Heat switches are commonly used in space applications to thermally isolate sensitive detectors during high-temperature decontamination processes, protecting them from potential damage. They are also employed to ensure cryocooler redundancy by allowing selective thermal connection or disconnection, which enhances system reliability throughout the mission.
However, passive actuation heat switches often face challenges such as limited switching speed, sensitivity to environmental variations, and difficulty in precise control of the switching temperature.
To address these challenges, we are developing an actively actuated DTE-type heat switch with a weight of 200 g, designed to operate at 100 K with a 102 μm gap between the connecting interfaces. Different materials with distinct physical properties were selected to ensure optimal performance. Ultem 1000 was used for its high coefficient of thermal expansion (CTE), which plays a critical role in bridging the 102 μm gap during actuation.
A detailed thermo-structural simulation was carried out, followed by experimental validation. The simulated switching ratio achieved was 182. In the OFF state, the thermal resistance was measured experimentally as 77.2 °C/W, compared to 80.11 °C/W in simulation. In the ON state, the thermal resistance was 1.63 °C/W experimentally and 0.56 °C/W in simulation. This design combines simplicity, a wide operational range, an appropriate switching ratio , and a switching time constant ( switch), making it an attractive solution for cryogenic thermal management in spaceborne sensor and cryocooler systems.
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