System and method for managing heat dissipation in an antenna array

A method comprising:

• generating a first substrate layer adjacent to a ground plane of a patch antenna array in a radar system;
• etching an opening in the substrate layer;
• inserting a mechanically-locking foot of a threaded insert into the opening;
• inserting a coated temporary plug into the threaded insert;
• adding a second substrate layer adjacent to the first substrate layer to embed the threaded insert;
• adding a third layer that covers the threaded insert and coated temporary plug;
• etching an opening in the third layer to enable removal of the coated temporary plug;
• applying a thermal coupling between a heat sink layer and the third substrate layer of the radar system;
• and
• screwing a screw through the heat sink layer and into the threaded insert to removably adhere the heat sink layer to the patch antenna array.

A radar system generated by a process comprising:

• generating a first substrate layer adjacent to a ground plane of a patch antenna array in the radar system;
• etching an opening in the substrate layer;
• inserting a mechanically-locking foot of a threaded insert into the opening;
• inserting a coated plug into the threaded insert;
• adding a second substrate layer adjacent to the first substrate layer to embed the threaded insert;
• adding a third substrate layer covering the threaded insert and coated plug;
• etching an opening in the third substrate layer to enable removal of the coated plug;
• applying a thermal coupling between a heat sink layer and the third substrate layer of the radar system;
• and
• screwing a screw through the heat sink layer and into the threaded insert to adhere the heat sink layer to the patch antenna array.