CN104347956B - Wave-transparent structure and preparation method thereof - Google Patents
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Abstract
The invention discloses a wave-transparent structure and a preparation method thereof, wherein the wave-transparent structure comprises: at least one first material layer; and each first material layer is arranged between the two second material layers, wherein the design parameters of the first material layers and the thickness of the second material layers are determined by respectively simulating the thicknesses of the first material layers and the second material layers through preset electromagnetic wave transmittance and mechanical strength. In the technical scheme of the invention, the thickness of the second material layer and the design parameters of the first material layer can be freely designed according to the preset electromagnetic wave transmittance and mechanical strength, so that the wave-transmitting structure can be suitable for various occasions requiring electromagnetic transmission.
Description
Technical Field
The present invention relates to wave-transparent materials, and more particularly, to a wave-transparent structure having a sandwich configuration and a method of making the same.
Background
The wave-transmitting material is a material with high transmittance to electromagnetic waves in a certain frequency band, and is generally used for preparing antenna covers or certain electromagnetic wave windows. The wave-transmitting material with the sandwich structure has good mechanical property, good broadband electromagnetic wave permeability and strong designability. The most simple wave-transparent material of the sandwich structure is a three-layer symmetrical sandwich structure, namely an 'ABA' type laminated structure. Specifically, as shown in fig. 1, the upper and lower portions are skin layers made of material a, and the middle portion is a core layer made of material B. A is generally a dense, high-strength, high-modulus material, B is generally a material with low density and poor mechanical properties, and the dielectric constant of the core layer material is generally lower than that of the surface skin material. Further, the skin material a and the core material B are generally bonded together by an adhesive.
In prior wave-transparent structure designs of patent application nos. 201110189540.5 and 201010618765.3, the skin material a is typically a fiber reinforced resin, the core material is typically a plastic foam or honeycomb, and the raw materials involved in processing the skin and core are typically expensive. Moreover, because the skin and the core layer belong to different material systems, the skin and the core layer are usually prepared separately or in steps, so that the process is complex, the preparation cost is high, and the bonding strength between the skin and the core layer can restrict the mechanical strength of the whole sandwich structure. Due to the factors, the wave-transmitting material with the sandwich structure, which is applied at present, has low processing efficiency and high cost, and is mostly only applied in the military industry.
Therefore, a need exists for a wave-transparent structure that is inexpensive and easy to manufacture.
Disclosure of Invention
To address the problems in the related art, the present invention proposes a wave-transparent structure that enables a reduction in cost and an improvement in processing complexity.
According to an aspect of the present invention, there is provided a wave-transparent structure comprising: at least one first material layer; and at least two second material layers, wherein each first material layer is arranged between the two second material layers, and the design parameters of the first material layers and the thickness of the second material layers are determined by respectively simulating the thicknesses of the first material layers and the second material layers through preset electromagnetic wave transmittance and mechanical strength.
Preferably, the design parameters include thickness, dielectric constant, and dielectric loss tangent.
Preferably, the first material layer is a foamed material layer.
Preferably, the first material layer is PVC and/or UPVC, and the second material layer is PVC and/or UPVC; or the first material layer and the second material layer are ABS.
More preferably, the wave-transparent structure comprises one said first material layer and two said second material layers.
Preferably, the thickness of the first material layer is in the range of 2mm to 20 mm.
Preferably, the dielectric loss tangent of the first material layer is in the range of 0.005 to 0.03.
More preferably, the dielectric loss tangent of the first material layer is 0.01.
Preferably, the dielectric constant of the first material layer is in the range of 1.5 to 3.3.
Preferably, the thickness of the second material layer is in the range of 0.5mm to 1 mm.
Preferably, the dielectric loss tangent of the second material layer is in the range of 0.02 to 0.05.
More preferably, the dielectric loss tangent of the second material layer is 0.03.
Preferably, the dielectric constant of the second material layer is in the range of 3.1 to 3.5.
More preferably, the dielectric constant of the second material layer is 3.3.
More preferably, the thickness of the first material layer is 8mm, the thickness of the second material layer is 0.6mm, the dielectric constant of the first material layer is 1.5, the dielectric constant of the second material layer is 3.3, the dielectric loss tangent of the first material layer is 0.01, and the dielectric loss tangent of the second material layer is 0.03.
More preferably, the thickness of the first material layer is 3mm, the thickness of the second material layer is 0.6mm, the dielectric constant of the first material layer is 1.5, the dielectric constant of the second material layer is 3.3, the dielectric loss tangent of the first material layer is 0.01, and the dielectric loss tangent of the second material layer is 0.03.
