Marotta Controls has been awarded a patent for a new synchronous rectification technique that enhances the efficiency and reduces the size of high-current power supplies, a key innovation for military and aerospace applications.
Montville-based Marotta Controls, an innovator in aerospace and defense technology, has been awarded a U.S. patent for a new technique in high-current power conversion. The patented method, developed by Joseph Youssef, the company’s senior director of Electrical Engineering, is a significant leap forward in designing more efficient and compact power supplies for military and aerospace platforms.
The new technology, U.S. Patent No. 12,283,877, focuses on synchronous rectification, a process used in power supplies to reduce energy loss. Traditional methods of synchronous rectification rely on real-time current sensing, which becomes difficult and unreliable at high current levels—specifically those exceeding 400 amps.
Youssef’s innovative solution bypasses this limitation by using a “current mirror signal” to replicate high-current behavior without direct measurement. This enables the precise timing and control of the synchronous rectifier, ensuring accurate and efficient operation even at very high power levels.
“This innovation was born out of necessity,” Youssef said. “We developed a new technique that allowed us to optimize performance without complex sensing circuitry. It’s a breakthrough that gives us and our customers a meaningful edge, especially where performance and packaging constraints are non-negotiable.”
The technology has already been integrated into several of Marotta’s military and aerospace product lines, leading to the creation of smaller, lighter, and more efficient power conversion systems. The company is currently developing a new 28V, 500-amp converter that utilizes this patented approach, with more high-power designs in development.
“This patent strengthens our ability to lead in size, weight, and efficiency for advanced power systems,” Steve Fox, senior vice president of power and actuation systems said. “It reflects our ongoing commitment to engineer smarter, more capable solutions for our defense and aerospace partners.”
The patented technology is particularly well-suited for mission-critical platforms in naval, military, and aerospace settings where high current, minimal weight, and operational efficiency are essential for success. This latest patent adds to Marotta’s extensive portfolio of over 200 patents.
