EP3061112B1 - Electrical fastener assembly with thermal fuse - Google Patents

Electrical fastener assembly with thermal fuse Download PDF

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Publication number
EP3061112B1
EP3061112B1 EP13785587.0A EP13785587A EP3061112B1 EP 3061112 B1 EP3061112 B1 EP 3061112B1 EP 13785587 A EP13785587 A EP 13785587A EP 3061112 B1 EP3061112 B1 EP 3061112B1
Authority
EP
European Patent Office
Prior art keywords
electrical
terminal
fastener assembly
washer
solder
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP13785587.0A
Other languages
German (de)
English (en)
French (fr)
Other versions
EP3061112A1 (en
Inventor
John Michael BRETT
John Oliver Collins
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
GE Aviation Systems Ltd
Original Assignee
GE Aviation Systems Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by GE Aviation Systems Ltd filed Critical GE Aviation Systems Ltd
Publication of EP3061112A1 publication Critical patent/EP3061112A1/en
Application granted granted Critical
Publication of EP3061112B1 publication Critical patent/EP3061112B1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/66—Structural association with built-in electrical component
    • H01R13/70—Structural association with built-in electrical component with built-in switch
    • H01R13/713—Structural association with built-in electrical component with built-in switch the switch being a safety switch
    • H01R13/7137—Structural association with built-in electrical component with built-in switch the switch being a safety switch with thermal interrupter
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H37/00—Thermally-actuated switches
    • H01H37/74—Switches in which only the opening movement or only the closing movement of a contact is effected by heating or cooling
    • H01H37/76—Contact member actuated by melting of fusible material, actuated due to burning of combustible material or due to explosion of explosive material
    • H01H37/761—Contact member actuated by melting of fusible material, actuated due to burning of combustible material or due to explosion of explosive material with a fusible element forming part of the switched circuit
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H85/00—Protective devices in which the current flows through a part of fusible material and this current is interrupted by displacement of the fusible material when this current becomes excessive
    • H01H85/02—Details
    • H01H85/0241—Structural association of a fuse and another component or apparatus
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/28—Clamped connections, spring connections
    • H01R4/30—Clamped connections, spring connections utilising a screw or nut clamping member

