WO2012143871A1

WO2012143871A1 - Surge protection device

Info

Publication number: WO2012143871A1
Application number: PCT/IB2012/051953
Authority: WO
Inventors: Martin MERCIER
Original assignee: Koninklijke Philips Electronics N.V.
Priority date: 2011-04-20
Filing date: 2012-04-19
Publication date: 2012-10-26
Also published as: TW201315283A

Abstract

Methods and apparatus related to a surge protection device (10) that may optionally be implemented in a lighting fixture (100). The surge protection device (10) may be of a sufficiently small size and/or may securely retain surge protection structure within a casing (40) to provide protection of the surge protection structure from physical shock and/or vibration. The surge protection device (10) may optionally include one or more shrink wraps (40, 24A-C, 261A-264C) or other enclosing structure that may enclose all or portions of the surge protection structure and/or may enclose connections of the surge protection structure.

Description

Surge Protection Device

TECHNICAL FIELD

[0001] The present invention is directed generally to a surge protection device. More particularly, various inventive methods and apparatus disclosed herein relate to a surge protection device that may be implemented in a lighting fixture such as a LED-based lighting fixture.

BACKGROUND

[0002] Digital lighting technologies, i.e. illumination based on semiconductor light sources, such as light-emitting diodes (LEDs), offer a viable alternative to traditional fluorescent, HID, and incandescent lamps. Functional advantages and benefits of LEDs include high energy conversion and optical efficiency, durability, lower operating costs, and many others. Recent advances in LED technology have provided efficient and robust full-spectrum lighting sources that enable a variety of lighting effects in many applications. Some of the fixtures embodying these LED lighting sources feature a power supply and/or other electronics that may be sensitive to electrical stresses. For example, the power supply may be sensitive to power surges caused by lightning activity, unclean power, large electrical loads switching on/off, etc.

[0003] It has been proposed to implement some known surge protection devices in some LED-based lighting fixtures to protect the power supply. However, such surge protection devices suffer from one or more drawbacks. For example, some surge protection devices are integrated in a large stand alone box which must be installed within a lighting fixture. The large stand alone boxes may be difficult to physically place within a lighting fixture due to their size - especially within a small form lighting fixture. Also, the stand alone boxes themselves may represent an unwanted materials cost for the lighting fixture. Also, for example, some surge protection implementations directly connect varistors to a block connector externally of the block connector. Such implementations may lead to disconnection of the varistors when a high voltage event occurs and/or when physical shock and/or vibration is applied to all or portions of the lighting fixture. [0004] Thus, there is a need in the art to provide a surge protection device that may be implemented in a lighting fixture and that may optionally overcome one or more drawbacks associated with current surge protection devices.

SUMMARY

[0005] The present disclosure is directed to inventive methods and apparatus for a surge protection device. For example, a surge protection device may be provided that may be implemented in a lighting fixture and that may be of a sufficiently small size and/or that may securely retain surge protection structure within a casing to provide protection of the surge protection structure from physical shock and/or vibration. The surge protection device may optionally include one or more shrink wraps or other enclosing structure. The shrink wraps or other enclosing structure may enclose all or portions of the surge protection structure and/or may enclose connections of the surge protection structure.

[0006] Generally, in one aspect, an LED-based lighting unit is provided and includes a power source input, an LED driver electrically connected to the power source input, and at least one LED electrically connected to the LED driver. The lighting unit also includes a surge protector electrically interposed between the power source input and the LED driver. The surge protector has a live connection, a neutral connection, and a ground connection electrically connected between respective connections of the power source input and the LED driver. The surge protector further includes a first varistor in electrical communication with the live connection and the neutral connection, a second varistor in electrical communication with the live connection and the neutral connection, a third varistor in electrical communication with the live connection and the ground connection, and a fourth varistor in electrical

communication with the neutral connection and the ground connection. The surge protector has a shrink wrap that contacts and encloses all of the first varistor, the second varistor, the third varistor, and the fourth varistor.

