CN104162995B - 一种碳纤维天线面的制造方法 - Google Patents
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Abstract
本发明涉及一种碳纤维天线面的制造方法,包括以下步骤：1、预制模具；2、抛光模具；3、化学电镀铬模具；4、测量精度并清理杂质；5、涂覆脱模剂；6、在阳模上铺设碳纤维布；7、在阳模的表面铺设PVC泡沫；8、在阳模的表面铺设碳纤维布；9、把阳模与阴模合拢、密封和紧固；10、抽真空使模具内部的真空度小于-0.096MPa；11、从阴模的进料口注射环氧树脂和固化剂；12、外观检验合格后在毛坯的外表面贴一层玻璃纸；13、打孔并装配；14、检验合格后即得到碳纤维天线面。本发明的碳纤维天线面表面光滑，精度可达0.1R.M.S，常温固化节约能源并降低成本。
Description
技术领域
本发明属于天线制备领域，具体涉及一种碳纤维天线面的制造方法。
背景技术
目前我国生产加工碳纤维天线的工艺主要以热压罐工艺为主，但是热压罐设备使用高温高压生产的产品能保证设计需求的同时，却存在了生产成本高昂、生产设备占地面积大等缺点，导致热压罐设备无法大批量应用生产。对于广大发展中国家而言，利用热压罐设备制备的天线，其价格是很难被消费者所接受的，从而导致卫星通信的用户仍然局限在大型企业、政府、军队等团体型用户。
发明内容
发明目的：本发明针对上述现有技术存在的问题做出改进，即本发明公开了一种碳纤维天线面的制造方法。
技术方案：一种碳纤维天线面的制造方法，包括以下步骤：
(1)预制碳纤维天线面的模具，所述模具分为阴模和阳模；
(2)将步骤(1)所述模具抛光；
(3)对步骤(2)所述模具进行化学电镀铬；
(4)使用三坐标测量仪测量步骤(3)所述模具的曲面精度并检查模具有无缺损，并清理所述模具的表面杂质；
(5)在所述步骤(4)所述模具内表面涂覆脱模剂；
(6)在步骤(5)所述的模具的阳模上依次铺设3层或4层3K碳纤维布，所述3K碳纤维布的边沿预留90～100mm长；
(7)在步骤(6)所述阳模的表面铺设PVC泡沫并用所述3K碳纤维布边沿预折叠包住所述PVC泡沫；
(8)在步骤(7)所述阳模的表面铺设3K碳纤维布并裁边；
(9)把步骤(8)所述阳模与所述阴模合拢，并把周边密封和紧固；
(10)在步骤(9)所述阴模上方接通真空管道，用真空泵抽真空，使所述模具内部的真空度小于-0.096MPa；
(11)使用环氧树脂注胶机从所述阴模的进料口注射环氧树脂和固化剂，所述环氧树脂注胶机的混合注胶的压力为0.35～0.45MPa,在20～30℃下反应120～150min后脱模得到所述碳纤维天线面毛坯；
(12)外观检验合格后，在步骤(11)所述毛坯的外表面贴一层玻璃纸；
(13)对步骤(12)所述毛坯打孔并装配反射面背架；
(14)使用三坐标测量仪对步骤(13)所述毛坯进行表面精度检测，合格后即得到所述碳纤维天线面。
作为本发明中一种碳纤维天线面的制造方法的一种优选方案：步骤(5)所述脱模剂为汉高NC700脱模剂。
作为本发明中一种碳纤维天线面的制造方法的一种优选方案：步骤(7)所述PVC泡沫的厚度为14.8～15mm。
作为本发明中一种碳纤维天线面的制造方法的一种优选方案：步骤(11)所述的固化剂是乙二胺、己二胺、二乙烯三胺、三乙烯四胺、二乙氨基丙胺中的一种或几种。
作为本发明中一种碳纤维天线面的制造方法的一种优选方案：上述固化剂的含量为所述环氧树脂的10％～15％。
作为本发明中一种碳纤维天线面的制造方法的一种优选方案：步骤(11)所述环氧树脂是选择耐温环氧体系树脂2040/2042。
有益效果：
1、无需喷漆即可为构件提供光滑表面，能制造出具有良好表面的高精度复杂天线面,精度可达0.1R.M.S，可生产大尺寸大口径大批量碳纤维天线面，常温固化节约能源降低成本，产品可大面积应用卫星通信；
2、模具制造及选材灵活性大，设备及模具投资小，产品只需做小幅度的修边；
3、产品铺层过程中可加入嵌件及对局部进行加强；
4、制品纤维含量高，孔隙率低(<0.2％)；
5、可以生产高性能、尺寸较大、批量中等的产品。
