Patent Publication Number: US-2022216626-A1

Title: Surge protection module and related components and methods

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This is a continuation of U.S. application Ser. No. 16/972,188 filed Dec. 4, 2020, entitled “Surge Protection Module and Related Components and Methods,” which is a U.S. national stage application of International Application No. PCT/US19/35492 entitled “Surge Protection Module and Related Components and Methods,” filed Jun. 5, 2019, which claims the benefit of priority of U.S. Provisional Application No. 62/680,865, entitled “Surge Protection Module and Related Components and Methods,” filed Jun. 5, 2018, all of which are expressly incorporated herein by reference in their entirety. 
    
    
     DESCRIPTION 
     Background 
     Many electrical devices are susceptible to damage resulting from power and/or voltage spikes. As a result, surge protectors are often used to protect electrical devices from such surges. Some surge protectors take the form of a separate power strip that may be plugged into an electric outlet and to which an electrical device is connected. In such examples, the power strip is in series between the electric outlet and the electrical device, and may serve as a buffer between spikes associated with the electric outlet and the electrical device. 
     Such surge protectors may suffer from possible drawbacks. For example, because the surge protector is itself a separate electrical device, its use may be overlooked, resulting in a lack of surge protection for an electrical device. Thus, some surge protectors are integrated into an electrical device to ensure that the surge protector is provided for protection of its associated electrical device. Such integrated surge protectors may also suffer from possible drawbacks. For example, they may create packaging problems due to a desire to reduce the size of some electrical devices. There may be other possible drawbacks. At least some of the examples described herein may mitigate or overcome some such possible drawbacks. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The detailed description is described with reference to the accompanying figures. The same reference numbers in different figures indicate similar or identical items. 
         FIG. 1  is a schematic diagram showing an example surge protection module electrically coupled to an example electrical device in a first example connection configuration. 
         FIG. 2  is a schematic diagram showing an example surge protection module electrically coupled to an example electrical device in another example connection configuration. 
         FIG. 3  is a schematic diagram showing an example surge protection module electrically coupled to an example terminal block in an example connection configuration. 
         FIG. 4  is a schematic diagram showing an example surge protection module electrically coupled to an example terminal block in another example connection configuration. 
         FIG. 5  is a schematic diagram showing an example surge protection module electrically coupled to an example electrical device in another example connection configuration. 
         FIG. 6A  is a perspective view of an example surge protection module coupled to an example electrical device. 
         FIG. 6B  is a perspective view of an example surge protection module coupled to an example electrical device via an example rotational connection. 
         FIG. 6C  is a perspective view of an example surge protection module coupled to an example electrical device via an example push-in connection. 
         FIG. 6D  is a perspective view of an example surge protection module coupled to an example electrical device in an example manner including example fasteners. 
         FIG. 7A  is a perspective view of an example surge protection module separated from an example electrical device showing an example electrical coupling. 
         FIG. 7B  is a perspective view of an example electrical device showing an example electrical coupling. 
         FIG. 7C  is a perspective view of another example electrical device showing another example electrical coupling. 
         FIG. 7D  is a perspective view of another example electrical device showing another example electrical coupling including an example printed circuit board including contact pads. 
         FIG. 8  is a perspective view of an example surge protection module. 
         FIG. 9  is an exploded perspective view of the example surge protection module shown in  FIG. 8 . 
         FIG. 10  is a perspective view of an example carrier of a surge protection module. 
         FIG. 11  is a view of a first side of the example carrier shown in  FIG. 10 . 
         FIG. 12  is a view of a second side of the example carrier shown in  FIG. 10 . 
         FIG. 13  is a view from a third side of the example carrier shown in  FIG. 10 . 
         FIG. 14  is a view from a first side of another example carrier. 
         FIG. 15  is a view from another side of the example carrier shown in  FIG. 14 . 
         FIG. 16  is a perspective view of another example carrier with a detailed view of an example notch configured to facilitate separation of different portions of the carrier from one another. 
         FIG. 17A  is a partial perspective view of an example surge protection module including an example mounting boss configured to facilitate mounting of the surge protection module to a support. 
         FIG. 17B  is a partial perspective view of another example surge protection module including another example mounting boss configured to facilitate mounting of the surge protection module to a support. 
         FIG. 17C  is a partial perspective view of a further example surge protection module including a further example mounting boss configured to facilitate mounting of the surge protection module to a support. 
         FIG. 17D  is a partial perspective view of another example surge protection module including another example mounting boss configured to facilitate mounting of the surge protection module to a support. 
         FIG. 18  is an exploded perspective view of the example surge protection module including an example carrier, example lugs, example electrical conductors, and example surge protection components including example electrical leads. 
         FIG. 19A  is a perspective view of an example surge protection component including electrical leads having example bends. 
         FIG. 19B  is a top view of the example surge protection component shown in  FIG. 19A . 
         FIG. 19C  is a side view of the example surge protection component shown in  FIG. 19A . 
         FIG. 20A  is a perspective view of another example surge protection component including electrical leads having example bends. 
         FIG. 20B  is a top view of the example surge protection component shown in  FIG. 20A . 
         FIG. 20C  is a side view of the example surge protection component shown in  FIG. 20A . 
         FIG. 21  is a view of an example carrier, example lugs, example electrical conductors, and example surge protection components laid out for assembly. 
         FIG. 22  is a view of example lugs provided in example pockets of an example carrier for assembly of an example surge protection module. 
         FIG. 23  is a view of two example surge protection components provided in example recesses on a second side of an example carrier, with example electrical leads of the surge protection components passing through respective example openings for facilitating passage of the electrical leads from the second side of the carrier to the first side of the carrier, and with the electrical leads provided in the hollow spaces of the three lugs according to an example construction. 
         FIG. 24  is a view showing three example electrical conductors provided in the respective hollow spaces of the three lugs with the electrical leads of the two surge protection components and with the three electrical conductors received in example conductor channels. 
         FIG. 25  is a view showing third and fourth example surge protection components received in respective third and fourth example recesses in the carrier with the respective electrical leads of the third and fourth surge protection components provided in the hollow spaces of the three lugs. 
         FIG. 26  is a perspective view showing example bands for securing the first, second, third, and fourth surge protection components to the carrier. 
         FIG. 27  is a perspective view of an example partially assembled surge protection module shown in  FIG. 26  provided in an example press configured to press the three respective lugs such that the lugs are crimped onto the electrical leads of the first, second, third, and fourth surge protection components, and the three electrical conductors, such that they are physically coupled and electrically coupled to one another. 
         FIG. 28  is a perspective view of the example press shown in  FIG. 27 . 
         FIG. 29  is a perspective view of showing example lower dies of the example press and an example surge protection module (excluding a surge protection component for ease of viewing) following pressing including crimped lugs having respective substantially rectangular cross-sectional shapes following crimping. 
         FIG. 30  shows a view of example upper dies and corresponding example lower dies in respective die holders for the example press shown in  FIGS. 27-29 . 
         FIG. 31  is a detailed perspective view of three example dies removed from a die holder to show details of the example dies, including example dimensions relative to an example lug. 
         FIG. 32  is a sequence of views showing an example insulation sleeve being provide over an example carrier having crimped lugs, with one end of the example insulation sleeve abutting an example flange at an end of the carrier so the example mounting boss remains exposed, all prior to heating the example insulation sleeve to shrink the insulation sleeve, thereby securing it to the carrier and covering the surge protection components, the lugs, and ends of the electrical conductors received in the lugs. 
         FIG. 33  is a schematic partial section view showing three example surface-scorings of example leads for example electrical components. 
     
    
    
     DETAILED DESCRIPTION 
     This disclosure is generally directed to a surge protection module and related components and methods. As discussed above, many electrical devices are susceptible to damage resulting from power and/or voltage spikes. As a result, surge protectors are often used to protect electrical devices from such surges. Some surge protectors, however, may suffer from a number of possible drawbacks. For example, if the surge protector is a separate electrical device, its use may be overlooked, resulting in a lack of surge protection for an electrical device. Surge protectors integrated into an electrical device to ensure that the surge protector is provided for protection of its associated electrical device may also suffer from possible drawbacks. For example, they may create packaging problems due to a desire to reduce the size of some electrical devices. There may be other possible drawbacks. 
