Safety devices for electrical circuits and systems

[0002] This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional application Ser. No. 60/070,996 filed Nov. 21, 1997 for SAFETY DEVICES FOR ELECTRICAL CIRCUITS AND SYSTEMS by JAMES L. KITCHENS, which application is also hereby incorporated by reference.

[0003] This invention relates to systems and devices for preventing fires, and for minimizing fire danger, from overheating and overloading conditions that might arise in or affect electrical wiring in residential and commercial installations.

[0004] Many residential and commercial fires result from causes that are generally, and sometimes inaccurately, described as faulty electrical wiring, or electrical circuit failures. One common cause of such failures is overheating of or by an extension cord because of circuit overload or other conditions, separately or in combination. For example, when a temperature is reached within or outside the extension cord at which the synthetic or rubber compound insulation melts or decomposes, a heated interior wire may become exposed and come in contact with and ignite flammable material. Also, insulation failures can also allow high amperage arcing to occur between interior wires. The result is a type of fire which is known to cause loss of a number of lives and much residential and commercial structure damage each year. Electrical circuits and interconnecting cords and cables are designed to function with an expected degree of resistive heating, and to accommodate temperature buildup as heat is conducted along the circuits from one point to another. A long extension cord, for example, transfers heat along its conductive wiring from the outlet or source from which it derives current, and from an appliance or device at which electrical power is consumed. Combinations of operating factors thus can result in overheating of an extension cord, for example, and temperatures can reach a level at which decomposition begins and incipient danger exists.

[0005] Electrical codes require protection against electrical overload conditions in permanent installations by compelling inclusion of fuses or circuit breakers in the wiring system between the main power supply and the points of usage in a residential or commercial building. There are, nonetheless, a number of types of potential wiring-originated fires that are not precluded by fuse or circuit breaker protection, including those mentioned above.

[0006] Although product manufacturers and electrical equipment code requirements provide instructions as to preferred and limiting conditions for use of components such as receptacles, extension cords, and circuit breakers, there can be no guarantee that users will comply with these stated instructions. Extension cords, for example, are nominally intended to carry from 1200-1600 watts, but users may in practice drastically overload an extension cord in a number of ways. For example, there is a tendency to use extension cords and circuits beyond their rated capacities, as by attaching a cord to an appliance of higher power than is nominally permitted. At the receptacles and outlets, there is a tendency to attach multiple devices, and if too many are coupled in this, may exceed the load carrying capacity of the receptacle even though individual appliances and devices may not demand much power individually.

[0007] Special problems can arise from environmental and building conditions. For example, when exterior temperatures in a region approach or exceed 100° F., the temperature in attics, under-roof crawl spaces, and inside walls can approach considerably higher levels. In these uninsulated interior spaces the temperature can be 40-60° F. higher than the outside air temperature from the sun heating the exterior surfaces, which transmit radiant energy to heat the interior spaces. Extensions and other wiring are often placed in such spaces. The insulation of such wiring can approach threshold levels merely because of extremely high ambient temperature, because of being in a confined space, or because of an increase in resistance heating caused by increased ambient temperature. The resistance of copper conductors increases by a factor of 0.0047 for each degree Celsius above zero, thus increasing resistive heating with temperature when current is constant. The effect can be compounded if multiple wires are run in the same space or, as in the case of extension cords, the wire is bundled or coiled to fit within a limited space. Under these circumstances, relatively minor overheating of lines, receptacles and/or appliances can substantially increase danger of combustion.

[0008] Electrical fuses protect substantially only against current overloading, as do circuit breakers. Furthermore, circuit breakers can malfunction and fail to operate. Under such conditions, they may overheat, and even if they do not themselves fail, they act as a heat source for interconnected elements in the wiring system. The larger the gauge of the copper wires used in an extension cord, for example, the more current it can carry for each degree of temperature rise. At the same time, the copper, which is an extremely good thermal conductor, becomes more efficient in transferring heat energy along its length. Consequently, there can be bi-directional interaction between different points in an electrical system, so that a fire need not necessarily arise at some point of malfunction, but may be initiated at a remote location that is in effect a weak link in the system. It is evident that protection is needed whether there is an overheating danger from causes other than electrical malfunction, or some misoperation or misuse of electrical equipment. It is obvious, furthermore, given the large installed inventory of receptacles, outlets, circuit breakers and fuses, as well as the widespread employment of semipermanent adapter outlets and extension cords, that the patterns of usage in residential and commercial buildings will not substantially change. Consequently, the dangers inherent in many usage habits will remain unless a convenient means is found for protecting against fire danger from these causes. For these and other reasons, there is a need for compact and inexpensive safety elements which cooperate with standard electrical circuitry to protect against the types of failures in electrical wiring systems that endanger individuals and cause damage or destruction to buildings.

