U.S. patent application number 16/972188 was filed with the patent office on 2021-07-29 for surge protection module and related components and methods.
The applicant listed for this patent is Viza Electronics Pte. Ltd.. Invention is credited to Jack Lula, Anthony Mangiaracina, Simon Christopher Smith, Robert Zamora.
Application Number | 20210234289 16/972188 |
Document ID | / |
Family ID | 1000005570596 |
Filed Date | 2021-07-29 |
United States Patent
Application |
20210234289 |
Kind Code |
A1 |
Smith; Simon Christopher ;
et al. |
July 29, 2021 |
SURGE PROTECTION MODULE AND RELATED COMPONENTS AND METHODS
Abstract
A surge protection module configured to limit power surge
exposure to an electrical device may include a carrier defining a
first end and a second end opposite the first end and a
longitudinal axis extending between the first end and the second
end. The surge protection module may also include at least two
electrical conductors coupled to the carrier. The surge protection
module may also include a surge protection component electrically
coupled to the at least two electrical conductors and configured to
limit power surge conducted to an electrical device to which the at
least two electrical conductors are electrically coupled. The
carrier may include at least one conductor channel extending
between ends of the carrier and configured to receive at least one
electrical conductor. The carrier may also define a recess
configured to receive at least a portion of a surge protection
component, and at least one pocket configured to receive a lug for
electrically coupling and for physically coupling a first
electrical conductor to a lead of a surge protection component.
Inventors: |
Smith; Simon Christopher;
(Benfleet, GB) ; Lula; Jack; (Burlington, CA)
; Zamora; Robert; (Huntersville, NC) ;
Mangiaracina; Anthony; (Mobile, AL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Viza Electronics Pte. Ltd. |
Charlotte |
NC |
US |
|
|
Family ID: |
1000005570596 |
Appl. No.: |
16/972188 |
Filed: |
June 5, 2019 |
PCT Filed: |
June 5, 2019 |
PCT NO: |
PCT/US19/35492 |
371 Date: |
December 4, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62680865 |
Jun 5, 2018 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H02H 9/02 20130101; H02H
3/04 20130101; H01R 9/2441 20130101; H02H 9/042 20130101 |
International
Class: |
H01R 9/24 20060101
H01R009/24; H02H 9/04 20060101 H02H009/04; H02H 3/04 20060101
H02H003/04 |
Claims
1-97. (canceled)
98. A surge protection module configured to limit power surge
exposure to an electrical device, the surge protection module
comprising: three terminals configured to be electrically coupled
to an electrical device, the three terminals being configured to
provide at least one of a series connection or a parallel
connection to an electrical device to which the three terminals are
electrically coupled; at least one surge protection component
electrically coupled to the three terminals and configured to limit
power surge conducted to an electrical device to which the three
terminals are electrically coupled; and a mechanical connection
configured to mechanically couple the surge protection module to an
electrical device to which the surge protection module is
electrically coupled.
99. The surge protection module of claim 98, wherein the three
terminals are configured to be electrically coupled to at least one
of a light emitting diode (LED) driver, an electrical ballast, or a
terminal block.
100. The surge protection module of claim 98, whereon the three
electrical contacts are configured to be electrically coupled to an
electrical device via at least one of terminal block pins, spring
pins, spring clips, push-in connections, or self-piercing pins.
101. The surge protection module of claim 98, wherein the at least
one surge protection component comprises at least one of a metal
oxide varistor (MOV), a gas discharge tube (GDT), a transient
voltage suppression (TVS) diode, a thyristor surge protection
device (TSPD), a fuse, an inductor, or a capacitor.
102. The surge protection module of claim 98, wherein the
mechanical connection comprises at least one of a screw, a clip,
prongs, a complimentary groove-and-recess connection, a twist-in
connection, a plug-in connection, or a push-in connection.
103. The surge protection module of claim 98, wherein the
mechanical connection is configured to be coupled directly to at
least one of an LED driver, a terminal block, or an electrical
ballast.
104. The surge protection module of claim 98, further comprising a
status indicator configured to provide an indication of at least
one of operability of the surge protection module, remaining
service life of the surge protection module, or failure of the
surge protection module.
105. A surge protection module configured to limit power surge
exposure to an electrical device, the surge protection module
comprising: a carrier defining a first end and a second end
opposite the first end and a longitudinal axis extending between
the first end and the second end; at least two electrical
conductors coupled to the carrier; and a surge protection component
electrically coupled to the at least two electrical conductors and
configured to limit power surge conducted to an electrical device
to which the at least two electrical conductors are electrically
coupled.
106. The surge protection module of claim 105, wherein the surge
protection component comprises at least two electrical leads, and
the surge protection module further comprises at least two lugs,
wherein each of the at least two lugs receives at least one of the
at least two electrical conductors and one of the at least two
electrical leads and electrically couples the at least one
electrical conductor and the one electrical lead to one
another.
107. The surge protection module of claim 106, wherein the at least
two lugs are configured to be one or more of pressed onto the at
least one electrical conductor and the one electrical lead or
welded onto the at least one electrical conductor and the one
electrical lead, such that the at least one electrical conductor
and the one electrical lead are electrically coupled to one another
and physically coupled to one another.
108. The surge protection module of claim 105, wherein the at least
two electrical conductors comprise three electrical conductor, and
wherein the surge protection component is a first surge protection
component, and the surge protection module further comprises a
second surge protection component electrically coupled to at least
two electrical conductors of the three electrical conductors, and
is configured to limit power surge conducted to an electrical
device to which the at least two electrical conductors are
electrically coupled.
109. The surge protection module of claim 108, wherein the first
surge protection component is electrically coupled to a first one
of the three electrical conductors and a second one of the three
electrical conductors, and wherein the second surge protection
component is electrically coupled to the first one of the three
electrical conductors and a third one of the three electrical
conductors.
110. The surge protection module of claim 109, wherein each of the
first and second surge protection components comprises at least two
electrical leads, and the surge protection module further comprises
at least three lugs, wherein a first one of the at least three lugs
receives: the first one of the three electrical conductors; a first
one of the at least two electrical leads of the first surge
protection component; and a first one of the at least two
electrical leads of the second surge protection component.
111. The surge protection module of claim 109, wherein a second one
of the three lugs receives a second one of the three electrical
conductors and a second one of the at least two electrical leads of
the first surge protection component, and wherein a third one of
the three lugs receives a third one of the three electrical
conductors and a second one of the at least two electrical leads of
the second surge protection component.
112. The surge protection module of claim 105, wherein the carrier
defines a recess receiving at least a portion of the surge
protection component, and wherein the carrier defines at least one
conductor channel extending from the first end of the carrier
toward the second end of the carrier and receiving at least one of
the at least two electrical conductors, and the recess is located
between the at least one conductor channel and the second end of
the carrier.
113. The surge protection module of claim 105, wherein the carrier
defines at least one lead channel extending between the recess and
the at least one conductor channel and receiving a lead of the
surge protection component.
114. The surge protection module of claim 105, wherein the second
end of the carrier defines a mounting boss configured to facilitate
mounting of the surge protection module to a support.
115. The surge protection module of claim 105, wherein the carrier
defines a notch between the mounting boss and a remainder of the
carrier, the notch being configured to facilitate separation of the
mounting boss from the remainder of the carrier.
116. The surge protection module of claim 105, wherein the mounting
boss defines a flange defining a mounting hole configured to
receive a fastener for mounting the surge protection module to the
support.
117. The surge protection module of claim 105, wherein the flange
comprises a first flange, and the mounting boss further comprises a
second flange defining a mounting hole configured to receive a
fastener for mounting the surge protection module to the support,
wherein each of the first flange and the second flange defines a
flange plane, and wherein the flange plane of first flange and the
flange plane of the second flange are at an angle with respect to
one another.
Description
[0001] This PCT International Patent application claims the benefit
of priority of U.S. Provisional Application No. 62/680,865, filed
Jun. 5, 2018, the entire disclosure of which is incorporated herein
by reference.
BACKGROUND
[0002] Many electrical devices are susceptible to damage resulting
from power and/or voltage spikes. As a result, surge protectors are
often used to protect electrical devices from such surges. Some
surge protectors take the form of a separate power strip that may
be plugged into an electric outlet and to which an electrical
device is connected. In such examples, the power strip is in series
between the electric outlet and the electrical device, and may
serve as a buffer between spikes associated with the electric
outlet and the electrical device.
[0003] Such surge protectors may suffer from possible drawbacks.
For example, because the surge protector is itself a separate
electrical device, its use may be overlooked, resulting in a lack
of surge protection for an electrical device. Thus, some surge
protectors are integrated into an electrical device to ensure that
the surge protector is provided for protection of its associated
electrical device. Such integrated surge protectors may also suffer
from possible drawbacks. For example, they may create packaging
problems due to a desire to reduce the size of some electrical
devices. There may be other possible drawbacks. At least some of
the examples described herein may mitigate or overcome some such
possible drawbacks.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] The detailed description is described with reference to the
accompanying figures. The same reference numbers in different
figures indicate similar or identical items.
[0005] FIG. 1 is a schematic diagram showing an example surge
protection module electrically coupled to an example electrical
device in a first example connection configuration.
[0006] FIG. 2 is a schematic diagram showing an example surge
protection module electrically coupled to an example electrical
device in another example connection configuration.
[0007] FIG. 3 is a schematic diagram showing an example surge
protection module electrically coupled to an example terminal block
in an example connection configuration.
[0008] FIG. 4 is a schematic diagram showing an example surge
protection module electrically coupled to an example terminal block
in another example connection configuration.
[0009] FIG. 5 is a schematic diagram showing an example surge
protection module electrically coupled to an example electrical
device in another example connection configuration.
[0010] FIG. 6A is a perspective view of an example surge protection
module coupled to an example electrical device.
[0011] FIG. 6B is a perspective view of an example surge protection
module coupled to an example electrical device via an example
rotational connection.
[0012] FIG. 6C is a perspective view of an example surge protection
module coupled to an example electrical device via an example
push-in connection.
[0013] FIG. 6D is a perspective view of an example surge protection
module coupled to an example electrical device in an example manner
including example fasteners.
