Abstract:
A metal oxide varistor module, and variations thereof for use in surge protectors and the like combining internally a thermally activated disconnect means and an excessive current disconnect means, such that when the module is subject to excessive overvoltage or overcurrent conditions, the connection is interrupted from the phase to neutral, phase to ground and any other combination of voltage or current before the metal oxide varistor device is physically damaged, ruptured or cracked.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to surge arresters and/or transient voltage surge suppressor devices, and in particular, to surge arresters or suppressors that employ Metal Oxide Varistors, Silicon Avalanche Diodes, Selenium Rectifiers, Silicon Controlled Rectifiers, Triacs and other semiconductor devices, singly or in combination. The term MOV will describe the application of Metal Oxide Varistors specifically but will also be employed as a generally representative term for the equivalent application of the above mentioned technologies. 
     The objective of a surge arrester is to provide a low impedance path for a high voltage transient at a defined voltage level. Some surge arresters, especially those for power conditioning circuits, employ a multiplicity of Metal Oxide Varistor modules to accomplish this task. 
     Metal Oxide Varistors are surge protection devices that are connected across power circuits and provide protection for equipment connected to such power circuits from temporary voltage peaks and transients. 
     Metal oxide Varistors have a standard operating mode for normal conditions where the voltage across the circuit is stable and a clamping mode for transient and overvoltage conditions. During clamping mode the MOV acts to reduce the maximum voltage across the circuit to a predefined level. 
     There are several problems with MOV based surge arresters. One problem is that MOV modules when subjected to an excessive voltage will overheat rendering the surge arrester inoperable. For example, when power sources are subject to long duration surge conditions, these lines may produce large voltages and associated currents large. The MOV when subject to these extreme conditions will overheat, rupture, and/or produce noxious gases and/or particles. Further, the ruptured MOV will permit a plasma arc to occur between the sections of the MOV thereby endangering the electronic device to which the surge arrester is attached. 
     Furthermore, over time and through use, MOV modules deteriorate thereby lowering the maximum voltage the modules can adequately handle. Specifically, when the clamping threshold of the MOV module deteriorates to the point where it descends into the peak of the power line sine-wave voltage the module will overheat and fail in the manner described above. This effect may also occur if the clamp threshold descends to at or slightly below the DC level. 
     Additionally, MOV&#39;s can fail in an essentially short circuit mode when subjected to excessive transient peak currents. For example, conventional 40 mm diameter MOV&#39;s are rated to handle 40 kA, {fraction (8/20)} microsecond waveforms for 1 event. At peak currents in excess of 40 kA the MOV will fail as a “short circuit”. If the MOV is not properly fused, excessively current flow through the MOV will cause it to rupture and permit a plasma arc to occur between the sections of the MOV thereby endangering the electronic device to which the surge arrester is attached. 
     Attempts have been made to solve the problems described above by individually fusing each of the MOV modules within a given surge arrester. For example, U.S. Pat. No. 5,808,850 to Carpenter discloses a three phase MOV surge arrester that employs a plurality of MOV modules, each of the MOV modules having an associated external fuse. Improper fuse coordination with the MOV characteristics or improper substitution in the field personnel can permit a plasma arc to occur between the sections of the MOV thereby endangering the electronic device to which the surge arrester is attached. In addition, fuses of this type are rated on a current, i.e. ampere basis and as a consequence do not operate or otherwise measure the thermal state of the MOV module. Thus, over time, and as the MOV module begins to deteriorate, an external fuse is inadequate to protect the MOV from failure as the MOV will overheat long before the fuse is triggered, if ever. 
     It is therefore, an object of the present invention to provide an improved MOV module for use with surge arresters that overcomes the disadvantages and shortcoming found in the prior art. 
     It is further object of the present invention to provide an improved MOV module that will not greatly overheat, rupture or otherwise fail when subject to extreme voltage or current conditions. 
     It is further object of the present invention to provide an improved MOV module that will permit the manufacturer to integrate, within the MOV housing, both thermal and overcurrent disconnect capabilities which will prevent overheating, rupture or otherwise catastrophic failure when subject to extreme voltage or current conditions. 
     Other objects and features of the present invention will be apparent from the following disclosure. 
     SUMMARY OF THE INVENTION 
     According to the present invention an improved MOV module is provided for use in surge protectors or the like, that will provide an excessive current disconnect capability and a thermal disconnect capability, such that when the MOV module is subject to excessive current or voltage conditions, the connection is interrupted from the phase to neutral, phase to ground and any other combination of voltage before the MOV device is physically damaged, ruptured or cracked. In this manner, the formation of destructive plasma is avoided. These disconnect capabilities can function together in an integrated fashion or operate independently to provide a variety of device disconnect options. 