[0009] Systems and devices in accordance with the invention provide a heat responsive function to open a circuit when an overheating condition exists that may be wholly independent or electrical overload. They may utilize a circuit configuration in which a part of a spring-loaded element that conducts current in a circuit is physically retained in position in the circuit by a thermally responsive alloy or other joinder element. The joinder element is in a thermally conductive path with the circuit or device, and any surrounding environment, that has the potential to cause overheating. A protective device of this kind responds to some physically separate overheating condition, regardless of the source, by causing the heated joinder element to yield at a predetermined threshold, so as to release the spring-loaded circuit element and open the circuit. The threshold temperature is selected in accordance with the operating parameters of the unit of concern, such as in relation to the temperature at which the insulation of an extension cord begins to decompose or degrade. Alternatively, the threshold temperature may be chosen with respect to the permissible temperature limits for a circuit breaker or an appliance. In any event, whatever the cause, whether it is due to an environmental temperature condition that exposes bare wire in an extension cord, or an electrical malfunction, or overloading of the electrical circuits themselves, the current is cut off and the power using element and associated circuits no longer function as heat sources.

[0010] Such protective devices in accordance with the invention can be fabricated as integral parts of complete units, or they can be fabricated as separate adapters to be attached to existing installations. By this means, an adapter can be interposed between an extension cord and a wall receptacle, between an appliance and a cord, or between a wall receptacle and a multi-outlet plug to assure that the circuits do not overload or overheat due to internal or external causes.

[0011] In a more particular example of a device in accordance with the invention, a male plug for an extension or appliance cord may either be integral with a cord or in the form of a separate adapter unit. The male plug is fabricated with extending prongs at least one of which includes an interior conductive spring element which may be of cantilever or sinuous shape and is in electrical circuit with the conductor or unit to be protected. The spring element is configured to have conductivity characteristics so that its resistive heating does not exceed that of the conductors to which it is coupled. The spring element is held under tension or compression within the completed circuit by the temperature responsive joinder material. In most instances, the temperature responsive material is a bismuth and lead-containing alloy having a melt or yield temperature in the range of 130° F.-350° F., usually 135° F. to 145° F. if commercial insulated extension cord is used. The temperature that is needed for actuation in particular circumstances can be quite precisely varied however, by selection of the alloy constituents.

[0012] When the device takes the form of an adapter, it includes female terminals on one side into which the male connectors of a conventional extension or appliance cord may be inserted. The adapter plug then can be inserted in a wall receptacle or other outlet, where it is responsive to above threshold temperature levels, whether caused by overheating from the extension cord/appliance side or from the receptacle or outlet itself, or from the circuit breaker side. Consequently the thermal protection device functions in response to sources from at least two directions, and irrespective of the manner in which overheating arises. Power to an insulated cord or associated appliance is shut off, eliminating power drain that may alternatively affect the wall receptacle or the circuit breaker. In addition, the protective device functions as a secondary current overload protector, responding, for example, to a current load if a circuit breaker fails in the closed circuit condition. When the male plug is integral with an extension cord, it preferably includes stress relief elements to resist the strain of pulling on the cord to detach the plug. All devices are of materials consistent with standard building codes and industrial design practices.

[0013] The thermal protective element can incorporate a means for indicating that the threshold condition has been exceeded and the device is in the open condition. As one example, a transparent window in at least one side of the element enables viewing of the position of one or more of the spring loaded elements. As another example, an element moveable in the side of the protective device can be engaged and moved outwardly by the spring loaded element when the fusible material yields, indicating the failure condition in a manner visible from the outside.

