Rope light and methods of forming and using same

Abstract

 A rope light (R) has a plurality of exposed main body conductors (10) and an exposed light string conductor (20) connected to the main body conductors and extending substantially the entire length of the rope light substantially parallel to the main body conductors. The rope light also includes a plurality of lights (30) positioned along the light string conductor (20) and a substantially solid and translucent, flexible sheath (50) which encases the exposed main body conductors (10), the exposed light string conductor (20) and the plurality of lights (30) along substantially the entire length of the rope light so that conducting outer surfaces of the exposed main body conductors, the exposed light string conductor and the lights are readily visible to a user through the sheath and so that light illumination through the sheath is enhanced.

Description

[0001] The present invention relates to the field of lights and,more particularly, to ornamental lights and methods of forming same.

[0002] Consumers who purchase ornamental lights often encounter the problem of lights that do not illuminate brilliantly. Furthermore, current ornamental rope light systems do not provide a proper combination of flexibility and rigidity needed for customers to configure rope type lights in any arrangement with ease and little effort. Current ornamental rope light systems tend to tangle easily when positioned in a configuration suitable for storage. Current rope light applications are also costly to manufacture due to the complexity with which they are manufactured.

[0003] Manufacturers of ornamental rope type lights have been able to provide flexible lights, but only in very limited scope. Examples include traditional Christmas rope lights used to decorate and illuminate various objects. These types of lights tend to easily tangle when placed in a rolled configuration suitable for storage. Another disadvantage associated with this typical type of rope light is that the lighting tends to be dull because the only source of light is emitted at each individual light.

[0004] With the foregoing in mind, the present invention advantageously provides an elongate rope light which can easily be placed in a rolled configuration for storage without tangling. The present invention also advantageously provides brilliant, crystal like illumination of lights throughout the entire length of a rope light. The present invention still also advantageously provides a rope light that is easy for customers to handle. Additionally, the present invention also provides a rope light that is very inexpensive to manufacture. Furthermore, the present invention provides methods for forming and using a rope light that advantageously provide enhanced illumination and easy handling capabilities.

[0005] More particularly, the present invention provides an elongate rope light having a plurality of exposed elongate main body conductors. The plurality of main body conductors each have first and second ends and are positioned to extend substantially parallel for substantially the entire length of the rope light. The rope light further includes at least one exposed elongate light string conductor connected to at least one of the main body conductors and positioned to extend substantially the entire length of the rope light. The light string conductor is positioned substantially parallel to the plurality of main body conductors. The light string conductor is defined by a plurality of light string conductors connected along respective end points. The rope light still further preferably includes a plurality of spaced-apart lights connected to and positioned along the exposed elongate light string conductor to extend outwardly therefrom. The rope light additionally includes a substantially solid and translucent, flexible sheath having a continuous annular shape. The sheath is positioned to encase each of the plurality of exposed main body conductors, the at least one exposed light string conductor, and the plurality of lights along substantially the entire length of the rope light, so that conducting outer surfaces of the plurality of exposed main body conductors, conducting outer surfaces of the at least one exposed light string conductor and the plurality of lights are readily visible to a user through the sheath and so that light illumination through the sheath is enhanced.

[0006] The present invention also provides a method of forming an elongate rope light. The method includes the step of attaching a first end of at least one exposed elongate main body conductor to a first end of at least one exposed elongate light string conductor. The method also includes the step of positioning the at least one exposed elongate main body conductor and the at least one exposed light string conductor to extend substantially parallel the entire length of the rope light. The method still further includes the step of attaching at least one light to the at least one exposed elongate light string conductor. The method additionally includes the step of enclosing the at least one exposed elongate main body conductor, the at least one exposed elongate light string conductor and the at least one light in a substantially solid, translucent, flexible sheath so that conductive outer surfaces of the at least one exposed elongate main body conductor, conductive outer surfaces of the at least one exposed elongate light string conductor, and the at least one light are readily visible to a user through the sheath and so that light illumination through the sheath is enhanced.

[0007] Brilliant and crystal like illumination of rope light systems is very important to consumers and therefore, the present invention advantageously provides a rope light and methods of forming and using the same with enhanced illumination throughout the entire length of the rope light. The present invention also advantageously saves time and effort for consumers by providing a rope light system that will not tangle.

