Surge Protector Retention Structure for Controlled Thermal Disconnect
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing overload protection arrangements for overvoltage protection components often result in uncontrolled movement and potential damage due to the lack of secure mechanical connection after electrical separation during thermal overload, leading to safety hazards and component destruction.
Innovation Solution
The design incorporates a second connection element that maintains mechanical contact with the carrier during the movement of the overvoltage protection component from the first to the second position, ensuring safe separation and defined positioning, using a thermosensitive contact element and an actuator to facilitate this movement, while maintaining electrical isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the surge protection device is disconnected from the circuit via melting soldered connections during thermal overload, then the electrical connection is interrupted and the device is protected, but the surge protection device moves uncontrollably in the housing and may cause damage to surrounding materials
Solution Approach 1:
The connection system is segmented into two independent parts: thermosensitive soldered connections for electrical disconnection and a separate mechanical retention system (second connection element) for physical restraint. This segmentation allows the electrical function to be disconnected while the mechanical function remains intact, preventing uncontrolled movement.
Solution Approach 2:
The second connection element acts as an intermediary mechanical retention system that maintains physical connection between the surge protection device and carrier even after electrical disconnection. This intermediary element mediates between the need for electrical isolation and the need for mechanical stability.
2Reliability
If both electrical connections are disconnected during thermal overload, then complete electrical isolation is achieved, but the device complexity increases and the movement control becomes insufficient
Solution Approach 1:
The connection system is divided into electrical connection functions (soldered connections) and mechanical retention functions (second connection element). This segmentation allows selective disconnection of electrical paths while maintaining mechanical stability, achieving electrical isolation without requiring complete physical separation.
Solution Approach 2:
The mechanical retention function is extracted from the electrical connection system. The second connection element provides purely mechanical retention without carrying electrical current, separating the electrical isolation requirement from the mechanical stability requirement and simplifying the overall system design.
3Reliability
If the surge protection device is completely disconnected from the carrier, then maximum electrical isolation is achieved, but the device may move uncontrollably in the housing environment
Solution Approach 1:
The connection system is segmented into electrical connection elements (first connection element with soldered joints) and mechanical retention elements (second connection element). This allows electrical disconnection while maintaining mechanical position stability through the second connection element.
Solution Approach 2:
Instead of disconnecting both electrical and mechanical connections, the invention inverts the approach by maintaining mechanical connection while disconnecting only electrical connections. The second connection element provides mechanical retention without electrical function, reversing the traditional approach where mechanical connection implies electrical connection.
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
This configuration ensures safe and controlled separation of the overvoltage protection component from the circuit, preventing uncontrolled movement and potential damage, while maintaining mechanical connection to the carrier, thus enhancing safety and reliability.
Implementation Method 1
In the event of a thermal overload of the surge protection device, the soldered connections melt
Implementation Method 2
the surge protection device can be moved by at least one actuator into a second position in which the electrical contact is interrupted
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Described and illustrated is an overload protection arrangement (1) for protecting an overvoltage protection device (2) comprising at least one overvoltage protection device (2), two connection elements (3, 4) for connecting the overvoltage protection device (2) to the current or signal path to be protected, a carrier (5) with current-carrying elements, and at least one actuator (7), wherein the first connection element (3) comprises a thermosensitive contact element (6), wherein the at least one overvoltage protection device (2) is connected in a first position with its first pole to the carrier (5) via the thermosensitive contact element (6) such that an electrical connection to the circuit to be protected is established via the thermosensitive contact element (6), wherein furthermore the second pole of the overvoltage protection device (2) is connected via the second connection element (4) to a current-carrying element of the carrier (5),wherein the at least one overvoltage protection element (2) can be moved into a second position by the at least one actuator (7) in the event of a thermal overload, wherein in the second position the electrical contact is interrupted via the thermosensitive contact element (6). The overload protection arrangement (1) is characterized in that the second connection element (4) is designed and arranged such that it allows the overvoltage protection element (2) to move from the first position to the second position.