[0014] FIG. 7A is a perspective view of an example surge protection
module separated from an example electrical device showing an
example electrical coupling.
[0015] FIG. 7B is a perspective view of an example electrical
device showing an example electrical coupling.
[0016] FIG. 7C is a perspective view of another example electrical
device showing another example electrical coupling.
[0017] FIG. 7D is a perspective view of another example electrical
device showing another example electrical coupling including an
example printed circuit board including contact pads.
[0018] FIG. 8 is a perspective view of an example surge protection
module.
[0019] FIG. 9 is an exploded perspective view of the example surge
protection module shown in FIG. 8.
[0020] FIG. 10 is a perspective view of an example carrier of a
surge protection module.
[0021] FIG. 11 is a view of a first side of the example carrier
shown in FIG. 10.
[0022] FIG. 12 is a view of a second side of the example carrier
shown in FIG. 10.
[0023] FIG. 13 is a view from a third side of the example carrier
shown in FIG. 10.
[0024] FIG. 14 is a view from a first side of another example
carrier.
[0025] FIG. 15 is a view from another side of the example carrier
shown in FIG. 14.
[0026] FIG. 16 is a perspective view of another example carrier
with a detailed view of an example notch configured to facilitate
separation of different portions of the carrier from one
another.
[0027] FIG. 17A is a partial perspective view of an example surge
protection module including an example mounting boss configured to
facilitate mounting of the surge protection module to a
support.
[0028] FIG. 17B is a partial perspective view of another example
surge protection module including another example mounting boss
configured to facilitate mounting of the surge protection module to
a support.
[0029] FIG. 17C is a partial perspective view of a further example
surge protection module including a further example mounting boss
configured to facilitate mounting of the surge protection module to
a support.
[0030] FIG. 17D is a partial perspective view of another example
surge protection module including another example mounting boss
configured to facilitate mounting of the surge protection module to
a support.
[0031] FIG. 18 is an exploded perspective view of the example surge
protection module including an example carrier, example lugs,
example electrical conductors, and example surge protection
components including example electrical leads.
[0032] FIG. 19A is a perspective view of an example surge
protection component including electrical leads having example
bends.
[0033] FIG. 19B is a top view of the example surge protection
component shown in FIG. 19A.
[0034] FIG. 19C is a side view of the example surge protection
component shown in FIG. 19A.
[0035] FIG. 20A is a perspective view of another example surge
protection component including electrical leads having example
bends.
[0036] FIG. 20B is a top view of the example surge protection
component shown in FIG. 20A.
[0037] FIG. 20C is a side view of the example surge protection
component shown in FIG. 20A.
[0038] FIG. 21 is a view of an example carrier, example lugs,
example electrical conductors, and example surge protection
components laid out for assembly.
[0039] FIG. 22 is a view of example lugs provided in example
pockets of an example carrier for assembly of an example surge
protection module.
[0040] FIG. 23 is a view of two example surge protection components
provided in example recesses on a second side of an example
carrier, with example electrical leads of the surge protection
components passing through respective example openings for
facilitating passage of the electrical leads from the second side
of the carrier to the first side of the carrier, and with the
electrical leads provided in the hollow spaces of the three lugs
according to an example construction.
[0041] FIG. 24 is a view showing three example electrical
conductors provided in the respective hollow spaces of the three
lugs with the electrical leads of the two surge protection
components and with the three electrical conductors received in
example conductor channels.
[0042] FIG. 25 is a view showing third and fourth example surge
protection components received in respective third and fourth
example recesses in the carrier with the respective electrical
leads of the third and fourth surge protection components provided
in the hollow spaces of the three lugs.
[0043] FIG. 26 is a perspective view showing example bands for
securing the first, second, third, and fourth surge protection
components to the carrier.
[0044] FIG. 27 is a perspective view of an example partially
assembled surge protection module shown in FIG. 26 provided in an
example press configured to press the three respective lugs such
that the lugs are crimped onto the electrical leads of the first,
second, third, and fourth surge protection components, and the
three electrical conductors, such that they are physically coupled
and electrically coupled to one another.
[0045] FIG. 28 is a perspective view of the example press shown in
FIG. 27.
[0046] FIG. 29 is a perspective view of showing example lower dies
of the example press and an example surge protection module
(excluding a surge protection component for ease of viewing)
following pressing including crimped lugs having respective
substantially rectangular cross-sectional shapes following
crimping.
[0047] FIG. 30 shows a view of example upper dies and corresponding
example lower dies in respective die holders for the example press
shown in FIGS. 27-29.
[0048] FIG. 31 is a detailed perspective view of three example dies
removed from a die holder to show details of the example dies,
including example dimensions relative to an example lug.
[0049] FIG. 32 is a sequence of views showing an example insulation
sleeve being provide over an example carrier having crimped lugs,
with one end of the example insulation sleeve abutting an example
flange at an end of the carrier so the example mounting boss
remains exposed, all prior to heating the example insulation sleeve
to shrink the insulation sleeve, thereby securing it to the carrier
and covering the surge protection components, the lugs, and ends of
the electrical conductors received in the lugs.
[0050] FIG. 33 is a schematic partial section view showing three
example surface-scorings of example leads for example electrical
components.
DETAILED DESCRIPTION
[0051] This disclosure is generally directed to a surge protection
module and related components and methods. As discussed above, many
electrical devices are susceptible to damage resulting from power
and/or voltage spikes. As a result, surge protectors are often used
to protect electrical devices from such surges. Some surge
protectors, however, may suffer from a number of possible
drawbacks. For example, if the surge protector is a separate
electrical device, its use may be overlooked, resulting in a lack
of surge protection for an electrical device. Surge protectors
integrated into an electrical device to ensure that the surge
protector is provided for protection of its associated electrical
device may also suffer from possible drawbacks. For example, they
may create packaging problems due to a desire to reduce the size of
some electrical devices. There may be other possible drawbacks.
[0052] The surge protection modules and related components and
methods disclosed herein may mitigate or overcome some possible
drawbacks associated with existing surge protectors. For example,
some examples of the surge protection modules disclosed herein may
allow for selective electrical connection to an electrical device.
In some examples, the surge protection modules may be configured
for ease of physical and electrical coupling to an electrical
device. In some examples, the surge protection modules may be
applied on alternating current (AC) main inputs and may be the
first point of contact for a surge event. In some examples, the
surge protection modules may operate in a standalone manner and/or
in association with additional surge protection associated with the
electrical device (e.g., surge protection associated with a light
emitting diode (LED) driver), for example, depending on whether the
surge protection module is electrically coupled in series or
parallel with respect to the electrical device. In some examples,
the surge protection module may be used in combination with fusing
elements, thermal elements, and/or high-power dissipation elements,
such as, for example, gas discharge tubes. In some examples, the
surge protection module may be integrated into a power electronics
circuit or may be used as a stand-alone device (e.g., a device
external and independent from an electrical device being
protected). In some examples, the surge protection modules may
include an indicator of the status of operation of the surge
protection module, such as, for example, the remaining service life
of the module, failure of the module, and/or operation of the
module. In some examples, the surge protection modules may be
configured to facilitate an electrical path including line (L),
neutral (N), and/or ground (G) connection conductors (e.g., wires)
for installation with an electrical device. In some examples, the
surge protection modules may be configured (e.g., optimized) for
use with LED lighting fixture and/or applications. In some
examples, the surge protection modules may be configured (e.g.,
optimized) for 120 volts (V), 120V-277V, 240V, 347V and/or
347V-480V.
[0053] In some examples, the surge protection modules may be
configured to provide a compact unit, for example, having elongated
and/or thin structure. In some examples, the surge protection
modules may be configured to be easily removed and/or replaced.
Some examples may include a mounting feature to facilitate mounting
to a support. Some examples may not include a mounting feature. As
explained herein, some examples of the surge protection modules may
be assembled and/or manufactured, for example, without soldering to
achieve electrical and/or physical coupling. For example, some
electrical and/or physical connections may be formed via a crimping
process. As explained herein, some examples of the surge protection
modules may include a carrier (e.g., a plastic injection-molded
carrier), which may in some examples, facilitate automated and/or
consistent manufacturing of the surge protection modules. In some
examples including a carrier, the carrier may provide at least
partial shielding of electrical conductors. In some examples, the
manufacturing may be used to achieve surge protection modules
having an inline/wire look appearance.
[0054] According to one aspect, a surge protection module may be
configured to limit power surge exposure to an electrical device,
and the surge protection module may include three terminals
configured to be electrically coupled to an electrical device. The
three terminals may be configured to provide a series connection
and/or a parallel connection to an electrical device to which the
three terminals are electrically coupled. The surge protection
module may also include at least one surge protection component
electrically coupled to the three terminals and configured to limit
power surge conducted to an electrical device to which the three
terminals are electrically coupled. The surge protection module may
also include a mechanical connection configured to mechanically
couple the surge protection module to an electrical device to which
the surge protection module is electrically coupled. In some
examples, the three terminals may be configured to be electrically
coupled to at least one of a light emitting diode (LED) driver, an
electrical ballast, or a terminal block. In some examples, the
three electrical contacts may be configured to be electrically
coupled to an electrical device via terminal block pins, spring
pins, spring clips, push-in connections, self-piercing pins, and/or
any other mechanical wire connection. In some examples, the at
least one surge protection component may include one or more of a
metal oxide varistor (MOV), a gas discharge tube (GDT), a transient
voltage suppression (TV S) diode, a thyristor surge protection
device (TSPD), a fuse, an inductor, or a capacitor. In some
examples, the mechanical connection may include at least one of a
screw, a clip, prongs, a complimentary groove-and-recess
connection, a twist-in connection, a plug-in connection, or a
push-in connection. In some examples, the mechanical connection may
be configured to be coupled directly to at least one of an LED
driver, a terminal block, or an electrical ballast. In some
examples, the surge protection module may include a status
indicator configured to provide an indication of at least one of
operability of the surge protection module, remaining service life
of the surge protection module, or failure of the surge protection
module.
[0055] According to another aspect, a surge protection module
configured to limit power surge exposure to an electrical device
may include a carrier defining a first end and a second end
opposite the first end and a longitudinal axis extending between
the first end and the second end. The surge protection module may
also include at least two electrical conductors coupled to the
carrier, and a surge protection component electrically coupled to
the at least two electrical conductors and configured to limit
power surge conducted to an electrical device to which the at least
two electrical conductors are electrically coupled.
