AC linear anti-surge high-voltage-resistant module

Abstract

The utility model discloses an AC linear anti-surge high-voltage-resistant module, the stress of common-mode surge is improved by increasing the thickness of an insulating dielectric layer, and when the thickness of the insulating dielectric layer is more than 360 microns, the stress of common-mode surge resistance can reach more than 4KV. Therefore, when the module faces high common-mode surge voltage, the PCB is not prone to breakdown, and circuit faults caused by breakdown of the surge voltage are effectively avoided. The differential mode surge voltage is reduced step by step by adopting a four-stage protection circuit formed by the piezoresistors VR1-VR4 and the winding resistors RT1-RT4, so that the voltage finally reaching a rear-end circuit is in a safe range, the rear-end circuit is protected from being damaged by the high differential mode surge voltage, the differential mode surge stress resistance of the module is improved, and the differential mode surge stress resistance of the module is up to more than 6KV. According to the invention, the surge resistance and high-voltage stress resistance of the AC linear module are effectively improved.

Description

Technical Field

[0001] This utility model relates to the field of intelligent lighting technology, specifically to an AC linear surge-resistant and high-voltage-resistant module. Background Technology

[0002] Lightning surges (primarily simulating indirect lightning) refer to interference voltages generated when lightning strikes outdoor power lines, causing a large current to flow into the external lines or grounding resistance; voltages or currents induced in power lines by indirect lightning strikes (such as lightning strikes within clouds); voltages and currents induced in outdoor power lines when they pass through an electromagnetic field created by a lightning strike on a nearby object; and interference introduced by ground currents when lightning strikes the ground nearby and passes through the common grounding system.

[0003] To assess the surge withstand capability of electronic equipment under lightning conditions, surge testing is one of the safety testing methods for AC linear modules. It involves testing the AC linear module for transient voltage and current. By simulating voltage and current surge conditions that may be encountered in actual operation, the surge withstand capability of the AC linear module is tested.

[0004] Currently, the common-mode surge stress resistance of existing high-voltage modules is usually addressed by placing various surge protection components between the live wire or neutral wire and the ground wire on the aluminum substrate to suppress common-mode surges. However, this method has relatively limited surge stress resistance, generally only able to withstand surge voltages of around 2KV. Exceeding this value may cause breakdown, resulting in damage to downstream circuits or loads.

[0005] Therefore, there is an urgent need to provide an AC linear surge-resistant and high-voltage-resistant module to solve the above problems. Utility Model Content

[0006] The purpose of this invention is to overcome the shortcomings and defects of the existing technology and provide an AC linear surge-resistant high-voltage module that improves the common-mode surge stress and differential-mode surge stress resistance of the AC linear module, so that the common-mode surge stress resistance reaches above 4KV and the differential-mode surge stress resistance reaches above 6KV.

[0007] The objective of this utility model is achieved through the following technical solution:

[0008] An AC linear surge-resistant high-voltage module is disclosed, which simulates high-voltage surge impact using a lightning surge generator to test the surge stress of the module. The module comprises a PCB board and a varistor VR. The PCB board includes a solder mask layer, a circuit layer, an insulating dielectric layer, and an aluminum layer connected in sequence. The insulating dielectric layer has a thickness greater than 360 μm. The live wire interface L1 of the lightning surge generator is connected to the live wire interface L of the solder mask layer, the neutral wire interface N1 of the lightning surge generator is connected to the neutral wire interface N of the solder mask layer, and the ground wire interface G1 of the lightning surge generator is connected to the ground wire interface G of the aluminum layer.

[0009] Meanwhile, the live wire interface L1 of the lightning surge generator is connected to the first pin of the varistor VR, the second pin of the varistor VR is connected to the neutral wire interface N1 of the lightning surge generator, and the varistor VR is connected to the load.

[0010] As a preferred embodiment of this utility model, the module further includes a fuse F1, the input terminal of which is connected to the live wire interface L1 of the lightning surge generator, and the output terminal of which is connected to the first pin of the varistor VR1.

[0011] As a preferred embodiment of this utility model, a rectifier bridge circuit is further provided between the varistor VR and the load. The varistor VR is connected to the input terminal of the rectifier bridge circuit, and the output terminal of the rectifier bridge circuit is connected to the load.