[0008] In order that the present invention may be more readily understood, reference will now be made to the accompanying drawings, in which:-

FIG. 1 is a fragmentary perspective view of a first embodiment of a rope light according to the present invention;

FIG. 2 is a fragmentary perspective view of the first embodiment illustrating first and second end portions;

FIG. 3 is a sectional view of the first embodiment taken along line 3-3 of FIG. 2;

FIG. 4 is an exploded perspective view showing connector portions and connectors of a rope light according to the present invention;

FIG. 5 is a fragmentary perspective view of a connector inserted into connector portions of a rope light according to the present invention;

FIG. 6 is a fragmentary perspective view of a second embodiment of a rope light according to the present invention;

FIG. 7 is a fragmentary perspective view of the second embodiment illustrating first and second end portions;

FIG. 8 is a sectional view of the second embodiment taken along line 8-8 of FIG. 7;

FIG. 9 is an exploded top plan view of a rope light according to the present invention having connector portions;

FIG. 10 is a fragmentary perspective view of the first embodiment having soldered light string conductor connections; and

FIG. 11 is a fragmentary perspective view of a rope light according to the present invention having twisted light string conductor connections.

[0009] In the accompanying drawings, like numbers refer to like elements throughout, the prime notation, if used, indicates similar elements in alternative embodiments.

[0010] FIG. 1 illustrates a first embodiment of an elongate rope light R. The elongate rope light R preferably has a plurality of exposed elongate main body conductors 10 and, more preferably, two main body conductors, as shown in FIG. 3. Each exposed main body conductors 10 has first 40 and second 45 ends and is positioned to extend substantially parallel the entire length of the elongate rope light R. The elongate rope light R further includes at least one exposed elongate light string conductor 20 connected to at least one of the plurality of main body conductors 10. The light string conductor 20 is connected to the main body conductor 10 at an end of the rope light R. The light string conductor 20 is positioned to extend substantially the entire length of the rope light R and also positioned parallel to the plurality of main body conductors 10. The elongate rope light R still further includes a plurality of spaced-apart lights 30 connected to and positioned along the exposed elongate light string conductor 20 to extend outwardly therefrom. The plurality of lights 30 are preferably connected in series along the light string conductor 20. Each of the plurality of lights 30 are preferably light emitting diode lamps and may also be provided in a plurality of colors.

[0011] The present invention also includes a substantially solid, flexible, translucent sheath 50. The sheath 50 includes a hollow portion 52 positioned in the middle of the sheath 50 and extending substantially the length of the elongate rope light R. The solid material extends from an outer surface of the hollow portion 52 to an outer surface of the sheath 50. The solid material is preferably a plastic or polymeric material such as polyvinyl chloride (PVC). The at least one light string conductor 20 and each of the plurality of lights 30 is positioned within the hollow portion 52 of the sheath 50. This embodiment of the rope light R advantageously enhances illumination of each of the plurality of lights 30. In the preferred embodiment, the sheath 50 of the elongate rope light R is substantially clear throughout the entire thickness of the rope light R. This advantageously provides enhanced illumination to the elongate rope light R.

[0012] In another embodiment of the present invention, the elongate rope light R' preferably includes a substantially solid and translucent sheath 50'. The sheath 50' has a continuous annular shape and is positioned to encase each of the plurality of exposed main body conductors 10', the at least one exposed light string conductor 20', and the plurality of lights 30' along substantially the entire length of the elongate rope light R' so that conducting outer surfaces of the plurality of exposed main body conductors 10' and the at least one light string conductor 20' and the plurality of lights 30' are readily visible to a user through the sheath 50'. The substantially solid sheath 50' has solid material extending from an outer surface of the sheath 50' to abuttingly contact each of the plurality of main body conductors 10', the at least one light string conductor 20' and each of the plurality of lights 30' positioned along the at least one light string conductor 20'. In this embodiment of the elongate rope light R' the outer sheath 50' can advantageously include formed ridges, ribs, or rough regions which provide the outer sheath 50' with texture for ease of handling and gripping and enhancing visual appearance for many desired applications. The rope light R' is integrally formed from a single extruded piece of plastic.

[0013] Each of the plurality of main body conductors 10 and the at least one light string conductor 20 are made of a reflective metallic material. The combination of the illuminated lights 30, the reflective main body conductors 10, reflective light string conductor 20 and substantially clear sheath 50 advantageously enhance the illumination of the elongate rope light R. This embodiment advantageously provides crystal-like illumination and provides a rope light R that has the appearance of illuminated glass.