     The surge protection modules and related components and methods disclosed herein may mitigate or overcome some possible drawbacks associated with existing surge protectors. For example, some examples of the surge protection modules disclosed herein may allow for selective electrical connection to an electrical device. In some examples, the surge protection modules may be configured for ease of physical and electrical coupling to an electrical device. In some examples, the surge protection modules may be applied on alternating current (AC) main inputs and may be the first point of contact for a surge event. In some examples, the surge protection modules may operate in a standalone manner and/or in association with additional surge protection associated with the electrical device (e.g., surge protection associated with a light emitting diode (LED) driver), for example, depending on whether the surge protection module is electrically coupled in series or parallel with respect to the electrical device. In some examples, the surge protection module may be used in combination with fusing elements, thermal elements, and/or high-power dissipation elements, such as, for example, gas discharge tubes. In some examples, the surge protection module may be integrated into a power electronics circuit or may be used as a stand-alone device (e.g., a device external and independent from an electrical device being protected). In some examples, the surge protection modules may include an indicator of the status of operation of the surge protection module, such as, for example, the remaining service life of the module, failure of the module, and/or operation of the module. In some examples, the surge protection modules may be configured to facilitate an electrical path including line (L), neutral (N), and/or ground (G) connection conductors (e.g., wires) for installation with an electrical device. In some examples, the surge protection modules may be configured (e.g., optimized) for use with LED lighting fixture and/or applications. In some examples, the surge protection modules may be configured (e.g., optimized) for 120 volts (V), 120V-277V, 240V, 347V and/or 347V-480V. 
     In some examples, the surge protection modules may be configured to provide a compact unit, for example, having elongated and/or thin structure. In some examples, the surge protection modules may be configured to be easily removed and/or replaced. Some examples may include a mounting feature to facilitate mounting to a support. Some examples may not include a mounting feature. As explained herein, some examples of the surge protection modules may be assembled and/or manufactured, for example, without soldering to achieve electrical and/or physical coupling. For example, some electrical and/or physical connections may be formed via a crimping process. As explained herein, some examples of the surge protection modules may include a carrier (e.g., a plastic injection-molded carrier), which may in some examples, facilitate automated and/or consistent manufacturing of the surge protection modules. In some examples including a carrier, the carrier may provide at least partial shielding of electrical conductors. In some examples, the manufacturing may be used to achieve surge protection modules having an inline/wire look appearance. 
     According to one aspect, a surge protection module may be configured to limit power surge exposure to an electrical device, and the surge protection module may include three terminals configured to be electrically coupled to an electrical device. The three terminals may be configured to provide a series connection and/or a parallel connection to an electrical device to which the three terminals are electrically coupled. The surge protection module may also include at least one surge protection component electrically coupled to the three terminals and configured to limit power surge conducted to an electrical device to which the three terminals are electrically coupled. The surge protection module may also include a mechanical connection configured to mechanically couple the surge protection module to an electrical device to which the surge protection module is electrically coupled. In some examples, the three terminals may be configured to be electrically coupled to at least one of a light emitting diode (LED) driver, an electrical ballast, or a terminal block. In some examples, the three electrical contacts may be configured to be electrically coupled to an electrical device via terminal block pins, spring pins, spring clips, push-in connections, self-piercing pins, and/or any other mechanical wire connection. In some examples, the at least one surge protection component may include one or more of a metal oxide varistor (MOV), a gas discharge tube (GDT), a transient voltage suppression (TVS) diode, a thyristor surge protection device (TSPD), a fuse, an inductor, or a capacitor. In some examples, the mechanical connection may include at least one of a screw, a clip, prongs, a complimentary groove-and-recess connection, a twist-in connection, a plug-in connection, or a push-in connection. In some examples, the mechanical connection may be configured to be coupled directly to at least one of an LED driver, a terminal block, or an electrical ballast. In some examples, the surge protection module may include a status indicator configured to provide an indication of at least one of operability of the surge protection module, remaining service life of the surge protection module, or failure of the surge protection module. 
     According to another aspect, a surge protection module configured to limit power surge exposure to an electrical device may include a carrier defining a first end and a second end opposite the first end and a longitudinal axis extending between the first end and the second end. The surge protection module may also include at least two electrical conductors coupled to the carrier, and a surge protection component electrically coupled to the at least two electrical conductors and configured to limit power surge conducted to an electrical device to which the at least two electrical conductors are electrically coupled. 
     In some examples, the surge protection component may include at least two electrical leads, and the surge protection module may further include at least two lugs, wherein each of the at least two lugs receives at least one of the at least two electrical conductors and one of the at least two electrical leads, and electrically couples the at least one electrical conductor and the one electrical lead to one another. In some examples, the at least two lugs are configured to be pressed onto the at least one electrical conductor and the one electrical lead, such that the at least one electrical conductor and the one electrical lead are electrically coupled to one another and physically coupled to one another. In some examples, the at least two lugs may be welded (e.g., electrically-welded and/or thermally-welded) to the at least one electrical conductor and the one electrical lead, such that the at least one electrical conductor and the one electrical lead are electrically coupled to one another and physically coupled to one another. In some examples, the at least two lugs may include a tubular member (e.g., a hollow cylindrical member) receiving an end of the at least one electrical conductor and an end of the one electrical lead. 
     In some examples, the surge protection module may also include an insulating layer covering at least a portion of the carrier to electrically insulate the electrical connection between the at least two electrical conductors and the surge protection component. In some examples, the insulating layer may include an insulation sleeve covering at least a portion of the carrier to electrically insulate the electrical connection between the at least two electrical conductors and the surge protection component. In some examples, the insulation sleeve may be configured tighten around the at least a portion of the carrier upon exposure to heat (e.g., it may be a heat-shrink sleeve). In some examples, the insulation layer may include a conformal coating, or similar coating, covering at least a portion of the carrier to electrically insulate the electrical connection between the at least two electrical conductors and the surge protection component. For example, the conformal coating may be applied via one or more of brushing, spraying, dipping, or selective coating by machine, and may include conformal coating compositions, such as, for example, one or more of acrylic, epoxy, polyurethane, silicone, fluorinated or non-fluorinated polyparaxylylene (parylene), or amorphous fluoropolymer. 
     In some examples, the at least two electrical conductors may include three electrical conductors. For example, the surge protection component may be a first surge protection component, and the surge protection module may further include a second surge protection component electrically coupled to at least two electrical conductors of the three electrical conductors, and may be configured to limit power surge conducted to an electrical device to which the at least two electrical conductors are electrically coupled. In some such examples, the first surge protection component may be electrically coupled to a first one of the three electrical conductors and a second one of the three electrical conductors, and the second surge protection component may be electrically coupled to the first one of the three electrical conductors and a third one of the three electrical conductors. In some such examples, each of the first and second surge protection components may include at least two electrical leads, and the surge protection module may further include at least three lugs. In some examples, a first one of the at least three lugs may receive: the first one of the three electrical conductors, a first one of the at least two electrical leads of the first surge protection component, and a first one of the at least two electrical leads of the second surge protection component. In some such examples, a second one of the three lugs may receive a second one of the three electrical conductors and a second one of the at least two electrical leads of the first surge protection component. In some examples, a third one of the three lugs may receive a third one of the three electrical conductors and a second one of the at least two electrical leads of the second surge protection component. 
     In some examples, the surge protection module may include a third surge protection component electrically coupled to the at least two electrical conductors. In some such examples, the surge protection module may also include a fourth surge protection component electrically coupled to the at least two electrical conductors. 
     In some examples, the carrier may define at least one conductor channel extending from the first end of the carrier toward the second end of the carrier and receiving at least one of the at least two electrical conductors. In some examples, the at least one conductor channel may include three conductor channels, and each of the conductor channels may be configured to receive an electrical conductor. In some examples, the at least one conductor channel may include a grip engaged with the at least one electrical conductor. Some examples may include a grip in each of two or three conductor channels. 
     In some examples, the first end of the carrier may define an outer surface that tapers in a direction away from the second end of the carrier. In some examples, the first end of the carrier may define an inner surface that tapers in a direction away from the second end of the carrier. 
     In some examples, the carrier may define a recess receiving at least a portion of a surge protection component. In some examples, the carrier may define at least one conductor channel extending from the first end of the carrier toward the second end of the carrier and receiving at least one of the at least two electrical conductors, and the recess may be located between the at least one conductor channel and the second end of the carrier. In some examples, the carrier may define at least one lead channel extending between the recess and the at least one conductor channel and receiving a lead of the surge protection component. 
     In some examples, the carrier may define at least one pocket receiving a lug electrically coupling and physically coupling a first electrical conductor to a lead of the surge protection component. In some examples, the at least one pocket may include a first pocket receiving a first lug and a second pocket adjacent the first pocket and receiving a second lug. The carrier may further include a pocket barrier between the first pocket and the second pocket and separating the first lug and the second lug from one another. In some examples, the at least one pocket may pass through the carrier (e.g., from a first side of the carrier to a second side of the carrier). In some examples, the at least one pocket may define at least one tab configured to prevent the lug from passing through the carrier. 