[0012] As a preferred embodiment of this utility model, the module further includes wire-wound resistors RT1 and RT2. The first pin of the varistor VR is connected to the first pin of the wire-wound resistor RT1, and the second pin of the varistor VR is connected to the first pin of the wire-wound resistor RT2. The second pins of the wire-wound resistors RT1 and RT2 are respectively connected to the input terminal of the rectifier bridge circuit, and the output terminal of the rectifier bridge circuit is connected to the load.

[0013] Compared with the prior art, the present invention has the following beneficial effects:

[0014] This invention improves the common-mode surge withstand capability by increasing the thickness of the insulating dielectric layer. When the thickness of the insulating dielectric layer is above 360um, the common-mode surge withstand capability can reach above 4KV. This makes the PCB board less prone to breakdown when facing high common-mode surge voltages, effectively avoiding circuit failures caused by surge voltage breakdown. A four-stage protection circuit composed of varistors VR1-VR4 and wire-wound resistors RT1-RT4 is used to progressively reduce the differential-mode surge voltage, ensuring that the voltage reaching the downstream circuit is within a safe range. This protects the downstream circuit from damage by high differential-mode surge voltages, improving the differential-mode surge withstand capability of the AC linear module to above 6KV. This application effectively improves the surge resistance and high-voltage withstand capability of the AC linear module. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the common-mode surge generation of this utility model.

[0016] Figure 2 This is a schematic diagram of the differential mode surge generation of this utility model.

[0017] Figure 3 The waveform diagram is a test waveform diagram of an embodiment of this utility model. Detailed Implementation

[0018] The present invention will be further described in detail below with reference to the embodiments and accompanying drawings, but the implementation of the present invention is not limited thereto.

[0019] The specific implementation process of this utility model is as follows:

[0020] An AC linear surge-resistant high-voltage module is disclosed. The surge stress of the module is tested by simulating a high-voltage surge impact using a lightning surge generator. The module includes a PCB board and a varistor VR. The PCB board comprises a solder mask layer, a circuit layer, an insulating dielectric layer, and an aluminum layer connected in sequence. The insulating dielectric layer has a thickness greater than 360µm. The live wire interface L1 of the lightning surge generator is connected to the live wire interface L of the solder mask layer, the neutral wire interface N1 of the lightning surge generator is connected to the neutral wire interface N of the solder mask layer, and the ground wire interface G1 of the lightning surge generator is connected to the ground wire interface G of the aluminum layer. Further, in this embodiment, as... Figure 1As shown, when a lightning surge occurs simultaneously between the neutral wire N1 and the ground wire G1, with the same phase and direction, the surge voltage propagates from the solder mask layer L, diffuses through the circuit layer, and is contained within an insulating dielectric layer below the circuit layer. This insulating dielectric layer prevents the surge voltage from penetrating the dielectric layer and flowing into the underlying aluminum layer, thus limiting the surge voltage between the circuit layer and the insulating dielectric layer. Simultaneously, the surge voltage from the ground wire G1 diffuses through the aluminum layer and also cannot penetrate the insulating dielectric layer, preventing the PCB board from being damaged. Similarly, when a lightning surge occurs simultaneously between the live wire L1 and the ground wire G1, with the same phase and direction, the common-mode surge voltage propagates from the solder mask layer N, diffuses through the circuit layer, and is again contained within the insulating dielectric layer. The common-mode surge voltage from the ground wire G1 diffuses through the aluminum layer and also cannot penetrate the insulating dielectric layer. By setting the thickness of the insulating dielectric layer to over 360um, even if the peak common-mode surge voltage is as high as 4KV, it is not easy to break down the PCB board, which improves the module's common-mode surge resistance and effectively avoids circuit failures caused by surge voltage breakdown.

[0021] Simultaneously, the live wire interface L1 of the surge generator is connected to the first pin of the varistor VR, the second pin of the varistor VR is connected to the neutral wire interface N1 of the surge generator, and the varistor VR is connected to the load. When a differential-mode surge voltage with the same phase and opposite direction occurs simultaneously between the live wire L1 and the neutral wire N1, the varistor clamps the voltage to around its maximum limiting voltage. The differential-mode surge voltage is suppressed by the varistor before flowing to the downstream circuit to supply power to the load, ensuring that the voltage reaching the downstream circuit is within a safe range. This protects the downstream circuit from damage by high differential-mode surge voltages and improves the module's resistance to high differential-mode surge stress, making it withstand differential-mode surge stresses of up to 6KV or higher.

