Abstract:
In one aspect, a system includes a first circuit board that includes integrated circuits, a first thermal spreader coupled to the integrated circuits of the first circuit board, a first compliant board coupled to the first circuit board, a second circuit board that includes integrated circuits and a second thermal spreader coupled to the integrated circuits of the second circuit board. The first circuit board and the first thermal spreader have a first thickness. The second daughter board and the second thermal spreader have a second thickness. The system further includes a second compliant board coupled to the second circuit board, a board assembly coupled to first and second compliant boards and a cold-plate assembly in contact with the first and second thermal spreaders. Either of the first or the second compliant boards is configured to expand or contract to account for the differences between the first and second thicknesses.

Description:
BACKGROUND 
     As is known in the art, a phased array antenna includes a plurality of active circuits spaced apart from each other by known distances. Each of the active circuits is coupled through a plurality of phase shifter circuits, amplifier circuits and/or other circuits to either or both of a transmitter and receiver. In some cases, the phase shifter, amplifier circuits and other circuits (e.g., mixer circuits) are provided in a so-called transmit/receive (T/R) module and are considered to be part of the transmitter and/or receiver. 
     The phase shifters, amplifier and other circuits (e.g., T/R modules) often require an external power supply (e.g., a DC power supply) to operate correctly. Thus, the circuits are referred to as “active circuits” or “active components.” Accordingly, phased array antennas which include active circuits are often referred to as “active phased arrays.” 
     Active circuits dissipate power in the form of heat. High amounts of heat can cause active circuits to be inoperable. Thus, active phased arrays must be cooled. In one example heat-sink(s) are attached to each active circuit to dissipate the heat. 
     SUMMARY 
     In one example, an active, electronically scanned array (AESA) panel architecture system includes a first daughter board that include active circuits, a first thermal spreader coupled to the active circuits of the first daughter board, a first compliant board coupled to the first daughter board, a second daughter board that includes active circuits, a second thermal spreader coupled to the active circuits of the second daughter board, a second compliant board coupled to the second daughter board, a mother board assembly coupled to first and second compliant boards and a cold-plate assembly in contact with the first thermal spreader and the second thermal spreader. The first daughter board and the first thermal spreader have a first thickness and the second daughter board and the second thermal spreader have a second thickness different from the first thickness. Either of the first or second compliant boards is configured to expand or contract to account for the differences between the first and second thicknesses. 
     In another aspect, an active, electronically scanned array (AESA) panel architecture system includes a first daughter board that includes active circuits, a first thermal spreader coupled to the active circuits of the first daughter board, a first RF interface board coupled to the first daughter board, a second daughter board that includes active circuits, a second thermal spreader coupled to the active circuits of the second daughter board, a second RF interface board coupled to the second daughter board, a mother board assembly coupled to first and second RF interface boards, and a cold-plate assembly in contact with the first and second thermal spreaders. The first daughter board and the first thermal spreader have a first thickness and the second daughter board and the second thermal spreader have a second thickness different from the first thickness. The first and second RF interface boards each include compliant elements on at least one side of the first RF interface board. The first and second RF interface boards are configured to expand or contract to account for the differences in thicknesses between the first thickness and the second thickness. The first RF interface board provides electrical coupling between the active circuits of the first daughter board and the mother board and the second RF interface board provides electrical coupling between the active circuits of the second daughter board and the mother board. 
     In a further aspect, a system includes a first circuit board that includes integrated circuits, a first thermal spreader coupled to the integrated circuits of the first circuit board, a first compliant board coupled to the first circuit board, a second circuit board that includes integrated circuits and a second thermal spreader coupled to the integrated circuits of the second circuit board. The first circuit board and the first thermal spreader have a first thickness. The second daughter board and the second thermal spreader have a second thickness. The system further includes a second compliant board coupled to the second circuit board, a board assembly coupled to first and second compliant boards and a cold-plate assembly in contact with the first and second thermal spreaders. Either of the first or the second compliant boards is configured to expand or contract to account for the differences between the first and second thicknesses. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a plan view of an array antenna formed from a plurality of tile sub-arrays. 
         FIG. 2A  is a partially exploded perspective view of an example of a tile sub-array. 
         FIG. 2B  is a cross-sectional view of the tile sub-array of  FIG. 2A  taken along lines  2 B- 2 B. 
         FIG. 2C  is a cross-sectional view of the tile sub-array of  FIG. 2B  with a cold plate. 
         FIG. 3  is a cross-sectional view of a tile sub-array with the cold plate and a compliant member. 
