Crimped Surge Protection Module for Compact Device Integration
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Solution Overview
Problem
Existing surge protectors, whether separate devices or integrated into electrical devices, face issues such as overlooked protection and packaging challenges due to size constraints, leading to inadequate surge protection for electrical devices.
Innovation Solution
The development of a surge protection module that can be selectively connected to electrical devices, featuring a compact design with three terminals for series or parallel connections, incorporating surge protection components like metal oxide varistors and gas discharge tubes, and including a mechanical connection for easy mounting, with an optional status indicator for operational monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If surge protectors are integrated into electrical devices, then surge protection reliability is improved, but device size increases causing packaging problems
Solution Approach 1:
The surge protection module is designed to be nested within the electrical device housing, utilizing existing internal spaces and mounting structures. The module integrates with the device's existing terminal blocks and circuit board layouts, effectively hiding the surge protection components within the device's internal volume without increasing external dimensions.
Solution Approach 2:
The surge protection module is segmented into separate functional components (surge protection circuitry, terminal connections, indicator lights) that can be independently mounted and configured. This segmentation allows for flexible space utilization within the device, enabling installation in available gaps and spaces without requiring a dedicated large compartment.
2Volume of moving object
If surge protectors are made as separate power strips, then device size is reduced, but ease of operation deteriorates due to being overlooked
Solution Approach 1:
The surge protection module is designed with self-contained mounting features including pre-installed terminal blocks, snap-fit connectors, and integrated wiring harnesses that automatically align with the device's electrical connections. This self-service design eliminates the need for complex installation procedures, making the module as easy to install as traditional separate surge protectors while being integrated into the device.
3Reliability
If surge protection components are added to electrical devices, then surge protection capability is improved, but device complexity increases
Solution Approach 1:
The surge protection module is designed with universal mounting features and standardized electrical connections that can be adapted to various device types and configurations. The module includes multiple terminal options and can be installed in different locations within the device, providing surge protection capability across multiple application scenarios without requiring device-specific customization.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The surge protection module effectively limits power surge exposure to electrical devices, provides compact and easy-to-install protection, and offers a status indication for operational monitoring, addressing the drawbacks of existing surge protectors.
Implementation Method 1
incorporating surge protection components like metal oxide varistors and gas discharge tubes
Implementation Method 2
incorporating surge protection components like metal oxide varistors and gas discharge tubes
Data Source
AI summary
A method for assembling a module configured to limit power surge exposure to an electrical device may include providing a carrier configured to receive at least one electrical conductor and at least one surge protection component. A lug defining a hollow space is provided in a pocket of the carrier, and an electrical lead of a surge protection component and an electrical conductor are provided in the hollow space of the lug. The method includes crimping the lug onto the electrical lead of the surge protection component and the electrical conductor such that the electrical lead and the electrical conductor are physically and electrically coupled to one another. The carrier may include multiple pockets receiving multiple lugs, and the multiple lugs may be crimped substantially simultaneously to physically and electrically couple corresponding pairs of electrical leads and conductors.