A flex-resistant wire has a conductor portion configured as a multiple-stranded wire. The multiple-stranded wire has a plurality of bunched strands that are twisted together. Each of the bunched strands has a plurality of conductors that are twisted together. In each of the bunched strands, the lay length of the conductors that are twisted together is at least 10 times greater than a strand diameter of the bunched strand but not greater than 47.2 times the strand diameter. The lay length of the bunched strands that are twisted together is at least 5 times greater than a pitch diameter of the multiple-stranded wire but not greater than 30 times the pitch diameter. The lay length of the conductors is smaller than or equal to the lay length of the bunched strands. The flex-resistant wire may be provided as one of the wires forming a wire harness.

Aspects of the present invention relate to reinforced electric wires, particularly reinforced electric wires as used in holiday lighting such as Christmas light strings. In some embodiments, the reinforced electric wire can comprise a conductor, a reinforcing string or one or more reinforcing threads, and an insulator jacket. In some embodiments, the conductor comprises a plurality of conductor strands and one or more reinforcing strands arranged within an insulator jacket. Methods of making wires in accordance with various embodiments are also provided herein.

The present disclosure relates to a tensile conducting monofilament and a conducting wire and a manufacturing method thereof. The tensile conducting monofilament is composed of a conducting filament and at least one tensile thread. The conducting filament is a flat conducting filament. The flat conducting filament is wound on the tensile thread. The conducting wire includes a circular conducting monofilament, at least one tensile conducting monofilament, and an insulation cover. The tensile conducting monofilament and the circular conducting monofilament are wrapped in the insulation cover. The method to manufacture a tensile conducting monofilament includes the steps of flattening a circular conducting monofilament to a flat conducting filament; and winding the flat conducting filament on at least one tensile thread. The method to manufacture a conducting wire includes the steps of stranding the tensile conducting monofilament and a circular conducting monofilament to be disposed in an insulation cover.

The present disclosure relates to a tensile conducting monofilament and a conducting wire and a manufacturing method thereof. The tensile conducting monofilament is composed of a conducting filament and at least one tensile thread. The conducting filament is a flat conducting filament. The flat conducting filament is wound on the tensile thread. The conducting wire includes a circular conducting monofilament, at least one tensile conducting monofilament, and an insulation cover. The tensile conducting monofilament and the circular conducting monofilament are wrapped in the insulation cover. The method to manufacture a tensile conducting monofilament includes the steps of flattening a circular conducting monofilament to a flat conducting filament; and winding the flat conducting filament on at least one tensile thread. The method to manufacture a conducting wire includes the steps of stranding the tensile conducting monofilament and a circular conducting monofilament to be disposed in an insulation cover.

A covered wire includes a wire including a metal, a covering layer provided at a periphery of the wire, and inclusions including at least one of a metal and a metal oxide. The inclusions are provided between the wire and the covering layer or in the covering layer, and an average size of each of the inclusions is less than a thickness of the covering layer.

A covered wire includes a wire including a metal, a covering layer provided at a periphery of the wire, and inclusions including at least one of a metal and a metal oxide. The inclusions are provided between the wire and the covering layer or in the covering layer, and an average size of each of the inclusions is less than a thickness of the covering layer.