         FIG. 4A  is a cross-sectional view of an example of a single daughter board/thermal spreader assembly mounted to a mother board. 
         FIG. 4B  is a cross-sectional view of a thermal spreader of  FIG. 4B . 
         FIG. 5A to 5F  are cross-sectional views of single daughter board/thermal spreader assembly of  FIG. 4A  with different tolerance stack-ups. 
     
    
    
     DETAILED DESCRIPTION 
     A “panel array” (or more simply “panel”) refers to a multilayer printed wiring board 
     (PWB) which includes an array of active circuits (or more simply “radiating elements” or “radiators”), as well as RF, logic and DC distribution circuits in one highly integrated PWB. A panel is also sometimes referred to herein as a tile array (or more simply, a “tile”). 
     An array antenna may be provided from a single panel (or tile) or from a plurality of panels. In the case where an array antenna is provided from a plurality of panels, a single one of the plurality of panels is sometimes referred to herein as a “panel sub-array” (or a “tile sub-array”). 
     Reference is sometimes made herein to an array antenna having a particular number of panels. It should of course, be appreciated that an array antenna may be comprised of any number of panels and that one of ordinary skill in the art will appreciate how to select the particular number of panels to use in any particular application. 
     It should also be noted that reference is sometimes made herein to a panel or an array antenna having a particular array shape and/or physical size or a particular number of active circuits. One of ordinary skill in the art will appreciate that the techniques described herein are applicable to various sizes and shapes of panels and/or array antennas and that any number of active circuits may be used. 
     Similarly, reference is sometimes made herein to panel or tile sub-arrays having a particular geometric shape (e.g., square, rectangular, round) and/or size (e.g., a particular number of active circuits) or a particular lattice type or spacing of active circuits. One of ordinary skill in the art will appreciate that the techniques described herein are applicable to various sizes and shapes of array antennas as well as to various sizes and shapes of panels (or tiles) and/or panel sub-arrays (or tile sub-arrays). 
     Thus, although the description provided herein below describes the inventive concepts in the context of an array antenna having a substantially square or rectangular shape and comprised of a plurality of tile sub-arrays having a substantially square or rectangular-shape, those of ordinary skill in the art will appreciate that the concepts equally apply to other sizes and shapes of array antennas and panels (or tile sub-arrays) having a variety of different sizes, shapes, and types of elements. Also, the panels (or tiles) may be arranged in a variety of different lattice arrangements including, but not limited to, periodic lattice arrangements or configurations (e.g., rectangular, circular, equilateral or isosceles triangular and spiral configurations) as well as non-periodic or other geometric arrangements including arbitrarily shaped array geometries. 
     Reference is also sometimes made herein to the array antenna including an antenna element (active circuit) of a particular type, size and/or shape. For example, one type of radiating element is a so-called patch antenna element having a square shape and a size compatible with operation at a particular frequency (e.g., 10 GHz) or range of frequencies (e.g., the X-band frequency range). Reference is also sometimes made herein to a so-called “stacked patch” antenna element. Those of ordinary skill in the art will recognize, of course, that other shapes and types of antenna elements (e.g., an antenna element other than a stacked patch antenna element) may also be used and that the size of one or more active circuits may be selected for operation at any frequency in the RF frequency range (e.g., any frequency in the range of about 1 GHz to about 100 GHz). The types of radiating elements which may be used in the antenna of the present invention include but are not limited to notch elements, dipoles, slots or any other antenna elements (regardless of whether the antenna element is a printed circuit element) known to those of ordinary skill in the art. It should also be appreciated that the active circuits in each panel or tile sub-array can be provided having any one of a plurality of different antenna element lattice arrangements including periodic lattice arrangements (or configurations) such as rectangular, square, triangular (e.g., equilateral or isosceles triangular), and spiral configurations as well as non-periodic or arbitrary lattice arrangements. Applications of at least some examples of the panel array (sometimes referred to as a “tile array”) architectures described herein include, but are not limited to, radar, electronic warfare (EW) and communication systems for a wide variety of applications including ship based, airborne, missile and satellite applications. It should thus be appreciated that the panel (or tile sub-array) described herein can be used as part of a radar system or a communications system. 
     At least some examples as described herein are applicable, but not limited to, military, airborne, shipborne, communications, unmanned aerial vehicles (UAV) and/or commercial wireless applications. 
