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A method and system for packaging electronics with an electronic card rack of radial panels, an outer casing, a stabilizing ring, and a flex-circuit interconnect, whereby electronic cards inserted into the sectors formed by the radial panels do not carry the structural load. The card-mounted devices

A method and system for packaging electronics with an electronic card rack of radial panels, an outer casing, a stabilizing ring, and a flex-circuit interconnect, whereby electronic cards inserted into the sectors formed by the radial panels do not carry the structural load. The card-mounted devices are optimally oriented for set back forces, and minimal potting and/or structural foam is required, if any. The present invention provides a lightweight, highly serviceable assembly that is relatively less expensive to produce, test and rework compared with potted assemblies.

대표청구항 ▼

1. A system for packing electronics exposed to a gun-launched environment comprising: a card rack comprising: a base portion having an upper side, a lower side, an edge and a center axis;a wall portion extending from the base portion and having a principal axis substantially aligned with the base

1. A system for packing electronics exposed to a gun-launched environment comprising: a card rack comprising: a base portion having an upper side, a lower side, an edge and a center axis;a wall portion extending from the base portion and having a principal axis substantially aligned with the base center axis and substantially perpendicular to the upper side of the base, wherein the wall portion has an inward side facing the principal axis, an outward side facing away from the principal axis and a top edge;and a plurality of panel portions, each of the plurality of panel portions extending from the base portion and having a top side, a negative rotation facing side, a positive rotation facing side and an outer edge, each of the top sides of the plurality of panel portions oriented radially from the principal axis of the wall portion and thereby extending outwardly from the outward side of the wall portion;and a plurality of mounting sectors wherein any two adjacent panel portions of the plurality of radially oriented panel portions, an interstitial sector of the upper side of the base, and an interstitial portion of the outward side of the wall portion form a mounting sector;at least one circuit card assembly having a top edge, the at least one circuit card mechanically inserted into a respective mounting sector of the plurality of mounting sectors of the card rack; anda circuit interconnect member in electrical communication with the inserted at least one circuit card assembly, the circuit interconnect member mounted to the top side of each of the plurality of panels.2. The system as claimed in claim 1 wherein the at least one circuit assembly is bonded to the card rack.3. The system as claimed in claim 1 wherein the at least one circuit assembly mechanically inserted into a respective mounting sector comprises a first card bonded to a negative rotation facing side of a panel portion, a second card bonded to a positive rotation facing side of an adjacent panel portion, wherein the first card and second card are interconnected via flex ribbon.4. The system as claimed in claim 3 wherein the at least one circuit assembly mechanically inserted into a respective mounting sector further comprises a third panel, bonded to the interstitial sector of the upper side of the base, wherein the third card is interconnected via a flex ribbon to the second card.5. The system as claimed in claim 3 wherein the at least one circuit assembly mechanically inserted into a respective mounting sector further comprises a third panel, bonded to the interstitial sector of the upper side of the base, wherein the third card is interconnected via a flex ribbon to the first card.6. The system as claimed in claim 1 wherein the base portion has a disc shape.7. The system as claimed in claim 1 wherein the lower side of the base portion has a central aperture for receiving a recessable aft member.8. The system as claimed in claim 7 wherein the recessable aft member is a safe and arming device.9. The system as claimed in claim 1 wherein the wall portion is substantially cylindrical.10. The system as claimed in claim 1 wherein the circuit interconnect member has a disc shape.11. The system as claimed in claim 10 wherein the circuit interconnect member has a central aperture for receiving a recessable forward member.12. The system as claimed in claim 11 wherein the recessable forward member is an inertial measurement unit.13. The system as claimed in claim 1 further comprising a stabilizing member for mechanically stabilizing the inserted at least one circuit card assembly.14. The system as claimed in claim 13 wherein the stabilizing member has a disc shape.15. The system as claimed in claim 14 wherein the stabilizing member has a central aperture for receiving a recessable forward member.16. The system as claimed in claim 15 wherein the recessable forward member is an inertial measurement unit.17. The system as claimed in claim 1 wherein each of the at least o ne circuit card assembly has a plurality of connector pins.18. The system as claimed in claim 17 wherein the circuit interconnect member has a plurality of apertures in at least one radial linear array for receiving the polarity of circuit card connector pins.19. The system as claimed in claim 1 wherein the at least one circuit card assembly comprises at least one multi-layer polyimide circuit card.20. The system as claimed in claim 1 wherein the at least one