Abstract:
According to one aspect, a thermal protection device is provided having an electrical input for receiving input DC power and an electrical output for connection to a load. A heating circuit is coupled to the electrical input for developing one of first and second different heat magnitudes depending upon a temperature magnitude in the housing. An additional circuit is in thermal communication with the heating circuit for providing output DC power to the electrical output when the first heat magnitude is developed and for interrupting the output DC power when the second heat magnitude is developed.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. patent application Ser. No. 13/728,761, filed Dec. 27, 2012, entitled “Thermal Protection Device” (Cree docket No. P1838US1). 
     
    
     REFERENCE REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not applicable 
       SEQUENTIAL LISTING 
       [0003]    Not applicable 
       BACKGROUND 
       [0004]    1. Field of the Invention 
         [0005]    The present invention relates generally to protection devices for loads, and more particularly to a thermal protection device for protecting a heat-producing load, such as an LED luminaire. 
         [0006]    2. Description of the Background 
         [0007]    Solid state light emitters including organic, inorganic, and polymer light emitting diodes (LEDs) may be utilized as an energy-efficient alternative to more traditional lighting systems. Many modern lighting applications utilize high power solid state emitters to provide a desired level of brightness. Generally, the lifetime of an LED is inversely related to the operating junction temperature thereof. Therefore, thermal management of the junction temperature is an important design consideration of a luminaire (i.e., a lighting fixture) incorporating one or more LED&#39;s. Many solid state luminaires utilize a heat exchanger that dissipates heat into the ambient environment so as to obtain a desired life of the solid state emitters. However, such luminaires can be installed in spaces containing insulation that can prevent the necessary airflow to maintain the junction temperature at or below an upper temperature limit. Because of this possibility, solid state luminaires typically are provided with a thermal protection circuit that disconnects the LEDs from a power source when a sensed temperature is reached. Often, such a circuit includes a bi-metal switch that opens when the sensed temperature exceeds a threshold and/or a one-time thermal fuse that breaks a circuit connection when a fusing temperature is reached. 
         [0008]    LEDs operate more efficiently when powered by a direct current (DC) voltage rather than an alternating current (AC) voltage. Some known solid state luminaires utilize low power DC (i.e., at 60 volts or below). While low power DC solid state luminaires have some inherent advantages (including the ability to control the fixture with low power components and cabling), the use of low power DC can be problematic when designing a thermal protection circuit for the luminaire. Specifically, the lack of AC power at the fixture prevents the use of AC rated RP (thermal overload protection) devices and still meet UL1598 requirements. Also, the cost of the AC RP devices has been increasing of late due to the existence of few manufacturers. An off-the-shelf DC rated UL XAPX2/8 recognized thermal protection bi-metal switch is typically not specified for operation up to 60 VDC because such a device is too large and quite expensive. A UL XCMQ2/ 8  recognized TCO (thermal cutoff fuse) typically has a temperature difference between the fusing and the holding temperatures (i.e., the maximum normal operating temperature) that renders the device impossible to use with typical luminaire maximum operating temperatures. 
       SUMMARY 
       [0009]    According to one aspect, a thermal protection device is provided having an electrical input for receiving input DC power and an electrical output for connection to a load. A heating circuit is coupled to the electrical input for developing one of first and second different heat magnitudes depending upon a temperature magnitude in the housing. An additional circuit is in thermal communication with the heating circuit for providing output DC power to the electrical output when the first heat magnitude is developed and for interrupting the output DC power when the second heat magnitude is developed. 
         [0010]    According to a further aspect, a thermal protection device is provided having a housing, an electrical input for receiving input DC power, and an electrical output for connection to a load. A heating circuit is disposed in the housing and coupled to the electrical input and develops first and second different heat magnitudes depending upon a temperature in the housing. An additional circuit is operative to provide output DC power to the electrical output when the first heat magnitude is developed and to interrupt the output DC power when the second heat magnitude is developed. 
         [0011]    According to yet another aspect, a thermal protection device is provided having a housing, an electrical input for receiving input DC power at a voltage magnitude up to 60 volts, and an electrical output for connection to a load. A heating circuit is disposed in the housing and coupled to the electrical input and includes first and second series-connected heating resistors and a thermal switch coupled in parallel across the second heating resistor, wherein the thermal switch causes the heating circuit to develop a first heat magnitude when the thermal switch is exposed to a temperature in the housing below a threshold temperature and causes the heating circuit to develop a second heat magnitude greater than the first heat magnitude when the thermal switch is exposed to the temperature in the housing above the threshold temperature. An additional circuit is disposed in the housing and coupled to the heating circuit and provides output DC power to the electrical output when the first heat magnitude is developed and interrupts the output DC power when the second heat magnitude is developed, wherein the additional circuit includes a thermal circuit breaker having a holding temperature greater than the threshold temperature and a fusing temperature greater than the holding temperature. 
