CONTINUOUS FLEXIBLE ELECTRIC CONDUCTOR CAPABLE OF FUNCTIONING AS AN ELECTRIC SWITCH

Abstract: A conductor comprising a first elongated electric conduct­ ing element; a spacer element formed from insulating mate­ rial and placed over the surface of the first conducting element, so as to shield all but given portions of the aforementioned surface; a second tubular electric conduct­ ing element placed over the outside of the aforementioned spacer element; a third tubular electric conducting ele­ ment placed over the outside of the aforementioned second element; and a tubular insulating sheath placed over the outside of the aforementioned third conducting element. The structure of the aforementioned second conducting ele­ ment comprises a supporting matrix formed from flexible, electrically-insulating material and particles of electri­ cally-conductive material scattered in random, substan­ tially uniform manner inside cells on the aforementioned matrix; which cells communicate at least partially with one another, and are at least partially larger in size than the respective particles of electrically-conductive material housed inside the same.

Description: The present invention relates to a continuous, flexible electric conductor suitable for employment on an electric line, and capable of functioning as an electric switch. Electric current is known to be supplied between source and user equipment over an electric line, to which the said elements are series-connected, and which also comprises at least one electric switch, also series-connected to the line and which, when closed, allows current to flow from the source to the user equipment. For controlling the electric circuit at various points along the said line, provision is made for a number of switches, each series-connected electrically to the source and user equipment. In this case, the line comprises at least two conducting wires, which must be connected, e.g. welded, to the connecting terminals on said switches, as well as to the terminals on the source and user equipment. An electric line of the aforementioned type therefore involves a considerable number of both connections and component parts (i.e. switches), the consequences of which are high cost and greater breakdown potential along the line caused, for example, by loose wires or infiltration, e.g. by water, on tie switch connecting terminals. Furthermore, changes to such a line, e.g. re-allocation of the switches, can only be made with difficulty, which also applies to re-utilization of the component parts of the line (conducting wires and switches). US-A-4 060 705 discloses a continuous, flexible electric conductor with a semi-conductive second conductor element made of graphite-filled plastic; US-A-2 134 800 discloses no flexible intermediate conductor element. DE-A-1 942 565 discloses a switch with a flexible foam conductor element. The aim of the present invention is to provide a continuous, flexible electric conductor also capable of functioning as an electric switch, and which provides for forming electric lines with advantages over the prior art. With this aim in view, according to the present invention, there is provided a continuous, flexible electric conductor with the features of claim 1. The said structure of the said second electric conducting element is of the type described in Italian Patent Application n. 67072-A/87 filed on 5 February, 1987, and entitled: "Electric resistor designed for use as an electric conducting element in an electric circuit, and relative manufacturing process." The present invention will be described, by way of example, with reference to the accompanying drawings, in which : Fig.1 shows a longitudnal section of a length of the conductor according to the present invention; Fig.2 shows an enlarged longitudinal section of a length of the said conductor; Fig.3 shows the structure of the material with which is formed the second electric conducting element forming part of the electric conductor according to the present invention; Fig.4 shows a view in perspective of a length of the conductor according to the present invention connected to an electrical source, a user device, and a device for generating pressure on the conductor and so closing the electric circuit formed by the said components and conductor. The continuous, flexible electric conductor according to the present invention, a short length of which is shown in Fig.1, comprises a first elongated electric conducting element 1, and a spacer element 2 formed from insulating material and placed over surface 3 of the said first element, in such a manner as to shield all but given portions of the said surface 3. In the embodiment shown in the accompanying drawings, the said spacer element 2 substantially consists of a continuous tape wound about the said surface 3, the said exposed portions therefore consisting of the portions of surface 3 lying between successive turns of the said tape. The conductor according to the present invention also comprises a second, tubular electric conducting element 4 having its inner surface resting on the outer surface of the said spacer element 2; a third, tubular electric conducting element 5 having its inner surface resting on the outer surface of the said second element 4, as shown clearly in Fig.1; and a tubular sheath 6 formed from insulating material and placed over the said third conducting element 5. The structure of the material from which the said second conducting element 4 is formed is as shown in Fig.3, and substantially comprises a supporting matrix 7 formed from flexible, electrically-insulating material and particles 8 of electrically-conductive material scattered in random, substantially uniform manner inside cells on the said matrix. The said cells communicate, at least partially, with one another, and are, at least partially, larger than the respective particles of electrically-conductive material housed inside the same, so as to leave a gap 9 (Fig.3) between the outer surface of each particle and the surface of the respective cell. The above material is described in detail in Patent Application n. 67072-A/87 filed on 5 February, 1987, by the present Applicant and entitled: "Electric resistor designed for use as an electric conducting element in an electric circuit, and relative manufacturing process". As stated in the above patent application, the said material is electrically-conductive enough for it to be actually employed as an electric conductor. Furthermore, when pressure is applied on the said material, there is a fall in electric resistance measured parallel to the pressure direction; which fall in resistance increases alongside increasing pressure. Such favorable performance is probably due to improved electrical conductivity of chains of particles 8. In fact, in addition to improving the conductivity of contacting-particle chains, increasing pressure also renders conductive any chains having gaps 9 between adjacent particles, by bridging the said gaps 9 and so enabling adjacent pairs of otherwise non-conductive particles to become conductive when sufficient external pressure is applied. The said first conducting element 1 conveniently consists simply of a number of metal wires, whereas the said third electric conducting element 5 consists of a plait of metal wires defining a tubular casing. The said spacer element 2 may be formed differently from the one described herein, and may comprise, for example, a number of separate spacer elements arranged contacting the outer surface 3 of conducting element 1; or a tube of flexible material having perforations for exposing given portions of surface 3 of conducting element 1; or even a braid formed from insulating material. Conducting elements 1 and 5 may also be structured differently from those described herein. The electric conductor according to the present invention may be connected to an electric current as shown in Fig.4, by series-connecting the first and third electric conductors, 1 and 5, to a current source, of which Fig.4 shows terminals 10, and to a user device 11. When connected as shown, the conductor may also be operated as a switch, by applying given, relatively low pressure in any manner on the outer surface of the conductor. For this purpose, provision may be made for a grip 12 inside which a length of the conductor is placed, and which provides for exerting substantially radial pressure on the outer surface of the conductor, when arms 13 on the said grip 12 are pressed together in the direction of the conductor axis. Manual pressure applied directly on the conductor by the user, e.g. by gripping the conductor between two fingers, is also sufficient for the purpose. If no pressure is applied on the outer surface of the conductor, no current circulates in the line so formed. In fact, the said first and third conductors, 1 and 5, connected to the current source and user device, are insulated from each other by spacer element 2; and the portions of surface 3 of conducting element 1 left exposed by the said spacer element 2 are separated from the inner surface of conducting element 4 by a layer of air, thus cutting off current flow between conducting elements 1 and 4. When, on the other hand, pressure is applied on the outer surface of the conductor according to the present invention, e.g. using grip 12 in Fig.4, portion 14 (Fig.2) on which the said pressure is applied flexes radially, substantially as shown in Fig.2, so as to bring inner surface 15 of the said portion 14 substantially into contact with outer surface 3 of conducting element 1 left exposed by spacer element 2. Localised electrical contact is thus established between conducting elements 1 and 4 on portion 14, thus enabling current to flow substantially radially along conducting element 4, so as to close the Fig.4 electric circuit inside which current is allowed to flow. Flexed portion 14 of the conductor according to the present invention thus functions as a switch, capable of closing the said circuit when radial pressure is applied on the said portion 14. The said switch function may, of course, be performed by any short portion along conductor 4, which thus provides, in a simple, straightforward manner, for forming an electric line requiring a number of electric switches. What is more, the said line may be formed with no connections required to switch terminals or electric conductors. Switches formed according to the present invention also provide for greater reliability, by virtue of the contact surfaces for closing the said circuit being airtight and fully insulated from the outside atmosphere. When pressure is removed from the outer surface of the conductor according to the present invention, the said second conducting element 4 returns to its original shape, thus opening the said circuit. This is achieved by virtue of the high degree of elasticity of the material from which the said conducting element 4 is formed, and the characteristics of which are described in detail in the aforementioned patent application. A further characteristic of the said material is that its electrical conductivity, and therefore also the amount of current flowing along the said line, increases alongside increasing pressure on the material, which favourable property may be employed to advantage in the construction of the said line. Furthermore, by replacing the said conducting element 1 with a calibrated resistor and selectivity flexing a number of conductor portions, one at a time, it is possible to determine which of the said portions has been flexed, by measuring total resistance along the line. In other words, the system functions in the same way as a rheostat, the wiper of which is set to various flexure points on element 4. To those skilled in the art it will be clear that changes may be made to the electric conductor as described and illustrated herein without, however, departing from the scope of the present invention.