[0007] In some embodiments a first interior shrink wrap is located interiorly of the shrink wrap and encloses a first interface between a first structure in electrical communication with the live connection and the first varistor, the second varistor, and the third varistor. The first structure may optionally be wiring that is cohesively formed with the live connection. In some versions of those embodiments a second interior shrink wrap is located interiorly of the shrink wrap and encloses a second interface between a second structure in electrical communication with the neutral connection and the first varistor, the second varistor, and the fourth varistor. The second structure may optionally be wiring that is cohesively formed with neutral connection. In some versions of those embodiments a third interior shrink wrap is located interiorly of the shrink wrap and encloses a third interface between a third structure in electrical communication with the ground connection and the third varistor and the fourth varistor.

[0008] In some embodiments a plurality of varistor shrink wraps are located interiorly of the shrink wrap. Each of the varistor shrink wraps encloses at least a portion of a single lead extending from one of the first varistor, the second varistor, the third varistor, and the fourth varistor.

[0009] Generally, in another aspect, An LED-based lighting unit is provided and includes a power source input, LED electronics electrically connected to the power source input, and at least one LED electrically connected to the LED driver. The lighting unit also includes a surge protector electrically interposed between the power source input and the LED electronics. The surge protector has a live connection, a neutral connection, and a ground connection electrically connected to respective connections of the power source input and the LED electronics. The surge protector further includes a first varistor in electrical communication with the live connection and the neutral connection, a second varistor in electrical

communication with the live connection and the ground connection, and a third varistor in electrical communication with the neutral connection and the ground connection . The surge protector also includes a casing enclosing all of the first varistor, the second varistor, the third varistor, and the fourth varistor. At least two of the first varistor, the second varistor, and the third varistor are generally stacked atop one another within the casing.

[0010] In some embodiments a fourth varistor is also provided and is in electrical communication with the live connection and the neutral connection. In some versions of those embodiments a first pair of the first varistor, the second varistor, the third varistor, and the fourth varistor is stacked atop one another within the casing and a second pair of the first varistor, the second varistor, the third varistor, and the fourth varistor are separately stacked atop one another within the casing. Optionally, the first pair consists of the first varistor and the second varistor.

[0011] In some embodiments the casing is a heat shrink enclosure.

[0012] In some embodiments live wiring coupled to the live connection is connected to the first varistor and the second varistor. In some versions of those embodiments an interior shrink wrap located interiorly of the casing encloses the connection between the live wiring and the first varistor and the second varistor.

[0013] Generally, in another aspect, an LED-based lighting unit is provided and includes a power source input, an LED driver electrically connected to the power source input, at least one LED electrically connected to the LED driver, and a transformer electrically interposed between the power source input and the LED driver. A surge protector is also provided and is electrically interposed between the power source input and the LED driver. The surge protector has a live connection, a neutral connection, and a ground connection electrically connected to respective connections of the power source input and the LED driver. The surge protector further includes a first varistor in electrical communication with the live connection and the neutral connection, a second varistor in electrical communication with the live connection and the ground connection, and a third varistor in electrical communication with the neutral connection and the ground connection. The surge protector also includes a shrink wrap contacting and enclosing all of the first varistor, the second varistor, and the third varistor.

[0014] In some embodiments at least two of the first varistor, the second varistor, and the third varistor are generally stacked atop one another within the shrink wrap.

[0015] In some embodiments a fourth varistor is also provided and is in electrical communication with the live connection and the neutral connection.

[0016] In some embodiments an interior shrink wrap is located interiorly of the shrink wrap and encloses at least a portion of a first varistor leg of the first varistor and a second varistor leg of the second varistor. [0017] As used herein for purposes of the present disclosure, the term "LED" should be understood to include any electroluminescent diode or other type of carrier injection/junction- based system that is capable of generating radiation in response to an electric signal. Thus, the term LED includes, but is not limited to, various semiconductor-based structures that emit light in response to current, light emitting polymers, organic light emitting diodes (OLEDs), electroluminescent strips, and the like. In particular, the term LED refers to light emitting diodes of all types (including semi-conductor and organic light emitting diodes) that may be configured to generate radiation in one or more of the infrared spectrum, ultraviolet spectrum, and various portions of the visible spectrum (generally including radiation wavelengths from approximately 400 nanometers to approximately 700 nanometers). Some examples of LEDs include, but are not limited to, various types of infrared LEDs, ultraviolet LEDs, red LEDs, blue LEDs, green LEDs, yellow LEDs, amber LEDs, orange LEDs, and white LEDs. It also should be appreciated that LEDs may be configured and/or controlled to generate radiation having various bandwidths (e.g., full widths at half maximum, or FWHM) for a given spectrum (e.g., narrow bandwidth, broad bandwidth), and a variety of dominant wavelengths within a given general color categorization.