Definitions

  • Electrical power systems such as those found in an aircraft power distribution system, employ electrical bus bars for delivering power from electrical power sources to electrical loads.
  • high voltage components may be shunted across unintended electrical contacts, resulting in high current flow at the failure of the power distribution system.
  • the high current flow in turn, generates excessively high levels of heat, and may lead to possible electrical or thermal damage.
  • WO 2013/025175 A1 discloses an air heater fuse for diesel engines and an electrical fastener assembly according to the preamble of claim 1.
  • US 3385940 A discloses a thermal switch for preventing damage to a combustion engine.
  • the described embodiment of the present invention is directed to an electrical fastener assembly, which may be used, for example, in a power distribution system for an aircraft. While this description is primarily directed toward a power distribution system for an aircraft, it is also applicable to any environment using electrical fastener assemblies for electrically connecting portions of one electrical network to another
  • an aircraft 10 is shown having at least one gas turbine engine, shown as a left engine system 12 and a right engine system 14.
  • the power system may have fewer or additional engine systems.
  • the left and right engine systems 12, 14 may be substantially identical, and may further comprise at least one electric machine, such as a generator 18.
  • the aircraft is shown further comprising a plurality of power-consuming components, or electrical loads 20, for instance, an actuator load, flight critical loads, and non-flight critical loads.
  • Each of the electrical loads 20 are electrically coupled with at least one of the generators 18 via a power distribution system, for instance, bus bars 28.
  • the operating left and right engine systems 12, 14 provide mechanical energy which may be extracted via a spool, to provide a driving force for the generator 18.
  • the generator 18, in turn, provides the generated power to the bus bars 28, which delivers the power to the electrical loads 20 for load operations.
  • Additional power sources for providing power to the electrical loads 20, such as emergency power sources, ram air turbine systems, starter/generators, or batteries, are envisioned. It will be understood that while one embodiment of the invention is shown in an aircraft environment, the invention is not so limited and has general application to electrical power systems in non-aircraft applications, such as other mobile applications and non-mobile industrial, commercial, and residential applications.
  • FIG. 2 illustrates an exemplary electrical fastener assembly 24 comprising an electrically conductive DC power contactor 26 having at least one electrical terminal 32, at least a second electrical terminal, shown as an electrically conductive bus bar support 28, and solder washer assembly 30.
  • the terminal 32 of the DC contactor 26 may be electrically coupled with the bus bar support 28, via the solder washer assembly 30.
  • the solder washer assembly 30 is positioned between, and physically separating, the terminal 32 and the bus bar support 28.
  • the electrical terminal 32, solder washer assembly 30, and bus bar support 28 are shown having openings 36 for receiving a removable coupling via a mechanical fastener, such as a contactor fixing screw 34 or threaded stud.
  • solder washer assembly 30 is described, alternative geometric shapes are envisioned wherein, for example, the solder assembly 30 may comprise one or more blocks without an opening 36 and positioned aside from the contactor fixing screw 34, physically separating the terminal 32 from the bus bar support 28.
  • the solder washer assembly 30 is illustrated as a washer-type and may comprise an outer interface collar 38, shown shaped as a ring, an inner separator, such as an insulating ring 40, also shaped as a ring, and an electrically conductive and meltable element, such as solder ring 42 or disk, received in between the collar and ring 38, 40.
  • the interface collar 38, insulating ring 40, and solder ring 42 When assembled, the interface collar 38, insulating ring 40, and solder ring 42 also define an opening 36 which extends axially through the center of solder washer assembly 30. While an interface collar 38, insulating ring 40, and solder ring 42 are described, alternative geometric shapes are envisioned.
  • the interface collar 38 comprises an electrically conductive material, and is shown including a radial sidewall 44 and bottom plate 46 that extends radially inward toward the opening 36.
  • the bottom plate 46, sidewall 44, and insulating ring 40 may collectively define a reservoir 47 capable of containing at least a volume of liquid equal to the volume of the melted solder ring 42.
  • the solder ring 42 may be configured to abut at least a portion of the bottom plate 46 such that the solder 42 and plate 46 are in electrically coupled.
  • the insulating ring 40 may comprise a nonconductive material that, when assembled, lines the opening 36 of the solder washer assembly 30 to inhibit radial electrical contact between the interface collar 38 and/or the solder ring 42, and an object received into the opening 36 (for example, the contactor fixing screw 34). Additionally, as shown, the axial height of the solder ring 42 is greater than the axial height of either the interface collar 38 or insulating ring 40, and the axial height of the insulating ring 40 may be greater than the axial height of the interface collar 38.
  • solder is described, alternative electrically conductive and meltable elements are envisioned.
  • One example melting point for the solder ring 42 may be between 200 and 250 degrees Celsius; however various solder alloys and/or alloy combinations are envisioned such that the melting point of the meltable element may be defined with reference to desired thermal operating or failure conditions of the electrical fastener assembly 24.
  • FIG. 4 illustrates a cross section of the assembled electrical fastener assembly 24.
  • the assembly 24 may further comprise an electrically insulating sleeve 48, a compressive or biasing element, shown as a Belleville washer 50, and an optional electrically insulating washer 52.