[0014] Each of the plurality of main body conductors 10 further includes a plurality of strands positioned in a twisted configuration. This twisted configuration also advantageously enhances illumination of each of the elongate rope lights R.

[0015] The present invention can also advantageously include a plurality of light string conductors 20. One of the plurality of light string conductors 20 can advantageously be connected to another of the plurality of light string conductors 20 along respective end portions. The connected plurality of light string conductors 20 define the at least one exposed elongate light string conductor 20. The end portions of the plurality of light string conductors 20 are advantageously welded, e.g., soldered, together, as best illustrated in FIG. 10. Welding the end portions of the plurality of light string conductors 20 advantageously provides a strong connection between the plurality of light string conductors 20.

[0016] In another embodiment of the present invention, end portions of one of the plurality of light string conductors 20" are positioned to overlap and abuttingly contact, e.g., twisting, end portions of another of the plurality of light string conductors 20", as best illustrated in FIG. 11. This connection of the plurality of light string conductors 20" advantageously provides an increased surface area along which the end portions of the plurality of light string conductors 20" connect, provides a strong connection between each of the plurality of light string conductors 20" and also advantageously increases the brilliance of the illumination of the rope light R". Overlapping and abuttingly contacting the plurality of light string conductors 20" still further advantageously enhances manufacturing efficiency by decreasing manufacturing costs and time required to manufacture the rope light R". The connection also advantageously enhances the flexibility of the rope light R".

[0017] The elongate rope light R also includes an end cap 60 positioned to overlie a first end of the sheath 50 and also positioned adjacent the first ends 40 of the plurality of main body conductors 10. The elongate rope light R further includes a plurality of connector portions 62 formed in a second end of the sheath 50. Each of the plurality of connector portions 62 includes an opening formed in the sheath 50 and has one of the plurality of main body conductors 10 positioned therein forreceiving a connector 70. The connector 70 includes a plurality of insert portions 72 that matingly contact each of the plurality of openings formed in the sheath 50 so that each of the plurality of main body conductors 10 surrounds each of the plurality of insert portions 72 when inserted into each of the plurality of openings. This connector 70 advantageously allows consumers to customize the length of the elongate rope light R by adding additional rope lights to a first or second end of an elongate rope light R and allows the manufacturer to readily cut and strip different lengths of rope light R.

[0018] The present invention also advantageously provides a method of forming an elongate rope light R. The method includes the step of attaching a first end 40 of at least one exposed elongate main body conductor 10 to a first end of at least one exposed elongate light string conductor 20. The method further advantageously includes the step of positioning the at least one exposed elongate main body conductor 10 and the at least one exposed light string conductor 20 to extend substantially parallel the entire length of the rope light R. The method also includes the step of attaching the at least one exposed elongate light string conductor 20. The method of forming the elongate rope light R further includes the step of forming a hollow portion 52 positioned in the middle of the sheath 50. Solid material extends from outer surface of the hollow portion 52 to the outer surface of the sheath 50. The method also includes the step of positioning the at least one light string conductor 20 and the at least one light 30 within the hollow portion 52. This method advantageously reduces shadowing and thereby enhances illumination.

[0019] In another embodiment of the present invention, the method of forming an elongate rope light R' includes the step of enclosing the at least one exposed elongate main body conductor 10', the at least one exposed elongate light string conductor 20' and the at least one light 30' in a substantially solid, translucent, flexible sheath 50' so that conductive outer surfaces of the at least one exposed elongate main body conductor 10', conductive outer surfaces of the at least one exposed elongate light string conductor 20' and the at least one light 30' are readily visible to a user through the sheath 50'. This method advantageously enhances illumination of the at least one light 30' through the substantially solid, translucent, flexible sheath 50'. The method of forming the elongate rope light R' further includes the step of extending solid material from the outer surface of the sheath 50' to abuttingly contact the at least one main body conductor 10', the at least one exposed light string conductor 20' and the at least one light 30'.

[0020] The method of forming an elongate rope light R also includes the step of twisting a plurality of elongate reflective, metallic strands to form the at least one elongate main body conductor 10. The plurality of reflective, metallic strands positioned in a twisted configuration to enhance illumination of the rope light R.

[0021] The method of forming the rope light R further comprises connecting end portions of one of a plurality of light string conductors 20 to end portions of another of a plurality of light string conductors 20 to thereby define the at least one exposed elongate light string conductor 20. The step of connecting the plurality of light string conductors 20 can also advantageously include the step of welding, e.g., soldering, the plurality of light string conductors 20 as best illustrated in FIG. 10. This method of connecting the light string conductors 20 advantageously provides a strong connection between each of the plurality of light string conductors 20 to thereby provide a stronger rope light R.

