Patent ID: 12228257

While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION OF THE FIGURES

FIG.1is a plan view showing an illustrative embodiment of a decorative lighting assembly100. Decorative lighting assembly100comprises a first power wire102and a second power wire104. InFIG.1, first power wire102and second power wire104are cooperating to surround a display area106of decorative lighting assembly100. With reference toFIG.1it will be appreciated that decorative lighting assembly100includes a plurality of lamp assemblies108distributed across display area106. The plurality of lamp assemblies108include a first column120A of lamp assemblies108aligned along a first line122A, a second column120B of lamp assemblies108aligned along a second line122B, and a third column120C of lamp assemblies108aligned along a third line122C.

A plurality of lamp assemblies108of decorative lighting assembly100may be inter-connected by wires to form one or more electrical circuits. A plurality of lamp assemblies108of decorative lighting assembly100may be mechanically coupled by cords which provide mechanical support. In some embodiments, the wires and the cords cooperate to form a net-like structure. In the embodiment ofFIG.1, the plurality of lamp assemblies108include a fourth column120D of lamp assemblies108aligned along a first line122D and a fifth column120E of lamp assemblies aligned along a fifth line122E.

Decorative lighting assembly100ofFIG.1includes a power plug124. Power plug124may comprise a traditional power plug comprising housing126, first power terminal128A and a second power terminal128B for plugging into an outlet of an external power source, which may be an alternating-current (AC) power source. First power wire102is electrically connected to first power terminal128A of power plug124. Second power wire104is electrically connected to second power terminal128B of power plug124. In some embodiments, first power wire102and second power wire104may comprise a reinforced wire such as the reinforced wire described in issued U.S. Pat. No. 9,243,788, which is herein incorporated by reference in its entirety. Reinforced wire is depicted inFIGS.19-22and described herein.

With reference toFIG.1, it will be appreciated that display area106of decorative lighting assembly100has a shape generally corresponding to a four-sided polygon. In the embodiment ofFIG.1, the shape of display area generally corresponds to a rectangle having a first long side, a second long side, a first short side, and a second short side. First power wire102defines the first short side, the first long side, and the second short side of a rectangle in the embodiment ofFIG.1. Second power wire104defines the second long side of a rectangle in the embodiment ofFIG.1.

FIG.2is a plan view showing an additional illustrative embodiment of decorative lighting assembly100shown in the previous figure. Decorative lighting assembly100comprises a first power wire102and a second power wire104. InFIG.2, first power wire102and second power wire104are cooperating to surround a display area106of decorative lighting assembly100. With reference toFIG.2it will be appreciated that decorative lighting assembly100includes a plurality of lamp assemblies108distributed across display area106. The plurality of lamp assemblies108include a first column120A of lamp assemblies108, a second column120B of lamp assemblies108, a third column120C of lamp assemblies108, and a fourth column120D of lamp assemblies108.

In the embodiment ofFIG.2, a plurality of intermediate wires130are disposed along a first zig-zag path132A connecting the lamp assemblies in first column120A with the lamp assemblies in second column120B. In some embodiments, decorative lighting assembly100may include a cord that is disposed along a second zig-zag path connecting the lamp assemblies in second column120B with the lamp assemblies in third column120C. In the embodiment ofFIG.2, decorative lighting assembly100includes a plurality of intermediate wires130that are disposed along a third zig-zag path132C connecting the lamp assemblies in third column120C with the lamp assemblies in fourth column120D. In some embodiments, intermediate wires130, first power wire102and second power wire104may comprise a reinforced wire such as the reinforced wire described in issued U.S. Pat. No. 9,243,788, which is herein incorporated by reference in its entirety. Reinforced wire is depicted inFIGS.19-22and described herein.

Decorative lighting assembly100ofFIG.2, includes a first series circuit134A comprising a first lamp assembly108A electrically connected to first power wire102at a connector B1and an nth lamp assembly108N electrically connected to second power wire104at a connector B2. In the embodiment ofFIG.2, a plurality of intermediate lamp assemblies108are electrically connected in series between first lamp assembly108A and nth lamp assembly108A.

With reference toFIG.2, it will be appreciated that first series circuit134follows a winding path between connector B1and connector B2so that the lamp assemblies108are distributed across display area106. In the embodiment ofFIG.2, the winding path of first series circuit134includes a plurality of intermediate wires130disposed along the first zig-zag path132A connecting the lamp assemblies in first column120A with the lamp assemblies108in second column120B. First series circuit134also includes the plurality of intermediate wires130disposed along third zig-zag path132C connecting the lamp assemblies108in third column120C with the lamp assemblies108in fourth column120D.

FIG.3is a plan view showing an additional illustrative embodiment of decorative lighting assembly100shown in the previous figure. Decorative lighting assembly100comprises a first power wire102and a second power wire104. InFIG.3, first power wire102and second power wire104are cooperating to surround a display area106of decorative lighting assembly100. With reference toFIG.3it will be appreciated that decorative lighting assembly100includes a plurality of lamp assemblies108distributed across display area106. The plurality of lamp assemblies108include a first column120A of lamp assemblies108, a second column120B of lamp assemblies108, a third column120C of lamp assemblies108, a fourth column120of lamp assemblies108, and a fifth column120E of lamp assemblies108.

In the embodiment ofFIG.3, a plurality of lamp assemblies108of decorative lighting assembly100are mechanically coupled by cords136which provide mechanical support. In some embodiments, a plurality of lamp assemblies108of decorative lighting assembly100may be inter-connected by wires to form one or more electrical circuits. In some embodiments, the wires and the cords cooperate to form a net-like structure.

Decorative lighting assembly100ofFIG.1, includes a cord136that is disposed along a second zig-zag path132A connecting the lamp assemblies in second column120B with the lamp assemblies in third column120C. In the embodiment ofFIG.3, cord136also extends along a fourth zig-zag path132D connecting the lamp assemblies in fourth column120D with the lamp assemblies in fifth column120E. Cord136is illustrated using dashed lines inFIG.3. In some embodiments, cord136may comprise a plurality of cord segments.

In the embodiment ofFIG.3, cord136A comprises a single cord that extends through both second zig-zag path132B and the fourth zig-zag path132D. Decorative lighting assembly100ofFIG.3, includes a fastener C that mechanically couples a first end of cord136A and a second end of cord136A to first power wire102. In the embodiment ofFIG.3, first power wire102extends through a passageway defined by fastener C.

Decorative lighting assembly100ofFIG.3also includes a bushing A2that mechanically couples an intermediate portion of cord136A to second power wire104. In the embodiment ofFIG.3, cord136A and second power wire104extend through a passageway defined by bushing A2. Also in the embodiment ofFIG.3, cord136A extends through a passageway defined by a clip of each lamp assembly108in second column120A and each lamp assembly108in third column120C.

FIG.4is a plan view showing an additional illustrative embodiment of decorative lighting assembly100shown in the previous figure. Decorative lighting assembly100comprises a first power wire102and a second power wire104. InFIG.4, first power wire102and second power wire104are cooperating to surround a display area106of decorative lighting assembly100. With reference toFIG.4it will be appreciated that decorative lighting assembly100includes a plurality of lamp assemblies108distributed across display area106. The plurality of lamp assemblies108include a first column120A of lamp assemblies108, a second column120B of lamp assemblies108, a third column120C of lamp assemblies108, a fourth column120of lamp assemblies108, and a fifth column120E of lamp assemblies108.

In the embodiment ofFIG.4, a plurality of lamp assemblies108of decorative lighting assembly100are inter-connected by intermediate wires130to form electrical circuits. Also in the embodiment ofFIG.4, a plurality of lamp assemblies108of decorative lighting assembly100are mechanically coupled by cords136which provide mechanical support. In the embodiment ofFIG.4, the wires and the cords cooperate to form a net-like structure. For purposes of illustration, the cords are illustrated using dashed lines and the wires are illustrated using solid lines inFIG.4.

In the embodiment ofFIG.4, a plurality of intermediate wires130are disposed along a first zig-zag path132A connecting the lamp assemblies in first column120A with the lamp assemblies in second column120B. Also in the embodiment ofFIG.4, decorative lighting assembly100includes a cord136A that extends along a second zig-zag path132B connecting the lamp assemblies in second column120B with the lamp assemblies in third column120C. A plurality of intermediate wires130are disposed along a third zig-zag path132C connecting the lamp assemblies in third column120C with the lamp assemblies in fourth column120D. In the embodiment ofFIG.4, cord136A extends along a fourth zig-zag path132D connecting the lamp assemblies in fourth column120D with the lamp assemblies in fifth column120E. Cord136A is illustrated using dashed lines inFIG.4. In some embodiments, cord136A may comprise a plurality of cord segments.

In the embodiment ofFIG.4, cord136A comprises a single cord that extends through both second zig-zag path132B and the fourth zig-zag path132D. Decorative lighting assembly100ofFIG.4, includes a fastener C that mechanically couples a first end of cord136A and a second end of cord136A to first power wire102. In the embodiment ofFIG.4, first power wire102extends through a passageway defined by fastener C.