     In some examples, the second end of the carrier may define a mounting boss configured to facilitate mounting of the surge protection module to a support. In some examples, the carrier may define a notch between the mounting boss and a remainder of the carrier, and the notch may be configured to facilitate separation of the mounting boss from the remainder of the carrier. In some examples, the mounting boss may define a flange defining a mounting hole configured to receive a fastener for mounting the surge protection module to the support. In some examples, the flange may define a plane extending either substantially parallel with respect to the longitudinal axis of the carrier, obliquely with respect to longitudinal axis of the carrier, or substantially perpendicular with respect to the longitudinal axis of the carrier. In some examples, the flange may include a first flange, and the mounting boss may further include a second flange defining a mounting hole configured to receive a fastener for mounting the surge protection module to the support. In some such examples, each of the first flange and the second flange may define a flange plane, and the flange plane of first flange and the flange plane of the second flange may be at an angle with respect to one another, for example, a non-zero angle, an angle of about 30 degrees, an angle of about 45 degrees, an angle of about 60 degrees, an angle of about 90 degrees, an angle of about 120 degrees, an angle of about 135 degrees, or an angle of about 150 degrees. In some examples, the mounting boss may include at least one reinforcement rib (e.g., two, three, or four reinforcement ribs) configured to strengthen the mounting boss. 
     In some examples, the carrier may define a flange at the second end of the carrier and configured to provide a stop for the insulation sleeve, for example, to prevent the insulation sleeve from extending over the mounting boss. For example, in examples having an insulation sleeve, the insulation sleeve may be pushed from the first end of the carrier, over the carrier until the leading end of the insulation sleeve abuts the flange. 
     According to yet another aspect, a carrier configured to receive components of a surge protection module may define an elongated carrier body. The elongated carrier body may define a first end and a second end opposite the first end and a longitudinal axis extending between the first end and the second end. The carrier body may further define at least one conductor channel extending from the first end toward the second end and configured to receive at least one electrical conductor. The carrier body may also define a recess configured to receive at least a portion of a surge protection component, and at least one pocket configured to receive a lug for electrically coupling and for physically coupling a first electrical conductor to a lead of a surge protection component. In some examples, the carrier body may define two or three conductor channels, each configured to receive an electrical conductor. In some examples, the at least one conductor channel may include a grip configured to engage at least one electrical conductor. 
     In some examples of the carrier, the first end of the carrier body may define an outer surface that tapers in a direction away from the second end of the carrier body. In some examples, the first end of the carrier body may define an inner surface that tapers in a direction away from the second end of the carrier body. This may bring the electrical conductors closer to one another, which may reduce inductance generated in the electrical conductors. In some examples, two or more of the electrical conductors may be included in a zip-cord wire (e.g., a pre-bonded zip-cord wire). 
     In some examples of the carrier, the carrier body may define at least one conductor channel extending from the first end of the carrier body toward the second end of the carrier and configured to receive at least one electrical conductor. In some such examples, the recess may be located between the at least one conductor channel and the second end of the carrier body. In some examples, the carrier body may define at least one lead channel extending between the recess and the at least one conductor channel and configured to receive a lead of a surge protection component. 
     In some examples, the at least one pocket may include a first pocket configured to receive a first lug and a second pocket adjacent the first pocket and configured to receive a second lug. In some such examples, the carrier body may also include a pocket barrier between the first pocket and the second pocket and configured to separate a first lug and a second lug from one another. Such examples may provide electrical insulation between the lugs, which may provide compliance with some electrical regulations. 
     In some examples, the at least one pocket may pass through the carrier body, for example, from a first side of the carrier body to an opposite second side of the carrier body. This may facilitate pressing the lugs using a press having opposing dies that approach one another during the pressing process and contact the lugs from opposite sides to facilitate crimping the lugs. In some examples, the at least one pocket may define at least one tab configured to prevent a lug from passing through the carrier body. In some such examples, the lug may be provided in the pocket but be prevented from passing through the pocket and separating from the carrier body. 
     In some examples of the carrier, the second end of the carrier body may define a mounting boss configured to facilitate mounting of the carrier to a support. In some such examples, the carrier body may define a notch between the mounting boss and a remainder of the carrier body, and the notch may be configured to facilitate separation of the mounting boss from the remainder of the carrier body, for example, with or without using a cutting device. In some examples, the mounting boss may be frangible and thus separable from the remainder of the carrier body. 
     In some examples of the carrier, the mounting boss may define a flange defining a mounting hole configured to receive a fastener for mounting the carrier to a support. In some examples, the flange may define a plane extending either substantially parallel with respect to the longitudinal axis of the carrier body, obliquely with respect to longitudinal axis of the carrier body, or substantially perpendicular with respect to the longitudinal axis of the carrier body. In some examples, the flange may include a first flange, and the mounting boss may further include a second flange defining a mounting hole configured to receive a fastener for mounting the carrier to a support. Each of the first flange and the second flange may define a flange plane, and the flange plane of first flange and the flange plane of the second flange may be at an angle with respect to one another, for example, as described herein. In some examples, the mounting boss may include at least one reinforcement rib configured to strengthen the mounting boss, for example, as described herein. 
     In some examples, the carrier body may include a flange at the second end of the carrier body and configured to provide a stop for an insulation sleeve, for example, as described herein. 
     In some examples of the carrier, the carrier body may define a first side and a second side opposite the first side, and the at least one recess may include a first recess in the first side of the carrier body and a second recess in the second side of the carrier body. In some examples, the carrier body may define an opening configured to permit at least one electrical lead of a surge protection component to pass from the first side of the carrier body to the second side of the carrier body. In some examples, the at least one recess may further include a third recess in the first side of the carrier body and a fourth recess in the second side of the carrier body. Each of the first recess, the second recess, the third recess, and the fourth recess may be configured to receive at least a portion a surge protection component. 
     In some examples, the carrier body may define at least one opening configured to: facilitate electrical leads of a surge protection component at least partially received in the second recess to pass from the second side of the carrier body to the first side of the carrier body; and facilitate electrical leads of a surge protection component at least partially received in the fourth recess to pass from the second side of the carrier body to the first side of the carrier body. 
     According to still a further aspect, a method (e.g., for assembling a surge protection module) may include providing a carrier configured to receive at least one electrical conductor and at least one surge protection component, with the carrier defining a pocket. The method may further include providing a lug in the pocket of the carrier, with the lug defining a hollow space. The method may also include providing an electrical lead of a surge protection component in the hollow space of the lug, and providing an electrical conductor in the hollow space of the lug. The method may also include one or more of pressing the lug to crimp the lug onto the electrical lead of the surge protection component and the electrical conductor or welding the lug onto the electrical lead of the surge protection component and the electrical conductor (with or without the lone or more of the lugs), such that the electrical lead and the electrical conductor are physically coupled to one another and electrically coupled to one another. 
     In some examples of the method, the carrier may define a first pocket and a second pocket, with each of the first pocket and the second pocket being configured for receiving a lug defining a hollow space. In such examples, providing the lug in the pocket of the carrier may include providing a first lug in the first pocket, with the first lug defining a first hollow space, and providing a second lug in the second pocket, with the second lug defining a second hollow space. In some such examples, providing the electrical lead of the surge protection component in the hollow space of the lug may include providing a first electrical lead of the surge protection component in the first hollow space of the first lug, and providing a second electrical lead of the surge protection component in the second hollow space of the second lug. 
     In some examples, providing an electrical conductor in the hollow space of the lug may include providing a first electrical conductor in the first hollow space of the first lug, and providing a second electrical conductor in the second hollow space of the second lug. In some examples, pressing the lug to crimp the lug may include: (1) pressing the first lug to crimp the first lug onto the first electrical lead of the surge protection component and the first electrical conductor, such that the first electrical lead and the first electrical conductor are physically coupled to one another and electrically coupled to one another; and (2) pressing the second lug to crimp the second lug onto the second electrical lead of the surge protection component and the second electrical conductor, such that the second electrical lead and the second electrical conductor are physically coupled to one another and electrically coupled to one another. 
     In some examples, the carrier may further define a third pocket configured for receiving a lug defining a hollow space. In such examples, providing the lug in the pocket of the carrier may include providing a third lug in the third pocket, with the third lug defining a third hollow space, and providing an electrical conductor in the hollow space of the lug may include providing a third electrical conductor in the third hollow space of the third lug. In some such examples, pressing the lug to crimp the lug may include: (1) pressing the first lug to crimp the first lug onto the first electrical lead of the surge protection component and the first electrical conductor, such that the first electrical lead and the first electrical conductor are physically coupled to one another and electrically coupled to one another; (2) pressing the second lug to crimp the second lug onto the second electrical lead of the surge protection component and the second electrical conductor, such that the second electrical lead and the second electrical conductor are physically coupled to one another and electrically coupled to one another; and (3) pressing the third lug to crimp the third lug onto the third electrical conductor, such that the third lug and the third electrical conductor are physically coupled to one another and electrically coupled to one another. 
     In some examples, the method may further include providing an insulation layer over at least a portion of the carrier. For example, the method may include sliding an insulation sleeve over at least a portion of the carrier. In some examples, the carrier may include a flange at an end of the carrier, and sliding the insulation sleeve over at least a portion of the carrier may include sliding the insulation sleeve over the carrier, such that an end of the insulation sleeve abuts the flange of the carrier. In some examples, the method may further include heating the insulation sleeve such that the insulation sleeve shrinks tightly around the carrier. In some examples, the method may include providing an insulating layer including a conformal coating, or similar coating, covering at least a portion of the carrier to electrically insulate the electrical connection between the at least two electrical conductors and the surge protection component. For example, the conformal coating may be applied via one or more of brushing, spraying, dipping, or selective coating by machine, and may include conformal coating compositions, such as, for example, one or more of acrylic, epoxy, polyurethane, silicone, fluorinated or non-fluorinated polyparaxylylene (parylene), or amorphous fluoropolymer. 
