Vehicle electrical protection device and system employing same

• US 7,233,474 B2
• Filed: 11/24/2004
• Issued: 06/19/2007
• Est. Priority Date: 11/26/2003
• Status: Active Grant

• Current Assignee: Littlefuse Incorporated
• Original Assignee: Littelfuse Incorporated
• Inventors: Brown, William P., Harris, Edwin James, Ribordy, Jeffrey John
• Primary Examiner(s): Jackson; Stephen W.
• Assistant Examiner(s): Benenson; Boris
• Application Number:
  US10/996,638
• Publication Number:
  US 20050190519A1
• Time in Patent Office: 937 Days
• Field of Search: 361/104, 307/10.1
• US Class Current: 361/104
• CPC Class Codes: B60R 16/023 for transmission of signals between vehicle parts or subsystems
• CPC Class Codes: H01F 17/02 without magnetic core
• CPC Class Codes: H01F 2005/006 with conical spiral form
• CPC Class Codes: H01F 27/2847 Sheets; Strips H01F27/2866 takes precedence
• CPC Class Codes: H01F 27/402 Association of measuring or protective means
• CPC Class Codes: H01F 37/00 Fixed inductances not covered by group H01F17/00
• CPC Class Codes: H01H 2085/025 Structural association with a binding post of a storage battery
• CPC Class Codes: H01H 2085/266 with replacement of a fuse which is part of a printed circuit
• CPC Class Codes: H01H 2085/466 with remote controlled forced fusing
• CPC Class Codes: H01H 85/044 General constructions or structure of low voltage fuses, i.e. below 1000 V, or of fuses where the applicable voltage is not specified H01H85/046 - H01H85/048 take precedence
• CPC Class Codes: H02J 7/00304 Overcurrent protection
• CPC Class Codes: H02J 7/00308 Overvoltage protection

Abstract

An electrical protection device is provided. The device can be removably attached to or mounted inside of a power source, such as a vehicle, e.g., automobile, battery and can employ a replaceable fuse element. The device includes an overcurrent protection element, such as a fuse element, and provides any one or more of the following types of electrical protection: (i) overcurrent protection; (ii) accident or catastrophic event power cutout protection; and (iii) load dump protection. The system is configurable to protect certain vehicle electrical components from an overcurrent and allow others to operate independent of the overcurrent protection. Systems and methods employing the protection device are also illustrated and discussed.

Claims

1. An electrical protection device comprising:

a first contact electrically coupled to a first terminal of a vehicle battery and electrically coupled to a first load line;

a second contact electrically coupled to a second terminal of the vehicle battery and electrically coupled a second load line, the second contact having a different electrical polarity than the first contact;

a third contact electrically coupled to a third load line;

a fuse element electrically coupled to the first contact and the third contact, wherein the fuse element provides overcurrent protection to the third load line but not the first load line; and

a switching apparatus electrically coupled to the second contact and the third contact, wherein if the switching apparatus is closed the fuse element opens a connection between the first contact and the third contact.

2. The electrical protection device of claim 1, wherein the first contact comprises an electrically positive contact and the second contact comprises an electrically negative contact.

3. The electrical protection device of claim 1, wherein the first contact comprises an electrically negative contact and the second contact comprises an electrically positive contact.

4. The electrical protection device of claim 1, wherein the switching apparatus is electrically coupled to at least one of the second contact and the third contact via an inductor.

5. The electrical protection device of claim 4, wherein the inductor and the fuse element are formed from a single metal piece.

6. The electrical protection device of claim 4, wherein the inductor is formed as a helical metal piece.

7. The electrical protection device of claim 6, wherein the inductor and the fuse element are formed from a single metal piece.

8. The electrical protection device of claim 1, wherein the first contact and the second contact have a first shape and the third contact has a second different shape.

9. The electrical protection device of claim 1, wherein the switching apparatus has a first side and a second side and the first side is mechanically biased toward the second side.

10. The electrical protection device of claim 1, which is arranged to be mounted inside of the vehicle battery.

11. The electrical protection device of claim 10, including a viewing window over the fuse element.

12. The electrical protection device of claim 11, wherein the fuse element is coated with a material that vaporizes with heat and collects on the viewing window.

13. The electrical protection device of claim 1, which is arranged to be mounted outside of the vehicle battery.

14. The electrical protection device of claim 1, wherein the switching apparatus includes a device selected from the group consisting of a silicon controlled rectifier (“

SCR”

) a solenoid, a relay and a metal oxide semiconductor field effect transistor (“

MOSFET”

).

15. The electrical protection device of claim 1, which includes a load dump protection device connected electrically to the second contact and the third contact.