With reference toFIG.4, it will be appreciated that a top-most intermediate wire extends between a top-most lamp assembly in first column120A and a top-most lamp assembly in third column120C. In the embodiment ofFIG.4, a bushing A1mechanically couples an intermediate portion of the first top-most intermediate wire to second power wire104. In the embodiment ofFIG.4, the second power wire104and the top-most intermediate wire extend through a passageway defined by bushing A1.

In some embodiments of decorative lighting assembly100, the intermediate wires130have a first outer diameter, the cords136have a second outer diameter, and the second outer diameter is substantially equal to the first outer diameter so that decorative lighting assembly100has a uniform appearance.

In some embodiments of decorative lighting assembly100, the intermediate wires130comprise a plurality of conductor strands and an outer insulating layer adjacent to, and covering, one or more of the conductor strands. The cords136may comprise a solid strand. In some embodiments of decorative lighting assembly100, the insulating layer of the intermediate wires130and the solid strand of the cords136comprise the same material so that the decorative lighting assembly has a uniform appearance. In some embodiments of decorative lighting assembly100, the insulating layer of the intermediate wires130and the solid strand of the cords136are substantially the same color so that the decorative lighting assembly has a uniform appearance.

In some embodiments of decorative lighting assembly100, the first power wire comprises 18 AWG wire, the second power wire comprises 18 AWG wire, and the intermediate wires comprise 22 AWG wire.

In some embodiments of decorative lighting assembly100, the first power wire comprises 18 AWG wire, the second power wire comprises 18 AWG wire, and the intermediate wires comprise 22 AWG reinforced wire.

In some embodiments of decorative lighting assembly100, the first power wire comprises 18 AWG wire, the second power wire comprises 18 AWG wire, and the intermediate wires comprise 25 AWG reinforced wire.

FIG.5Ais an exploded perspective view showing a second power wire104, an intermediate wire130, and a bushing A1.FIG.5Bis a perspective view showing second power wire104, intermediate wire130, and bushing A1ofFIG.5Ain an assembled state. InFIG.5B, intermediate wire130and second power wire104can be see extending through a passageway P defined by bushing A1.

FIG.5Cis a perspective view showing a second power wire104, a cord136, and a bushing A2. In the embodiment ofFIG.5C, cord136A and second power wire104extend through a passageway P defined by bushing A2.

FIG.6Ais an exploded perspective view showing portions of a cord136A and a male portion142M of fastener C. A first end140A and a second end140B of cord136A are visible inFIG.6A.

FIG.6Bis an additional perspective view showing portions of cord136A and male portion142M of fastener C. In the embodiment ofFIG.6B, first end140A and second end140B of cord136A are fixed to male portion142M of fastener C.

FIG.6Cis an exploded perspective view showing a male portion142M of fastener C and a female portion142F of fastener C. In the embodiment ofFIG.6C, first end140A and second end140B of cord136A are fixed to male portion142M of fastener C. InFIG.6C, a first power wire102can be seen extending through a passageway P defined by female portion142F of fastener C.

FIG.6Dis an exploded perspective view showing cord136coupled to first power wire102A by fastener C. In the embodiment ofFIG.6D, first end140A and second end140B of cord136A are fixed to male portion142M of fastener C. InFIG.6D, first power wire102can be seen extending through a passageway P defined by fastener C.

FIG.7Ais a perspective view showing a connector B2. In the embodiment ofFIG.7A, a first portion144A of a power wire102, a second portion144B of power wire102and an intermediate wire130are electrically connected to each other by connector B2. The embodiment ofFIG.7Aalso includes a cord136. In the embodiment ofFIG.7A, cord136, first portion144A of power wire102, second portion144B of power wire102, and intermediate wire130are all mechanically coupled to each other by connector B2.

FIG.7Bis a perspective view showing a connector B2. In the embodiment ofFIG.7B, connector B2is sectioned so that one end of cord136can be seen captured inside connector B2. In the embodiment ofFIG.7B, cord136, first portion144A of power wire102, second portion144B of power wire102, and intermediate wire130are all mechanically coupled to each other by connector B2. First portion144A of a power wire102, a second portion144B of power wire102and an intermediate wire130are electrically connected to each other by connector B2in the embodiment ofFIG.7B.

FIG.8Ais a perspective view showing an alternate embodiment of connector B2shown inFIG.7AandFIG.7B.

FIG.8Bis a plan view showing the connector B2shown inFIG.8A.

FIG.9Ais a perspective view showing an alternate embodiment of connector B2shown inFIG.7AandFIG.7B.

FIG.9Bis a plan view showing the connector B2shown inFIG.9A.

FIG.10Ais an exploded perspective view showing a male portion154M of connector B1and a female portion152F of connector B1. A first portion154A of a power wire102, a second portion154B of power wire102and an intermediate wire130are all illustrated in the exploded view ofFIG.10A.

FIG.10Bis a partially assembled perspective view showing male portion154M of connector B1and female portion152F of connector B1. In the embodiment ofFIG.10B, first portion154A of power wire102has been inserted into male portion154M of connector B1. Also in the embodiment ofFIG.10B, a second portion154B of power wire102and an intermediate wire130have been inserted into female portion154F of connector B1.

FIG.10Cis an assembled perspective view showing a male portion154M of connector B1and a female portion152F of connector B1. In the embodiment ofFIG.10C, male portion154M of connector B1has been inserted into female portion152F of connector B1. First portion154A of power wire102, second portion154B of power wire102and intermediate wire130all are electrically connected to each other by connector B2in the embodiment ofFIG.10C. First portion154A of power wire102, second portion154B of power wire102, and intermediate wire130are also mechanically coupled to each other by connector B2in the embodiment ofFIG.10C.

FIG.10Dis a section view further illustrating male portion154M of connector B1and female portion152F of connector B1.

FIG.11is a plan view showing an illustrative embodiment of a decorative lighting assembly300. Decorative lighting assembly300comprises a first power wire302and a second power wire304. InFIG.11, first power wire302and second power wire304are cooperating to surround a display area306of decorative lighting assembly300. With reference toFIG.11it will be appreciated that decorative lighting assembly300includes a plurality of lamp assemblies308distributed across display area306. The plurality of lamp assemblies308include a first row320A of lamp assemblies308aligned along a first line322A, a second row320B of lamp assemblies308aligned along a second line322B, and a third row320C of lamp assemblies308aligned along a third line322C.

A plurality of lamp assemblies308of decorative lighting assembly300may be inter-connected by wires to form one or more electrical circuits. A plurality of lamp assemblies308of decorative lighting assembly300may be mechanically coupled by cords which provide mechanical support. In some embodiments, the wires and the cords cooperate to form a net-like structure. In the embodiment ofFIG.11, the plurality of lamp assemblies308include a fourth row320D of lamp assemblies308aligned along a first line322D and a fifth row320E of lamp assemblies308aligned along a fifth line322E. The decorative lighting assembly300also includes a zeroth row320Z of lamp assemblies308aligned along a zeroth line322Z in the embodiment ofFIG.11.

Decorative lighting assembly300ofFIG.11includes a power plug324. Power plug324may comprise a traditional power plug comprising housing326, first power terminal328A and a second power terminal328B for plugging into an outlet of an external power source, which may be an alternating-current (AC) power source. First power wire302is electrically connected to first power terminal328A of power plug324. Second power wire304is electrically connected to second power terminal328B of power plug324. In some embodiments, first power wire302and second power wire304may comprise a reinforced wire such as the reinforced wire described in issued U.S. Pat. No. 9,243,788, which is herein incorporated by reference in its entirety. Reinforced wire is depicted inFIGS.19-22and described herein.

With reference toFIG.11, it will be appreciated that display area306of decorative lighting assembly300has a shape generally corresponding to a four-sided polygon. In the embodiment ofFIG.11, the shape of display area generally corresponds to a rectangle having a first long side, a second long side, a first short side, and a second short side. First power wire302defines the first short side and the first long side of a rectangle in the embodiment ofFIG.11. Second power wire304defines the second short side and the second long side of a rectangle in the embodiment ofFIG.11.

FIG.12is a plan view showing an additional illustrative embodiment of decorative lighting assembly300shown in the previous figure. Decorative lighting assembly300comprises a first power wire302and a second power wire304. InFIG.12, first power wire302and second power wire304are cooperating to surround a display area306of decorative lighting assembly300. With reference toFIG.12it will be appreciated that decorative lighting assembly300includes a plurality of lamp assemblies308distributed across display area306. The plurality of lamp assemblies308include a first row320A of lamp assemblies308, a second row320B of lamp assemblies308, a third row320C of lamp assemblies308, a fourth row320of lamp assemblies308, and a fifth row320E of lamp assemblies308.

In the embodiment ofFIG.12, a plurality of lamp assemblies308of decorative lighting assembly300are mechanically coupled by cords336which provide mechanical support. In some embodiments, a plurality of lamp assemblies308of decorative lighting assembly300may be inter-connected by wires to form one or more electrical circuits. In some embodiments, the wires and the cords cooperate to form a net-like structure.

In the embodiment ofFIG.12, a first cord336A is disposed along a first zig-zag path332A mechanically coupling the lamp assemblies308in the first row320A with the lamp assemblies308in the second row320B. A second cord336B is disposed along a third zig-zag path332C mechanically coupling the lamp assemblies308in the third row320C with the lamp assemblies in the fourth row320D in the embodiment ofFIG.12. In some embodiments, each cord336comprises a plurality of cord segments.

