Self heating thermal protector

• US 20040136194A1
• Filed: 12/26/2003
• Published: 07/15/2004
• Est. Priority Date: 08/13/2002
• Status: Active Grant

• Current Assignee: Nicholas L. Disalvo
• Original Assignee: Nicholas L. Disalvo
• Inventors: Disalvo, Nicholas L.
• Granted Patent: US 6,921,884 B2
• Time in Patent Office: Days
• US Class Current: 362/373
• CPC Class Codes: F21S 8/02 of recess-mounted type, e.g. downlighters specially adapted for vehicle exteriors F21S41/00-F21S45/00
• CPC Class Codes: F21V 25/04 breaking the electric circuit
• CPC Class Codes: F21V 25/10 coming into action when lighting device is overloaded, e.g. thermal switch
• CPC Class Codes: H01H 37/004 with thermal image
• CPC Class Codes: H01H 37/5436 mounted on controlled apparatus

Abstract

The present invention is a self heating thermal protector located in close proximity to an incandescent light fixture for controlling the flow of current to the associated lighting fixture by measuring the rate of heat flow from a dedicated heat source. Current is permitted to flow to the lighting fixture when the temperature of the self heating thermal detector is sufficient to avoid deterioration of electrical components such as plastic parts and wire insulation in the associated fixture. The thermal detector interrupts the flow of current to the associated fixture when the temperature of the self heating thermal protector increases to a temperature that is not safe.

Specifically, the self heating thermal protector of the present invention uses a resistor as a heat source, a bimetallic element as a switch located within a thermally conducting enclosure located proximate the heat source for controlling the flow of current to a fixture and thermally conductive potting compound which encapsulates both the heat source and the bimetallic element. The potting compound provides good thermal conductivity between the resistor, the bimetallic element and the surrounding air. A mounting member for mounting the thermal detector to a junction box is composed of thermally insulating material and provides dual functions, one of mounting the thermal detector to a junction box, and a second of thermally isolating the thermal protector from the junction box.

Claims

1. A self heating thermal protector for recessed incandescent fixtures comprising:

an enclosure,

a temperature sensitive switch located within the enclosure comprising a temperature sensitive movable element and an electrical contact integral thereto aligned to contact a fixed electrical contact, the contacts of the temperature sensitive switch being capable of being preset to open at a desired temperature by movement of the electrical contact integral with the movable element away from the fixed contact,

a heat source located in proximity to the enclosure housing the temperature sensitive switch, and

thermally conductive potting compound encapsulating both the enclosure having the temperature sensitive switch and

the heat source located in proximity to the enclosure wherein restricted air flow over the thermally conductive potting compound effects opening of the electrical contacts during heating of the thermally conductive potting compound by the heat source.

2. The self heating thermal protector of claim 1 wherein the heat source comprises a resistor adapted to generate heat upon being energized from a source of electricity.

3. The self heating thermal protector of claim 2 wherein the thermally conductive potting compound is electrically insulating.

4. The self heating thermal protector of claim 2 wherein the enclosure is thermally conducting.

5. The self heating thermal protector of claim 2 further comprising:

a mounting member of thermal insulating material coupled to the thermal protector to thermally isolate the thermal protector from a support member.

6. The self heating thermal protector of claim 5 wherein the mounting member has an axially aligned opening for receiving conductive wires connecting the heat source to a source of electricity.

7. The self heating thermal protector of claim 2 wherein the resistor is of a carbon composition.

8. The self heating thermal protector of claim 2 wherein the resistor is of a metal composition.

9. The self heating thermal protector of claim 1 wherein the temperature sensitive switch is a bimetallic switch.

10. The self heating thermal protector of claim 5 wherein the mounting member of thermal insulating material is coupled to the thermally conductive potting compound encapsulating both the enclosure and the heat source.