Abstract:
An apparatus includes a coldplate (104, 200, 300) configured to be thermally coupled to a structure (100) to be cooled and to remove thermal energy from the structure. The coldplate includes (i) first and second outer layers (202 and 206, 302 and 306) having at least one first material and (ii) a third layer (204, 304) embedded in the outer layers and having at least one second material. The first and second materials have different coefficients of thermal expansion (CTEs). The third layer is embedded non-uniformly in the outer layers so that different zones (114a-114c, 212a-212c, 312a-312c) of the coldplate have different local CTEs. The third layer may include openings (210, 310) extending through the second material(s), and projections (208, 308) of the first material(s) from at least one of the first and second outer layers may partially or completely fill the openings. The first and second outer layers may include aluminum or an aluminum alloy, and the third layer may include aluminum silicon carbide or thermal pyrolytic graphite.
Abstract:
A coolant interface includes a line replaceable unit (LRU) (103) inserted into a slot within a modular assembly such as a chassis (101) for an electronics assembly. Quick disconnect fluid coupling fittings (131) on the LRU mate with counterpart fittings (111) on a fluid distribution manifold (110) within the chassis when the LRU is inserted into the slot. A seal (133) surrounding the quick disconnect fluid coupling fittings on a flat surface (132) abutting a counterpart surface on the fluid distribution manifold when the LRU is inserted into the slot compresses the seal against the counterpart surface. Alignment pin(s) (134) projecting from the flat surface and received by corresponding guide holes within the counterpart surface, and captive hardware (135) provides pressure between the flat surface and the counterpart surface to increase and maintain compression of the seal. The alignment pins and captive hardware are arranged to increase mechanical stability of the connection.
Abstract:
A method of forming a cooling structure for a heat-dissipating surface includes arranging a heat spreader layer adjacent the heat-dissipating surface, bonding a coldplate directly to the heat spreader layer opposite the heat-dissipating surface, and forming an intermetallic bond between the heat spreader layer and the coldplate. The coldplate is bonded to the heat spreader layer using ultrasonic additive manufacturing.
Abstract:
A modular phased array antenna that includes a plurality of modular antenna array blocks assembled together as a single antenna array and an array face having an array plate and a radiator and radome assembly for each modular block interlocked and aligned to create a single monolithic array face. Each modular antenna array block includes: a plurality of transmit/receive integrated multichannel module (TRIMM) cards, each TRIMM card including power and beamforming signals, where power and beamforming signals are connected in parallel to each modular antenna array block, a plurality of radiators for radiating antenna signals having a radiator face, a radome integrated with the plurality of radiators and interfacing directly to the radiator face, where the radome does not extend beyond the radiator face, and a frame for supporting the TRIMM cards.
Abstract:
An air-cooled heat exchanger 102 includes a housing 201 having an intake 202 for air flowing through the housing and at least one outlet 203, 204 for the air flowing through the housing. A set of segmented fins 206 extend within the housing between the intake and the at least one outlet, configured to direct the air flowing through the housing. Each segment of the segmented fins has a length selected based on a throw distance for an environmental protection coating process employed to apply an environmental protection coating to surfaces of the fin segments. Access ports 207 extend through at least one wall of the housing at locations allowing connection, when the access ports are unblocked, of electrical conductors used in the environmental protection coating process to both ends of each of the fin segments. Access port covers 401 block each of the access ports during operation of the air-cooled heat exchanger.
Abstract:
An air-cooled heat exchanger includes a housing having an intake for air flowing through the housing and at least one outlet for the air flowing through the housing. A set of segmented fins extend within the housing between the intake and the at least one outlet, configured to direct the air flowing through the housing. Each segment of the segmented fins has a length selected based on a throw distance for an environmental protection coating process employed to apply an environmental protection coating to surfaces of the fin segments. Access ports extend through at least one wall of the housing at locations allowing connection, when the access ports are unblocked, of electrical conductors used in the environmental protection coating process to both ends of each of the fin segments. Access port covers block each of the access ports during operation of the air-cooled heat exchanger.