circuit card assembly comprises a plurality of multi-layer polyimide circuit cards interconnected with flex ribbon.21. The system as claimed in claim 1 wherein the at least one circuit card assembly comprises at least one multi-layer circuit card of epoxy laminates.22. The system as claimed in claim 1 wherein the at least one circuit card assembly comprises a plurality of multi-layer circuit cards of epoxy laminates interconnected with flex ribbon.23. The system as claimed in claim 1 wherein the at least one circuit card assembly comprises at least one multi-layer ceramic circuit card.24. The system as claimed in claim 1 wherein the at least one circuit card assembly comprises a plurality of multi-layer ceramic circuit cards interconnected with flex ribbon.25. The system as claimed in claim 1 wherein the electrical interconnections of the system are wave soldered.26. The system as claimed in claim 1 wherein the electrical interconnections of the system are made with connectors.27. The system as claimed in claim 1 further comprising: at least one outer case fastener and an outer casing, having a plurality of internal ribs aligned with the plurality of panel portions of the card rack, the outer casing fastened to the card rack with at least one outer case fastener. 28. The system as claimed in claim 27 wherein the outer casing is welded to the card rack.29. The system as claimed in claim 27 wherein the outer casing is a shell casing.30. The system as claimed in claim 27 wherein the outer casing is a shell casing in the shape of a frustro-conical section.31. The system as claimed in claim 27 further comprising at least one alignment bushing mounted within the outer casing for receiving the at least one fastener.32. The system as claimed in claim 27 wherein the card rack and outer casing are cast titanium.33. The system as claimed in claim 27 wherein the card rack and outer casing are cast steel.34. The system as claimed in claim 27 wherein the at least one outer case fastener is a bolt.35. The system as claimed in claim 27 wherein the at least one outer case fastener comprises four bolts.36. A structure for packing electronics exposed to a gun-launched environment comprising: a card rack comprising: a base portion having an upper side, a lower side, an edge and a center axis;a wall portion extending from the base portion and having a principal axis substantially aligned with the base center axis and substantially perpendicular to the upper side of the base, wherein the wall portion has an inward side facing the principal axis, an outward side facing away from the principal axis and a top edge;and a plurality of panel portions, each of the plurality of panel portions extending from the base portion and having a top side, a negative rotation facing side, a positive rotation facing side and an outer edge, each of the top sides of the plurality of panel portions oriented radially from the principal axis of the wall portion and thereby extending outwardly from the outward side of the wall portion;and a plurality of mounting sectors wherein any two adjacent panel portions of the plurality of radially oriented panel portions, an interstitial sector of the upper side of the base, and an interstitial portion of the outward side of the wall portion form a mounting sector;at least one circuit card assembly having a top edge, the at least one circuit card mechanically inserted into a respective mounting sector of the plurality of mounting sectors of the card rack; anda circuit inte rconnect member in electrical communication with the inserted at least one circuit card assembly, the circuit interconnect member mounted to the top side of each of the plurality of panels;at least one outer case fastener; andan outer casing, having a plurality of internal ribs aligned with the plurality of panels of the card rack, the outer casing fastened to the card rack with at least one outer case fastener.37. The structure as claimed in claim 36 wherein the base portion has a disc shape.38. The structure as claimed in claim 36 wherein the wall portion is substantially cylindrical.39. The structure as claimed in claim 36 wherein the outer casing is welded to the card rack.40. The structure as claimed in claim 36 wherein the outer casing is a shell casing.41. The structure as claimed in claim 36 wherein the outer casing is a shell casing in the shape of a frustro-conical section.42. The structure claimed in claim 36 further comprising at least one alignment bushing, positioned within the outer casing, for receiving the at least one outer case fastener.43. The structure as claimed in claim 36 wherein the card rack and outer casing are cast titanium.44. The structure as claimed in claim 36 wherein the card rack and outer casing are cast steel.45. The structure as claimed in claim 36 wherein the least one outer case fastener is a bolt.46. The structure as claimed in claim 36 wherein the least one outer case fastener comprises four bolts.47. A method of packing electronics exposed to a gun-launched environment, the method comprising: fabricating a card rack comprising: a base portion having an upper side, a lower side, an edge and a center axis;a wall portion extending from the base portion and having a principal axis substantially aligned with the base center axis and substantially perpendicular to the upper side of the base, wherein the wall portion has an inward side facing the principal axis, an outward side facing away from the principal axis and a top edge;and a plurality of panel portions, each of the plurality of panel portions extending from the base portion and having a top side, a negative rotation facing side, a positive