Case Studies

This page covers a range of our customers products.  We manufacture custom thick film hybrids for them to use in these products.  Each thick film hybrid component we manufacture is especially designed for each customers needs. 

Click on one of the links below to read about each product and why it uses a thick film hybrid.

Water Pump Flow Controller

High Value Resistors

Baggage X-Ray Machines

Ear Muffs

Protection from the Sun

Safety Switch

 

 

Water Pump Flow Controller

The water pump flow controller, incorporating a thick film hybrid substrate, designed jointly by Hybrid Electronics and our customer gives strong, even water pressure. This enables you to have a great shower! Also the flow controller is designed to automatically turn the pump off if the supply of water is insufficient for the pump to operate. This protects the pump from dry running.
The latest model also has a unique cold start feature which enables the pump to function in the most extreme saltwater environments as well as reducing standby power and heat. The benefit of the thick film hybrid is calibration precision, wider temperature range of operation and encapsulation for the high moisture environment.

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High Value Resistors

Text to Hybrid Electronics manufacture thick film hybrid dynode resistor chains for high vacuum photomultiplier amplifiers & electron multipliers.
They can be external to the vacuum system or they can be incorporated into mechanical assemblies inside the high vacuum system. Dynode resistor chains require very stable, high value resistors, which can withstand high voltages, and, if incorporated inside the vacuum system, can be baked and subject to ionic bombardment.
In addition to the above requirements, thick film hybrid circuits can be tailored to be an integral part of the mechanical dynode assembly.
In this high vacuum application, ceramic active and passive hybrid circuits are used where standard printed circuit boards are completely impractical.
We believe that Stainless Steel hybrids will add another dimension to this technology, especially for the innovative photomultiplier & electron multiplier designer.

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Baggage X-Ray Machines

One of our overseas customers is using thick film hybrids for x-ray detector amplifiers in baggage x-ray machines at airports. Many hybrids are used in the baggage machines. The benefit of the thick film hybrids is in the versatility of resistor performance and the operating environment range of the ceramic substrate. Hybrid Electronics have achieved price savings and quality improvement over international competitors and is working with the customer on other hybrid circuit projects.

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Ear Muffs

With our customer, we are making a noise limiting circuit designed to be fitted into earmuffs that lets you hear while it protects you, doing both jobs at the same time! It allows a wide variety of users to hear normal conversations and sounds when noise levels are below 82 dB(A). When environmental noise exceeds this level the new calibrated stereo circuit switches off instantly. Users then have the full protection capabilities of their earmuffs until the noise levels decrease below 82 dB(A), when the circuit automatically switches itself on again. Encapsulation of the hybrid circuit means that it will operate reliably under extreme hot, humid and dusty environmental conditions - conditions where standard PCB electronics are subject to corrosion and failure.

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Protection from the Sun

How a Hybrid is helping in the prevention of skin cancer

Skin cancer is a significant health issue in Australia. Exposure to ultraviolet radiation emitted by the sun in the UVB wavelengths is the primary cause.

The combination of the predominantly light-skinned population, tropical latitude and cultural emphasis on outdoor activities have contributed to this problem.

The Australian government has taken measures to educate the public, reduce skin cancer rates and advocate early cancer detection however an Australian company, Healthtronics P/L, has taken one step further in the prevention of skin cancer by inventing a U-B-SAFE 1 product using a hybrid. U-B-SAFE 1 is an outdoor ultraviolet alarm which warns people when they have been exposed to the ultraviolet for a period of time that may cause him/her skin disease.

An ultraviolet detector is sitting on the top of the unit which generates a current when it is exposed to an ultraviolet source and this energy is stored electronically. Once the stored energy reaches a certain level which indicates that the wearer has been exposed to the ultraviolet long enough to cause damage to their skin, continuous music from a music IC is played in order to warn the person and remind them to go indoors or seek shade for protection. Different types of skin can be selected on the unit depending on how sensitive it is to the ultraviolet.