Claims: A continuous, flexible electric conductor comprising: a first (1) and a second (4) electric conducting elements of substantially elongated shape and which extend for the whole length of the flexible electric conductor, said second conducting element (4) being formed from a, conductive material and being shaped as a tubular member surrounding said first conducting element (1); a spacer element (2) formed from electrically-insulating material and interposed between said first and second conducting elements (1,4) for the whole length thereof, said spacer element (2) being placed over an outer surface (3) of the first conducting element (1) in such a manner to cover all but given portions thereof and the second conducting element (4) resting with its inner surface on the outer surface of the spacer element (2) so that the spacer element electrically insulates from each other said conducting elements (1,4) leaving an air gap therebetween in correspondence with said given portions; a third electric conducting element (5) shaped as a tubular member and having its inner surface resting on the outer surface of said second conducting element (4); and a tubular insulating sheath (6) placed over the outside of said third conducting element (5); the structure of the material from which said second conducting element (4) is formed comprising a supporting matrix (7) formed from flexible, electrically-insulating material and particles (8) of electrically-conductive material homogeneously dispersed in said matrix (7), characterized in that said matrix (7) has cells communicating at least partially with one another and inside which said particles (8) are scattered, at least some of the cells being, larger in size than the respective particles (8) housed inside the same so as to leave a gap (9) between the outer surface of each particle (8) and the surface of the respective cell, so that the material from which said second conducting element (4) is formed is conductive enough to be employed as an electric conductor when the material itself is not deformed, and increases in electric conductivity when deformed by an external pressure in the direction parallel to the pressure due to an increasing fall in electric resistance with increasing external pressure. An electric conductor as claimed in Claim 1, characterised by the fact that the said spacer element (2) consists of a tape wound about the said surface of the said first conducting element (1). An electric conductor as claimed in Claim 1 or 2, characterised by the fact that the said first conducting element (1) consists of a number of metal wires. An electric conductor as claimed in one of the foregoing Claims, characterised by the fact that the said third conducting element (5) consists of a metal plait defining a tubular casing.

Inventors: LODINI, PAOLO
Applicants: LEDA LOGARITHMIC ELECTRICAL DEVICES FOR AUTOMATION S.R.L.
Application year: 1988
Main classification: H01H3
IPC codes: H01H13, H01H1, H01B7, H01H3