[0056] In some examples, the surge protection component may include
at least two electrical leads, and the surge protection module may
further include at least two lugs, wherein each of the at least two
lugs receives at least one of the at least two electrical
conductors and one of the at least two electrical leads, and
electrically couples the at least one electrical conductor and the
one electrical lead to one another. In some examples, the at least
two lugs are configured to be pressed onto the at least one
electrical conductor and the one electrical lead, such that the at
least one electrical conductor and the one electrical lead are
electrically coupled to one another and physically coupled to one
another. In some examples, the at least two lugs may be welded
(e.g., electrically-welded and/or thermally-welded) to the at least
one electrical conductor and the one electrical lead, such that the
at least one electrical conductor and the one electrical lead are
electrically coupled to one another and physically coupled to one
another. In some examples, the at least two lugs may include a
tubular member (e.g., a hollow cylindrical member) receiving an end
of the at least one electrical conductor and an end of the one
electrical lead.
[0057] In some examples, the surge protection module may also
include an insulating layer covering at least a portion of the
carrier to electrically insulate the electrical connection between
the at least two electrical conductors and the surge protection
component. In some examples, the insulating layer may include an
insulation sleeve covering at least a portion of the carrier to
electrically insulate the electrical connection between the at
least two electrical conductors and the surge protection component.
In some examples, the insulation sleeve may be configured tighten
around the at least a portion of the carrier upon exposure to heat
(e.g., it may be a heat-shrink sleeve). In some examples, the
insulation layer may include a conformal coating, or similar
coating, covering at least a portion of the carrier to electrically
insulate the electrical connection between the at least two
electrical conductors and the surge protection component. For
example, the conformal coating may be applied via one or more of
brushing, spraying, dipping, or selective coating by machine, and
may include conformal coating compositions, such as, for example,
one or more of acrylic, epoxy, polyurethane, silicone, fluorinated
or non-fluorinated polyparaxylylene (parylene), or amorphous
fluoropolymer.
[0058] In some examples, the at least two electrical conductors may
include three electrical conductors. For example, the surge
protection component may be a first surge protection component, and
the surge protection module may further include a second surge
protection component electrically coupled to at least two
electrical conductors of the three electrical conductors, and may
be configured to limit power surge conducted to an electrical
device to which the at least two electrical conductors are
electrically coupled. In some such examples, the first surge
protection component may be electrically coupled to a first one of
the three electrical conductors and a second one of the three
electrical conductors, and the second surge protection component
may be electrically coupled to the first one of the three
electrical conductors and a third one of the three electrical
conductors. In some such examples, each of the first and second
surge protection components may include at least two electrical
leads, and the surge protection module may further include at least
three lugs. In some examples, a first one of the at least three
lugs may receive: the first one of the three electrical conductors,
a first one of the at least two electrical leads of the first surge
protection component, and a first one of the at least two
electrical leads of the second surge protection component. In some
such examples, a second one of the three lugs may receive a second
one of the three electrical conductors and a second one of the at
least two electrical leads of the first surge protection component.
In some examples, a third one of the three lugs may receive a third
one of the three electrical conductors and a second one of the at
least two electrical leads of the second surge protection
component.
[0059] In some examples, the surge protection module may include a
third surge protection component electrically coupled to the at
least two electrical conductors. In some such examples, the surge
protection module may also include a fourth surge protection
component electrically coupled to the at least two electrical
conductors.
[0060] In some examples, the carrier may define at least one
conductor channel extending from the first end of the carrier
toward the second end of the carrier and receiving at least one of
the at least two electrical conductors. In some examples, the at
least one conductor channel may include three conductor channels,
and each of the conductor channels may be configured to receive an
electrical conductor. In some examples, the at least one conductor
channel may include a grip engaged with the at least one electrical
conductor. Some examples may include a grip in each of two or three
conductor channels.
[0061] In some examples, the first end of the carrier may define an
outer surface that tapers in a direction away from the second end
of the carrier. In some examples, the first end of the carrier may
define an inner surface that tapers in a direction away from the
second end of the carrier.
[0062] In some examples, the carrier may define a recess receiving
at least a portion of a surge protection component. In some
examples, the carrier may define at least one conductor channel
extending from the first end of the carrier toward the second end
of the carrier and receiving at least one of the at least two
electrical conductors, and the recess may be located between the at
least one conductor channel and the second end of the carrier. In
some examples, the carrier may define at least one lead channel
extending between the recess and the at least one conductor channel
and receiving a lead of the surge protection component.
[0063] In some examples, the carrier may define at least one pocket
receiving a lug electrically coupling and physically coupling a
first electrical conductor to a lead of the surge protection
component. In some examples, the at least one pocket may include a
first pocket receiving a first lug and a second pocket adjacent the
first pocket and receiving a second lug. The carrier may further
include a pocket barrier between the first pocket and the second
pocket and separating the first lug and the second lug from one
another. In some examples, the at least one pocket may pass through
the carrier (e.g., from a first side of the carrier to a second
side of the carrier). In some examples, the at least one pocket may
define at least one tab configured to prevent the lug from passing
through the carrier.
[0064] In some examples, the second end of the carrier may define a
mounting boss configured to facilitate mounting of the surge
protection module to a support. In some examples, the carrier may
define a notch between the mounting boss and a remainder of the
carrier, and the notch may be configured to facilitate separation
of the mounting boss from the remainder of the carrier. In some
examples, the mounting boss may define a flange defining a mounting
hole configured to receive a fastener for mounting the surge
protection module to the support. In some examples, the flange may
define a plane extending either substantially parallel with respect
to the longitudinal axis of the carrier, obliquely with respect to
longitudinal axis of the carrier, or substantially perpendicular
with respect to the longitudinal axis of the carrier. In some
examples, the flange may include a first flange, and the mounting
boss may further include a second flange defining a mounting hole
configured to receive a fastener for mounting the surge protection
module to the support. In some such examples, each of the first
flange and the second flange may define a flange plane, and the
flange plane of first flange and the flange plane of the second
flange may be at an angle with respect to one another, for example,
a non-zero angle, an angle of about 30 degrees, an angle of about
45 degrees, an angle of about 60 degrees, an angle of about 90
degrees, an angle of about 120 degrees, an angle of about 135
degrees, or an angle of about 150 degrees. In some examples, the
mounting boss may include at least one reinforcement rib (e.g.,
two, three, or four reinforcement ribs) configured to strengthen
the mounting boss.
[0065] In some examples, the carrier may define a flange at the
second end of the carrier and configured to provide a stop for the
insulation sleeve, for example, to prevent the insulation sleeve
from extending over the mounting boss. For example, in examples
having an insulation sleeve, the insulation sleeve may be pushed
from the first end of the carrier, over the carrier until the
leading end of the insulation sleeve abuts the flange.
[0066] According to yet another aspect, a carrier configured to
receive components of a surge protection module may define an
elongated carrier body. The elongated carrier body may define a
first end and a second end opposite the first end and a
longitudinal axis extending between the first end and the second
end. The carrier body may further define at least one conductor
channel extending from the first end toward the second end and
configured to receive at least one electrical conductor. The
carrier body may also define a recess configured to receive at
least a portion of a surge protection component, and at least one
pocket configured to receive a lug for electrically coupling and
for physically coupling a first electrical conductor to a lead of a
surge protection component. In some examples, the carrier body may
define two or three conductor channels, each configured to receive
an electrical conductor. In some examples, the at least one
conductor channel may include a grip configured to engage at least
one electrical conductor.
[0067] In some examples of the carrier, the first end of the
carrier body may define an outer surface that tapers in a direction
away from the second end of the carrier body. In some examples, the
first end of the carrier body may define an inner surface that
tapers in a direction away from the second end of the carrier body.
This may bring the electrical conductors closer to one another,
which may reduce inductance generated in the electrical conductors.
In some examples, two or more of the electrical conductors may be
included in a zip-cord wire (e.g., a pre-bonded zip-cord wire).
[0068] In some examples of the carrier, the carrier body may define
at least one conductor channel extending from the first end of the
carrier body toward the second end of the carrier and configured to
receive at least one electrical conductor. In some such examples,
the recess may be located between the at least one conductor
channel and the second end of the carrier body. In some examples,
the carrier body may define at least one lead channel extending
between the recess and the at least one conductor channel and
configured to receive a lead of a surge protection component.
[0069] In some examples, the at least one pocket may include a
first pocket configured to receive a first lug and a second pocket
adjacent the first pocket and configured to receive a second lug.
In some such examples, the carrier body may also include a pocket
barrier between the first pocket and the second pocket and
configured to separate a first lug and a second lug from one
another. Such examples may provide electrical insulation between
the lugs, which may provide compliance with some electrical
regulations.
[0070] In some examples, the at least one pocket may pass through
the carrier body, for example, from a first side of the carrier
body to an opposite second side of the carrier body. This may
facilitate pressing the lugs using a press having opposing dies
that approach one another during the pressing process and contact
the lugs from opposite sides to facilitate crimping the lugs. In
some examples, the at least one pocket may define at least one tab
configured to prevent a lug from passing through the carrier body.
In some such examples, the lug may be provided in the pocket but be
prevented from passing through the pocket and separating from the
carrier body.
[0071] In some examples of the carrier, the second end of the
carrier body may define a mounting boss configured to facilitate
mounting of the carrier to a support. In some such examples, the
carrier body may define a notch between the mounting boss and a
remainder of the carrier body, and the notch may be configured to
facilitate separation of the mounting boss from the remainder of
the carrier body, for example, with or without using a cutting
device. In some examples, the mounting boss may be frangible and
thus separable from the remainder of the carrier body.
