Enhanced Safety Device for an Electrical Appliance

FIG. 1 is a representational view of an electric hand-held hair dryer incorporating the present invention;

FIG. 2 is a view substantially identical to FIG. 1 illustrating an alternate embodiment of the current interruption mechanisms;

FIGS. 3 and 4 show two alternate circuit configurations for effecting current interruption;

FIG. 5 shows an additional circuit configuration for effecting current interruption using a module approach; and

FIG. 6 illustrates yet another circuit configuration for effecting current interruption.

Referring now to FIG. 1, there is shown a diagrammatic view of the device encompassing the preferred embodiment of the present invention. Shown is an electric hand-held hair dryer 10. It is to be understood that other types of hand-held electric devices can and may be used without departing from the spirit and scope of the present invention such as, for example, electric curling irons, hand tools, mixers, blenders the like. The hair dryer 10 is comprised of a barrel 12 and handle 14 housing a number of components therein. At one end of handle 14 is an electric cord 16 which terminates at plug 18 and is suitable for typical household use. An ON/OFF lever 20 is disposed at the base of handle 14 and functions to actuate an ON/OFF switch 32, which may be of any suitable type such as slide, rotary or the may be single pole, double pole or any other suitable or desired configuration. At one end of barrel 12 is a front grill 22 which permits the passage of heated air therethrough as described more fully below. A screen 24 is typically located at the rear end of barrel 12 and is utilized so that foreign matter, i.e., hair, cannot be sucked into barrel 12. A blower or fan is generally disposed adjacent to screen 24 and takes air in through screen 24 and passes air over heating element 28. Heating element 28, in turn, heats the air before the air exits through the front grill 22. A ground screen or plane 30 is used to electrically connect front grill 22 to screen 24. Further, screen/plane 30 provides a continuous electrical path throughout the interior of hair dryer 10 By grcund screen/plane 30 is meant any electrically conductive means to direct the current to a current interrupter device and, therefore, the ground plane 30 is not necessarily at earth "ground" potential. In this manner, should hair dryer 10 fall into water or should hair dryer 10 become wet to an unacceptable level, a ground path is provided between electrically conductive "live" areas in the hair dryer 10 and the ground screen. This electrical path is represented by dashed line 202, which is representative of an electrical short. The electrical connection between grill and screen 22 and 24 respectively via a ground screen/plane 30 may be accomplished in any number of suitable ways, such as crimp type fits, compression type fits, soldering or welding to mention a few. Any of the live areas can and may include exposed portions of hot or neutral wires 50,52 respectively, portions of heating element 28 or blower motor 26 as well as portions of ON/OFF switoh 32 having load contacts 34 therein.

It has been determined that the ground screen/plane 30 may be in a number of embodiments or configurations, although all are acceptable as long as a continuous electrically conductive ground path is provided. Accordingly, the ground screen/plane 30 may be in the form of a metal screen, or plating disposed on the interior portions of hair dryer 10, or on one side of heating insulators (not shown) which are typically disposed in barrel 12, and may be fabricated from aluminum or other type of metal foil. In this manner, a current return path is readily available between any of the electrically "live" components inside hair dryer 10 (as previously discussed) through water and hence to ground screen/plane 30. It has been found that this provision of an alternate return or ground path minimizes or eliminates the chance of current flow through a user, particularly when the dryer 10 merely has too much water present such as having water splashed on to it as it lies adjacent a sink or, in the case of a hand tool, it is laid down or adjacent to a puddle.

It has been found that the provision of a qround screen/plane 30 provides another distinot and significant advantage in that present hair dryer or appliance design need not be changed from two conductor to three conductor cord sets (not shown) since present designs are most cost sensitive. For this reason I have found that provision of an interrupt device 35, which is contained directly in handle 14, is appropriate. The interrupt device 35 is generally comprised of two portions, an electronic components portion 37 and a mechanical interlock portion 39. The function of the electronic component portion 37 is to detect and utilize electrical energy passing through or present on ground screen/plane 30. The mechanical interlock 39 including a ball 36, a coil 40 and a movable rod 42, is used to physically disconnect incoming power via electric cord 16 to the remainder of hair dryer 10.

The electronic components 37 include field effect transistor (FET) 48 having its gate terminal (G) connected to a terminal of biasing battery B.sub.a, with the remaining lead of the battery B.sub.a connected to ground screen/plane 30. Therefore, the biasing battery B.sub.a will render the FET 48 conductive in the event of any current leakage between ground screen/plane 30 and elsewhere in the device 10. Battery B.sub.a, a lithium or hearing-aid type (or other long shelf life battery) is utilized to provide an internal power supply which causes mechanical interlock 39 to be energized regardless of whether plug 18 has power applied thereto, should the shock hazard be present. Therefore, before plug 18 is energized, the interrupt device 35 was previously tripped and no chance of electrical short or the like can be applied to the user.