[0018] The term "light source" should be understood to refer to any one or more of a variety of radiation sources, including, but not limited to, LED-based sources (including one or more LEDs as defined above), incandescent sources (e.g., filament lamps, halogen lamps), fluorescent sources, phosphorescent sources, high-intensity discharge sources (e.g., sodium vapor, mercury vapor, and metal halide lamps), lasers, other types of electroluminescent sources, pyro-luminescent sources (e.g., flames), candle-luminescent sources (e.g., gas mantles, carbon arc radiation sources), photo-luminescent sources (e.g., gaseous discharge sources), cathode luminescent sources using electronic satiation, galvano-luminescent sources, crystallo- luminescent sources, kine-luminescent sources, thermo-luminescent sources, triboluminescent sources, sonoluminescent sources, radioluminescent sources, and luminescent polymers.

[0019] The term "lighting fixture" is used herein to refer to an implementation or arrangement of one or more lighting units in a particular form factor, assembly, or package. The term "lighting unit" is used herein to refer to an apparatus including one or more light sources of same or different types. A given lighting unit may have any one of a variety of mounting arrangements for the light source(s), enclosure/housing arrangements and shapes, and/or electrical and mechanical connection configurations. Additionally, a given lighting unit optionally may be associated with (e.g., include, be coupled to and/or packaged together with) various other components (e.g., control circuitry) relating to the operation of the light source(s). An "LED-based lighting unit" refers to a lighting unit that includes one or more LED- based light sources as discussed above, alone or in combination with other non LED-based light sources.

[0020] It should be appreciated that all combinations of the foregoing concepts and additional concepts discussed in greater detail below (provided such concepts are not mutually inconsistent) are contemplated as being part of the inventive subject matter disclosed herein. In particular, all combinations of claimed subject matter appearing at the end of this disclosure are contemplated as being part of the inventive subject matter disclosed herein. It should also be appreciated that terminology explicitly employed herein that also may appear in any disclosure incorporated by reference should be accorded a meaning most consistent with the particular concepts disclosed herein.

BRIEF DESCRIPTION OF THE DRAWINGS:

[0021] In the drawings, like reference characters generally refer to the same parts throughout the different views. Also, the drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention.

[0022] FIG. 1 illustrates an embodiment of a surge protection device implemented within a LED-based lighting fixture.

[0023] FIG. 2 illustrates a schematic of the surge protection device of FIG. 1.

[0024] FIG. 3A illustrates a top view of the surge protection device of FIG. 1 with heat shrink of the surge protection device being shown in a pre-contraction state; only the outline of the outer heat shrink is illustrated in order to provide a view of internal portions of the surge protection device. [0025] FIG. 3B illustrates a bottom view of the surge protection device of FIG. 1 with heat shrink of the surge protection device being shown in a pre-contraction state; only the outline of the outer heat shrink is illustrated in order to provide a view of internal portions of the surge protection device.

[0026] FIG. 4 illustrates a perspective view of the surge protection device of FIG. 1 with heat shrink of the surge protection device being shown in a post-contraction state.

[0027] FIG. 5 illustrates a side view of the surge protection device of FIG. 1 with heat shrink of the surge protection device being shown in a post-contraction state.

DETAILED DESCRIPTION:

[0028] Some lighting fixtures, such as LED-based lighting fixtures, may include a power supply or other electronic device(s) that may be sensitive to power surges or other electrical stresses. It has been proposed to implement surge protection devices in some LED-based lighting fixtures to protect the power supply. However, such surge protection devices may suffer from one or more drawbacks. For example, some surge protection devices are integrated in a large stand alone box which may be costly and/or difficult to physically place within a lighting fixture due to their size and construct. Also, for example, some surge protection implementations directly connect varistors to a block connector which may lead to disconnection of the varistors when a high voltage event occurs and/or when physical shock is applied to all or portions of the lighting fixture.