[0072] In some examples of the carrier, the mounting boss may
define a flange defining a mounting hole configured to receive a
fastener for mounting the carrier to a support. In some examples,
the flange may define a plane extending either substantially
parallel with respect to the longitudinal axis of the carrier body,
obliquely with respect to longitudinal axis of the carrier body, or
substantially perpendicular with respect to the longitudinal axis
of the carrier body. In some examples, the flange may include a
first flange, and the mounting boss may further include a second
flange defining a mounting hole configured to receive a fastener
for mounting the carrier to a support. Each of the first flange and
the second flange may define a flange plane, and the flange plane
of first flange and the flange plane of the second flange may be at
an angle with respect to one another, for example, as described
herein. In some examples, the mounting boss may include at least
one reinforcement rib configured to strengthen the mounting boss,
for example, as described herein.
[0073] In some examples, the carrier body may include a flange at
the second end of the carrier body and configured to provide a stop
for an insulation sleeve, for example, as described herein.
[0074] In some examples of the carrier, the carrier body may define
a first side and a second side opposite the first side, and the at
least one recess may include a first recess in the first side of
the carrier body and a second recess in the second side of the
carrier body. In some examples, the carrier body may define an
opening configured to permit at least one electrical lead of a
surge protection component to pass from the first side of the
carrier body to the second side of the carrier body. In some
examples, the at least one recess may further include a third
recess in the first side of the carrier body and a fourth recess in
the second side of the carrier body. Each of the first recess, the
second recess, the third recess, and the fourth recess may be
configured to receive at least a portion a surge protection
component.
[0075] In some examples, the carrier body may define at least one
opening configured to: facilitate electrical leads of a surge
protection component at least partially received in the second
recess to pass from the second side of the carrier body to the
first side of the carrier body; and facilitate electrical leads of
a surge protection component at least partially received in the
fourth recess to pass from the second side of the carrier body to
the first side of the carrier body.
[0076] According to still a further aspect, a method (e.g., for
assembling a surge protection module) may include providing a
carrier configured to receive at least one electrical conductor and
at least one surge protection component, with the carrier defining
a pocket. The method may further include providing a lug in the
pocket of the carrier, with the lug defining a hollow space. The
method may also include providing an electrical lead of a surge
protection component in the hollow space of the lug, and providing
an electrical conductor in the hollow space of the lug. The method
may also include one or more of pressing the lug to crimp the lug
onto the electrical lead of the surge protection component and the
electrical conductor or welding the lug onto the electrical lead of
the surge protection component and the electrical conductor (with
or without the lone or more of the lugs), such that the electrical
lead and the electrical conductor are physically coupled to one
another and electrically coupled to one another.
[0077] In some examples of the method, the carrier may define a
first pocket and a second pocket, with each of the first pocket and
the second pocket being configured for receiving a lug defining a
hollow space. In such examples, providing the lug in the pocket of
the carrier may include providing a first lug in the first pocket,
with the first lug defining a first hollow space, and providing a
second lug in the second pocket, with the second lug defining a
second hollow space. In some such examples, providing the
electrical lead of the surge protection component in the hollow
space of the lug may include providing a first electrical lead of
the surge protection component in the first hollow space of the
first lug, and providing a second electrical lead of the surge
protection component in the second hollow space of the second
lug.
[0078] In some examples, providing an electrical conductor in the
hollow space of the lug may include providing a first electrical
conductor in the first hollow space of the first lug, and providing
a second electrical conductor in the second hollow space of the
second lug. In some examples, pressing the lug to crimp the lug may
include: (1) pressing the first lug to crimp the first lug onto the
first electrical lead of the surge protection component and the
first electrical conductor, such that the first electrical lead and
the first electrical conductor are physically coupled to one
another and electrically coupled to one another; and (2) pressing
the second lug to crimp the second lug onto the second electrical
lead of the surge protection component and the second electrical
conductor, such that the second electrical lead and the second
electrical conductor are physically coupled to one another and
electrically coupled to one another.
[0079] In some examples, the carrier may further define a third
pocket configured for receiving a lug defining a hollow space. In
such examples, providing the lug in the pocket of the carrier may
include providing a third lug in the third pocket, with the third
lug defining a third hollow space, and providing an electrical
conductor in the hollow space of the lug may include providing a
third electrical conductor in the third hollow space of the third
lug. In some such examples, pressing the lug to crimp the lug may
include: (1) pressing the first lug to crimp the first lug onto the
first electrical lead of the surge protection component and the
first electrical conductor, such that the first electrical lead and
the first electrical conductor are physically coupled to one
another and electrically coupled to one another; (2) pressing the
second lug to crimp the second lug onto the second electrical lead
of the surge protection component and the second electrical
conductor, such that the second electrical lead and the second
electrical conductor are physically coupled to one another and
electrically coupled to one another; and (3) pressing the third lug
to crimp the third lug onto the third electrical conductor, such
that the third lug and the third electrical conductor are
physically coupled to one another and electrically coupled to one
another.
[0080] In some examples, the method may further include providing
an insulation layer over at least a portion of the carrier. For
example, the method may include sliding an insulation sleeve over
at least a portion of the carrier. In some examples, the carrier
may include a flange at an end of the carrier, and sliding the
insulation sleeve over at least a portion of the carrier may
include sliding the insulation sleeve over the carrier, such that
an end of the insulation sleeve abuts the flange of the carrier. In
some examples, the method may further include heating the
insulation sleeve such that the insulation sleeve shrinks tightly
around the carrier. In some examples, the method may include
providing an insulating layer including a conformal coating, or
similar coating, covering at least a portion of the carrier to
electrically insulate the electrical connection between the at
least two electrical conductors and the surge protection component.
For example, the conformal coating may be applied via one or more
of brushing, spraying, dipping, or selective coating by machine,
and may include conformal coating compositions, such as, for
example, one or more of acrylic, epoxy, polyurethane, silicone,
fluorinated or non-fluorinated polyparaxylylene (parylene), or
amorphous fluoropolymer.
[0081] In some examples of the method, the surge protection
component may include a first surge protection component, and the
method may further include: providing a first electrical lead of a
second surge protection component in the first lug, and providing a
second electrical lead of the second surge protection component in
one of the second hollow space of the second lug or the third
hollow space of the third lug. In some such examples, pressing the
lug to crimp the lug may include: (1) pressing the first lug to
crimp the first lug onto the first electrical lead of the first
surge protection component, the first electrical lead of the second
surge protection component, and the first electrical conductor,
such that the first electrical lead of the first surge protection
component, the first electrical lead of the second surge protection
component, and the first electrical conductor are physically
coupled to one another and electrically coupled to one another; (2)
pressing the second lug to crimp the second lug onto the second
electrical lead of the first surge protection component and the
second electrical conductor, such that the second electrical lead
and the second electrical conductor are physically coupled to one
another and electrically coupled to one another; and (3) pressing
the third lug to crimp the third lug onto the second electrical
lead of the second surge protection component and the third
electrical conductor, such that the second electrical lead of the
second surge protection component and the third electrical
conductor are physically coupled to one another and electrically
coupled to one another.
[0082] In some examples of the method, it may further include
providing a first electrical lead of a third surge protection
component in the first lug, and providing a second electrical lead
of the third surge protection component in one of the second hollow
space of the second lug or the third hollow space of the third lug.
In some such examples, pressing the lug to crimp the lug may
include: (1) pressing the first lug to crimp the first lug onto the
first electrical lead of the first surge protection component, the
first electrical lead of the second surge protection component, the
first electrical lead of the third surge protection component, and
the first electrical conductor, such that the first electrical lead
of the first surge protection component, the first electrical lead
of the second surge protection component, the first electrical lead
of the third surge protection component, and the first electrical
conductor are physically coupled to one another and electrically
coupled to one another; (2) pressing the second lug to crimp the
second lug onto and the second electrical lead of the first surge
protection component, the second electrical lead of the third surge
protection component, and the second electrical conductor, such
that the second electrical lead of the first surge protection
component, the second electrical lead of the third surge protection
component, and the second electrical conductor are physically
coupled to one another and electrically coupled to one another; and
(3) pressing the third lug to crimp the third lug onto the second
electrical lead of the second surge protection component and the
third electrical conductor, such that the second electrical lead of
the second surge protection component and the third electrical
conductor are physically coupled to one another and electrically
coupled to one another.
[0083] In some examples, the method may further include providing a
first electrical lead of a fourth surge protection component in the
first lug, and providing a second electrical lead of the fourth
surge protection component in one of the second hollow space of the
second lug or the third hollow space of the third lug. In some such
examples, pressing the lug to crimp the lug may include: (1)
pressing the first lug to crimp the first lug onto the first
electrical lead of the first surge protection component, the first
electrical lead of the second surge protection component, the first
electrical lead of the third surge protection component, the first
electrical lead of the fourth surge protection component, and the
first electrical conductor, such that the first electrical lead of
the first surge protection component, the first electrical lead of
the second surge protection component, the first electrical lead of
the third surge protection component, the first electrical lead of
the fourth surge protection component, and the first electrical
conductor are physically coupled to one another and electrically
coupled to one another; (2) pressing the second lug to crimp the
second lug onto and the second electrical lead of the first surge
protection component, the second electrical lead of the third surge
protection component, and the second electrical conductor, such
that the second electrical lead of the first surge protection
component, the second electrical lead of the third surge protection
component, and the second electrical conductor are physically
coupled to one another and electrically coupled to one another; and
(3) pressing the third lug to crimp the third lug onto the second
electrical lead of the second surge protection component, the
second electrical lead of the fourth surge protection component,
and the third electrical conductor, such that the second electrical
lead of the second surge protection component, the second
electrical lead of the fourth surge protection component, and the
third electrical conductor are physically coupled to one another
and electrically coupled to one another.
[0084] In some examples of the method, pressing the first lug and
pressing the second lug may include pressing the first lug and the
second lug substantially simultaneously (e.g., concurrently). In
some examples, pressing the first lug, pressing the second lug, and
pressing the third lug may include pressing the first lug, the
second lug, and the third lug substantially simultaneously (e.g.,
concurrently).
[0085] In some examples of the method, the carrier may define a
first side and a second side opposite the first side, and the
method may include providing the first surge protection component
on the first side of the carrier, and providing the second surge
protection component on the second side of the carrier. In some
such examples, the first side of the carrier may define a first
recess, the second side of the carrier may define a second recess,
and the method may include providing at least a portion of the
first surge protection component in the first recess of the
carrier, and providing at least a portion of the second surge
protection component in the second recess of the carrier.
