Development of a Turn Key Cryogenic Cooling Module for Space Flight Based on a Commercial Cryocooler

Commercial cryocoolers have significant price and lead time advantages over coolers built exclusively for the space market, but there are many challenges that must be overcome before using a COTS cooler for flight. The initial cost advantage is significantly narrowed by the cost of adapting the COTS cooler for flight. JPL is developing a “turn key” cryogenic cooling solution based on a commercial cryocooler with the intention that it can become a standard product. The goal is to develop a complete, fully redundant cryogenic cooling solution based on the Thales 9310. The system includes the cooler, brackets to provide mounting and cooling, supporting structures, vibration isolation, thermal straps, thermal switches, and drive electronics. The 9310 is a split pulse tube cooler in the five watt class. It is designed for ground operation. Use in space will require addition of structures suitable for securely mounting and for waste heat removal. Bond-on aluminum brackets will provide rigid structural support and include interfaces for heat pipes for cooling the compressor and expander. Low cost drive electronics provide power, as well as temperature and exported vibration control. The two cryocoolers mount on a single central plate. Visco-elastic isolators provide vibration isolation, both to reduce launch loads into the cooler and exported forces and torques from the operating cooler. Flexible connection to the payload is provided by graphite foil thermal straps. Differential CTE thermal switches thermally isolate the non-operating cryocooler. The paper discusses qualification of the various components for flight, including launch vibration and thermal performance testing, as well as a full up testing of the completed assembly.