CN109462019B - 一种超轻型混杂复合材料管状天线及其制造方法 - Google Patents

一种超轻型混杂复合材料管状天线及其制造方法 Download PDF

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CN109462019B
CN109462019B CN201811375108.3A CN201811375108A CN109462019B CN 109462019 B CN109462019 B CN 109462019B CN 201811375108 A CN201811375108 A CN 201811375108A CN 109462019 B CN109462019 B CN 109462019B
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copper foil
cyanate
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CN109462019A (zh
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朱永明
袁文峰
杨春霞
张彦
孙为民
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Nanjing Guorui Defense System Co ltd
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Abstract

本发明公开了一种超轻型混杂复合材料管状天线及其制造方法，其3层碳纤维织物‑氰酸脂预浸料构成碳纤维织物‑氰酸脂层，作为管状天线的承力主材；在碳纤维织物‑氰酸脂层外表面缠绕铜箔，再进行真空加压，形成铜箔层；在铜箔层表面铺贴石英玻纤‑氰酸脂复合材料，形成石英玻纤‑氰酸脂保护层，再进行缠带固化、打磨抛光、形成超轻型混杂复合材料管，通过机械加工到电讯设计需求的不同长度组合；在超轻型混杂复合材料管外涂覆三防涂层。超轻型混杂复合材料管状天线表面精度高，重量轻，可承受‑55℃～85℃温度循环冲击50次以上，可耐酸性盐雾试验，耐环境性能优异，比传统的铝合金天线减重60％以上，天线增益水平等同于铝合金天线。