[0086] In some examples of the method, the carrier may define a
first side and a second side opposite the first side, and the
method may include providing the first surge protection component
on the first side of the carrier, providing the second surge
protection component on the second side of the carrier, and
providing the third surge protection component on either the first
side of the carrier or the second side of the carrier. In some such
examples, the first side of the carrier may define a first recess
and a second recess, and the second side of the carrier defines a
third recess. In such examples, the method may include providing at
least a portion of the first surge protection component in the
first recess of the carrier, providing at least a portion of the
second surge protection component in the second recess of the
carrier, and providing at least a portion of the third surge
protection component in the third recess of the carrier.
[0087] In some examples of the method, the carrier may define a
first side and a second side opposite the first side, and wherein
the method may include providing the first surge protection
component on the first side of the carrier, providing the second
surge protection component on the first side of the carrier,
providing the third surge protection component on the second side
of the carrier, and providing the fourth surge protection component
on the second side of the carrier. In some such examples, the first
side of the carrier may define a first recess and a second recess,
and the second side of the carrier may define a third recess and a
fourth recess. In such examples, the method may include providing
at least a portion of the first surge protection component in the
first recess of the carrier, providing at least a portion of the
second surge protection component in the second recess of the
carrier, providing at least a portion of the third surge protection
component in the third recess of the carrier, and providing at
least a portion of the fourth surge protection component in the
fourth recess of the carrier. In some such examples, the method may
further include securing the first surge protection component, the
second surge protection component, the third surge protection
component, and the fourth surge protection component to the carrier
prior to pressing the first lug, second lug, and third lug.
[0088] According to yet a further aspect, a method may include
providing at least one electrical conductor in a first lug having a
first hollow space, providing at least one electrical conductor in
a second lug having a second hollow space, and providing at least
one electrical conductor in a third lug having a third hollow
space. The method may further include pressing the first lug, the
second lug, and the third lug to physically couple and electrically
couple the first lug, the second lug, and the third lug to the
respective electrical conductors. In some examples, the pressing
may include forming at least one of the first lug, the second lug,
or the third lug, such that the first lug, the second lug, or the
third lug has a substantially rectangular cross-sectional shape
(e.g., a substantially square or substantially diamond
cross-sectional shape).
[0089] In some examples, pressing the first lug, the second lug,
and the third lug may include pressing the first lug, the second
lug, and the third lug substantially simultaneously (e.g.,
concurrently). In some examples, pressing the first lug, the second
lug, and the third lug may include pressing the first lug, the
second lug, and the third lug at substantially equal force and/or
pressure.
[0090] According to still a further aspect, a method may include
providing a surge protection component including a first electrical
lead and a second electrical lead, and forming the first electrical
lead and/or the second electrical lead, such that the at least one
electrical lead includes at least one bend (e.g., two or more
bends). In some examples of the method, forming the first
electrical lead and/or the second electrical lead may include
placing the least one electrical lead into a forming die configured
to bend the at least one electrical lead. In some such examples,
the method may further include pressing the at least one electrical
lead such that it is formed to include at least one bend (e.g., two
or more bends).
[0091] In some examples, the pressing may include activating a
press device (e.g., a press device as described herein) or
operating a hand-operated pressing tool.
[0092] FIG. 1 is a schematic diagram showing a first example
connection configuration 10 including an example surge protection
module 12 electrically coupled to an example electrical device 14.
In the example shown in FIG. 1, the electrical device 14 includes a
light emitting diode (LED) driver 16 including internal LED driver
circuitry 18. Other types of electrical devices are contemplated.
The example connection configuration 10 shown in FIG. 1 is a
parallel connection in which three alternating current (AC) input
lines 20 from external alternating current connections are
electrically coupled to three electrical conductors 22 of the
example surge protection module 12 and three electrical conductors
24 coupled to the LED driver 16 to electrically couple the LED
driver circuitry 18 to provide a parallel connection. The three
electrical conductors 22 are electrically coupled to surge
protection components 26 of the surge protection module 12 to
provide surge protection for the LED driver 16. The surge
protection components 26 may include, for example, one or more
metal oxide varistors (MOVs), gas discharge tubes (GDTs), transient
voltage suppression (TVS) diodes, thyristor surge protection
devices (TSPDs), fuses, inductors, and/or capacitors. In the
example shown in FIG. 1, the surge protection module 12 is coupled
directly the LED driver 16. Other coupling strategies are
contemplated. The AC input lines 20 may be connected according to
the following connection configurations: line/neutral,
line/neutral/ground, line 1/line 2, or line 1/line 2/ground.
Although shown with external AC input lines 20, the example shown
may be coupled to direct current (DC) input lines, which may be
connected according to the following connection configurations:
DC+/DC- or DC+/DC-/ground.
[0093] FIG. 2 is a schematic diagram showing another example
connection configuration 28 including an example surge protection
module 12 electrically coupled to an example electrical device 14.
In the example shown in FIG. 2, the electrical device 14 includes
an LED driver 16 including internal LED driver circuitry 18. Other
types of electrical devices are contemplated. The example
connection configuration 28 shown in FIG. 2 is a series connection
in which three AC input lines 20 from external alternating current
connections are electrically coupled to three electrical conductors
22 of the example surge protection module 12. Two of the three
electrical conductors 22 are electrically coupled to two surge
protection components 26 and two connection elements 29, and the
output of each of the two surge protection components 26 is
electrically coupled to an electrical conductor 24 coupled to the
LED driver circuitry of the LED driver 16. The connection elements
29 may include, for example, wires, fuses, and/or inductors. A
third one of the AC input lines 20 is electrically coupled to a
third one of the electrical conductors 22 of the surge protection
module 12 and to a third electrical conductor 24 coupled to the LED
driver circuitry of the LED driver 16. The surge protection
components 26 may include, for example, one or more metal oxide
varistors (MOVs), gas discharge tubes (GDTs), transient voltage
suppression (TVS) diodes, thyristor surge protection devices
(TSPDs), fuses, inductors, and/or capacitors. In the example shown
in FIG. 2, the surge protection module 12 is coupled directly the
LED driver 16. Other coupling strategies are contemplated. The AC
input lines 20 may be connected according to the following
connection configurations: line/neutral, line/neutral/ground, line
1/line 2, or line 1/line 2/ground. Although shown with external AC
input lines 20, the example shown may be coupled to direct current
(DC) input lines, which may be connected according to the following
connection configurations: DC+/DC- or DC+/DC-/ground.
[0094] FIG. 3 is a schematic diagram showing another example
connection configuration 30 including an example surge protection
module 12 electrically coupled to an example electrical device 14
via an example terminal block 32. In the example shown in FIG. 3,
the electrical device 14 is an LED driver 16. Other types of
electrical devices are contemplated. The example connection
configuration 30 shown in FIG. 3 is a parallel connection in which
three alternating current (AC) input lines 20 from external
alternating current connections are electrically coupled to three
electrical conductors 22 of the example surge protection module 12
and three terminal connections 34, which, in turn, are electrically
coupled to three electrical conductors 24 coupled to the LED driver
16 to electrically couple the LED driver 16 to provide a parallel
connection. The three electrical conductors 22 are electrically
coupled to surge protection components 26 of the surge protection
module 12 to provide surge protection for the LED driver 16. The
surge protection components 26 may include, for example, one or
more metal oxide varistors (MOVs), gas discharge tubes (GDTs),
transient voltage suppression (TVS) diodes, thyristor surge
protection devices (TSPDs), fuses, inductors, and/or capacitors. In
the example shown in FIG. 3, the surge protection module 12 is
coupled directly the terminal block 32. Other coupling strategies
are contemplated. The terminal connections 34 may include one or
more screw terminals, poke-in connections, insulation displacement,
and/or any other form of electrical connections.
[0095] FIG. 4 is a schematic diagram showing another example
connection configuration 36 including an example surge protection
module 12 electrically coupled to an example terminal block 32. In
the example shown in FIG. 4, the electrical device 14 is an LED
driver 16. Other types of electrical devices are contemplated. The
example connection configuration 36 shown in FIG. 4 is a series
connection in which three AC input lines 20 from external
alternating current connections are electrically coupled to three
terminal connections 34, which, in turn, are electrically coupled
to three electrical conductors 22 of the example surge protection
module 12. Two of the three electrical conductors 22 are
electrically coupled to two surge protection components 26 and two
connection elements 29, and the output of each of the two surge
protection components 26 is electrically coupled via a terminal
connection 34 to an electrical conductor 24 coupled to the LED
driver circuitry of the LED driver 16. The connection elements 29
may include, for example, wires, fuses, and/or inductors. A third
one of the AC input lines 20 is electrically coupled to a third one
of the terminal connections 34, which is electrically coupled to an
electrical conductor 22 of the surge protection module 12 and to a
third electrical conductor 24 coupled to the LED driver circuitry
of the LED driver 16. The surge protection components 26 may
include, for example, one or more metal oxide varistors (MOVs), gas
discharge tubes (GDTs), transient voltage suppression (TVS) diodes,
thyristor surge protection devices (TSPDs), fuses, inductors,
and/or capacitors. In the example shown in FIG. 4, the surge
protection module 12 is coupled directly the terminal block 32.
Other coupling strategies are contemplated. The terminal
connections 34 may include one or more screw terminals, poke-in
connections, insulation displacement, and/or any other form of
electrical connections.
[0096] FIG. 5 is a schematic diagram showing another example
connection configuration 38 including an example surge protection
module 12 electrically coupled to an example electrical device 14.