附图说明
图1为注塑成型的示意图；
图2为本发明的碳纤维天线面的结构示意图
其中：
1-环氧树脂注胶机2-树脂料筒
3-固化剂料筒4-注胶管道
5-锁紧机构6-真空泵
7-定位销孔8-阳模
9-阴模10-密封条
11-3K碳纤维布12-密封槽
13-PVC泡沫14-反射面背架
15-碳纤维反射面
具体实施方式：
下面结合附图，对本发明的具体实施方式详细说明。
具体实施例1
一种碳纤维天线面的制造方法，包括以下步骤：
(1)、预制碳纤维天线面的模具，模具分为阴模9和阳模8；
因碳纤维天线面对面精度要求较高，所以：(1)模具的选材为45#钢，其厚度和长宽根据碳纤维天线面的弦高和大小确定；(2)模具设计为阴阳对合模(也就是阴模9和阳模8)，沿模具腔外100mm处加工两条放置∮10橡胶密封条10的密封槽12。如密封不好漏气，产品易报废，密封是整个模具制作过程中较为关键的一步，根据产品大小结构的不同，生产碳纤维天线面的模具则选用简单的半圆形两道密封(见图1)。
(2)将步骤(1)模具抛光；
手工抛光，先用320#油石将模具粗抛，去除毛边；再接着用600#油石、1000#油石、1500#油石依次抛光，最后用3000#抛光膏配合羊毛抛光轮将模具被表面抛成镜面，模具内表面的粗糙度小于0.2。
(3)对步骤(2)模具进行化学电镀铬；
抛光完成后，表面进行化学电镀铬，目的是为了增加抛光后镜面模具的硬度，防止在后续生产划伤模具；同时可以有效的提高产品的表面光洁度，免去向表面喷漆的工序，节约了生产成本；
化学电镀铬包括以下步骤：
首先利用化学试剂清洗模具表面的油污，化学试剂的成分为：氢氧化钠50g/L、碳酸钠40g/L、磷酸钠35g/L、硅酸钠6g/L、OP乳化剂10ml/L；
再对模具放入电镀池中电镀120min，静止10小时后备用，电镀铬的工艺条件为：铬酐250g/L，硫酸2.5g/L、三价铬4g/L，阴极电流密度55A/dm2,反应为温度为55～60℃。
(4)使用三坐标测量仪测量步骤(3)模具的曲面精度并检查模具有无缺损，并用压缩空气把模具表面的杂质清理干净(尤其是进料口和排气口)。
(5)在步骤(4)模具内表面涂覆脱模剂；
用汉高NC700脱模剂均匀涂抹于模具的内表面，涂布5次，每次间隔10分钟。正常生产每天涂布脱模剂1次，涂布完成后2min内用无尘布擦拭模具上涂布的脱模剂，同方向擦拭3～5次，直至模具还原镜面即可。
(6)在步骤(5)的模具的阳模8上依次铺设3层3K碳纤维布11，3K碳纤维布11的边沿预留约90mm长；
(7)在步骤(6)阳模8的表面铺设15mm厚的PVC泡沫13并用3K碳纤维布11边沿预折叠包住PVC泡沫13；
(8)在步骤(7)阳模8的表面铺设3K碳纤维布11，并裁边；
(9)把步骤(8)阳模8与阴模9合拢并把周边密封，通过锁紧机构5(销钉和螺栓)将模具紧固；
(10)在步骤(9)阴模9上方接通真空管道，用真空泵6抽真空，使模具内部的真空度小于-0.096MPa；
(11)使用环氧树脂注胶机从阴模9的进料口注射环氧树脂和固化剂，环氧树脂注胶机的混合注胶的压力为3.5bar,在20℃下反应150min后脱模得到碳纤维天线面毛坯；
如图1所示，阴模9通过注胶管道4分别与真空泵6及环氧树脂注胶机1相连通，环氧指数注胶机包括一个树脂料筒2和一个固化剂料筒3。模具设有定位销孔7。注射前先通过真空泵6进行抽真空，辅助后续注射，真空度小于-0.096MPa后，进行注射。
注胶时，提前在PLC上设置注射温度25℃，注射量为每平方800～1000g、注射压力3.5～4.5bar。
环氧树脂注胶机具有以下特点：1.适合环氧、酚醛树脂体系；2.具有树脂预处理功能；3.能精确控制树脂的注射量；4.PLC控制自动注射；5.最大注射压力30bar。
(12)外观检验合格后，在步骤(11)毛坯的外表面贴一层玻璃纸(防止刮花产品表面)；
(13)对步骤(12)毛坯打孔并装配反射面背架14；
(14)使用三坐标测量仪对步骤(13)毛坯进行表面精度检测(精度满足设计生产需要达到0.1R.M.S.)，合格后即得到碳纤维天线面。
如图2所示，碳纤维天线面包括碳纤维反射面15和反射面背架14。
