Decorative lighting with reinforced wiring
A reinforced wire for decorative lighting, the wire defining a central longitudinal wire axis and including: a longitudinally-extending reinforcing strand, the reinforcing strand comprising one or more fibers comprising a polymer material and defining a reinforcing-strand axis; a plurality of conductor strands wound about the reinforcing strand, each of the plurality of conductor strands defining a conductor strand axis; and an outer insulating layer adjacent to, and covering, one or more of the conductor strands. The reinforcing strand in cross section normal to the wire axis defines an asymmetrical shape.
1. An artificial tree, comprising:
a power cord configured to receive power from an external power source,
a trunk portion,
a plurality of branches, each of the plurality of branches having a connected end and a non-connected end, the connected end pivotally connected to the trunk portion such that the non-connected end is configured to be moved relative to the trunk portion, the plurality of branches including a first branch and a second branch,
and a light set distributed on the plurality of branches, including on the first branch and the second branch, the light set including a first power wire and a second power wire in electrical connection with the power cord, a plurality of lamp assemblies, and a plurality of reinforced wires, the plurality of reinforced wires electrically connecting the plurality of lamp assemblies, wherein each of the reinforced wires defines a longitudinal wire axis along a length of the reinforced wire, and comprises:
a plurality of non-metallic reinforcing strands extending longitudinally;
a plurality of metal conductor strands extending longitudinally, each of the plurality of metal conductor strands comprising copper, each of the plurality of metal conductor strands helically wound with each other, and the plurality of polymer reinforcing strands and the metal conductor strands helically wound with each other;
an insulating layer forming an outer layer over the plurality of conductor strands and the plurality of reinforcing strands, the insulating layer comprising a polymer material, the insulating layer in contact with portions of the plurality of metal conductor strands at multiple points along the longitudinal axis, and also in contact with portions of the plurality of polymer reinforcing strands at multiple points along the longitudinal axis.
2. The artificial tree of claim 1 , wherein the first branch and the second branch are connected to the trunk portion adjacent each other, and one or more reinforced wires of the light set span from the first branch to the second branch.
3. The artificial tree of claim 1 , wherein the first branch and the second branch are displaced from one another along a lengthwise axis of the trunk portion, and one or more reinforced wires of the light set span from the first branch to the second branch.
4. The artificial tree of claim 1 , wherein each of the plurality of reinforcing strands comprises a fibrous polymer material.
5. The artificial tree of claim 1 , wherein one or more of the plurality of conductor strands is disposed at a central portion of the reinforced wire.
6. The artificial tree of claim 1 , wherein one or more of the plurality of reinforcing strands is disposed at a central portion of the reinforced wire.
7. The artificial tree of claim 1 , wherein each of the plurality of reinforced wires comprises a 22 AWG wire, and the first power wire and second power comprise 22 AWG reinforced wires.
8. An artificial tree, comprising:
a power cord configured to receive power from an external power source,
a first tree portion, including:
a first trunk portion;
a first plurality of movable branches connected to the first trunk portion;
a first trunk electrical connector;
a first set of tree-portion power wires electrically connected to the power cord and the first trunk electrical connector; and
a first light set distributed on the first plurality of movable branches, the first light set in electrical connection with the first set of tree-portion power wires, and including a first plurality of lamp assemblies, and a first plurality of reinforced wires, the plurality of reinforced wires electrically connecting the plurality of lamp assemblies, wherein each of the reinforced wires of the first plurality of reinforced wires comprises:
one or more non-metallic reinforcing strands extending along a length of the reinforced wire;
a plurality of metal conductor strands extending along the length of the reinforced wire, each of the plurality of metal conductor strands comprising copper, each of the plurality of metal conductor strands helically wound with each other;
an insulating layer forming an outer layer over the plurality of conductor strands and the one or more reinforcing strands, the insulating layer comprising a polymer material, the insulating layer in contact with portions of the plurality of metal conductor strands, and also in contact with portions of the one or more polymer reinforcing strands; and
a second tree portion, including:
a second trunk portion;
a second plurality of movable branches connected to the second trunk portion;
a second trunk electrical connector configured to electrically connect to the first trunk electrical connector;
a second set of tree-portion power wires in electrical connection with the second trunk electrical connector; and
a second light set distributed on the second plurality of movable branches, the second light set in electrical connection with second set of tree-portion power wires, and including a second plurality of lamp assemblies, and a second plurality of reinforced wires, the second plurality of reinforced wires electrically connecting the second plurality of lamp assemblies, wherein each of the reinforced wires of the second plurality of reinforced wires comprises:
one or more non-metallic reinforcing strands extending along a length of the reinforced wire;
a plurality of metal conductor strands extending along the length of the reinforced wire, each of the plurality of metal conductor strands comprising copper, each of the plurality of metal conductor strands helically wound with each other;
an insulating layer forming an outer layer over the plurality of conductor strands and the one or more reinforcing strands, the insulating layer comprising a polymer material, the insulating layer in contact with portions of the plurality of metal conductor strands, and also in contact with portions of the one or more polymer reinforcing strands.
