High-Reliability Switches & Interconnects for Extreme Environments
Hermetically sealed micro switches and interconnects for high-reliability applications. -184°C to +260°C, hermetic sealing, vibration resistant. GJB 809B-2013, MIL-PRF-8805.
Industry Overview
Aerospace applications demand switches and interconnects that operate reliably across extreme temperature ranges (-184°C to +260°C), sustain vibration levels exceeding 50G at 10-2000Hz, maintain contact integrity through rapid pressure changes from sea level to space vacuum, and meet the reliability standards of MIL-PRF-8805, GJB 809B-2013, and DO-160.
Our hermetically sealed micro switches use all-welded metal shell construction with gold-plated contacts and inert gas fill to prevent oxidation, eliminate outgassing, and maintain consistent contact resistance across the full environmental envelope. Each model is qualified to GJB 809B-2013 (General Specification for Micro Switches) and tested per GJB 360B-2009 for vibration, shock, and temperature cycling.
Industry Standards
| Standard | Description | Relevance |
|---|---|---|
| GJB 809B-2013 | General Specification for Micro Switches | Primary qualification standard — all HK micro switches |
| GJB 360B-2009 | Test Methods for Electronic Components | Vibration, shock, thermal, sealing test procedures |
| MIL-PRF-8805 | Switches, Sensitive | US high-reliability industrial switch specification (equivalent to GJB 809B) |
| MIL-DTL-38999 | Connectors, Circular, High Density | Standard for circular connectors in aerospace |
| DO-160 | Environmental Conditions and Test Procedures for Airborne Equipment | RTCA standard for flight systems environmental testing |
| AS9100 | Quality Management Systems — Aerospace | Quality system standard for aerospace manufacturing |
| CASTPS04/026-2018 | high-altitude platform Procurement Specification | China Academy of Space Technology procurement standard |
Recommended Series
KWQM4 Series
Hermetically sealed SPDT micro switch
- Temperature: -184°C to +260°C
- 8 electrical variants (0.5A – 5A)
- Vibration: 15G sinusoidal, random per GJB 360B
- 4 actuator accessory options
- GJB 809B-2013 · Q/MA20347/Z-2019
KWQM5 Series
Screw-clamp terminal · Anti-radiation
- Temperature: -184°C to +260°C
- Screw-clamp for field replacement
- Explicit radiation resistance rating
- 2× M3 mounting
- GJB 809B-2013 qualified
KWQMY2-3AT Series
Miniature EMI-shielded · Radiation hardened
- Temperature: -184°C to +260°C
- 28V DC 1A / 0.5A rated
- EMI shielded for flight systems
- Dual-switch assembly available
- Potting sealed for extreme environments
Recommended Models
| Model | Temp Range | Current | Sealing | Vibration | Best For |
|---|---|---|---|---|---|
| HK-KWQM4-4Z | -184°C to +260°C | 5A Res / 3A Ind | Hermetic Welded | 15G sin · random Grade D | Flight control, engine monitoring |
| HK-KWQM5-2-28 | -184°C to +260°C | 5A | Hermetic Welded | 15G sin | Cryogenic fuel systems, radiation areas |
| HK-KWQMY1-0Z | -55°C to +125°C | 3A | Hermetic Miniature | 15G sin | Space-constrained flight systems |
| HK-KWQMY2-3AT11-1 | -184°C to +260°C | 1A / 0.5A | EMI Shielded Hermetic | 15G sin | flight systems, EMI-sensitive circuits |
Related Resources
Frequently Asked Questions
What is a hermetically sealed micro switch?
A hermetically sealed micro switch has its contacts enclosed in a welded metal shell filled with inert gas. The leak rate is ≤1×10⁻³ Pa·cm³/s, meaning no external atmosphere can enter. This is essential for aerospace applications where altitude changes cause pressure differentials that would compromise standard seals.
Why are MIL-DTL-38999 / MIL-PRF-8805 standards important for aerospace?
These high-reliability industrial specifications define performance requirements for connectors and switches in extreme environments. They cover temperature cycling, vibration, shock, altitude, and sealing. Products qualified to these standards have been independently tested to perform reliably in aerospace conditions.
What is the difference between hermetic sealing and IP67?
IP67 means protection against dust and temporary water immersion. Hermetic sealing means a true gas-tight seal with leakage rate ≤1×10⁻³ Pa·cm³/s — essential at altitude where pressure differentials can defeat IP-rated seals. For aerospace, hermetic is mandatory in unpressurized areas.
How do I select a switch for high-vibration aerospace environments?
Key criteria: (1) Welded hermetic shell construction — eliminates seal failure paths; (2) GJB 360B-2009 vibration qualification — confirms sinusoidal and random vibration tolerance; (3) Gold-plated contacts — prevent oxidation at high temperatures; (4) Contact force ≥ specified minimum — prevents bounce.
Does Postek offer custom aerospace configurations?
Yes. We provide custom actuator attachments, wire-lead termination, and application-specific environmental testing. Contact our engineering team with your requirements for a custom proposal.
Need a Customized Solution?
Our engineers can help select or develop a switch for your specific requirements.
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