Composite Coldplate Interlocking Joints for Radar Thermal Management
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Solution Overview
Problem
Existing forward coldplate assemblies for radar antenna systems face challenges in dimensional stability and thermal conductivity due to the friction-stir welding process, which often results in warping and require a separate faceplate for mounting, making them difficult and costly to manufacture.
Innovation Solution
A composite coldplate assembly is developed using interlocking members at the edges of multiple coldplates, eliminating the need for a separate faceplate, with each coldplate featuring internal coolant channels and interlocking members that securely join together, enhancing dimensional stability and thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If friction-stir welding is used to join coldplates, then thermal conductivity is improved, but dimensional stability deteriorates due to warping
Solution Approach 1:
The coldplate assembly is divided into multiple smaller coldplate sections, each with manageable dimensions. This segmentation allows each section to maintain dimensional stability while collectively providing the required thermal conductivity through modular interlocking joints that eliminate the need for friction-stir welding of large single pieces.
Solution Approach 2:
Multiple coldplate sections are combined through interlocking joints to form a unified thermal management system. The interlocking mechanism merges the thermal pathways of individual sections while avoiding the warping issues of friction-stir welding, achieving both thermal conductivity and dimensional stability.
2Strength
If friction-stir welding is used to join coldplates, then thermal conductivity is improved, but manufacturing complexity increases
Solution Approach 1:
By segmenting the coldplate into smaller sections with interlocking joints, the manufacturing process avoids the complexity of friction-stir welding. Each section can be manufactured independently using simpler processes, and assembly is facilitated by the interlocking mechanism.
Solution Approach 2:
The interlocking joints use simpler, more cost-effective connection methods compared to friction-stir welding. The design prioritizes ease of manufacture and assembly over the absolute maximum thermal conductivity that would require complex welding processes.
3Device complexity
If a single large forward coldplate is manufactured, then device complexity is reduced by eliminating the faceplate, but manufacturing precision deteriorates due to warping
Solution Approach 1:
The large coldplate is segmented into multiple smaller sections that can be manufactured with high dimensional accuracy. The interlocking joints maintain the unified structure needed to eliminate the separate faceplate, achieving both reduced device complexity and maintained manufacturing precision.
4Stability of the object's composition
If multiple smaller coldplates are mounted to a faceplate, then dimensional stability is maintained, but device complexity increases
Solution Approach 1:
The coldplate sections are merged through interlocking joints that integrate the mounting function into the coldplate structure itself. This eliminates the need for a separate faceplate, maintaining dimensional stability while reducing overall device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The interlocking coldplate assembly improves dimensional stability and thermal conductivity while reducing warping and manufacturing complexity, allowing for more efficient cooling of high-power electronic components in radar systems.
Implementation Method 1
One or more interlocking members of the first coldplate are engaged with the one or more interlocking members of the second coldplate to interlock the first coldplate with the second coldplate
Implementation Method 2
Each coldplate comprises one or more trenches formed in a surface thereof, and a plurality of covers welded thereto. The covers close the trenches so as to define coolant channels in the coldplate for circulating coolant therethrough
Data Source
AI summary
A coldplate assembly for a phased array antenna has a first coldplate having one or more internal coolant channels and one or more interlocking members disposed at side edges thereof; and a second coldplate having one or more internal coolant channels and one or more interlocking members disposed at side edges thereof. The one or more interlocking members of the first coldplate interlock with the one or more interlocking members of the second coldplate.