9. The artificial tree of claim 8 , wherein each of the first plurality of movable branches is pivotally connected to the first trunk portion.
10. The artificial tree of claim 8 , wherein the first branch and the second branch are connected to the trunk portion adjacent each other, and one or more reinforced wires of the light set span from the first branch to the second branch.
11. The artificial tree of claim 8 , wherein the first branch and the second branch are displaced from one another along a lengthwise axis of the trunk portion, and one or more reinforced wires of the light set span from the first branch to the second branch.
12. The artificial tree of claim 8 , wherein the first plurality of reinforcing strands and the first plurality of conductor strands are helically wound together.
13. The artificial tree of claim 8 , wherein one or more of the first plurality of conductor strands is disposed at a central portion of the reinforced wire.
14. The artificial tree of claim 1 , wherein one or more of the plurality of reinforcing strands is disposed at a central portion of the reinforced wire.
15. An artificial tree, comprising:
a power cord configured to receive power from an external power source,
a trunk portion,
a plurality of branches, each of the branches having a connected end and a non-connected end, the connected end pivotally connected to the trunk portion such that the non-connected end is configured to be moved relative to the trunk portion, the plurality of branches including a first branch and a second branch,
and a light set distributed on the plurality of branches, including on the first branch and the second branch, the light set in electrical connection with the power cord, and comprising:
a plurality of lamp assemblies, each lamp assembly including a socket and a lamp element in the socket; and
a plurality of reinforced wires, the plurality of reinforced wires electrically connecting the plurality of lamp assemblies, wherein each of the reinforced wires comprises:
one or more non-metallic reinforcing strands extending along a length of the reinforced wire;
a plurality of metal conductor strands extending along the length of the reinforced wire, each of the plurality of metal conductor strands comprising copper;
an insulating layer forming an outer layer over the plurality of conductor strands and the one or more reinforcing strands;
wherein each of the plurality of reinforced wires includes a wire end that is stripped of the insulating layer, thereby exposing the plurality of metal conductor strands, and a wire terminal is crimped to the reinforced wire at multiple contact points, including a first contact point at the wire end that is stripped of the insulating layer, and at a second contact point at a portion of the reinforced wire that includes the insulating layer, such that the wire terminal is electrically connected to the reinforced wire at the wire end and mechanically connected to a portion of the reinforced wire that includes the insulating layer, the plurality of metal conductor strands, and the one or more reinforcing strands.
16. The artificial tree of claim 15 , wherein the wire terminal is secured to the lamp socket and makes an electrical connection with a lamp element in the socket.
17. The artificial tree of claim 15 , wherein the first branch and the second branch are displaced from one another along a lengthwise axis of the trunk portion, and one or more reinforced wires of the light set extend from the first branch to the second branch.
18. The artificial tree of claim 15 , wherein the insulating layer is in contact with portions of the plurality of metal conductor strands, and also in contact with portions of the one or more polymer reinforcing strands.
19. The artificial tree of claim 15 , wherein the first plurality of reinforcing strands and the first plurality of conductor strands are helically wound together.
20. The artificial tree of claim 15 , wherein one or more of the first plurality of conductor strands is disposed at a central portion of the reinforced wire.
21. The artificial tree of claim 15 , wherein one or more of the reinforcing strands is disposed at a central portion of the reinforced wire.