  • the bus bar support 28 further comprises a fastener base, such as a screw base 54 or screw nut, configured to securely receive the fastener.
  • the screw base 54 may be fixedly attached to, or integrated with, the bus bar support 28, and provide insulating qualities to insulate a coupled screw 34 from the bus bar support 28.
  • the screw base 54 may comprise of an insulating material or the screw base 54 may be affixed to the bus bar support 28 via an insulating adhesive. Additional insulating methods and/or materials are envisioned.
  • the Belleville washer 50 is configured such that it may have a biasing force toward an expanded state when not under an opposite axial pressure or compressive force, and wherein the axial length of the washer 50 is longer in the expanded state than when under a compressed state.
  • the Belleville washer 50 may fluidly switch between the compressed and expanded states, depending on the pressure or force acting opposite to the biasing force. While a Belleville washer 50 is described, additional biasing elements are envisioned having a biasing force opposed which may act opposite to a retaining pressure or retaining force, and wherein the axial length of the element is longer when not exposed to a retaining force than the axial length of the element when exposed to a retaining force.
  • alternative biasing elements may include mechanical springs.
  • the contactor fixing screw 34 is shown at least partially received within the insulating sleeve 48 such that the at least a portion of the screw 34 is electrically insulated by the insulating sleeve 48. While the insulating sleeve 48 is illustrated only enveloping a portion of the contactor fixing screw 34, embodiments of the invention are envisioned wherein the whole screw 34 is received within the sleeve 48. Alternatively, the insulating sleeve 48 may be replaced by an insulating coating or resin. In this alternative example, wherein the whole contactor fixing screw 34 is insulated by, for example, a sleeve 48, coating, or resin, the other insulating elements 40, 52, 54 may optionally provide insulating properties.
  • the electrical fastener assembly 24 is assembled, as illustrated, by layering, from bottom to top, the bus bar support 28, the solder washer assembly 30, the terminal 32 of the DC contactor 26, the Belleville washer 50, and the insulating washer 52, such that the layering aligns the openings 36 of each washer and element 28, 30, 32, 50, 52.
  • the contactor fixing screw 34 (having the insulating sleeve 48) is axially received through the openings 36 and removably coupled with the screw base 54 such that the coupling provides sufficient mechanical constriction to axially force and/or couple the elements 28, 30, 32, 50, 52 together, and to compress the Belleville washer 50.
  • biasing force of the Belleville washer 50 biases the terminal 32 and bus bar support 28 toward each other, and is opposite to the structural retaining force of the solder washer assembly 30, and specifically the structural retaining force of the solder ring 42.
  • This biasing force is overcome by the contactor fixing screw 34 having been secured to the screw base 54, compressing the Belleville washer 50 against the terminal 32 and the solder ring 42.
  • the combination of the insulating sleeve 48, insulating washer 52, insulating ring 40, and screw base 54 are configured to electrically isolate the contactor fixing screw 34 from both the terminal 32 and the bus bar support 28.
  • the terminal 32 of the DC contactor 26 and the bus bar support 28 of the electrical fastener assembly 24 may only be electrically connected through the solder ring 42 and interface collar 38 of the solder washer assembly 30.
  • the point of failure may be in thermal contact, or thermally connected with, the electrical fastener assembly 24. Excessive heat from the point of failure may be thermally conducted to the solder washer assembly 30 via the DC contactor 26 (and terminal 32) and/or the bus bar support 28. If the heat conducted is sufficiently greater than the melting point of the solder, the solder ring 42 may melt. The melting of the solder ring 42, which was at least a portion of the electrical connection between the DC contactor 26 and the bus bar support 28, breaks the electrical connection between the terminal 32 of the contactor 26 and the support 28. The breaking of the electrical connection will disrupt the current flow of the electrical fault, failure, or short, and thus, render the system safe.
  • FIG. 5 illustrates an alternative configuration of the above described embodiment wherein the melting of the solder ring 142 of the electrical fastener assembly 124 has broken the electrical connection between the DC contactor 26 and bus bar support 28.
  • Parts having an alternative configuration will be identified with like numerals increased by 100, with it being understood that the description of the primary parts applies to the alternative configuration, unless otherwise noted.
  • the solder ring 142 has been melted due to thermal conduction from a failure condition, and the melted ring 142 has been contained in the reservoir 47.
  • the conductive melted solder ring 142 fluid has cascaded away from the terminal 32 due to gravity , and consequently, the bus bar support 28 is no longer in physical or electrical contact with the terminal 32 of the DC contactor 26.
  • the washer 150 is shown in an axially expanded state.
  • the biasing force of the Belleville washer 150 forces the terminal 32 away from the washer 150 until the terminal 32 is retained or supported by the insulating ring 40, which is now the tallest aspect of the solder washer assembly 30 once that the solder ring 150 has melted, thus maintaining physical separation between the terminal 32 and bus bar support 28.
  • FIG. 6 illustrates an alternative electrical fastener assembly 224 illustrative of the context of the invention,.
  • the illustrative example is similar to the first embodiment; therefore, like parts will be identified with like numerals increased by 200, with it being understood that the description of the like parts of the first embodiment applies to the second embodiment, unless otherwise noted.
