IP Library › Granted Patent US 12,300,892
Granted Patent B2
US 12,300,892 · App. 17/660,386 · Granted May 13, 2025

Integrated structure, two radar modular assembly (RMA) stackable radar

Inventors: Craig H. McCordic (Medfield, MA); Michael P. Martinez (Worcester, MA); Craig Richardson (Watertown, MA); Mark J. Beaulieu (Sutton, MA)
Assignee: Raytheon Company
H01Q21/0025G01S7/027H01Q1/12G01S2013/0245
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Quick Facts
Patent No.
US 12,300,892
App. No.
17/660,386
Granted
May 13, 2025
Kind
B2
Abstract

A radar array assembly is provided, comprising a first chassis and a first vertical stiffener. The first chassis is configured to house a first set of array electronics and a second set of array electronics. The first vertical stiffener is disposed within and operably coupled to the first chassis to enable the first chassis to be resistant to buckling and to define a first cavity in which the first set of array electronics is disposed and a second cavity in which the second set of array electronics is disposed, wherein the first vertical stiffener is configured to be embedded within the first set of array electronics and the second set of array electronics, wherein the first vertical stiffener comprises a first integrated cooling manifold configured to cool both the first set of array electronics and the second set of array electronics.

Claims (70)

1. A radar array assembly comprising:

a first chassis configured to house a first set of array electronics and a second set of array electronics;

a first vertical stiffener disposed within and operably coupled to the first chassis to enable the first chassis to be resistant to buckling and to define a first cavity in which the first set of array electronics is disposed and a second cavity in which the second set of array electronics is disposed, wherein the first vertical stiffener is configured to be embedded within the first set of array electronics and the second set of array electronics, wherein the first vertical stiffener comprises a first integrated cooling manifold configured to cool both the first set of array electronics and the second set of array electronics; and

a first array plate having a first side and a second side opposite the first side, the first array plate coupled to the first vertical stiffener;

wherein the first vertical stiffener and the first array plate, in combination with the first chassis, provide a built-in self-support for the radar array assembly.

2. The radar array assembly of claim 1 , wherein:

the first chassis comprises a first channel configured to allow coolant flow of a fluid coolant therethrough;

the first vertical stiffener comprises a second channel configured to allow coolant flow of the fluid coolant therethrough; and

the first and second channels are in fluid communication.

3. The radar array assembly of claim 2 , wherein:

the first array plate comprises a third channel configured to allow coolant flow of the fluid coolant therethrough; and

the third channel is in fluid communication with at least one of the first and second channels.

4. The radar array assembly of claim 1 , wherein:

the first array plate is configured to support first and second radiator assemblies that are in operable communication with, respectively, the first set of array electronics and the second set of array electronics; and

the first array plate is configured to enable the first radiator assembly and the second radiator assembly to be interlocked and aligned to create a single monolithic array face.

5. The radar array assembly of claim 4 , wherein the first vertical stiffener and the first array plate, in combination with the first chassis, are configured to enable the first chassis to be stacked on top of a second chassis that is identical to the first chassis in order to double a size of the single monolithic array face.

6. The radar array assembly of claim 1 , wherein:

a first portion of the first array plate is associated with the first set of array electronics and a second portion of the first array plate is associated with the second set of array electronics;

the radar array assembly further comprises:

a first radiator assembly operably coupled to the first portion of the first array plate and configured for operable communication with the first set of array electronics; and

a second radiator assembly operably coupled to the second portion of the first array plate and configured for operable communication with the second set of array electronics; and

the first array plate is configured to support the first radiator assembly and the second radiator assembly and is configured to enable the first radiator assembly and the second radiator assembly to be interlocked and aligned to create a single monolithic array face.

7. The radar array assembly of claim 1 , wherein:

the first array plate is configured to support first and second radiator assemblies that are in operable communication with, respectively, the first and second sets of array electronics;

the first array plate is configured to enable the first radiator assembly and the second radiator assembly to be interlocked and aligned to create a single monolithic array face; and

the radar array assembly further comprises:

a second chassis operably coupled to the first chassis, the second chassis configured to house a third set of array electronics and a fourth set of array electronics, wherein the third set of array electronics and the fourth set of array electronics are coupled to the second chassis via a respective second support structure contained within the second chassis;

a second vertical stiffener disposed within and operably coupled to the second chassis so as to enable the second chassis to be resistant to buckling and to define a third cavity in which the third set of array electronics is disposed and a fourth cavity in which the fourth set of array electronics is disposed, wherein the second vertical stiffener is configured to be embedded within the third set of array electronics and the fourth set of array electronics, wherein the second vertical stiffener comprises a second integrated cooling manifold configured to cool both the third set of array electronics and the fourth set of array electronics; and

a second array plate having a first side and a second side opposite the first side, the second array plate coupled to the second vertical stiffener, wherein the second array plate is configured to support third and fourth radiator assemblies that are in operable communication with, respectively, the third and fourth sets of array electronics, wherein the second array plate is configured to enable the third and fourth radiator assemblies to be interlocked and aligned to the first radiator assembly and the second radiator assembly as part of the single monolithic array face.

8. The radar array assembly of claim 7 , wherein:

the first chassis comprises a first side disposed adjacent the first cavity and a second side disposed adjacent the second cavity; and

the second chassis is operably coupled to the first chassis along one of the first and second sides.

9. The radar array assembly of claim 7 , wherein the second chassis is stacked on top of the first chassis.

10. The radar array assembly of claim 9 , wherein:

the first chassis comprises a first side disposed adjacent the first cavity and a second side disposed adjacent the second cavity;

the second chassis comprises a third side disposed adjacent the third cavity and a fourth side disposed adjacent the fourth cavity; and

the radar array assembly further comprises a splice plate configured to secure at least one of the first and second sides of the first chassis to at least one of the third and fourth sides of the second chassis.