[0029] Thus, there is a need in the art to provide a surge protection device that may be implemented in a lighting fixture and that may optionally overcome one or more drawbacks associated with current surge protection devices.

[0030] More generally, Applicants have recognized and appreciated that it would be beneficial to provide a surge protection device that may be of a sufficiently small size and/or that may securely retain surge protection structure within a casing to provide protection of the surge protection structure from physical shock and/or vibration. [0031] In view of the foregoing, various embodiments and implementations of the present invention are directed to a surge protection device.

[0032] Referring to FIG. 1, in one embodiment, the surge protection device 10 may be implemented in a LED-based lighting fixture 100. A power source input connection 71 of the lighting fixture 100 is coupled to a corresponding power source output connection 3 of a power source 2. A live connection wiring and a neutral connection wiring extend from power source input connection 71 to step-down transformer 72. The step-down transformer 72 steps down the voltage of power source 2 to a lower voltage and may optionally convert the voltage of the power source 2 from AC to DC. The step-down transformer 72 may be omitted in some embodiments of lighting fixture 100.

[0033] The step-down transformer 72 is electrically connected to an LED driver 74. The LED driver 74 is electrically coupled to live and neutral outputs from step-down transformer 72 and to ground wiring from power source 2. In alternative embodiments the ground wiring may optionally pass through step-down transformer 72. In some embodiments LED driver 74 and/or power source 2 may be configured such that LED driver 74 may accept voltage from power source 2 that has not first been stepped down by step-down transformer 72. The LED driver 74 has an electrical connection output 75A that is electrically connected to an electrical connection input 75B of LED board 76. LED board 76 may include one or more LEDs and optionally one or more optical components associated with the LED(s). In alternative embodiments LEDs and/or other light sources may be provided that are not mounted on a board.

[0034] The surge protection device 10 is electrically interposed in parallel between the step- down transformer 72 and the LED driver 74. The surge protection device 10 is coupled to live and neutral outputs from step-down transformer 72 and to ground wiring from power source 2 via respective of a live connection 20A, a neutral connection 20C, and a ground connection input 20B (FIGS. 2-4). In some embodiments of lighting fixtures that omit the step-down transformer 72, surge protection device 10 may be electrically interposed directly between the power source input connection 71 and the LED driver 74. Although a particular lighting fixture 100 is illustrated herein, one of ordinary skill in the art, having had the benefit of the instant disclosure, will recognize and appreciate that alternative lighting fixtures may incorporate an embodiment of the surge protection device described herein. For example, in some

embodiments the lighting fixture may not include any LEDs, may include an occupancy sensor, and/or may include a dimming module.

[0035] Referring to FIG. 2, a schematic of the surge protection device 10 of FIG. 1 is illustrated. The surge protection device 10 includes a first varistor 61, a second varistor 62, a third varistor 63, and a fourth varistor 64. The first varistor 61 is in electrical communication with the live connection 20A via lead 61A and the neutral connection 20C via lead 61C. The second varistor 62 is in electrical communication with the live connection 20A via lead 62A and the neutral connection 20C via lead 62C. In alternative embodiments only one of the first varistor 61 and the second varistor 62 may be provided. The third varistor 63 is in electrical communication with the live connection 20A via lead 63A and the ground connection 20B via lead 63B. The fourth varistor 64 is in electrical communication with the neutral connection 20C via lead 64C and the ground connection 20B via lead 64B. The depicted varistor

implementation may provide surge protection in accordance with IEEE C62.41 2002 Cat C high level exposure and/or IEC 1000-4-5 class 4 certification requirements. In some embodiments the varistors may be Metal Oxide Varistors (MOVs). In some versions of those embodiments the varistors may be V20E320P MOVS available from Littelfuse, Inc. of Chicago, IL.

