

FIG. 3 is an exploded side sectional view of a 2-wire flat conductor for use in a loudspeaker system;

FIG. 4 is an exploded side cross-sectional view of a 6-wire flat conductor for use in a telephone;

FIG. 5 is an exploded side sectional view of a 2-wire flat conductor for CATV;

FIG. 6 is an exploded side cross-sectional view of a 2-wire flat conductor for use in a low voltage system;

FIG. 7 is a perspective block diagram of pluggable and stand-alone outlets connected by a flat wire;

FIG. 8A is an exploded perspective view of the outlet end assembly of the present invention;

FIG. 8B is another exploded perspective view of the outlet end assembly of the present invention;

FIG. 8C is a bottom perspective view of the fully constructed outlet assembly of the present invention;

FIG. 9A is a perspective view of the flat wire to outlet frame connector interface of the present invention;

FIGS. 9B, 9C and 9D are top, side and bottom views, respectively, of the flat wire to outlet frame connector interface of FIG. 9A;

FIG. 9E is a bottom perspective view of the flat wire to outlet frame connector of FIG. 9A showing the elongated slots and brushes;

FIG. 10A is a perspective view of a flat wire to conventional wire connector of the present invention;

FIGS. 10B, 10C and 10D are top, side and bottom views, respectively, of the flat-wire to conventional-wire connector of FIG. 10A;

FIG. 11A is a three-dimensional perspective view of a three-brush female plug receptacle system of the present invention;

FIGS. 11B and 11C are front and side perspective views, respectively, of a side-mounted switch;

FIG. 12A is a perspective view of a surface mount flat wire attached to a ceiling fan;

FIG. 12B is a perspective view of an embodiment of the switch of the present invention with wires separated;

FIG. 13 is a schematic diagram of a flat wire/speaker system configuration;

FIG. 14 is a schematic view of a flat wire/telephone jack system;

FIG. 15 is a schematic of the configuration of a flat wire/CATV system;

FIG. 16 is a schematic view of a flat wire/embedded illumination system configuration;

FIG. 17 is a schematic diagram of a flat wire/DC power system configuration;

FIG. 18 is a schematic diagram of a GFI detection circuit with 4-out and 3-terminal without a switchable input plug;

FIG. 19 is a schematic representation of an 8-output GFI detection circuit without a switchable input plug;

fig. 20 is a diagram of an 8-output GFI detection circuit with a switchable input plug;

Detailed Description

In general, as noted above, the present invention is useful or suitable for use in a wide range of applications, including: standard electrical wiring, telephone wiring, speaker wiring, low voltage system wiring, such as intercom and security systems, subsurface lighting, and cable television wiring. The invention also includes unique outputs and switches that connect to existing conventional round wires. Moreover, the present invention also utilizes tape, a dielectric stripping tool, and a unique connector to implement embodiments. Each individual unit will be discussed in detail and the application of the invention will be subsequently described.

Each of the wiring embodiments share a substantially common structure. The basic common structure and the dimensions of the structural elements may be modified in various ways depending on the particular application to achieve the desired end result.

For simplicity, this basic structure is discussed in detail with respect to the first wire embodiment. The principles of this basic structure should be considered applicable to all wire embodiments. Modifications to the basic structure will be discussed as appropriate. Like reference numerals are used to designate like parts in the figures.

Wire embodiments

AC electric wire

Referring now to the drawings, and more particularly to FIG. 1, there is shown an exploded side cross-sectional view of a standard 110VAC 3-conductor wire embodiment of the present invention. The exploded cross-sectional view is for illustration and discussion only. In a practical 3-conductor embodiment, no gaps are visible between the conductor, insulation and adhesive elements (i.e., white areas in fig. 1). These conductor, insulation and adhesive units will be further described below.

Generally, the power cord 10 is flat and flexible, which allows a user to direct electricity to any area of a wall or ceiling within a room. The power line 10 is mounted to the surface of a wall or ceiling so that expensive rewiring within the wall or ceiling is not required. The line may be painted or papered over to make it fit flat against the rest of the wall.

Power line 10 includes a plurality of long parallel spaced apart multilayer conductors 11, as shown in FIG. 1, a typical 110VAC 3-line embodiment includes: an AC ground conductor, an AC neutral conductor and a live conductor.