In the embodiment ofFIG.12, a first connector398A mechanically couples a first end of a first cord336A to the first power wire304and a second connector398B mechanically couples a second end of the first cord336A to the second power wire306. A third connector398C mechanically couples a first end of the second cord336B to the first power wire304and a fourth connector398D mechanically couples a second end of the second cord336B to the second power wire306in the embodiment ofFIG.12.

FIG.13is a plan view showing an additional illustrative embodiment of decorative lighting assembly300shown in the previous figure. Decorative lighting assembly300comprises a first power wire302and a second power wire304. InFIG.13, first power wire302and second power wire304are cooperating to surround a display area306of decorative lighting assembly300. With reference toFIG.13it will be appreciated that decorative lighting assembly300includes a plurality of lamp assemblies308distributed across display area306. The plurality of lamp assemblies308include a first row320A of lamp assemblies308, a second row320B of lamp assemblies308, a third row320C of lamp assemblies308, and a fourth row320D of lamp assemblies308.

In the embodiment ofFIG.13, a plurality of intermediate wires330are disposed along a zeroth zig-zag path332Z connecting the lamp assemblies308in the zeroth row320Z with the lamp assemblies308in the first row320A. Also in the embodiment ofFIG.13, a plurality of intermediate wires330are disposed along a second zig-zag path332B connecting the lamp assemblies308in the second row320B with the lamp assemblies308in the third row320C. A plurality of intermediate wires330disposed along a fourth zig-zag path332D connecting the lamp assemblies308in the fourth row320D with the lamp assemblies308in the fifth row320E in the embodiment ofFIG.13.

In some embodiments, intermediate wires330, first power wire302and second power wire304may comprise a reinforced wire such as the reinforced wire described in issued U.S. Pat. No. 9,243,788, which is herein incorporated by reference in its entirety. Reinforced wire is depicted inFIGS.19-22and described herein.

Decorative lighting assembly300ofFIG.13, includes a first series circuit334A comprising a plurality of lamp assemblies308and intermediate wires330connected between the first power wire304and second power wire306. In the embodiment ofFIG.13, the first series circuit334A includes a plurality of intermediate wires330disposed along a zeroth zig-zag path332Z connecting the lamp assemblies308in the zeroth row320Z with the lamp assemblies308in the first row320A. In the embodiment ofFIG.13, a zeroth connector398Z electrically connects a first end of the first series circuit334A to the first power wire304and a second connector398B electrically connects a second end of the first series circuit334A to the second power wire306.

Decorative lighting assembly300ofFIG.13, also includes a second series circuit334B comprising a plurality of lamp assemblies308and intermediate wires330connected between the first power wire304and second power wire306. A third series circuit334C of decorative lighting assembly300can also be seen inFIG.13. The third series circuit334C comprises a plurality of lamp assemblies308and intermediate wires330connected between the first power wire304and second power wire306.

In the embodiment ofFIG.13, the second series circuit334B includes a plurality of intermediate wires330disposed along the second zig-zag path332B connecting the lamp assemblies308in the second row320B with the lamp assemblies308in the third row320C. In the embodiment ofFIG.13, the third series circuit334C includes a plurality of intermediate wires330disposed along the fourth zig-zag path332D connecting the lamp assemblies308in the fourth row320D with the lamp assemblies308in the fifth row320E. In the embodiment ofFIG.13, a first connector398A electrically connects a first end of the second series circuit334B to the first power wire304and a fourth connector398D electrically connects a second end of the second series circuit334B to the second power wire306. In the embodiment ofFIG.13, a third connector398C electrically connects a first end of the third series circuit334B to the first power wire304and a fifth connector398E electrically connects a second end of the third series circuit334B to the second power wire306.

FIG.14is a plan view showing an additional illustrative embodiment of decorative lighting assembly300shown in the previous figure. Decorative lighting assembly300comprises a first power wire302and a second power wire304. InFIG.14, first power wire302and second power wire304are cooperating to surround a display area306of decorative lighting assembly300. With reference toFIG.14it will be appreciated that decorative lighting assembly300includes a plurality of lamp assemblies308distributed across display area306. The plurality of lamp assemblies308include a zeroth row320Z of lamp assemblies308, a first row320A of lamp assemblies308, a second row320B of lamp assemblies308, a third row320C of lamp assemblies308, a fourth row320of lamp assemblies308, and a fifth row320E of lamp assemblies308.

In the embodiment ofFIG.14, a plurality of lamp assemblies308of decorative lighting assembly300are inter-connected by intermediate wires330to form electrical circuits. Also in the embodiment ofFIG.14, a plurality of lamp assemblies308of decorative lighting assembly300are mechanically coupled by cords336which provide mechanical support. In the embodiment ofFIG.14, the wires and the cords cooperate to form a net-like structure.

In the embodiment ofFIG.14, a plurality of intermediate wires330are disposed along a zeroth zig-zag path332Z connecting the lamp assemblies308in the zeroth row320Z with the lamp assemblies308in the first row320A. A first cord336A is disposed along a first zig-zag path332A mechanically coupling the lamp assemblies308in the first row320A with the lamp assemblies308in the second row320B in the embodiment ofFIG.14. Also in the embodiment ofFIG.14, a plurality of intermediate wires330are disposed along a second zig-zag path332B connecting the lamp assemblies308in the second row320B with the lamp assemblies308in the third row320C.

A second cord336B is disposed along a third zig-zag path332C mechanically coupling the lamp assemblies308in the third row320C with the lamp assemblies in the fourth row320D in the embodiment ofFIG.14. A plurality of intermediate wires330disposed along a fourth zig-zag path332D connecting the lamp assemblies308in the fourth row320D with the lamp assemblies308in the fifth row320E in the embodiment ofFIG.14.

Decorative lighting assembly300ofFIG.14, includes a first series circuit334A comprising a plurality of lamp assemblies308and intermediate wires330connected between the first power wire304and second power wire306. In the embodiment ofFIG.14, the first series circuit334A includes a plurality of intermediate wires330disposed along a zeroth zig-zag path332Z connecting the lamp assemblies308in the zeroth row320Z with the lamp assemblies308in the first row320A. In the embodiment ofFIG.14, a zeroth connector398Z electrically connects a first end of the first series circuit334A to the first power wire304and a second connector398B electrically connects a second end of the first series circuit334A to the second power wire306.

Decorative lighting assembly300ofFIG.14, also includes a second series circuit334B comprising a plurality of lamp assemblies308and intermediate wires330connected between the first power wire304and second power wire306. A third series circuit334C of decorative lighting assembly300can also be seen inFIG.14. The third series circuit334C comprises a plurality of lamp assemblies308and intermediate wires330connected between the first power wire304and second power wire306.

In the embodiment ofFIG.14, the second series circuit334B includes a plurality of intermediate wires330disposed along the second zig-zag path332B connecting the lamp assemblies308in the second row320B with the lamp assemblies308in the third row320C. In the embodiment ofFIG.14, the third series circuit334C includes a plurality of intermediate wires330disposed along the fourth zig-zag path332D connecting the lamp assemblies308in the fourth row320D with the lamp assemblies308in the fifth row320E. In the embodiment ofFIG.13, a first connector398A electrically connects a first end of the second series circuit334B to the first power wire304and a fourth connector398D electrically connects a second end of the second series circuit334B to the second power wire306. In the embodiment ofFIG.13, a third connector398C electrically connects a first end of the third series circuit334B to the first power wire304and a fifth connector398E electrically connects a second end of the third series circuit334B to the second power wire306.

FIG.15is an enlarged plan view showing a portion of the decorative lighting assembly300shown in the previous figure. The portion of decorative lighting assembly300shown in FIG. includes a zeroth row320Z of lamp assemblies308, a first row320A of lamp assemblies308, a second row320B of lamp assemblies308and a third row320C of lamp assemblies308. In the embodiment ofFIG.15, a plurality of intermediate wires330are disposed along a zeroth zig-zag path332Z connecting the lamp assemblies308in the zeroth row320Z with the lamp assemblies308in the first row320A. A first cord336A is disposed along a first zig-zag path332A mechanically coupling the lamp assemblies308in the first row320A with the lamp assemblies308in the second row320B in the embodiment ofFIG.15. Also in the embodiment ofFIG.15, a plurality of intermediate wires330are disposed along a second zig-zag path332B connecting the lamp assemblies308in the second row320B with the lamp assemblies308in the third row320C.

With reference toFIG.15, it will be appreciated that a first loop of wire is fixed to each of the lamp assemblies308in the first row320A. A second loop of wire is also fixed to each of the lamp assemblies308in the first row320A. InFIG.15, the first cord336A can be seen extending through the first and second loops of wire fixed to each of the lamp assemblies308in the second row first row320A.

FIG.16is an enlarged perspective view further illustrating a portion of a decorative lighting assembly300. The portion of decorative lighting assembly300shown inFIG.16includes a plurality of lamp assemblies308distributed across a display area306. The plurality of lamp assemblies308include a first row320A of lamp assemblies308aligned along a first line322A, a second row320B of lamp assemblies308aligned along a second line322B, a third row320C of lamp assemblies308aligned along a third line322C, and a fourth row320D of lamp assemblies308aligned along a fourth line322D.

