Reinforced Decorative Light Wiring for Tensile Strength Without Bulk
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Solution Overview
Problem
Existing decorative lighting wiring lacks sufficient mechanical strength and durability, often relying on oversized wires or complex non-conductive reinforcing strands that increase material costs and bulkiness, while also being aesthetically unappealing.
Innovation Solution
The development of reinforced decorative lighting wires featuring a longitudinally-extending polymer reinforcing strand with conductor strands helically twisted around it, forming an asymmetrical shape, which provides enhanced tensile strength and elongation without the need for oversized wires or complex reinforcing strands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If oversized wire gauge is used to increase mechanical strength, then tensile strength is improved, but material cost increases
Solution Approach 1:
The patent applies composite materials by combining a polymer reinforcing strand with copper conductor strands. The polymer strand provides mechanical strength while the copper strands provide electrical conductivity. This composite structure allows the use of smaller wire gauge (reducing material cost) while maintaining sufficient tensile strength through the polymer reinforcement.
2Strength
If complex non-conductive reinforcing strands are used to increase mechanical strength, then tensile strength is improved, but device complexity and bulkiness increase
Solution Approach 1:
The patent merges the reinforcing strand and conductor strands into a single integrated wire structure. The polymer reinforcing strand and copper conductor strands are combined concentrically, with the conductor strands wrapped around the central polymer strand. This unified structure provides both mechanical strength and electrical conductivity without requiring separate complex reinforcing components.
3Strength
If complex non-conductive reinforcing strands are used to increase mechanical strength, then tensile strength is improved, but aesthetic appearance deteriorates
Solution Approach 1:
The patent uses a polymer reinforcing strand that is covered by an insulating jacket, creating a smooth, uniform outer surface. This thin film coverage conceals the internal composite structure and provides an aesthetically pleasing appearance suitable for decorative lighting applications, while the underlying polymer strand maintains mechanical strength.
Data Source
AI summary
A decorative light string for draping on an external structure, comprising a plurality of decorative-lighting wires, each of the plurality of decorative-lighting wires including an outer insulation layer, one or more conductors, and one or more reinforcing strands; and a plurality of lamps electrically connected to one another by the plurality of decorative-lighting wires.