As shown in fig. 1, the inner adhesive material 13 separates the flat conductors 11 and forms the sealing edges of the outer flat conductors. The adhesive material 13 and the conductor 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 attach the power wire to a desired surface.

Each conductor 11 comprises one or more layers of copper material having a thickness of 0.0004 to 0.020 inches, preferably 0.002 inches. Three copper layers 11a, 11b and 11c are illustrated in fig. 1. The thickness of the conductor layer should be uniform across its length and width so as to eliminate any resistive hot spots.

The current carrying or signal rating for a particular application may be achieved in any of three ways, either individually or in combination. First, the width "w" of the conductor may vary. Second, an additional thin copper layer may be overlaid on each conductor 11. Third, the thickness "t" of the conductor 11 may be increased.

For most load and current applications, each conductor typically consists of about 2-5 copper layers. It should be recognized that it is within the scope of the invention for more or less layers to be used for the embodiments disclosed below.

For example, a five layer copper layer conductor includes insulation about 0.012 inches thick, with each layer being about 0.002 inches thick. Even at such thicknesses, the flat wire has a very thin cross-section, the presence of which is barely perceptible on a surface once painted or papered over.

The insulating layer 15 will now be described in detail. Insulation is achieved with only minimal thickness and conduction is prevented only under ideal conditions. The primary purpose of this insulating layer 15 is to help make the wire look unobtrusive when it is applied to a surface so that a pleasing appearance is achieved when mounted.

The insulating layer 15 also orients the copper conductor layer. Additionally, insulating materials may be used alone or in combination with internal adhesives to separate the conductive layers and maintain a safe dielectric distance (e.g., AC ground versus neutral and live) between conductors for different applications.

As shown, the insulation may, but need not, be tapered on the sides of the multi-layer flat wire 10 so that it is not obtrusive. The insulating material may be selected from materials such as polyester film (e.g., Dupont Mylar), urethane film, or polytetrafluoroethylene film.

It should be recognized that other insulating materials are within the scope of the present invention, so long as the insulation is flexible, paintable, and capable of being applied to a surface. The insulation should also be compatible with the adhesive, uv resistant, and have similar thermal expansion and contraction characteristics to the surface to which the conductor and insulation are bonded.

Other desirable properties are that the insulation should withstand pulling forces during installation, not shrink or relax under storage conditions, and be removable when used up.

The electronic device for failure detection, which prevents any insulation from being worn, cracked, cut, perforated or otherwise damaged, which would result in unsafe exposure to electrical damage, promptly disconnects the user from the harmful current within a time frame that prevents permanent damage. This electronic fault detection device, i.e., a Ground Fault Interrupter (GFI) circuit, is discussed later in this specification.

Returning now to fig. 1, the internal adhesive material 13 should be capable of adhering to the insulation layer 15. For example, tape (e.g., 3M 9500PC), liquid adhesive, or a combination of the two may be used as the internal adhesive. The internal adhesive also has the function of separating the groups of conductive layers and maintaining a safe dielectric distance between the different acting conductors. In addition, the adhesive 13 can fill up gaps in the components within the wire so as to be invisible on the surface.

The thickness of the internal adhesive material 13 is about the cross-sectional height't' of the conductor 11, and specifically refers to the location where the internal adhesive separates the conductor 11. As shown in fig. 1, the internal adhesive 13 may be tapered on the edges of the flat wire so that it is not obtrusive.

An outer adhesive layer 17 is formed to attach the thread to the surface to which it is desired to attach. For example, the outer adhesive layer may be a double-sided tape, one side secured to the back of the flat wire and the other side secured to a wall or surface. Alternatively, a chemical adhesive may be used, respectively, which may consist of any adhesive having good adhesive properties to both the insulation layer 15 and the surface to which the flat wire 10 is to be attached.

For example, a 3-conductor flat wire 10 having three copper layers of 0.002 inches in thickness, the cross-sectional height't' would be about 0.007 to 0.010 inches thick, the overall width 'W' of the 3-conductor flat wire 10 for a 15 amp rated current wire would be about 2.0 to 2.5 inches, and the width 'W' of each conductor would be about 2.0 inches to 2.5 inches_c'about 0.4-0.6 inch, space between conductors' W_s' is about 0.2-0.3 inches.

