Modular electrical assemblies with plastic film barriers

Claim 2

A modular electrical assembly, comprising: a plurality of conductive electrical components, aligned in a column along an axis and having axially directed ends, said electrical components being electrically connected at said axially directed ends; a plastic film barrier laterally surrounding and tightly engaging said electrical components; first and second conductive end members located at opposite ends of said column, said end members having shoulders extending radially relative to said axis; and a non-conductive filament winding wrapped about said plastic film barrier, said electrical components and said end members, engaging said shoulders and applying an axially directed compressive force through said shoulders on said electrical components and end members to maintain electrical connection therebetween, said plastic film barrier separating said non-conductive filament winding from said electrical components.

Claim 3

A modular electrical assembly according to claim 1 wherein said film is polypropylene.

Claim 4

A modular electrical assembly according to claim 1 wherein said filament winding comprises wet epoxy coated fiberglass.

Claim 5

A modular electrical assembly according to claim 3 wherein said non-conductive filament winding is wrapped about said electrical components and said end members while said electrical components and said end members are axially compressed.

Claim 6

A modular electrical assembly according to claim 1 wherein said plastic film comprises a plastic sheet wrapped about said electrical components.

Claim 7

A modular electrical assembly according to claim 4 wherein said plastic film comprises two superimposed layers.

Claim 8

A modular electrical assembly according to claim 5 wherein each said layer is about 0.0005 inch thick.

Claim 9

A modular electrical assembly according to claim 1 wherein said electrical components are varistors.

Claim 10

A modular electrical assembly according to claim 8 wherein said varistors are generally cylindrical metal oxide varistors.

Claim 11

A modular electrical assembly according to claim 1 wherein said film barrier extends over and surrounds a portion of each of said end members between said shoulder thereof and an end face thereof adjacent said components.

Claim 12

A modular electrical assembly according to claim 10 wherein said electrical components are generally cylindrical varistor blocks; and said end members are generally cylindrical, said varistor blocks and said end members having substantially equal transverse diameters.

Claim 13

An electrical device, comprising: a plurality of electrical assemblies oriented in an end-to-end serial array, each electrical assembly having first and second ends; end means, coupled to each pair of adjacent electrical assemblies, for electrically and mechanically coupling each adjacent pair of electrical assemblies, said mechanical coupling resisting relative axial movement between said electrical assemblies; watershed means, enclosing said assemblies, for protecting said assemblies; and terminal means coupled to each of the two electrical assemblies at opposite ends of said serial array; each of said electrical assemblies including a plurality of conductive electrical components aligned in a column along an axis and being electrically connected through axially-directed ends thereof, a plastic film barrier laterally surrounding and tightly engaging said electrical components, first and second conductive end members coupled to said end means and located at opposite ends of said column, said end members having shoulders extending radially relative to said axis, and a non-conductive filament winding wrapped around said plastic film barrier, said end members and said components, engaging said shoulders and applying an axially-directed compressive force through said shoulders on said plurality of electrical components and said end members to maintain said electrical connection thereof, said plastic film barrier separating said non-conductive filament winding from said electrical components.

Claim 14

An electrical device, comprising: a plurality of electrical assemblies oriented in an end-to-end serial array, each electrical assembly having first and second ends; end means, coupled to each pair of adjacent electrical assemblies, for electrically and mechanically coupling each adjacent pair of electrical assemblies, said mechanical coupling resisting relative axial movement between said electrical assemblies; watershed means, enclosing said assemblies, for protecting said assemblies; and terminal means coupled to each of the two electrical assemblies at opposite ends of said serial array; each of said electrical assemblies including a plurality of conductive electrical components aligned in a column along an axis and being electrically connected through axially-directed ends thereof, a plastic film barrier laterally surrounding and tightly engaging said electrical components, first and second conductive end members coupled to said end means and located at opposite ends of said column, said end members having shoulders extending radially relative to said axis, and a non-conductive filament winding wrapped around said plastic film barrier, said end members and said components, engaging said shoulders and applying an axially-directed compressive force through said shoulders on said plurality of electrical components and said end members to maintain said electrical connection thereof, said plastic film barrier separating said non-conductive filament winding from said electrical components.

Claim 15

An electrical device according to claim 12 wherein each said film is polypropylene.

Claim 16

An electrical device according to claim 12 wherein each said filament winding comprises resin soaked glass fibers.

Claim 17

An electrical device according to claim 12 wherein each said plastic film comprises a plastic sheet wrapped about said electrical components.

Claim 18

An electrical device according to claim 15 wherein each said plastic film comprises two superposed layers.

Claim 19

An electrical device according to claim 16 wherein each said layer is about 0.0005 inch thick.

Claim 20

An electrical device according to claim 14 wherein each said non-conductive filament winding is wrapped about said electrical components and said end members of each said electrical assembly while said electrical components and said end members of the respective electrical assembly are axially compressed.

Claim 21

An electrical device according to claim 12 wherein said electrical components are generally cylindrical metal oxide varistor blocks.