         [0012]    Although not so limited, the present invention finds particular utility in one or more aspects of providing thermal protection for a DC load, such as an LED luminaire, so that an over-temperature condition is avoided. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]    Further aspects of the present invention will become evident by a reading of the attached specification and inspection of the attached drawings in which: 
           [0014]      FIG. 1  is an isometric view of a luminaire incorporating a thermal protection device according to the present invention; 
           [0015]      FIG. 2  is an enlarged, fragmentary, perspective view of a portion of the luminaire of  FIG. 1  showing the thermal protection device in greater detail; 
           [0016]      FIG. 3  is an exploded isometric view of an embodiment of the present invention; 
           [0017]      FIGS. 4 and 5  are front and back elevational views of a circuit board illustrating the mounting and positioning of circuit elements of the embodiment of  FIGS. 1-3  thereon; and 
           [0018]      FIG. 6  is a schematic diagram of the circuit mounted on the circuit board of  FIGS. 4 and 5 . 
       
    
    
     DETAILED DESCRIPTION 
       [0019]    Referring first to  FIGS. 1-3 , a thermal protection device  11  includes components disposed in a housing  12  comprising housing portions  12   a  and  12   b.  The housing portions  12   a,    12   b  may be secured together in any suitable fashion, such as by fasteners comprising rivets or screws  14   a,    14   b.  The housing  12  is adapted to be secured in any known fashion to a luminaire  16 , such as an LED luminaire as seen in  FIG. 2 . In the illustrated embodiment, the housing  12  includes a threaded portion  18  (including threaded sections  18   a,    18   b ) that may be inserted into a knock-out opening of a junction box  19 . The threaded portion may receive a threaded nut (not shown) that secures the housing  12  to the junction box  19 . The housing includes openings comprising vent holes  20   a,    20   b  in the housing portions  12   a,    12   b,  respectively, and a further opening comprising vent hole  22  in the portion  12   a  that permit air flow into the housing  12  such that the components therein are disposed in heat transfer relationship with the ambient environment surrounding the luminaire  12 , particularly when the luminaire  16  is installed at or in a structure, such as a ceiling, wall, or other surface. As is event to one of ordinary skill, the space behind the ceiling, wall, or other surface occupied by the luminaire  16  may be filled with thermal insulation, which may interfere with the dissipation of heat developed by the luminaire  16 . The LED(s) used in the luminaire  16  may heat to damaging or destructive levels and/or the useful lifetime of the LED(s) may be undesirably shortened if the luminaire  16  is not thermally protected. 
         [0020]    Referring to  FIG. 6 , the thermal protection circuit  11  includes an input  30  coupled to conductors  32   a,    32   b  and an output  34  coupled to a conductor  36 . The input  30  receives DC power from a wall-mounted switch and power converter circuit (not shown) and components comprising LEDs of the luminaire  12  are coupled to the output  34 . The thermal protection circuit includes a heating circuit  38  comprising at least a first heating element  40 , a second heating element  42 , and a thermal switch  44 . In the preferred embodiment, each of the first and second heating elements  40 ,  42  is implemented by at least one heating resistor. In the illustrated embodiment, the first heating element  40  is implemented by a first pair of parallel-connected heating resistors R 1 , R 2  and the second heating element  42  is implemented by a second pair of parallel-connected heating resistors R 3 , R 4 . In addition, the thermal switch  44  preferably comprises a bi-metal thermal switch. The heating circuit  38  develops a first heat magnitude when the housing  12 , and/or the components therein is (are) exposed to a temperature below a threshold and further develops a second heat magnitude greater than the first heat magnitude when exposed to a temperature above the threshold. This functionality is achieved by selecting a thermal switch  44  having a switching point at the threshold temperature as noted in greater detail hereinafter such that the thermal switch is closed when exposed to a temperature below the threshold and is open when the temperature is above the threshold. As should be evident, the first heating element  40  develops heat when the thermal switch  44  is closed and the first and second elements  40 ,  42  both develop heat when the thermal switch  44  is open. In the preferred embodiment, the switching point of the thermal switch  44  is between about 65 degrees C. and about 70 degrees C., and is most preferably equal to about 70 degrees C. 