To ensure easy identification and a proper and secure connection, the width' W of the AC ground conductor_c' may be slightly increased compared to AC neutral and live. The width of the AC ground conductor may thus be closer to 0.6 inches, while the other two conductors may be closer to 0.4 inches, as an alternative, the width of the AC ground conductor may also be smaller than the other conductors.

Similar dimensions may be used for wires for other applications, but it is understood that the dimensions can vary considerably in the practice of the invention.

The flat wire 10 provides a simple and inexpensive alternative to expensive rewiring work for fans, ceiling lighting or wall or artistic lighting, providing power to specific locations of walls and ceilings.

An exploded side cross-sectional view of a 110VAC 5-conductor wire 20 of the invention having five parallel spaced apart multi-layer copper conductors is shown in fig. 2. This 5-conductor wire embodiment includes all of the features of the 3-conductor wire embodiment described above, with the additional two conductors 11 providing a second circuit. Identical or similar parts are indicated with the same reference numerals.

The 110VAC 5-conductor line is used where two circuits are desired on one line. Such as a wire leading to a light and a fan, or a place with a switch plug. In this embodiment, the five conductors include two AC neutral conductors, two live conductors and one ground conductor.

The number and thickness of copper layers, the width' W of the conductor 11_c'thickness't 'and interval between conductors' W_s' is substantially the same as a 110VAC 3-conductor wire. The resulting flat wire 20 has an overall width 'w' of about 3.5-4.25 inches.

The flat wire conductor of the present invention may also be used to construct an embodiment of a 220VAC wire, as shown in fig. 1, a 3-conductor flat wire is made, for example, with four copper layers about 0.002 inches thick with a cross-sectional height't' of about 0.012 inches. The overall width ` W ` is about 3.0-3.5 inches, and the width ` W ` of the neutral and line conductors_c' about 0.4-0.6 inch, while the width ' W ' of the ground conductors is about 0.2-0.4 inch, the spacing ' W ' between the conductors_s' about 0.4-0.6 inches.

As in the 3-conductor 110VAC power line, the difference in ground conductor width in the 3-conductor 220VAC power line is to facilitate proper connection of the line to the connector.

Loudspeaker line

As shown in fig. 3, the speaker wire 30 of the present invention is a thin flat flexible wire that allows a user to position a speaker on any area of a wall or ceiling of a room, as in the previous embodiment. The speaker line 30 may be used, for example, with stereo or mono components, or for connecting external speakers such as 'surround sound' enhanced television or sound systems.

The speaker 30 may be mounted to the surface of a wall or ceiling so that expensive in-wall or in-ceiling rewiring is not required. The wire may also be painted or papered to provide a smooth fit with the rest of the surface.

Referring now to fig. 3, the speaker wire 30 includes a pair of multi-layer copper conductors 11, the speaker wire 30 preferably having a conductive capacity equal to 10 gauge twisted wire, each conductor 11 typically having two to three copper layers, the former having copper layers 11a and 11b in fig. 3, the copper layers having a thickness of about 0.0004-0.020 inches, preferably about 0.002 inches, it being understood that the copper layers may be smaller or larger depending on the particular application.

The pair of conductors 11 are separated by a suitable adhesive material 13 and are surrounded by two layers of insulation 15 as previously described, with similar insulation and adhesives as previously described.

Depending on its use, the speaker wire 30 may also include a shielding material 18 surrounding the conductor 1 for reducing external signals and crosstalk, the shielding material 18 may be one or more layers of any suitable metallic or semi-metallic shielding material, such as aluminum or metallized polyester film.

The resulting speaker wire 30 has three copper layers with a cross-sectional height't ' of about 0.008 inches, an overall width ' W ' of about 2.5-3.0 inches, and a width ' W of each conductor_c'about 0.6-0.8 inch, spacing between conductors' W_s' about 0.2-0.3 inches.

As shown in fig. 3, the edges of the wire 30 may be formed to be slanted so as not to be prominent, or a similar adhesive layer 17 as previously described may be provided for attaching the speaker wire 30 to a suitable surface.