[0014] In another example in accordance with the invention, existing circuit breakers can be augmented by an augmentation or backup protective device that is responsive to both thermal and electrical loads. A small unit having a mechanically biased conductive element held in place by a chosen temperature responsive alloy is electrically coupled into the circuit breaker and itself receives power-carrying wires for supplying exterior circuits in the building. The unit includes means for exerting pressure on the wire for better electrical contact, but limits conduction of heat to the exterior by incorporating a thermally non-conductive element in the force-exerting structure. The augmentation device is designed to have a maximum current limit greater than the circuit breaker, so that as long as the circuit breaker is functional, the augmentation device is not actuated by a current overload. However, in the event of circuit breaker overheating, or failure for any other reason, the augmentation device provides an added protection, including safeguarding against electrical overload if permitted by the circuit breaker failure condition.

[0015] In accordance with another feature of the invention, a separate circuit unit is provided that can be incorporated wherever insulated cable is disposed in the likely path of a fire. The interior-circuit device includes parallel conductors for each of the three lines of a grounded cable, one of the conductors including a conductive spring held by a meltable alloy in circuit with a current carrying wire, such as the positive line in a building system. This in-circuit device opens under any of several dangerous conditions, including excessively high wire temperature, excessively high environmental temperature, and severe current overload.

[0016] A different circuit unit in accordance with the invention is also provided that couples directly into the circuits of appliances or other electrical devices and is responsive to appliance temperature. By actuating when the appliance overheats, this unit independently assures against excessive heating of the appliance if the conventional temperature regulating element, usually a bimetallic switching device, fails. The unit may be compact, and replaceably inserted into a small recess in the appliance.

[0017] A better understanding of the invention may be had by reference to the following description, taken in conjunction with the accompanying drawings, in which:

[0018] FIG. 1 is a somewhat idealized perspective view of an electrical cord installation between an appliance and wall receptacle in a building, the installation incorporating a thermally protected adapter plug in accordance with the invention;

[0019] FIG. 2 is side sectional view of the thermally protected adapter plug of FIG. 1, showing the circuit in the closed condition;

[0020] FIG. 3 is a side sectional view of the adapter plug of FIGS. 1 and 2, showing the open circuit condition;

[0021] FIG. 4 is an end view of the adapter plug of FIGS. 1-3;

[0022] FIG. 5 is a side sectional view, partially broken away, of a thermally protected plug formed integrally with an extension cord and including a different type of visual indicator device;

[0023] FIG. 6 is a perspective view, partially broken away, of a circuit breaker unit including an augmentation device in accordance with the invention for providing additional protection against thermal overload;

[0024] FIG. 7 is a side sectional view, viewed from the opposite side of the circuit breaker and installed augmentation device of FIG. 6, with the unit in closed circuit condition;

[0025] FIG. 8 is a side sectional view of a portion of the device of FIGS. 6 and 7, showing the augmentation device in open circuit condition;

[0026] FIG. 9 is a perspective view, partially broken away, of an installation including an in-circuit protection device coupled into a three-wire cable in a location in which thermal protection may be needed;

[0027] FIG. 10 is a top view of the arrangement of FIG. 9, with the cover removed;

[0028] FIG. 11 is a side sectional view of the device of FIGS. 9 and 10;

[0029] FIG. 12 is a diagrammatic representation of an in-circuit thermal protector for electrical appliances and devices; and

[0030] FIG. 13 is a fragmentary perspective view of a replaceable plug-in thermal protector unit that may advantageously be used in the device of FIG. 12.

[0031] The simplified perspective view of FIG. 1 depicts a typical building installation in which there is a danger of possible overheating from any of a number of causes including failure of an electrical circuit or other indication of a fire. In this example the marginal conditions being guarded against are principally the use of degradable material such as the insulation on an extension cord, the possibility of wear or damage to the circuits themselves and ambient temperature conditions that might exist in a confined space. In a typical residential installation, electrical energy coming from electrical mains 10 and a circuit breaker system 12 is distributed to wall receptacles or outlets 14 at a specific number of locations, inherently limited in number because these are part of the building structure. Appliances 16 and other electrically powered devices are often utilized temporarily or permanently wherever circumstances dictate, and thus under somewhat or highly unsafe conditions. As one example, a potential for overheating can exist wherever a length of extension cord 20 is used to connect an appliance 16 to a wall receptacle 14. The appliance 16 may itself malfunction and overheat, or the extension cord itself may present special problems. If the extension cord is worn or frayed, if it is in a confined space or and the building is in a hot environment, if there is electrical overloading or a combination of hot temperatures exterior and interior to the insulation, then the extension cord 20 may overheat and tend to ignite flammable material.