  • a difference between the first embodiment and the illustrative example is that the meltable element does not provide an electrically conductive path, as in the first embodiment, but rather provides a retaining force for securing the electrically conductive path between the terminal 32 of the DC contactor 26 and the bus bar support 228, and wherein the melting of the meltable retainer releases the electrically conductive path between the terminal 32 and support 228.
  • the terminal 32 and bus bar support 228 may be in direct electrical contact.
  • the electrical fastener assembly 224 may include multiple biasing elements, such as Belleville washers 50, and the bus bar support 228 further comprises a solder assembly 230 having an axially extending insulating ring 240 and a screw base 254, at least a portion of which may be axially retained or affixed, relative to the bus bar support 228, by a meltable retainer, such as a solder ring 242, or a thermally-releasing glue or adhesive.
  • the meltable retainer does not need to have electrically conductive properties.
  • an (optional) insulating sleeve 48, insulating washer 52, and insulating ring 240 electrically isolate the contactor fixing screw 34 from both the DC contactor 26 and the bus bar support 228.
  • the electrical fastener assembly 224 is assembled, as illustrated, by layering, from bottom to top, the bus bar support 228, a Belleville washer 50, the terminal 32 of the DC contactor 26, a second Belleville washer 50, and the insulating washer 52, such that the layering aligns the openings 36 of each washer and element 228, 32, 50, 52.
  • the contactor fixing screw 34 (having the insulating sleeve 48) is axially received through the openings 36 and removably coupled with the screw base 254 such that the coupling provides sufficient mechanical constriction to axially force the elements 228, 32, 50, 52 together, and to compress the Belleville washer 50.
  • the biasing force of the Belleville washer 50 biases the terminal 32 and bus bar support 228 away from each other, and is opposed to, and overcome by, the retaining force of the contactor fixing screw 34 having been secured to the screw base 254, which is retained or anchored by the solder ring 242.
  • the terminal 32 of the DC contactor 26 and the bus bar support 228 are electrically coupled, allowing power to be transferred between the components 32, 228.
  • a failure condition may generate excessive heat, which, when sufficiently conducted along the electrically conductive path to the bus bar support 228, may melt the solder ring 242, releasing the affixed screw base 254.
  • the screw base 254 and terminal 32 of the DC contactor 26, which are no longer axially retained by the bus bar support 228 via the screw base 254, are forced upward due to the biasing force of the Belleville washers 50, both physically and electrically separating the terminal 32 from the bus bar support 228.
  • the breaking of the electrical connection will disrupt the current flow of the electrical fault, failure, or short, and thus, render the system safe during an overheating condition.
  • FIG. 7 illustrates an alternative configuration of the above described illustrative example wherein the melting of the solder ring 342 of the electrical fastener assembly 324 has broken the electrical connection between the DC contactor 26 and bus bar support 228.
  • the solder ring 342 has been melted due to thermal conduction from a failure condition, releasing the screw base 254.
  • each Belleville washers 50 have an axially expanded state, which has physically and electrically separated the terminal 32 of the DC contactor 26 from the bus bar support 228.
  • one embodiment of the invention contemplates a solder washer assembly 30 without an interface collar 38, wherein the melted solder ring 142 is allowed to otherwise flow away from the electrical fastener assembly 124, without constraint.
  • a solder washer assembly 30 as shown, or without an interface collar 38 may allow for side-mounting of the electrical fastener assembly 24, as any melted solder ring 142 would simply flow away from the contact junction.
  • more or fewer biasing elements such as the Belleville washers 50, may be used to allow for increased or decreased expansion while in an expanded state, compared to that expansion illustrated and described above.
  • the design and placement of the various components may be rearranged such that a number of different in-line configurations could be realized.
  • the embodiment disclosed herein provide an electrical fastener assembly.
  • One advantage that may be realized in the above embodiment is that the above described embodiment provides for meltable interconnection points between various high current components of an electrical power distribution system which will disrupt current flow in a fault, failure, short, or otherwise over-temperature condition. This purposeful disruption may prevent further damage to the electrical system or larger structure, such as an aircraft, by preventing or limiting smoke and fire, which may lead to one or more catastrophic failures.
  • Another advantage to the above described embodiment is that embodiment may be installed at any or all relay points in the electrical system wherein two terminals are coupled together. This may allow for a very robust system wherein excessive thermal conditions may be quickly located (and safely interrupted) due to the proximity of one or more electrical fastener assemblies to any given failure point.
  • the above described embodiment thus, provides for increased safety for an aircraft electrical power distribution system and hence improve the overall safety of the aircraft and air travel.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Fuses (AREA)
  • Connections By Means Of Piercing Elements, Nuts, Or Screws (AREA)
  • Details Of Connecting Devices For Male And Female Coupling (AREA)
  • Patch Boards (AREA)
EP13785587.0A 2013-10-25 2013-10-25 Electrical fastener assembly with thermal fuse Active EP3061112B1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/GB2013/052789 WO2015059435A1 (en) 2013-10-25 2013-10-25 Electrical fastener assembly with thermal fuse