Source terminal (S) of FET 48 is connected to hot lead 50 and to one terminal of condenser C1. The remaining terminal of condenser Cl is connected to one terminal of coil 40 and to the cathode of diode Dl. The remaining terminal of diode D1 is connected to neutral lead 52. The drain terminal (D) of FET 48 is connected directly to the remaining terminal of coil 40. A person skilled in the art can appreciate that the substrate of FET 48 must be connected such that the battery B.sub.a provides a signal to the gate of FET 48 whenver the ground plane 30 is electrically connected to either lead 50 or 52 as indicated by 202.

Coil 40 is preferably a "latch" type solenoid coil having movable rod 42 disposed therein. In the preferred embodiment of the present invention, movable rod 42 is either an integral part of or connected to ball 36. Therefore, energization of coil 40 causes ball 36 to be urged downward. However, it is to be understood that rather than rod 42 pulling ball 36 downward, similar satisfactory results may be obtained by having rod 42 merely push ball 36 upward. A stop 38 is provided to maintain ball 36 in a stationary position with ball 36 being used to bias spring-type load contacts 34 against appropriate terminals of ON/OFF switch 32. In this manner, when rod 42 is urged downward, due to electromotive force present in coil 40, ball 36 is similarly urged downwards with the result that load contacts 34 will electrically and mechanically disconnect from the contacts lo of ON/OFF switch 32.

Therefore, when current exists between ground screen 30 and hot wire 50 or neutral wire 52 as indicated by 202, current will be permitted to flow through the drain source path of FET 48 with the result that coil 40 will be energized. Accordingly, in the preferred embodiment of the present invention, a ground fault in the traditional sense is not required in order to "trip" the present invention and prevent user injury. Rather, a current between ground screen/plane 30 and any electrically live component, such as is present during a shock hazard, will be detected and will result in operation of interrupt device 35. This shock hazard may be the result of immersion, high humidity, steel wool used during cleaning, or as a result of damage. Such damage may occur when, for example, a user tries to clean a toaster by using a knife and causes a short therein.

If a shock hazard exists, the "user" is not in the electrical return path and hence is not subject to shock before the interrupt device 35 will trip. Accordingly, FET 48 and coil 42 are "biased" to ensure rapid response time. As can be ascertained from FIG. 1, a signal applied to the gate of FET 48 causes the FET 48 to conduct along tis drain-source path, thereby allowing condenser C1 to energize the coil 40. Consequently, when dryer 10 is eventually plugged in, there will be no chance of a shock hazard. A signficant advantage of a battery B.sub.a in this type of circuit operation is that even if plug 18 is not plugged into a receptacle, the battery supplies the power to enable the interrupt device 35 to function.

When tripped, rod 42 will, as previously mentioned, be urged downward. Further, in the preferred embodiment of the present invention, rod 42 is of an appropriate length such that after tripping it cannot and will not emerge through a reset aperture/keyway 44 present in the underside of handle 14. In the preferred embodiment of the present invention, return of rod 42 to the normal position which enables load contacts 34 to be energized, cannot be accomplished except by use of a reset key 46. Accordingly, reset key 46 must be passed through reset aperture/keyway 44 in order to properly reorient rod 42. Preferably, keyway 44 and hence reset key 46 are of a cross-type configuration. In this manner, reset may only be accomplished by an individual having the correct reset key. Accordingly, it is preferred that only qualified service individuals be given a reset key 46, thereby adding an extra level of safety. Should interrupt device 35 trip, the user would be required to bring the dryer 10 to any service center having qualified technicians who will then examine hair dryer 10 to ensure that its interior is dry, and that there are no damaged components, frayed wires or extraneous matter or the like, befor the resetting of interrupt device 35.

Additionally, in the preferred embodiment of the present invention, it is preferred that load contacts 34 and ON/OFF switch 32 be at least moisture proof and preferably waterproof. Therefore, should a hair dryer 10 be immersed in water, water current flow into the switch 32 which might permit a flow of current through ON/OF switch 32 to load contacts 34 at any time. Alternately, in the present invention, a reset aperture/keyway may not be utilized with the result that a trained service technician must open up the hair dryer 10 to ensure that they physically inspect the interior thereof and to effectuate reset of mechanical interlock 39.