[0022] In another embodiment of the present invention, the step of connecting end portions of the plurality of light string conductors 20" can also advantageously include the step of overlapping and abuttingly contacting, e.g., twisting, end portions of one of the plurality of light string conductors 20" to end portions of another of the plurality of light string conductors 20" to thereby define the at least one elongate light string conductor 20" as best illustrated in FIG. 11. This method of connecting the plurality of light string conductors 20" advantageously provides an increased surface area along which the respective end portions of the plurality of light string conductors 20" contact and provides a strong connection between each of the plurality of light string conductors 20". This method also advantageously provides a rope light R" with enhanced brilliance, greater flexibility and low manufacturing cost.

[0023] The method of forming the rope light R also advantageously includes the step of positioning an end cap 60 to overlie a first end of the sheath 50 adjacent. a first end of the at least one main body conductor 10. The method still further includes a step of forming a plurality of connector portions 62 that include openings in a second end of the sheath 50 adjacent the second end of the at least one main body conductor 10. This method advantageously simplifies the insertion of a connector 70 having insert portions 72 to the second end of the at least one elongate main body conductor 10. The insert portions 72 of the connector 70 are inserted into the connector portions 62 formed in the sheath 50 and the main body conductors 10 advantageously surround the insert portions 72 to make good electrical contact between the insert portions 72 and each of the plurality of main body conductors 10.

[0024] Some of the advantages of the rope light R include inexpensive manufacturing and increased handling ease. The sheath 50 positioned to enclose the main body conductor 10, the light string conductor 20 and the lights 30 is flexible, but still has rigid characteristics to increase ease of handling the rope light R. A consumer will now be able to position a rope light R in a desired location without the assistance of another individual.

[0025] Another advantage of the present invention is that the conductors can remain exposed within the outer sheath 50. The outer sheath 50 acts as an insulator for the conductors. Therefore, the conductors on the rope light R do not require additional insulators in order to operate in a safe and efficient manner. The conductors can therefore remain exposed thereby reflecting the illumination from each of the plurality of lights 30. The reflective properties of the exposed conductors enhance the crystal-like illumination of the rope light R.

[0026] As stated above, the manufacturing cost of the present invention is advantageously decreased. In the preferred embodiment of the rope light R, the combination of the main body conductor 10, light string conductor 20 and lights 30 is positioned within a split interior plastic tube 80. The split interior plastic tube 80 containing the main body conductor 10, the light string conductor 20 and the lights 30 is then passed through an extrusion device to enclose the inner plastic tube 80 within an outer sheath 50.

[0027] The manufacturing cost of another embodiment of the rope light R' is also decreased. The main body conductor 10', the light string conductor 20' and each of the plurality of lights 30' are simply encased in a solid, translucent sheath 50'. The main body conductor 10', light string conductor 20' and lights 30' are connected to one another. The combination is then placed through an extrusion device to thereby encase the main body conductor 10', light string conductor 20' and lights 30' in the translucent sheath 50'.

Claims

1. A rope light (R) comprising

at least one exposed main body conductor (10) extending for substantially the entire length of the rope light;

at least one exposed light string conductor (20) connected to at least one main body conductor (10) and extending substantially the entire length of the rope light;

at least one light (30) connected to the exposed elongate light string conductor(s); and

a substantially solid and translucent, flexible sheath (50) encasing the exposed main body conductor(s), the exposed light string conductor(s) and the light(s) along substantially the entire length of the rope light so that conducting outer surfaces of the exposed main body conductor(s), conducting outer surfaces of the exposed light string conductor(s) and the light(s) are readily visible to a user through the sheath.

2. The rope light as claimed in claim 1, wherein the main body conductor(s) (10) and the light string conductor(s) (20) each comprises reflective metallic material for enhancing illumination of the one light(s).

3. The rope light as claimed in claim 1 or 2, wherein the or each main body conductor (1) comprises a plurality of elongate strands positioned in a twisted configuration.

4. The rope light as claimed in claim 1, 2 or 3, including an end cap (60) positioned to overlie a first end of the sheath (50) and positioned adjacent a first end of the or each main body conductor (10), and at least one connector portion (62) formed in a second end of the sheath, the at least one connector portion including at least one opening formed in the sheath and having the at least one main body conductor positioned therein for receiving a connector, the connector comprising at least one insert portion (72) which matingly contacts the at least one opening formed in the sheath so that the at least one main body conductor surrounds the at least one connector portion when inserted into the at least one opening.