Telephone line

An illustrative embodiment of a telephone line 40 of the present invention is shown in fig. 4, in which six multi-layer copper conductors 11 are provided, separated by adhesive material 13 and surrounded by insulation 15, the six conductor lines facilitating the use of a patch panel in a personal branch exchange (PBX) providing a personal exchange with a public telephone line access. Conductor 11 is roughly equivalent to a standard 22-gauge telephone line.

Two, four and eight multilayer copper conductor telephone lines are available, and the example of eight conductors is approximately four wire-to-strand wires (e.g., unshielded wire-to-strand (UTP)), which is suitable for carrying data.

Each conductor 11 typically has two or three copper layers, the former being represented by copper layers 11a and 11b in fig. 4. The copper layer is about 0.0004 to 0.020 inches thick, and preferably about 0.002 inches thick. It is understood that the copper layer may be thicker or thinner, depending on the particular application.

The resulting telephone wire 40, with three copper layers, has a cross-sectional height of about 0.008 inches and an overall width 'w' of about 1.5-3.5 inches, depending on the number of conductors 11 used; width' W of each conductor_c'about 0.2-0.4 inch, spacing between conductors' W_s' about 0.125-0.25 inch.

As shown in fig. 4, the edges of the cord 40 may be beveled to make it less obtrusive, or an outer adhesive layer 17 similar to that described above may be provided to attach the cord 40 to an appropriate surface.

CATV cable for cable television

An embodiment of a cable television CATV line 50 of the present invention is shown in fig. 5. In this embodiment, a pair of conductors 11 are provided, each of which may typically have two or three copper layers, with copper layers 11a and 11b being shown in fig. 5 as the former, which are about 0.0004 to 0.020 inches thick, and preferably about 0.002 inches thick, it being understood that thicker or thinner copper layers may be used, depending on the application.

As in the previous embodiment, the conductors 11 are separated by adhesive material 13 and surrounded by an insulating layer 15, as shown in figure 5, the edges of the wire 50 may be bevelled so that they are not obtrusive, and an outer adhesive layer 17 similar to that described above may also be provided for attaching the wire 50 to a suitable surface.

The resulting antenna/CATV wire 50, with three copper layers, has a cross-sectional height't' of about 0.008 inches, an overall width 'W' of about 1.8-2.2 inches, and a width 'W' of each conductor_c'about 0.4 to 0.6 inches, as shown in FIG. 5, the spacing between conductors' W_s' about 0.4 to 0.6 inchesThis is slightly larger than in the previous embodiment, in order to reduce radio frequency interference and improve transmission quality. The CATV line is rated at 300 ohms.

Low-voltage line

Fig. 6 shows a low voltage line 60 embodiment of the present invention, the use of which includes walkie talkies, security systems and 'intelligent indoor units'. Fig. 6 shows two DC electrical conductors 11. The structure of the conductor 11 is substantially the same as the aforementioned multilayer conductor. The inner adhesive material 13, the insulating layer 15 and the outer tie layer 17 are the same as in the previous embodiment.

Each conductor 11 typically has two or three copper layers, the latter being represented by copper layers 11a, 11b and 11c in fig. 6. The copper layer is about 0.0004 to 0.020 inches thick, and preferably about 0.002 inches thick. It is understood that the copper layer may be thicker or thinner depending on the application.

The resulting low voltage wire 60 with three copper layers has a cross-sectional height't' of about 0.008 inches and an overall width 'w' of about 1.2-1.6 inches. The width 'W' of each conductor is about 0.3-0.5 inches, the width 'W' of each conductor_c'0.3-0.5 inch, space between conductors' W_s' about 0.2-0.3 inches.

As shown in fig. 6, the edges of the line 60 may be formed to be inclined so as not to be prominent. An outer adhesive layer 17 similar to that described above may also be provided to attach the phone wire 60 to a suitable surface.

Line for subsurface illumination

While the thin, flexible wire used for subsurface lighting is similar in structure to the 110VAC 3-conductor and 5-conductor wire embodiments described above, it is unique in that the subsurface lighting wire has a nested lamp 169 attached. See fig. 16. This enables a user to install lighting beneath a surface in a compartment, shelf or other location where subsurface lighting is desired. This embodiment will be described in detail later in this specification when discussing conventional wire and flat wire system connection devices.

