Packaging architecture for a high frequency active electronically scanned array
A packaging architecture for a high frequency active electronically scanned array is described. The packaging architecture enables the thermal management benefits of a card-fed approach to be extended to higher-frequency AESA to operate with higher output power and/or duty cycle. The packaging architecture includes circuit cards that are non-rectangular in shape to provide room for thermal management solutions that are placed between adjacent circuit cards.
1 . A card-fed array comprising:
a first plurality of circuit cards;
a second plurality of circuit cards; wherein the first plurality of circuit cards alternate with the second plurality of circuit cards; wherein each of the first plurality of circuit cards and the second plurality of circuit cards comprise:
a substrate; wherein the substrate comprises one or more wide portions and one or more narrow portions; wherein the one or more wide portions are wider than the one or more narrow portions; wherein the one or more narrow portions extend from the one or more wide portions;
a plurality of radiating elements; wherein the plurality of radiating elements are disposed on the one or more wide portions of the substrate;
wherein the plurality of radiating elements are arranged in a line;
a plurality of transmission lines;
a plurality of transmit/receive modules; wherein the plurality of transmit/receive modules are disposed on the one or more narrow portions of the substrate; wherein the plurality of transmission lines connect the plurality of radiating elements with the plurality of transmit/receive modules; and
a plurality of backplane interfaces; wherein the plurality of backplane interfaces are coupled to the plurality of transmit/receive modules;
a first plurality of thermal spreaders; wherein the first plurality of thermal spreaders are coupled to the one or more narrow portions of the substrates of the first plurality of circuit cards; and
a second plurality of thermal spreaders; wherein the second plurality of thermal spreaders are coupled to the one or more narrow portions of the substrates of the second plurality of circuit cards;
wherein the card-fed array is an active electronically scanned array; wherein the second plurality of circuit cards are mirrored to the first plurality of circuit cards; wherein the one or more narrow portions of the substrates of the second plurality of circuit cards are inverted to the one or more narrow portions of the substrates of the first plurality of circuit cards.
2 . The card-fed array of claim 1 , wherein the first plurality of circuit cards and the second plurality of circuit cards are arranged in parallel.
3 . The card-fed array of claim 1 , wherein each of the first plurality of thermal spreaders and the second plurality of thermal spreaders comprise a plate and a flange; wherein the flange extends from the plate;
wherein the plates of the first plurality of thermal spreaders are coupled to the one or more narrow portions of the substrates of the first plurality of circuit cards; wherein the plates of the second plurality of thermal spreaders are coupled to the one or more narrow portions of the substrates of the second plurality of circuit cards.
4 . The card-fed array of claim 3 , wherein the flanges of the first plurality of thermal spreaders abut with adjacent flanges of the first plurality of thermal spreaders; wherein the flanges of the second plurality of thermal spreaders abut with adjacent flanges of the second plurality of thermal spreaders.
5 . The card-fed array of claim 3 , wherein the first plurality of thermal spreaders and the second plurality of thermal spreader each comprise a spreader-to-spreader interface; wherein the spreader-to-spreader interfaces connect the plates of the first plurality of thermal spreaders and the plates of the second plurality of thermal spreaders.
6 . The card-fed array of claim 5 , wherein the plates of the first plurality of thermal spreaders are offset from the plates of the second plurality of thermal spreaders.
7 . A card-fed array comprising:
a first plurality of circuit cards;
a second plurality of circuit cards; wherein the first plurality of circuit cards alternate with the second plurality of circuit cards; wherein each of the first plurality of circuit cards and the second plurality of circuit cards comprise:
a substrate; wherein the substrate comprises one or more wide portions and one or more narrow portions; wherein the one or more wide portions are wider than the one or more narrow portions; wherein the one or more narrow portions extend from the one or more wide portions;
a plurality of connectors; wherein the plurality of connectors are disposed on the wide portion of the substrate; wherein the plurality of connectors are arranged in a line;
a plurality of transmission lines;
a plurality of transmit/receive modules; wherein the plurality of transmit/receive modules are disposed on the one or more narrow portions of the substrate; wherein the plurality of transmission lines connect the plurality of connectors with the plurality of transmit/receive modules; and
a plurality of backplane interfaces; wherein the plurality of backplane interfaces are coupled to the plurality of transmit/receive modules;
a first plurality of thermal spreaders; wherein the first plurality of thermal spreaders are coupled to the one or more narrow portions of the substrates of the first plurality of circuit cards;
a second plurality of thermal spreaders; wherein the second plurality of thermal spreaders are coupled to the one or more narrow portions of the substrates of the second plurality of circuit cards; and
one or more third circuit cards; wherein the one or more third circuit cards are orthogonal to the first plurality of circuit cards and the second plurality of circuit cards; wherein the one or more third circuit cards comprise a plurality of radiating elements; wherein the plurality of radiating elements are connected to the plurality of connectors; wherein the card-fed array is an active electronically scanned array; wherein the second plurality of circuit cards are mirrored to the first plurality of circuit cards; wherein the one or more narrow portions of the substrates of the second plurality of circuit cards are inverted to the one or more narrow portions of the substrates of the first plurality of circuit cards.
8 . The card-fed array of claim 1 , wherein an operational frequency of the first plurality of circuit cards and the second plurality of circuit cards is in at least one of a Ka-band, a V-band, or a W-band.
9 . The card-fed array of claim 8 , wherein the operational frequency is between 40 to 100 GHz.
10 . The card-fed array of claim 1 , wherein the plurality of transmit/receive modules are staggered on the substrate.
11 . The card-fed array of claim 10 , wherein the plurality of transmit/receive modules are staggered on the substrate along a pair of diagonal lines.
12 . The card-fed array of claim 1 , wherein each of the plurality of transmit/receive modules are connected to a respective radiating element of the plurality of radiating elements.
13 . The card-fed array of claim 1 , wherein the one or more wide portions are at least twice as wide as the one or more narrow portions.
14 . The card-fed array of claim 1 , wherein the substrate is one of an L-shape or a U-shape.
15 . The card-fed array of claim 1 , wherein the plurality of radiating elements are disposed on an edge of the one or more wide portions of the substrate.
16 . The card-fed array of claim 1 , wherein the one or more wide portions and the one or more narrow portions are co-planar.