A wire comprising a wire core with a surface, the wire core having a coating layer superimposed on its surface, wherein the wire core itself consists of: (a) pure silver consisting of (a1) silver in an amount in the range of from 99.99 to 100 wt.-% and (a2) further components in a total amount of from 0 to 100 wt.-ppm or (b) doped silver consisting of (b1) silver in an amount in the range of from >99.49 to 99.997 wt.-%, (b2) at least one doping element selected from the group consisting of calcium, nickel, platinum, palladium, gold, copper, rhodium and ruthenium in a total amount of from 30 to <5000 wt.-ppm and (b3) further components in a total amount of from 0 to 100 wt.-ppm, or (c) a silver alloy consisting of (c1) silver in an amount in the range of from 89.99 to 99.5 wt.-%, (c2) at least one alloying element selected from the group consisting of nickel, platinum, palladium, gold, copper, rhodium and ruthenium in a total amount in the range of from 0.5 to 10 wt.-% and (c3) further components in a total amount of from 0 to 100 wt.-ppm, or (d) a doped silver alloy consisting of (d1) silver in an amount in the range of from >89.49 to 99.497 wt.-%, (d2) at least one doping element selected from the group consisting of calcium, nickel, platinum, palladium, gold, copper, rhodium and ruthenium in a total amount of from 30 to <5000 wt.-ppm, (d3) at least one alloying element selected from the group consisting of nickel, platinum, palladium, gold, copper, rhodium and ruthenium in a total amount in the range of from 0.5 to 10 wt.-% and (d4) further components in a total amount of from 0 to 100 wt.-ppm, wherein the at least one doping element (d2) is other than the at least one alloying element (d3), wherein the individual amount of any further component is less than 30 wt.-ppm, wherein the individual amount of any doping element is at least 30 wt.-ppm, wherein all amounts in wt.-% and wt.-ppm are based on the total weight of the core, and wherein the coating layer is a double-layer comprised of a 1 to 1000 nm inner layer of gold and an adjacent 0.5 to 100 nm thick outer layer of palladium or a double-layer comprised of a 0.5 to 100 nm thick inner layer of palladium and an adjacent >200 to 1000 nm thick outer layer of gold.

A wire comprising a wire core with a surface, the wire core having a coating layer superimposed on its surface, wherein the wire core itself consists of: (a) pure silver consisting of (a1) silver in an amount in the range of from 99.99 to 100 wt.-% and (a2) further components in a total amount of from 0 to 100 wt.-ppm or (b) doped silver consisting of (b1) silver in an amount in the range of from >99.49 to 99.997 wt.-%, (b2) at least one doping element selected from the group consisting of calcium, nickel, platinum, palladium, gold, copper, rhodium and ruthenium in a total amount of from 30 to <5000 wt.-ppm and (b3) further components in a total amount of from 0 to 100 wt.-ppm, or (c) a silver alloy consisting of (c1) silver in an amount in the range of from 89.99 to 99.5 wt.-%, (c2) at least one alloying element selected from the group consisting of nickel, platinum, palladium, gold, copper, rhodium and ruthenium in a total amount in the range of from 0.5 to 10 wt.-% and (c3) further components in a total amount of from 0 to 100 wt.-ppm, or (d) a doped silver alloy consisting of (d1) silver in an amount in the range of from >89.49 to 99.497 wt.-%, (d2) at least one doping element selected from the group consisting of calcium, nickel, platinum, palladium, gold, copper, rhodium and ruthenium in a total amount of from 30 to <5000 wt.-ppm, (d3) at least one alloying element selected from the group consisting of nickel, platinum, palladium, gold, copper, rhodium and ruthenium in a total amount in the range of from 0.5 to 10 wt.-% and (d4) further components in a total amount of from 0 to 100 wt.-ppm, wherein the at least one doping element (d2) is other than the at least one alloying element (d3), wherein the individual amount of any further component is less than 30 wt.-ppm, wherein the individual amount of any doping element is at least 30 wt.-ppm, wherein all amounts in wt.-% and wt.-ppm are based on the total weight of the core, and wherein the coating layer is a double-layer comprised of a 1 to 1000 nm inner layer of gold and an adjacent 0.5 to 100 nm thick outer layer of palladium or a double-layer comprised of a 0.5 to 100 nm thick inner layer of palladium and an adjacent >200 to 1000 nm thick outer layer of gold.

A direct write dispensing nozzle assembly and method of forming traces and twisted pairs via direct write dispensing. The method includes dispensing conductive material via an inner nozzle so as to form a conductive core. Non-conductive material may be dispensed via a peripheral nozzle surrounding the inner nozzle so as to form a non-conductive casing surrounding the conductive core. The first conductive core and the non-conductive casing may then be deposited on a substrate or other surface. The trace may be positioned on the substrate such that the non-conductive casing contacts a previously deposited trace. An additional conductive core may be dispensed within the non-conductive casing and the direct write dispensing nozzle assembly may be rotated so as to form a twisted pair.

Continuously transposed conductor (“CTC”) cables are described. A CTC cable may include a plurality of electrically insulated strands connected in parallel at their ends. Additionally, each strand may include one or more conductors and an extruded insulation layer formed at least partially around the one or more conductors.