[0022] In an embodiment of this utility model, the module further includes a fuse F1. The input terminal of fuse F1 is connected to the live wire interface L1 of the lightning surge generator, and the output terminal of fuse F1 is connected to the first pin of varistor VR1. Fuse F1 is used to quickly melt and disconnect the circuit when a short circuit or high current abnormality occurs in the back-end circuit, thereby protecting the back-end circuit and preventing the electronic equipment from spontaneously combusting.

[0023] In an embodiment of this invention, a rectifier bridge circuit is further provided between the varistor VR and the load. The varistor VR is connected to the input terminal of the rectifier bridge circuit, and the output terminal of the rectifier bridge circuit is connected to the load. The rectifier bridge circuit is used to rectify the input AC power into DC power for output. Specifically, the AC power suppressed by the varistor VR enters the rectifier bridge circuit through the input terminal, is rectified by the rectifier bridge circuit into pulsating DC power, and is output to the load. Alternatively, a varistor can be set after the rectifier bridge circuit as a final line of defense to ensure that the voltage is completely reduced to a safe range before being output to the load.

[0024] In an embodiment of this invention, the module further includes wire-wound resistors RT1 and RT2. The first pin of the varistor VR is connected to the first pin of the wire-wound resistor RT1, and the second pin of the varistor VR is connected to the first pin of the wire-wound resistor RT2. The second pins of the wire-wound resistors RT1 and RT2 are respectively connected to the input terminals of the rectifier bridge circuit, and the output terminal of the rectifier bridge circuit is connected to the load. The wire-wound resistors are used to absorb residual voltage after clamping by the varistor. Specifically, when the differential-mode surge voltage is too high, if the voltage still cannot be reduced to a safe range after overvoltage clamping suppression by the first-stage varistor VR, the remaining excessive voltage is absorbed by the wire-wound resistors and sent to the next-stage surge circuit or other protection circuits for suppression clamping until the voltage is reduced to a safe range. Then, the voltage is rectified by the rectifier circuit and supplied to the downstream circuit or load.

[0025] In this embodiment, to protect the module from damage caused by higher differential mode surge voltages, a multi-level protection circuit is used to suppress surge voltages step by step. This embodiment uses a four-level protection circuit as an example, such as... Figure 2As shown, when a lightning surge occurs simultaneously between the live wire L1 and the neutral wire N1, producing differential-mode surge voltages with the same phase but opposite directions, the varistor VR clamps the voltage to around its maximum limiting voltage. Specifically, when the lightning surge generator outputs a differential-mode surge voltage, the first-stage varistor VR1 responds first, clamping the voltage to around its maximum limiting voltage. This voltage is much higher than the normal operating voltage but much lower than the voltage that could damage the circuit. The residual voltage after being clamped by varistor VR1 is absorbed by the winding resistors RT1 and RT2 and sent to the second stage. The second-stage varistor VR2 further reduces the amplitude of the residual voltage, which is then absorbed by the winding resistors RT3 and RT4 and sent to the third stage. The third-stage varistor VR3 further reduces the amplitude of the residual voltage. The residual voltage after being clamped in the third stage is rectified by the rectifier circuit DB1 and then clamped again by varistor VR4. The voltage is reduced to a safe range before being transmitted to the load RL. After four levels of protection, the high differential surge voltage has been greatly reduced, allowing it to safely supply power to downstream circuits or loads. The protection circuit is constructed using varistors VR1-VR4 and wire-wound resistors RT1-RT4, with each stage having a lower voltage than the previous one. This gradually reduces the surge voltage amplitude, ensuring that the voltage reaching the downstream circuit remains within a safe range.

[0026] Experimental tests were conducted on the module of this embodiment, which features an increased insulating dielectric layer thickness and a four-level protection circuit. The experimental waveforms are shown below. Figure 3 As shown, the experimental steps are as follows:

[0027] Experimental Step 1

[0028] Test voltage: +6000V; Surge cycles: 5 / Auto; Surge interval: 60s; Trigger phase: Phase synchronization / Cruise; Coupling path: L3->N; Output impedance: 2Ω

[0029] Experimental Step 2

[0030] Test voltage: -6000V; Surge cycles: 5 / Auto; Surge interval: 60s; Trigger phase: Phase synchronization / Cruise; Coupling path: L3->N; Output impedance: 2Ω

[0031] Experimental Step 3

[0032] Test voltage: +4000V; Surge cycles: 5 / Auto; Surge interval: 60s; Trigger phase: Phase synchronization / Cruise; Coupling path: L3->PE; Output impedance: 12Ω