[0032] A thermal protection device 22, as seen in FIGS. 1-4, is in the form of an adapter plug insertable between the plug 21 of an extension cord 20 and a wall receptacle 14. The thermal protection device 22 can be of low cost construction and disposable, once it has been actuated, and it can later be replaced with another unit. The thermal protection device 22 has a body 24 of insulative material with an interior cavity 25, best seen in FIGS. 2 and 3. First and second male prongs 26, 27 protrude from one end of the body 24, for insertion into a wall receptacle 14. The prongs 26, 27 are of conductive and conventionally acceptable material such as USN 260 brass alloy, and include transverse retainers 28 in the wall 29 of the body 24, and internally projecting extensions 30 within the cavity 25. The extensions 30 are adhered to the ends of beryllium copper cantilever springs 32, 33 which extend into the cavity 25 from the opposite side. Each spring 32, 33 has an interior end engaging the side surface of a different extension 30 of a prong 26 or 27. The springs 32, 33 are normally curved outwardly away from each other and the extensions 30. Thus they are mechanically biased and spring-loaded when brought into engagement with the extensions 30. The springs 32, 33 are part of, or attached to female receiving elements 34, 35 which are embedded in a second wall 35, 36 of the body 24 to define the receiving socket for the inserted male prongs at the end of the male plug 21 of an extension cord 20. Here the cord 20 is depicted as a two wire line.

[0033] The cantilever spring ends 32, 33 in the cavity 25 are held in tensioned position in contact with the facing surfaces of the associated extensions 30 by interposed meltable alloy joinders 37, 38 respectively. The beryllium copper springs 32, 33 are designed to provide both the desired electrical conductivity in the electrical circuit and spring compliance. The cross sectional dimensions of the springs 32, 33 are chosen to be such that the springs have inherent conductivity which causes them to heat resistively to levels no greater than the copper of the associated extension cord. In other words, they heat no more than the wire they are protecting, and can respond proportionally to overheating along the line.

[0034] The alloy joinders 37, 38 are here of a material having a melting point of approximately 125°-350° F., although it will usually be in the lower end of this range. A suitable temperature-responsive alloy is “Cerro Alloy No. 5000-7, Cerro Bend”, which is a true Eutectic, having an electrical conductivity of 4.17% AICS and capable of withstanding loads up to 300 psi. This alloy is composed of Bi-50%, PB-26.7%, SN-13.3% and CD-10%. This joinder material holds each cantilever spring arm in spring-loaded position, but the adapter plug 22 is vibration and shock resistant and the circuit remains closed until a joinder 37 or 38 yields, melts or fuses due to thermal effects. The spring-loading need not be large since the alloy yields, melts or fuses within a narrow temperature range, thus allowing the spring element to move to the open circuit position.

[0035] The yield temperature is usually chosen, at least in part, relative to the degradation temperature of the rubber or synthetic plastic insulation that is used. For commonly used materials, such as in household insulation cord, the rated temperature is in the range of 140° F. Thus, with a yield point for the alloy selected at 141° F., there is assurance that temperature conditions will not cause cord failure. Choice of the yield point can, however, involve a number of other considerations. There is a margin of safety in the temperature rating of the cord, because cord degradation is affected both by the temperature level and the length of exposure. Thus short term use or other special factors may justify a lesser safety factor. Moreover, resistive heating is not fully taken into account in other factors that are considered by the commonly accepted testing organization (Underwriter's Laboratories). That organization allows cord sets to be certified if they withstand up to 54° F. resistive heating above ambient temperature, which would limit usage to ambient temperature of 86° F. The important criteria in choosing the safety margin thus involve the consideration of the temperature of the environment in which the extension cord is located, in relation to that in which the safety device is positioned. The safety device may be in a controlled (e.g. air-conditioned) location and consequently a higher yield temperature may be used than when the safety device is substantially heated by its environment. Also, if a cord is in an exposed position where it might burn or injure individuals who contact it, the melting point threshold should be selected at a level which prevents this from happening.