     The tile sub-arrays to be described herein below can also utilize embedded circulators; a slot-coupled, polarized egg-crate radiator; a single integrated monolithic microwave integrated circuit (MMIC); and a passive radio frequency (RF) circuit architecture. For example, as described further herein, technology described in the following commonly assigned United States Patents can be used in whole or in part and/or adapted to be used with at least some embodiments of the tile subarrays described herein: U.S. Pat. No. 6,611,180, entitled “Embedded Planar Circulator”; U.S. Pat. No. 6,624,787, entitled “Slot Coupled, Polarized, Egg-Crate Radiator”; and/or U.S. Pat. No. 6,731,189, entitled “Multilayer stripline radio frequency circuits and interconnection methods.” Each of the above patents is hereby incorporated herein by reference in their entireties. 
     Referring now to  FIG. 1 , an array antenna  10  is comprised of a plurality of tile sub-arrays  12   a - 12 N. It should be appreciated that in this example, N total tile sub-arrays  12  include the entire array antenna  10 . In one particular example, the total number of tile sub-arrays is sixteen tile sub-arrays (i.e., N=16). The particular number of tile sub-arrays  12  used to provide a complete array antenna can be selected in accordance with a variety of factors including, but not limited to, the frequency of operation, array gain, the space available for the array antenna and the particular application for which the array antenna  10  is intended to be used. Those of ordinary skill in the art will appreciate how to select the number of tile sub-arrays  12  to use in providing a complete array antenna. 
     As illustrated in tiles  12   b  and  12   i,  in the example of  FIG. 1 , each tile sub-array  12   a - 12 N includes eight rows  13   a - 13   h  of active circuits  15  (also known as antenna elements) with each row containing eight active circuits  15 . Each of the tile sub-arrays  12   a - 12 N is thus said to be an eight by eight (or 8×8) tile sub-array. It should be noted that each active circuit  15  is shown in phantom in  FIG. 1  since the active circuits  15  are not directly visible on the exposed surface (or front face) of the array antenna  10 . Thus, in this particular example, each tile sub-array  12   a - 12 N includes sixty-four (64) active circuits. In the case where the array  10  includes sixteen (16) such tiles, the array  10  includes a total of one-thousand and twenty-four (1,024) active circuits  15 . 
     In another example, each of the tile sub-arrays  12   a - 12 N includes  16  active circuits. Thus, in the case where the array  10  includes sixteen (16) such tiles and each tiles includes sixteen (16) active circuits  15 , the array  10  includes a total of two-hundred and fifty-six (256) active circuits  15 . 
     In view of the above examples, it should thus be appreciated that each of the tile sub-arrays can include any desired number of active circuits  15 . The particular number of active circuits to include in each of the tile sub-arrays  12   a - 12 N can be selected in accordance with a variety of factors including but not limited to the desired frequency of operation, array gain, the space available for the antenna and the particular application for which the array antenna  10  is intended to be used and the size of each tile sub-array  12 . For any given application, those of ordinary skill in the art will appreciate how to select an appropriate number of radiating active circuits to include in each tile sub-array. The total number of active circuits  15  included in an antenna array such as antenna array  10  depends upon the number of tiles included in the antenna array and as well as the number of active circuits included in each tile. 
     Each tile sub-array is electrically autonomous (except any mutual coupling which occurs between active circuits  15  within a tile and on different tiles). Thus, the RF feed circuitry which couples RF energy to and from each radiator on a tile is incorporated entirely within that tile (i.e., all of the RF feed and beamforming circuitry which couples RF signals to and from active circuits  15  in tile  12   b  are contained within tile  12   b ). In one example, each tile includes one or more RF connectors and the RF signals are provided to the tile through the RF connector(s) provided on each tile sub-array. 
     Also, signal paths for logic signals and signal paths for power signals which couple signals to and from transmit/receive (T/R) circuits are contained within the tile in which the T/R circuits exist. RF signals are provided to the tile through one or more power/logic connectors provided on the tile sub-array. 
     The RF beam for the entire array  10  is formed by an external beamformer (i.e., external to each of the tile subarrays  12 ) that combines the RF outputs from each of the tile sub-arrays  12   a - 12 N. As is known to those of ordinary skill in the art, the beamformer may be conventionally implemented as a printed wiring board stripline circuit that combines N sub-arrays into one RF signal port (and hence the beamformer may be referred to as a 1:N beamformer). 
     It should be appreciated that the examples of the tile sub-arrays described herein (e.g., tile sub-arrays  12   a - 12 N) differ from conventional array architectures in that the microwave circuits of the tile sub-arrays are contained in circuit layers which are disposed in planes that are parallel to a plane defined by a face (or surface) of an array antenna (e.g., surface  10   a  of array antenna  10 ) made up from the tiles. In  FIG. 1 , for example, the circuits  15  provided on the layers of circuit boards from which the tiles  12   a - 12 N are provided are all parallel to the surface  10   a  of array antenna  10 . By utilizing circuit layers that are parallel to a plane defined by a face of an array antenna, the tile architecture approach results in an array antenna having a reduced profile (i.e., a thickness which is reduced compared with the thickness of conventional array antennas). 