     In some examples of the method, the surge protection component may include a first surge protection component, and the method may further include: providing a first electrical lead of a second surge protection component in the first lug, and providing a second electrical lead of the second surge protection component in one of the second hollow space of the second lug or the third hollow space of the third lug. In some such examples, pressing the lug to crimp the lug may include: (1) pressing the first lug to crimp the first lug onto the first electrical lead of the first surge protection component, the first electrical lead of the second surge protection component, and the first electrical conductor, such that the first electrical lead of the first surge protection component, the first electrical lead of the second surge protection component, and the first electrical conductor are physically coupled to one another and electrically coupled to one another; (2) pressing the second lug to crimp the second lug onto the second electrical lead of the first surge protection component and the second electrical conductor, such that the second electrical lead and the second electrical conductor are physically coupled to one another and electrically coupled to one another; and (3) pressing the third lug to crimp the third lug onto the second electrical lead of the second surge protection component and the third electrical conductor, such that the second electrical lead of the second surge protection component and the third electrical conductor are physically coupled to one another and electrically coupled to one another. 
     In some examples of the method, it may further include providing a first electrical lead of a third surge protection component in the first lug, and providing a second electrical lead of the third surge protection component in one of the second hollow space of the second lug or the third hollow space of the third lug. In some such examples, pressing the lug to crimp the lug may include: (1) pressing the first lug to crimp the first lug onto the first electrical lead of the first surge protection component, the first electrical lead of the second surge protection component, the first electrical lead of the third surge protection component, and the first electrical conductor, such that the first electrical lead of the first surge protection component, the first electrical lead of the second surge protection component, the first electrical lead of the third surge protection component, and the first electrical conductor are physically coupled to one another and electrically coupled to one another; (2) pressing the second lug to crimp the second lug onto and the second electrical lead of the first surge protection component, the second electrical lead of the third surge protection component, and the second electrical conductor, such that the second electrical lead of the first surge protection component, the second electrical lead of the third surge protection component, and the second electrical conductor are physically coupled to one another and electrically coupled to one another; and (3) pressing the third lug to crimp the third lug onto the second electrical lead of the second surge protection component and the third electrical conductor, such that the second electrical lead of the second surge protection component and the third electrical conductor are physically coupled to one another and electrically coupled to one another. 
     In some examples, the method may further include providing a first electrical lead of a fourth surge protection component in the first lug, and providing a second electrical lead of the fourth surge protection component in one of the second hollow space of the second lug or the third hollow space of the third lug. In some such examples, pressing the lug to crimp the lug may include: (1) pressing the first lug to crimp the first lug onto the first electrical lead of the first surge protection component, the first electrical lead of the second surge protection component, the first electrical lead of the third surge protection component, the first electrical lead of the fourth surge protection component, and the first electrical conductor, such that the first electrical lead of the first surge protection component, the first electrical lead of the second surge protection component, the first electrical lead of the third surge protection component, the first electrical lead of the fourth surge protection component, and the first electrical conductor are physically coupled to one another and electrically coupled to one another; (2) pressing the second lug to crimp the second lug onto and the second electrical lead of the first surge protection component, the second electrical lead of the third surge protection component, and the second electrical conductor, such that the second electrical lead of the first surge protection component, the second electrical lead of the third surge protection component, and the second electrical conductor are physically coupled to one another and electrically coupled to one another; and (3) pressing the third lug to crimp the third lug onto the second electrical lead of the second surge protection component, the second electrical lead of the fourth surge protection component, and the third electrical conductor, such that the second electrical lead of the second surge protection component, the second electrical lead of the fourth surge protection component, and the third electrical conductor are physically coupled to one another and electrically coupled to one another. 
     In some examples of the method, pressing the first lug and pressing the second lug may include pressing the first lug and the second lug substantially simultaneously (e.g., concurrently). In some examples, pressing the first lug, pressing the second lug, and pressing the third lug may include pressing the first lug, the second lug, and the third lug substantially simultaneously (e.g., concurrently). 
     In some examples of the method, the carrier may define a first side and a second side opposite the first side, and the method may include providing the first surge protection component on the first side of the carrier, and providing the second surge protection component on the second side of the carrier. In some such examples, the first side of the carrier may define a first recess, the second side of the carrier may define a second recess, and the method may include providing at least a portion of the first surge protection component in the first recess of the carrier, and providing at least a portion of the second surge protection component in the second recess of the carrier. 
     In some examples of the method, the carrier may define a first side and a second side opposite the first side, and the method may include providing the first surge protection component on the first side of the carrier, providing the second surge protection component on the second side of the carrier, and providing the third surge protection component on either the first side of the carrier or the second side of the carrier. In some such examples, the first side of the carrier may define a first recess and a second recess, and the second side of the carrier defines a third recess. In such examples, the method may include providing at least a portion of the first surge protection component in the first recess of the carrier, providing at least a portion of the second surge protection component in the second recess of the carrier, and providing at least a portion of the third surge protection component in the third recess of the carrier. 
     In some examples of the method, the carrier may define a first side and a second side opposite the first side, and wherein the method may include providing the first surge protection component on the first side of the carrier, providing the second surge protection component on the first side of the carrier, providing the third surge protection component on the second side of the carrier, and providing the fourth surge protection component on the second side of the carrier. In some such examples, the first side of the carrier may define a first recess and a second recess, and the second side of the carrier may define a third recess and a fourth recess. In such examples, the method may include providing at least a portion of the first surge protection component in the first recess of the carrier, providing at least a portion of the second surge protection component in the second recess of the carrier, providing at least a portion of the third surge protection component in the third recess of the carrier, and providing at least a portion of the fourth surge protection component in the fourth recess of the carrier. In some such examples, the method may further include securing the first surge protection component, the second surge protection component, the third surge protection component, and the fourth surge protection component to the carrier prior to pressing the first lug, second lug, and third lug. 
     According to yet a further aspect, a method may include providing at least one electrical conductor in a first lug having a first hollow space, providing at least one electrical conductor in a second lug having a second hollow space, and providing at least one electrical conductor in a third lug having a third hollow space. The method may further include pressing the first lug, the second lug, and the third lug to physically couple and electrically couple the first lug, the second lug, and the third lug to the respective electrical conductors. In some examples, the pressing may include forming at least one of the first lug, the second lug, or the third lug, such that the first lug, the second lug, or the third lug has a substantially rectangular cross-sectional shape (e.g., a substantially square or substantially diamond cross-sectional shape). 
     In some examples, pressing the first lug, the second lug, and the third lug may include pressing the first lug, the second lug, and the third lug substantially simultaneously (e.g., concurrently). In some examples, pressing the first lug, the second lug, and the third lug may include pressing the first lug, the second lug, and the third lug at substantially equal force and/or pressure. 
     According to still a further aspect, a method may include providing a surge protection component including a first electrical lead and a second electrical lead, and forming the first electrical lead and/or the second electrical lead, such that the at least one electrical lead includes at least one bend (e.g., two or more bends). In some examples of the method, forming the first electrical lead and/or the second electrical lead may include placing the least one electrical lead into a forming die configured to bend the at least one electrical lead. In some such examples, the method may further include pressing the at least one electrical lead such that it is formed to include at least one bend (e.g., two or more bends). 
     In some examples, the pressing may include activating a press device (e.g., a press device as described herein) or operating a hand-operated pressing tool. 
       FIG. 1  is a schematic diagram showing a first example connection configuration  10  including an example surge protection module  12  electrically coupled to an example electrical device  14 . In the example shown in  FIG. 1 , the electrical device  14  includes a light emitting diode (LED) driver  16  including internal LED driver circuitry  18 . Other types of electrical devices are contemplated. The example connection configuration  10  shown in  FIG. 1  is a parallel connection in which three alternating current (AC) input lines  20  from external alternating current connections are electrically coupled to three electrical conductors  22  of the example surge protection module  12  and three electrical conductors  24  coupled to the LED driver  16  to electrically couple the LED driver circuitry  18  to provide a parallel connection. The three electrical conductors  22  are electrically coupled to surge protection components  26  of the surge protection module  12  to provide surge protection for the LED driver  16 . The surge protection components  26  may include, for example, one or more metal oxide varistors (MOVs), gas discharge tubes (GDTs), transient voltage suppression (TVS) diodes, thyristor surge protection devices (TSPDs), fuses, inductors, and/or capacitors. In the example shown in  FIG. 1 , the surge protection module  12  is coupled directly the LED driver  16 . Other coupling strategies are contemplated. The AC input lines  20  may be connected according to the following connection configurations: line/neutral, line/neutral/ground, line 1/line 2, or line 1/line 2/ground. Although shown with external AC input lines  20 , the example shown may be coupled to direct current (DC) input lines, which may be connected according to the following connection configurations: DC+/DC− or DC+/DC−/ground. 