         [0021]    A thermal circuit breaker  45  is coupled between the elements  40 ,  42  and the LEDs coupled to the output  34 . Specifically, a controllable switch comprising a MOSFET transistor Q 1  is coupled between the heating elements  40 ,  42  and a thermal fuse (in this case a thermal cut-out or TCO)  50 . The TCO  50  is coupled to the output  34  and has a holding temperature and a trip or fusing temperature. 
         [0022]    In the preferred embodiment, the holding temperature of the TCO  50  is about 100 degrees C. Also, the trip or fusing temperature is between about 119 degrees C. and about 125 degrees C., and is most preferably equal to about 125 degrees C. 
         [0023]    From the foregoing, it can be ascertained that the holding temperature of the TCO  50  is preferably greater than the switching point of the thermal switch  44 . Also, of course, the trip or fusing temperature is greater than the holding temperature. 
         [0024]    The controllable switch Q 1  is operated by a control circuit  52  in accordance with a negative temperature coefficient (NTC) signal so that the controllable switch Q 1  can be controlled to interrupt current to the TCO  50  before the TCO trip or fusing temperature is reached. Specifically, referring to  FIG. 6 , under ordinary operating conditions (i.e., when an over-temperature condition is not being experienced), a resistor R 8 , a zener diode D 2 , and a capacitor C level shift and develop a regulated voltage of 15 volts across the capacitor C and the zener diode D 2 . A voltage divider comprising resistors R 10  and R 11  receive the 15 volt regulated signal and cause a voltage of less than 2.5 volts to be provided to a precision adjustable shunt regulator integrated circuit (IC)  54 . The IC  54  is thereby maintained in an off condition at this time. In addition, a MOSFET transistor Q 2  is on due to the biasing provided by resistors R 8  and R 9 , thereby maintaining the controllable switch Q 1  in the on state. The current through the transistor Q 2  is limited by resistors R 5  and R 6 , and the gate to source voltage of the controllable switch Q 1  is limited by a zener diode D 1 . If the temperature in the housing  12  rises above the threshold temperature of the thermal switch  44 , the thermal switch  44  opens, thereby causing current to flow through the resistors R 3  and R 4  and quickly increasing the temperature within the housing  12 . When a housing temperature of, for example, about 90 degrees C., is reached, the regulated voltage delivered to the IC  54  rises above 2.5 volts, thereby turning IC  54  on and turning off transistor Q 2  and the controllable switch Q 1 . The LEDs are thereby turned off and current flow through the resistors R 1 -R 4  is interrupted until the temperature in the housing drops to a further level of, for example, about 80 degrees C. At this point the voltage delivered to the IC  54  drops below 2.5 volts, thereby turning off IC  54  and turning on transistor Q 2  and the controllable switch Q 1 . The LEDs are turned back on and current flow is reestablished through the resistors R 1 -R 4 . The cycle then repeats indefinitely until power is removed from the luminaire. The LEDs thereby flash on and off without causing the TCO  50  to trip, thereby indicating to an observer that an over-temperature condition is being encountered. 
         [0025]    The components of the device  11  are carried by a circuit board  60  as seen in  FIGS. 3-5 . The circuit board  60  is secured inside the housing  12  in any suitable fashion. Electrical connections to the inputs and output are accomplished via a header connector  62  and/or card edge connectors  63 . 