16. The electrical protection device of claim 15, wherein the load dump protection device is selected from the group consisting of:

a transient voltage suppression (“

TVS”

) diode, a silicon avalanche diode (“

SAD”

), a multilayer varistor (“

MLV”

) and a metal oxide varistor (“

MOV”

).

17. The electrical protection device of claim 1, wherein the switching apparatus is activated upon receiving a signal from a signal source.

18. The electrical protection device of claim 1, wherein the fuse element is rated between 20 amps and 2,000 amps.

19. The electrical protection device of claim 1, wherein the fuse element is connected electrically to a load dump protection device and the switching apparatus.

20. The electrical protection device of claim 1, wherein the fuse element is connected electrically to the first contact and the switching apparatus.

21. The electrical protection device of claim 1, wherein the fuse element is connected electrically to the first contact and the switching apparatus via an inductor.

22. A power source comprising:

a body;

positive and negative terminals extending from the body; and

a protection device connected electrically to the positive and negative terminals, the device including (i) a load contact, (ii) a fuse element located between the load contact and one of the positive and negative terminals, (iii) a switching apparatus positioned to cause the fuse element to open upon receiving a signal from a signal source, and (iv) an inductor located between the fuse element and the switching apparatus to reduce a rate of current rise applied to the switching apparatus.

23. The power source of claim 22, wherein the inductor and the fuse element are formed from a single metal piece.

24. The power source of claim 22, wherein the inductor is formed as a helical metal piece.

25. The power source of claim 24, wherein the inductor and the fuse element are formed from a single metal piece.

26. The electrical protection device of claim 22, wherein the switching apparatus has a first side and a second side and the first side is mechanically biased toward the second side.

27. The power source of claim 22, which includes a load dump device placed in parallel with the switching apparatus.

28. The power source of claim 22, wherein the positive and negative terminals are configured to connect to a bypass load line, wherein the bypass load line operates independent of the fuse element.

29. The power source of claim 22, wherein the positive and negative terminals are first such terminals and which includes second positive and negative terminals operating independent of the fuse element.

30. The power source of claim 22, wherein the protection device is located at least in part inside the body.

31. The power source of claim 30, wherein the fuse element is replaceable.

32. The power source of claim 30, including a viewing window over the fuse element.

33. The power source of claim 32, wherein the fuse element is coated with a material that vaporizes with heat and collects on the viewing window.

34. The power source of claim 22, wherein the protection device is located outside the body.

35. The power source of claim 34, wherein the protection device is replaceable.

36. The power source of claim 34, wherein the fuse element is replaceable.

37. An automobile electrical system comprising:

a power supply;

a protection device connected electrically to the power supply, the device including a fuse element and a switching apparatus operable to open the element upon receiving a signal from a signal source;

at least one first load component connected electrically to the power supply and the device and subject to surge protection provided by the fuse element;

at least one second load component coupled electrically to the power supply and operating independent of the fuse element of the device;

an inductor connected to reduce a rate of current rise applied to the switching apparatus.

38. The system of claim 37, wherein the fuse is a positive temperature coefficient overcurrent device.

39. The power source of claim 38, wherein the inductor and the fuse element are formed from a single metal piece.

40. The power source of claim 38, wherein the inductor is formed as a helical metal piece.

41. The electrical protection device of claim 37, wherein the switching apparatus has a first side and a second side and the first side is mechanically biased toward the second side.

42. The system of claim 37, further comprising a load dump apparatus operable to discharge a voltage from the first load component.

43. The system of claim 37, wherein the signal source is selected from the group consisting of:

an airbag, an airbag sensor, an airbag controller, a heat sensor, a motion sensor, an impact sensor, a fuel sensor, a pressure sensor, a liquid sensor and any combination thereof.

44. The system of claim 37, wherein the first load component comprises a battery cable.

45. The system of claim 37, wherein the first load component is selected from the group consisting of:

a fuel injector, an engine fan, a starter, a heater, a compressor and any combination thereof.

46. The system of claim 37, wherein the second load component is selected from the group consisting of a power locking device, a flashing light, a power window motor, a communications device and any combination thereof.

47. A vehicle electrical supply protection method comprising:

receiving a signal indicative of an emergency event;

closing a switch in response to receiving the signal, wherein closing the switch comprises mechanically biasing the switch;

opening a fuse in response to closing the switch;

stopping the supply of electrical current to a first load component in response to opening the fuse; and

continuing to supply electrical current to a second load component after opening the fuse.

48. The method of claim 47, wherein closing the switch comprises permanently closing the switch.

49. The method of claim 47, wherein opening the fuse comprises permanently opening the fuse.

50. The method of claim 47, further comprising providing load dump protection to discharge energy stored in the first load component and the second load component.

51. The method of claim 47, wherein opening the fuse comprises increasing resistance in a positive temperature coefficient overcurrent device.