Preferably, the wave-transparent structure is applied to a radome. The thickness of each part of the antenna housing is different according to the preset electromagnetic wave transmittance.
Preferably, the wave-transparent structure is applied to a communication system, an aircraft, or a vehicle.
According to another aspect of the present invention, a method for manufacturing the wave-transparent structure is provided, wherein the wave-transparent structure is manufactured through a co-extrusion and foaming process, and the design parameters of the first material layer are determined by adjusting the foaming rate of the first material layer.
Preferably, the above process comprises the steps of: mixing the materials of the first material layer and the second material layer; respectively forming the first material layer and the second material layer; and bonding the first material layer and the second material layer together to form the wave-transparent structure.
Preferably, the components of the first material layer are calculated by weight parts as follows: 100 parts of UPVC or PVC or ABS, 3 parts of tribasic lead sulfate, 4 parts of composite stabilizer, 2 parts of dibasic lead phosphite, 1.2 parts of lead stearate, 0.8 part of cadmium stearate, 0-0.4 part of AC foaming agent and 0.6 part of stearic acid.
More preferably, the composition of the first material layer further comprises: 0-10 parts of chlorinated polyethylene, 0.8 part of paraffin and processing aid0 to 4 parts of CaCO30 to 10 parts of nucleating agent, CaCO3&And nbsp 0-30 parts.
Preferably, the second material layer comprises the following components in parts by weight: 100 parts of UPVC or PVC or ABS, 5 parts of composite stabilizer, 5 parts of plasticizer and ordinary CaCO3Or modified CaCO3And 20 parts.
Preferably, the first material layer and the second material layer are bonded together while the first material layer and the second material layer are formed and in a viscous state.
According to another aspect of the present invention, there is provided a wave-transparent cover using the above wave-transparent structure.
According to a further aspect of the invention, the wave-transparent cover in the above-described aspect is provided on the housing of a communication device on an aircraft, a motor vehicle or a ship.
In the technical scheme of the invention, the design parameters such as the thickness, the dielectric constant, the dielectric loss tangent and the like of the material layer depend on the preset electromagnetic wave transmittance and the mechanical strength, so that when the wave-transmitting structure is applied to structures such as an antenna cover and the like, different thicknesses at different positions can be freely designed according to requirements, the expected electromagnetic wave transmittance can be obtained, the expected mechanical strength can be met, and the wave-transmitting structure can be suitable for various occasions requiring electromagnetic transmission.
In addition, the wave-transmitting structure is prepared by UPVC or PVC or ABS resin, so that the preparation cost is greatly reduced, the requirement of an adhesive is eliminated by adopting a preparation process of co-extrusion and foaming, and the mass production is easy to carry out.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings without creative efforts.
Fig. 1 is a schematic diagram showing a general structure of a wave-transparent structure;
FIG. 2 is a graph showing a simulated structure of examples 1-4 of wave-transparent structures according to the present invention;
FIG. 3 is a graph showing simulated structures of examples 5-8 of wave-transparent structures according to the present invention;
FIG. 4 is a graph showing a simulated structure of examples 9-10 of wave-transparent structures according to the present invention; and
fig. 5 is a schematic diagram illustrating a process flow for making the wave-transparent structure of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments that can be derived by one of ordinary skill in the art from the embodiments given herein are intended to be within the scope of the present invention.
The present invention is described in detail below with reference to the accompanying drawings.
The wave-transparent structure according to the embodiment of the invention comprises: at least one first material layer; and at least two second material layers, each first material layer being disposed between two second material layers. The design parameters of the first material layer and the thickness of the second material layer are determined by respectively simulating the thicknesses of the first material layer and the second material layer through the preset electromagnetic wave transmittance and mechanical strength.
Among the design parameters mentioned above are thickness, dielectric constant, dielectric loss tangent.
Furthermore, the first material layer is a foamed material layer. Preferably, the first material layer is PVC and/or UPVC and the second material layer is PVC and/or UPVC. Or the first material layer and the second material layer are ABS (acrylonitrile-butadiene-styrene copolymer). UPVC, also known as PVC-U, refers to the preparation of polyvinyl chloride (PVC) raw material without the addition of plasticizers. The UPVC polymer material has excellent physical and chemical performance, high impact strength, high ageing resistance, long service life, capacity of being used in outdoor environment for over 50 years and low cost. By adopting cheap PVC and UPVC, the cost of the wave-transmitting material can be greatly reduced. ABS is a thermoplastic high polymer material with high strength, good toughness and easy processing and molding, and has the characteristics similar to PVC or UPVC.
