Active electronically scanned array (AESA) card

• US 9,019,166 B2
• Filed: 11/14/2011
• Issued: 04/28/2015
• Est. Priority Date: 06/15/2009
• Status: Active Grant

• Current Assignee: Raytheon Company (Rtx Corporation)
• Original Assignee: Raytheon Company (Rtx Corporation)
• Inventors: Puzella, Angelo M., Dupuis, Patricia S., Lemmler, Craig C., Bozza, Donald A., Bellahrossi, Kassam K., Robbins, James A., Francis, John B.
• Primary Examiner(s): DUONG, DIEU HIEN
• Application Number:
  US13/295,437
• Publication Number:
  US 20120313818A1
• Time in Patent Office: 1,261 Days
• Field of Search: 343/700.MS, 343/850, 343/853, 342/371
• US Class Current: 343/853
• CPC Class Codes: H01Q 1/02 Arrangements for de-icing; Arrangements for drying-out ; Arrangements for cooling; Arrangements for preventing corrosion
• CPC Class Codes: H01Q 21/00 Antenna arrays or systems arrangements for changing or varying the orientation or the shape of the directional pattern of the waves radiated from an antenna or antenna system H01Q3/00
• CPC Class Codes: H01Q 21/0025 Modular arrays
• CPC Class Codes: H01Q 21/0087 Apparatus or processes specially adapted for manufacturing antenna arrays manufacturing waveguides H01P11/00
• CPC Class Codes: H01Q 21/065 Patch antenna array
• CPC Class Codes: H01Q 9/0414 in a stacked or folded configuration

Abstract

In one aspect, an active electronically scanned array (AESA) card includes a printed wiring board (PWB) that includes a first set of metal layers used to provide RF signal distribution, a second set of metal layers used to provide digital logical distribution, a third set of metal layers used to provide power distribution and a fourth set of metal layers used to provide RF signal distribution. The PWB comprises at least one transmit/receive (T/R) channel used in an AESA.

Claims

1. An active electronically scanned array (AESA) card comprising:

a printed wiring board (PWB) comprising;

a first set of metal layers used to provide RF signal distribution;

a second set of metal layers used to provide digital logical distribution;

a third set of metal layers used to provide power distribution; and

a fourth set of metal layers used to provide RF signal distribution,

wherein the PWB comprises at least one transmit/receive (T/R) channel used in an AESA.

2. The AESA card of claim 1 wherein the PWB further comprises:

a first composite layer of carbon fibers and epoxy between a metal layer of the second set of metal layers and a metal layer of the third set of metal layers; and

a second composite layer of carbon fibers and epoxy between a metal layer of the third set of metal layers and a metal layer of the fourth set of metal layers.

3. The AESA card of claim 2 wherein the PWB further comprises:

a layer of epoxy resin between two metal layers of the first set of metal layers;

a layer of epoxy resin between two metal layers of the second set of metal layers; and

a layer of epoxy resin between two metal layers of the third set of metal layers.

4. The AESA card of claim 2 wherein the PWB further comprises a layer of polyimide dielectric between two metal layers of the third set of metal layers.

5. The AESA card of claim 1, further comprising one or more monolithic microwave integrated circuits (MMICs) disposed on the surface of the PWB.

6. The AESA card of claim 1 wherein the MMICs are attached to the PWB using solder balls.

7. The AESA card of claim 1 wherein the PWB further comprises:

a plurality of metal conduits, each electrical conduit coupling one of the plurality of layers to another one of the plurality of layers.

8. The AESA card of claim 7 wherein the PWB further comprises an RF via having a first end coupled to a first metal conduit of the plurality of metal conduits and a second end opposite to the first end coupled to a second metal conduit of the plurality of metal conduits,

wherein the RF via extends through the third set of metal layers used for power distribution from the first set of metal layers used to provide RF signal distribution to the second set of metal layers used to provide digital logical distribution without extending through the fourth set of metal layers used to provide RF signal distribution.

9. The AESA card of claim 1 wherein the PWB further comprises:

a layer of epoxy resin between two metal layers of the first set of metal layers;

a layer of epoxy resin between two metal layers of the second set of metal layers;

a layer of epoxy resin between two metal layers of the third set of metal layers; and

a layer of polyimide dielectric between two metal layers of the third set of metal layers.

10. The AESA card of claim 1 wherein the AESA card does not include wire bonds.

11. An active electronically scanned array (AESA) assembly comprising:

an AESA card comprising;

a printed wiring board (PWB) comprising;

a first set of metal layers used to provide RF signal distribution;

a second set of metal layers used to provide digital logical distribution;

a third set of metal layers used to provide power distribution;

a fourth set of metal layers used to provide RF signal distribution; and

one or more monolithic microwave integrated circuits (MMICs) disposed on the surface of the PWB,

wherein the PWB comprises at least one transmit/receive (T/R) channel used in an AESA.

12. The ASEA assembly of claim 11, further comprising a cooling mechanism in contact with the one or more of the MMICs.

13. The ASEA assembly of claim 12 wherein the cooling mechanism comprises:

a thermal heat spreader in contact with the MMICs; and

a cold plate in contact with the thermal spreader.

14. The ASEA assembly of claim 13 wherein the MMICs are attached to the PWB using solder balls.

15. The ASEA assembly of claim 11 wherein the PWB further comprises:

a plurality of metal conduits, each electrical conduit coupling one of the plurality of layers to another one of the plurality of layers.

16. The ASEA assembly of claim 15 wherein the PWB further comprises a via having a first end coupled to a first metal conduit of the plurality of metal conduits and a second end opposite to the first end connected to a second metal conduit of the plurality of metal conduits,

wherein the via extends through the third set of metal layers used for power distribution from the first set of metal layers used to provide RF signal distribution to the second set of metal layers used to provide digital logical distribution without extending through the fourth set of metal layers used to provide RF signal distribution.

17. The ASEA assembly of claim 11 wherein the PWB further comprises:

a first composite layer of carbon fibers and epoxy between a metal layer of the second set of metal layers and a metal layer of the third set of metal layers; and

a second composite layer of carbon fibers and epoxy between a metal layer of the third set of metal layers and a metal layer of the fourth set of metal layers.

18. The ASEA assembly of claim 17 wherein the PWB further comprises:

a layer of epoxy resin between two metal layers of the first set of metal layers;

a layer of epoxy resin between two metal layers of the second set of metal layers;

a layer of epoxy resin between two metal layers of the third set of metal layers; and

a layer of polyimide dielectric between two metal layers of the third set of metal layers.

19. The ASEA assembly of claim 11 wherein the AESA card does not include wire bonds.

20. An active electronically scanned array (AESA) card comprising:

a printed wiring board (PWB) comprising;

a first set of metal layers used to provide RF signal distribution;

a second set of metal layers used to provide digital logical distribution;

a third set of metal layers used to provide power distribution; and

a fourth set of metal layers used to provide RF signal distribution,

one or more monolithic microwave integrated circuits (MMICs) disposed on the surface of the PWB;

a plurality of metal conduits, each electrical conduit coupling one of the plurality of layers to another one of the plurality of layers; and

an RF via having a first end coupled to a first metal conduit of the plurality of metal conduits and a second end opposite to the first end coupled to a second metal conduit of the plurality of metal conduits,

wherein the RF via extends through the third set of metal layers used for power distribution from the first set of metal layers used to provide RF signal distribution to the second set of metal layers used to provide digital logical distribution without extending through the fourth set of metal layers used to provide RF signal distribution,

wherein the PWB comprises at least one transmit/receive (T/R) channel used in an AESA, and

wherein the AESA card does not include wire bonds.