[0036] Also depicted in phantom in FIG. 2 are interior shrink wraps 24A, 24B, and 24C. As described in detail herein, shrink wrap 24A, after heating, encloses and contacts the connection between varistors 61, 62, and 63 and the wiring associated with live connection 20A. Similarly, shrink wrap 24C, after heating, encloses and contacts the connection between varistors 61, 62, and 64 and the wiring associated with neutral connection 20C. Also, shrink wrap 24B, after heating, encloses and contacts the connections between varistors 63 and 64 and the wiring associated with ground connection 20B. In some embodiments the connection between varistors 61, 62, 63, 64 and wiring associated with respective connections 20A-C may include solder. In some embodiments the connection may additionally or alternatively include twisting, crimping, adhesive, and/or other connection methods and/or apparatus. The interior shrink wraps 24A-C strengthen, protect, and/or maintain the connections between respective varistors 61-64 and wiring associated with respective connections 20A-C. In alternative embodiments one or more of the interior shrink wraps 24A-C may optionally be omitted. In some of those embodiments, for example, the varistors 61-64 may be connected to respective connections 20A-C via connection structure that includes non-conductive exterior components to insulate connection structure thereof. In some of those embodiments, for example, the connections between varistors 61-64 and wiring (or other conductive structure) of respective connections 20A-C may be coated with a non-conductive coating and/or may be wrapped in non-conductive material.

[0037] Referring to FIGS. 3A and 3B, a top and bottom view, respectively, of the surge protection device 10 is illustrated. Interior shrink wraps 24A, 24B, and 24C and shrink wrap 40 are all shown in a pre-heated, pre-contraction state. Moreover, only the outline of shrink wrap 40 is illustrated in order to provide a view of internal portions of the surge protection device 10 such as, for example, the varistors 61-64 and interior shrink wraps 24A-C. The shrink wrap 40 includes a first end 41 and a second end 42 opposite the first end 41. The second end 42 is provided with an opening 43 therethrough. Opening 43 may be sized for a fastener to be received therethrough to enable the surge protection device 10 to be secured within a lighting fixture. For example, a screw, strap, or other fastener may be utilized to secure the surge protection device 10 within a lighting fixture. Opening 43 may be omitted in some

embodiments. In such embodiments, the surge protection device 10 may optionally be otherwise secured within a lighting fixture. For example, surge protection device 10 may optionally be secured within a lighting fixture using an adhesive and/or a harness.

[0038] The first end 41 of shrink wrap 40 may be open (at least prior to contraction of shrink wrap 40) to enable receipt of various components therein. Live connection 20A is intergrally formed with wiring that includes an insulator 22A therearound and extends into the shrink wrap 40. Similarly, neutral connection 20C is intergrally formed with wiring that includes an insulator 22C therearound and extends into the shrink wrap 40. Ground connection lug 20B includes an opening for securing the ground connection lug 20B utilizing a screw or other fastener. Ground connection lug 20B is attached to wiring that includes an insulator 22B therearound and extends into the shrink wrap 40. [0039] In some embodiments one or more of connections 20A-C may optionally be in electrical communication with non-wiring conductive structure between the connections 20A-C and the varistors 61-64. For example, in some embodiments a terminal block may be provided that enables attachment of one or more of the varistors 61-64 and one or more of the wiring extending from connections 20A-C. Also, for example, in some embodiments a quick attachment mechanism, wiring nut, and/or bridge connector may be interposed between one or more of varistors 61-64 and connections 20A-C. In some embodiments connections 20A-C may take on alternative configurations. For example, in some embodiments the connections 20A-C may include a quick connection structure, clamping structure, a plug in connector, etc.

[0040] The varistors 61-64 are provided interiorly of the shrink wrap 40. The lead 61A of the first varistor 61 is in electrical communication with the live connection 20A via exposed conductive structure of the wiring of live connection 20A under interior shrink wrap 24A. The lead 61A extends into interior shrink wrap 24A via an open end thereof. Lead 61A is also covered exteriorly of the interior shrink wrap 24A (and optionally partially covered interiorly of the shrink wrap 24A) by lead shrink wrap 261A. Lead 61C is similarly in electrical

communication with the neutral connection 20C via exposed conductive structure of the wiring of neutral connection 20C under interior shrink wrap 24C and is partially covered by lead shrink wrap 261C.