In the embodiment ofFIG.16, a plurality of intermediate wires330are disposed along a zeroth zig-zag path332Z connecting the lamp assemblies308in the zeroth row320Z with the lamp assemblies308in the first row320A. A first cord336A is disposed along a first zig-zag path332A mechanically coupling the lamp assemblies308in the first row320A with the lamp assemblies308in the second row320B in the embodiment ofFIG.16. Also in the embodiment ofFIG.16, a plurality of intermediate wires330are disposed along a second zig-zag path332B connecting the lamp assemblies308in the second row320B with the lamp assemblies308in the third row320C.

A second cord336B is disposed along a third zig-zag path332C mechanically coupling the lamp assemblies308in the third row320C with the lamp assemblies in the fourth row320D in the embodiment ofFIG.16. A plurality of intermediate wires330disposed along a fourth zig-zag path332D connecting the lamp assemblies308in the fourth row320D with the lamp assemblies308in the fifth row320E in the embodiment ofFIG.16.

FIG.17Ais a perspective view showing one side of a lamp assembly308.FIG.17Bis a perspective view showing another side of the lamp assembly308shown inFIG.17A.FIG.17AandFIG.17Bmay be collectively referred to asFIG.17. A connection396is formed between the lamp assembly308and a cord336. In the embodiment ofFIG.17, the connection396comprises a portion of the cord336that is extending through a tortuous path394defined by the lamp assembly308. A portion of the cord336extends through a first lumen392A and a second lumen392B defined by the housing of the lamp assembly308. A bight390of the cord336extends along the outside surface of the housing between the first lumen392A and the second lumen392B. A first bend389A is formed in the cord336between the first lumen392A and the bight390. A second bend389B is formed in the cord336between the second lumen392B and the bight390.

FIG.18Ais a perspective view showing one side of a lamp assembly308.FIG.18Bis a perspective view showing another side of the lamp assembly308shown inFIG.18A.FIG.18AandFIG.18Bmay be collectively referred to asFIG.18. A connection396is formed between the lamp assembly308and a cord336. In the embodiment ofFIG.18, the connection396comprises a portion of the cord336that is extending through a tortuous path394defined by the lamp assembly308. A portion of the cord336extends through a first lumen392A and a second lumen392B defined by the housing of the lamp assembly308. A bight390of the cord336extends along the outside surface of the housing between the first lumen392A and the second lumen392B. A first bend389A is formed in the cord336between the first lumen392A and the bight390. A second bend389B is formed in the cord336between the second lumen392B and the bight390.

Referring toFIG.19, an embodiment of reinforced decorative-lighting wire or cord1100is depicted. In an embodiment, reinforced decorative-lighting wire1100includes one or more reinforcing strands or threads1102, one or more conductor strands1104, and insulating layer or jacket1106. Conductor strands1104may form one or more layers, such as the depicted first conductor layer1108and second conductor layer1110. As will be described further below, reinforcing strands1102and conductor strands1104may be arranged in a variety of manners, and in a variety of quantities, dependent upon a number of factors, including desired wire properties, including, but not limited to, tensile strength, resistivity and conductivity.

Reinforced decorative-lighting wire1100may comprise a variety of sizes, resistances, and ampacities, and may be described in terms of electrically-equivalent wire gauge standards, e.g., 20 AWG (American Wire Gauge), 22 AWG, 24 AWG, etc. For example, in an embodiment, wire1100may comprise a conductive equivalent to a wire normally described as a 22 AWG wire having an equivalent cross sectional area of conductive copper of approximately 0.326 mm2 and having a typical resistance of approximately 52.96 ohms/km, though the overall diameter of the complete wire may be greater than a standard 22 AWG wire due to the additional reinforcing strands.

Reinforced decorative-lighting wire1100may also be described in terms of other equivalent wire standards, such as Underwriter's Laboratories Standard UL 62 insofar as it pertains to decorative-lighting wire, including standards directed to Type XTW or Type CXTW as typically used in decorative-lighting applications. For example, an embodiment of a reinforced decorative-lighting wire1100may be designed to include characteristics equivalent to selected characteristics of an 18, 20 22, 25, or 25 AWG CXTW wire, particularly conductive characteristics such as DC resistance per conductor strand, and insulative characteristics.

As depicted inFIG.19, an embodiment of reinforced decorative-lighting wire1100comprises a single reinforcing strand1102, and multiple conductor strands1104. In an embodiment, conductor strands1104form two layers: first conductor layer1108and second layer1110, though it will be understood that conductors1104may form one, two, or more than two layers. Layers1108and1110form a stranded conductor of reinforced wire1100. A reinforced wire1100having the stranded conductor comprising multiple conductor strands1104may also be referred to as a “single” conductor reinforced wire1100to differentiate from standard twisted pairs of wires typically used in decorative lighting. However, it will be understood that in some applications, pairs of single-conductor reinforced wires1100may be twisted about one another to form reinforced twisted-pair wire sets.

In an embodiment, and as depicted, reinforcing strand1102extends axially along a length of wire1100, and along central wire Axis A, surrounded by, or adjacent to, conductor strands1104. In an embodiment, reinforcing strand1102is generally located radially at a center of wire1100.

Reinforcing strand1102may define a generally cylindrical shape defining a circular cross-sectional area, though the cross-sectional area may define other shapes, such as square, oval, rectangular, and so on. In other embodiments, and as will be described further below with respect toFIGS.20B, reinforcing strand1102may define a generally circular cross-sectional shape prior to assembly into wire1100, but then define a different, shape, such as an asymmetrical shape, after a manufacturing assembly process.

In an embodiment, central reinforcing strand1102comprises one or more fibers or strands of fibrous reinforcing material. In the depicted embodiment, reinforcing strand1102comprises a single strand or fiber of reinforcing material. In other embodiments, reinforcing strand1102comprises multiple strands of reinforcing material that may comprise twisted strands, threads or fibers such that reinforcing strand1102comprises a yarn of multiple strands or fibers.

In the embodiment depicted, reinforcing strand1102comprises a single 1500 Denier fiber having an outside diameter of approximately 0.45 mm. In another embodiment, reinforcing strand1102comprises a fiber ranging from 500 Denier to 2500 Denier. In other embodiments, reinforcing strand1102may comprise a larger or smaller diameter and/or greater or lesser Denier fiber depending on the properties of the reinforcing material and desired reinforcing properties. In an embodiment, reinforcing strand1102comprises a single or multi-fiber strand sized to be within the range of 1000 to 1500 Denier. Reinforced wire1100with reinforcing strands1102comprising such a size may provide appropriate reinforcing strength for wires1100that most decorative lighting applications that would typically use an 118-24 AWG standard wire.

The reinforcing material of reinforcing strand1102may comprise a generally non-conductive or nonmetallic material, such as a plastic or polymer, including a polyester or polyethylene (PE) material. In one such embodiment, reinforcing strand1102comprises a polyethylene terephthalate (PET) material. Other reinforcing materials may include, though will not be limited to, polystyrene, polyvinyl chloride (PVC), polyamide (PA), and so on. Reinforcing strand1102may consist entirely or substantially of a non-conductive or nonmetallic material, such as PET, though in some embodiments, reinforcing strand1102may comprise a composite material. Such a composite material may comprise a non-conductive material, such as PET, as well as some other conductive, partially-conductive, or other non-conductive material.

In an embodiment, and as depicted, reinforcing strand1102comprises a substantially solid structure in cross section (radially), as compared to a hollow core strand such as a pipe or other annular shape. Further, in an embodiment, reinforcing strand1102comprises the same material continuously along its axial length. In an embodiment, reinforcing strand1102may have a hardness that is less than a hardness of a conductor strand1104. In an embodiment, reinforcing strand1102has a Rockwell hardness of R117.

In an embodiment, reinforcing strand1102comprises primarily a PET material, having a specific gravity ranging from 1380-1405 kg/m3, and a melting point of 200-250 degrees Celsius. In other embodiments, reinforcing strand1102comprises a polymer having a specific gravity that ranges from 1000-2000 kg/m3, and a melting point of 1150-300 degrees Celsius. Material in such a range may provide an appropriate balance of strength and flexibility for decorative light string applications. Further, as will be explained further below, such properties allow for deformation of reinforcing strand1102during the manufacturing assembly process.

In an embodiment, wherein reinforcing strand1102comprises primarily a PET material, strand1102comprises an elongation at break of 300%, or may comprise an elongation range of 200% to 400%, and a tensile strength of 55 MPa (7,977 psi). Herein, tensile strength refers to its ordinary meaning as understood in the field of conductive wires, including tensile strength being the maximum amount of stress that wire1100can withstand before failing or breaking, while being stretched or pulled axially along axis A (along a length of wire1100) by opposing axial forces labeled F1 and F2 inFIG.19.

