Development of an Ultra-Compact High-Voltage DC-DC Converter for Modular Sensor Systems

This paper presents the development and miniaturization of a high-voltage DC-DC converter module designed to power FPGA (Field Programmable Gate Array) units and sensor nodes in next generation seismic streamer systems for marine seabed analysis. The module converts a fixed input voltage of 120 V into two regulated output voltages of 12 V and 3.3 V, enabling decentralized power supply along the streamer sections. A cascaded topology using two buck converters was selected based on efficiency and thermal performance simulations with PSpice. Initial validation was conducted on prototype boards, followed by the implementation of a miniaturization concept through embedding active and passive components into the PCB’s dielectric layers. The embedded module was designed with an opening in the center to give room for passing cables as the strain relief and data/power lines. The size of the module is limited by the diameter of the stream to ≤3.5 cm. Electrical measurements confirmed a reliable performance with efficiencies of up to 77.9%, supporting the suitability of the concept for future integration into the next-generation seismic ocean streamer.