[0041] The other varistors 62, 63, and 64 are similarly attached to respective of connections 20A-C interiorly of respective interior shrink wrap 24A-C. Also, the varistors 62, 63, and 64 similarly have lead shrink wrap 262A, 262C, 263A, 263B, 264B, 264C, provided over portions of respective leads 62A, 62C, 63A, 63B, 64B, and 64C. The lead shrink wraps 261A, 261C, 262A, 262C, 263A, 263B, 264B, 264C provide electrical insulation of respective leads 62A, 62C, 63A, 63B, 64B, and 64C and prevent inadvertent contact and/or direct electrical communication of two or more leads. The lead shrink wraps 261A, 261C, 262A, 262C, 263A, 263B, 264B, 264C may also provide structural strength to respective leads. One or more of the lead shrink wraps 261A, 261C, 262A, 262C, 263A, 263B, 264B, 264C may optionally be omitted in some embodiments. In some of those embodiments, for example, one or more of the leads 61A, 61C, 62A, 62C, 63A, 63B, 64B, and/or 64C may be shortened and/or at least partially enclosed within a respective of interior shrink wraps 24A-C. In some of those embodiments, for example, one or more of the leads 61A, 61C, 62A, 62C, 63A, 63B, 64B, and/or 64C may optionally be partially coated with a non-conductive coating.

[0042] As illustrated in FIGS. 3A and 3B, first varistor 61 and second varistor 62 are stacked directly atop one another prior to contraction of shrink wrap 40. Also, third varistor 63 and fourth varistor 64 are stacked atop one another and slightly offset from one another prior to contraction of shrink wrap 40. It is noted that leads 63B and 64B are directly atop one another in FIGS. 3A and 3B. Although a particular arrangement of varistors 61-64 and associated leads thereof are depicted in FIGS. 3A and 3B, one of ordinary skill in the art, having had the benefit of the present disclosure, will recognize and appreciate that alternative arrangements may be utilized in alternative embodiments. For example, leads 61A, 61C, 62A, and 62C may be substantially straight in some embodiments. Also, for example, the location of varistors 63 and 64 may be swapped with the location of varistors 61 and 62. Also, for example, varistors 63 and 64 may be directly atop one another prior to contraction of shrink wrap 40.

[0043] Referring now to FIG. 4 and FIG. 5, a perspective view and side view, respectively, of the surge protection device 10 is depicted. The shrink wrap 40 is shown in a post-heating contracted state. The interior shrink wraps 24A-C and lead shrink wraps 261A, 261C, 262A, 262C, 263A, 263B, 264B, 264C are also in a post-heating contracted state. In some

embodiments the interior shrink wraps 24A-C and/or lead shrink wraps 261A, 261C, 262A, 262C, 263A, 263B, 264B, 264C may be contracted (partially or fully) prior to insertion within shrink wrap 40. In some embodiments the interior shrink wraps 24A-C and/or lead shrink wraps 261A, 261C, 262A, 262C, 263A, 263B, 264B, 264C may be contracted (partially or fully) after insertion within shrink wrap 40.

[0044] In the contracted state of the shrink wrap 40, two bulbous varistor retaining areas 44 and 46 are visible. Viewing varistor retaining area 46, it is recognized that third and fourth varistors 63, 64 therein shifted within the shrink wrap 40 upon contracting thereof so as to be directly atop one another. The first end 41 of the shrink wrap 40 is substantially sealed around insulators 22A-C. The shrink wrap 40 substantially seals and isolates varistors 61-64 therein and prevents access to the varistors 61-64 (and connections thereof) without destroying the shrink wrap 40. It is noted that the ground connection input lug 20B is omitted in FIGS. 4 and 5 and only the ground connection wire input 20B1 to which it was attached is shown.

