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.

Abstract: A modular radar system comprises an antenna assembly, a support structure to which the antenna assembly is mounted, and a set of modular radar subsystems. The antenna assembly comprises an antenna array, an antenna enclosure to which the antenna array is attached and which is configured to house the antenna array and to distribute communications signals and power signals to the antenna array, and an antenna enclosure interface configured to receive inputs to and provide outputs from, the antenna array. The support structure positions the antenna array at an orientation and elevation for antenna operation. The set of modular radar subsystems is separate from the support structure and in operable communication with the antenna enclosure interface and comprises a data processing subsystem, a cooling subsystem, and an AC power subsystem supplying power to the antenna enclosure, the data processing subsystem, the cooling subsystem and to a DC power conversion subsystem.

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: 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: 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.

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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.