Further, in the preferred embodiment of the present invention, condenser C1 is an electret which is well known and understood by one skilled in the art. An electret is highly desirable since it retains a charge, absent outside electrical stimulation. In this regard, it is not necessary for condenser C1 to build a charge prior to energization of coil 40. Since the electret retains its own charge, quick energization of coil 40 is inherent. Hence, this cuts down significantly on the interrupt time of mechanical interlock 39. This is especially important since electromagnets, such as coil 40, typically have a relatively "long" energization time when viewed in terms of the time required for an electrical hazard to harm an individual. For this reason, a fast-acting FET is preferred. Additionally, should it be desired, a transient filter (not shown) may be inserted in series circuit relationship between the source terminal of FET 48 and the electrical connection to the ground screen/plane 30 should nuisance trips be a concern or a problem.

Referring now to FIG. 2, a view substantially similar to FIG. 1 is shown. Accordingly, only the differences between FIGS. 1 and 2 will be explained herein. Shown is trigger mechanism 54 which has a number of electrical appliances connected thereto. Ground screen/plane 30 is connected via terminal A to trigger mechanism 54 while similarly terminals D and E of trigger mechanism 54 are respectively connected to coil 40. Terminal B is connected to the hot lead 50 while terminal C is connected to neutral lead 52, although, for the reasons previously mentioned, terminals B and C may be reversed. Accordingly, trigger mechanism 54 may encompass a variety of different comppnents or alternate embodiments.

Referring now to FIGS. 3 and 4, schematic representations of alternate embodiments of the present invention may be viewed. More particularly, trigger mechanism 54, as shown in FIG. 3, would supplant electronic components 37 disposed in FIG. 1 while similarly trigger mechanism 54 of FIG. 4 would supplant electronic components 37 of FIG. 1. Referring to FIG. 3, terminal A connected to ground screen/plane 30 is connected to one terminal of condenser C2. The remaining terminal of condenser C2 is connected to the gate terminal (G) of FET 56. The drain terminal (D) of FET 56 is connected to terminal D or one terminal of coil 40. Terminal B, connected to hot lead 50, is connected to the source terminal (S) FET 56 and to one terminal of condenser C3. The remaining terminal of condenser C3 is connected to the remaining lead of terminal E and hence, coil 42 and also to the cathode of diode D2. The anode of diode D2 is connected to terminal C, neutral lead 52. It is preferred that condensers C2 and C3 be electrets, thereby providing a certain amount of bias to FET 56 and coil 42 for the purpose of decreasing the "trip time" of mechanical interlock 39. Additionally, by connecting to neutral lead 52, one half-cycle of delay time is eliminated since alternating current is utilized and hence lead 52 is at a high potential when lead 50 is at a low potential.

FIG. 4 functions in a manner similar to that of FIG. 3 but is, of course, somewhat simpler. There, terminal A is connected to one terminal of condenser C4 while the remaining terminal of condenser C4 is connected to the gate terminal (G) of FET 58. The drain terminal (D) of FET 58 is connected to the D terminal while the source terminal of FET 58 is connected to terminal B and to one terminal of condenser C5. The remaining terminal of condenser C5 is connected to terminal E. As before, it is preferred that condensers C4 and C5 be electrets, thereby shortening the interrupt time.

Referring now to FIG. 5, another alternate embodiment is shown. Accordingly, only the differences between FIGS. 1 and 5 will be explained herein. Shown is safety cartridge 110 which is preferably a "module" containing the components indicated therein, and which is disposable within the hair dryer 10. By safety cartridge or module is meant the enclosure of the electrical and/or mechanical components or interlock of the present invention into a package. Therefore, the detection and current interruption portions may be packaged in a single enclosure (or separately) either in a case, or encapsulated, or any other similar means for manufacturing purposes. It is preferred, although not absolutely necessary, that safety cartridge 110 be sealed so as to be waterproofed, such as by hermetic sealing or encapsulation or the like. Therefore, the cartridge 110 may be an off-the-shelf item that is readily distributed to manufacturers of hand-held electrical devices. Disposed within safety cartridge 110 is current interruption circuitry, that would make the module perform the same function as electronic and mechanical components 37, 39 previously described in FIG. 1.

Readily apparent when viewing FIG. 5 is that due to the preferred encapsulation of the cartridge 110 and the position of disconnect 122 prior to the contacts of the on/off switch 20, all components in the dryer 10 are automatically and electrically isolated from the line cord 16.