[0033] Experimental Step 4

[0034] Test voltage: -4000V; Surge cycles: 5 / Auto; Surge interval: 60s; Trigger phase: Phase synchronization / Cruise; Coupling path: L3->PE; Output impedance: 12Ω

[0035] Experimental Step 5

[0036] Test voltage: +4000V; Surge count: 5 / Auto; Surge interval: 60s; Trigger phase: Phase synchronization / Cruise; Coupling path: N->PE; Output impedance: 12Ω;

[0037] Experimental Step 6

[0038] Test voltage: -4000V; Surge count: 5 / Auto; Surge interval: 60s; Trigger phase: Phase synchronization / Cruise; Coupling path: N->PE; Output impedance: 12Ω;

[0039] The experimental results show that by increasing the thickness of the insulating dielectric layer to over 360um, the common mode surge withstand capability can reach over 4KV; by setting up a four-level protection circuit, the module's differential mode surge withstand capability can reach over 6KV.

[0040] This utility model has the following beneficial effects:

[0041] 1. The circuit is simple and clear, requiring no additional differential mode protection components, which effectively reduces the complexity and cost of the system;

[0042] 2. Low cost, no need for expensive discharge tubes or other equipment, only a few varistors and wire-wound resistors are needed to achieve differential mode protection of up to 6KV or more;

[0043] 3. All electronic components are common products on the market, with high replaceability;

[0044] 4. The use of a reference power switch avoids switching frequency issues, reduces conducted and radiated interference, eliminates the need for additional safety devices, lowers costs, and facilitates certification.

[0045] 5. By increasing the thickness of the insulating dielectric layer, the common mode surge stress is improved. When the insulating dielectric layer is above 360um, the common mode surge stress can reach above 4KV.

[0046] 6. The use of highly thermally conductive aluminum-based material improves the product's thermal conductivity, ensuring a long lifespan and high reliability.

[0047] This application has broad application prospects and can be widely used in various lighting fixtures in the fields of intelligent lighting, health lighting, plant lighting, commercial lighting, outdoor lighting, and entertainment lighting, including but not limited to indoor downlights, ceiling lights, pendant lights, floor lamps, explosion-proof lights and floodlights required for specific occasions, as well as fan lights that combine lighting and practical functions.

[0048] The embodiments described above are merely illustrative of the implementation of this utility model, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of this utility model patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and these all fall within the protection scope of this utility model. Therefore, the protection scope of this utility model patent should be determined by the appended claims.

Claims

1. An AC linear surge-resistant high-voltage module, characterized in that, a lightning surge generator is used to simulate high-voltage surge impact to test the surge stress of the module, and the module is characterized in that, The device includes a PCB board and a varistor VR. The PCB board includes a solder mask layer, a circuit layer, an insulating dielectric layer, and an aluminum material layer connected in sequence. The insulating dielectric layer has a thickness greater than 360 μm. The live wire interface L1 of the lightning surge generator is connected to the live wire interface L of the solder mask layer. The neutral wire interface N1 of the lightning surge generator is connected to the neutral wire interface N of the solder mask layer. The ground wire interface G1 of the lightning surge generator is connected to the ground wire interface G of the aluminum material layer. Meanwhile, the live wire interface L1 of the lightning surge generator is connected to the first pin of the varistor VR, the second pin of the varistor VR is connected to the neutral wire interface N1 of the lightning surge generator, and the varistor VR is connected to the load.

2. The AC linear surge-resistant and high-voltage-resistant module according to claim 1, characterized in that, The module also includes a fuse F1, the input terminal of which is connected to the live wire interface L1 of the lightning surge generator, and the output terminal of which is connected to the first pin of the varistor VR1.

3. The AC linear surge-resistant and high-voltage-resistant module according to claim 1, characterized in that, A rectifier bridge circuit is also provided between the varistor VR and the load. The varistor VR is connected to the input terminal of the rectifier bridge circuit, and the output terminal of the rectifier bridge circuit is connected to the load.

4. The AC linear surge-resistant and high-voltage-resistant module according to claim 3, characterized in that, The module also includes wire-wound resistors RT1 and RT2. The first pin of the varistor VR is connected to the first pin of the wire-wound resistor RT1, and the second pin of the varistor VR is connected to the first pin of the wire-wound resistor RT2. The second pins of the wire-wound resistors RT1 and RT2 are respectively connected to the input terminal of the rectifier bridge circuit, and the output terminal of the rectifier bridge circuit is connected to the load.

Images