Overvoltage Protection Module With Meltable Piston Trigger
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Solution Overview
Problem
Existing overvoltage protection modules with varistors face challenges in rapidly and reliably creating a short circuit to protect devices from surge voltages, as they often rely on inefficient thermal overload mechanisms that may not effectively intercept high voltages in time to prevent damage.
Innovation Solution
An overvoltage protection module design featuring a varistor, a piston with meltable material, and a spring mechanism, where the meltable material melts to release the spring, pushing a short-circuit plate against the housing wall, thereby creating a short circuit when the varistor overheats due to increased voltage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a varistor is used to protect against surge voltages, then devices are protected from overvoltage damage, but the response time may be delayed due to thermal overload mechanisms
Solution Approach 1:
The spring mechanism is pre-loaded in a compressed state before overvoltage occurs. When the varistor heats up due to surge voltage, the pre-loaded spring immediately pushes the conductive plate against the housing wall to create a short circuit, eliminating the need for thermal expansion or gradual melting processes and achieving rapid response while maintaining reliable protection
Solution Approach 2:
The patent replaces purely thermal-based short circuit mechanisms (such as melting materials or thermal expansion) with a mechanically-driven system. The spring provides direct mechanical force to position the conductive plate, and the friction-based heating mechanism converts mechanical pressure into thermal energy for sustained short circuit, achieving both speed and reliability
2Speed
If a meltable material is used to release the spring mechanism, then rapid short circuit is achieved, but the device complexity increases
Solution Approach 1:
The patent utilizes the phase transition (melting) of a low-melting-point material as the trigger mechanism. When the varistor overheats due to surge voltage, the heat causes the meltable material to transition from solid to liquid state, automatically releasing the spring mechanism. This phase change provides a simple, reliable, and rapid response without requiring complex sensors, control circuits, or multiple moving parts
Solution Approach 2:
The system is self-activating through the thermal coupling between the varistor and the meltable material. The overvoltage condition directly heats the varistor, which in turn heats the meltable material, causing it to melt and release the spring. The spring then automatically pushes the conductive plate to create the short circuit. The entire process occurs without external control, sensors, or power sources, simplifying the device architecture while achieving rapid response
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 ensures rapid and reliable short-circuit creation, effectively intercepting high voltages and preventing damage to connected devices by utilizing a meltable material to release a spring that pushes a short-circuit plate against the housing, providing enhanced protection against surge voltages.
Implementation Method 1
A meltable material is poured or inserted into said drilled holes 3a and 3b and the parallel drilled holes 4a and 4b
Implementation Method 2
The internal side of the plate 4 is provided with a holder of a spring 5 compressed in a way that the external part of the plate 4 is level with the external edges of the piston 3
Implementation Method 3
The bottom of the housing 1 is provided with a varistor 2, above which there is a piston 3
Data Source
Figure 1
Figure 2
AI summary
The invention belongs to the field of devices for energy overvoltage protection, more precisely to the field of modules provided with a varistor and a system for triggering short circuit upon occurrence of overvoltage in a network. An overvoltage protection module is characterised in that a varistor (2) gets heated in case of overvoltage and causes heating of the meltable material in a piston (3) which releases a pre-stressed spring (5) that pushes a plate (4) against a wall of a housing (1) thus creating short circuit between supply pins (1a and 8a).