[0036] While the degree of resistive heating of a wire depends upon its gauge or thickness, as well as the load (copper being assumed to be used in substantially all cases) resistive heating in the range of 20-40° F. greater than ambient temperature is often encountered when maximum wattage is applied. When the wattage increases above rated load the cord temperature increases disproportionately. When the ambient temperature itself becomes high, as in an attic or crawl space when the weather approaches 100° F. or more, the on-site temperature can reach 120-130° F., and it is obvious that a danger threshold is imminent. Consequently a safety device with a lower yield temperature may be advisable.

[0037] This fire danger can be presented by a combination of electrical and thermal conditions, as well as by such conditions existing separately. The safety device functions even though remote from the hot spot in the electrical system or along the length of the extension cord, or both, transfers heat along the thermally conductive portion of the extension cord, to the safety device. Conversely, if a defect exists in the receptacle causing or aiding overheating, one or both of the alloy joinders 37, 38 also melts, releasing the associated spring 32, 33 to assume the open condition of FIG. 3. This turns off the associated appliance 16, reducing the load in the supply portion of the system. If the appliance 16 overheats, while other thresholds are approached, the adapter 22 can actuate to eliminate the appliance as a load in the system, while at the same time assuring that the extension cord 20 does not act as initiator of a flammable source. Circuit breaker and fuse protection, assuming no malfunction, protect against related electrical causes of failure, but a thermal protective device augments this with a different security function that also can provide an open circuit response in the event of failure of a circuit breaker when in the closed circuit position. The safety device thus can be regarded as bi-directional in its ability to respond to heat sources from different sources.

[0038] To enable the user to know whether the safety device 22 has been actuated, a transparent non-conductive window 39 is incorporated in a side wall of the body 24 in a position spanning and permitting viewing of one or both cantilever springs 32, 33. Preferably the window 39 is wide enough to enable both springs 32, 33 to be checked.

[0039] It is understood that the two prong adapter plug is shown by way of example only, and that an externally grounded connector, such as a three prong device, follows the same construction and principles and therefore need not be illustrated. The separate adapter plug 22, used in conjunction with an extension cord, will often be advantageous because in the event of failure only the adapter device need be discarded. Furthermore, this enables usage of adapter plugs 22 of different design specifications for different situations and conditions.

[0040] As depicted in FIG. 5, however, an extension cord 20′ can itself include a male plug 40 integrally incorporated in the extension cord 20′ at the time of manufacture. In this example, the male prongs 42, 43 which project from the forward end of the plug 40 are of USN 260 brass, and secured by retainers 28′ in the wall 29′. They include bifurcated bases 44 which are solder joined to interior cantilevered lengths 45, 46 of beryllium copper spring extending into the cavity 25′ of the body 24′, and which are shaped to tend to spring outwardly. The base ends of the springs 45, 46 are held to conductive terminals 52, 53 which have been tinned with low temperature fusible alloy surfaces forming joinders 48, 49. For strain relief, these conductors 52, 53 are held against the adjacent wall 50 of the body 24′ through which they extend by strain relief sleeves 54. Stresses on the plug end of the unit, such as might arise during repeated pulling of the plug from the electrical socket using the cord, therefore do not tend to separate any part of the plug. As depicted, if one of the alloy joinders 48 or 49 yields at its temperature threshold, it releases the associated cantilevered end 45 or 46 in circuit with a male prong 42 or 43 to swing outwardly from the extension cord 20′ central axis. In this instance the cantilevered end engages a non-conductive indicator pin 55 or 56 which is frictionally seated in a side wall of the male plug 40, moving it outwardly to indicate the existence of the threshold overheating condition, and the opening of the circuit. The indicator pins 55, 56 are of insulative material, and preferably of a contrasting and vivid color, such as red, so that the open circuit condition can readily be detected.