5. The rope light as claimed in any preceding claim, wherein the sheath (50) comprises solid material extending from an outer surface of the sheath to abuttingly contact the main body conductors(s) (10), the light string conductor(s) (20) and the light(s) (30) positioned along the light string conductor(s).

6. The rope light as claimed in claim 5, including a hollow portion (52) positioned within the sheath and extending substantially the length of the rope light, the solid material extending from an outer surface of the hollow portion to an outer surface of the sheath (50), and the light string conductor(s) (20) and the light(s) being positioned within said hollow portion.

7. The rope light as claimed in any preceding claim wherein the outer surface of the sheath (50) is textured and ribbed for enhancing illumination of the one light(s).

8. The rope light as claimed in any preceding claim, wherein the or each exposed light string conductor (20) comprises a plurality of light string conductor sections, each being connected to another one of the light string conductor sections along respective end portions thereof so that the plurality of light string conductor sections in combination define the light string conductor (20).

9. The rope light as claimed in claim 8, wherein the respective end portions of the plurality of light string conductor sections are welded together or overlap and abuttingly contact.

10. A method of forming a rope light (R), comprising the steps of

attaching a first end of at least one exposed main body conductor (10) to a first end of at least one exposed light string conductor (20);

positioning the exposed main body conductor(s) (10) and the exposed light string conductor(s) (20) to extend substantially parallel the entire length of the rope light;

attaching at least one light (30) to the exposed light string conductor(s); and

enclosing the exposed main body conductor(s), the exposed light string conductor(s) and the light(s) in a substantially solid, translucent, flexible sheath (50) so that conductive outer surfaces of the exposed main body conductor(s), the exposed light string conductor(s), and the light(s) are readily visible to a user through the sheath.

11. The method as claimed in claim 10, including the step of twisting a plurality of elongate reflective, metallic strands to form the main body conductor(s) (10).

12. The method as claimed in claim 10 or 11, including positioning an end cap (60) to overlie a first end of the sheath (50) adjacent a first end of the or each main body conductor (10) and forming a plurality of connector portions (62) including openings in a second end of the sheath adjacent a second end of the or each main body conductor for receiving a connector (70) having insert portions (72).

13. The method as claimed in claim 12, including the step of matingly attaching the connector having a plurality of insert portions (72) to the plurality of connector portions (62) positioned in the second end of the sheath (50) so that the main body conductors (10) positioned within the connector portions surrounds the insert portions of the connector when inserting the connector into the connector portions.

14. The method as claimed in any preceding claim 10 to 13, including the step of extending solid material from the outer surface of the sheath (50) to abuttingly contact the main body conductor(s) (10), the exposed light string(s) (20) and the light(s) (30).

15. The method as claimed in claim 14, including the step of forming a hollow portion (52) in the sheath with solid material extending from an outer surface of the hollow portion (52) to an outer surface of the sheath.

16. The method as claimed in claim 15, including the step of positioning the light string conductor(s) and the light(s) within the hollow portion for enhancing illumination of the light(s).

17. The method as claimed in any preceding claim 10 to 16, including connecting a plurality of light string conductor sections end to end so that the plurality of light string conductor sections in combination define the exposed light string conductor(s) (20).

18. The method as claimed in claim 17, wherein the step of connecting a plurality of the light string conductor sections comprises welding or overlapping and abuttingly contacting a first of the plurality of light string conductor sections with another of the plurality of light string conductor sections thereby to define the exposed light string conductor(s) (20).

19. A method of using a rope light (R), comprising the steps of

connecting a plurality of exposed conductors (20) having a plurality of lights (30) attached thereto to a power source, the combination of the plurality of exposed conductors having the plurality of lights attached thereto being encased in a substantially solid and translucent sheath (50); and

enhancing illumination of the plurality of lights by reflecting light illumination from each of the plurality of exposed conductors.

20. The method as claimed in claim 19, including the step of connecting a first elongate rope light (R) to a second elongate rope light (R) by inserting portions (72) of a connector (70) into connector portions positioned on the first and second rope lights.

21. The method as claimed in claim 19 or 20, including the step of viewing the plurality of exposed conductors (20) through the translucent sheath (50).

Drawing