CN111863993A - 一种适用于柔性太阳翼的基板结构及其成型方法 - Google Patents

一种适用于柔性太阳翼的基板结构及其成型方法 Download PDF

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CN111863993A
CN111863993A CN202010599381.5A CN202010599381A CN111863993A CN 111863993 A CN111863993 A CN 111863993A CN 202010599381 A CN202010599381 A CN 202010599381A CN 111863993 A CN111863993 A CN 111863993A
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许文彬
咸奎成
陈建祥
余守莉
汤亮
张雷
程雷
王治易
霍杰
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Shanghai Aerospace System Engineering Institute
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Abstract

本发明公开了一种适用于柔性太阳翼的基板结构及其成型方法，具有一定的柔性、厚度薄(0.3mm)、尺寸大、具有较好的力学性能和耐空间环境性能。柔性基板采用综合挠性板和刚性板特点的新颖设计思路，为五层平面对称结构，其中中间层为纤维增强的复合材料，最外层为聚酰亚胺薄膜，聚酰亚胺薄膜与中间增强层采用柔性胶黏剂粘贴固化成型。适用于低轨环境的柔性基板，为了对低轨原子氧进行防护，在聚酰亚胺薄膜外表面还有一层原子氧防护层。为了保证柔性基板成型后各层之间无分层、无气泡，表面平整，创新性的提出了软硬板结合的成型工艺进行成型。

