Surge protection module and related components and methods

Abstract

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. The surge protection module may also include 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. The carrier may include at least one conductor channel extending between ends of the carrier and configured to receive at least one electrical conductor. The carrier 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.

1 - 97 . (canceled) 
     
     
         98 . A surge protection module configured to limit power surge exposure to an electrical device, the surge protection module comprising:
 three terminals configured to be electrically coupled to an electrical device, the three terminals being configured to provide at least one of a series connection or a parallel connection to an electrical device to which the three terminals are electrically coupled;   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; and   a mechanical connection configured to mechanically couple the surge protection module to an electrical device to which the surge protection module is electrically coupled.   
     
     
         99 . The surge protection module of  claim 98 , wherein the three terminals are configured to be electrically coupled to at least one of a light emitting diode (LED) driver, an electrical ballast, or a terminal block. 
     
     
         100 . The surge protection module of  claim 98 , whereon the three electrical contacts are configured to be electrically coupled to an electrical device via at least one of terminal block pins, spring pins, spring clips, push-in connections, or self-piercing pins. 
     
     
         101 . The surge protection module of  claim 98 , wherein the at least one surge protection component comprises at least one 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. 
     
     
         102 . The surge protection module of  claim 98 , wherein the mechanical connection comprises 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. 
     
     
         103 . The surge protection module of  claim 98 , wherein the mechanical connection is configured to be coupled directly to at least one of an LED driver, a terminal block, or an electrical ballast. 
     
     
         104 . The surge protection module of  claim 98 , further comprising 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. 
     
     
         105 . A surge protection module configured to limit power surge exposure to an electrical device, the surge protection module comprising:
 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;   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.   
     
     
         106 . The surge protection module of  claim 105 , wherein the surge protection component comprises at least two electrical leads, and the surge protection module further comprises 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. 
     
     
         107 . The surge protection module of  claim 106 , wherein the at least two lugs are configured to be one or more of pressed onto the at least one electrical conductor and the one electrical lead or welded 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. 
     
     
         108 . The surge protection module of  claim 105 , wherein the at least two electrical conductors comprise three electrical conductor, and wherein the surge protection component is a first surge protection component, and the surge protection module further comprises a second surge protection component electrically coupled to at least two electrical conductors of the three electrical conductors, and is configured to limit power surge conducted to an electrical device to which the at least two electrical conductors are electrically coupled. 
     
     
         109 . The surge protection module of  claim 108 , wherein the first surge protection component is electrically coupled to a first one of the three electrical conductors and a second one of the three electrical conductors, and wherein the second surge protection component is electrically coupled to the first one of the three electrical conductors and a third one of the three electrical conductors. 
     
     
         110 . The surge protection module of  claim 109 , wherein each of the first and second surge protection components comprises at least two electrical leads, and the surge protection module further comprises at least three lugs, wherein a first one of the at least three lugs receives:
 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.   
     
     
         111 . The surge protection module of  claim 109 , wherein a second one of the three lugs receives 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, and
 wherein a third one of the three lugs receives 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.   
     
     
         112 . The surge protection module of  claim 105 , wherein the carrier defines a recess receiving at least a portion of the surge protection component, and wherein the carrier defines 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 is located between the at least one conductor channel and the second end of the carrier. 
     
     
         113 . The surge protection module of  claim 105 , wherein the carrier defines 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. 
     
     
         114 . The surge protection module of  claim 105 , wherein the second end of the carrier defines a mounting boss configured to facilitate mounting of the surge protection module to a support. 
     
     
         115 . The surge protection module of  claim 105 , wherein the carrier defines a notch between the mounting boss and a remainder of the carrier, the notch being configured to facilitate separation of the mounting boss from the remainder of the carrier. 
     
     
         116 . The surge protection module of  claim 105 , wherein the mounting boss defines a flange defining a mounting hole configured to receive a fastener for mounting the surge protection module to the support. 
     
     
         117 . The surge protection module of  claim 105 , wherein the flange comprises a first flange, and the mounting boss further comprises a second flange defining a mounting hole configured to receive a fastener for mounting the surge protection module to the support, wherein each of the first flange and the second flange defines a flange plane, and wherein the flange plane of first flange and the flange plane of the second flange are at an angle with respect to one another.