       FIG. 2  is a schematic diagram showing another example connection configuration  28  including an example surge protection module  12  electrically coupled to an example electrical device  14 . In the example shown in  FIG. 2 , the electrical device  14  includes an LED driver  16  including internal LED driver circuitry  18 . Other types of electrical devices are contemplated. The example connection configuration  28  shown in  FIG. 2  is a series connection in which three AC input lines  20  from external alternating current connections are electrically coupled to three electrical conductors  22  of the example surge protection module  12 . Two of the three electrical conductors  22  are electrically coupled to two surge protection components  26  and two connection elements  29 , and the output of each of the two surge protection components  26  is electrically coupled to an electrical conductor  24  coupled to the LED driver circuitry of the LED driver  16 . The connection elements  29  may include, for example, wires, fuses, and/or inductors. A third one of the AC input lines  20  is electrically coupled to a third one of the electrical conductors  22  of the surge protection module  12  and to a third electrical conductor  24  coupled to the LED driver circuitry of the LED driver  16 . The surge protection components  26  may include, for example, one or more metal oxide varistors (MOVs), gas discharge tubes (GDTs), transient voltage suppression (TVS) diodes, thyristor surge protection devices (TSPDs), fuses, inductors, and/or capacitors. In the example shown in  FIG. 2 , the surge protection module  12  is coupled directly the LED driver  16 . Other coupling strategies are contemplated. The AC input lines  20  may be connected according to the following connection configurations: line/neutral, line/neutral/ground, line 1/line 2, or line 1/line 2/ground. Although shown with external AC input lines  20 , the example shown may be coupled to direct current (DC) input lines, which may be connected according to the following connection configurations: DC+/DC− or DC+/DC−/ground. 
       FIG. 3  is a schematic diagram showing another example connection configuration  30  including an example surge protection module  12  electrically coupled to an example electrical device  14  via an example terminal block  32 . In the example shown in  FIG. 3 , the electrical device  14  is an LED driver  16 . Other types of electrical devices are contemplated. The example connection configuration  30  shown in  FIG. 3  is a parallel connection in which three alternating current (AC) input lines  20  from external alternating current connections are electrically coupled to three electrical conductors  22  of the example surge protection module  12  and three terminal connections  34 , which, in turn, are electrically coupled to three electrical conductors  24  coupled to the LED driver  16  to electrically couple the LED driver  16  to provide a parallel connection. The three electrical conductors  22  are electrically coupled to surge protection components  26  of the surge protection module  12  to provide surge protection for the LED driver  16 . The surge protection components  26  may include, for example, one or more metal oxide varistors (MOVs), gas discharge tubes (GDTs), transient voltage suppression (TVS) diodes, thyristor surge protection devices (TSPDs), fuses, inductors, and/or capacitors. In the example shown in  FIG. 3 , the surge protection module  12  is coupled directly the terminal block  32 . Other coupling strategies are contemplated. The terminal connections  34  may include one or more screw terminals, poke-in connections, insulation displacement, and/or any other form of electrical connections. 
       FIG. 4  is a schematic diagram showing another example connection configuration  36  including an example surge protection module  12  electrically coupled to an example terminal block  32 . In the example shown in  FIG. 4 , the electrical device  14  is an LED driver  16 . Other types of electrical devices are contemplated. The example connection configuration  36  shown in  FIG. 4  is a series connection in which three AC input lines  20  from external alternating current connections are electrically coupled to three terminal connections  34 , which, in turn, are electrically coupled to three electrical conductors  22  of the example surge protection module  12 . Two of the three electrical conductors  22  are electrically coupled to two surge protection components  26  and two connection elements  29 , and the output of each of the two surge protection components  26  is electrically coupled via a terminal connection  34  to an electrical conductor  24  coupled to the LED driver circuitry of the LED driver  16 . The connection elements  29  may include, for example, wires, fuses, and/or inductors. A third one of the AC input lines  20  is electrically coupled to a third one of the terminal connections  34 , which is electrically coupled to an electrical conductor  22  of the surge protection module  12  and to a third electrical conductor  24  coupled to the LED driver circuitry of the LED driver  16 . The surge protection components  26  may include, for example, one or more metal oxide varistors (MOVs), gas discharge tubes (GDTs), transient voltage suppression (TVS) diodes, thyristor surge protection devices (TSPDs), fuses, inductors, and/or capacitors. In the example shown in  FIG. 4 , the surge protection module  12  is coupled directly the terminal block  32 . Other coupling strategies are contemplated. The terminal connections  34  may include one or more screw terminals, poke-in connections, insulation displacement, and/or any other form of electrical connections. 
       FIG. 5  is a schematic diagram showing another example connection configuration  38  including an example surge protection module  12  electrically coupled to an example electrical device  14 . In the example shown in  FIG. 5 , the electrical device  14  includes an LED driver  16  including internal LED driver circuitry  18 . Other types of electrical devices are contemplated. The example connection configuration  38  shown in  FIG. 5  is a series connection in which three AC input lines  20  from external AC connections are electrically coupled to three terminal connections  34  electrically coupled to the surge protection components  26  and two connection elements  29  of the example surge protection module  12 . The outputs of the surge protection module  12  are electrically coupled to three electrical conductors  40 , which are electrically coupled to three terminal connections  34  of the LED driver circuitry  18  of the LED driver  16 . The connection elements  29  may include, for example, wires, fuses, and/or inductors. A third one of the AC input lines  20  is electrically coupled to a third terminal connection  34  of the surge protection module  12 , and to a third terminal connection  34  of the LED driver circuitry  18  of the LED driver  16 . The surge protection components  26  may include, for example, one or more metal oxide varistors (MOVs), gas discharge tubes (GDTs), transient voltage suppression (TVS) diodes, thyristor surge protection devices (TSPDs), fuses, inductors, and/or capacitors. The terminal connections  34  may include one or more screw terminals, poke-in connections, insulation displacement, and/or any other form of electrical connections. In the example shown in  FIG. 5 , the surge protection module  12  is coupled directly the LED driver  16 . Other coupling strategies are contemplated. The AC input lines  20  may be connected according to the following connection configurations: line/neutral, line/neutral/ground, line 1/line 2, or line 1/line 2/ground. Although shown with external AC input lines  20 , the example shown may be coupled to direct current (DC) input lines, which may be connected according to the following connection configurations: DC+/DC− or DC+/DC−/ground. 
       FIG. 6A  is a perspective view of an example surge protection module  12  coupled to an example electrical device  14 . In the example shown in  FIG. 6A , the example surge protection module  12  is physically and electrically coupled to the electrical device  14 , which may be, for example, an LED driver for an LED lighting fixture. In the example shown, the surge protection module  12  is configured to be coupled directly to a housing  42  of the electrical device  14  in a modular manner, such that the surge protection module  12  is both physically and electrically coupled to the electrical device  14 , for example, as explained with respect to  FIGS. 6B, 6C, 6D, 7A, 7B, 7C, and 7D . 
       FIG. 6B  is a perspective view of an example surge protection module  12  configured to be coupled to the electrical device  14  according to a screw-in action. For example, a portion of the surge protection module  12  may include external threads  44  configured to threadedly engage internal threads  46  of the housing  42  and facilitate a screw-on engagement between the surge protection module  12  and the housing  42 . The surge protection module  12  may include electrical terminals configured to electrically couple to corresponding electrical terminals coupled to the electrical device  14 . 
       FIG. 6C  is a perspective view of an example surge protection module  12  coupled to an example electrical device  14  via an example push-in connection. For example, a portion of the surge protection module  12  may include a structure configured to provide a push-in engagement between the surge protection module  12  and the housing  42  of the electrical device  14 . The surge protection module  12  may include electrical terminals configured to electrically couple to corresponding electrical terminals coupled to the electrical device  14 . 
       FIG. 6D  is a perspective view of an example surge protection module  12  coupled to an example electrical device  14  in an example manner including example fasteners  48 , such as, for example, screws, bolts, and/or clips. For example, the surge protection module  12  may include one or more flanges  50  having holes configured to receive fasteners  48  for coupling the surge protection module to the electrical device  14 . The surge protection module  12  may include electrical terminals configured to electrically couple to corresponding electrical terminals coupled to the electrical device  14 . 
       FIG. 7A  is a perspective view of an example surge protection module  12  separated from an example electrical device  14  showing an example electrical coupling  52 . As shown in  FIG. 7A , the housing  42  of the electrical device  14  includes a recess  54  configured to receive a complimentary portion of the surge protection module  12  therein. The electrical device  14  includes terminals  56  configured to electrically couple with complimentary electrical terminals of the surge protection module  12  when the surge protection module  12  is engaged with the electrical device  14 . 
