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. A reinforced wire for decorative lighting, the wire defining a central longitudinal wire axis and comprising:
a longitudinally-extending reinforcing strand, the reinforcing strand comprising one or more fibers comprising a polymer material and defining a longitudinal 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 each of the plurality of conductor strands in contact with the reinforcing strand;
an outer insulating layer adjacent to, and covering, one or more of the conductor strands; wherein the reinforcing strand in cross section normal to the longitudinal reinforcing-strand axis defines an asymmetrical shape.
2. The reinforced wire of claim 1 , wherein the plurality of conductor strands are not evenly circumferentially spaced about the reinforcing strand.
3. The reinforced wire of claim 1 , wherein at least some of the plurality of conductor strands are embedded into the reinforcing strand and conform to the asymmetrical shape of the reinforcing strand.
4. The reinforced wire of claim 1 , wherein the plurality of conductor strands are wound asymmetrically about the reinforcing strand.
5. The reinforced wire of claim 1 , wherein the reinforcing strand axis is a central longitudinal axis passing through a centroid of the reinforcing strand in the cross section, the reinforcing strand axis being offset from the wire axis.
6. The reinforced wire of claim 5 , wherein the reinforcing strand axis is offset from the wire axis by a distance ranging from 5% to 35% of a maximum diameter of the reinforcing strand.
7. The reinforced wire of claim 1 , wherein the insulating layer overlays a portion of the reinforcing strand such that the insulating layer directly contacts the portion of the reinforcing strand.
8. The reinforced wire of claim 7 , wherein the insulating layer comprises a polymer material, the polymer material of the insulating material being different from the polymer of the reinforcing strand.
9. The reinforced wire of claim 8 , wherein the polymer material of the reinforcing strand comprises a single-fiber 1000 to 1500 Denier polyethylene terephthalate (PET) material.
10. The reinforced wire of claim 1 , wherein the plurality of conductor strands ranges from six strands to ten strands.
11. The reinforced wire of claim 10 , wherein the plurality of conductor strands consists of eight strands.
12. The reinforced wire of claim 10 , wherein an average diameter of each of the plurality of conductor strands ranges from 0.15 mm to 0.16 mm.
13. The reinforced wire of claim 10 , wherein an average diameter of each of the plurality of conductor strands ranges from 0.20 mm to 0.30 mm.
14. The reinforced wire of claim 1 , wherein the reinforcing strand exhibits tensile strength ranging from 45 to 65 MPa, and each of the plurality of conductor strands comprises a tensile strength ranging from 200-250 N/mm 2 .
15. The reinforced wire of claim 1 , wherein each of the plurality of conductor strands defines a diameter ranging from 0.15 mm to 0.16 mm.
16. A reinforced wire for decorative lighting, the wire defining a central longitudinal wire axis and comprising:
a longitudinally-extending reinforcing strand, the reinforcing strand comprising a polymer material and defining a central reinforcing-strand axis;
a plurality of conductor strands wound about the reinforcing strand, each of the plurality of conductor strands defining a central conductor-strand axis, and each of the plurality of conductor strands in contact with the reinforcing strand;
an outer insulating layer adjacent to, and covering, one or more of the conductor strands; wherein the central reinforcing-strand is arranged within the wire such that the central reinforcing-strand axis is offset from the wire axis and the plurality of conductor strands are asymmetrically wound about the reinforcing strand.
17. The reinforced wire of claim 16 , wherein the plurality of conductor strands are asymmetrically wound about the reinforcing strand such that the central conductor-strand axes are not equidistant from either the wire axis or the central reinforcing-strand axis.
18. The reinforced wire of claim 16 , wherein the reinforcing strand in cross section normal to the wire axis defines an asymmetrical shape.
19. The reinforced wire of claim 16 , wherein the reinforcing strand comprises a polyethylene terephthalate (PET) material, the conductor strands comprise seven to ten strands of copper material, and the reinforced wire exhibits a tensile strength ranging from 2,000 to 3,500 PSI.
20. The reinforced wire of claim 16 , wherein the insulating layer overlays a portion of the reinforcing strand such that the insulating layer directly contacts the portion of the reinforcing strand.
21. The reinforced wire of claim 20 , wherein the insulating layer comprises a polymer material, the polymer material of the insulating material being different from the polymer of the reinforcing strand.