rotation facing side and an outer edge, each of the top sides of the plurality of panel portions oriented radially from the principal axis of the wall portion and thereby extending outwardly from the outward side of the wall portion;and a plurality of mounting sectors wherein any two adjacent panel portions of the plurality of radially oriented panel portions, an interstitial sector of the upper side of the base, and an interstitial portion of the outward side of the wall portion form a mounting sector;fabricating at least one circuit card assembly;inserting the at least one circuit assembly into a mounting sector of the plurality of mounting sectors of the card rack;fabricating a circuit interconnect member;mounting the circuit interconnect member to the top side of each of the plurality of panel portions with the circuit interconnect member in electrical communication with the at least one circuit card assembly,whereby a gun-hardened electronics system is made.48. The method as claimed in claim 47 wherein after inserting the at least one circuit assembly further comprises bonding the at least one circuit assembly to the card rack.49. The method as claimed in claim 47 wherein after inserting the at least one circuit assembly further comprises bonding a first card to a negative rotation facing side of a panel portion and bonding a second card to a positive rotation facing side of an adjacent panel portion, wherein the first card and second card are interconnected via flex ribbon.50. The method as claimed in claim 49 wherein after bonding the first card and the second card further comprises bonding a third card to the interstitial sector of the upper side of the base, wherein the third card is interconnected via a flex ribbon to the second card.51. The method as claimed in claim 49 wherein after bonding the first card and the second card further comprises bonding a third card to the interstitial sector of the upper side of the base, wherein the third card is interconnected via a flex ribbon to the first card.52. The method as claimed in claim 47 wherein the base portion has a disc shape.53. The method as claimed in claim 47 wherein the wall portion is substantially cylindrical.54. The method as claimed in claim 47 wherein the circuit interconnect member has a disc shape.55. The method as claimed in claim 47 wherein each of the at least one circuit card assembly has a plurality of connector pins.56. The method as claimed in claim 47 wherein the circuit interconnect member has a plurality of apertures in at least one radial linear array for receiving the polarity of circuit card connector pins.57. The method as claimed in claim 47 wherein the at least one circuit card assembly comprises at least one multi-layer polyimide circuit card.58. The method as claimed in claim 47 wherein the at least one circuit card assembly comprises a plurality of multi-layer polyimide circuit cards interconnected with flex ribbon.59. The method as claimed in claim 47 wherein the at least one circuit card assembly comprises at least one multi-layer circuit card of epoxy laminates.60. The method as claimed in claim 47 wherein the at least one circuit card assembly comprises a plurality of multi-layer circuit cards of epoxy laminates interconnected with flex ribbon.61. The method as claimed in claim 47 wherein the at least one circuit card assembly comprises at least one multi-layer ceramic circuit card.62. The method as claimed in claim 47 wherein the at least one circuit card assembly comprises a plurality of multi-layer ceramic circuit cards interconnected with flex ribbon.63. The method as claimed in claim 47 further comprising wave soldering the electrical interconnections of the gun-hardened electronics system.64. The method as claimed in claim 47 further comprising establishing electrical interconnections of the gun-hardened electronics system with connectors.65. The method as claimed in claim 47 further comprising: aligning a plurality of internal ribs of an outer casing with the plurality of panel portions of the card rack, and fastening the outer casing to the card rack with at least one outer case fastener. 66. The method as claimed in claim 65 further comprising, following the fastening of the outer casing to the card rack with at least one outer case fastener, welding the outer casing to the card rack. 67. The method as claimed in claim 65 wherein the outer casing is a shell casing.68. The method as claimed in claim 65 wherein the outer casing is a shell casing in the shape of a frustro-conical section.69. The method claimed in claim 65 further comprising, preceding the fastening of the outer casing to the card rack with at least one outer case fastener, providing at least one alignment bushing, positioned within the outer casing, for receiving the at least one outer case fastener.70. The method as claimed in claim 65 wherein the card rack and outer casing are cast titanium.71. The method as claimed in claim 65 wherein the card rack and outer casing are cast steel.72. The method as claimed in claim 65 wherein the at least one outer case fastener is a bolt.73. The method as claimed in claim 65 wherein the at least one outer case fastener comprises four bolts.74. The method as claimed in claim 47 further comprising the step, preceding the step of mounting the circuit interconnect member, of mounting a stabilizing member to the top side of each of the plurality of panels for mechanically stabilizing the inserted at least one circuit card assembly and thereafter mounting the circuit interconnect member to the stabilizing member.75. The method as claimed in claim 74 wherein the stabilizing member has a disc shape.