Here, sensing electret 114 has one terminal connected to ground screen/plane 30 and the remaining terminal connected to the base terminal of PNP transistor 112. It is understood that an NPN, a FET or any other type of electronic triggering or gating device may be utilized without departing from the spirit and scope of the present invention. The collector,of transistor 112 is connected to one terminal of the coil 119 of /magnetic trip switch 118. The emitter terminal of PNP transistor 112 is connected to one terminal of tripping electret 116 with the remaining terminal of tripping electret 116 connected to the remaining terminal of the coil 119 comprising trip switch 118. The emitter of PNP transistor 112 is also connected to hot lead 50 lo inside the hand-held device itself. An actuating bar 120 disconnects contact arms 122 from contacts 124 during energization. of the device during an electrical hazard. A reset aperature 126 is axially disposed from actuating bar 120 and is an optional item which may be used to reset the coil 119 when tripped similar to the reset aperature 44 of FIG. 1. Aperture 126 is preferably a seal and is adjacent sealing plug 130 disposed in the housing of the hand held electrical device 10. Therefore, reset of the cartridge 110 tripping may be accomplished by removal of plug 130 and the insertion of a reset tool as described above. Accordingly, the seal of aperture 126 may be replaceable or a "self sealing" type of seal.

A plurality of termination points 128 are utilized to interconnect the safety cartridge 110 with the different eleotrioal oontaot points inside the hair dryer 10. It is to be understood, however, that these termination points 128 should be internal to the safety cartridge 110, thereby minimizing the chances of electrical short therebetween should an electrically hazardous condition present itself. Accordingly, each termination point 128 is hermetically sealed in the form of plugs which can be molded into place similar to reset aperatures 126 and 132. Similarly, seal 132 hermetically seals the joint between the cartridge 110 and cord 16. However, any arrangement which prohibits the introduction of extraneous matter into the electrical connection is acceptable, such as waterproof type connectors which are readily available and known to one skilled in the art. Similarly, with respect to electric cord 16 and plug 18, the entire safety cartridge 110 is preferably sold with the cord and plug 16, 18 attached thereto or electrical connection may be thereafter made by the manufacturer or assembler of the hair dryer 10. The operation of the cartridge 110 can be ascertained from FIG. 5. Moisture designated by 202, which is present during a hazardous condition, completes a circuit between the base-emitter path of the PNP transistor 112 and the sensing electret 114. The resulting signal sent to the base of the PNP transistor 112 causes the transistor 112 to conduct, which allows tripping electret 116 to energize the coil 119 and thereby disconnect the dryer 10 from the line cord 16.

Referring to FIG. 6 there is shown still another alternate embodiment of the present invention. It is to be understood that the overall operation of the safety cartridge 110 is substantially similar to previously described embodiments and in this regard a description thereof will not be reiterated. Shown is the use of a full-wave bridge rectifier 210 having its inputs connected across the contact arms 122. The positive output terminal of full wave bridge rectifier 210 is connected to the emitter of switching transistor 212, one terminal of tripping electret 216 and to hot lead 50. The negative output terminal of full-wave bridge 210 is connected to one terminal of the coil 219 of magnetic trip switch 218 and to the remaining terminal of tripping electret 216. The remaining terminal of coil 218 is connected to the collector of transistor 212. The base of transistor 212 is connected to one terminal of sensing electret 214. The remaining terminal of sensing electret 214 is connected to ground screen/plane 30. It is to be remembered that although a bipolar NPN transistor is shown, other types of transistors such as PNP transistors may be utilized while similarly, other types of rectifier circuits can be utilized.

Accordingly, during operation the device full-wave bridge rectifier 210 maintains electret 216 in a charged state thereby in effect, "prebiasing" coil 218. Accordingly, during a ground fault condition, transistor 212 is caused to conduct with the result that coil 218 would be energized and contact alarms 122 will be urged by actuating bar 120 and being disconnected from contacts 124. An important feature of this prebiasing of coil 218, is to substantially diminish the delay time from an actual ground fault condition and energization of coil 218 and subsequent disconnection of contact arms 122. It is to be remembered that electrets 214 and 216 may have substituted therefore a standard capacitors without departing from the spirit and scope of the present invention.

It is to be understood that although only several variations of electronic components are shown, other variations may be utilized without departing from the spirit and scope of the present invention. For example, a standard ground fault interrupter circuit such as LM1851 Ground Fault Interrupter produced by National Semiconductor Corporation which are readily available and known to one skilled in the art may be utilized. Additionally, other types of mechanical interlocks may be utilized without departing from the spirit and scope of the present invention. Further, current interruption may be accomplished by replacing the electronic components and/or mechanical interrupt with other suitable current interrupting devices, such as, for example, high current transistors, latching relays, opto-isolators, and the like.

Having thus described the present invention in detail, it is to be understood that the foregoing description is not intended to limit the spirit and scope thereof. What is desired to be protected by Letters Patent is set forth in the appended claims.