Power supply output terminal and connector

The present invention includes a set of power outlets that form connection points between the flat wire of the present invention and conventional existing power outlets as well as conventional round wire systems, these connection outlets being of two basic types, one being a device that is 'pluggable' directly into a conventional existing power outlet and the other being a 'stand-alone' surface mount device.

The pluggable connection outlet always forms a compatible interface between the standard household electrical wiring device and the various flat wire embodiments of the present invention. Thus, the pluggable power supply output is always on the standard current source. The stand-alone device is connected to the pluggable device through various flat wire embodiments of the present invention.

Fig. 7 shows a typical interface configuration between pluggable and stand-alone devices, assuming a conventional two-outlet receptacle is provided behind the power outlet 65 and powered by conventional round wires 69 from behind the wall 66. Thus, the power output terminal 65 is of a directly pluggable type. And power output 67 is a separate power output that is fixed to the wall without a plug attachment. The separate power outlet may therefore be located anywhere in the room, regardless of the existing power outlet location.

In the power line embodiment, for example, current from conventional line 69 is delivered to separate power outlets 67 via pluggable power outlets 65 and 110VAC flat wire 68 of the present invention.

Fig. 8A is an exploded perspective view of the pluggable outlet device showing the various internal and external components of the device. As shown, the outlet 65 includes side-mounted receptacles 72 and 73 that are received in an outlet end cap 74. Alternatively, the receptacles 72 and 73 may be mounted on the front face as in a standard receptacle configuration. The side-mounted receptacle form has the advantage that the output end cap can be painted or papered over to make it flush with the surface. Also, as shown in FIG. 8B, additional receptacles 72 'and 73' may be provided on the other side of the output end cap 74, which results in four receptacles.

The outlet bottom 75 of the pluggable outlet 65 includes openings 75a and 75b that can be placed over a conventional existing outlet socket and secured to a surface with screws or other similar means, with the outlet cover 74 resting on the bottom 75.

The pluggable outlet 65 also includes a flat wire connector 76 and a Ground Fault Interrupter (GFI) unit 77 with a reset button 78. The GFI unit 77 (the operation of which will be discussed later herein) includes two sets of male contacts 79 and 79' that are inserted through openings 75a and 75b into corresponding receptacles associated with conventional wiring systems, the function of the GFI unit 77 being to cut off current to the load when a flat wire is pierced or broken. Fig. 8C is a bottom perspective view of the assembled pluggable outlet assembly 65 showing the GFI male contacts 79 and 79' extending through the openings 75a and 75b of the base member 75.

The separate power output 67 (see fig. 7) differs from the pluggable output 65 in two ways. First, the GFI unit 77 and its associated reset button 78 need not be provided in a separate output. Second, the bottom 75 of the stand-alone outlet does not require openings 75 and 75' because the stand-alone outlet is not directly connected to conventional wiring systems, and is identical to the pluggable and stand-alone power outlet in all other respects.

The bottom of the individual power output terminals can be provided with stamped openings 75a and 75b to allow it to be used on pluggable or stand-alone output terminal assemblies.

Fig. 8B is another perspective view of the pluggable power outlet showing two sets of male contacts 81 and 83 connected to the flat wire connector 76 and GFI unit 77, respectively, noting that the flat wire connector 76 and FGI unit 77 are not secured to the base member 75 but are alternatively connected to the outlet cap 74 through male contacts 81 and 83.

Also shown in fig. 8B is a copper frame 84 on the bottom surface of the cover 74. The copper frame 84 functions to form an electrically conductive connection with the receptacles 72, 72 ', 73 and 73' and the two sets of male contacts 81 and 83. as shown in fig. 8A, the male contacts 83 are inserted into corresponding slots 82 on one face of the GFI unit 77.

Turning now in detail to the flat wire connector 76 that is common to both the pluggable and stand-alone power outlets, the flat wire connector 76 forms a connection point between the flat wire of the present invention and the copper outlet frame 84.

One example of such a flat wire to outlet frame connector 90 is shown in the perspective view of fig. 9A. A 5-conductor connector assembly is shown for illustration, but it should be understood that the connector can be manufactured in configurations to connect with any number of flat conductors, which may have any number of copper layers.