In the example shown in FIG. 5, the electrical device 14 includes
an LED driver 16 including internal LED driver circuitry 18. Other
types of electrical devices are contemplated. The example
connection configuration 38 shown in FIG. 5 is a series connection
in which three AC input lines 20 from external AC connections are
electrically coupled to three terminal connections 34 electrically
coupled to the surge protection components 26 and two connection
elements 29 of the example surge protection module 12. The outputs
of the surge protection module 12 are electrically coupled to three
electrical conductors 40, which are electrically coupled to three
terminal connections 34 of the LED driver circuitry 18 of the LED
driver 16. The connection elements 29 may include, for example,
wires, fuses, and/or inductors. A third one of the AC input lines
20 is electrically coupled to a third terminal connection 34 of the
surge protection module 12, and to a third terminal connection 34
of the LED driver circuitry 18 of the LED driver 16. The surge
protection components 26 may include, for example, one or more
metal oxide varistors (MOVs), gas discharge tubes (GDTs), transient
voltage suppression (TVS) diodes, thyristor surge protection
devices (TSPDs), fuses, inductors, and/or capacitors. The terminal
connections 34 may include one or more screw terminals, poke-in
connections, insulation displacement, and/or any other form of
electrical connections. In the example shown in FIG. 5, the surge
protection module 12 is coupled directly the LED driver 16. Other
coupling strategies are contemplated. The AC input lines 20 may be
connected according to the following connection configurations:
line/neutral, line/neutral/ground, line 1/line 2, or line 1/line
2/ground. Although shown with external AC input lines 20, the
example shown may be coupled to direct current (DC) input lines,
which may be connected according to the following connection
configurations: DC+/DC- or DC+/DC-/ground.
[0097] FIG. 6A is a perspective view of an example surge protection
module 12 coupled to an example electrical device 14. In the
example shown in FIG. 6A, the example surge protection module 12 is
physically and electrically coupled to the electrical device 14,
which may be, for example, an LED driver for an LED lighting
fixture. In the example shown, the surge protection module 12 is
configured to be coupled directly to a housing 42 of the electrical
device 14 in a modular manner, such that the surge protection
module 12 is both physically and electrically coupled to the
electrical device 14, for example, as explained with respect to
FIGS. 6B, 6C, 6D, 7A, 7B, 7C, and 7D.
[0098] FIG. 6B is a perspective view of an example surge protection
module 12 configured to be coupled to the electrical device 14
according to a screw-in action. For example, a portion of the surge
protection module 12 may include external threads 44 configured to
threadedly engage internal threads 46 of the housing 42 and
facilitate a screw-on engagement between the surge protection
module 12 and the housing 42. The surge protection module 12 may
include electrical terminals configured to electrically couple to
corresponding electrical terminals coupled to the electrical device
14.
[0099] FIG. 6C is a perspective view of an example surge protection
module 12 coupled to an example electrical device 14 via an example
push-in connection. For example, a portion of the surge protection
module 12 may include a structure configured to provide a push-in
engagement between the surge protection module 12 and the housing
42 of the electrical device 14. The surge protection module 12 may
include electrical terminals configured to electrically couple to
corresponding electrical terminals coupled to the electrical device
14.
[0100] FIG. 6D is a perspective view of an example surge protection
module 12 coupled to an example electrical device 14 in an example
manner including example fasteners 48, such as, for example,
screws, bolts, and/or clips. For example, the surge protection
module 12 may include one or more flanges 50 having holes
configured to receive fasteners 48 for coupling the surge
protection module to the electrical device 14. The surge protection
module 12 may include electrical terminals configured to
electrically couple to corresponding electrical terminals coupled
to the electrical device 14.
[0101] FIG. 7A is a perspective view of an example surge protection
module 12 separated from an example electrical device 14 showing an
example electrical coupling 52. As shown in FIG. 7A, the housing 42
of the electrical device 14 includes a recess 54 configured to
receive a complimentary portion of the surge protection module 12
therein. The electrical device 14 includes terminals 56 configured
to electrically couple with complimentary electrical terminals of
the surge protection module 12 when the surge protection module 12
is engaged with the electrical device 14.
[0102] FIG. 7B is a perspective view of an example electrical
device 14 showing an example electrical coupling 52. The example
electrical device 14 shown in FIG. 7B includes a recess 54
including internal threads 46 for engaging complimentary external
threaded on a portion of the surge protection module 12. The
electrical device 14 shown in FIG. 7B includes terminals 56
configured to electrically couple with complimentary electrical
terminals of the surge protection module 12 when the surge
protection module 12 is threadedly engaged with the electrical
device 14, and the surge protection module is screwed onto the
electrical device 14.
[0103] FIG. 7C is a perspective view of another example electrical
device 14 showing another example electrical coupling 52. As shown
in FIG. 7C, the housing 42 of the electrical device 14 includes a
recess 54 configured to receive a complimentary portion of the
surge protection module 12 therein. The electrical device 14
includes terminals 56 configured to electrically couple with
complimentary electrical terminals of the surge protection module
12 when the surge protection module 12 is engaged with the
electrical device 14, for example, via a push-in action.
[0104] FIG. 7D is a perspective view of another example electrical
coupling 52 including an example printed circuit board 58 including
contact pads 60. The example electrical coupling shown in FIG. 7D
may be used to electrically couple some examples of the surge
protection module 12 with some examples of electrical device 14
when the surge protection module 12 and electrical device 14 are
physically coupled to one another.
[0105] FIG. 8 is a perspective view of an example surge protection
module 62 configured to limit power surge exposure to an electrical
device, for example, as described herein, and FIG. 9 is an exploded
perspective view of the example surge protection module 62 shown in
FIG. 8. The example surge protection module 62 shown in FIGS. 8 and
9 includes a carrier 64 including a carrier body 66 defining a
first end 68 and a second end 70 opposite the first end 68 and a
longitudinal axis X extending between the first end 68 and the
second end 70. The example surge protection module 62 also includes
three electrical conductors 72 (e.g., at least partially
electrically insulated wires) coupled to the carrier 64. The surge
protection module 62 also includes at least one surge protection
component 74 electrically coupled to the electrical conductors 72
and configured to limit power surge conducted to an electrical
device to which the electrical conductors 72 are electrically
coupled. The example shown in FIGS. 8 and 9 includes four surge
protection components 74, although fewer (e.g., three, two, or one)
or more surge protection components 74 are contemplated. The surge
protection components 26 may include, for example, one or more
metal oxide varistors (MOVs), gas discharge tubes (GDTs), transient
voltage suppression (TVS) diodes, thyristor surge protection
devices (TSPDs), fuses, inductors, and/or capacitors.
[0106] In the example shown in FIGS. 8 and 9, each of the surge
protection components 74 includes two electrical leads 76, and the
surge protection module 62 further includes three lugs 78. Each of
the three lugs 78 receives at least one of the electrical
conductors 72 and one or more of the two electrical leads 76 of the
surge protection components 74 and electrically couples the at
least one electrical conductor 72 and the at least one electrical
lead 76 to one another. In some examples, as explained herein, the
lugs 78 are configured to be pressed onto the at least one
electrical conductor 72 and the at least one electrical lead 76,
such that the at least one electrical conductor 72 and the at least
one electrical lead 74 are electrically coupled to one another and
physically coupled to one another. In some examples, the lugs 78
include a tubular member (e.g., a hollow cylindrical member)
receiving an end of the at least one electrical conductor 72 and an
end of the at least one electrical lead 76.
[0107] The example surge protection module 62 shown in FIGS. 8 and
9 includes four surge protection components 74a, 74b, 74c, and 74d.
A first surge protection component 74a is electrically coupled to a
first electrical conductor 72a and a second electrical conductor
72b. In the example shown, a second surge protection component 74b
is electrically coupled to the first electrical conductor 72a and a
third electrical conductor 72c. In the example shown, the surge
protection module 62 includes three lugs 78a, 78b, and 78c. The
first lug 78a receives the first electrical conductor 74a, the
first electrical lead 76a of the first surge protection component
74a, and the first electrical lead 76a of the second surge
protection component 74b. A second lug 78b receives the second
electrical conductor 72b and a second electrical lead 76b of the
first surge protection component 74a. In the example shown, a third
lug 78c receives the third electrical conductor 72c and a second
electrical lead 76b of the second surge protection component
74b.
[0108] The example shown in FIGS. 8 and 9 also includes a third
surge protection component 74c electrically coupled to two of the
electrical conductors 72, and a fourth surge protection component
74d electrically coupled to two of the electrical conductors 72.
For example, as shown, the third surge protection component 74c is
electrically coupled to the second electrical conductor 72b and the
third electrical conductor 74c. In the example shown, the fourth
surge protection component 74d is electrically coupled to the first
electrical conductor 72a and the third electrical conductor 72c. In
the example shown, the second lug 78b receives a first electrical
lead 76a of the third surge protection component 74c, and the third
lug 78c receives a second electrical lead 76b of the third surge
protection component 74c. In addition, the first lug 78a receives a
first electrical lead 76a of the fourth surge protection component
74d, and the third lug 78c receives a second electrical lead 76b of
the fourth surge protection component 74d.
[0109] FIG. 10 is a perspective view of an example carrier 64 of an
example surge protection module 62. FIGS. 11-13 show different
views of the example carrier 64 shown in FIG. 10. In the example
shown, the carrier 64 defines three conductor channels 80 extending
from the first end 68 of the carrier 64 toward the second end 70 of
the carrier 64. Each of the conductor channels 80 is configured to
receive an electrical conductor 72. Some examples may include may
include more or fewer conductor channels 80, and the conductor
channels 80, in some examples, may receive more than one electrical
conductor 72. In the example shown in FIGS. 10-13, one or more of
the conductor channels 80 may include a grip 82 configured to
engage with an electrical conductor 72. The grip 82 may be defined
by the carrier 64 (or incorporated into the carrier 64) and may
include a recess having dimensions configured to press tightly
against an electrical conductor 72 received in the corresponding
conductor channel 80.
[0110] As shown in FIGS. 10-13, the first end 68 of the carrier 64
may define an outer surface 84 that tapers in a direction away from
the second end 70 of the carrier 64. In some examples, the first
end 68 of the carrier 64 may define an inner surface 86 that tapers
in a direction away from the second end 70 of the carrier 64, for
example, as shown.
[0111] As shown in FIGS. 10-13, the example carrier 64 defines a
recess 88 configured to receive at least a portion of a surge
protection component 74. For example, FIG. 13 shows four recesses
88, each for receiving a portion of respective surge protection
components 74. In the example shown, some of the recesses 88 are
located between the conductor channels 80 and the second end 70 of
the carrier 64.
[0112] In the example shown in FIGS. 10-13, the carrier 64 defines
lead channels 90 extending between the recesses 88 and the
conductor channels 80. The lead channels are configured to receive
electrical leads 76 of the surge protection components 74.
