# Patent

## Title
Thermal protection device

## Abstract

A thermal protection device includes a heating circuit that develops a first heat magnitude when 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. A thermal circuit breaker is disposed in heat communication with the heating circuit and has component having a holding temperature greater than the threshold and a trip temperature greater than the holding temperature.

## Background
CROSS REFERENCE TO RELATED APPLICATIONS
None
REFERENCE REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable
SEQUENTIAL LISTING
Not applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
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.
2. Description of the Background of the Invention
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'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.
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 OF THE INVENTION
According to one aspect of the present invention, a thermal protection device includes a heating circuit that develops a first heat magnitude when exposed to a temperature below a threshold and that develops a second heat magnitude greater than the first heat magnitude when exposed to a temperature above the threshold. A thermal circuit breaker is disposed in heat communication with the heating circuit and includes a thermal component having a holding temperature greater than the threshold and a trip temperature greater than the holding temperature.
According to a further aspect of the present invention, a thermal protection device comprises a housing having an opening and a heating circuit disposed in the housing and having a first heating element, a second heating element coupled to the first heating element, and a thermal switch coupled across the second heating element. The thermal switch shorts out the second heating element and the first heating element develops a first heat magnitude when the thermal switch is exposed to a temperature below a threshold and the thermal switch opens and causes the first and second heating elements to develop a second heat magnitude greater than the first heat magnitude when the thermal switch is exposed to a temperature above the threshold. A controllable switch is coupled to the heating circuit and a control circuit is coupled to the controllable switch for controlling the controllable switch. A thermal fuse is disposed in the housing in heat communication with the heating circuit and is coupled to the controllable switch and has a holding temperature greater than the threshold and a fusing temperature greater than the holding temperature.
According to yet another aspect of the present invention, a method of operating a load includes the step of providing a thermal protection device coupled in series with the load wherein the thermal protection device includes a housing, a heating circuit disposed in the housing, a control circuit disposed in the housing, and a controllable switch connected between the heating circuit and a thermal circuit breaker disposed in the housing in heat communication with the heating circuit. The thermal circuit breaker includes a component having a holding temperature greater than the threshold and a trip temperature greater than the holding temperature. The method further includes the step of operating the heating circuit to develop a first heat magnitude in the housing during a first time period when the housing is exposed to a temperature below a threshold wherein electrical power is provided to the load during the first time period and operating the heating circuit to develop a second heat magnitude in the housing greater than the first heat magnitude during a second time period when the housing is exposed to a temperature above the threshold such that the control circuit repeatedly opens and closes the controllable switch during the second time period and when the temperatures in the housing are at first and second temperatures less than the trip temperature and interrupts electrical power to the load.
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
Further aspects of the present invention will become evident by a reading of the attached specification and inspection of the attached drawings in which:
FIG. 1 is an isometric view of a luminaire incorporating a thermal protection device according to the present invention;
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;
FIG. 3 is an exploded isometric view of an embodiment of the present invention;
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
FIG. 6 is a schematic diagram of the circuit mounted on the circuit board of FIGS. 4 and 5.



DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIGS. 1-3, a thermal protection device 11 includes components disposed in a housing 12 comprising housing portions 12a and 12b. The housing portions 12a, 12b may be secured together in any suitable fashion, such as by fasteners comprising rivets or screws 14a, 14b. 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 18a, 18b) 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 20a, 20b in the housing portions 12a, 12b, respectively, and a further opening comprising vent hole 22 in the portion 12a 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.
Referring to FIG. 6, the thermal protection circuit 11 includes an input 30 coupled to conductors 32a, 32b 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 R1, R2 and the second heating element 42 is implemented by a second pair of parallel-connected heating resistors R3, R4. 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.
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 Q1 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.
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.
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.
The controllable switch Q1 is operated by a control circuit 52 in accordance with a negative temperature coefficient (NTC) signal so that the controllable switch Q1 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 R8, a zener diode D2, and a capacitor C level shift and develop a regulated voltage of 15 volts across the capacitor C and the zener diode D2. A voltage divider comprising resistors R10 and R11 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 Q2 is on due to the biasing provided by resistors R8 and R9, thereby maintaining the controllable switch Q1 in the on state. The current through the transistor Q2 is limited by resistors R5 and R6, and the gate to source voltage of the controllable switch Q1 is limited by a zener diode D1. 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 R3 and R4 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 Q2 and the controllable switch Q1. The LEDs are thereby turned of and current flow through the resistors R1-R4 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 Q2 and the controllable switch Q1. The LEDs are turned back on and current flow is reestablished through the resistors R1-R4. 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.
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.
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 R3, R4 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 Q1 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 Q1 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.
Because the TCO 50 is a one-time-only fuse it is protected by the controllable switch Q1 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 Q1 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 Q1 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 Q1 may be maintained in the off condition so that no current will flow and no heat is developed in the housing.
INDUSTRIAL APPLICABILITY
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 Q1 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).
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 Q1 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.
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.
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.

