Thermal Straps
Flexible Thermal Links
Custom thermal conduction solutions for cryogenic, aerospace, and precision systems.
What is a Thermal Strap?
Thermal straps (or thermal links) are passive devices that thermally connect two points — heat source and heat sink — using flexible conductive materials, allowing heat dissipation without transmitting mechanical vibrations.
Thermal + Flexibility
High thermal conductivity with mechanical flexibility
Vibration Isolation
Decouples thermal paths from mechanical vibrations
No Moving Parts
Passive solution, highly reliable, maintenance-free
Typical Applications
Cryogenic Systems
Cryogenic refrigeration and ultra-low temperature systems (< 4K)
Scientific Instrumentation
High-precision instruments, particle detectors, telescopes
Aerospace & Satellites
Thermal management in space environments and satellites
Critical Electronics
Heat dissipation for high-power density electronics
Quantum Computing
Maintaining stable cryogenic environments for quantum processors
Vibration-Sensitive Systems
Systems requiring mechanical isolation with thermal coupling
Types and Materials
Copper Thermal Straps (Cu-OFHC)
- Very high conductivity - Ideal for low temperatures (< 77 K)
- High flexibility - Excellent mechanical properties
- Good mechanical strength - Durable and reliable
- Conductivity: > 400 W/mK @ 300K, > 1000 W/mK @ 77K
Aluminum Thermal Straps (Al-1100 / Al-6061)
- Lower weight - Critical for aerospace applications
- Good conductivity - > 200 W/mK @ 300K
- Space-grade - Meets aerospace standards
- Excellent weight/performance ratio
TEC-Integrated Thermal Straps
- Active temperature control - Built-in thermoelectric cooling
- Precise thermal regulation - Closed-loop control available
- Advanced option - For systems requiring dynamic thermal management
- Custom integration - Tailored to specific requirements
Design Criteria & Technical Specifications
Thermal Conductance
G = k·A / L - Optimized geometry for maximum heat transfer
Minimize Contact Resistance
Advanced terminal design and surface treatment for low thermal resistance
CTE Compatibility
Matched coefficient of thermal expansion between materials to prevent stress
Mechanical Flexibility
Designed to withstand vibrations and thermal cycles without fatigue
Electrical Isolation (Optional)
Insulating layers available when electrical decoupling is required
Operating Range
Typical operation from 4 K to 300 K, validated at cryogenic temperatures
Individual Validation
Every strap tested for thermal conductance - guaranteed performance
Protection & Encapsulation
Options for protective coating, insulation, and environmental sealing
Material Comparison & Recommendations
| Property | Copper (Cu-OFHC) | Aluminum (Al-1100/6061) | TEC-Integrated |
|---|---|---|---|
| Thermal Conductivity | Very High (> 400 W/mK) | Good (> 200 W/mK) | Variable + Active Control |
| Weight | Heavy | Lightweight | Medium |
| Temperature Range | 4 K - 300 K (Excellent at < 77K) | 4 K - 300 K | Controlled Range |
| Ideal Applications | Cryogenics, Quantum Systems | Aerospace, Weight-Critical | Precision Thermal Control |
Selection Recommendations
Maximum thermal conductance is critical, especially at cryogenic temperatures (< 77K)
Weight is a critical constraint, such as in aerospace or satellite applications
Precise, active temperature regulation is required for your application
Frequently Asked Questions
It depends on your specific requirements. For maximum thermal conductivity at cryogenic temperatures, choose copper. For weight-critical applications like aerospace, aluminum is ideal. For precise temperature control, consider TEC-integrated options. Contact our engineering team for personalized recommendations.
Yes, absolutely. All our thermal straps are custom-designed to meet your exact specifications, including length, width, terminal geometry, and mounting configurations. We work closely with clients to ensure optimal integration.
Yes, we can integrate electrical insulation layers between the thermal strap and the terminals when electrical decoupling is required. This is particularly important in systems where ground loops or electrical interference must be avoided.
Every thermal strap undergoes individual thermal conductance measurement at cryogenic temperatures in our test facility. We provide certified test data with each unit, guaranteeing the specified thermal performance.
Lead times vary depending on complexity and quantity. Typical custom orders range from 4-8 weeks from design approval to delivery. Contact us for specific timeline estimates for your project.
Yes, our engineering team provides comprehensive design assistance, including thermal modeling, material selection, and integration support to ensure optimal performance in your system.
Get Started with Custom Thermal Solutions
Ready to discuss your thermal management requirements? Our engineering team is here to help design the perfect thermal strap solution for your application.