       FIG. 7B  is a perspective view of an example electrical device  14  showing an example electrical coupling  52 . The example electrical device  14  shown in  FIG. 7B  includes a recess  54  including internal threads  46  for engaging complimentary external threaded on a portion of the surge protection module  12 . The electrical device  14  shown in  FIG. 7B  includes terminals  56  configured to electrically couple with complimentary electrical terminals of the surge protection module  12  when the surge protection module  12  is threadedly engaged with the electrical device  14 , and the surge protection module is screwed onto the electrical device  14 . 
       FIG. 7C  is a perspective view of another example electrical device  14  showing another example electrical coupling  52 . As shown in  FIG. 7C , the housing  42  of the electrical device  14  includes a recess  54  configured to receive a complimentary portion of the surge protection module  12  therein. The electrical device  14  includes terminals  56  configured to electrically couple with complimentary electrical terminals of the surge protection module  12  when the surge protection module  12  is engaged with the electrical device  14 , for example, via a push-in action. 
       FIG. 7D  is a perspective view of another example electrical coupling  52  including an example printed circuit board  58  including contact pads  60 . The example electrical coupling shown in  FIG. 7D  may be used to electrically couple some examples of the surge protection module  12  with some examples of electrical device  14  when the surge protection module  12  and electrical device  14  are physically coupled to one another. 
       FIG. 8  is a perspective view of an example surge protection module  62  configured to limit power surge exposure to an electrical device, for example, as described herein, and  FIG. 9  is an exploded perspective view of the example surge protection module  62  shown in  FIG. 8 . The example surge protection module  62  shown in  FIGS. 8 and 9  includes a carrier  64  including a carrier body  66  defining a first end  68  and a second end  70  opposite the first end  68  and a longitudinal axis X extending between the first end  68  and the second end  70 . The example surge protection module  62  also includes three electrical conductors  72  (e.g., at least partially electrically insulated wires) coupled to the carrier  64 . The surge protection module  62  also includes at least one surge protection component  74  electrically coupled to the electrical conductors  72  and configured to limit power surge conducted to an electrical device to which the electrical conductors  72  are electrically coupled. The example shown in  FIGS. 8 and 9  includes four surge protection components  74 , although fewer (e.g., three, two, or one) or more surge protection components  74  are contemplated. The surge protection components  26  may include, for example, one or more metal oxide varistors (MOVs), gas discharge tubes (GDTs), transient voltage suppression (TVS) diodes, thyristor surge protection devices (TSPDs), fuses, inductors, and/or capacitors. 
     In the example shown in  FIGS. 8 and 9 , each of the surge protection components  74  includes two electrical leads  76 , and the surge protection module  62  further includes three lugs  78 . Each of the three lugs  78  receives at least one of the electrical conductors  72  and one or more of the two electrical leads  76  of the surge protection components  74  and electrically couples the at least one electrical conductor  72  and the at least one electrical lead  76  to one another. In some examples, as explained herein, the lugs  78  are configured to be pressed onto the at least one electrical conductor  72  and the at least one electrical lead  76 , such that the at least one electrical conductor  72  and the at least one electrical lead  74  are electrically coupled to one another and physically coupled to one another. In some examples, the lugs  78  include a tubular member (e.g., a hollow cylindrical member) receiving an end of the at least one electrical conductor  72  and an end of the at least one electrical lead  76 . 
     The example surge protection module  62  shown in  FIGS. 8 and 9  includes four surge protection components  74   a,    74   b,    74   c,  and  74   d.  A first surge protection component  74   a  is electrically coupled to a first electrical conductor  72   a  and a second electrical conductor  72   b.  In the example shown, a second surge protection component  74   b  is electrically coupled to the first electrical conductor  72   a  and a third electrical conductor  72   c.  In the example shown, the surge protection module  62  includes three lugs  78   a,    78   b,  and  78   c.  The first lug  78   a  receives the first electrical conductor  74   a,  the first electrical lead  76   a  of the first surge protection component  74   a , and the first electrical lead  76   a  of the second surge protection component  74   b.  A second lug  78   b  receives the second electrical conductor  72   b  and a second electrical lead  76   b  of the first surge protection component  74   a.  In the example shown, a third lug  78   c  receives the third electrical conductor  72   c  and a second electrical lead  76   b  of the second surge protection component  74   b.    
     The example shown in  FIGS. 8 and 9  also includes a third surge protection component  74   c  electrically coupled to two of the electrical conductors  72 , and a fourth surge protection component  74   d  electrically coupled to two of the electrical conductors  72 . For example, as shown, the third surge protection component  74   c  is electrically coupled to the second electrical conductor  72   b  and the third electrical conductor  74   c.  In the example shown, the fourth surge protection component  74   d  is electrically coupled to the first electrical conductor  72   a  and the third electrical conductor  72   c.  In the example shown, the second lug  78   b  receives a first electrical lead  76   a  of the third surge protection component  74   c,  and the third lug  78   c  receives a second electrical lead  76   b  of the third surge protection component  74   c.  In addition, the first lug  78   a  receives a first electrical lead  76   a  of the fourth surge protection component  74   d,  and the third lug  78   c  receives a second electrical lead  76   b  of the fourth surge protection component  74   d.    
       FIG. 10  is a perspective view of an example carrier  64  of an example surge protection module  62 .  FIGS. 11-13  show different views of the example carrier  64  shown in  FIG. 10 . In the example shown, the carrier  64  defines three conductor channels  80  extending from the first end  68  of the carrier  64  toward the second end  70  of the carrier  64 . Each of the conductor channels  80  is configured to receive an electrical conductor  72 . Some examples may include may include more or fewer conductor channels  80 , and the conductor channels  80 , in some examples, may receive more than one electrical conductor  72 . In the example shown in  FIGS. 10-13 , one or more of the conductor channels  80  may include a grip  82  configured to engage with an electrical conductor  72 . The grip  82  may be defined by the carrier  64  (or incorporated into the carrier  64 ) and may include a recess having dimensions configured to press tightly against an electrical conductor  72  received in the corresponding conductor channel  80 . 
     As shown in  FIGS. 10-13 , the first end  68  of the carrier  64  may define an outer surface  84  that tapers in a direction away from the second end  70  of the carrier  64 . In some examples, the first end  68  of the carrier  64  may define an inner surface  86  that tapers in a direction away from the second end  70  of the carrier  64 , for example, as shown. 
     As shown in  FIGS. 10-13 , the example carrier  64  defines a recess  88  configured to receive at least a portion of a surge protection component  74 . For example,  FIG. 13  shows four recesses  88 , each for receiving a portion of respective surge protection components  74 . In the example shown, some of the recesses  88  are located between the conductor channels  80  and the second end  70  of the carrier  64 . 
     In the example shown in  FIGS. 10-13 , the carrier  64  defines lead channels  90  extending between the recesses  88  and the conductor channels  80 . The lead channels are configured to receive electrical leads  76  of the surge protection components  74 . 
     As shown in  FIGS. 10-13 , the carrier  64  may define pockets  92 , each configured to receive a lug  78  electrically coupling and physically coupling one of the electrical conductors  72  to one or more electrical leads  76  the surge protection components  74 . In some examples, the pockets  92  may include a first pocket  92   a  for receiving a first lug  78   a,  a second pocket  92   b  adjacent the first pocket  92   a  for receiving a second lug  78   b,  and a third pocket  92   c  adjacent the second pocket  92   b  for receiving a third lug  78   c.  In some examples, the carrier  64  may also include pocket barriers  94  between adjacent pockets  92 , for example, a first pocket barrier  94   a  between the first pocket  92   a  and the second pocket  92   b,  and a second pocket barrier  94   b  between the second pocket  92   b  and the third pocket  92   c.  The packet barriers  94  may serve to separate (e.g., electrically insulate) the first lug  78   a,  the second lug  78   b,  and the third lug  78   c  from one another. 
     In some examples, for example, as shown in  FIGS. 10-13 , the pockets  92  pass through the carrier  64 , for example, from a first side  96  of the carrier  64  to a second side  98  of the carrier  64 . In such examples, the pockets  92  may define at least one tab  100  configured to prevent a lug  78  received in the pocket  92  from passing through the carrier  64  (e.g., falling out of the carrier  64 ). This example configuration may facilitate pressing the lugs  78  to crimp them tightly around any electrical conductors  72  and/or electrical leads  76  of the surge protection components  74  received in the lugs  78 , for example, as explained herein. 
       FIGS. 14 and 15  show two views of another example carrier  64  that omits outside barriers adjacent the outboard pockets  92  (i.e., the pockets  92   a  and  92   c ). This example configuration provides a lower profile relative to the example carrier  64  shown in  FIGS. 10-13 . The example shown in  FIGS. 14 and 15  also includes the pocket barriers  94  discussed with respect to  FIGS. 10-13 . The pocket barriers  94  may provide electrical clearance (e.g., insulation) to help meet or exceed certain electrical regulatory rules (e.g., codes). 