Claim 22

A surge arrester, comprising: a plurality of arrester modules arranged in an end-to-end array, each of said modules including: a plurality of generally cylindrical, metal oxide varistor blocks aligned in a column along an axis and having axially directed ends, said varistor blocks being in electrical connection with one another through said axially directed ends, first and second generally cylindrical, conductive terminals at opposite ends of each said column, each said terminal having a first axial end in contact with one of said varistor blocks, an opposite second axial end with an internally threaded socket and a shoulder extending radially relative to said axis, said varistor blocks and said terminals having substantially equal transverse diameters, a plastic film barrier laterally surrounding and tightly engaging said varistor blocks and adjacent portions of said terminals, and a non-conductive filament winding wrapped around said plastic film barrier, said varistor blocks and said terminals, engaging said shoulders and applying an axially-directed compressive force through said shoulders on said varistor blocks and said terminals to maintain electrical connection thereof, said plastic film barrier separating said non-conductive filament winding from said varistor blocks; conductive externally threaded studs electrically and mechanically coupling each adjacent pair of said modules by threadedly engaging said sockets, said mechanical coupling resisting axial movement between said modules; and elastomeric weathershed means, enclosing said modules, for protecting said modules, said watershed means having a substantially cylindrical throughbore with a diameter substantially equal to transverse diameters of said modules.

Claim 23

A surge arrester, comprising: a plurality of arrester modules arranged in an end-to-end array, each of said modules including: a plurality of generally cylindrical, metal oxide varistor blocks aligned in a column along an axis and having axially directed ends, said varistor blocks being in electrical connection with one another through said axially directed ends, first and second generally cylindrical, conductive terminals at opposite ends of each said column, each said terminal having a first axial end in contact with one of said varistor blocks, an opposite second axial end with an internally threaded socket and a shoulder extending radially relative to said axis, said varistor blocks and said terminals having substantially equal transverse diameters, a plastic film barrier laterally surrounding and tightly engaging said varistor blocks and adjacent portions of said terminals, and a non-conductive filament winding wrapped around said plastic film barrier, said varistor blocks and said terminals, engaging said shoulders and applying an axially-directed compressive force through said shoulders on said varistor blocks and said terminals to maintain electrical connection thereof, said plastic film barrier separating said non-conductive filament winding from said varistor blocks; conductive externally threaded studs electrically and mechanically coupling each adjacent pair of said modules by threadedly engaging said sockets, said mechanical coupling resisting axial movement between said modules; and elastomeric weathershed means, enclosing said modules, for protecting said modules, said watershed means having a substantially cylindrical throughbore with a diameter substantially equal to transverse diameters of said modules.

Claim 24

A surge arrester, comprising: an arrester module including a plurality of generally cylindrical, metal oxide varistor blocks aligned in a column along an axis and having axially directed ends, said varistor blocks being in electrical connection with one another through said axially directed ends, first and second generally cylindrical, conductive terminals at opposite ends of each said column, each said terminal having a first axial end in contact with one of said varistor blocks, and opposite second axial end with an internally threaded socket and a shoulder extending radially relative to said axis, said varistor blocks and said terminals having substantially equal transverse diameters, a plastic film barrier laterally surrounding and tightly engaging said varistor blocks and adjacent portions of said terminals, and a non-conductive filament winding wrapped around said plastic film barrier, said varistor blocks and said terminals, engaging said shoulders and applying an axially-directed compressive force through said shoulders on said varistor blocks and said terminals to maintain electrical connection thereof, said plastic film barrier separating said non-conductive filament winding from said varistor blocks; conductive externally threaded studs threadedly engaging said sockets; and elastomeric weathershed means, enclosing said module, for protecting said module, said weathershed means having a substantially cylindrical throughbore with a diameter substantially equal to a transverse diameter of said module.

Claim 25

A surge arrester, comprising: an arrester module including a plurality of generally cylindrical, metal oxide varistor blocks aligned in a column along an axis and having axially directed ends, said varistor blocks being in electrical connection with one another through said axially directed ends, first and second generally cylindrical, conductive terminals at opposite ends of each said column, each said terminal having a first axial end in contact with one of said varistor blocks, and opposite second axial end with an internally threaded socket and a shoulder extending radially relative to said axis, said varistor blocks and said terminals having substantially equal transverse diameters, a plastic film barrier laterally surrounding and tightly engaging said varistor blocks and adjacent portions of said terminals, and a non-conductive filament winding wrapped around said plastic film barrier, said varistor blocks and said terminals, engaging said shoulders and applying an axially-directed compressive force through said shoulders on said varistor blocks and said terminals to maintain electrical connection thereof, said plastic film barrier separating said non-conductive filament winding from said varistor blocks; conductive externally threaded studs threadedly engaging said sockets; and elastomeric weathershed means, enclosing said module, for protecting said module, said weathershed means having a substantially cylindrical throughbore with a diameter substantially equal to a transverse diameter of said module.

Claim 26

A surge arrestor according to claim 21 wherein said non-conductive filament winding is a wet epoxy coated fiberglass wrapped about said varistor blocks and said terminals while said varistor blocks and said terminals are axially compressed.