All of these functions are achieved on a 3.5cm by 2.2cm circuit, thanks to Hybrid Electronics Australia P/L. The hybrid circuit is lighter, smaller and more reliable compared to the old PCB circuit. With solar power and the UV detector attached, the hybrid circuit is mounted into a special designed case, which can be attached to hats or clothes by the safety-pin in the case. No battery is required, it’s solar powered!

U-B-SAFE 1 is the only UV alarm monitor with these essential features

• Unlike other monitors, it is waterproof down to two metres.
• A special angle of the design ensures it is always in the sun, like your skin, whether you are standing, sitting or lying down.
• It is designed to pin to your hat so it can’t be shaded by your body and is always in sun, unlike monitors that dangle from a necklace or are worn on the wrist.
• An audible alarm means you don’t have to keep checking a display.
• It will give a short alarm if moved out of the sun whilst your skin is still exposed.
• It will alarm continuously if anything blocks the detector.
• It is designed to monitor unprotected skin.
• Its special biological memory registers past ultraviolet doses to compute today’s safe dose.
• Designed small and tough enough for children to use.
• All made possible with our Hybrid circuit!

 

Skin cancer in Australia statistics

• Australia has the highest rate of skin cancer in the world, with over 380,000 people diagnosed every year*.
• Over 1,600 Australians die from skin cancer each year*.
• Skin cancers account for over 80% of all new cancers diagnosed each year in Australia*.

*Source:www.sunsmart.com.au

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Safety Switch

How a hybrid is helping keep children and builders safe

Protectelec Pty. Ltd. and Hybrid Electronics have developed a unique “Breaker Release” technology designed for electric shock and equipment leakage protection with isolated power supplies.

The safety component called Protex isolates electrical faults up to four times faster than traditional safety switches. Protex is used in generators and industrial power outlets, where it has improved electrical safety by removing the need for earth staking.

Why use a Hybrid in Electrical Safety?

The hybrid is small in size, high in reliability, allows for a more precise resistor tolerances, and can withstand up to 10,000 volts (a PCB wouldn’t be able to do this).

The hybrid allows the unit to be self testing all the time. The hybrid is designed for regular testing and regular turning back on.

The hybrid is heat resistant, shatter proof and water resistant.

Protex does not draw any power until a fault is detected. Then Protex quickly isolates the electricity, which remains isolated until the fault has been removed. When the fault has been removed the appliance is simply turned on again and Protex gets back to the business of detecting the next fault.

For example: If Protex is wired into an isolated supply home, it protects bathing children if a hairdryer is dropped into their bath potentially electrocuting them.

How does it work?

Protex solves the expensive “Solid Earth” requirement for environments such as building construction generators where electric shock protection is achieved using RCD’s (residual current detectors.

The Protex unit supplies a reference “connection wire” that is connected to the equipment chassis. It senses current in that “connection wire” referenced to either one arm of the isolated transformer or to the centre tap of the isolation transformer. When the sensed current exceeds the “Breaker Release” calibrated trigger current (usually 5mA) a circuit breaker is triggered. The circuit breaker is triggered in under 10 milliseconds after the high current occurs.

The Protex also does much more;

• It is as close as possible to being “fail safe” so any circuit failure triggers the circuit breaker.
• It fully “self tests” regularly without the circuit breaker triggering and monitors the test result.
• It turns the breaker off if the self testing fails.
• Two separate circuits (in communication) and two power supplies are used independently for the self testing to provide redundancy in the case of one testing circuit (or power supply) failing.
• The testing circuits are independent of the current sensing and triggering and are only involved with the regular self testing.
• It limits the current in the sensing “connection wire” to under 10mA so that, should a person receive an electric shock, the current received will be insufficient to prevent them from letting go. This is the ultimate “fail safe” feature of the development.
• It uses encapsulated ceramic thick hybrid circuit modules for maximum calibration accuracy, wide temperature operation, environment protection, high transient voltage performance and high reliability.

 

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