     In general, the present invention provides a MOV module including, a pair of planar contact plates, a layer of MOV material, and an excessive current and/or thermally operated disconnect switch. The disconnect switch being operable from a first standard connected position to a second disconnected position. In this manner, when the MOV material reaches a predetermined temperature, or the MOV material is exposed to excessive current, or both, the switch is triggered to disconnect thereby breaking the circuit and protecting the MOV module from any further connection to the power source and any physical damage that may result therefrom. In this way, the MOV module is disconnected before physical damage of the same. 
    
    
     BRIEF DESCRIPTION OF THE FIGURES 
     FIG. 1 is a perspective view of the MOV module according to the present invention; 
     FIG. 2 is an exploded perspective view of the MOV module shown in FIG. 1; 
     FIG. 3 is a sectional view of the MOV module shown in FIG. 1 taken along line  3 — 3 ; 
     FIG. 4 is a sectional view of a second embodiment of the MOV module according to the present invention; 
     FIG. 5 is a sectional view of a third embodiment of the MOV module according to the present invention; 
     FIG. 6 is a sectional view of a fourth embodiment of the MOV module according to the present invention; 
     FIG. 6A is an exploded view of a one version of the fourth embodiment of the MOV module according to the present invention; 
     FIG. 6B is an exploded view of a second version of the fourth embodiment of the MOV module according to the present invention; 
     FIG. 7A is an exploded view of a fifth embodiment of the MOV module according to the present invention; 
     FIG. 7B is an exploded view of a one version of the fifth embodiment of the MOV module according to the present invention; 
     FIG. 7C is an exploded view of a second version of the fifth embodiment of the MOV module according to the present invention; 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     As seen in the FIGS. 1 and 2, the Metal Oxide Varistor module according to the present invention, generally depicted by the numeral  10 , has a laminar construction including first and second parallel conductive contact plates,  12  and  14  respectively, a layer of metal oxide varistor material  16 , an intermediate layer of conductive material  18 , a layer of insulating material  20  and a activated trigger assembly  22 . 
     As seen in FIG. 2, the MOV module according to the present invention has a pair of parallel planar contact plates  12  and  14 . The lower contact plate  14  comprises a generally disk-like metallic body having a tab  24  extending from the peripheral edge thereof. The tab  24  is configured to receive an electrical lead for the introduction of current into the MOV module. The current as introduced into the module is depicted as I in  FIGS. 1 and 2. The other, or upper contact plate  12 , has a washer-like body as shown, having a hole passing through the center of its body. Extending from the peripheral edge of upper contact plate  12  is a tab  26  for connection to an electrical lead for the current leaving the MOV module. The current leaving the MOV module is depicted as I out  in FIGS. 1 and 2. 
     The contact plates  12  and  14  are preferably constructed from Aluminum, as Aluminum has favorable heat dissipation and conductivity characteristics. Nonetheless, other suitable materials may also be used. 
     Superimposed over the upper surface of contact plate  14  is a layer of MOV material  16 . As shown, the layer of MOV material  16  extends across and over the upper surface of contact plate  14  so that it covers the entire upper surface of the contact plate  14 . The layer of MOV material  16  has planar and parallel upper and lower faces that permits effective transmission into and through the MOV layer. Further, the layer of MOV material is shaped so that it overlies the contact plate  14  such that its peripheral edge is coextensive with the peripheral edge of the contact plate. It is preferable that Aluminum Oxide be used in the construction of the MOV layer, however other suitable materials may be used. 
     Mounted to the upper surface of the MOV material  16  is an intermediate layer of conductive material  18  preferably constructed from the same material as the upper and lower contact plates  12  and  14 , e.g. aluminum. As shown, the intermediate layer of conductive material has a disk like body that planar in construction and is shaped so that it overlies and extends across the upper surface of the MOV layer  16 . The intermediate layer of conductive material  18  is mounted such that its lower surface abuts the upper surface of the MOV material  16 . Further, as shown, the peripheral edge of the conductive material  18  is coextensive with the peripheral edge of the MOV layer  16 . The construction as defined above permits the efficient transmission of energy through and into the intermediate conductive layer  18 . 
     Mounted to the upper surface of the intermediate conductive layer  18  is a layer of insulating material  20 . As shown, the layer of insulating material  20  has a washer-like body having planar upper and lower surfaces with a central orifice  28  passing therethrough. The central orifice or gap  28 , as will be described in greater detail hereinafter, permits the activated trigger assembly  22  access to intermediate conductive layer  18 . The insulating layer  20  is shaped so that its peripheral edge is substantially coextensive with the peripheral edge of the intermediate conductive layer  18 . 