Description

一种超轻型混杂复合材料管状天线及其制造方法
技术领域
本发明涉及一种管状天线及其制造方法，尤其涉及一种超轻型混杂复合材料管状天线及其制造方法。
背景技术
自雷达发明以来，管状天线一直是使用最为广泛的天线之一，八木天线、方框天线，蛛网天线等均使用管状天线组合，是最具有悠久历史的传统天线。在雷达天线系统方面有着广泛的应用。传统管状天线一般是由铜、铝等金属材料加工成基础元件，再通过组合连接组装成天线。随着我国海军战略发生转变，建立了建设海洋强国的战略目标。机载电子装备对雷达的重量有严格的限制，对管状天线在满足性能的同时要求最大限度实现轻量化，同时为了实现雷达性能提升，要求天线能承受高功率辐射引起的温升。
碳纤维是一种含碳量高于90％的无机高性能纤维，与有机树脂复合成的材料具有重量轻、强度高、刚度好等特点，碳纤维复合材料密度不到钢的1/4，强度和模量均优于钢，特别适合于制造对重量要求苛刻的航天、航空结构件。目前碳纤维复合材料以广泛用于制造雷达卫星、军用飞机承力框架、火箭发射筒等力学结构件，在军用电子行业，碳纤维复合材料也用于制造机载雷达天线承力框架，球载雷达天线支撑等结构件，也用于制造高精度天线反射面，大型轻型喇叭天线等功能结构件。由于碳纤维复合材料本身导电性较差，作为天线使用，必须进行金属化处理，达到天线电性能使用要求，我国有广域的海洋面积，其所处环境较为恶劣，要求载机雷达天线具有优异的耐酸性盐雾大气性能。2012年的《装备制造技术》刊登了一篇关于大型喇叭状碳纤维天线成型工艺研究的文章，其方法为使用阳模制造碳纤维喇叭天线，在内部通过电镀进行金属化处理的方法，其不足之处是无法做到超薄壁厚，减重效果不明显；但是采用碳纤维-氰酸脂树脂+铜箔+石英纤维-氰酸脂组合一体成型超轻型混杂复合材料管状天线还未见报道。
发明内容
针对以上问题，本发明提供了一种超轻型混杂复合材料管状天线及其制造方法。本发明制造的管状天线能满足机载环境要求以及机载雷达系统对天线的重量及性能要求，组成八木天线阵，天线增益不小于使用铝合金天线阵以及能耐受高功率微波辐射引起的温升。
为了解决以上问题，本发明采用了如下技术方案：
一种超轻型混杂复合材料管状天线，其特征在于：包括碳纤维织物和氰酸脂树脂构成的碳纤维织物-氰酸脂复合材料层，包裹在碳纤维织物-氰酸脂复合材料层外的铜箔层，铺贴在铜箔层外的石英玻纤-氰酸脂复合材料层，涂覆在石英玻纤-氰酸脂复合材料层外的三防涂层。
所述的超轻型混杂复合材料管状天线整体的管壁厚0.5mm。所述的铜箔层的厚度为0.05mm，铜箔采用反转铜箔(也称为双面毛面电解铜箔)，铜箔搭接宽度，3～5mm。所述的石英玻纤-氰酸脂复合材料层的厚度为0.1mm，接缝与铜箔接缝错开180°，石英玻纤-氰酸脂层和碳纤维织物-氰酸脂层采用正交铺层。
一种超轻型混杂复合材料管状天线的制造方法，其特征在于，包括以下步骤：
步骤1，承力层卷制预成型：3层碳纤维织物-氰酸脂预浸料构成碳纤维织物-氰酸脂层，作为管状天线的承力主材；
步骤2，铜箔真空加压预成型：在碳纤维织物-氰酸脂层外表面缠绕铜箔，再进行真空加压，形成铜箔层，作为功能层；
步骤3，保护层预成型：在铜箔层表面铺贴超低介电损耗的石英玻纤-氰酸脂预浸料层作为保护层，实现混杂复合材料管状天线耐酸性盐雾试验的要求以及实现天线阵高增益电性能要求；
步骤4，缠带固化成型：在步骤1，2，3完成后在外表面进行缠带加压并进行固化、固化后的管子进行打磨抛光后形成超轻型混杂复合材料管，机械加工到电讯设计长度；
步骤5：三防处理，在超轻型混杂复合材料管外涂覆三防涂层。
所述的步骤1、2、3完成后，步骤4固化成型温度180℃～200℃，时间2-4hr。
所述的超轻型混杂复合材料管状天线管壁厚0.5mm，其中碳纤维织物-氰酸脂层总厚度为0.3mm；铜箔层采用厚度0.05mm的反转铜箔(也称双面毛面电解铜箔)，铜箔搭接宽度，3～5mm；外层石英玻纤-氰酸脂层厚度为0.1mm，接缝与铜箔接缝错开180°，实现混杂复合材料管状天线耐高低温温度冲击性能，碳纤维织物-氰酸脂层及石英玻纤-氰酸脂层采用正交铺层。
所述的三防涂层为喷清漆防护，或清漆+面漆防护，实现耐酸性盐雾的性能要求。
有益效果：超轻型混杂复合材料管状天线表面精度高，重量轻，可承受-55℃～85℃温度循环冲击50次以上，可耐酸性盐雾试验，耐环境性能优异，比传统的铝合金天线减重60％以上，天线增益水平等同于铝合金天线，组合成天线阵列总体增益水平超过美军类似机载雷达天线，性能优异，减重效果明显。该超轻型混杂复合材料管状天线是新一代超轻型、高精度管状天线产品，可以满足机载环境技术条件，也可以用于其他有苛刻的耐环境性能以及重量要求严格的阵列天线。
附图说明
图1超轻型混杂复合材料管状天线示意图；
其中，1～3-碳纤维织物-氰酸脂层；4-铜箔层；5一石英玻纤织物-氰酸脂层；6-三防涂层。
图2超轻型混杂复合材料管状天线截面示意图；
图3超轻型混杂复合材料管状天线制备工艺流程图。
具体实施方式
下面结合对本发明做进一步阐述。
如图1、2所示，本发明提供了一种超轻型混杂复合材料管状天线，包括碳纤维织物和氰酸脂树脂构成的碳纤维织物-氰酸脂层1～3，包裹在碳纤维织物-氰酸脂层外的铜箔层4，铺贴在铜箔层的石英玻纤-氰酸脂层5，涂覆在石英玻纤-氰酸脂层外的三防涂层6。
超轻型混杂复合材料管状天线整体的管壁厚为0.5mm，所述的铜箔层4的厚度为0.05mm的反转铜箔(也叫做双面毛面电解铜箔)，铜箔搭接宽度，3～5mm。所述的石英玻纤-氰酸脂层5的厚度为0.1mm，接缝与铜箔接缝错开180°，实现混杂复合材料管状天线耐高低温温度冲击性能。石英玻纤-氰酸脂层5和碳纤维织物-氰酸脂层6采用正交铺层。所述的三防涂层厚度为0.05mm，表面粗糙度优于3.2。
如图3所示，超轻型混杂复合材料管状天线的制造方法，包括以下步骤：
步骤1：承力层卷制预成型，3层碳纤维织物-氰酸脂预浸料构成碳纤维织物-氰酸脂层，作为管状天线的承力主材，碳纤维织物-氰酸脂层总厚度为0.3mm，碳纤维织物-氰酸脂层采用正交铺层，成型温度180℃～200℃，时间2-4hr。
步骤2：铜箔真空加压预成型，在碳纤维织物-氰酸脂层外表面缠绕铜箔，再进行加压，形成铜箔层，铜箔层采用厚度0.05mm双面毛面电解铜箔，铜箔搭接宽度，3～5mm，成型温度180℃～200℃，时间2-4hr。
步骤3：保护层预成型，在铜箔表面铺贴超低介电损耗的石英玻纤-氰酸脂复合材料层作为保护层，外层石英玻纤-氰酸脂层厚度为0.1mm，铺贴2层，接缝与铜箔接缝错开180°，实现混杂复合材料管状天线耐高低温温度冲击性能，石英玻纤-氰酸脂层采用正交铺层，实现混杂复合材料管状天线耐酸性盐雾试验的要求以及实现天线阵高增益电性能要求；
步骤4，固化成型，在步骤1，2，3完成后进行缠带加压并进行固化，成型固化温度180℃～200℃，时间2-4hr。固化成型后对外表面进行打磨抛光去除多余的1层，形成表面光滑的超轻型混杂复合材料管，通过机械加工到电讯设计需要的不同长度组合；
步骤5：三防处理，在超轻型混杂复合材料管外涂覆三防涂层，所述的三防涂层为喷清漆防护或喷清漆+面漆防护，实现耐酸性盐雾的性能要求。
由超轻型混杂复合材料管状天线组成的天线阵列，实现天线性能。
通过控制模芯尺寸精度以及预浸料面密度精度实现金属层直径精度要求。毛坯制件表面经过专业打磨机和抛光处理，经机械加工到电讯设计要求的不同长度组合，然后进行三防处理，满足管状天线阵耐环境性能要求。
以上所述仅是本发明的优选实施方式，应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明技术原理的前提下，还可以做出若干改进和变形，这些改进和变形也应视为本发明的保护范围。