The present invention will be described in detail below by taking as an example a structure having one first material layer (hereinafter referred to as a core layer) and two second material layers (hereinafter referred to as skins). It should be noted that the present invention is not limited to this case, but may include more than one core layer and more than two skins as long as each core layer is sandwiched between two skins.
The wave-transparent structure of the preferred embodiment of the present invention may comprise one first material layer and two second material layers as shown in fig. 1. I.e. comprising two skins a and one core B. In this case, the skin is a common, dense PVC or UPVC plastic, or ABS resin, and the core layer is a foamed PVC or UPVC material, or ABS resin. UPVC material or ABS resin is preferably used because the UPVC and ABS resin have better physical and chemical properties and weather resistance than PVC.
The following describes in detail the design parameters of the wave-transparent structure of the present invention. It should be noted that after determining the material of the skin, only the thickness of the skin can be adjusted, and the design parameters of the core layer (including thickness, dielectric constant, dielectric loss tangent, etc.) can be determined by adjusting the foaming ratio of the core layer.
Specifically, the thickness of the foam core layer is in the range of 2mm to 20mm, the dielectric loss tangent of the foam core layer is in the range of 0.005 to 0.03 (preferably 0.01), and the dielectric constant of the foam core layer is in the range of 1.5 to 3.3.
The thickness of the skin is in the range of 0.5mm to 1mm, the dielectric loss tangent of the skin is in the range of 0.02 to 0.05 (preferably 0.03), and the dielectric constant of the skin is in the range of 3.1 to 3.5 (preferably 3.3).
The inventors of the present application conducted a number of experiments on the thickness, dielectric constant, dielectric loss tangent of the foam core layer and the skin, 10 examples of which are shown in the following table.
From the above, it can be seen that the good wave-transparent performance of the wave-transparent structure according to the present invention has been verified in practical applications. Specifically, electromagnetic wave permeability of the full UPVC sandwich structure with different thicknesses and different core layer dielectric constants is verified through electromagnetic simulation software CST. Of course, similar results can be obtained for sandwich constructions using all PVC or a combination of PVC and UPVC or ABS. Among them, the most preferred embodiments are examples 9 and 10 thereof.
Fig. 2 is a graph showing the simulation structures of examples 1 to 4 of the wave-transparent structure according to the present invention, fig. 3 is a graph showing the simulation structures of examples 5 to 8 of the wave-transparent structure according to the present invention, and fig. 4 is a graph showing the simulation structures of examples 9 to 10 of the wave-transparent structure according to the present invention.
The simulation result shows the energy loss of the electromagnetic wave in the frequency range of 0-18GHz after the electromagnetic wave penetrates through the material, and the more negative the S21 value is, the larger the loss is.
As can be seen from the simulation results of fig. 2 to fig. 4, the full UPVC sandwich structure with greatly different wave-transparent performance can be obtained by different parameter combinations. Generally, the thicker the overall thickness, the better the mechanical strength of the sandwich structure, but at the same time the wave-transparent properties will also deteriorate. For example, the total thickness of the wave-transparent material in example 9 is 9.2mm, and the electromagnetic wave loss is less than 1dB in the frequency range of 0-18GHz, while the requirements of wave-transparent performance and mechanical strength can be satisfied.
A schematic diagram of a process flow for preparing the wave-transparent structure of the present invention is described in detail below with reference to fig. 5. The wave-transmitting structure can be prepared by a three-layer co-extrusion and core layer foaming process.
Specifically, the process comprises the following steps: mixing materials of the foaming core layer and the skin in a kneading machine; respectively extruding the foam core layer and the skin in a plurality of extruders; and combining the foamed core layer and the skin together in a co-extrusion head to form the wave-transparent structure.
The foaming core layer comprises the following components in parts by weight: 98-102 parts of UPVC or PVC or ABS, 2-4 parts of tribasic lead sulfate, 5-6 parts of composite stabilizer (containing stabilizer for promoting uniform foaming), 1-3 parts of dibasic lead phosphite, 1.0-1.3 parts of lead stearate, 0.7-0.9 part of cadmium stearate, 0-0.4 part of AC foaming agent and 0.5-0.7 part of stearic acid. Preferably, the components of the foamed core layer may further include: 0.8 to 1.2 parts of paraffin and CaCO30-10 parts of nucleating agent, 0-4 parts of processing aid, 0-10 parts of chlorinated polyethylene and CaCO3&And nbsp 0-30 parts.
The skin comprises the following components in parts by weight: 98-102 parts of UPVC or PVC or ABS, 4-6 parts of composite stabilizer, 4-6 parts of plasticizer and common CaCO3Or modified CaCO318-22 parts.