     The insulating material  20  is mounted to contact plate  18  so that its lower surface abuts the upper surface of contact plate  18  as shown. 
     Mounted to the upper surface of the insulating layer  20  is the contact plate  12 . Finally, mounted to the upper or exterior surface of plate  12  is the activated trigger assembly  22 . 
     In one embodiment, the trigger assembly  22  comprises a spring element  30  connected at a first end to the upper surface of the plate  12  and at a second end to the upper surface of intermediate contact plate  18 . The upper surface of the contact plate  12  may be provided with a cut out or seat  32  for receiving the spring element as shown in FIG.  2 . The trigger assembly  22  may, alternately be an integral part of plate  12  to facilitate manufacturing and minimize production costs. 
     As best seen in FIG. 3, the second end of the spring element  30  is secured to the upper surface of the intermediate conductive layer  18  using a low temperature solder, or the like. During overvoltage conditions, the temperature of conductive layer  18  will rise as a result of the heat generated in the MOV material  16 . When the conductive layer  18  reaches a selected temperature below the melting or failure temperature of the MOV material  16  the solder melts, thereby releasing the second end of the spring element. The spring element  30  is biased so that when the solder melts the spring element travels from a first position in electrical connection with and abutting the intermediate contact plate  18  to a second position remote from and electrically disconnected from the plate  18 . The second position is depicted by the dotted lines  35  as seen in FIG.  3 . It is critical that the second position be sufficiently spaced from the intermediate conductive layer  18  to prevent arc over from the conductive layer  18  to the spring element  30  when the spring element is in the second position. 
     During overcurrent situations,it should be noted that the spring element  30  individually, or as an integral part of contact plate  12 , can be designed with a specific cross-sectional area permitting the finger to melt open and thus operate directly as a fuse for excessive current passing through the MOV material. The overcurrent disconnect would operate at a current level less than the failure point of the MOV material. 
     Although only a single spring element is shown in FIG. 3, it is appreciated that multiple spring elements could be employed by securing them to the contact plate  12  and the intermediate conductive layer in the fashion described above. Multiple spring elements would provide a larger range of current fusing capability while retaining the independent thermal character of the invention. 
     The construction of the MOV module is completed by chamber covers  34  and  36  that are configured to conceal and protect the interior components of the MOV module. The chamber covers are constructed from a suitable insulator and are provided with cut out sections to allow access to terminal tabs  24  and  26 . The chamber may be fitted to be gas tight so that a gas or other means to assist in extinguishing an arc may be used. In lieu of chamber covers, an epoxy encapsulation procedure may be used to seal the MOV module if desired. 
     A second embodiment of the MOV module according to the present invention, generally depicted by the numeral  38 , is shown in FIG.  4 . In the second embodiment, the trigger assembly comprises a plastic sheet  40  or the like having a thin layer of metal  42  on the undersurface thereof. The central portion of the plastic sheet is connected along its lower surface to the intermediate conductive layer  18  using a low temperature solder. In this manner, when the MOV material  16  heats to a predetermined temperature the low temperature solder will melt releasing the plastic sheet. The plastic sheet is biased so that when it releases it travels from a position where its lower surface is adjacent to and abutting the upper surface of the conductive layer  18  to a second position remote from the conductive layer as shown by the dotted lines in FIG.  4 . In all other respects the MOV module according the alternate embodiment is identical to the MOV module described above. 
     It should be noted that the MOV module  38  embodies a dual protection method, i.e., it will respond independently to a thermally activated disconnect condition as well as performing an excessive current disconnect function. The current disconnect capability is a function of foil geometry and thickness and would be designed to be less than the current damage level of the MOV material. 
     A third embodiment of the MOV module according to the present invention, generally depicted by the numeral  43 , is shown in FIG.  5 . In this embodiment the trigger assembly comprises a metallic foil sheet  44  that is electrically connected at its edges to the contact plate  12 . In this embodiment the contact plate  12  may be provided with two seats, or a cut out perimeter section, for receiving the edges of the metallic foil sheet as seen in FIG.  5 . Alternately, sheet  44  may be combined or integrated with plate  12  to faciliate manufacturing and reduce production costs. The central portion of the metallic foil sheet  44  is electrically connected along its lower surface to the intermediate conductive layer  18  either by using a solder, by welding or applying sufficient pressure to the same. In this way, the metallic foil  44  is held in abutment with the upper surface of the intermediate conductive layer  18 , under normal operating condition. 