Claims (10)

1.一种超轻型混杂复合材料管状天线，其特征在于：包括碳纤维织物和氰酸脂树脂构成的碳纤维织物-氰酸脂复合材料层，包裹在碳纤维织物-氰酸脂复合材料层外的铜箔层，铺贴在铜箔层外的石英玻纤-氰酸脂复合材料层，涂覆在石英玻纤-氰酸脂复合材料层外的三防涂层。
2.根据权利要求1所述的一种超轻型混杂复合材料管状天线，其特征在于：整体的管壁厚度0.5mm。
3.根据权利要求1所述的一种超轻型混杂复合材料管状天线，其特征在于：所述的铜箔层的厚度为0.05mm的反转铜箔，铜箔搭接宽度,3～5mm。
4.根据权利要求1所述的一种超轻型混杂复合材料管状天线，其特征在于：所述的石英玻纤-氰酸脂层的厚度为0.1mm，接缝与铜箔接缝错开180°，石英玻纤-氰酸脂层采用正交铺层。
5.根据权利要求1所述的一种超轻型混杂复合材料管状天线，其特征在于：所述的碳纤维织物-氰酸脂层采用正交铺层。
6.根据权利要求1所述的一种超轻型混杂复合材料管状天线，其特征在于：所述的三防涂层厚度为0.05mm。
7.根据权利要求1所述的一种超轻型混杂复合材料管状天线的制造方法，其特征在于，
步骤1,承力层卷制预成型:3层碳纤维织物-氰酸脂预浸料构成碳纤维织物-氰酸脂复合材料层，作为管状天线的承力主材；
步骤2,铜箔层真空加压预成型:在碳纤维织物-氰酸脂层外表面缠绕铜箔，再进行真空加压预成型，形成铜箔层；
步骤3,保护层与成型：在铜箔层表面铺贴石英玻纤-氰酸脂预浸料形成石英玻纤-氰酸脂复合材料保护层；
步骤4,缠带固化成型：将步骤1，2，3与成型后的管子缠带并进行固化、打磨抛光形成超轻型混杂复合材料管，通过机械加工到电讯设计需求的不同长度组合；
步骤5,三防处理，在超轻型混杂复合材料管外涂覆三防涂层。
8.根据权利要求7所述的一种超轻型混杂复合材料管状天线的制造方法，其特征在于，所述的步骤4，固化成型温度180℃～200℃，时间2-4hr。
9.根据权利要求7所述的一种超轻型混杂复合材料管状天线的制造方法，其特征在于，所述的超轻型混杂复合材料管状天线管壁厚0.5mm，其中碳纤维织物-氰酸脂层总厚度为0.3mm；铜箔层采用厚度0.05mm反转铜箔，铜箔搭接宽度,3～5mm；外层石英玻纤-氰酸脂层厚度为0.1mm，接缝与铜箔接缝错开180°，碳纤维织物-氰酸脂层及石英玻纤-氰酸脂层采用正交铺层。
10.根据权利要求7所述的超轻型混杂复合材料管状天线制造方法，其特征在于，所述的三防涂层为喷清漆防护,或喷清漆+面漆防护。
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