IP Library › Granted Patent US 12706445
Granted Patent B2
US 12706445 · App. 18/622,607 · Granted Aug 11, 2026

Printed circuit spark gap with enhanced spark over voltage to protect an electronic device connected to the spark gap

Inventors: Paul Bailey (Camillus, NY); David Barany (Syracuse, NY)
Assignee: PPC BROADBAND, INC.
H01T4/02
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Quick Facts
Patent No.
US 12706445
App. No.
18/622,607
Granted
Aug 11, 2026
Kind
B2
Abstract

A spark gap is configured to provide an enhanced spark over voltage. The spark gap includes a non-smooth textured substrate surface, a first conducting electrode, a second conducting electrode, a gap configured to be disposed between the first and second conducting electrodes, and a conductive material configured to be disposed in a non-continuous and irregular manner on the non-smooth textured substrate surface and in the gap between the first and second conducting electrodes, wherein the spark gap is structurally configured to provide an enhanced spark over voltage to protect any device connected to the spark gap.

Claims (68)

1 . A spark gap device configured to provide an enhanced spark over voltage so as to protect an electronic device connected to the spark gap device, comprising:

a printed circuit board;

an input disposed on the printed circuit board and configured to receive signals;

a non-smooth textured substrate surface disposed on a surface of the printed circuit board;

a spark gap disposed on the printed circuit board, the spark gap comprising:

a first conducting electrode configured to be connected to the input;

a second conducting electrode configured to be connected to a ground;

a gap between the first and second conducting electrodes comprising an exposed portion of the substrate surface; and

a conductive material configured to be disposed in a non-continuous and irregular manner on the non-smooth textured substrate surface and in the gap between the first and second conducting electrodes;

an output disposed on the printed circuit board;

a capacitor configured to connect between the input and the output;

a first conductive tab and a second conductive tab connected to the first conducting electrode and to the second conducting electrode, respectively, to increase an effective mass of the first and second conducting electrodes so as to provide a surge withstand capacity of 96 events; and

wherein the spark gap is structurally configured to provide the enhanced spark over voltage to protect the capacitor and/or an external device connected to the output.

2 . The spark gap device of claim 1 , wherein the conductive material is non-continuous graphite configured with gaps between graphite particles of not more than 0.004 inches.

3 . The spark gap device of claim 1 , wherein the enhanced spark over voltage is 1064V±500V.

4 . The spark gap device of claim 1 , wherein the spark gap is structurally configured to provide a surge withstand capacity of 96 events.

5 . The spark gap device of claim 1 , wherein a width of the spark gap is about 0.025 inches.

6 . The spark gap device of claim 5 , wherein a length of the first and second conducting electrodes is 0.040 to 0.080 inches and a thickness of the first and second conducting electrodes is 0.055 to 0.065 inches.

7 . The spark gap device of claim 1 , further comprising at least one through hole formed in each of the first and second conducting electrodes, and a conductive wire attached to the through holes to increase an effective mass of the first and second conducting electrodes so as to provide a surge withstand capacity of 96 events.

8 . The spark gap device of claim 1 , wherein a width of the spark gap is about 0.0325 inches configured to provide a spark over voltage of over 200 V to a device connected to the spark gap device.

9 . A spark gap device configured to provide an enhanced spark over voltage so as to protect an electronic device connected to the spark gap device, comprising:

a printed circuit board;

a non-smooth textured substrate surface configured to be disposed on a surface of the printed circuit board;

a spark gap configured on the printed circuit board, the spark gap comprising:

a first conducting electrode configured to be connected to an input;

a second conducting electrode configured to be connected to a ground;

a gap having an exposed surface of the substrate configured to be disposed between the first and second conducting electrodes; and

a conductive material configured to be disposed in a non-continuous and irregular manner on the non-smooth textured substrate surface and between the first and second conducting electrodes;

at least one through hole formed in each of the first and second conducting electrodes, and a conductive wire attached to the through holes to increase an effective mass of the first and second conducting electrodes so as to provide a surge withstand capacity of 96 events; and

wherein the spark gap is structurally configured to provide the enhanced spark over voltage to the spark gap device to protect an external device connected to the spark gap device.

10 . The spark gap device of claim 9 , wherein the conductive material is non-continuous graphite configured with gaps between graphite particles of not more than 0.004 inches.

11 . The spark gap device of claim 9 , wherein the enhanced spark over voltage is 1064V±500V.

12 . The spark gap device of claim 9 , wherein the spark gap is structurally configured to provide a surge withstand capacity of 96 events.

