MOV Surge Protector Containment for Thermal Disintegration
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Solution Overview
Problem
Existing power surge protectors using metal oxide varistors (MOVs) can lead to thermal disintegration during power spikes, causing equipment damage and potential fires due to the limited capacity to absorb surge energy, which is not effectively managed by current designs.
Innovation Solution
The solution involves housing MOVs in a containment unit with insulating and thermally resistant materials, allowing safe discharge of expansion gases and using power-pressure technology to transform excess electrical energy into kinetic energy, reducing the risk of damage and fire through the use of dielectric and heat-resistant materials, and a secondary containment unit with fire-resistant properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If MOVs are used to protect against power surges, then equipment is protected from voltage spikes, but the MOVs undergo thermal disintegration when absorbing excessive surge energy, causing equipment damage and potential fires
Solution Approach 1:
A containment unit filled with dielectric and heat-resistant material is introduced as an intermediary between the MOV and the surrounding environment. This containment unit absorbs and manages the thermal energy and expansion gases produced during MOV disintegration, preventing direct contact with flammable materials and eliminating the fire hazard while preserving the surge protection function.
Solution Approach 2:
The harmful thermal energy and expansion gases produced during MOV disintegration are converted into a manageable form by the containment unit. The dielectric material absorbs the thermal energy, and the containment structure channels the expansion gases safely, transforming the potentially destructive disintegration process into a controlled event that does not pose a fire risk.
2Duration of action of moving object
If MOVs absorb power surges until main breaker trips, then surge protection is maintained, but the time to absorb power is limited before MOV disintegration occurs
Solution Approach 1:
The containment unit is pre-filled with dielectric and heat-resistant material that acts as a cushion against thermal disintegration. This cushioning material absorbs the thermal energy generated during surge absorption, allowing the MOV to continue functioning longer before disintegration occurs, thereby extending the protection duration and maintaining reliability.
3Duration of action of moving object
If containment unit with dielectric material is used to extend MOV absorption time, then surge protection duration is increased, but device complexity increases
Solution Approach 1:
The containment unit performs multiple functions simultaneously: it provides mechanical containment for the MOV, supplies thermal insulation through dielectric material, manages expansion gases during disintegration, and prevents fire hazards. This multi-functionality achieves extended surge absorption duration without proportionally increasing device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design extends the time MOVs can absorb power before disintegration, safely managing expansion gases and reducing the risk of damage and fire, thereby effectively protecting electrical systems from power surges.
Implementation Method 1
a first containment unit at least partially filled with a material having dielectric, heat resistance and elastic properties embedding said at least one MOV unit within said first containment unit
Implementation Method 2
when said at least one MOV unit undergoes thermal disintegration due to a surge in said current network said opening allows expansion gases created by said at least one MOV unit to be discharged from said first containment unit
Implementation Method 3
a second containment unit having fire-resistant properties receiving said expansion gases
Data Source
AI summary
The present disclosure provides a surge protector device comprising an electrical connector for connecting said surge protector device to a current network, at least one metal oxide varistor (MOV) connected to said electrical connector; and a first containment unit at least partially filled with a medium having dielectric, heat resistance and elastic properties embedding said at least one MOV unit within said first containment unit, said containment unit having at least one opening; wherein upon failure of said at least one MOV unit due to a surge in said current network said opening allows expansion gases created by said at least one MOV unit to be discharged from said first containment unit. In another embodiment, the surge protector connects directing to an electrical board and discharges expansion gases therein.