[0045] In some embodiments the shrink wrap 40 may optionally be overlaid or replaced with a non-shrink wrap covering such as a polymeric moldable covering. In some embodiments the shrink wrap 40 or other casing may have a United Laboratories (UL) rating of at least 5VA. In some embodiments the shrink wrap 40 may include adhesive on the interior thereof to provide a good seal and/or improve adhesion. In some embodiments the shrink wrap 40 may be approximately 115 mm in length with a diameter of approximately 25 mm. In some embodiments the interior shrink wraps 24A-C may each be approximately 10 mm in length and have a diameter of approximately 5 mm. In some embodiments the lead shrink wraps 262A, 262C, 263A, 263B, 264B, 264C may each be approximately 15 mm in length and have a diameter of approximately 1 mm. In some embodiments the length of the surge protection device 10 (from second end 42 to ends of connectors 20A, 20C) may be approximately 270 mm. In some embodiments the wiring of the surge protection device 10 may be approximately 14 gauge wiring. In some embodiments one or more of the shrink wraps described herein may comprise nylon and/or polyolefin. In some embodiments one or more of the shrink wraps described herein may be cold shrink wrap or other wrap that contracts upon the occurrence of an event other than heating.

[0046] In some embodiments an LED or other indicator may be included with the surge protection device 10 and may be electrically coupled with one or more of the varistors 61, 62, 63, and 64 to provide information regarding the status thereof. For example, the LED may be visible and may be lit when one or more of the varistors 61, 62, 63, and 64 is damaged or not working, thereby notifying a user that the varistor(s) 61, 62, 63, 64 or the surge protection device 10 needs to be replaced. Additional circuitry may optionally be utilized to determine the status of the varistor(s) 61, 62, 63, and/or 64.

[0047] While several inventive embodiments have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and/or structures for performing the function and/or obtaining the results and/or one or more of the advantages described herein, and each of such variations and/or modifications is deemed to be within the scope of the inventive embodiments described herein. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the inventive teachings is/are used. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific inventive embodiments described herein. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, inventive embodiments may be practiced otherwise than as specifically described and claimed. Inventive embodiments of the present disclosure are directed to each individual feature, system, article, material, kit, and/or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and/or methods, if such features, systems, articles, materials, kits, and/or methods are not mutually inconsistent, is included within the inventive scope of the present disclosure.

[0048] All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and/or ordinary meanings of the defined terms.

[0049] The indefinite articles "a" and "an," as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean "at least one."

[0050] The phrase "and/or," as used herein in the specification and in the claims, should be understood to mean "either or both" of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with "and/or" should be construed in the same fashion, i.e., "one or more" of the elements so conjoined. Other elements may optionally be present other than the elements specifically identified by the "and/or" clause, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to "A and/or B", when used in conjunction with open-ended language such as "comprising" can refer, in one embodiment, to A only (optionally including elements other than B); in another embodiment, to B only (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); etc.

[0051] It should also be understood that, unless clearly indicated to the contrary, in any methods claimed herein that include more than one step or act, the order of the steps or acts of the method is not necessarily limited to the order in which the steps or acts of the method are recited.

[0052] Any reference numerals appearing in parentheses in the claims are merely for convenience and should be interpreted as limiting in any way.

[0053] In the claims, as well as in the specification above, all transitional phrases such as "comprising," "including," "carrying," "having," "containing," "involving," "holding," "composed of," and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases "consisting of" and "consisting essentially of" shall be closed or semi-closed transitional phrases, respectively, as set forth in the United States Patent Office Manual of Patent Examining Procedures, Section 2111.03.

What is claimed is:

Claims

CLAIMS:

1. A LED-based lighting unit, comprising:

a power source input;

an LED driver (74) electrically connected to said power source input; at least one LED electrically connected to said LED driver (74);

a surge protector (10) electrically interposed between said power source input and said LED driver (74); said surge protector (10) having a live connection (20A), a neutral connection (20C), and a ground connection (20B) electrically connected between respective connections of said power source input and said LED driver (74); said surge protector (10) further including a first varistor (61) in electrical communication with said live connection (20A) and said neutral connection (20C), a second varistor (62) in electrical communication with said live connection (20A) and said neutral connection (20C), a third varistor (63) in electrical communication with said live connection (20A) and said ground connection (20B), and a fourth varistor (64) in electrical communication with said neutral connection (20C) and said ground connection (20B); and

a shrink wrap (40) contacting and enclosing all of said first varistor (61), said second varistor (62), said third varistor (63), and said fourth varistor (64).

