Combined surge protector

Abstract

This utility model discloses a combined surge protector, comprising two stacked varistors and a discharge tube, with the discharge tube sandwiched between the two varistors and connected in series with them. An insulating sleeve covers the two varistors and the discharge tube. A first pin is located on the upper surface of the upper varistor, and a second pin is located on the lower surface of the lower varistor, extending from the insulating sleeve. A receiving groove is provided on the side of the varistor near the discharge tube, and the discharge tube is embedded in the receiving groove. A ceramic plate is provided between the varistor and the discharge tube to prevent arc interference and improve withstand voltage performance. This surge protector flexibly adapts to system voltage and reduces residual voltage through voltage superposition. Its planar design reduces board area and is compatible with automated insertion processes. An integrated thermal fuse or mechanical tripping mechanism can cut off the circuit in case of failure, improving safety and reliability.

Description

Technical Field

[0001] This utility model relates to the field of surge protector equipment, and in particular to a combined surge protector. Background Technology

[0002] Existing surge protectors face significant technical bottlenecks in structural design and functional adaptability. Firstly, traditional surge protectors often employ discrete components or composite modular designs (such as a three-phase 3PN structure), resulting in bulky designs that occupy a large area on the circuit board. For example, a three-phase protection module integrating multiple levels of varistors and gas discharge tubes significantly increases the installation density pressure on distribution cabinets, making it difficult to meet the needs of highly integrated electrical equipment. Furthermore, their pin layout and packaging are not optimized for automated production processes. For instance, non-standard pitch soldering terminals or irregularly shaped housings cannot be adapted to high-speed surface mount machines or wave soldering lines, requiring manual insertion and soldering. This not only increases production costs but also increases the risk of reliability degradation due to process errors.

[0003] Moreover, existing surge protectors lack sufficient voltage parameter adaptability, making it difficult to flexibly match the voltage requirements of different application scenarios. For example, in low-voltage systems, the maximum continuous operating voltage (Uc) needs to be dynamically selected based on the phase voltage / line voltage. However, most mainstream products on the market are fixed voltage levels (such as 385V and 440V), and parameters cannot be adjusted through modular combinations. This forces users to maintain multiple models in stock to cope with different power grid environments (e.g., a 220V system requires Uc≥320V, while a 254V system requires 385V), significantly increasing supply chain management costs. At the same time, when dealing with complex electromagnetic environments (such as high harmonics or voltage fluctuations in industrial scenarios), such fixed-configuration products may experience reduced protection performance or accelerated device aging due to parameter mismatch.

[0004] Furthermore, the lack of intelligent and integrated design in existing technologies further limits their engineering applicability. For example, the degradation detection of surge protectors often relies on periodic manual inspections or simple thermal tripping devices, which cannot monitor the device status in real time (such as changes in varistor leakage current or the decay of gas discharge tube life), resulting in delayed maintenance and an inability to predict faults. Therefore, there is an urgent need for an innovative solution that combines compactness, automation compatibility, and voltage configurability to overcome these technical bottlenecks. Utility Model Content

[0005] In view of this, the present invention addresses the shortcomings of existing technologies, and its main objective is to provide a combined surge protector. This protector flexibly adapts to system voltage through voltage superposition and reduces residual voltage. Its planar design reduces board area and is compatible with automated component insertion processes. An integrated thermal fuse or mechanical tripping mechanism can cut off the circuit in case of failure, improving safety and reliability.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] A combined surge protector includes two stacked varistors and a discharge tube, the discharge tube being sandwiched between the two varistors and connected in series with them; an insulating sleeve covers the two varistors and the discharge tube; a first pin is provided on the upper surface of the upper varistor, and a second pin is provided on the lower surface of the lower varistor, the first pin and the second pin extending out from the insulating sleeve; a receiving groove is provided on the side of the varistor near the discharge tube, and the discharge tube is embedded in the receiving groove; and a ceramic plate is provided between the varistor and the discharge tube to prevent arc interference and improve withstand voltage performance.

[0008] As a preferred embodiment: the ceramic sheet has a receiving hole in the middle, and the discharge tube is located in the receiving hole.

[0009] As a preferred embodiment, the insulating sleeve is made of epoxy resin or silicone.

[0010] As a preferred embodiment: the ceramic sheet has a surrounding edge corresponding to the receiving hole, and the discharge tube is embedded in the surrounding edge.

[0011] As a preferred embodiment, it also includes a mechanical tripping mechanism, which is tightly connected to one of the varistor resistors.