       FIG. 16  is a perspective view of another example carrier  64  with a detailed view of an example notch  102  configured to facilitate separation of different portions of the carrier  64  from one another. For example, the example carriers  64  shown in  FIGS. 10-16  include a second end  70  defining a mounting boss  104  configured to facilitate mounting of the surge protection module  62  to a support. For example, the carrier  64  may define a notch  102  between the mounting boss  104  and a remainder of the carrier  64 , and the notch  102  may be configured to facilitate separation of the mounting boss  104  from the remainder of the carrier  64 . In some examples, the mounting boss  104  may be separated from the remainder of the carrier  64  by using a cutting device or by hand. In some examples, for example, as shown in  FIGS. 10-16 , the mounting boss  104  defines a flange  106  defining a mounting hole  108  configured to receive a fastener for mounting the surge protection module  62  to a support. 
       FIG. 17A, 17B, 17C, and 17D  are partial perspective views of examples of surge protection module  62  including examples of mounting bosses  104  configured to facilitate mounting of the surge protection module  62  to a support. In some examples, the flange  106  defines a plane extending substantially parallel with respect to the longitudinal axis X of the carrier  64 , obliquely with respect to longitudinal axis X of the carrier  64 , or substantially perpendicular with respect to the longitudinal axis X of the carrier  64  (see, e.g.,  FIG. 17B ). In some examples, the mounting boss  104  includes a first flange  106   a  and a second flange  106   b , each defining respective mounting holes  108   a  and  108   b  configured to receive a fastener  110  for mounting the surge protection module  62  to a support (see, e.g.,  FIGS. 17B-17D ). Each of the first flange  106   a  and the second flange  106   b  may define a flange plane, and the flange plane of first flange  106   a  and the flange plane of the second flange  106   b  may be at an angle with respect to one another (e.g., a non-zero angle, such as, for example, an angle of about 30 degrees, an angle of about 45 degrees, an angle of about 60 degrees, an angle of about 90 degrees, an angle of about 120 degrees, an angle of about 135 degrees, or an angle of about 150 degrees). 
     In the example carrier  64  shown in  FIGS. 10-13 , the mounting boss  104  includes reinforcement ribs  112  configured to strengthen the mounting boss  104 . In the example carriers  64  shown in  FIGS. 10-16 , the carrier  64  defines a flange  114  at the second end  70  of the carrier  64  and configured to provide a stop for an insulation sleeve, for example, as described herein with respect to  FIG. 32 . For example, the flange  114  may prevent the insulation sleeve from extending over the mounting boss  104 . For example, in examples having an insulation sleeve, the insulation sleeve may be pushed from the first end  68  of the carrier  64 , over the carrier  64  until the leading end of the insulation sleeve abuts the flange  114 . 
       FIG. 18  is an exploded perspective view of the example surge protection module  62  including an example carrier  64 , example lugs  78 , example electrical conductors  72 , and example surge protection components  74  including example electrical leads  76 . The example shown in  FIG. 18  is similar to the example shown in  FIGS. 8 and 9 . The example surge protection module  62  shown in  FIG. 18  includes a carrier  64  including a carrier body  66  defining a first end  68  and a second end  70  opposite the first end  68  and a longitudinal axis X extending between the first end  68  and the second end  70 . The example surge protection module  62  also includes three electrical conductors  72  (e.g., at least partially electrically insulated wires) coupled to the carrier  64 . The surge protection module  62  also includes at least one surge protection component  74  electrically coupled to the electrical conductors  72  and configured to limit power surge conducted to an electrical device to which the electrical conductors  72  are electrically coupled. The example shown in  FIG. 18  includes four surge protection components  74 , although fewer (e.g., three, two, or one) or more surge protection components  74  are contemplated. The surge protection components  26  may include, for example, one or more metal oxide varistors (MOVs), gas discharge tubes (GDTs), transient voltage suppression (TVS) diodes, thyristor surge protection devices (TSPDs), fuses, inductors, and/or capacitors. 
     In the example shown in  FIG. 18 , each of the surge protection components  74  includes two electrical leads  76 , and the surge protection module  62  further includes three lugs  78 . Each of the three lugs  78  receives at least one of the electrical conductors  72  and one or more of the two electrical leads  76  of the surge protection components  74  and electrically couples the at least one electrical conductor  72  and the at least one electrical lead  76  to one another. In some examples, as explained herein, the lugs  78  are configured to be pressed onto the at least one electrical conductor  72  and the at least one electrical lead  76 , such that the at least one electrical conductor  72  and the at least one electrical lead  74  are electrically coupled to one another and physically coupled to one another. In some examples, the lugs  78  include a tubular member (e.g., a hollow cylindrical member) receiving an end of the at least one electrical conductor  72  and an end of the at least one electrical lead  76 . 
     The example surge protection module  62  shown in  FIG. 18  includes four surge protection components  74   a,    74   b,    74   c,  and  74   d.  A first surge protection component  74   a  is electrically coupled to a first electrical conductor  72   a  and a second electrical conductor  72   b.  In the example shown, a second surge protection component  74   b  is electrically coupled to the first electrical conductor  72   a  and a third electrical conductor  72   c.  In the example shown, the surge protection module  62  includes three lugs  78   a,    78   b,  and  78   c.  The first lug  78   a  receives the first electrical conductor  74   a,  the first electrical lead  76   a  of the first surge protection component  74   a , and the first electrical lead  76   a  of the second surge protection component  74   b.  A second lug  78   b  receives the second electrical conductor  72   b  and a second electrical lead  76   b  of the first surge protection component  74   a.  In the example shown, a third lug  78   c  receives the third electrical conductor  72   c  and a second electrical lead  76   b  of the second surge protection component  74   b.    
     The example shown in  FIG. 18  also includes a third surge protection component  74   c  electrically coupled to two of the electrical conductors  72 , and a fourth surge protection component  74   d  electrically coupled to two of the electrical conductors  72 . For example, as shown, the third surge protection component  74   c  is electrically coupled to the second electrical conductor  72   b  and the third electrical conductor  74   c.  In the example shown, the fourth surge protection component  74   d  is electrically coupled to the first electrical conductor  72   a  and the third electrical conductor  72   c.  In the example shown, the second lug  78   b  receives a first electrical lead  76   a  of the third surge protection component  74   c,  and the third lug  78   c  receives a second electrical lead  76   b  of the third surge protection component  74   c.  In addition, the first lug  78   a  receives a first electrical lead  76   a  of the fourth surge protection component  74   d,  and the third lug  78   c  receives a second electrical lead  76   b  of the fourth surge protection component  74   d.    
       FIGS. 19A, 19B, and 19C  are a perspective view, top view, and side view, respectively, of an example surge protection component  74  including two electrical leads  76   a  and  76   b  having example bends  116 . The example bends  116  in the example shown in  FIGS. 19A-19C  are configured to facilitate coupling of the electrical leads  76   a  and  76   b  to the first and third electrical conductors  72   a  and  72   c,  for example, as shown in  FIGS. 8, 9, and 18 . In some examples, the example bends  116  of the electrical leads  76   a  and  76   b  are configured such that when the surge protection component  74  is positioned in a recess  88  of the carrier  64 , the remote ends  118  of the electrical leads  76   a  and  76   b  lie in a common plane and have respective longitudinal axes that are aligned with the corresponding first and third lugs  78   a  and  78   c.    
       FIGS. 20A, 20B, and 20C  are a perspective view, top view, and side view, respectively, of an example surge protection component  74  including two electrical leads  76   a  and  76   b  having example bends  116 . The example bends  116  in the example shown in  FIGS. 20A-20C  are configured to facilitate coupling of the electrical leads  76   a  and  76   b  to either the first and second electrical conductors  72   a  and  72   b  or the second and third electrical conductors  72   b  and  72   c,  for example, as shown in  FIGS. 8, 9, and 18 . In some examples, the example bends  116  of the electrical leads  76   a  and  76   b  are configured such that when the surge protection component  74  is positioned in a recess  88  of the carrier  64 , the remote ends  118  of the electrical leads  76   a  and  76   b  lie in a common plane and have respective longitudinal axes that are aligned with the corresponding first and second lugs  78   a  and  78   b  or second and third lugs  78   b  and  78   c.    
       FIG. 21  is a view of an example carrier  64 , example lugs  78 , example electrical conductors  72 , and example surge protection components  74  laid out for assembly. 
       FIG. 22  is a view of example lugs  78  provided in example pockets  92  of an example carrier  64  for assembly of an example surge protection module  62 . In the example shown, the lugs  78  have been placed in the pockets  92 , which pass through the carrier  64  and include tabs  100  to prevent the lugs  78  from dropping through the pockets  92  and separating from the carrier  64 . The tabs  100 , in some examples, may act to position the lugs  78  longitudinally with respect to the carrier  64 . In the example shown, the carrier  64  also includes pocket barriers  94  to separate (e.g., electrically insulate) the lugs  78  from one another. 