A plurality of flat wire receptacles 92 are formed along one surface of the connector 90 for receiving respective flat wire conductors 11. When using a 3-conductor wire, the same 5-conductor connector assembly 90 can be used for both 3-conductor and 5-conductor wires provided the outside wire receptacle is not crowded. Other wire embodiments have their own interface connectors 90. The need for multiple connectors is not problematic because the connectors can be easily swapped and easily inserted into the output end cap 74 by inserting the connectors into the male contacts 81 secured to the output end cap 74.

Each flat wire receptacle includes a plurality of slotted springs 94 for connecting to corresponding copper layers in the multi-layer conductor 11 (see also fig. 9B), typically forming two to five slotted springs 94 corresponding to the multi-layer copper conductor embodiment described above.

As shown in the perspective views of fig. 9A and 9B and the side view of fig. 9C, a plurality of long grooves 98 are included on the other surface of the connector 90. As shown in fig. 8B, these elongated grooves 98 are connected to a corresponding set of male contacts 81, and the male contacts 81 need only be slid into the grooves 98 to make the connection.

As seen more clearly in fig. 9E, each elongated slot 98 includes a series of brushes or wipers 98a-98d, each of which moves independently of the other, forming a better connection and a larger contact surface with the male contact 81.

The sequence of connecting the flat wire to the connector 90 will now be described with respect to a typical 5-conductor embodiment having three copper layers per conductor. Each conductor 11 is first aligned with a corresponding flat wire receptacle 92. Each copper layer of each conductor 11 is then inserted between the slotted springs 94. As shown in fig. 9D, the slotted spring 94 is slightly biased by a screw 96. Tightening the screws ensures that both the top and bottom of each copper layer are in contact with the slotted spring. This ensures the best conductor contact and ensures that each copper layer (and thus each conductor) has the same resistance.

Finally, the male contact 81 and the elongated recess 98 are aligned to form a connection to a pluggable or stand-alone power outlet, and the outlet cover 74 has a small cut-out on the side facing the flat wire receptacle 93 of the connector 90 to allow flat wire to pass through the outlet cover 74 to the connector 90.

In addition to the flat wire to outlet frame connector, a second type of connector is required to interface between the conventional round wire and the various flat wire embodiments described above. This is needed, for example, when the flat wire is connected to a wall lamp, fan, or intercom system.

An example of such a connector 100 is shown in the perspective view of fig. 10A. It shows a connector of a 5-conductor flat wire to a conventional wire. For purposes of illustration, a 5-conductor connector is shown here, but it should be understood that any number of flat conductors can be made to connect with any number of conventional round wires. When using 3-conductor power lines, the 3-conductor and 3-conductor wires may share a 5-conductor connector assembly 100 if the outside line receptacle is not congested, with other wire embodiments having their own interface connectors.

As shown in fig. 10A, connector 100 has a plurality of conventional set screws along one surface thereof to provide an interface for a common standard 'wire wrap' connection in a conventional round wire routing system (see fig. 10B), and one or more flat wire receptacles 102 along the other surface for receiving each of the flat wire conductors. Each flat wire receptacle 102 includes a plurality of slotted springs 104 (see fig. 10D) for contacting each layer in each of the multi-layer conductors. As shown in fig. 10A and 10C, the slotted spring 104 is slightly biased by the screw 96 and functions the same as described with respect to the connector 90. The connection of the flat wire conductors to the flat wire receptacles is the same as described with respect to connector 90.

Fig. 11A shows a modified three brush socket 110 that can be installed in the pluggable 65 and stand-alone 67 power outputs of the present invention.

Socket 110 includes molded copper leads 111 and 112 that contact respective brush assemblies 114 and 116. Each brush assembly includes three brushes (114a, 114b, 114 c; 116a, 116b, 116c), each brush in each assembly moving independently of the other two.

Thus, the assembly of the three brushes provides a better connection and a larger contact surface with the copper leads 111 and 112. The other ends of the copper leads 111 and 112 extend to the copper frame 84 (see fig. 8B). In addition, because the three brushes move independently, the socket can better accommodate the torque of the plug.