[0012] As a preferred embodiment: the mechanical tripping mechanism includes a ceramic housing, a first pin and a second pin installed in the ceramic housing, the ceramic housing being tightly attached to one of the varistors; the first pin is located on the lower surface of the ceramic housing and is electrically connected to the varistor, with one end of the first pin extending upward into the ceramic housing to form a solder joint; a winding post is provided in the ceramic housing corresponding to the second pin; the second pin includes a fixing part and an elastic end and a limiting end connected to both ends of the fixing part, the fixing part being sleeved on the winding post, the elastic end being soldered to the solder joint by low-temperature tin, and the limiting end being held on the ceramic housing and extending outward from the outside of the insulating sleeve.

[0013] As a preferred embodiment: the ceramic box body is provided with protrusion holes corresponding to the welding feet, and the welding feet extend upward from the protrusion holes.

[0014] As a preferred embodiment: a thermal fuse is connected in series with one of the varistors, the insulating sleeve covers the outside of the thermal fuse, and the leads of the thermal fuse extend out of the outside of the insulating sleeve.

[0015] Compared with existing technologies, this invention has significant advantages and beneficial effects. Specifically, as shown in the above technical solution, by stacking and connecting two varistors and a discharge tube in series to form a surge protector, the protector achieves flexible voltage adaptation through the series varistor structure, improving overvoltage suppression performance while meeting system voltage requirements. Furthermore, the planar built-in design of the varistor, discharge tube, and varistor results in a small overall size, reducing the lateral board area occupied by the device. The standardized pin layout is compatible with automated insertion processes, solving the space redundancy and manufacturing process compatibility issues of traditional discrete components. In addition, the protector integrates a thermal fuse or mechanical tripping mechanism, providing fail-safe protection and improving operational safety.

[0016] To more clearly illustrate the structural features and effects of this utility model, the following detailed description is provided in conjunction with the accompanying drawings and specific embodiments. Attached Figure Description

[0017] Figure 1 This is a three-dimensional structural diagram of the first type of protector of this utility model;

[0018] Figure 2 This is a cross-sectional view of the first type of protector of this utility model;

[0019] Figure 3 This is an exploded three-dimensional structural diagram of the first type of protector of this utility model;

[0020] Figure 4 This is an exploded three-dimensional structural diagram of the first type of protector of this utility model from another perspective;

[0021] Figure 5 This is a three-dimensional structural diagram of the second type of protector of this utility model;

[0022] Figure 6 This is a cross-sectional view of the second type of protector of this utility model;

[0023] Figure 7 This is an exploded three-dimensional structural diagram of the second type of protector of this utility model;

[0024] Figure 8 This is an exploded three-dimensional structural diagram of the second type of protector of this utility model from another perspective;

[0025] Figure 9 This is an exploded three-dimensional schematic diagram of the mechanical tripping mechanism and the varistor of this utility model;

[0026] Figure 10 This is an exploded perspective view of the mechanical tripping mechanism and varistor of this utility model.

[0027] Figure 11This is a three-dimensional structural diagram of the third type of protector of this utility model;

[0028] Figure 12 This is a cross-sectional view of the third type of protector of this utility model;

[0029] Figure 13 This is an exploded three-dimensional structural diagram of the third type of protector of this utility model;

[0030] Figure 14 This is an exploded three-dimensional structural diagram of the third type of protector of this utility model from another perspective.

[0031] Explanation of reference numerals in the attached diagram:

[0032] 10. Varistor; 11. Receiving groove; 12. First pin; 13. Second pin; 20. Discharge tube; 30. Insulating sleeve; 40. Ceramic plate; 41. Receiving hole; 42. Surrounding edge; 50. Mechanical tripping mechanism; 51. Ceramic housing; 511. Protrusion hole; 52. First pin; 521. Solder foot; 53. Second pin; 531. Fixing part; 532. Elastic end; 533. Limiting end; 54. Column; 60. Thermal fuse. Detailed Implementation

[0033] This utility model is as follows Figures 1 to 4 As shown, a combined surge protector includes two varistors 10 stacked together and a discharge tube 20, wherein:

[0034] The discharge tube 20 is sandwiched between two varistors 10, and the discharge tube 20 and the two varistors 10 are connected in series. An insulating sleeve 30 is wrapped around the two varistors 10 and the discharge tube 20. The insulating sleeve 30 is made of epoxy resin or silicone. The upper surface of the upper varistor 10 is provided with a first electrode 12, and the lower surface of the lower varistor 10 is provided with a second electrode 13. The first electrode 12 and the second electrode 13 extend from the insulating sleeve 30. Each varistor 10 has a receiving groove 11 on the side near the discharge tube 20, and the discharge tube 20 is embedded in the receiving groove 11. The receiving groove 11 of each varistor 10 is mainly welded to the electrode of the discharge tube 20. The discharge tube 20 is embedded inside the varistor 10, which can save the overall structural space of the protector. A ceramic plate 40 is provided between the varistor 10 and the discharge tube 20 to prevent arc interference and improve the withstand voltage performance. The ceramic sheet 40 has a receiving hole 41 in its center, and the discharge tube 20 is located in the receiving hole 41. Furthermore, a surrounding edge 42 is provided on the ceramic sheet 40 corresponding to the receiving hole 41, and the discharge tube 20 is embedded in the surrounding edge 42, making the connection between the discharge tube 20 and the ceramic sheet 40 more stable. The high insulation (high dielectric strength) of the ceramic sheet 40 ensures that the varistor 10 and the discharge tube 20 have no leakage current or breakdown risk under high voltage, maintaining independent operation. The ceramic sheet 40 provides rigid isolation, enhances structural compactness, reduces displacement caused by vibration or temperature changes, and ensures long-term stability.

[0035] By adopting a series topology of varistor 10 + discharge tube 20 + varistor 10, the discharge tube 20 is built-in and formed into a planar structure, significantly reducing the lateral space occupied by the components on the PCB board. At the same time, the pin layout of the three components meets the standardized spacing requirements, which can be directly adapted to high-speed pick-and-place machines or wave soldering processes, improving the efficiency of automated insertion.

[0036] The series structure allows for flexible system voltage adaptation by adjusting the combination of varistor parameters. For example, in a single high nominal voltage solution: using a 680V varistor, its residual voltage is approximately 1.5 times the nominal voltage, i.e., 680V × 1.5 = 1020V; using two 330V varistors in series (combined nominal voltage Vn = 330V × 2 = 660V), each varistor has a residual voltage of 330V × 1.5 = 495V, for a total residual voltage of 495V × 2 = 990V. This combination, while having a lower total nominal voltage (660V) than the single-unit solution (680V), also reduces the residual voltage by 30V (990V vs 1020V), satisfying voltage matching requirements while improving overvoltage suppression performance. This solution is suitable for high-density installation scenarios such as communication base stations and intelligent distribution cabinets.

[0037] As a second embodiment of this utility model, such as Figure 5-10As shown, the protector also includes a mechanical tripping mechanism 50, which is tightly connected to one of the varistor 10. The mechanical tripping mechanism 50 includes a ceramic housing 51, a first pin 52 and a second pin 53 installed in the ceramic housing 51, and the ceramic housing 51 is in close contact with one of the varistor 10. The first pin 52 is located on the lower surface of the ceramic housing 51 and is electrically connected to the varistor 10, with one end of the first pin 52 extending upward into the ceramic housing 51 to form a... Solder foot 521 (the ceramic housing 51 has an extension hole 511 corresponding to solder foot 521, and the solder foot 521 extends upward from the extension hole 511); a winding post 54 is provided in the ceramic housing 51 corresponding to the second pin 53; the second pin 53 includes a fixing part 531 and an elastic end 532 and a limiting end 533 connected to both ends of the fixing part 531, the fixing part 531 is sleeved on the winding post 54, and the elastic end 532 is connected to the solder foot 521 by low-temperature soldering (low-temperature solder melting point is 160 degrees). Figure 9 The diagram shows the state after the low-temperature tin melts, with the elastic end 532 separated from the solder foot 521. The limiting end 533 is held on the ceramic box 51 and extends out of the insulating sleeve 30, which is equivalent to the first electrode foot 12.

[0038] The ceramic housing 51 is made of ceramic material, which has stable heat absorption and transfer, and can effectively transfer the heat generated by the varistor 10 to the solder foot 521. During soldering, the elastic end 532 is elastically bent towards the solder foot 521, thus storing elastic stress. When the low-temperature tin melts, the elastic stress will cause the elastic end 532 to separate from the solder foot 521. The limiting end 533 is held in place by the ceramic housing 51 and extends beyond the insulating sleeve 30 to provide support for the stored stress of the elastic end 532. The second pin 53 is essentially a torsion spring; the connection between the elastic end 532 and the solder foot 521 represents an effective circuit connection, while the separation of the elastic end 532 and the solder foot 521 represents a circuit failure.