In another embodiment wherein strand1102comprises a PET material, an elongation property of strand1102ranges from 200% to 400%, and a tensile strength ranges from 45 to 65 MPa. In an embodiment, the elongation of strand1102may be less than an elongation of conductor strand1104. In another embodiment, the elongation of a strand1102may be approximately the same as, or greater than, a conductor strand1104. In an embodiment, the tensile strength of a strand1102may be less than the tensile strength of a conductor strand1104. In another embodiment, the tensile strength may be approximately the same as, or greater than, a conductor strand1104. In an embodiment, the elongation of a strand1102may be less than the overall elongation of reinforced wire1100. In another embodiment, the elongation may be approximately the same as, or greater than, reinforced wire1100. In an embodiment, the tensile strength of a strand1102may be less than the overall tensile strength of reinforced wire1100. In another embodiment, the tensile strength may be approximately the same as, or greater than, reinforced wire1100.

Conductor strands1104may comprise any number of known conductive materials, including metals and metal alloys, such as copper, aluminum, steel, nickel, aluminum, and so on. Embodiments of alloys may include copper aluminum alloy, copper steel alloy, and so on. In an embodiment, one or more conductor strands comprise soft-annealed copper strands, which may be uncoated, or in some embodiments, coated with tin. Conductor strands1104comprised of copper, including comprised primarily of copper, provide not only superior tensile strength, but also superior ductility properties as compared to conductor strands1104comprising other metals, such as aluminum. A relatively higher ductility deriving from the use of copper conductor strands1104, in combination with a polymer reinforcing strand1102, allows deformation, particularly elongation when wire1100is subjected to tensile stress. Such a feature provides advantages in decorative lighting. In contrast, stranded conductors commonly used in overhead power line applications typically rely on aluminum conductors having low ductility, resulting in low elongation. In such an application, sagging of the heavy power lines/conductors is a concern, and the desirable low ductility or inability to elongate, is an important consideration. On the other hand, in decorative lighting, the ability of a wire to deform or elongate (relatively high ductility, e.g., the ductility of copper) may be advantageous. For example, when subjected to a tensile stress or force, wire1100may elongate rather than break, thereby preventing exposure of conductor strands1104, and preventing a potentially hazardous situation. Elongation properties of reinforced decorative lighting wire1100are discussed further below.

Further, properties of high tensile strength, flexibility, and the ability to stretch or elongate when subjected to axial pulling may be advantageous for reinforced wire1100when applied to a decorative lighting apparatus. Unlike cables and wires used in overhead power transmission applications, wires used in decorative lighting applications tend to be supported over much of their length. For example, decorative light strings applied to trees, such as Christmas trees, are generally affixed to the branches of the tree and are well supported, with only very short runs of wire that are unsupported. Conversely, in overhead power transmission applications, extremely long lengths of wire are unsupported between power poles. Consequently, the materials and properties of cables and wires for such power transmission applications may be significantly different than those of reinforced decorative lighting wire1100as described herein.

In addition to ductility, tensile strength of conductor strands1104and associated conductor layers1106and1108, as well as overall tensile strength of reinforced wire1100remains a consideration. In an embodiment of reinforced wire1100comprising soft-annealed copper conductor strands1104, a tensile strength of each copper strand1104will have a higher tensile strength, for example, ranging from 200-250 N/mm2, as compared to aluminum alloys, for example, 100 N/mm2. In an embodiment, each conductor strand1104has a tensile strength that is less than a tensile strength of reinforcing strand1102. In one such embodiment, conductor strands1104comprise a copper material, and reinforcing strand1102comprises PET.

In an embodiment, each conductor strand1104comprises a continuous, solid-core strand, though the entire wire1100comprises a multi-stranded wire. In other embodiments, each conductor strand1104may comprise multiple, individual strands. In an embodiment, all strands have approximately the same average diameter.

In a stranded conductor embodiment of wire1100, individual conductor strands comprise 27 to 36 AWG copper conductor strands. In an embodiment, conductor strands comprise 27 AWG strands. In an embodiment, conductor strands comprise copper strands having diameters measuring, on average, 0.16 mm (34 AWG, or 0.16 AS). In other embodiments, copper strands comprise other diameters, including strands that have average diameters of 0.16 mm, or average diameters of approximately 0.16 mm, such as 0.16 mm+/−10%. In another embodiment, average diameters of copper strands used in a single wire1100range from 0.15 mm to 0.16 mm, or in another embodiment 0.25 mm+/−10%. In decorative lighting applications, a relatively wide range or tolerance in strand diameter may be sufficient due to a common practice of operating decorative light strands at currents significantly below maximum safe ampacity limits. Conductor strands1104may comprise copper strands complying with ASTM B 3-90 standards.

Conductor strands1104extend axially along Axis A, and may or may not be twisted about reinforcing strand1102or other conductor strands1104.

Conductor strands1104may generally be cylindrical, presenting a generally circular cross section, though in other embodiments, each strand1104may present other cross-sectional shapes.

The number of conductor strands1104may vary based on a combination of factors, including desired conductive properties, and mechanical design characteristics. For example, for a 22 AWG equivalent wire, which in the decorative lighting industry may typically comprise 116 copper strands, reinforced decorative-lighting wire1100may also comprise 116 conductor strands. In another embodiment reinforced wire1100may be equivalent to 25 AWG in its current-carrying capability (maximum of 0.73 A), and may comprise 8 conductor strands, which in an embodiment comprises (8) 0.16 mm diameter strands. In other embodiments of 25 AWG equivalent wire, reinforced wire1100may include 8-10 conductor strands1104; in an embodiment, each conductor strand1104may have a diameter averaging 0.16 mm, or alternatively, 0.157-0.154 mm.

In other embodiments of wire1100, which in an embodiment may comprise 24 AWG equivalent wire, reinforced wire1100may include 8 conductor strands1104; in an embodiment, each conductor strand1104may have a diameter averaging 0.16 mm, or alternatively, 0.157-0.154 mm.

In embodiments, the above configurations of strands1104may be combined with polymer reinforcing strands1102sized to fall within a range of 1000 to 1500 Denier.

The number of conductor strands1104may be greater or fewer than that of an equivalent wire having similar conductive properties, though it will be understood that particular embodiments of wire1100are intended to match the electrical or conductive properties of equivalent standard wires described by the American Wire Gauge standard, e.g., 22 AWG wire, such that even if the number of strands is not equal to the number of strands in an equivalent standard wire, the size of each conductor strand1104will be increased or decreased to maintain electrical equivalence. An embodiment of a reinforced decorative wire1100having electrical properties similar or equivalent to a 22 AWG wire will be described below to further clarify and emphasize the above.

Referring also toFIG.20AandFIG.20B, in the embodiment depicted, first conductor layer1108is formed of multiple conductor strands1104twisted about centrally-positioned reinforcing fiber1102. In the depicted embodiment, first conductor layer1108comprises five conductor strands1104. In other embodiments, first conductor layer1108comprises more or fewer strands. In an embodiment, the number of strands1104in first conductor layer1108ranges from three strands to eight strands.

Strands1104extend axially along Axis A and in an embodiment, are twisted about reinforcing strand1102. As depicted, strands1104are helically twisted about reinforcing strand1102in a counter-clockwise direction, though in other embodiments, strands1104may be twisted or wrapped about reinforcing wire1102in a clockwise direction.

Central axes of conductor strands1104are depicted inFIGS.19,20A and20Bby arrows B1′-B5(first layer1108) and C1-C11 (second layer1110).

The twist or “pitch” of conductor strands1104may be defined by a “length of lay”, or the length of conductor strand1104required to turn a full rotation, or turn 360 degrees. As compared to standard gauge wire having equivalent electrical properties, wire1100of the claimed invention may have lesser lengths of lay when the same number of conductor strands1104are used. For example, in an embodiment of a 22 AWG equivalent wire, a length of lay of a conductor strand1104of first layer1108is approximately 118.5 mm, as compared to approximately 32 mm for an equivalent standard 22 AWG wire commonly used for decorative lighting. The additional twists per unit of length, or decreased length of lay provides axial reinforcing strength in addition to the reinforcing strength added by reinforcing strands1102.

Furthermore, the shorter length of lay may allow further stretching and elongation of wire1100without breakage when subjected to axial opposing forces, such as F1 and F2 as depicted inFIG.19.

In an embodiment, conductor strands1104of layer1108each have an approximately equal length of lay, though in other embodiments, including some described further below, conductor strands1104may have different lengths of lay.

Additionally, unlike typical wires used in decorative lighting that comprise only conductive strands, i.e., no reinforcing strand, the use of one or more reinforcing strands1102in wire1100may allow for some slight radial compression of strands1102by conductor strands1104when wire1100is subjected to axial forces. This provides the added advantage of allowing wire1100to elongate even further than a typical decorative lighting wire of a similar wire gauge and ampacity.

Second conductor layer1110is formed on first conductor layer1108, and also comprises a plurality of conductor strands1104. In an embodiment, and as depicted, second conductor layer1110comprises eleven conductor strands1104. In other embodiments, second conductor layer1110comprises more or fewer strands1104. In an embodiment, the number of conductor strands1104in second layer1110ranges from four strands to 30 strands.

