As industries continue to push the boundaries of technology, there's an increasing need for electronic equipment capable of functioning effectively in harsh conditions like extreme heat. Traditionally, engineers rely on active or passive cooling methods when designing electronics that must operate beyond standard temperature ranges. However, in certain scenarios, cooling might not be feasible or could even prove counterproductive, especially if operating at elevated temperatures enhances system reliability or cuts costs.
One of the oldest and largest markets for high-temperature electronics (greater than 150°C) is the oil and gas sector (as shown in Figure 1). Here, the operational temperature depends on the depth of the well. On average, global geothermal gradients hover around 25°C per kilometer of depth, though some regions exceed this figure.
Historically, drilling activities took place within a temperature range of 150°C to 175°C. Yet, with dwindling natural resources and technological advancements, drilling depths have increased, along with corresponding geothermal gradients. These severe underground environments often surpass 200°C in temperature and exert pressures exceeding 25 kpsi. Active cooling solutions are impractical under such conditions, while passive cooling proves ineffective when heat isn't confined solely to the electronics.
High-temperature electronics play a crucial role in the oil and gas industry—tasks include guiding drilling equipment via sensors and monitoring their performance. Directional drilling demands precise geosteering tools to ensure accurate targeting of geological formations. Additionally, during drilling, downhole instruments gather vital geological data, such as resistivity, radioactivity, acoustic transit time, and magnetic resonance, aiding in identifying lithology, porosity, permeability, and fluid saturation levels. These insights help geologists classify rocks, identify fluids present, and assess potential hydrocarbon yields.
During completion and production stages, electronic systems monitor parameters like pressure, temperature, vibration, and multiphase flow while controlling valves. A robust signal chain is essential for optimal performance (refer to Figure 2). Reliability is paramount since equipment failure incurs massive downtime costs—replacing a mile-long drill string can take over a day and cost approximately $1 million daily for a sophisticated offshore rig!
Beyond oil and gas, there’s growing interest in high-temperature electronics across sectors like avionics. The aviation industry is transitioning toward "more electric aircraft" (MEA) designs, aiming to replace centralized engine controllers with decentralized ones. Centralized setups involve bulky wiring harnesses comprising hundreds of conductors and numerous connectors. Decentralizing control brings engines closer to the control systems, simplifying connections by a factor of ten, reducing aircraft weight significantly, and boosting reliability. However, this comes at the cost of higher ambient temperatures near engines, ranging from –55°C to +200°C. Even with cooling measures, this presents challenges: first, cooling adds weight and expense; second, and more critically, cooling system malfunctions could jeopardize critical electronic controls.
Another facet of MEA involves replacing hydraulic systems with power electronics and electronic controls to enhance reliability and reduce maintenance. Ideally, control electronics should be placed near actuators, generating elevated ambient temperatures.
The automotive sector also sees promise in high-temperature electronics. Similar to avionics, automobiles are evolving from purely mechanical and hydraulic systems to mechatronic ones, necessitating sensors, signal conditioners, and control electronics positioned close to heat sources. Maximum operating temperatures vary based on vehicle type and component placement (see Figure 4). Integrated electrical-mechanical systems, including gearboxes and controllers, streamline production, testing, and maintenance. Electric and hybrid vehicles require high-energy-density electronics for converters, motor control, and charging circuits.
This shift underscores the importance of developing advanced electronics that thrive in extreme conditions—a challenge that holds immense potential across diverse industries.
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