[0039] When the protector encounters high temperatures due to a lightning strike or when the varistor 10 malfunctions (due to aging, overvoltage, or surge voltage), the varistor 10 will continuously heat up. When the temperature reaches the low-temperature solder softening state, the low-temperature solder at the solder joint 521 melts. Driven by its own elastic stress, the elastic end 532 of the second pin 53 will disconnect from the solder joint 521, thus promptly interrupting the current and preventing the varistor 10 from overheating and generating an open flame. The first pin 12 and the second pin 13 disconnect the circuit, cutting off the circuit to the connected devices and preventing further damage.

[0040] As a third embodiment of this utility model, such as Figure 11-14As shown, a thermal fuse 60 is connected in series with one of the varistor 10. The insulating sleeve 30 covers the outside of the thermal fuse 60, and the leads of the thermal fuse 60 extend outside the insulating sleeve 30, corresponding to the first terminal 12. When overcurrent or overvoltage passes through the varistor 10, causing its temperature rise to exceed the rated temperature of the thermal fuse 60, the thermal fuse 60 melts and disconnects at the connection point where it is connected in series with the varistor 10. This causes the thermal fuse 60 to fail, the circuit to break, and prevents damage to the equipment.

[0041] The key design feature of this invention lies in forming a surge protector by stacking and connecting two varistors and a discharge tube in series. This protector achieves flexible voltage adaptation through the series varistor structure, improving overvoltage suppression performance while meeting system voltage requirements. Furthermore, the planar integrated design of the varistor, discharge tube, and varistor results in a small overall size, reducing the lateral board area occupied by the device. The standardized pin layout is compatible with automated insertion processes, solving the space redundancy and manufacturing process compatibility issues of traditional discrete components. Additionally, the protector integrates a thermal fuse or mechanical tripping mechanism, providing fail-safe protection and improving operational safety.

[0042] The above description is merely a preferred embodiment of the present utility model and does not constitute any limitation on the technical scope of the present utility model. Therefore, any minor modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present utility model shall still fall within the scope of the technical solution of the present utility model.

Claims

1. A combined surge protector, characterized in that: It includes two varistors stacked together and a discharge tube, wherein the discharge tube is sandwiched between the two varistors and the discharge tube is connected in series with the two varistors. The two varistors and the discharge tube are covered with an insulating sleeve. The upper surface of the varistor located above is provided with a first electrode, and the lower surface of the varistor located below is provided with a second electrode, with the first electrode and the second electrode extending out from the insulating sleeve; The varistor has a receiving groove on the side near the discharge tube, and the discharge tube is embedded in the receiving groove; A ceramic sheet is provided between the varistor and the discharge tube to prevent arc interference and improve the withstand voltage performance.

2. The combined surge protector according to claim 1, characterized in that: The ceramic sheet has a receiving hole in the middle, and the discharge tube is located in the receiving hole.

3. The combined surge protector according to claim 1, characterized in that: The insulating sleeve is made of epoxy resin or silicone.

4. The combined surge protector according to claim 2, characterized in that: The ceramic sheet has a surrounding edge corresponding to the receiving hole, and the discharge tube is embedded in the surrounding edge.

5. The combined surge protector according to claim 1, characterized in that: It also includes a mechanical tripping mechanism, which is tightly connected to one of the varistors.

6. The combined surge protector according to claim 5, characterized in that: The mechanical tripping mechanism includes a ceramic housing, a first pin and a second pin installed in the ceramic housing, the ceramic housing being tightly attached to one of the varistors; the first pin is located on the lower surface of the ceramic housing and is electrically connected to the varistor, with one end of the first pin extending upward into the ceramic housing to form a solder joint; a winding post is provided in the ceramic housing corresponding to the second pin; the second pin includes a fixing part and an elastic end and a limiting end connected to both ends of the fixing part, the fixing part being sleeved on the winding post, the elastic end being soldered to the solder joint by low-temperature tin, and the limiting end being held on the ceramic housing and extending out of the outside of the insulating sleeve.

7. The combined surge protector according to claim 6, characterized in that: The ceramic box body has protrusion holes corresponding to the welding feet, and the welding feet extend upward from the protrusion holes.

8. The combined surge protector according to claim 1, characterized in that: A thermal fuse is connected in series with one of the varistors, and the insulating sleeve covers the outside of the thermal fuse, with the leads of the thermal fuse extending out of the insulating sleeve.

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