Strands1104extend axially along Axis A, and are adjacent strands1104of first layer1108. In an embodiment, strands1104of second layer1110are adjacent to, and twisted about first layer1108. As depicted, strands1104are twisted about layer1108and its strands1104in a counter-clockwise direction. As such, in an embodiment, conductor strands1104of second conductor layer1110twists in the same direction as the direction that conductor strands1104of second conductor layer1108twist. In other embodiments, strands1104may be twisted over layer1108in a clockwise direction, and may twist in a direction opposite to a twist direction of first conductor layer1110. Strands1104forming conductor layer1108generally are positioned adjacent one another.

In an embodiment, conductor strands1104of layer1110each have an approximately equal length of lay, though in other embodiments, including some described further below, conductor strands1104may have different lengths of lay.

Insulating layer (or jacket)1106wraps about second conductive layer1110, covering and insulating conductor strands1104and reinforcing strand1102. Insulating layer1106may comprise any of a variety of known insulating materials, including polymers such as PVC, PE, thermoplastics, and so on. In addition to providing insulative properties, insulating layer1106may add mechanical strength through its other properties. In an embodiment, insulating layer1106has a minimum elongation percentage of 150%. In an embodiment, insulating layer1106comprises a polymer having a composition different than the polymer comprising reinforcing strand1102.

Referring still toFIG.39, in an embodiment, wire1100comprises a reinforced 22 AWG-electrically-equivalent wire comprising a single reinforcing strand1102extending axially along a center of wire1100, surrounded by 116 twisted conductor strands1104, and overlaid with an insulating jacket layer1106. The116conductor strands1104comprise first conductive layer1108, consisting of 5 conductive strands1104, and second conductive layer1110, consisting of 11 conductive strands1104. In an embodiment, reinforcing strand1102comprises PET material in the form of a 11500 Denier strand; conductive strands1104comprise primarily copper; and insulating layer1106comprises PVC.

Each conductive strand1104defines an approximately 0.16 mm diameter, circular or round wire, such that the equivalent cross-sectional area of the conductive portion of wire1100is approximately the same as a standard 22 AWG wire, also denoted as 116/0.16 AS, meaning116strands of 0.16 mm diameter conductor strands. In this embodiment, the resistivity ranges from 54 to 57 ohms/km. In an embodiment, the resistivity is 56.8 ohms/km or less. In an embodiment, the resistivity is substantially 55 ohms/km.

The length of lay, sometimes referred to as lay of strand, of each conductor strand1104of first layer1108, in an embodiment is 32 mm or less. In an embodiment, the length of lay of conductor strand1104of first layer1108ranges from 15 mm to 25 mm. In an embodiment, the length of lay of conductor strands1104of first layer1108is approximately 18.5 mm. In an embodiment the length of lay of all conductor strands1104of first layer1108are approximately the same. In an embodiment, a lineal length of each strand per unit length is within 5% of an average lineal length (note: the lineal length of a strand will be longer than a unit length due to the helical twisting of a wire, e.g., a 1 foot length of wire1100will include strands1104having lineal lengths longer than 1 ft. In other embodiments, the lineal length of individual strands1104may vary more substantially per unit length of wire1100, particularly when lengths of lay of individual strands1104are allowed to vary from strand to strand.

The length of lay of conductor strands1104of second conductive layer1110may be the same as conductor strands1104of first conductor layer1108, or in some embodiments, may be different. In an embodiment a length of lay of conductor strands1104of second layer1110is 32 mm or less. In an embodiment, the length of lay of conductor strand1104of second layer1110ranges from 15 mm to 25 mm. In an embodiment, the length of lay of conductor strands1104of second layer1110is substantially 18.5 mm. In an embodiment, lengths of lay of conductor strands1104of both layers1108and1110are, on average, approximately 18.5 mm. In an embodiment, the direction of twisting is the same, as depicted inFIG.19.

In an embodiment, including an embodiment of 22 AWG reinforced wire1100, insulation layer1106, comprising primarily PVC material, has a minimum thickness of 0.69 mm. In an embodiment, insulation1106comprises a thickness ranging from 0.69 mm to 1.0 mm. In an embodiment, an average thickness of insulating layer1106has an average thickness of 0.76 mm or greater. In one such embodiment, insulating layer1106has an average thickness of 0.84. In an embodiment insulating layer1106has an insulation resistance of at least 225 MΩ/Kft.

In an embodiment, the overall diameter of wire1100in 22 AWG ranges from 2.40 to 2.70 mm. In an embodiment, an average overall diameter is approximately 2.6 mm; in an embodiment, an average overall wire1100diameter is 101 mil.

With respect to elongation, in an embodiment, wire1100has an elongation of 150% or greater. In an embodiment, the elongation of wire1100ranges from 150% to 400%. In one embodiment, wire1100exhibits 300% elongation, significantly longer than standard, all-copper multi-stranded 22 AWG CXTW wire.

With respect to tensile strength, embodiments of wire1100have an improved tensile strength, which in one embodiment includes a tensile strength of 1,500 PSI or greater. In an embodiment, the tensile strength ranges from 1,500 PSI to 4,000 PSI, in another embodiment, the tensile strength ranges from 2,500 to 3,500 PSI. Such a range may provide sufficient strength for various decorative lighting applications, including trees, net lights, sculptures, and so on. In some applications where wires are affixed tightly to supporting structure, such as trees of metal frames, a required tensile strength may be on the lower end of the range, while wires of light strings that are not affixed to, or are less supported, may require higher tensile strength due to possible pulling or yanking by a user.

Another method of describing and measuring “strength” of a wire, including a reinforced wire1100, and as commonly used in decorative lighting is to measure an axially-applied pulling force required to cause the wire to begin to break, such that an outer insulation shows breakage, or an inner conductor shows breakage. In an embodiment, reinforced wire1100may withstand axial pulling forces of various ranges depending on the particular reinforced wire1100configuration.

In an embodiment, reinforced wire1100may withstand a minimum axially-applied pulling force ranging from 22 lbf to 46 lbf. In one such embodiment, reinforced wire1100comprises an ampacity equivalent to a 22 AWG wire, and can withstand a minimum 22.4 lbf without breaking; in another embodiment, reinforced wire1100comprises an ampacity equivalent to a 20 AWG wire, and can withstand a minimum 30 lbf without breaking; in another embodiment, reinforced wire1100comprises an ampacity equivalent to a 18 AWG wire, and can withstand a minimum 46 lbf without breaking.

In another embodiment, reinforced wire1100comprises 7-10 conductor strands1104defining a range of minimum axial pulling force ranging from 22.4 lbf to 46 lbf. In one such embodiment, reinforced wire1100comprises 8 conductor strands and has a minimum axial pulling force at breakage of 46 lbf; in one such embodiment, each conductor strand1104may have an average diameter in the range of 0.15 mm to 0.17 mm; alternatively, each conductor strand1104may have an average diameter of 0.154 mm to 0.157 mm. Such ranges accommodate expected current flows in various decorative lighting applications, while offering substantial overall tensile strength.

In an embodiment, wire1100includes a 1500 Denier PET reinforcing strand1102extending axially along Axis A, 16 copper conductor strands of 0.16 mm average diameter (5 first layer1108strands and 11 second layer1110strands) having a 55 Ω/km resistivity, and insulating layer1106of PVC material. In one such embodiment, elongation is greater than 300% (in an embodiment is 306%), with a tensile strength of 2800 PSI, requiring a force of approximately 21 kg to break. Such a wire may be used as a substitute for standard 22 AWG wire, including 22 AWG CXTW wire for improved decorative-lighting applications.

Referring toFIG.20B, the wire1100ofFIGS.19and20Ais depicted again, but in this case, the configuration of wire1100, namely the relative positions of conductor strands1104and reinforcing strand1102, are somewhat different. In an embodiment, because of the malleable properties of reinforcing strand1102, including the fibrous nature, pliability, and so on, during manufacturing of wire1100, reinforcing strand1102may be deformed somewhat, which in turn, may cause first and second layer strands1108and1110to move relative to one another, and relative to reinforcing strand1102. As depicted inFIG.20B, at a particular cross section, reinforcing strand1102does not comprise a circular cross section, but rather, comprises another shape due to deformation. Such “deformation”, may actually be the result of radial displacement of individual strands or fibers of reinforcing strand1102that occur when layers of conductor strands1104are wound or twisted about generally central reinforcing strand1102. Such variation, may be caused by radial movement or deformation of reinforcing strand1102and may vary axially, or along a length of wire1100. Consequently, whileFIG.20Adepicts an ideal embodiment of wire1100in cross section, in other embodiments wire1100may comprise the relative structure depicted inFIG.20B, or some other similar structure. As such, embodiments of reinforced decorative wire1100may include a central reinforcing strand that may only be substantially, or mostly centrally located. Further, in such an embodiment, conductor strands1104may not be evenly spaced about reinforcing strand1102, as depicted, nor will strands1104of layer1110be evenly spaced about layer1108.

As described above, embodiments of wire1100are not limited to the 1-5-11 configuration described above (1 reinforcing strand1102, 5 first layer conductors1105and 11 second layer conductors1110).