## Claims

1. A thermal protection device, comprising:
a heating circuit that develops a first heat magnitude when exposed to a temperature below a threshold and that develops a second heat magnitude greater than the first heat magnitude when exposed to a temperature above the threshold; and
a thermal circuit breaker in heat communication with the heating circuit and including a thermal component having a holding temperature greater than the threshold and a trip temperature greater than the holding temperature, wherein the thermal circuit breaker includes a controllable switch, and wherein the controllable switch is repeatedly opened and closed by a control circuit at first and second temperatures, respectively, wherein the first and second temperatures are greater than the threshold and below a holding temperature.

2. The thermal protection device of claim 1, wherein the heating circuit includes an input adapted to receive electrical power and the thermal circuit breaker is coupled to an output adapted to provide electrical power to a load.

3. The thermal protection device of claim 2, wherein the heating circuit and the thermal circuit breaker are disposed within a housing.

4. The thermal protection device of claim 1 in combination with a LEI) luminaire.

5. The thermal protection device of claim 4, in further combination with a source of electrical power coupled to an input.

6. The thermal protection device of claim 1, wherein the a controllable switch is coupled between the heating circuit and a thermal fuse.

7. The thermal protection device of claim 6, wherein the controllable switch is operated by the control circuit wherein the controllable switch is opened by the control circuit at a particular temperature greater than the threshold and below the trip temperature.

8. The thermal protection device of claim 7, wherein the control circuit comprises a further circuit that closes the controllable switch at a further temperature less than the particular temperature and greater than the threshold.

9. The thermal protection device of claim 6, wherein the holding temperature is below the trip temperature.

10. The thermal protection device of claim 1, wherein the heating circuit comprises first and second series-connected heating elements and a thermally responsive switch coupled across the second heating element.

11. The thermal protection device of claim 10, wherein the thermally responsive switch comprises a bi-metal switch.

12. The thermal protection device of claim 10, wherein each of the first and second heating elements comprises a pair of heating resistors.

13. A thermal protection device, comprising:
a housing having an opening;
a heating circuit disposed in the housing and having a first heating element, a second heating element coupled to the first heating element, and a thermal switch coupled across the second heating element wherein the thermal switch shorts out the second heating element and the first heating element develops a first heat magnitude when the thermal switch is exposed to a temperature below a threshold and the thermal switch opens and causes the first and second heating elements to develop a second heat magnitude greater than the first heat magnitude when the thermal switch is exposed to a temperature above the threshold;
a controllable switch coupled to the heating circuit;
a control circuit coupled to the controllable switch for controlling the controllable switch; and
a thermal fuse disposed in the housing in heat communication with the heating circuit and coupled to the controllable switch and having a holding temperature greater than the threshold and a fusing temperature greater than the holding temperature.

14. The thermal protection device of claim 13, wherein the housing is adapted to be mounted on a junction box of an LED luminaire.

15. The thermal protection device of claim 13, wherein the thermal fuse comprises a thermal cut out.

16. The thermal protection device of claim 13, wherein the thermal switch comprises a bi-metal switch.

17. The thermal protection device of claim 13, wherein the control circuit turns off the controllable switch at a first temperature greater than the threshold and less than the fusing temperature, thereby interrupting current flow through the heating circuit.

18. The thermal protection device of claim 17, wherein the control circuit further turns on the controllable switch at a second temperature greater than the threshold and less than the first temperature.

19. The thermal protection device of claim 16, wherein the controllable switch is repeatedly opened and closed by the control circuit at first and second temperatures, respectively, wherein the first and second temperatures are greater than the threshold and below the holding temperature.

20. A method of operating a load, comprising the steps of:
providing a thermal protection device coupled in series with the load wherein the thermal protection device includes a housing, a heating circuit disposed in the housing, a control circuit disposed in the housing, and a controllable switch connected between the heating circuit and a thermal circuit breaker disposed in the housing in heat communication with the heating circuit wherein the thermal circuit breaker includes a component having a holding temperature greater than the threshold and a trip temperature greater than the holding temperature, and further providing a negative temperature coefficient control circuit that operates the controllable switch; and
operating the heating circuit to develop a first heat magnitude in the housing during a first time period when the housing is exposed to a temperature below a threshold wherein electrical power is provided to the load during the first time period and operating the heating circuit to develop a second heat magnitude in the housing greater than the first heat magnitude during a second time period when the housing is exposed to a temperature above the threshold such that the control circuit repeatedly opens and closes the controllable switch during the second time period and when the temperatures in the housing are at first and second temperatures less than the trip temperature and interrupts electrical power to the load.

21. The method of claim 20, wherein the component comprises a thermal cut out (TCO) that fuses at the trip temperature.

22. The method of claim 20, wherein the step of providing comprises the step of supplying first and second heating elements and a thermal switch coupled across one of the heating elements.

23. The method of claim 20, wherein the step of providing includes the step of supplying first and second pairs of heating resistors and a bi-metal switch coupled across one of the pairs of heating resistors.

24. The method of claim 20, wherein the load comprises an LED.

25. The method of claim 24, wherein the LED is used in a luminaire.