[0113] As shown in FIGS. 10-13, the carrier 64 may define pockets
92, each configured to receive a lug 78 electrically coupling and
physically coupling one of the electrical conductors 72 to one or
more electrical leads 76 the surge protection components 74. In
some examples, the pockets 92 may include a first pocket 92a for
receiving a first lug 78a, a second pocket 92b adjacent the first
pocket 92a for receiving a second lug 78b, and a third pocket 92c
adjacent the second pocket 92b for receiving a third lug 78c. In
some examples, the carrier 64 may also include pocket barriers 94
between adjacent pockets 92, for example, a first pocket barrier
94a between the first pocket 92a and the second pocket 92b, and a
second pocket barrier 94b between the second pocket 92b and the
third pocket 92c. The packet barriers 94 may serve to separate
(e.g., electrically insulate) the first lug 78a, the second lug
78b, and the third lug 78c from one another.
[0114] In some examples, for example, as shown in FIGS. 10-13, the
pockets 92 pass through the carrier 64, for example, from a first
side 96 of the carrier 64 to a second side 98 of the carrier 64. In
such examples, the pockets 92 may define at least one tab 100
configured to prevent a lug 78 received in the pocket 92 from
passing through the carrier 64 (e.g., falling out of the carrier
64). This example configuration may facilitate pressing the lugs 78
to crimp them tightly around any electrical conductors 72 and/or
electrical leads 76 of the surge protection components 74 received
in the lugs 78, for example, as explained herein.
[0115] FIGS. 14 and 15 show two views of another example carrier 64
that omits outside barriers adjacent the outboard pockets 92 (i.e.,
the pockets 92a and 92c). This example configuration provides a
lower profile relative to the example carrier 64 shown in FIGS.
10-13. The example shown in FIGS. 14 and 15 also includes the
pocket barriers 94 discussed with respect to FIGS. 10-13. The
pocket barriers 94 may provide electrical clearance (e.g.,
insulation) to help meet or exceed certain electrical regulatory
rules (e.g., codes).
[0116] FIG. 16 is a perspective view of another example carrier 64
with a detailed view of an example notch 102 configured to
facilitate separation of different portions of the carrier 64 from
one another. For example, the example carriers 64 shown in FIGS.
10-16 include a second end 70 defining a mounting boss 104
configured to facilitate mounting of the surge protection module 62
to a support. For example, the carrier 64 may define a notch 102
between the mounting boss 104 and a remainder of the carrier 64,
and the notch 102 may be configured to facilitate separation of the
mounting boss 104 from the remainder of the carrier 64. In some
examples, the mounting boss 104 may be separated from the remainder
of the carrier 64 by using a cutting device or by hand. In some
examples, for example, as shown in FIGS. 10-16, the mounting boss
104 defines a flange 106 defining a mounting hole 108 configured to
receive a fastener for mounting the surge protection module 62 to a
support.
[0117] FIGS. 17A, 17B, 17C, and 17D are partial perspective views
of examples of surge protection module 62 including examples of
mounting bosses 104 configured to facilitate mounting of the surge
protection module 62 to a support. In some examples, the flange 106
defines a plane extending substantially parallel with respect to
the longitudinal axis X of the carrier 64, obliquely with respect
to longitudinal axis X of the carrier 64, or substantially
perpendicular with respect to the longitudinal axis X of the
carrier 64 (see, e.g., FIG. 17B). In some examples, the mounting
boss 104 includes a first flange 106a and a second flange 106b,
each defining respective mounting holes 108a and 108b configured to
receive a fastener 110 for mounting the surge protection module 62
to a support (see, e.g., FIGS. 17B-17D). Each of the first flange
106a and the second flange 106b may define a flange plane, and the
flange plane of first flange 106a and the flange plane of the
second flange 106b may be at an angle with respect to one another
(e.g., a non-zero angle, such as, for example, an angle of about 30
degrees, an angle of about 45 degrees, an angle of about 60
degrees, an angle of about 90 degrees, an angle of about 120
degrees, an angle of about 135 degrees, or an angle of about 150
degrees).
[0118] In the example carrier 64 shown in FIGS. 10-13, the mounting
boss 104 includes reinforcement ribs 112 configured to strengthen
the mounting boss 104. In the example carriers 64 shown in FIGS.
10-16, the carrier 64 defines a flange 114 at the second end 70 of
the carrier 64 and configured to provide a stop for an insulation
sleeve, for example, as described herein with respect to FIG. 32.
For example, the flange 114 may prevent the insulation sleeve from
extending over the mounting boss 104. For example, in examples
having an insulation sleeve, the insulation sleeve may be pushed
from the first end 68 of the carrier 64, over the carrier 64 until
the leading end of the insulation sleeve abuts the flange 114.
[0119] FIG. 18 is an exploded perspective view of the example surge
protection module 62 including an example carrier 64, example lugs
78, example electrical conductors 72, and example surge protection
components 74 including example electrical leads 76. The example
shown in FIG. 18 is similar to the example shown in FIGS. 8 and 9.
The example surge protection module 62 shown in FIG. 18 includes a
carrier 64 including a carrier body 66 defining a first end 68 and
a second end 70 opposite the first end 68 and a longitudinal axis X
extending between the first end 68 and the second end 70. The
example surge protection module 62 also includes three electrical
conductors 72 (e.g., at least partially electrically insulated
wires) coupled to the carrier 64. The surge protection module 62
also includes at least one surge protection component 74
electrically coupled to the electrical conductors 72 and configured
to limit power surge conducted to an electrical device to which the
electrical conductors 72 are electrically coupled. The example
shown in FIG. 18 includes four surge protection components 74,
although fewer (e.g., three, two, or one) or more surge protection
components 74 are contemplated. The surge protection components 26
may include, for example, one or more metal oxide varistors (MOVs),
gas discharge tubes (GDTs), transient voltage suppression (TVS)
diodes, thyristor surge protection devices (TSPDs), fuses,
inductors, and/or capacitors.
[0120] In the example shown in FIG. 18, each of the surge
protection components 74 includes two electrical leads 76, and the
surge protection module 62 further includes three lugs 78. Each of
the three lugs 78 receives at least one of the electrical
conductors 72 and one or more of the two electrical leads 76 of the
surge protection components 74 and electrically couples the at
least one electrical conductor 72 and the at least one electrical
lead 76 to one another. In some examples, as explained herein, the
lugs 78 are configured to be pressed onto the at least one
electrical conductor 72 and the at least one electrical lead 76,
such that the at least one electrical conductor 72 and the at least
one electrical lead 74 are electrically coupled to one another and
physically coupled to one another. In some examples, the lugs 78
include a tubular member (e.g., a hollow cylindrical member)
receiving an end of the at least one electrical conductor 72 and an
end of the at least one electrical lead 76.
[0121] The example surge protection module 62 shown in FIG. 18
includes four surge protection components 74a, 74b, 74c, and 74d. A
first surge protection component 74a is electrically coupled to a
first electrical conductor 72a and a second electrical conductor
72b. In the example shown, a second surge protection component 74b
is electrically coupled to the first electrical conductor 72a and a
third electrical conductor 72c. In the example shown, the surge
protection module 62 includes three lugs 78a, 78b, and 78c. The
first lug 78a receives the first electrical conductor 74a, the
first electrical lead 76a of the first surge protection component
74a, and the first electrical lead 76a of the second surge
protection component 74b. A second lug 78b receives the second
electrical conductor 72b and a second electrical lead 76b of the
first surge protection component 74a. In the example shown, a third
lug 78c receives the third electrical conductor 72c and a second
electrical lead 76b of the second surge protection component
74b.
[0122] The example shown in FIG. 18 also includes a third surge
protection component 74c electrically coupled to two of the
electrical conductors 72, and a fourth surge protection component
74d electrically coupled to two of the electrical conductors 72.
For example, as shown, the third surge protection component 74c is
electrically coupled to the second electrical conductor 72b and the
third electrical conductor 74c. In the example shown, the fourth
surge protection component 74d is electrically coupled to the first
electrical conductor 72a and the third electrical conductor 72c. In
the example shown, the second lug 78b receives a first electrical
lead 76a of the third surge protection component 74c, and the third
lug 78c receives a second electrical lead 76b of the third surge
protection component 74c. In addition, the first lug 78a receives a
first electrical lead 76a of the fourth surge protection component
74d, and the third lug 78c receives a second electrical lead 76b of
the fourth surge protection component 74d.
[0123] FIGS. 19A, 19B, and 19C are a perspective view, top view,
and side view, respectively, of an example surge protection
component 74 including two electrical leads 76a and 76b having
example bends 116. The example bends 116 in the example shown in
FIGS. 19A-19C are configured to facilitate coupling of the
electrical leads 76a and 76b to the first and third electrical
conductors 72a and 72c, for example, as shown in FIGS. 8, 9, and
18. In some examples, the example bends 116 of the electrical leads
76a and 76b are configured such that when the surge protection
component 74 is positioned in a recess 88 of the carrier 64, the
remote ends 118 of the electrical leads 76a and 76b lie in a common
plane and have respective longitudinal axes that are aligned with
the corresponding first and third lugs 78a and 78c.
[0124] FIGS. 20A, 20B, and 20C are a perspective view, top view,
and side view, respectively, of an example surge protection
component 74 including two electrical leads 76a and 76b having
example bends 116. The example bends 116 in the example shown in
FIGS. 20A-20C are configured to facilitate coupling of the
electrical leads 76a and 76b to either the first and second
electrical conductors 72a and 72b or the second and third
electrical conductors 72b and 72c, for example, as shown in FIGS.
8, 9, and 18. In some examples, the example bends 116 of the
electrical leads 76a and 76b are configured such that when the
surge protection component 74 is positioned in a recess 88 of the
carrier 64, the remote ends 118 of the electrical leads 76a and 76b
lie in a common plane and have respective longitudinal axes that
are aligned with the corresponding first and second lugs 78a and
78b or second and third lugs 78b and 78c.
[0125] FIG. 21 is a view of an example carrier 64, example lugs 78,
example electrical conductors 72, and example surge protection
components 74 laid out for assembly.
