Power Supply Lightning Protection via Surge Bypass

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Solution Overview

Problem

Existing power supplies with power factor correction (PFC) circuits have weak tolerance to lightning strikes, as the connection with MOSFETs and diodes leads to damage from excessive surge voltage and inrush current, particularly when diodes are used in full-wave rectifiers.

Innovation Solution

A power supply with lightning protection is designed, incorporating a surge voltage suppression apparatus using a gas discharge tube and varistor, a surge current bypass apparatus with differential-mode inductors and diode bridge arms, and a control circuit to manage the active bridge rectifier circuit, providing dual protection against lightning current and voltage for MOSFETs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If active bridge rectifier with MOSFETs is used to reduce conduction loss, then power efficiency is improved, but lightning strike tolerance deteriorates

Engineering Contradiction:
Improveconduction lossVSAvoidlightning strike tolerance
Core Design Contradiction:
Loss of energyVSReliability

Solution Approach 1:

A gas discharge tube is introduced as an intermediary protective device between the power input and the active bridge rectifier. During normal operation, the gas discharge tube remains non-conductive and does not affect the efficiency of the MOSFET-based rectifier. When lightning strike occurs, the gas discharge tube ionizes and provides a low-impedance bypass path for the surge current, protecting the MOSFETs from overvoltage and overcurrent damage.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention converts the harmful lightning surge energy into a beneficial protective action by utilizing the gas discharge tube's ability to ionize and conduct under high-voltage stress. The lightning energy that would otherwise destroy the MOSFETs is redirected through the gas discharge tube, which safely dissipates the energy through controlled ionization and subsequent current conduction, thereby transforming a destructive force into a protective mechanism.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

2Device complexity

If varistor alone is used for surge suppression, then circuit simplicity is maintained, but surge voltage suppression effectiveness is insufficient

Engineering Contradiction:
Improvecircuit structureVSAvoidsurge voltage
Core Design Contradiction:
Device complexityVSObject-affected harmful factors

Solution Approach 1:

The invention combines two different protective components - a gas discharge tube and a varistor - into a composite protective circuit. The gas discharge tube provides primary protection by ionizing and conducting the majority of the surge current at high voltage levels. The varistor provides secondary protection by clamping residual voltage and protecting against lower-level surges. This composite approach leverages the complementary strengths of both components to achieve superior surge suppression effectiveness.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The surge protection function is segmented into two distinct stages: primary protection handled by the gas discharge tube for high-voltage lightning surges, and secondary protection handled by the varistor for residual voltage and lower-level surges. This segmentation allows each component to operate in its optimal performance range, with the gas discharge tube handling the bulk of the energy dissipation and the varistor providing fine-tuned voltage clamping.

Inventive Principle:
Principle #1Segmentation

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

The solution effectively suppresses surge voltage and current, preventing damage to MOSFETs by redirecting lightning energy through a bypass path, ensuring the MOSFETs are protected from excessive voltage and current during lightning strikes.

Implementation Method 1

the surge voltage suppression apparatus includes a gas discharge tube and a varisor. The varisor is connected to the gas discharge tube in series and suppresses the surge voltage below a rated voltage

Methodology Applied
Scientific EffectGas discharge: Townsend Discharge

Implementation Method 2

The first differential-mode inductor is coupled between the active bridge rectifier circuit and a live wire end of the input voltage. The second differential-mode inductor is coupled between the active bridge rectifier circuit and a neutral wire end of the input voltage

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS11682965B2Power supply with lightning protection
Publication Date: 2023.06.20 CHICONY POWER TECH CO LTD
  • US11682965B2 patent drawing
  • US11682965B2 patent drawing
  • US11682965B2 patent drawing

AI summary

A power supply with lightning protection includes a surge voltage suppression apparatus, an electromagnetic interference control circuit, a surge current bypass apparatus, an active bridge rectifier circuit, a power factor correction circuit, and a DC-to-DC conversion circuit. The surge voltage suppression apparatus is used to increase a tolerance of a surge voltage for the power supply. The electromagnetic interference control circuit is coupled to the surge voltage suppression apparatus. The surge current bypass apparatus is used to increase a tolerance of a surge current for the power supply. The active bridge rectifier circuit is used to rectify an input voltage. The power factor correction circuit is used to adjust the rectified input voltage to provide an adjusted input voltage on a bulk capacitor. The DC-to-DC conversion circuit is used to convert the adjusted input voltage into a DC output voltage.