Surge Protection Module With Arc-Isolating Tripping Structure
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Solution Overview
Problem
Existing surge protectors face issues with solder adhesion and arcing after tripping, which can lead to safety risks and device failure, due to the complex internal structure and thermal protection tripping mechanisms.
Innovation Solution
A surge protection module with a tripping mechanism that includes a rotating body and a potential storage spring, which rotates to position an arc-isolating plate between the electrode connector and the pressure-sensitive resistor, effectively blocking arcs and preventing solder adhesion, while also providing a simple and compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thermal protection tripping device is arranged in the surge protector to disconnect the pressure-sensitive resistor when temperature increases, then fire safety is improved, but the internal structure becomes complex and solder adhesion problems occur
Solution Approach 1:
The patent extracts the tripping function from a complex thermal protection device and integrates it directly into the pressure-sensitive resistor structure. The tripping mechanism is built around the resistor itself, with the arc-isolating plate and rotating body forming a compact integrated structure that eliminates the need for separate thermal protection components, thereby reducing overall device complexity while maintaining fire safety.
Solution Approach 2:
The patent merges the thermal protection function with the pressure-sensitive resistor structure by integrating the tripping mechanism directly onto the resistor. The rotating body, arc-isolating plate, and spring assembly are combined into a single integrated tripping unit that works in conjunction with the pressure-sensitive resistor, reducing the number of separate components and simplifying the internal structure.
2Temperature
If a thermal protection tripping device is used to disconnect the pressure-sensitive resistor, then overheating protection is improved, but solder adhesion problems and arcing risks increase
Solution Approach 1:
The patent applies preliminary action by pre-positioning the arc-isolating plate in a ready state before tripping occurs. The spring assembly pre-loads the rotating body, and the arc-isolating plate is positioned to immediately block the welding point upon tripping. This preliminary preparation ensures that when the pressure-sensitive resistor trips due to overheating, the arc-isolating plate is already in position to prevent solder adhesion and arcing, eliminating the harmful effects rather than addressing them after they occur.
Solution Approach 2:
The arc-isolating plate serves as an intermediary element between the pressure-sensitive resistor and the external circuit. When the resistor trips due to overheating, the arc-isolating plate rotates into position to physically block and isolate the welding point, preventing direct contact between the disconnected resistor terminals and thereby eliminating solder adhesion problems and arcing risks.
3Object-affected harmful factors
If the arc-isolating plate is positioned to block the welding point upon tripping, then solder adhesion and arcing are prevented, but the tripping mechanism structure becomes more complex
Solution Approach 1:
The patent applies the nested doll principle by placing the arc-isolating plate within the rotating body structure. The rotating body contains the arc-isolating plate, which is mounted on the rotating body's surface. When the rotating body rotates upon tripping, the nested arc-isolating plate moves with it to block the welding point. This nested arrangement consolidates multiple functional elements into a compact hierarchical structure, reducing overall complexity compared to having separate independent components.
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 prevents solder adhesion and arcing, ensuring complete tripping and reducing the risk of device failure, while also simplifying the module's structure and shortening production cycles.
Implementation Method 1
a potential storage spring, arranged between the rotating body and the bearing frame and is in a compressed or stretched potential storage state
Implementation Method 2
the arc-isolating plate rotates to the electrode via hole and between the electrode connector and the second electrode
Implementation Method 3
When the voltage in a circuit exceeds a predetermined value, its resistance drops sharply, it is in a conductive state, which may discharge a large quantity of currents and limit an overvoltage level
Data Source
AI summary
A surge protection module (1) and a surge protection device. The surge protection module (1) comprises: a bearing frame (12), a mounting plate (121) of which is provided with an electrode via hole (1211); a pressure-sensitive resistor (13) having a first electrode (131) and a second electrode (132) on the first side of the mounting plate (121); an electrode connector (14) mounted on the second side of the mounting plate (121), one end of the electrode connector (14) being welded to the second electrode (132) by means of the electrode via hole (1211); and a tripping mechanism comprising a rotating body (15) and a potential storage spring (16), wherein the rotating body (15) is provided with an arc-isolating plate (154), when the electrode connector (14) and the second electrode (132) are in a welding state, the rotating body (15) is limited in the first position, and the arc-isolating plate (154) is located on the side of the rotating body (15) facing the electrode via hole (1211) and corresponds to the electrode via hole (1211); and when a solder between the electrode connector (14) and the second electrode (132) melts, the potential storage spring (16) drives the rotating body (15) to rotate, and the arc-isolating plate (154) rotates to the electrode via hole (1211) and between the electrode connector (14) and the second electrode (132). The surge protection module (1) and the surge protection device can effectively avoid the problem of solder adhesion and possibly arcing during tripping.