     During overvoltage conditions, the MOV material  16  heats, to a predetermined temperature, melting affixing low temperature solder and disconnecting the MOV layer  16  from the power source. The low temperature solder will melt at a temperature that is less than the MOV material damage level. 
     During overcurrent conditions, the metallic foil sheet  44  will melt when a predetermined current passes through the MOV material  16  and the foil sheet  44  thus disconnecting the MOV layer  16  from the power source. The foil will melt at a current level that is less than the rated MOV material damage level. 
     It should be noted that the MOV module  43  embodies a dual protection method, i.e., it will respond independently to a thermally activated disconnect situation as well as disconnecting in an excessive current situation. 
     A fourth embodiment of the MOV module according to the present invention, generally depicted by the numeral  46  is shown in FIG.  6 . In this embodiment, the MOV module includes a first or lower metallic contact plate  48  and a second or upper metallic contact plate  50 . Each of the contact plates have planar parallel upper and lower faces. Further, the peripheral edge of each of the contact plates are substantially coextensive with one another. 
     The lower contact plate  48  has a tab  52  extending from the peripheral edge thereof configured to receive an electrical lead for introduction of current Iin into the MOV module. The other or upper contact plate  50  has a connection tab  54  that is displaced, i.e. spaced, from the body of the contact plate  50 . The connection tab  54  is electrically connected to the body of the contact plate  50  by a conductive material  56  that functions as a disconnect element. 
     Interposed between the contact plates  48  and  50  is a layer of MOV material  58 . As shown, the layer of MOV material  58  is disk-like having upper and lower planar faces. The peripheral edge of the MOV material is substantially coextensive with the peripheral edges of contact plates  48  and  50 . 
     Disconnect element  56  can be constructed in at least two configurations, as shown in FIGS. 6A and 6B. 
     In configuration  56 A, as shown in FIG. 6A, the disconnect capability is achieved employing a metal spring finger  56 A that at the first end is connected to tab  54  and at the second end is connected to contact plate  50  using a low melting point solder. 
     During excessive voltage conditions, the MOV material  58  will heat the upper contact plate  50  thereby raising the temperature of the same. The contact plate  50  will heat the low temperature solder affixing disconnect element  56 A to the contact plate  50  as shown in FIG.  6 A. Once this selected temperature is reached the disconnect element  56 A will separate i.e., spring away, thereby disconnecting the MOV module  46  from any further electrical power source. It is critical that the selected melting temperature of the low temperature solder be less than the physical disintegration or rupturing temperature of the MOV material  58 . 
     In the presence of excessive currents, the disconnect element  56 A can be constructed with a specific cross-sectional area to interrupt a selective current. It is critical that the selected current disconnect level be less than the current damage level of the MOV material  58 . 
     In the disconnect element  56 A, the dual interrupt capabilities disclosed above can be dependent or independent of each other thus providing a thermal interrupt capability and an independent excessive current interrupt capability while preventing the MOV material from overheating and rupturing. 
     During excessive voltage conditions, as shown in FIG. 6B, the MOV material  58  will heat the upper contact plate  50  thereby raising the temperature of the same. The contact plate  50  will heat the metallic composite disconnect element  56 B. Once a selected temperature is reached the disconnect element  56 B will melt thereby disconnecting the MOV module  46  from the power source. It is critical that the selected melting temperature of disconnect element  56 B be less than the physical disintegration or rupturing temperature of the MOV material  58 . 
     In the presence of excessive currents, the disconnect element  56 B can be constructed with a specific cross-sectional area to interrupt a selective current. It is critical that the selected current disconnect level be less than the current damage level of the MOV material  58 . 
     In the disconnect element  56 B, the dual interrupt capabilities disclosed above can be dependent or independent of each other thus providing a thermal interrupt capability and an independent excessive current interrupt capability while preventing the MOV material from overheating and rupturing. 
     Although not shown in FIGS. 6,  6 A or  6 B, it is appreciated that the MOV module according to the fourth embodiment of the present may further include end caps or be otherwise encapsulated as described with reference to the other embodiments. 
     A fifth embodiments of the MOV module according to the present invention, generally depicted by the numeral  60  is shown in FIG.  7 . The MOV module according to the fifth embodiment includes a lower metallic contact plate  62 , an intermediate metallic contact plate  64 , and an upper metallic contact plate  66 . Each of the contact plates have planar upper and lower surfaces and have substantially coextensive peripheral edges. 
     Interposed between the upper surface of the lower contact plate  62  and the lower surface of the intermediate contact plate  64  is a first layer of MOV material  68 . Interposed between the upper surface of the intermediate contact plate  64  and the lower surface of the upper contact plate  66  is a second layer of MOV material  70 . The first layer of MOV material  68  provides protection between line  2  and neutral, while the second layer of MOV material  70  provides protection between line  1  and neutral. 