     Advantageously, the tile sub-array embodiments described herein can be manufactured using standard printed wiring board (PWB) manufacturing processes to produce highly integrated, passive RF circuits, using commercial, off-the-shelf (COTS) microwave materials, and highly integrated, active monolithic microwave integrated circuits (MMIC&#39;s). This results in reduced manufacturing costs. Array antenna manufacturing costs can also be reduced since the tile sub-arrays can be provided from relatively large panels or sheets of PWBs using conventional PWB manufacturing techniques. 
     Referring to  FIGS. 2A to 2C , in one particular example of the tile sub-arrays  12   a - 12 N is a tile sub-array  12 ′. The tile sub-array  12 ′ includes a mother board  20 , an RF interface board  24 , eight daughter boards (e.g., a daughter board  32   a - 32   h ) with active circuits  15  on each daughter board and eight thermal spreaders (e.g., a thermal spreader  34   a - 34   h ) attached to active circuits  15  of a corresponding daughter board. In one example, the active circuits  15  are secured to the thermal spreaders  34   a - 34   h  using solder techniques described in U.S. patent application Ser. No. 12/580,356 entitled “Cooling Active Circuits” which is incorporated herein in it entirety. 
     In one example, each daughter board  32   a - 32   h  includes sixteen active circuits  15 . Instead of having one large daughter board with active circuits  15  connected to one thermal spreader, this configuration increases yield during manufacturing by reducing the size of the daughter board into smaller pieces. In addition, it is easier to rework problems with smaller daughter boards as opposed to larger one piece daughter boards. For example, it is more cost effective to throw away sixteen active circuits  15  because of an active circuit failure than one hundred twenty-eight active circuits. 
     Cooling a number of substantially coplanar active circuits  15  (e.g., integrated circuits) with a single cold plate in direct contact with top surfaces of the thermal spreaders  34   a - 34   h  is difficult because of the many tolerances that exist resulting from height variations (thicknesses). In particular, a cold plate  40  with channels  42  for receiving coolant is unable to make contact with all of the thermal spreaders  34   e - 34   h  ( FIG. 2C ) leaving spaces  76   a - 76   c  between the thermal spreaders  34   e,    34   f,    34   h  and the cold plate  40 . By not being in direct contact with the cold plate  40 , the thermal spreaders  34   e,    34   f,    34   h  do not efficiently transfer heat away from the active circuits  15 . 
     In one example, the active circuits  15 , the thermal spreaders  34  and the daughter boards  32  may have different thicknesses. With respect to  FIG. 2B , the thickness, T h , which includes thicknesses of the thermal spreader  34   h,  the daughter board  32   h  and active circuits  15  is different from the thickness, T e , which includes thicknesses of the thermal spreader  34   e , the daughter board  32   e  and active circuits  15 . In one particular example, the daughter boards  32   a - 32   h,  which are about 0.100 inches thick have thickness tolerances of +/−0.01 inches and the thermal spreaders  34   a - 34   h  have thickness tolerances of +/−0.001 inches resulting in a total thickness tolerance of +/−0.011 inches. As described herein, a compliant member may be used to compensate for varying thicknesses between the daughter board and thermal spreader subassemblies, e.g., a compliant member that compensates for the 0.011 inches in the previous example. While this disclosure describes cooling active circuits in an environment of an active, electronically scanned array (AESA) panel architecture system, the techniques described herein may be used in any environment to cool multiple objects of varying thicknesses and/or are substantially coplanar. 
     Referring to  FIG. 3 , one technique to eliminate the air spaces  76   a - 76   c  ( FIG. 2C ) between the thermal spreaders  34   a - 34   h  and the cold plate  40  is to use the compliant member between the mother board  20  and the active circuits  15 . In one example, an RF interface board  124  is the compliant member. For example, the air spaces  76   a - 76   c  ( FIG. 2C ) between the thermal spreaders  34   e - 34   h  and the cold plate  40  are substantially eliminated (e.g., reduced to less than 0.002 inches) because the RF interface board  124  can compensate for the variances in the thicknesses of the different thermal spreader/daughter board assemblies. In one particular example, each side of the RF interface board  124  includes a plurality of conductive elastomeric contacts  200  capable of providing an adequate RF interconnect and having elastic properties such to minimize compression set over extended time and temperature ranges. The RF interface board  124  including the conductive elastomeric contacts  200  is also electrically conductive so that RF signals generated by the actives circuits  15  can be transmitted to the circulator/radiator assembly  150  (see  FIG. 4 ). In one example, the conductive elastomeric contacts  200  include a compliant material such as a silver-filled elastomer with a Shore A durometer of about 90. 