11. The radar array assembly of claim 1 , further comprising:

a top plate operably coupled to a top of the first chassis and configured to cover a top surface of the first vertical stiffener, a top side of the first cavity, and a top side of the second cavity; and

a bottom plate operably coupled to a bottom of the first chassis and configured to cover a bottom surface of the first vertical stiffener, a bottom side of the first cavity, and a bottom side of the second cavity;

wherein the top plate, the bottom plate, and the first chassis cooperate to provide a housing for the first set of array electronics and the second set of array electronics that is watertight and electromagnetic interference (EMI) tight.

12. A radar module, comprising:

a first set of array electronics in operable communication with a first set of radiators integrated into a first radiator assembly;

a second set of array electronics in operable communication with a second set of radiators integrated into a second radiator assembly;

a chassis configured to house the first set of array electronics and the second set of array electronics, wherein the first set of array electronics and the second set of array electronics are coupled to the chassis via a respective support structure contained within the chassis;

a vertical stiffener disposed within and operably coupled to the chassis so as to enable the chassis to be resistant to buckling, the vertical stiffener configured to be embedded within the first set of array electronics and the second set of array electronics and configured to define, in the chassis, a first cavity in which the first set of array electronics is disposed and a second cavity in which the second set of array electronics is disposed, wherein the vertical stiffener comprises an integrated cooling manifold configured to cool both the first set of array electronics and the second set of array electronics; and

an array plate having a first side and a second side opposite the first side, the array plate coupled to the vertical stiffener and configured to support the first radiator assembly and the second radiator assembly, wherein the array plate is configured to enable the first radiator assembly and the second radiator assembly to be interlocked and aligned to create a single monolithic array face for the radar module such that the vertical stiffener and the array plate, in combination with the chassis, provide a built-in self-support for the radar module.

13. The radar module of claim 12 , wherein:

the chassis comprises a first channel configured to allow coolant flow of a fluid coolant therethrough;

the vertical stiffener comprises a second channel configured to allow coolant flow of the fluid coolant therethrough; and

the first and second channels are in fluid communication.

14. The radar module of claim 13 , wherein:

the array plate comprises a third channel configured to allow coolant flow of the fluid coolant therethrough; and

the third channel is in fluid communication with at least one of the first and second channels.

15. The radar module of claim 13 , wherein the first channel is in fluid communication with at least one of a coolant input port and a coolant output port integrated into the vertical stiffener.

16. The radar module of claim 12 , wherein the integrated cooling manifold further comprises:

a supply manifold in fluid communication with a coolant input port; and

a return manifold in fluid communication with a coolant output port.

17. The radar module of claim 12 , wherein:

each of the first set of array electronics and the second set of array electronics comprises a respective plurality of radar transmit/receive (T/R) modules, each T/R module associated with power and beamforming signals; and

the power and beamforming signals are connected in parallel to each of the first set of radiators and the second set of radiators.

18. An antenna array comprising:

a plurality of stacked radar modules, each respective radar module comprising:

a first set of array electronics in operable communication with a first set of radiators integrated into a first radiator assembly;

a second set of array electronics in operable communication with a second set of radiators integrated into a second radiator assembly;

a chassis configured to house the first set of array electronics and the second set of array electronics, wherein the first set of array electronics and the second set of array electronics are coupled to the chassis via a respective support structure contained within the chassis;

a vertical stiffener disposed within and operably coupled to the chassis so as to enable the chassis to be resistant to buckling, the vertical stiffener configured to be embedded within the first set of array electronics and the second set of array electronics and configured to define, in the chassis, a first cavity in which the first set of array electronics is disposed and a second cavity in which the second set of array electronics is disposed, wherein the vertical stiffener comprises an integrated cooling manifold configured to cool both the first set of array electronics and the second set of array electronics; and

an array plate having a first side and a second side opposite the first side, the array plate coupled to the vertical stiffener and configured to support the first radiator assembly and the second radiator assembly, wherein the array plate is configured to enable the first radiator assembly and the second radiator assembly to be interlocked and aligned to create a single monolithic array face for the respective radar module such that the vertical stiffener and the array plate, in combination with the chassis, provide a built-in self-support for the respective radar module.

19. The antenna array of claim 18 , wherein the chassis, the vertical stiffener, and the array plate of each respective radar module are configured to enable a respective monolithic array face for each respective radar module to align with the respective monolithic array faces for every other respective radar module in order to create a single monolithic array face for the antenna array that has no interruptions in an array lattice for the single monolithic array face for the antenna array.

20. The antenna array of claim 19 , wherein elements of the first and second radiator assemblies have a common ground potential.

Assignments (2)
CORRECTIVE ASSIGNMENT TO CORRECT THE FOURTH INVENTOR'S NAME ON THE COVER SHEET PREVIOUSLY RECORDED AT REEL: 059758 FRAME: 0249. ASSIGNOR(S) HEREBY CONFIRMS THE ASSIGNMENT. Recorded Feb 10, 2023
From: MCCORDIC, CRAIG H.; MARTINEZ, MICHAEL P.; RICHARDSON, CRAIG; BEAULIEU, MARK J.
To: RAYTHEON COMPANY
Reel/Frame 063742/0746 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Apr 28, 2022
From: MCCORDIC, CRAIG H.; MARTINEZ, MICHAEL P.; RICHARDSON, CRAIG; BEAULIEU, MARJ J.
To: RAYTHEON COMPANY
Reel/Frame 059758/0249 →
Continuity (1)
Related Publication 20230344143A1 · Oct 26, 2023
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