Thick Film Technology based DC-DC Converter Hybrid for Space Applications

Hybrid electronic modules are always preferred over discrete versions due to smaller size, less weight, better performance and high reliability for Space applications. DC-DC Converter modules realized using Thick Film Technology are universally known as Hybrid converters being hybridized in order to realize miniaturized power supplies allowing ultimate power density & superior electrical & thermal performance. DC-DC Converters have multiple DC outputs for an intended input voltage range for Power distribution systems. This article details the newly developed Innovative Thick Film Process technology involving fabrication of special subassemblies & their attachment techniques for the realization of the miniature 15W DC-DC converter Hybrids. In addition to this, process qualification details for high reliability requirements for Space applications are presented. The major challenges faced during the development of 15W HMC DC-DC Converter, Thermal analysis for critical components, unique layout design in view of the best feasible production approach for miniaturization, overall Electrical Performance and EMI/EMC compatibility for Space applications are detailed in the article.