13 . The spark gap device of claim 9 , wherein a width of the spark gap is about 0.025 inches.

14 . The spark gap device of claim 13 , wherein a length of the first and second conducting terminals is 0.040 to 0.080 inches and a thickness of the first and second conducting terminals is 0.055 to 0.065 inches.

15 . The spark gap device of claim 9 , further comprising at least one through hole formed in each of the first and second conducting electrodes, and a conductive wire attached to the through holes to increase an effective mass of the first and second conducting electrodes so as to provide a surge withstand capacity of 96 events.

16 . The spark gap device of claim 9 , wherein a width of the spark gap is about 0.0325 inches configured to provide a spark over voltage of over 200 V to a device connected to the spark gap device.

17 . A spark gap configured to provide an enhanced spark over voltage so as to protect an electronic device connected to the spark gap device, comprising:

a non-smooth textured substrate surface configured to be disposed on a surface of a printed circuit board;

a first conducting electrode configured to be connected to an input;

a second conducting electrode configured to be connected to a ground;

a gap disposed between the first and second conducting electrodes;

a conductive material configured to be disposed in a non-continuous and irregular manner on the non-smooth textured substrate surface and in the gap between the first and second conducting electrodes;

at least one through hole formed in each of the first and second conducting electrodes, and a conductive wire attached to the through holes to increase an effective mass of the first and second conducting electrodes so as to provide a surge withstand capacity of 96 events; and

wherein the spark gap is structurally configured to provide the enhanced spark over voltage to protect the electronic device connected to the spark gap.

18 . The spark gap of claim 17 , wherein the conductive material is non-continuous graphite configured with gaps between graphite particles of not more than 0.004 inches.

19 . The spark gap of claim 17 , wherein the enhanced spark over voltage is 1064V±500V.

20 . The spark gap of claim 17 , wherein the spark gap is structurally configured to provide a surge withstand capacity of 96 events.

21 . The spark gap of claim 17 , wherein a width of the spark gap is about 0.025 inches.

22 . The spark gap of claim 21 , wherein a length of the first and second conducting terminals is 0.040 to 0.080 inches and a thickness of the first and second conducting terminals is 0.055 to 0.065 inches.

23 . The spark gap of claim 17 , further comprising a capacitor connected between the first conducting electrode and an output.

24 . The spark gap of claim 17 , further comprising at least one through hole formed in each of the first and second conducting electrodes, and a conductive wire attached to the through holes to increase an effective mass of the first and second conducting electrodes so as to provide a surge withstand capacity of 96 events.

25 . The spark gap device of claim 17 , wherein a width of the spark gap is about 0.0325 inches configured to provide a spark over voltage of over 200 V to a device connected to the spark gap device.

26 . A spark gap for providing an enhanced spark over voltage so as to protect an electronic device connected to the spark gap device during operation, comprising:

a non-smooth textured substrate surface structured to be disposed on a surface of a printed circuit board;

a first conducting electrode structured to be connected to an input;

a second conducting electrode structured to be connected to a ground;

a gap disposed between the first and second conducting electrodes;

a conductive material structured to be disposed in a non-continuous and irregular manner on the non-smooth textured substrate surface and in the gap between the first and second conducting electrodes;

at least one through hole formed in each of the first and second conducting electrodes, and a conductive wire attached to the through holes to increase an effective mass of the first and second conducting electrodes so as to provide a surge withstand capacity of 96 events; and

wherein the spark gap is structurally structured and arranged to provide the enhanced spark over voltage to protect the electronic device connected to the spark gap during operation.

27 . The spark gap of claim 26 , wherein the conductive material is non-continuous graphite configured with gaps between graphite particles of not more 0.004 inches.

28 . The spark gap of claim 26 , wherein the enhanced spark over voltage is 1064V±500V.

29 . The spark gap of claim 26 , wherein a width of the spark gap is about 0.025 inches.

30 . The spark gap of claim 29 , wherein a length of the first and second conducting terminals is 0.040 to 0.080 inches and a thickness of the first and second conducting terminals is 0.055 to 0.065 inches.

31 . The spark gap of claim 26 , further comprising a capacitor connected between the first conducting electrode and an output.

32 . The spark gap of claim 26 , further comprising at least one through hole formed in each of the first and second conducting electrodes, and a conductive wire attached to the through holes to increase an effective mass of the first and second conducting electrodes so as to provide a surge withstand capacity of 96 events.

33 . The spark gap device of claim 26 , wherein a width of the spark gap is about 0.0325 inches structured to provide a spark over voltage of over 200 V during operation to a device connected to the spark gap device.