[0041] In another application of a device in accordance with the invention, the principal electrical circuit component in a system to be protected is the positive (black insulated) wire in a building installation having a circuit breaker 60. The circuit breaker 60 itself is of conventional form, but the circuit includes an augmentation or supplementary safety device 62 as shown in FIGS. 6-8. The circuit breaker body 64 includes a wire clamp in the form of a screw 66 seated within a bore 68 in the body 64. A threaded nut 72 portion of a C-shaped structure in the bore 68 receives the clamp screw 66 which engages a copper bar 74 extending from the augmentation device 62. The clamp screw 66 also receives a bus bar 75 from the breaker circuits 77 (shown only diagrammatically) that is angled through the body 64 to overlap the copper bar 74 beneath the clamp screw 66. The bars 74, 75 are thus held in close engagement by the end of the clamp screw 66 which tightens the connection against the interior half of the C-shaped structure. Power is received from a building bus 78 coupled through the settable switch 79 to the breaker circuits 77 which function in conventional fashion. A toggle 83 operates the switch 79 to maintain one of two polar positions, on or off.

[0042] In this example the outgoing building wire 82 from the individual circuit breaker 60 is coupled into the intervening augmentation device 62 at a stripped end 84 which is spaced apart from the solid connector bar 74 that protrudes outwardly to engage in the circuit breaker 60. The stripped end 84 of the individual building wire circuit line 82 nests in a U-shaped wire seat 86 which extends into an inner cavity 88 in the augmentation device 62. Within this inner cavity, a circuit connection is made by an S-shaped beryllium copper spring 90, joined fixedly at one end of the S to the connector bar, and joined detachably to the wire seat 86 at the other end of the S by a Cerro alloy joint 92 (FIG. 7). The melting point of this Cerro alloy joint 92 is selected with respect to both thermal threshold conditions and electrical overload threshold conditions, as described below. Also, the cross-sectional area of the beryllium copper spring 90 is again dimensional to assure that resistive heating increases at a rate consistent with the other electrical circuit elements.

[0043] The stripped end 84 of the building wire 82 is held securely against the wire seat 86 by a second clamp screw 96 extending through a side bore 94 in a direction perpendicular to the line 82 axis. A nonconductive pressure block 98 in the second clamp screw 96 fits against the stripped end 84, and a nut plate 100 in an intermediate section of the side bore 94 retains the clamp screw 96, the end of which engages the nonconductive block 98, and which can then be tightened against the block 98 so as to assure contact between the power supply line 82 and the wire seat 86. The power supply conductor 74 for the augmentation device 62 is in the form of a short rod or bar that is suitably thick and strong to retain the augmentation device 62 and individual circuit power supply line 82 securely in any normal use.

[0044] The augmentation device 62 supports the circuit breaker 60 in both electrical and thermal overload modes. As seen in FIG. 8, if the Cerro alloy joint 92 melts, then the beryllium copper spring 90 is released and contracts, creating an adequate gap from the wire seat 86 to prevent arcing. The temperature threshold point is selected, by choice of the Cerro alloy material, so as to be higher than the threshold of the circuit breaker 60 for circuit overload conditions. Consequently, if the circuit breaker 60 is opened because of excessive current loading, such as a short, it may simply be reset and the augmentation device 62 will not have opened. If, however, the circuit breaker malfunctions, resistive heating at the Cerro alloy joint 92 and/or the S-shaped spring 90 will be sufficient to melt the joint, and to open the circuit in the augmentation device 62, providing a second level of protection. In addition, the thermal overload condition, whether arising from heat generated by interconnected circuits or from ambient or associated temperature levels, will melt the Cerro alloy joint, opening circuits and shutting off the power. An example of the latter situation is significant in areas having hot, dry climates, in which brush and forest fires can have devastating effect. A fire approaching a house may not itself ignite a fire, but if power continues to be supplied, as is usually the case, then the local overheating, which substantially increases interior temperatures, can lead to insulation failure. This may result in internal ignition, which is often seen in these devastating fires as a sudden explosion of flame from within the residence.