Switch with a switch body

A unique set of switches is provided to be suitable for use with the wireform of the present invention. These switches may be wired to existing switches, or plugged into existing outlet outlets or operated by a Radio Frequency (RF) remote power source. The switch is primarily used in the 3-conductor, 5-conductor line and subsurface lighting embodiments described above.

1. Handle control, fixed mounting and dispersed wiring;

2. controlling, fixedly installing and dispersedly wiring a capacitive touch switch or a film switch;

3. capacitive touch switch or membrane switch control, fixed mounting and radio frequency signal transmitter/receiver pair;

4. capacitive touch switches, or membrane switch controls, hand-held or wall-hung, radio frequency signal transmitters/receivers; and

5. a capacitive touch switch or a membrane switch controlled light chopper with an indicator light, a hand-held or wall-hung device and a radio frequency signal transmitter/receiver.

Regardless of the particular type of switch used, all switches share some common elements. Instead of switching the AC circuit, each switch 124' (see fig. 12B) sends a signal via a low voltage line 125(12VDC) to the corresponding plug, which switches the AC circuit, as shown in fig. 12B.

If the switching device is hardwired, it is coupled through a voltage circuit. This renders the switch unusable without an adapter plug device.

Tool with a locking mechanism

The unique flat wire of the present invention requires an equally unique insulation stripping tool to facilitate its connection to connectors and existing power outlet sockets. Each of the wire embodiments described above has its own special tool.

Two forms are envisaged: one for professional electricians or installers and one for non-professional persons. The specialized stripping tool is designed to cut and strip the insulation 17 from the wire 11 in a single operation similar to the operation of a conventional stripping tool. Given the small thickness of the conductor, it is clear that the stripping tool should be refined to enable precise cutting and stripping. This fine machining increases the cost of these tools, making it economically feasible only for professional use.

A second cutting tool for the unskilled person aligns the wire with the stripper and shaves it close to and perpendicular to the conductor so that the user can strip away the necessary insulation to reach the conductor layer. The insulation was then peeled off and cut with scissors.

Use of the system

An illustrative general system embodiment is shown in fig. 12A, including the various lines, output switches, and connectors described above.

Referring to fig. 12A, there is provided a conventional electrical outlet 120 and a switch 124. A person wishing to wire a ceiling fan 126 in the position shown typically has to perform expensive wall and ceiling wiring work to get power to the fan.

By using the flat wire, power outlet, switch and connector of the present invention, this task is greatly simplified as described below. A pluggable outlet 65 (fig. 8A) is first plugged into a conventional electrical outlet 120. A separate power output 67 is then secured to the wall at the desired location. Flat wires 123 (e.g., 3-conductor or 5-conductor wires) are routed between the pluggable outlet 65 and the isolated outlet 67, and between the isolated power outlet 67 and the fan.

Connector 90 (not shown in FIG. 12A, and of the type shown in FIG. 9A) connects flat wires 123 to pluggable and stand alone power outlets 65 and 67. In addition, another connector 100 (of the type shown in FIG. 10A) connects the conventional round wire of the fan 126 with the flat wire 123.

As described above, the flat wire 123 is secured to the wall surface with the adhesive layer 17, typically a double sided tape, and painted or papered over to shield the wire.

As shown, at the ceiling and wall junction 127, the flat wire 123 is bent 90 degrees along its width because the flat wire 123 is laid on a different plane. In addition to bending any angle along the width of the flat line to accommodate different planar corners, the bendable line can bend back on itself at virtually any angle to accommodate angle changes in the same plane.

For example, consider a second wall lighting device 126' in fig. 12A. Wall lamp 126' is connected to a standard switch 124 by flat wire 128. For aesthetic reasons, instead of mounting a second separate switch close to the conventional switch, the flat wire is bent at a 45 degree angle at points 129 and 129'. The flat wire is essentially folded back on itself to make a 45 turn.

Fig. 13-17 are illustrations of various system embodiments that are more specific to the use of the flat wires disclosed above. These systems are briefly described below.

Fig. 13 shows a flat wire/conventional speaker wire interface. For simplicity and ease of illustration, only one speaker 131 with stereo 130 is shown. It should be understood that any number of speakers may be used with the flat wire of the invention.