     Disconnect elements  74  and  78  can be each constructed in at least two configurations. FIG. 7A shows the spring finger disconnect approach while FIG. 7B shows the metallic composite material disconnect approach. 
     In FIG. 7A the disconnect capability is achieved by employing a metal spring finger  74 A that at the first end is connected to tab  72  and at the second end is connected to contact plate  62  using a low melting point solder. A further disconnect capability is achieved by employing a metal spring finger  78 A that at the first end is connected to tab  76  and at the second end is connected to contact plate  66  using a low melting point solder. 
     The intermediate contact plate  64  is provided with a contact tab  80  for electrical connection to the neutral phase. 
     During overvoltage conditions, as shown in FIG. 7A, MOV elements  68  and  70 , singly or together, will overheat. This temperature rise will be conveyed to contact plates  62  and  66 . Spring finger disconnects  74 A and  78 A will serve as thermally activated disconnects when the low temperature solder affixing them respectively to contact plates  62  and  66  melt and releases the spring fingers. The operation of the spring fingers will, singly or collectively, remove their associated layer of MOV material from the electrical power source when the disconnect elements  74 A and  78 A open at a selected temperature that is less than the melting or rupture temperature of the MOV material. 
     During overcurrent conditions the spring finger disconnect elements  74 A and  78 A, with specific cross-sectional areas, will operate as excessive current disconnects and will remove their associated layer of MOV material from the electrical power source when the spring finger disconnect elements  74 A and  78 A open at a selected excessive current that is less than the failure point of MOV materials  68  and  70 . 
     In FIG. 7B the disconnect capability is achieved by employing a metallic composite material  74 B that at the first end is connected to tab  72  and at the second end is connected to contact plate  62 . A further disconnect capability is achieved by employing a metallic composite material  78 B that at the first end is connected to tab  76  and at the second end is connected to contact plate  66 . 
     During overvoltage conditions, MOV elements  68  and  70 , as shown in FIG. 7B will overheat causing  74 B and  78 B to melt, singly or collectively, and disconnect their MOV materials  68  and  70  from the electrical power source. It is essential that the melt temperature of  74 B and  78 B occur at a selected temperature that is less than the melting or rupture temperature of the MOV materials  68  and  70 . 
     During overcurrent conditions the composite material disconnect elements  74 B and  78 B, with specific cross-sectional areas, will operate as excessive current disconnects and will remove their associated layer of MOV material  68  and  70  from the electrical power source. It is essential that the composite material disconnect elements  74 B and  78 B open at a selected excessive current that is less than the failure point of MOV materials  68  and  70 . 
     Connecting a single disconnect element in series with the neutral lead is hazardous and to be avoided. With a single MOV layer failure, for example if MOV  68  were to short circuit, then MOV material  70  would be directly exposed to the potential source between power lines Line  1  and Line  2  that would be twice its normal rating. MOV  70  would also fail as a short circuit and with no fuse available to disconnect the power source from the damaged MOV&#39;s the result would be catastrophic damage to the surge protector and possible serious damage to nearby equipment. 
     It should be appreciated that the MOV module in its various embodiments as described above may be provided with additional contact plates and/or MOV layers to accommodate multiple phase or multiple lead systems without departing from the scope or spirit of the present invention. 
     The MOV modules according to the present invention as heretofore described may be provided with monitoring devices that indicate the operability of the same. For example, the MOV module may be provided with a LED having an internal or external resistor and diode circuit that will be connected across one or more MOV elements to extinguish when the MOV is disconnected from the power source. The LED or other monitoring indicator, such as audible alarms, relay contact closures can be physically integrated into the protective device to provide a localized troubleshooting aid. The monitoring approaches described above are typical, nonetheless, other suitable monitoring methods may also be used. 
     As seen from the forgoing an improved MOV module for use with surge arresters that overcomes the disadvantages and shortcoming found in the prior art has been provided. 
     Specifically, the MOV module according to the present invention will not overheat, rupture or otherwise fail catastrophically when subject to extreme voltage conditions. 
     Specifically, the MOV module according to the present invention will not overheat, rupture or otherwise fail catastrophically when subject to extreme overcurrent conditions. 
     Specifically, the MOV module according to the present invention will eliminate the need, expense and misapplication of external overcurrent fusing means and external protective disconnect means of a thermal nature. 
     Although the present invention has been described in the foregoing, numerous modifications and variations can be made, and will be obvious to those skilled in the art, without departing from the spirit and scope of this invention.