[0045] A different form of protection is provided by an in-circuit protective device 110 (FIGS. 9-11) interposed in an intermediate portion of the length of an extension cord or other electrical connection system. The in-circuit protective device 110 is confined within a rectangular housing 112 having a cover 114 and anchor clamps 115 for receiving cord ends in the end walls. The device 110 is aligned with the principal axis of an insulated cord 116 of the type having separately insulated wires 117, 118 (conventionally referred to as the black and white wires) and a center ground wire 119. A pair of non-conductive crossbars 120, 121 extend laterally across the base of the housing 112, parallel to the end walls, providing separate connection terminals for the wires 117-119. The spaced apart stripped ends of the white wire 117 are interconnected by a first copper strip 122 between the tops of the crossbars 120, 121. The wire 117 ends are forced against the first copper strip 122 by separate hold down or wire mount screws 124, 125 threading into the respective crossbars, 120, 121. Similarly, a second copper strip 126 extending between the crossbars 120, 121 is engaged to couple the spaced apart opposite ends of the central or ground wire 119 by hold down screws.

[0046] The third parallel path interconnecting the separated ends of the black wire 118 is provided by a beryllium copper strip 128 extending between an elevated spring mount 130 on the first crossbar 120 and the top of the second crossbar 121, being retained at each end by a hold down screw as previously described. At the elevated spring mount 130, however, the beryllium copper strip 128 is seated against the underside of the uppermost part of the elevated mount 130. It is secured by a nut plate 131 in a bore 132 through which a pressure screw 134 extends against a nonconductive block 136. The nonconductive block 136 engages the stripped end of the black wire 118, which in turn rests against a copper U-shaped wire seat 138 in the same manner as the arrangement of FIGS. 6-8. An alloy joint 140 on the underside of the wire seat 138 engages the top side of a curved end section 144 of the beryllium copper strip 128 that is shaped to form a spring element that is mechanically biased away from the alloy joint 140, so as to be released when the alloy joint melts. The beryllium copper strip 128 is configured in its mid region to extend through one or more openings in the bottom wall of the housing base 112, so as to provide an adequate length of curvature of the spring end 144 for movement away from the seat 138 when released. The end 144, when free, moves downward within a cavity 146 in the elevated spring mount 130. The opposite end of the beryllium copper strip 128 includes a pair of 90° angles shaping it around and over the second crossbar 121. Contact between the stripped end of the black wire 118 and the static end 148 of the strip 128 is assured by a hold down screw as previously described. A bottom cover of nonconductive material may be used to assure that the underside of the beryllium copper strip 128 is not exposed.

[0047] By inserting the in-circuit protective device 10 in a region of maximum risk along a cord or cable, the device 110 provides protection against fire danger from individual or a combination of causes, as long as they are expressed in the form of a temperature variation. A single cause, or a combination of causes that may result in opening the protective device can include current overload and/or conductor temperature. This version has the advantage of enabling placement in a preselected position, as well as allowing selection of a specific actuation temperature by use of an appropriate alloy. Heat sources near the wire that are adequately electrically isolated can be thermally coupled to the beryllium copper strip 128 by heat conductor elements so that an overheating condition caused by a nonelectrical source can be protected against.

[0048] Additionally, it can be appreciated that melting of the alloy joint 140 does not require disposal of the entire unit 110. The beryllium copper strip 128 can simply be removed from the device along with the wire seat 138, from which it has separated, and a new joint combination of strip 128 and seat 138 can be reinserted and fixed mechanically in place so as to be joined to both ends of the wire 118.

[0049] FIGS. 12 and 13 show how a thermal protection device in accordance with the invention can be used as a thermal overheat protector for an electrically heated domestic appliance such as a toaster oven. The overall arrangement is depicted in somewhat simplified form in FIG. 12, while a replaceable thermal protection device is shown in FIG. 13. The toaster oven 150, seen from the back, has conventional upper and lower heating elements 152, 153 on opposite sides of a centrally disposed slide tray 155 accessible through a front door (not shown in FIG. 12) in the housing 159.