It should be noted that the processes related to the vacuum cooling of the setting bath, the cooling water bath, etc. in fig. 2 are not matters to which the present invention is focused, and thus their description is omitted here.
The core layer and the skin of the UPVC or ABS sandwich structure obtained by the process are fused and bonded into a whole under the hot bonding state when the UPVC or ABS is formed, and the two layers of materials can be basically regarded as one material and are easily bonded into a whole under the hot bonding state. Therefore, the adhesive effect is much better than that of the prior art, and the mechanical strength of the obtained sandwich structure is better.
It should be emphasized that, in the case of the structure of the present invention using more than one core layer and more than two skins, the parameters of the core layer and the skins are different from the above-listed numerical ranges and need to be specifically determined according to the desired electromagnetic transmittance and mechanical strength, but it is apparent to those skilled in the art that the specific implementation and the preparation method thereof are similar to the above-described embodiment, and thus a detailed description is omitted herein.
Preferably, the wave-transparent structure of the present invention is applicable to a radome. When the wave-transmitting structure is used for the antenna housing, in one antenna housing or shell, the thickness of each part can be designed according to the expected electromagnetic transmittance and the expected mechanical strength, so that the electromagnetic waves emitted by the antenna positioned in the antenna housing at angles in all directions have better wave-transmitting effect. Specifically, an optimal thickness combination can be found within a certain thickness range through electromagnetic simulation software, so that the whole sandwich structure has excellent electromagnetic wave transmission performance, and meanwhile, the thickness range can meet the requirement of mechanical performance. Further, the wave-transparent structure of the present invention can also be applied to communication systems, aircraft, transportation means, and the like.
In addition, through the design of the grinding tool, profiles in various shapes can be extruded, and the application occasions of various wave-transmitting materials are met. In other words, the wave-transparent structure of the present invention can be applied not only to the radome, but also to other situations requiring transmission of electromagnetic waves.
In conclusion, the invention provides a novel sandwich structure, wherein the skin material and the core layer material are both made of PVC or UPVC material or ABS resin with low price, the core layer and the skin can be formed at one time through the process of three-layer co-extrusion and core layer foaming, the core layer and the skin are fused into a whole during processing, bonding is not needed any more, and the novel sandwich structure has the characteristics of low cost and easiness in batch production.
In a specific implementation process, the wave-transparent cover in the scheme is arranged on the shell of communication equipment on an aircraft, a motor vehicle or a ship.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.
Claims (25)
1. A wave-transparent structure, comprising:
at least one first material layer; and
at least two layers of a second material, each of the layers of the first material being disposed between two of the layers of the second material,
the design parameters of the first material layer and the thickness of the second material layer are determined by respectively simulating the thicknesses of the first material layer and the second material layer through preset electromagnetic wave transmittance and mechanical strength;
the first material layer and the second material layer are ABS;
the wave-transparent structure comprises a wave-transparent structure and at least one first material layer and at least two second material layers, wherein the at least one first material layer and the at least two second material layers of the wave-transparent structure are manufactured in a one-step forming mode through combining the first material layer and the second material layer together in a viscous state when the first material layer and the second material layer are formed.
2. The wave-transparent structure of claim 1, wherein the design parameters include thickness, dielectric constant, and dielectric loss tangent.
3. The wave-transparent structure of claim 1, wherein the first material layer is a foamed material layer.
4. The wave-transparent structure of claim 3, comprising one layer of the first material and two layers of the second material.
5. The wave-transparent structure of claim 4, wherein the thickness of the first material layer is in the range of 2mm to 20 mm.
6. The wave-transparent structure of claim 4, wherein the first material layer has a dielectric loss tangent in the range of 0.005 to 0.03.
7. The wave-transparent structure of claim 6, wherein the first material layer has a dielectric loss tangent of 0.01.
8. The wave-transparent structure of claim 4, wherein the first material layer has a dielectric constant in the range of 1.5 to 3.3.
9. The wave-transparent structure of claim 4, wherein the thickness of the second material layer is in the range of 0.5mm to 1 mm.
10. The wave-transparent structure of claim 4, wherein the second material layer has a dielectric loss tangent in the range of 0.02 to 0.05.
11. The wave-transparent structure of claim 10, wherein the second material layer has a dielectric loss tangent of 0.03.
12. The wave-transparent structure of claim 4, wherein the second material layer has a dielectric constant in the range of 3.1 to 3.5.