2. The lighting unit of claim 1, further comprising a first nterior shrink wrap (24A-C)

located interiorly of said shrink wrap (40) and enclosing a first interface between a first structure in electrical communication with said live connection (20A) and said first varistor (61), said second varistor (62), and said third varistor (63).

3. The lighting unit of claim 2, wherein said first structure is wiring cohesively formed with said live connection (20A).

4. The lighting unit of claim 2, further comprising a second nterior shrink wrap (24A-C) located interiorly of said shrink wrap (40) and enclosing a second interface between a second structure in electrical communication with said neutral connection (20C) and said first varistor (61), said second varistor (62), and said fourth varistor (64).

5. The lighting unit of claim 4, further comprising a third nterior shrink wrap (24A-C) located interiorly of said shrink wrap (40) and enclosing a third interface between a third structure in electrical communication with said ground connection (20B) and said third varistor (63) and said fourth varistor (64).

6. The lighting unit of claim 5, wherein said second structure is wiring cohesively formed with said neutral connection (20C).

7. The lighting unit of claim 4, further comprising a plurality of varistor shrink wraps (261A- 264C) located interiorly of said shrink wrap (40); each of said varistor shrink wraps (261A-264C) enclosing at least a portion of a single lead extending from one of said first varistor (61), said second varistor (62), said third varistor (63), and said fourth varistor (64).

8. An LED-based lighting unit, comprising: a power source input;

an LED electronics (74) electrically connected to said power source input;

at least one LED electrically connected to said LED electronics (74);

a surge protector (10) electrically interposed between said power source input and said LED electronics (74); said surge protector (10) having a live connection (20A), a neutral connection (20C), and a ground connection (20B) electrically connected to respective connections of said power source input and said LED electronics (74);

said surge protector (10) further including a first varistor (61) in electrical communication with said live connection (20A) and said neutral connection (20C), a second varistor (62) in electrical communication with said live connection (20A) and said ground connection (20B), and a third varistor (63) in electrical communication with said neutral connection (20C) and said ground connection (20B); and

a casing enclosing all of said first varistor (61), said second varistor (62), said third varistor (63), and said fourth varistor (64);

wherein at least two of said first varistor (61), said second varistor (62), and said third varistor (63) are generally stacked atop one another within said casing.

9. The lighting unit of claim 8, further comprising a fourth varistor (64) in electrical communication with said live connection (20A) and said neutral connection (20C).

10. The lighting unit of claim 9, wherein a first pair of said first varistor (61), said second varistor (62), said third varistor (63), and said fourth varistor (64) are stacked atop one another within said casing and a second pair of said first varistor (61), said second varistor (62), said third varistor (63), and said fourth varistor (64) are separately stacked atop one another within said casing.

11. The lighting unit of claim 10, wherein said first pair consists of said first varistor (61) and said second varistor (62).

12. The lighting unit of claim 11, wherein said casing is a heat shrink enclosure (40).

13. The lighting unit of claim 8, wherein live wiring coupled to said live connection (20A) is connected to said first varistor (61) and said second varistor (62).

14. The lighting unit of claim 13, further comprising an nterior shrink wrap (24A-C) located interiorly of said casing and enclosing the connection between said live wiring and said first varistor (61) and said second varistor (62).

15. An LED-based lighting unit, comprising: a power source input;

a transformer (72) electrically interposed between said power source input and said LED driver (74);

a surge protector (10) electrically interposed between said power source input and said LED driver (74); said surge protector (10) having a live connection (20A), a neutral connection (20C), and a ground connection (20B) electrically connected to respective connections of said power source input and said LED driver (74);

a shrink wrap (40) contacting and enclosing all of said first varistor (61), said second varistor (62), and said third varistor (63).

16. The lighting unit of claim 15, wherein at least two of said first varistor (61), said second varistor (62), and said third varistor (63) are generally stacked atop one another within said shrink wrap (40).

17. The lighting unit of claim 16, further comprising a fourth varistor (64) in electrical communication with said live connection (20A) and said neutral connection (20C).

18. The lighting unit of claim 15, further comprising an nterior shrink wrap (24A-C) located interiorly of said shrink wrap (40) and enclosing at least a portion of a first varistor (61) leg of said first varistor (61) and a second varistor (62) leg of said second varistor (62).