本实施例中，步骤(11)环氧树脂是选择耐温环氧体系树脂2040/2042。树脂的选择，树脂决定了整个成型的成败，即需要常温即可固化、收缩率小、耐高温、低粘度等特点。所以经反复试验，选择耐温环氧体系树脂2040/2042用于碳纤维天线面的生产中。
在本实施例中，步骤(11)的固化剂是三乙烯四胺，其质量为环氧树脂的15％。
具体实施例2
与具体实施例1大致相同，区别在于：
1、步骤(6)：在步骤(5)的模具的阳模8上依次铺设4层3K碳纤维布11，3K碳纤维布11的边沿预留约100mm；
2、步骤(7)中PVC泡沫13的厚度是14.8mm；
3、步骤(11)：使用环氧树脂注胶机1从阴模9的进料口注射环氧树脂和固化剂(乙二胺，其含量为环氧树脂质量的10％)，环氧树脂注胶机的混合注胶的压力为4.5bar,在30℃下反应120min后脱模得到碳纤维天线面毛坯。
具体实施例3
与具体实施例1大致相同，区别在于：
步骤(11)：使用环氧树脂注胶机1从阴模9的进料口注射环氧树脂和固化剂(己二胺，其含量为环氧树脂质量的12％)，环氧树脂注胶机的混合注胶的压力为4bar,在25℃下反应135min后脱模得到碳纤维天线面毛坯。
具体实施例4
与具体实施例1大致相同，区别在于：步骤(11)中固化剂为二乙烯三胺，其含量为环氧树脂质量的12％。
具体实施例5
与具体实施例1大致相同，区别在于：步骤(11)中固化剂为二乙氨基丙胺，其含量为环氧树脂质量的15％。
具体实施例6
与具体实施例1大致相同，区别在于：步骤(11)中固化剂为等摩尔比的乙二胺、己二胺、二乙烯三胺、三乙烯四胺、二乙氨基丙胺，其含量为环氧树脂质量的10％。
上面结合附图对本发明的实施方式做了详细说明。但是本发明并不限于上述实施方式，在所属技术领域普通技术人员所具备的知识范围内，还可以在不脱离本发明宗旨的前提下做出各种变化。
Claims (6)
1.一种碳纤维天线面的制造方法，包括以下步骤：
(1)预制碳纤维天线面的模具，所述模具分为阴模和阳模；
(2)将步骤(1)所述模具抛光；
(3)对步骤(2)所述模具进行化学电镀铬；
(4)使用三坐标测量仪测量步骤(3)所述模具的曲面精度并检查模具有无缺损，并清理所述模具的表面杂质；
(5)在所述步骤(4)所述模具内表面涂覆脱模剂；
(6)在步骤(5)所述的模具的阳模上依次铺设3层或4层3K碳纤维布，所述3K碳纤维布的边沿预留90～100mm长；
(7)在步骤(6)所述阳模的表面铺设PVC泡沫并用所述3K碳纤维布边沿预折叠包住所述PVC泡沫；
(8)在步骤(7)所述阳模的表面铺设3K碳纤维布并裁边；
(9)把步骤(8)所述阳模与阴模合拢并把周边密封和紧固；
(10)在步骤(9)所述阴模上方接通真空管道，用真空泵抽真空，使模具内部的真空度小于-0.096MPa；
(11)使用环氧树脂注胶机从所述阴模的进料口注射环氧树脂和固化剂，所述环氧树脂混合注胶的压力为0.35～0.45MPa，在20～30℃下反应120～150min后脱模得到所述碳纤维天线面毛坯；
(12)外观检验合格后，在步骤(11)所述毛坯的外表面贴一层玻璃纸；
(13)对步骤(12)所述毛坯打孔并装配反射面背架；
(14)使用三坐标测量仪对步骤(13)所述毛坯进行表面精度检测，合格后即得到所述碳纤维天线面。
2.如权利要求1所述的一种碳纤维天线面的制造方法，其特征在于,步骤(5)所述脱模剂为汉高NC700脱模剂。
3.如权利要求1所述的一种碳纤维天线面的制造方法，其特征在于，步骤(7)所述PVC泡沫的厚度为14.8～15mm。
4.如权利要求1所述的一种碳纤维天线面的制造方法，其特征在于，步骤(11)所述的固化剂是乙二胺、己二胺、二乙烯三胺、三乙烯四胺、二乙氨基丙胺中的一种或几种。
5.如权利要求4所述的一种碳纤维天线面的制造方法，其特征在于，所述固化剂的含量为所述环氧树脂的10％～15％。
6.如权利要求1所述的一种碳纤维天线面的制造方法，其特征在于，步骤(11)所述环氧树脂是选择耐温环氧体系树脂2040/2042。
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