       FIG. 23  is a view of two example surge protection components  74  provided in example recesses  88  in the second side  98  (e.g., the underside as shown) of the example carrier  64 , with example electrical leads  76  of the surge protection components  74  passing through respective example openings  120  for facilitating passage of the electrical leads  76  from the second side  98  of the carrier  64  to the first side  96  (e.g., the upper side as shown) of the carrier  64 , and with the electrical leads  76  provided in the hollow spaces of the three lugs  78  according to an example construction. After the lugs  78  have been placed in the pockets  92 , each of the surge protection components  74  is placed in a respective recess  88  on the second side  98  of the carrier  64 , such that the electrical leads  76  pass through the carrier  64  to the first side  96  and into the appropriate lugs  78 , for example, as shown. 
       FIG. 24  is a view showing three example electrical conductors  72 , having respective insulation removed from the remote ends, provided in the respective hollow spaces of the three lugs  78 , with the electrical leads  76  of the two surge protection components  74  and the three electrical conductors  72  received in example conductor channels  80  of the carrier  64 . 
       FIG. 25  is a view showing third and fourth example surge protection components  74  received in respective third and fourth example recesses  88  in the carrier  64  with the respective electrical leads  76  of the third and fourth surge protection components  74  provided in the hollow spaces of the three lugs  78 . Each of the third and fourth surge protection components  74  is placed in a respective recess  88  on the first side  96  of the carrier  64 , such that the electrical leads  76  are received in the appropriate lugs  78 , for example, as shown. 
       FIG. 26  is a perspective view showing example bands  122  for securing the first, second, third, and fourth surge protection components  76  to the carrier  64 . After the electrical conductors  72  and the surge protection components  74  have been assembled relative to the carrier  64  using the lugs  78 , the surge protection components  74  may be secured in place using the bands  122 , which may be tape. This prevents unintended separation of the parts from the carrier  64  during movement of the carrier  64  and associated parts, for example, for the pressing process explained herein. 
       FIG. 27  is a perspective view of the example partially assembled surge protection module  62  shown in  FIG. 26  provided in an example press  124  configured to press the three respective lugs  78 , such that the lugs  78  are crimped onto the electrical leads  76  of the first, second, third, and fourth surge protection components  74 , and the three electrical conductors  72 , such that they are physically coupled and electrically coupled to one another.  FIG. 27  shows the partially assembled surge protection module  62  positioned on a lower die set  126  of the press  124 . In some examples, the carrier may be positioned in the lower die set  126  prior to providing the one or more surge protection components  74 . 
       FIG. 28  is a perspective view of the example press  124  shown in  FIG. 27 . The example press  124  shown includes the lower die set  126  and an upper die set  128  configured to press the lugs  78  between the lower die set  126  and the upper die set  128 , such that the lugs  78  are crimped onto the electrical leads  78  of the first, second, third, and fourth surge protection components  74 , and the three electrical conductors  72 . The example press  124  includes a pressure dial  130  for adjusting the force applied to the upper die set  128  and the lower die set  126 , and thus, to the lugs  78  during a pressing operation. In some examples, the press  124  may be a 2-ton press (e.g., a pedal-operated press), although other types and/or sizes of presses are contemplated. The example  124  also includes a locator pin  132  for positioning the partially assembled surge protection module  62  prior to pressing. 
       FIG. 29  is a perspective view of showing the example lower die set  126  of the example press  124  and an example surge protection module  62  (with one of the surge protection components  74  removed for ease of viewing) following pressing, including crimped lugs  78  having respective substantially rectangular cross-sectional shapes following crimping. For example, in some examples, the lugs  78  after crimping may have a substantially square-shaped or diamond-shaped cross-sectional shape following the pressing operation. In some examples, the final cross-section crimp shape may result in reducing at least one dimension of the overall crimp cross-section (e.g., from a pre-pressing diameter crimp of about 5.4 mm to about 5.0 mm at its widest cross-section dimension). For example, the crimping cross-section may result in compaction on both width and height of the cross-section. This may reduce the likelihood in some example of cracking the carrier  64  when crimping the lugs  78 , which might occur if the pressing caused an expansion of the crimping cross-section (e.g., a flattening and widening of the crimping cross-section). 
       FIG. 30  shows a view of example upper die set  128  and corresponding example lower die set  126  in respective die holders  134  for the example press  124  shown in  FIGS. 27-29 . In some examples, the lower die set  126  and/or the upper die set  128  may each include three individual dies  136  that may be independently removeable from the respective die set. 
       FIG. 31  is a detailed perspective view of three example dies  136  removed from a die holder  134  to show details of the example dies  136 , including example dimensions relative to an example lug  78 . As shown in  FIG. 31 , the example dies  136  include a core  138  and a die face  140  having a concave relief  142  (e.g., a triangular relief defining an apex and opposing obliquely-extending sides). The core  138  of the dies  136  may include a flat  144  configured to be engaged by a set screw  146  (see  FIG. 30 ) for securing the dies  136  in the die holder  134 . As shown in  FIG. 31 , the example dies  136  have die faces  140  dimensioned and shaped to crimp the lugs  78 , such that the electrical leads  78  of the first, second, third, and fourth surge protection components  74 , and the three electrical conductors  72 , are physically coupled and electrically coupled to one another in a secure manner. Although the dies  136  for the upper die set  128  and the lower die set  126  are of the same configuration in the example shown, one or more of the upper dies  136  may have a configuration differing from one or more of the lower dies  136 . In some examples, one or more of the die faces  140  may result in a final cross-section crimp shape that has at least one reduced dimension of the overall crimp cross-section (e.g., from a pre-pressing diameter crimp of about 5.4 mm to about 5.0 mm at its widest cross-section dimension). For example, the crimping cross-section may result in compaction on both width and height of the cross-section. 
       FIG. 32  is a sequence of views showing an example insulation sleeve  148  being provided over an example carrier  64  having crimped lugs  78 , with one end of the example insulation sleeve  148  abutting the example flange  114  at the second end  70  of the carrier  64 , so the example mounting boss  104  remains exposed, all prior to heating the example insulation sleeve  148  to shrink the insulation sleeve  148 , thereby securing it to the carrier  64  and covering the surge protection components  74 , the lugs  78 , and ends of the electrical conductors  72  received in the lugs  78 . In some examples, the insulation sleeve  148  may be configured tighten around at least a portion of the carrier upon exposure to heat (e.g., it may be a heat-shrink sleeve). Other configurations of insulation are contemplated. For example, the insulation layer may include a conformal coating, or similar coating, covering at least a portion of the carrier to electrically insulate the electrical connection between the at least two electrical conductors and the surge protection component. For example, the conformal coating may be applied via one or more of brushing, spraying, dipping, or selective coating by machine, and may include conformal coating compositions, such as, for example, one or more of acrylic, epoxy, polyurethane, silicone, fluorinated or non-fluorinated polyparaxylylene (parylene), or amorphous fluoropolymer. 
     Some examples of the leads  76  of the surge protection components  74  (or other leads) may be scored (e.g., surface-scored), which may, in some examples, result in a more secure physical joining of the leads  76  to one another and/or in an improved electrical conductivity performance of the connection between the leads  76 .  FIG. 33  is a schematic partial section view showing three example surface scorings of example leads  76 , for example, for surge protection components  74  coupled to one another via crimping an example lug  78  (shown un-crimped in  FIG. 33 ). As shown, in a first example, the scoring  150 A includes circumferential surface-scoring of the example lead  76 . In a second example, the scoring  150 B includes a helical surface-scoring about the example lead  76 . In a third example, the scoring  150 C includes a double-helical surface-scoring about the example lead  76 , with helical surface-scoring in both directions about the lead  76 . Other configurations of scoring are contemplated, for example, including any combination of the example scorings  150 A,  150 B, and/or  150 C. In some examples, the scoring may be formed via one or more pressings, via one or more clampings, via grinding, via machine turning, and/or any other processes to form scoring on the leads  76 . 
     A method for improving at least one of a physical connection or an electrical connection between two electrical leads  76  coupled to one another via crimping, in some examples, may include providing a first electrical lead  76  from a first electrical component, providing a second electrical lead  76  from a second electrical component, scoring at least one of the first electrical lead  76  or the second electrical lead  76  (e.g., both the first and second electrical leads  76 ). The method may also include providing a lug  78  around a portion of the first electrical lead  76  and around a portion of the second electrical lead  76 , and pressing the lug  78 , for example, as described herein, such that the lug  78 , the first electrical lead  76 , and the second electrical lead  76  are physically coupled to one another and electrically coupled to one another. In some example, scoring the at least one of the first electrical lead  76  or the second electrical lead  76  may include surface-scoring the at least one of the first electrical lead  76  or the second electrical lead  76 , such that the scoring includes at least one of circumferential scoring, helical scoring, or double-helical scoring. In some examples, scoring the at least one of the first electrical lead  76  or the second electrical lead  76  may include at least one of pressing, clamping, grinding, machining, or machine-turning. This may result in at least partial formation of an electrical component, such as for example, one or more of the electrical components described herein, as well as others. For example, the electrical component may include a surge protection device, and/or a component including a surge protection device. 
     Although this subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as illustrative forms of implementing the claims.