Although embodiments of reinforced wire1100may comprise multi-layer conductor strand embodiments, such as those depicted inFIGS.19-20B, embodiments of reinforced wire1100may include only a single layer of conductor strands1104and a single reinforcing strand1102. Some such embodiments will be further described below, and may include the following embodiments: 10 conductor strands1104with a single reinforcing strand1102, which in an embodiment includes 0.15-0.16 mm diameter strands1104and 1000 Denier strand1102; 9 conductor strands1104with a single reinforcing strand1102, which in an embodiment includes 0.15-0.16 mm diameter strands1104and 1000 Denier strand1102; 8 conductor strands1104with a single reinforcing strand1102, which in an embodiment includes 0.15-0.16 mm diameter strands1104and 1500 Denier strand1102; and 7 conductor strands1104with a single reinforcing strand1102, which in an embodiment includes 0.15-0.16 mm diameter strands1104and 1500 Denier strand1102. In some such 7, 8, 9, or 110 stranded embodiments, when fewer conductor strands1104are used, a larger diameter and stronger reinforcing strand1102may be included to make up for the decrease in tensile strength due to fewer conductor strands1104.

Referring toFIG.21, another embodiment of reinforced decorative-lighting wire1100is depicted. This alternate embodiment of wire1100is substantially the same as the embodiment depicted inFIGS.19,20A and20B, and described above, with the exception of reinforcing strands1102. In this embodiment, rather than a single reinforcing strand1102, wire1100includes three reinforcing strands1102a,1102b, and1102c. Reinforcing strands1102a-102cextend axially through the center portion of wire1102. Strands1102a-102cmay or may not be twisted about one another. Twisting multiple strands1102may provide an additional reinforcing strength.

In an embodiment, fewer than three strands1102, namely two strands may be used. In other embodiments, greater than three strands1102may be used.

In an embodiment, the cross-sectional area of the three reinforcing strands1102a,1102b, and1102cis equivalent to the 1500 Denier strand described above with respect to the embodiment ofFIGS.19,20A and20B. In other embodiments, the size of reinforcing strands1102may be larger or smaller, depending on desired wire1100strength, with larger size strands and/or more strands1102being used for stronger reinforced wire1100.

Referring toFIG.22, another embodiment of wire1100is depicted. In this embodiment, wire1100still includes multiple reinforcing strands1102, first conductor layer1108comprising multiple conductors1104, second conductor layer1110comprising multiple conductors1104, and outer insulating layer1106. In the depicted embodiment, first conductor layer1108includes five conductors1104and second conductor layer1110includes eleven conductors1104, similar to the embodiments described above with respect toFIGS.19-21. However, in this embodiment, wire1100includes four reinforcing strands1102.

As depicted, first conductor layer1108actually includes a single, central conductor1104asurrounded by four outer conductors1104b,1104c,1104d, and1104e. Between each outer conductor1104b,1104c,1104dand1104fis a reinforcing strand1102. Second conductor layer1110is adjacent both the four conductors1104b-e, and the four reinforcing strands1102.

Embodiments of the invention are not intended to be limited to the specific patterns and structures depicted inFIGS.19-22. It will be understood that the number of conductors1104, number of reinforcing strands1102, and their combinations, may vary.