     In another example, the interface board  124 , including the conductive elastomeric contacts  200 , is also electrically conductive and configured to provide an RF insertion loss of less than 0.1 dB. In other examples, only one side of the RF interface board  124  includes the conductive elastomeric contacts  200  and the opposite side is either integrated with the daughter board  32  or the mother board  20 . 
     Referring to  FIGS. 4A and 4B , the thermal spreaders/daughter board subassemblies may be configured in other ways. In particular, unlike  FIG. 3 , which depicts a simplistic thermal spreader  34   e,    FIGS. 4A and 4B  depict a thermal spreader  234   e,  which is a more complex thermal spreader configuration. The thermal spreader  234   e /daughter board  32   e  is coupled to the compliant RF interface board  124 , the mother board  20 , an RF interface board  24  and to a circulator/radiator assembly  150 . As used herein an RF panel assembly includes the circulator/radiator assembly  150 , an interface  174 , the mother board  20 , the compliant RF interface board  124 , the daughter board  32   e,  and the thermal spreader  234   e.    
     The thermal spreaders (e.g., the thermal spreader  234   e  shown in  FIG. 4 ) include bosses (e.g., a boss  210   a,  a boss  210   b,  a boss  212   a  and a boss  212   b ). The bosses  210   a ,  210   b  are configured to control any gaps between the thermal spreader  234   e  and the cold plate  40  (not shown in  FIG. 4 ). The bosses  212   a,    212   b  are configured to control any gaps between the active circuits  15  and the thermal spreader  234   e.    
     In one example, either of the bosses  210   a,    210   b  have a thickness tolerance, T B , of about +/−0.001 inches and either of the bosses  212   a,    212   b  have a thickness tolerance, T A , of about +/−0.001 inches. If the daughter board  32   e  has a thickness tolerance of about +/−0.010 inches, then the compliant RF interface board  124  is configured to have an adjustable thickness of at least +/−0.012 inches. 
     Screws  214   a,    214   b  are used to mount the thermal spreader  234   e /daughter board  32   e  subassembly to the mother board  20  and the circulator/radiator assembly  150 . The screws  214   a,    214   b  extend through the bosses  210   a,    210   b  respectively and through the mother board  20 , the interface  174  and the circulator/radiator assembly  150 . In one example, the screws  214   a,    214   b  pass through a clearance hole (not shown) in the respective bosses  210   a ,  210   b  and the mother board  20 , RF interface board  124  and engage threads (not shown) in the circulator/radiator assembly  150 . 
     Screws  202   a,    202   b  are used to mount the RF panel assembly to the cold plate  40  (not shown in  FIG. 4A ). In one example, the screws  202   a,    202   b  pass through clearance holes (not shown) in the circulator/radiator assembly  150 , the interface  74 , the mother board  20 , the compliant RF interface board  124 , the daughter board  32   e,  the thermal spreader  234   e  and engage threads (not shown) in the cold plate  40  (not shown in  FIG. 4A ). 
     The screws  202   a,    202   b,    214   a,    214   b  perform a clamping function ensuring that the RF interface board  124  has adequate compression for RF transmission and control the gap between the thermal spreader  234   e  and the cold plate  40  to ensure efficient transfer of heat. 
       FIG. 5A  depicts a minimum tolerance stack-up with the RF interface board  124  under minimum compression.  FIG. 5B  depicts a nominal tolerance stake-up with the RF interface board  124  under nominal compression.  FIG. 5C  depicts a maximum tolerance stake-up with the RF interface board  124  under maximum compression. 
     While screws  202   a,    202   b,    214   a,    214   b  have been described one of ordinary skill in the art would recognize that the screws  202   a,    202   b,    214   a,    214   b  may be replaced with fasteners (e.g., standoffs and so forth) or other clamping structures. Also, one of ordinary skill in the art would recognize other known methods or techniques to ensure contact between the cold plate and the thermal spreaders and to ensure compression between the daughter board  234   e,  mother board  20  and the compliant RF interface board  124 . 
     The processes described herein are not limited to the specific embodiments described. Elements of different embodiments described herein may be combined to form other embodiments not specifically set forth above. Other embodiments not specifically described herein are also within the scope of the following claims.