[0126] FIG. 22 is a view of example lugs 78 provided in example
pockets 92 of an example carrier 64 for assembly of an example
surge protection module 62. In the example shown, the lugs 78 have
been placed in the pockets 92, which pass through the carrier 64
and include tabs 100 to prevent the lugs 78 from dropping through
the pockets 92 and separating from the carrier 64. The tabs 100, in
some examples, may act to position the lugs 78 longitudinally with
respect to the carrier 64. In the example shown, the carrier 64
also includes pocket barriers 94 to separate (e.g., electrically
insulate) the lugs 78 from one another.
[0127] FIG. 23 is a view of two example surge protection components
74 provided in example recesses 88 in the second side 98 (e.g., the
underside as shown) of the example carrier 64, with example
electrical leads 76 of the surge protection components 74 passing
through respective example openings 120 for facilitating passage of
the electrical leads 76 from the second side 98 of the carrier 64
to the first side 96 (e.g., the upper side as shown) of the carrier
64, and with the electrical leads 76 provided in the hollow spaces
of the three lugs 78 according to an example construction. After
the lugs 78 have been placed in the pockets 92, each of the surge
protection components 74 is placed in a respective recess 88 on the
second side 98 of the carrier 64, such that the electrical leads 76
pass through the carrier 64 to the first side 96 and into the
appropriate lugs 78, for example, as shown.
[0128] FIG. 24 is a view showing three example electrical
conductors 72, having respective insulation removed from the remote
ends, provided in the respective hollow spaces of the three lugs
78, with the electrical leads 76 of the two surge protection
components 74 and the three electrical conductors 72 received in
example conductor channels 80 of the carrier 64.
[0129] FIG. 25 is a view showing third and fourth example surge
protection components 74 received in respective third and fourth
example recesses 88 in the carrier 64 with the respective
electrical leads 76 of the third and fourth surge protection
components 74 provided in the hollow spaces of the three lugs 78.
Each of the third and fourth surge protection components 74 is
placed in a respective recess 88 on the first side 96 of the
carrier 64, such that the electrical leads 76 are received in the
appropriate lugs 78, for example, as shown.
[0130] FIG. 26 is a perspective view showing example bands 122 for
securing the first, second, third, and fourth surge protection
components 76 to the carrier 64. After the electrical conductors 72
and the surge protection components 74 have been assembled relative
to the carrier 64 using the lugs 78, the surge protection
components 74 may be secured in place using the bands 122, which
may be tape. This prevents unintended separation of the parts from
the carrier 64 during movement of the carrier 64 and associated
parts, for example, for the pressing process explained herein.
[0131] FIG. 27 is a perspective view of the example partially
assembled surge protection module 62 shown in FIG. 26 provided in
an example press 124 configured to press the three respective lugs
78, such that the lugs 78 are crimped onto the electrical leads 76
of the first, second, third, and fourth surge protection components
74, and the three electrical conductors 72, such that they are
physically coupled and electrically coupled to one another. FIG. 27
shows the partially assembled surge protection module 62 positioned
on a lower die set 126 of the press 124. In some examples, the
carrier may be positioned in the lower die set 126 prior to
providing the one or more surge protection components 74.
[0132] FIG. 28 is a perspective view of the example press 124 shown
in FIG. 27. The example press 124 shown includes the lower die set
126 and an upper die set 128 configured to press the lugs 78
between the lower die set 126 and the upper die set 128, such that
the lugs 78 are crimped onto the electrical leads 78 of the first,
second, third, and fourth surge protection components 74, and the
three electrical conductors 72. The example press 124 includes a
pressure dial 130 for adjusting the force applied to the upper die
set 128 and the lower die set 126, and thus, to the lugs 78 during
a pressing operation. In some examples, the press 124 may be a
2-ton press (e.g., a pedal-operated press), although other types
and/or sizes of presses are contemplated. The example 124 also
includes a locator pin 132 for positioning the partially assembled
surge protection module 62 prior to pressing.
[0133] FIG. 29 is a perspective view of showing the example lower
die set 126 of the example press 124 and an example surge
protection module 62 (with one of the surge protection components
74 removed for ease of viewing) following pressing, including
crimped lugs 78 having respective substantially rectangular
cross-sectional shapes following crimping. For example, in some
examples, the lugs 78 after crimping may have a substantially
square-shaped or diamond-shaped cross-sectional shape following the
pressing operation. In some examples, the final cross-section crimp
shape may result in reducing at least one dimension of the overall
crimp cross-section (e.g., from a pre-pressing diameter crimp of
about 5.4 mm to about 5.0 mm at its widest cross-section
dimension). For example, the crimping cross-section may result in
compaction on both width and height of the cross-section. This may
reduce the likelihood in some example of cracking the carrier 64
when crimping the lugs 78, which might occur if the pressing caused
an expansion of the crimping cross-section (e.g., a flattening and
widening of the crimping cross-section).
[0134] FIG. 30 shows a view of example upper die set 128 and
corresponding example lower die set 126 in respective die holders
134 for the example press 124 shown in FIGS. 27-29. In some
examples, the lower die set 126 and/or the upper die set 128 may
each include three individual dies 136 that may be independently
removeable from the respective die set.
[0135] FIG. 31 is a detailed perspective view of three example dies
136 removed from a die holder 134 to show details of the example
dies 136, including example dimensions relative to an example lug
78. As shown in FIG. 31, the example dies 136 include a core 138
and a die face 140 having a concave relief 142 (e.g., a triangular
relief defining an apex and opposing obliquely-extending sides).
The core 138 of the dies 136 may include a flat 144 configured to
be engaged by a set screw 146 (see FIG. 30) for securing the dies
136 in the die holder 134. As shown in FIG. 31, the example dies
136 have die faces 140 dimensioned and shaped to crimp the lugs 78,
such that the electrical leads 78 of the first, second, third, and
fourth surge protection components 74, and the three electrical
conductors 72, are physically coupled and electrically coupled to
one another in a secure manner. Although the dies 136 for the upper
die set 128 and the lower die set 126 are of the same configuration
in the example shown, one or more of the upper dies 136 may have a
configuration differing from one or more of the lower dies 136. In
some examples, one or more of the die faces 140 may result in a
final cross-section crimp shape that has at least one reduced
dimension of the overall crimp cross-section (e.g., from a
pre-pressing diameter crimp of about 5.4 mm to about 5.0 mm at its
widest cross-section dimension). For example, the crimping
cross-section may result in compaction on both width and height of
the cross-section.
[0136] FIG. 32 is a sequence of views showing an example insulation
sleeve 148 being provided over an example carrier 64 having crimped
lugs 78, with one end of the example insulation sleeve 148 abutting
the example flange 114 at the second end 70 of the carrier 64, so
the example mounting boss 104 remains exposed, all prior to heating
the example insulation sleeve 148 to shrink the insulation sleeve
148, thereby securing it to the carrier 64 and covering the surge
protection components 74, the lugs 78, and ends of the electrical
conductors 72 received in the lugs 78. In some examples, the
insulation sleeve 148 may be configured tighten around at least a
portion of the carrier upon exposure to heat (e.g., it may be a
heat-shrink sleeve). Other configurations of insulation are
contemplated. For example, the insulation layer may include a
conformal coating, or similar coating, covering at least a portion
of the carrier to electrically insulate the electrical connection
between the at least two electrical conductors and the surge
protection component. For example, the conformal coating may be
applied via one or more of brushing, spraying, dipping, or
selective coating by machine, and may include conformal coating
compositions, such as, for example, one or more of acrylic, epoxy,
polyurethane, silicone, fluorinated or non-fluorinated
polyparaxylylene (parylene), or amorphous fluoropolymer.
[0137] Some examples of the leads 76 of the surge protection
components 74 (or other leads) may be scored (e.g.,
surface-scored), which may, in some examples, result in a more
secure physical joining of the leads 76 to one another and/or in an
improved electrical conductivity performance of the connection
between the leads 76. FIG. 33 is a schematic partial section view
showing three example surface scorings of example leads 76, for
example, for surge protection components 74 coupled to one another
via crimping an example lug 78 (shown un-crimped in FIG. 33). As
shown, in a first example, the scoring 150A includes
circumferential surface-scoring of the example lead 76. In a second
example, the scoring 150B includes a helical surface-scoring about
the example lead 76. In a third example, the scoring 150C includes
a double-helical surface-scoring about the example lead 76, with
helical surface-scoring in both directions about the lead 76. Other
configurations of scoring are contemplated, for example, including
any combination of the example scorings 150A, 150B, and/or 150C. In
some examples, the scoring may be formed via one or more pressings,
via one or more clampings, via grinding, via machine turning,
and/or any other processes to form scoring on the leads 76.
[0138] A method for improving at least one of a physical connection
or an electrical connection between two electrical leads 76 coupled
to one another via crimping, in some examples, may include
providing a first electrical lead 76 from a first electrical
component, providing a second electrical lead 76 from a second
electrical component, scoring at least one of the first electrical
lead 76 or the second electrical lead 76 (e.g., both the first and
second electrical leads 76). The method may also include providing
a lug 78 around a portion of the first electrical lead 76 and
around a portion of the second electrical lead 76, and pressing the
lug 78, for example, as described herein, such that the lug 78, the
first electrical lead 76, and the second electrical lead 76 are
physically coupled to one another and electrically coupled to one
another. In some example, scoring the at least one of the first
electrical lead 76 or the second electrical lead 76 may include
surface-scoring the at least one of the first electrical lead 76 or
the second electrical lead 76, such that the scoring includes at
least one of circumferential scoring, helical scoring, or
double-helical scoring. In some examples, scoring the at least one
of the first electrical lead 76 or the second electrical lead 76
may include at least one of pressing, clamping, grinding,
machining, or machine-turning. This may result in at least partial
formation of an electrical component, such as for example, one or
more of the electrical components described herein, as well as
others. For example, the electrical component may include a surge
protection device, and/or a component including a surge protection
device.
[0139] Although this subject matter has been described in language
specific to structural features and/or methodological acts, it is
to be understood that the subject matter defined in the appended
claims is not necessarily limited to the specific features or acts
described. Rather, the specific features and acts are disclosed as
illustrative forms of implementing the claims.
* * * * *