As shown, stereo system 130 is connected to speakers 131 by flat wires 133. The speaker 131 can be provided at any desired position. The conventional speaker wire 136 is then connected to a separate plug on the wall. A second separate plug is located at the desired location near the new speaker location. The flat wires 133 are then routed between two separate plugs. The entire length of the flat wire 133 may then be painted or papered over, thereby eliminating unsightly and annoying speaker wires.

Referring to fig. 14, there is shown a flat wire/conventional telephone jack forming a jack for an extension telephone.

As shown, a conventional telephone jack or telephone jack 141 is connected to an extension telephone jack 142 by a flat wire 143. As shown, a flat wire telephone device 147 is connected to the existing telephone jack 141. The extension jacks 142 are then positioned at the desired locations and connected to the flat wire telephone device 147'. The flat wire 143 is then connected between the flat wire telephone sets 147 and 147'. The entire length of the flat wire 143 can then be painted or papered over, so that unsightly and annoying phone lines are not visible.

FIG. 15 is a diagram of a CATV application. The cable input 151 enters the room through a 75 ohm coaxial cable 158. The cable 158 is then connected to a 75 ohm to 300 ohm conversion device 157, which 157 is placed on the wall near the room input 151. The second switching device 157' is positioned proximate to the desired television 152. The flat wire 153 is then connected between the two switch positions. All of the flat wires may then be painted or papered as described above, so that unsightly and annoying CATV wires are not visible.

FIG. 16 shows an embodiment of subsurface lighting comprising flat wires 163 and embedded lamps 169. A switch or plug 161 is connected to the flat wire 163. The embedded lamps 169 may be, for example, 20-100 watt double-ended RSC base 120V halogen lamps. The flat wire may be placed in any watch location where additional lighting is desired, such as under a booth or shelf. The flat wire may then be painted or papered over to conform flat to the remaining surface.

The flat wire of the present invention can also be used for Direct Current (DC). Referring to fig. 17, a dc power source 171 is connected to a dc output terminal 172 via flat wires 173. As in other system embodiments, a wall connector interfaces between the conventional DC wire 158 and the flat wire 153.

Ground fault circuit interrupter (GFI) circuit

Because the flat wire is barely visible after painting or taping, a nail or picture hook may be inadvertently passed through the flat wire at a later time, or the wire may be severed for other reasons.

Thus, in each system, a ground fault circuit interrupting (GFI) unit 77 (see fig. 8A-8C) is provided as a safety measure to prevent injury that could occur by accidentally penetrating through very thin insulation. The term ground means that any person or thing forms a ground line, not the usual internal ground.

The GFI circuit monitors the current of the AC circuit through the hot and neutral conductors and if an error greater than 10 milliamps is detected, opens both conductors through a circuit breaker. The circuit opens quickly enough to prevent any persistent harmful discharge.

This circuit forms a failsafe, and any circuit can be checked and rechecked before and after connection. The connection made by the power from the circuit may cause a circuit fault to leave the circuit breaker free of power.

As described above, the circuit is actually located in a pluggable power outlet 65 (see FIGS. 8A-8C), and the outlet 65 plugs into a conventional wall outlet. The GFI detection circuit is basically a normally closed relay. When the fault current to ground exceeds a predetermined value, which is less than the current required to operate the overcurrent protection device of the power supply circuit, the relay opens to interrupt the current to the load.

Fig. 18 shows a standard single circuit 180 non-switchable dual plug system having a GFI detection circuit connected to a 4-plug, 3-terminal device of the present invention.

Fig. 19 shows a standard single circuit 180 non-switchable dual plug system having a GFI detection circuit connected to the plug assembly of the present invention (4 main plugs and 4 drop plugs).

Fig. 20 shows a standard dual circuit 200 switchable 2-plug system, thus requiring two GFI detection circuits, each connected to a 4-plug (2 primary plugs and 2 drop) device of the present invention.

Although the invention has been described in relation to the above 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.

Claims (1)

1. A receptacle for use in an electrical outlet assembly, the receptacle having an opening in communication with a corresponding male contact of a plug and comprising:

a plurality of brush assemblies spaced along said opening in said receptacle for contacting said respective male contacts of a plug, each said brush assembly having a plurality of brushes, each said brush being movable independently of one another; and

one end of the conductive lead is coupled with the electric brush component, and the other end of the conductive lead is coupled with a power supply.