13. The wave-transparent structure of claim 12, wherein the second material layer has a dielectric constant of 3.3.
14. The wave-transparent structure of claim 4, wherein the thickness of the first material layer is 8mm, the thickness of the second material layer is 0.6mm, the dielectric constant of the first material layer is 1.5, the dielectric constant of the second material layer is 3.3, the dielectric loss tangent of the first material layer is 0.01, and the dielectric loss tangent of the second material layer is 0.03.
15. The wave-transparent structure of claim 4, wherein the first material layer has a thickness of 3mm, the second material layer has a thickness of 0.6mm, the first material layer has a dielectric constant of 1.5, the second material layer has a dielectric constant of 3.3, the first material layer has a dielectric loss tangent of 0.01, and the second material layer has a dielectric loss tangent of 0.03.
16. The wave-transparent structure according to any one of claims 1 to 15, applied to a radome.
17. The wave-transparent structure according to claim 16, wherein the thickness of each portion of the radome is different according to a predetermined electromagnetic wave transmittance.
18. The wave-transparent structure of any one of claims 1 to 15, wherein the wave-transparent structure is applied to a communication system, an aircraft, or a vehicle.
19. A method for preparing a wave-transparent structure, wherein the wave-transparent structure of any one of claims 1 to 18 is prepared by a co-extrusion and foaming process; wherein the design parameter of the first material layer is determined by adjusting the foaming rate of the first material layer; the preparation method comprises the following steps: the wave-transparent structure comprising at least one first material layer and at least two second material layers is prepared by one-step forming of forming the first material layer and the second material layer and bonding the first material layer and the second material layer together in a viscous state.
20. The method for preparing a wave-transparent structure according to claim 19, wherein the process comprises the steps of:
mixing the materials of the first material layer and the second material layer;
respectively forming the first material layer and the second material layer; and
bonding the first material layer and the second material layer together to form the wave-transparent structure.
21. The method for preparing a wave-transparent structure according to claim 20, wherein the first material layer comprises the following components in parts by weight: 98-102 parts of ABS, 2-4 parts of tribasic lead sulfate, 5-6 parts of a composite stabilizer, 1-3 parts of dibasic lead phosphite, 1.0-1.3 parts of lead stearate, 0.7-0.9 part of cadmium stearate, 0-0.4 part of an AC foaming agent and 0.5-0.7 part of stearic acid.
22. The method of making a wave-transparent structure according to claim 21, wherein the composition of the first material layer further comprises: 0-10 parts of chlorinated polyethylene, 0.8-1.2 parts of paraffin, 0-4 parts of processing aid and CaCO30 to 10 parts of nucleating agent, CaCO3&0-30 parts of nbsp.
23. The method for preparing a wave-transparent structure according to claim 20, wherein the second material layer comprises the following components in parts by weight: 98-102 parts of ABS, 4-6 parts of composite stabilizer, 4-6 parts of plasticizer and common CaCO3Or modified CaCO318-22 parts.
24. A wave-transparent cover, characterized in that a wave-transparent structure according to any one of claims 1 to 15 is used.
25. The wave-transparent cover according to claim 24, wherein the wave-transparent cover is provided on a housing of a communication device on an aircraft, a motor vehicle or a ship.
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| CN108461915A (en) * | 2018-01-26 | 2018-08-28 | 合肥驼峰电子科技发展有限公司 | A kind of millimetre-wave radar antenna house using electromagnetic wave transparent material |
| CN115084850A (en) * | 2019-06-30 | 2022-09-20 | Oppo广东移动通信有限公司 | Shell assembly, antenna assembly and electronic equipment |
| CN112290193B (en) * | 2019-07-26 | 2023-07-25 | Oppo广东移动通信有限公司 | Millimeter wave module, electronic equipment and adjusting method of millimeter wave module |
| CN110808465B (en) * | 2019-09-27 | 2021-02-02 | 浙江瑞堂塑料科技股份有限公司 | High-wave-transmittance radome and preparation process thereof |
| CN112028658A (en) * | 2020-08-04 | 2020-12-04 | 中国航天科工飞航技术研究院（中国航天海鹰机电技术研究院） | Wave-transparent structure with controllable electromagnetic performance |
| CN113290879B (en) * | 2020-09-22 | 2022-08-23 | 江苏集萃先进高分子材料研究所有限公司 | Preparation method of integrated multilayer broadband high-wave-permeability microporous foam material |
| CN112848034B (en) * | 2020-12-04 | 2022-11-18 | 京信通信技术(广州)有限公司 | Antenna housing, mold thereof and preparation method |
| CN112848022B (en) * | 2020-12-04 | 2022-11-18 | 京信通信技术(广州)有限公司 | Antenna housing and forming method and forming control device thereof |
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