         [0026]    As is evident from the foregoing, the present invention utilizes a heat source inside the housing  12  when the load is operational comprising one or both of the two heating elements  40 ,  42 . The current flowing through the first heating element produces heat that is transferred to the thermal switch  44  and the other components in the housing  12 , including the TCO  50 . The bi-metal thermal switch  44  is connected in parallel with one of the heating elements and is set to trip if the temperature inside the housing  12  reaches a certain point. When the thermal switch trip temperature is reached the thermal switch opens and current thereafter flows through the second heating element  42 , which increases the heat level inside the housing  12 . Significantly, when the thermal switch  44  opens, the switch  44  is only subjected to the current*resistance voltage drop (V=I*R). For example, assume that a current of 700 mA is flowing in the heating circuit  38  and that each heating element  40 ,  42  has an equivalent resistance of 3.4 ohms. The thermal switch  44  initially shorts out the resistors R 3 , R 4  and when the switch  44  trips (i.e., opens) the current transitions to the 3.4 ohm heating element  42  from the thermal switch  44 . The switch  44  has to break 700 mA at a voltage of 2.38 VDC, which is well within the specifications of off-the-shelf bi-metal switch devices. The second heating element  42  thereafter creates additional heat in the housing  12  and the temperature therein quickly rises. The use of the switch  44  opening and creating additional heat allows the TCO fusing temperature to be increased and keep the TCO holding temperature out of the normal operational range of the luminaire. (The range between the holding temperature and the fusing temperature (typically a 25 degree C. range) comprises a keep-out area in which the luminaire is prevented from operating). Eventually, the controllable switch Q 1  is turned off before the TCO fusing temperature is reached in the housing  12  so that the current is interrupted before the one-time TCO trips. On the other hand, if the controllable switch Q 1  fails to open before the fusing temperature is reached, the TCO trips, preventing power from reaching the LEDs of the luminaire. In either event, given the heat flow pattern in the housing  12 , this heat rise can only occur if the airflow through the housing is blocked (e.g., when insulation is covering the vent holes  20 ,  22 ) or if ambient temperature increases past a certain point. 
         [0027]    Because the TCO  50  is a one-time-only fuse it is protected by the controllable switch Q 1  that is operated in accordance with a negative temperature coefficient developed signal. Of significance is the fact that none of the solid state devices used in the present invention is rated for thermal overload protection and therefore all are specified solely on performance criteria. Further, the fact that the controllable switch Q 1  is in series with the resistors, TCO, and load facilitates satisfaction of UL requirements to short and open the semiconductor to evaluate fault conditions. Specifically, the switch Q 1  can be maintained in the on condition such that the TCO is not protected and the internal housing temperature may be allowed to rise to the TCO fusing temperature. Conversely, the switch Q 1  may be maintained in the off condition so that no current will flow and no heat is developed in the housing. 
       INDUSTRIAL APPLICABILITY 
       [0028]    The present invention utilizes a combination of a change in convective cooling due to insulation placement and a rapid increase in the housing. These cascading events permit the use of off-the-shelf UL rated reliable components. The three main components are UL “reliable” power resistors as the heating elements  40 ,  42 , the bi-metal thermal switch (which may be an XAPX2/8 device manufactured by Uchiya of Japan), and the TCO  50  (which may be an XCMQ2/8 device manufactured by Xiamen Set Electronics Co., Ltd. of Xiamen, China). The combination of these three components allows for a UL recognized device. The use of the switch Q 1  in combination with the heating elements and TCO allows the device to comply with UL standards and further permits the circuit to shut off and cool down from high temperatures without causing the one-time TCO to trip (and thereby require servicing). 
         [0029]    The present invention may be used in numerous applications, such as in EMI sensitive applications, such as MRI rooms, telephone central offices operating on 48 VDC, and safety lighting systems operating on DC backup. The present invention operates at 60V DC and at useful constant current inputs such as 525 mA and 1400 mA. New current levels can quickly be implemented with only a resistor value change. The circuit can pass UL tests as a stand-alone device. The circuit does not require the heating from the luminaire in order to operate. The circuit can mimic currently available AC thermal overload protector devices satisfying UL category XAPX2/8 specified ability to cycle on and off under thermal overload conditions and meets UL safety requirements for recessed devices using 25 VDC UL recognized bi-metal switches. The present invention further uses internal convective airflow to operate, and is not just a solid body. The TCO fusing temperature can be increased to ensure that an over-temperature condition does not cause operation in the temperature range between the holding temperature and the fusing temperature. Further, a fault resulting in the controllable switch remaining on during an over-temperature condition, as opposed to the intermittent operation of the switch Q 1  as discussed above, will result in rapid heating to the fusing temperature and subsequent tripping of the TCO  50 . Therefore, the time to trip in fault conditions is decreased. 
         [0030]    As should be evident to one of ordinary skill in the art, the present invention can be implemented by other embodiments, structures, and/or processes. While the present invention is useful to provide thermal protection for a DC powered LED luminaire, the present invention can provide thermal protection for other loads that may or may not receive DC power. 
         [0031]    Numerous modifications to the present invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is presented for the purpose of enabling those skilled in the art to make and use the invention and to teach the best mode of carrying out same. The exclusive rights to all modifications which come within the scope of the appended claims are reserved.