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Montville-based Marotta Controls recently announced it was awarded a patent.

The company is a leading innovator in aerospace and defense power conversion.

Marotta Senior Director of Electrical Engineering Joseph Youssef developed the novel synchronous rectification technique, which received U.S. Patent No. 12,283,877.

The technique enables precise power control without complex sensing circuitry. It improves efficiency in high-current power supply by removing a long-standing barrier in designing compact, high-performance converters.

“This innovation was born out of necessity,” said Youssef. “During our R&D on a high-current power supply, it became clear that conventional methods couldn’t deliver the precision control we needed. We developed a new technique that allowed us to optimize performance without complex sensing circuitry.”

Key things to know:

• Synchronous rectification is a common method in switch-mode power supplies to minimize energy loss. The process replaces diodes with low-resistance switches like MOSFETs. However, the typical approaches depend on real-time current sensing for regulation. This becomes impractical or unreliable at high current levels – such as those over 400 amps
• Youssef’s patented solution overcomes this limitation with an innovative approach: a current mirror signal that replicates high-current behavior without direct measurement
• New patented technology ideally suited for mission-critical platforms in military, aerospace and naval settings where high current, minimal weight and operational efficiency are essential
• Already implemented across multiple military and aerospace product lines
• Helps Marotta deliver smaller, lighter and more efficient power conversion systems

“It’s a breakthrough that gives us and our customers a meaningful edge, especially where performance and packaging constraints are non-negotiable,” said Youssef.

Marotta says it is currently developing a new 28V, 500-amp converter using the patented approach. Additional high-power designs are also in the pipeline.

“This patent strengthens our ability to lead in size, weight, and efficiency for advanced power systems,” said Steve Fox, senior vice president, Power and Actuation Systems, Marotta. “It reflects our ongoing commitment to engineer smarter, more capable solutions for our defense and aerospace partners.”