Electricity: conductors and insulators – Conduits – cables or conductors – Combined
Reexamination Certificate
1998-06-25
2001-02-06
Kincaid, Kristine (Department: 2831)
Electricity: conductors and insulators
Conduits, cables or conductors
Combined
C174S07000A, C174S079000, C174S092000, C174S1100PM, C174S255000, C439S492000
Reexamination Certificate
active
06184469
ABSTRACT:
BACKGROUND OF THE INVENTION
The field of the invention is electrical conductors and the invention relates more particularly to ribbon style of flexible conductors of the general type shown in U.S. Pat. No. 4,934,956 naming the applicant as the inventor and most widely used for low voltage lighting strips.
In U.S. Pat. No. 4,934,956 a single width of an insulative tape is laminated to a pair of parallel thin ribbon conductors. Next, a non-conductive ply is laminated to the exposed side of the ribbon conductors. This results in a continuous strip of two flat electrical conductors on a common carrier, the total surface of which is completely insulted, resulting in a flat ribbon equivalent of “zip cord.” To each conductor a jack is connected by punching the ribbon and suitably bonding the jack to said ribbon, providing electrical continuity for bi-pin lamps and similar components. This process is complicated by the fact that to achieve a positive electrical connection, the insulating matter has to be penetrated or removed while maintaining the integrity of the conductor. Swaging was determined to be the only suitable method of fixing the jacks to the conductors. Therefore, in order to permit swaging, a through hole is required on the bottom of the jack, creating a real and serious problem. This problem occurs when leads of lamps or other components are inserted in jacks. These leads have pointed ends which are quite sharp and often extend through the hole in the bottom of the jack. This condition creates the possibility of the tip of the pin being able to penetrate the insulation of the opposing conductor since said conductor is often positioned in alignment with the hole in the bottom of the jack causing a short circuit. Further, reliability of the system has been improved by orders of magnitude in the implementation of a new and superior system. Thus, an improved product and process is needed.
BRIEF SUMMARY OF THE INVENTION
It is an object of the present invention to provide a insulated ribbon conductor and a method of connecting components thereto which provide an improved electrical contact between the component and the ribbon conductor. Also, providing a material which is significantly more user friendly.
The present invention is for a folded insulated ribbon conductor having an insulator comprising a thin flexible length of an insulative material. A conductor comprising a thin flexible conductive ribbon is affixed to an inner surface of the insulator. A first fold is made which forms a first crease parallel to the central axis of the insulator and the conductor so that the insulator is on an outer edge of the first crease so that the conductive side of the conductor faces and is capable of electrically contacting the conductive side of the conductor. A second fold forms a second crease parallel to the central axis of the insulator and the conductor so that the insulator is on an outer edge of the second crease. Once again, the conductive side of the conductor faces an adjacent conductive side of the same conductor. Preferably, the insulator extends beyond the edges of the conductor so that the folded conductor is formed without any exposed conductor. The process of the present invention is the connecting of the conductor of the present invention to an electrically conductive jack by the process of unfolding the first fold sufficiently to expose a portion of the conductive side of the conductor to provide an exposed conductive area. A jack is inserted through the conductor and the insulator at the exposed conductive area and soldered to form a first contact point. Next, the first fold is refolded so that the termination of the jack is sandwiched between two plies of the copper conductor.
REFERENCES:
patent: 3697925 (1972-10-01), Henschen
patent: 3875478 (1975-04-01), Capstick
patent: 4563050 (1986-01-01), Greenwood et al.
patent: 4934956 (1990-06-01), Conti
patent: 5374788 (1994-12-01), Endoh et al.
patent: 5499170 (1996-03-01), Gagne
patent: 6098282 (2000-08-01), Frankeny et al.
Averill, Jr. Edgar W.
Kincaid Kristine
Nino Adolfo
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