As described above, embodiments of the disclosure include a number of decorative lighting assemblies that are tangle resistant and easier to manufacture as compared to known decorative lighting structures. Various embodiments include, but are not limited to the following embodiments:Embodiment 1. A decorative lighting assembly, comprising:a first power wire electrically connected to a first power contact;a second power wire electrically connected to a second power contact;the first power wire and the second power wire cooperating to surround a display area of the decorative lighting assembly;a plurality of lamp assemblies distributed across the display area, the plurality of lamp assemblies including a first row of lamp assemblies aligned along a first line, a second row of lamp assemblies aligned along a second line, a third row of lamp assemblies aligned along a third line, and a fourth row of lamp assemblies aligned along a fourth line;a first cord disposed along a first zig-zag path mechanically coupling the lamp assemblies in the first row with the lamp assemblies in the second row;a plurality of intermediate wires disposed along a second zig-zag path mechanically coupling and electrically connecting the lamp assemblies in the second row with the lamp assemblies in the third row; anda second cord disposed along a third zig-zag path mechanically coupling the lamp assemblies in the third row with the lamp assemblies in the fourth row.Embodiment 2. The decorative lighting assembly of Embodiment 1, wherein the display area has a shape generally corresponding to a four-sided polygon.Embodiment 3. The decorative lighting assembly of Embodiment 2, wherein the shape of the display area generally corresponds to a rectangle having a first long side, a second long side, a first short side, and a second short side.Embodiment 4. The decorative lighting assembly of Embodiment 3, wherein:the first power wire defines the first short side and the first long side of the rectangle; and the second power wire defines the second short side and the second long side of the rectangle.Embodiment 5. The decorative lighting assembly of Embodiment 1, further comprising a fifth row of lamp assemblies aligned along a fifth line and a plurality of intermediate wires disposed along a zig-zag path connecting the lamp assemblies in the fourth row with the lamp assemblies in the fifth row.Embodiment 6. The decorative lighting assembly of Embodiment 1, further comprising a zeroth row of lamp assemblies aligned along a zeroth line and a plurality of intermediate wires disposed along a zeroth zig-zag path connecting the lamp assemblies in the zeroth row with the lamp assemblies in the first row.Embodiment 7. The decorative lighting assembly of Embodiment 1, further comprising a first connector that mechanically couples a first end of a cord to the first power wire and a second connector that mechanically couples a second end of the cord to the second power wire.Embodiment 8. The decorative lighting assembly of Embodiment 7, wherein the first connector forms an electrical connection between two portions of the first power wire and the second connector forms an electrical connection between two portions of the second power wire.Embodiment 9. The decorative lighting assembly of Embodiment 1, wherein the first power wire and the second power wire comprise reinforced wire.Embodiment 10. The decorative lighting assembly of Embodiment 9, wherein the intermediate wires comprise reinforced wire.Embodiment 11. The decorative lighting assembly of Embodiment 10, wherein the reinforced wire comprises:a longitudinally-extending reinforcing strand, the reinforcing strand comprising one or more fibers comprising a polymer material;a plurality of conductor strands wound about the reinforcing strand; andan outer insulating layer adjacent to, and covering, one or more of the conductor strands.Embodiment 12. The decorative lighting assembly of Embodiment 1, wherein:the first power wire comprises 18 AWG wire;the second power wire comprises 18 AWG wire; andthe intermediate wires comprise 22 AWG wire.Embodiment 13. The decorative lighting assembly of Embodiment 1, wherein:the first power wire comprises 18 AWG wire;the second power wire comprises 18 AWG wire; andthe intermediate wires comprise 22 AWG reinforced wire.Embodiment 14. The decorative lighting assembly of Embodiment 1, wherein:the first power wire comprises 18 AWG wire;the second power wire comprises 18 AWG wire; andthe intermediate wires comprise 25 AWG reinforced wire.Embodiment 15. The decorative lighting assembly of Embodiment 1, wherein:the intermediate wires have a first outer diameter;the at least one cord has a second outer diameter; andthe second outer diameter is substantially equal to the first outer diameter so that the decorative lighting assembly has a uniform appearance.Embodiment 16. The decorative lighting assembly of Embodiment 1, wherein:the intermediate wires comprise a plurality of conductor strands and an outer insulating layer adjacent to, and covering, one or more of the conductor strands;the at least one cord comprises a solid strand; andthe insulating layer of the intermediate wires and the solid strand comprise the same material so that the decorative lighting assembly has a uniform appearance.Embodiment 17. The decorative lighting assembly of Embodiment 1, wherein:the intermediate wires comprise a plurality of conductor strands and an outer insulating layer adjacent to, and covering, one or more of the conductor strands;the at least one cord comprises a solid strand; andthe insulating layer of the intermediate wires and the solid strand are substantially the same color so that the decorative lighting assembly has a uniform appearance.Embodiment 18. The decorative lighting assembly of Embodiment 1, wherein a first series circuit of the decorative lighting assembly comprises:a first lamp assembly electrically connected to the first power wire;an nth lamp assembly connected to the second power wire; anda plurality of intermediate lamp assemblies electrically connected in series between the first lamp assembly and the nth lamp assembly.Embodiment 19. The decorative lighting assembly of Embodiment 18, further comprising a first connector electrically connecting a first end of the series circuit to the first power wire.Embodiment 20. The decorative lighting assembly of Embodiment 19, further comprising a second connector electrically connecting a second end of the series circuit to the second power wire.Embodiment 21. The decorative lighting assembly of Embodiment 20, wherein the second connector mechanically couples one end of a cord to the second power wire.Embodiment 22. The decorative lighting assembly of Embodiment 21, wherein the first series circuit follows a winding path between the first connector and the second connector so that the lamp assemblies are distributed across a portion of the display area.Embodiment 23. The decorative lighting assembly of Embodiment 22, wherein the winding path of the first series circuit comprises the plurality of intermediate wires disposed along the first zig-zag path connecting the lamp assemblies in the first row with the lamp assemblies in the second row.Embodiment 24. The decorative lighting assembly of Embodiment 23, wherein at least one cord extends between pairs of lamp assemblies that are adjacent to one another physically and are not adjacent to one another in the first series circuit.Embodiment 25. The decorative lighting assembly of Embodiment 1, wherein the at least one cord forms a connection with each of the lamp assemblies in the second row, each connection comprising a portion of the at least one cord extending through a loop.Embodiment 26. The decorative lighting assembly of Embodiment 1, wherein a loop of wire is fixed to each of the lamp assemblies in the second row and the at least one cord extends through the loop of wire fixed to each of the lamp assemblies in the second row.Embodiment 25. The decorative lighting assembly of Embodiment 1, wherein the at least one cord forms a connection with each of the lamp assemblies in the second row, each connection comprising a tortuous path defined by each lamp assembly and a portion of the at least one cord extending through the tortuous path.Embodiment 26. The decorative lighting assembly of Embodiment 25, wherein the portion of the at least one cord extends through a first eye defined by a lamp holder of each lamp assembly and a second eye defined by a lamp holder of each lamp assembly.Embodiment 27. The decorative lighting assembly of Embodiment 26, wherein a bight of the portion of the at least one cord extends along an outer surface of the lamp holder between the first eye and the second eye.Embodiment 28. The decorative lighting assembly of Embodiment 27, wherein the portion of the at least one cord includes a first bend disposed between the first eye and the bight.Embodiment 29. The decorative lighting assembly of Embodiment 27, wherein the portion of the at least one cord includes a second bend disposed between the second eye and the bight.Embodiment 31. A decorative lighting assembly, comprising:a first power wire electrically connected to a first power contact;a second power wire electrically connected to a second power contact;the first power wire and the second power wire cooperating to surround a display area of the decorative lighting assembly;a plurality of lamp assemblies distributed across the display area, the plurality of lamp assemblies including a first column of lamp assemblies aligned along a first line, a second column of lamp assemblies aligned along a second line, a third column of lamp assemblies aligned along a third line, and a fourth column of lamp assemblies aligned along a fourth line;a plurality of intermediate wires disposed along a first zig-zag path connecting the lamp assemblies in the first column with the lamp assemblies in the second column;at least one cord disposed along a second zig-zag path connecting the lamp assemblies in the second column with the lamp assemblies in the third column; anda plurality of intermediate wires disposed along a third zig-zag path connecting the lamp assemblies in the third column with the lamp assemblies in the fourth column.Embodiment 32. The decorative lighting assembly of Embodiment 31, wherein the display area has a shape generally corresponding to a four-sided polygon.Embodiment 33. The decorative lighting assembly of Embodiment 32, wherein the shape of the display area generally corresponds to a rectangle having a first long side, a second long side, a first short side, and a second short side.Embodiment 34. The decorative lighting assembly of Embodiment 33, wherein:the first power wire defines the first short side, the first long side, and the second short side of the rectangle; andthe second power wire defines the second long side of the rectangle.Embodiment 35. The decorative lighting assembly of Embodiment 31, further comprising a fifth column of lamp assemblies aligned along a fifth line; andwherein the at least one cord is disposed along a fourth zig-zag path connecting the lamp assemblies in the fourth column with the lamp assemblies in the fifth column.Embodiment 36. The decorative lighting assembly of Embodiment 35, wherein the at least one cord comprises a single cord that extends through both the first zig-zag path and the fourth zig-zag path.Embodiment 37. The decorative lighting assembly of Embodiment 36, further comprising a first fastener that mechanically couples a first end of the single cord and a second end of the single cord to the first power wire.Embodiment 38. The decorative lighting assembly of Embodiment 37, wherein the first power wire extends through a passageway defined by the first fastener.Embodiment 39. The decorative lighting assembly of Embodiment 36, further comprising a bushing that mechanically couples an intermediate portion of the single cord to the second power wire.Embodiment 40. The decorative lighting assembly of Embodiment 39, wherein the single cord and the second power wire extend through a passageway defined by the bushing.Embodiment 41. The decorative lighting assembly of Embodiment 36, wherein the single cord extends through a passageway defined by a clip of each lamp assembly in the second column and each lamp assembly in the third column.Embodiment 42. The decorative lighting assembly of Embodiment 35, further comprising:a first top-most intermediate wire that extends between a top-most lamp assembly in the first column and a top-most lamp assembly in the third column; anda bushing that mechanically couples an intermediate portion of the first top-most intermediate wire to the second power wire.Embodiment 43. The decorative lighting assembly of Embodiment 31, wherein the first power wire and the second power wire comprise reinforced wire.Embodiment 44. The decorative lighting assembly of Embodiment 43, wherein the intermediate wires comprise reinforced wire.Embodiment 45. The decorative lighting assembly of Embodiment 44, wherein the reinforced wire comprises:a longitudinally-extending reinforcing strand, the reinforcing strand comprising one or more fibers comprising a polymer material;a plurality of conductor strands wound about the reinforcing strand; andan outer insulating layer adjacent to, and covering, one or more of the conductor strands.Embodiment 46. The decorative lighting assembly of Embodiment 31, wherein:the first power wire comprises 18 AWG wire;the second power wire comprises 18 AWG wire; andthe intermediate wires comprise 22 AWG wire.Embodiment 47. The decorative lighting assembly of Embodiment 31, wherein:the first power wire comprises 18 AWG wire;the second power wire comprises 18 AWG wire; andthe intermediate wires comprise 22 AWG reinforced wire.Embodiment 48. The decorative lighting assembly of Embodiment 31, wherein:the first power wire comprises 18 AWG wire;the second power wire comprises 18 AWG wire; andthe intermediate wires comprise 25 AWG reinforced wire.Embodiment 49. The decorative lighting assembly of Embodiment 31, wherein:the intermediate wires have a first outer diameter;the at least one cord has a second outer diameter; andthe second outer diameter is substantially equal to the first outer diameter so that the decorative lighting assembly has a uniform appearance.Embodiment 50. The decorative lighting assembly of Embodiment 31, wherein:the intermediate wires comprise a plurality of conductor strands and an outer insulating layer adjacent to, and covering, one or more of the conductor strands;the at least one cord comprises a solid strand; andthe insulating layer of the intermediate wires and the solid strand comprise the same material so that the decorative lighting assembly has a uniform appearance.Embodiment 51. The decorative lighting assembly of Embodiment 31, wherein:the intermediate wires comprise a plurality of conductor strands and an outer insulating layer adjacent to, and covering, one or more of the conductor strands;the at least one cord comprises a solid strand; andthe insulating layer of the intermediate wires and the solid strand are substantially the same color so that the decorative lighting assembly has a uniform appearance.Embodiment 52. The decorative lighting assembly of Embodiment 31, wherein a first series circuit of the decorative lighting assembly comprises:a first lamp assembly electrically connected to the first power wire;an nth lamp assembly connected to the second power wire; anda plurality of intermediate lamp assemblies electrically connected in series between the first lamp assembly and the nth lamp assembly.Embodiment 53. The decorative lighting assembly of Embodiment 52, further comprising a first connector electrically connecting a first end of the series circuit to the first power wire.Embodiment 54. The decorative lighting assembly of Embodiment 53, further comprising a second connector electrically connecting a second end of the series circuit to the second power wire.Embodiment 55. The decorative lighting assembly of Embodiment 54, wherein the second connector mechanically couples one end of a third cord to the second power wire.Embodiment 56. The decorative lighting assembly of Embodiment 55, wherein the first series circuit follows a winding path between the first connector and the second connector so that the lamp assemblies are distributed across the display area.Embodiment 57. The decorative lighting assembly of Embodiment 56, wherein the winding path of the first series circuit includes:the plurality of intermediate wires disposed along the first zig-zag path connecting the lamp assemblies in the first column with the lamp assemblies in the second column; andthe plurality of intermediate wires disposed along the third zig-zag path connecting the lamp assemblies in the third column with the lamp assemblies in the fourth column.Embodiment 58. The decorative lighting assembly of Embodiment 52, wherein the at least one cord extends between pairs of lamp assemblies that are adjacent to one another physically and are not adjacent to one another in the first series circuit.

The embodiments above are intended to be illustrative and not limiting. Additional embodiments are within the claims. In addition, although aspects of the present invention have been described with reference to particular embodiments, those skilled in the art will recognize that changes can be made in form and detail without departing from the spirit and scope of the invention, as defined by the claims.

Persons of ordinary skill in the relevant arts will recognize that the invention may comprise fewer features than illustrated in any individual embodiment described above. The embodiments described herein are not meant to be an exhaustive presentation of the ways in which the various features of the invention may be combined. Accordingly, the embodiments are not mutually exclusive combinations of features; rather, the invention may comprise a combination of different individual features selected from different individual embodiments, as understood by persons of ordinary skill in the art.

Any incorporation by reference of documents above is limited such that no subject matter is incorporated that is contrary to the explicit disclosure herein. Any incorporation by reference of documents above is further limited such that no claims included in the documents are incorporated by reference herein. Any incorporation by reference of documents above is yet further limited such that any definitions provided in the documents are not incorporated by reference herein unless expressly included herein.

For purposes of interpreting the claims for the present invention, it is expressly intended that the provisions of Section 112, sixth paragraph of 35 U.S.C. are not to be invoked unless the specific terms “means for” or “step for” are recited in a claim.