Publications (2)

Publication Number Publication Date
EP3061112A1 EP3061112A1 (en) 2016-08-31
EP3061112B1 true EP3061112B1 (en) 2020-04-08

Family

ID=49515400

Family Applications (1)

Application Number Title Priority Date Filing Date
EP13785587.0A Active EP3061112B1 (en) 2013-10-25 2013-10-25 Electrical fastener assembly with thermal fuse

Country Status (5)

Country Link
EP (1) EP3061112B1 (ja)
JP (1) JP2016540343A (ja)
CN (1) CN105637609B (ja)
CA (1) CA2927552A1 (ja)
WO (1) WO2015059435A1 (ja)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3678265B1 (en) * 2019-01-03 2023-12-27 Hamilton Sundstrand Corporation High amperage component electrical mechanical installation

Families Citing this family (4)

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Publication number Priority date Publication date Assignee Title
JP6705396B2 (ja) * 2017-02-27 2020-06-03 株式会社オートネットワーク技術研究所 温度ヒューズ及び電気接続箱
CN111989834B (zh) * 2018-04-13 2023-07-04 Abb瑞士股份有限公司 用于将断路器连接到叠层式汇流条的传导层的组件和包括这样的组件的开关设备
CN110336146A (zh) * 2019-05-24 2019-10-15 珠海格力电器股份有限公司 压力敏感防松脱的连接端子及电器设备
EP3757379B1 (en) * 2019-06-24 2022-09-14 HIDRIA d.o.o. Electric air heating device comprising a tightening device with integrated fuse, engine and vehicle comprising the same

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JPS4631868Y1 (ja) * 1968-01-12 1971-11-04
JPS61126729A (ja) * 1984-11-21 1986-06-14 日産自動車株式会社 ヒユ−ジブルリンク
DE19741829A1 (de) * 1997-09-23 1999-03-25 Pudenz Wilhelm Gmbh Sicherungsanordnung zum Absichern von elektrischen Stromkreisen, insbesondere in Fahrzeugen
JP2001035332A (ja) * 1999-07-15 2001-02-09 Yazaki Corp 接続端子及び回路遮断装置
CN2427015Y (zh) * 2000-05-19 2001-04-18 许秀清 一种熔丝压紧装置
DE10113733B4 (de) * 2001-03-21 2010-12-16 Robert Bosch Gmbh Schraubkontaktvorrichtung insbesondere für Kraftfahrzeug-Starter
US7172462B1 (en) * 2005-08-15 2007-02-06 Yazaki North America, Inc. Fuse
US7192319B1 (en) * 2005-11-28 2007-03-20 Cooper Technologies Company Insulated cable termination assembly and method of fabrication
SI23826A (sl) * 2011-08-18 2013-02-28 Hidria AET Družba za proizvodnjo vžigalnih sistemov in elektronike d.o.o. Varovalka grelnika zraka diesel motorjev
CN102354641A (zh) * 2011-09-20 2012-02-15 中国北车股份有限公司大连电力牵引研发中心 熔断器

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3678265B1 (en) * 2019-01-03 2023-12-27 Hamilton Sundstrand Corporation High amperage component electrical mechanical installation

Also Published As

Publication number Publication date
EP3061112A1 (en) 2016-08-31
JP2016540343A (ja) 2016-12-22
CA2927552A1 (en) 2015-04-30
CN105637609A (zh) 2016-06-01
WO2015059435A1 (en) 2015-04-30
CN105637609B (zh) 2017-12-15

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