[0050] The housing 159 of the appliance is typically of metal, although it may have plastic insulating sections. A three wire electrical cord 161 coupled into the housing 159 is divided so that the ground line 163 is secured to the metal appliance case, and the input line (black insulated wire) 165 feeds to the heating elements 152, 153 while the return line (white insulated wire) 167 from the opposite end of the heating elements 152, 153 returns to the electrical cord 161. In circuit with the input line 165 (black wire) is a thermal protection device 170 which is in thermal conductive relation to the housing 159 wall, with the electrical circuit being completed to the heating elements 152, 153 by a conventional bimetallic temperature control switch 172.

[0051] The thermal protection device 170 may simply be wired permanently into the structure, but it can also be advantageous for the unit to be constructed as a replaceable or “drop-in” element in the housing 159. To this end, as seen particularly in FIG. 13, a small chamber 177 is provided as an insulated cubicle accessible through an opening in a side wall of the housing 159 electrical connections are made by a pair of electrodes 180, 181 on opposite sides of the cubicle 177, the electrodes being in circuit with the black wire 165 between the extension cord and the bi-metallic temperature control switch. The drop-in thermal protection device comprises insulated side walls 185 which may form a complete rectangle, together with conductive top and bottom walls 187, 188 which, when the protective device 170 is installed, contact the opposite electrodes 180, 181. The circuit is completed by an interior, S-shaped, compliant spring 190 of beryllium copper. This spring is configured to be under tension, when stretched between the opposite conductive walls 180, 181, but is stretched and held in place by a Cerro alloy joint 192.

[0052] The cross sectional dimensions of the beryllium copper spring 190 are again selected to provide resistive heating corresponding to the resistive heating interior to the toaster oven 150 in accordance with current load. The Cerro alloy joint 192 is selected to provide a desired margin of safety with relation to the construction of the appliance itself, which depends upon the degree of heating normally reached in the toaster oven 150, the construction of the toaster oven, the amount of non-metallic material that is used, and the extent to which users are to be protected against overheating. Cerro alloys are available with melt/yield temperatures of up to 740° F., and beryllium copper alloys are also available that maintain their spring compliance under stress even at high temperatures. Accordingly, the melt/yield temperature can be selected at a substantially higher range than for an extension cord or similar structure, the level being, for example, in the range of 250° F. to 450° F. Since appliances are a major cause of fire in residential and non-residential structures and since bi-metallic current protective elements will stick and malfunction, or be subject to hysteresis effects that will cause them to malfunction, overheating can often occur. In a toaster oven, for example, the appliance can be left on with food products inside which ultimately can catch on fire. In consequence, the interior temperature of the oven can become high enough to start other combustibles, such as the wiring to and within the appliance, on fire. In such a situation, the thermal protection device turns off the current, and the burning food by itself does not have sufficient thermal energy to breach the interior oven wall of the appliance, thus containing the fire. Because the current is turned off, even if the food fire melts wiring insulation or other components a secondary electrical fire is prevented.

[0053] The principle of having a secondary thermal protection device that is electrically effective but primarily thermally responsive can be applied to a number of other electrical appliance and mechanism situations, including electrical heaters that are portable or permanent. If the thermal overload condition triggers the device 170, the spring 190 contracts, providing a permanently opened circuit condition. The entire device 170 may simply be withdrawn from the cubicle 177 by an exteriorly accessible handle 194 which can then be replaced with a new unit in the event that the appliance has not been damaged by the internal fire or other cause of the thermal overload condition.

[0054] It is recognized that a replaceable or plug-in thermal protection unit may introduce another factor that can have adverse consequences. If, for example, an unknown down-line condition, such as a defective bimetallic switch, causes the failure, then replacing the thermal protection unit creates the possibility of again causing overheating and fire danger. Obviously, however, one exhibiting reasonable care knows that the possible sources of overheating of the thermal protective device are elsewhere than at the device, and must be definitively located before a replacement device is inserted.

[0055] Although specific types of alloys have been mentioned, other existing alloys may be used as well as new ones as they become available. The types mentioned have particular advantages because of the mechanical adhesion properties they possess together with their close control of temperature responsiveness. It should also be appreciated that the preferred usage of beryllium copper springs is indicated, but not necessary, because of the relatively high conductivity such elements possess, along with needed spring force.

[0056] While a number of forms and modifications in accordance with the invention have been described above, it should be appreciated that the invention is not limited thereto but encompasses all variations and alternatives within the scope of the appended claims.