Raytheon Company

Brazonics, Inc.

Craig H McCordic

Joseph R Ellsworth

Michael P Martinez

Scott R Cheyne

Travis L Mayberry

Jeffrey Paquette

Todd E Southard

Douglas Moriondo

James A Pruett

Gregory W Heinen

Mary K Herndon

David H Altman

Ethan Santosh Heinrich

Ralph P Mason

Dimitry Zarkh

Brian J Harkins

Caroline Margaret Manteiga

Edward I Holmes

Mark J Beaulieu

Craig Richardson

Steven M Lombardo

Joseph Angelo DelGenio

Christopher Robert White

Adam Carl Rickis

Brian K Bacon

Jordan Joel Castillo

Lee P Barber

Scott J Champagne

Leo S Ludwick

John A Mikutel

Douglas J Moriondo

A method of decreasing a cycle time of a brazing process is provided. The method includes arranging each of first and second pairs of braze parts together, each of the first and second pairs of the braze parts having braze material interposed between the braze parts, stacking the first and second pairs of the braze parts to form a stack, interposing pyrolytic graphite (PG) between the first pair of the braze parts and the second pair of the braze parts in the stack and heating the first and second pairs of the braze parts to a brazing temperature to braze the braze parts of each of the first and second pairs of the braze parts together.

Furnace braze cycle enhancement

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.

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

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.

Modular and stackable antenna array

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.

Ultrasonic additively manufactured coldplates on heat spreaders

An apparatus includes a coldplate configured to be thermally coupled to a structure to be cooled and to remove thermal energy from the structure. The coldplate includes (i) first and second outer layers having at least one first material and (ii) a third layer 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 of the coldplate have different local CTEs. The third layer may include openings extending through the second material(s), and projections 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.

Tailored coldplate geometries for forming multiple coefficient of thermal expansion (CTE) zones

A coolant interface includes a line replaceable unit (LRU) inserted into a slot within a modular assembly such as a chassis for an electronics assembly. Quick disconnect fluid coupling fittings on the LRU mate with counterpart fittings on a fluid distribution manifold within the chassis when the LRU is inserted into the slot. A seal surrounding the quick disconnect fluid coupling fittings on a flat surface 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) projecting from the flat surface and received by corresponding guide holes within the counterpart surface, and captive hardware 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.

Multi-purpose coolant interface

A manifold structure has at least one flow passage and a center manifold section that has at least one machined cavity. The manifold structure includes a plurality of ultrasonically additively manufactured (UAM) finstock layers arranged in the flow passage. After the finstock is formed by UAM, the finstock is permanently joined to the center manifold section via a brazing or welding process. Using UAM and a permanent joining process enables joining of the UAM finstock having enhanced thermal features to a vacuum brazement structure. UAM enables the finstock to be formed of dissimilar metal materials or multi-material laminate materials. UAM also enables bond joints of the finstock to be arranged at angles greater than ten degrees relative to a horizontal axis by using the same aluminum material in the UAM process and in the vacuum brazing process.

Integration of ultrasonic additive manufactured thermal structures in brazements

An apparatus includes a generator configured to generate electrical power. The apparatus also includes first and second tanks each configured to receive and store a refrigerant under pressure. The apparatus further includes a first piston assembly having a first piston that divides a volume within the first piston assembly into first and second spaces each configured to receive refrigerant from at least one of the tanks. In addition, the apparatus includes a second piston assembly having a second piston coupled to the first piston. The generator is configured to generate the electrical power based on movement of at least one of the first and second pistons. During use, flows of the refrigerant between the tanks and the spaces can be created based on a pressure differential, such as a pressure differential created by a temperature difference between the tanks.

System and method for free-piston power generation based on thermal differences

In one aspect, a radar array assembly includes two or more vertical stiffeners each having bores with threads and a first radar module. The first radar module includes radar transmit and receive (T/R) modules and a chassis having channels configured to receive a coolant. The chassis includes shelves having ribs. The ribs have channels configured to receive the coolant and the ribs form slots to receive circuit cards disposed in parallel. The circuit cards include the T/R modules. The chassis also includes set screws attached to opposing sides of the chassis. The set screws have bores to accept fasteners to engage the threads on a corresponding one of the two or more vertical stiffeners. The first radar module is configured to operate as a stand-alone radar array.

Modular architecture for scalable phased array radars

A heat sink includes a fluid channel and a cooling wall in contact with coolant flowing in the fluid channel. The channel is configured to vary the velocity of coolant along the length of the fluid channel to vary the coolant's heat transfer coefficient and thereby compensate for the coolant's temperature rise along the length of the fluid channel. The result is a heat sink that is isothermal along its length.

Heat sink and method of making same

An edge cooled graphite core aluminum cold plate for use in phased array radar systems, the cold plate including opposing aluminum skins, and a core layer sandwiched between the opposing aluminum skins. The core layer includes graphite surrounded by an aluminum body. The aluminum body includes inwardly directed tabs extending from opposing cooled edges of the cold plate, the inwardly directed aluminum tabs having orifices therethrough. The opposing aluminum skins also includes orifices therethrough aligned with the orifices in the tabs of the aluminum body to reduce the conductivity of the cooled edges of the cold plate thus reducing the temperature gradient between edge mounted heat sources and inwardly mounted heat sources without adversely affecting the structural integrity of the graphite core layer.

Cold plate assembly

A thermoelectric dehumidifier includes at least one thermoelectric chiller element disposed within a sealed cavity defined between hot and cold plates for removing moisture from an enclosure. The thermoelectric dehumidifier can include a gutter for receiving condensate from the coldplate surface. A drainage mechanism can be coupled to the gutter for removing the collected condensate from the enclosure. An antenna array enclosure can include a thermoelectric dehumidifier that passively reduces the relative humidity within the array enclosure.

Growing community of inventors

Medfield, MA, United States of America

Craig H McCordic