Description

一种适用于柔性太阳翼的基板结构及其成型方法
技术领域
本发明涉及一种柔性的太阳电池翼基板结构，可用于大面积柔性太阳翼电池电路的安装平台和支撑载体。
背景技术
目前，国内航天器太阳翼一般采用刚性太阳翼和半刚性太阳翼，对应的基板(电池电路安装平台和支撑载体)为刚性基板和半刚性基板，其重量较重(面密度一般为1.0kg/m2～2.5kg/m2)、收拢后尺寸较大(一般单块板的厚度为23mm)。随着航天技术的发展，大型航天器的功率需求越来越大，从而需要太阳电池翼的面积越来越大，在大面积太阳电池翼上如仍采用传统的刚性基板或半刚性基板，将会面临收拢后包络尺寸和重量不能满足要求的问题，因此急需发展收拢尺寸小、重量轻的柔性太阳翼技术。
发明内容
本发明在国内首创性的设计了一种适用于柔性太阳电池翼的柔性基板结构，其提供电池电路的安装平台和支撑载体，具有尺寸大、厚度薄、重量轻的特点。
本发明提供的柔性太阳翼基板结构，包括：
所涉及的柔性基板为柔性平面结构，从截面看为五层对称结构，该种结构结合了刚性板和挠性板的优点，具有较好的力学性能和柔韧性。其中中间为增强层，靠近增强层的上下两层为胶黏剂层，胶黏剂层的外侧为聚酰亚胺薄膜层，胶黏剂层将增强层和聚酰亚胺薄膜层粘贴成整体。适用于低轨环境的柔性基板，为了对低轨原子氧进行防护，在聚酰亚胺薄膜外表面还有一层原子氧防护层。
进一步，所述增强层为纤维增强环氧树脂基体的复合材料，其中增强材料采用SW110C-100a高强玻璃纤维布，树脂为SP120N环氧树脂，其为柔性树脂，成型后增强层具有较好的柔韧性。
进一步，为了保证增强层与PI膜之间具有较好的结合强度，所述胶黏剂采用牌号为JN02的聚酰亚胺改性环氧树脂类胶黏剂，同时其具有较好的耐空间环境性能，能够满足长期在轨±100℃温度环境的使用要求。
所述的柔性基板，如需适用于低轨环境，为了对低轨原子氧进行防护，在聚酰亚胺薄膜外表面还有一层原子氧防护层。原子氧防护层可以采用在柔性基板制备好后，在聚酰亚胺薄膜表面刷涂防原子氧有机硅胶，也可在聚酰亚胺薄膜表面采用PECVD(等离子体增强化学气相沉积)或活化硅烷化的方法生长一层硅氧烷的原子氧防护层，或采用体材改性(聚酰亚胺薄膜掺杂POSS笼型聚倍半硅氧烷基团进行改性)的具有原子氧防护能力的聚酰亚胺薄膜。
所述的柔性基板，其绝缘性能大于20MΩ，正反两面均能用于电池电路的粘贴。
所述的柔性基板，其成型方法特征在于，结合产品特点创新性的综合了软硬板的成型工艺方法，其步骤包括：
步骤一、将增强层用树脂SP120N按配方混合配制好后，采用上胶工艺将纤维布浸渍在树脂中，然后在上胶机内进行烘干固化，形成粘结片后收卷待用，此步骤主要将纤维布与树脂进行复合并半固化；
步骤二、将半固化的粘结片裁切成一定尺寸规格的片状材料，将这些片材材料与钢板、离型材料、缓冲材料等按照一定的顺序堆叠起来，称作“叠book”，再由输送装置将“book”送入真空层压机进行压合，压合温度为160℃±10℃/180min±20min、压合压力为10±5kg/cm2，压合固化而成增强层。此步骤通过真空平面模压工艺，保证增强层固化后平整、无气泡；
步骤三、将各层粘接用胶黏剂JN02按照配方混合配制好后，采用涂覆工艺制作PI覆盖膜。在涂覆机上通过在聚酰亚胺薄膜上连续化涂覆胶黏剂层，并将胶黏剂层用离型纸保护起来，生产出来的成品即为PI覆盖膜，收卷后待用；
步骤四、将卷状PI覆盖膜裁切成一定尺寸规格的片状材料，将片状PI覆盖膜、片状增强层材料与钢板、离型材料、缓冲材料等按照一定的顺序“叠book”起来，然后再将“叠book”后结构采用真空平面模压工艺进行压合固化，压合温度为190℃±10/50min±10min、压合压力为30±5kg/cm2；；
步骤五、采用激光加工的方式对基板外形和其上的孔位进行制作，采用菲林定位技术保证大尺寸柔性基板的孔位精度和外形尺寸精度。
该成型工艺方法可稳定大批量的生产柔性基板产品。
本发明的优点包括：
本发明所涉及的柔性基板即可用于大面积柔性太阳翼电池电路的安装平台和支撑载体，其具有尺寸大、厚度薄、重量轻的特点，具有较好的力学性能和耐空间环境性能，解决了传统刚性基板和半刚性基板所面临的问题，该发明在国内属于首创，填补了相关技术领域的空白。
采用纤维增强后其力学性能优越；同时其厚度薄(0.3mm)、重量轻(面密度小于0.5kg/m2)，尺寸可根据需求进行设计和生产制造。
本发明所涉及的柔性基板可用于大面积柔性太阳翼电池电路的安装平台和支撑载体，同时也可用于收纳空间小、展开面积大的柔性太阳翼，如扇形太阳翼等，具有广阔的应用前景。
本发明成型工艺能够保证基板成型后各层之间无分层、无气泡，表面平整。
附图说明
图1为柔性基板截面示意图；
图2为柔性基板生产流程示意图；
图3为柔性基板压合“叠book”各层示意图
图4为柔性基板上粘贴电池片后示意图，图中1为柔性基板，2为电池片。
具体实施方式
下面结合附图和实施例对本发明作进一步阐述。
结合参考图1，本发明提供的柔性基板亦称太阳翼的基板结构，包括：
柔性基板从截面看为五层对称结构，该种结构结合了刚性板和挠性板的优点，具有较好的力学性能和柔韧性。其中中间为增强层，靠近增强层的上下两层为胶黏剂层，胶黏剂层的外侧为聚酰亚胺薄膜层，胶黏剂层将增强层和聚酰亚胺薄膜层粘贴成整体。
在本实施例中，所述增强层采用SW110C-100a/SP120N的高强玻璃纤维布增强环氧树脂基体复合材料，所述聚酰亚胺薄膜厚度为0.05mm。SP120N环氧树脂，其为柔性树脂，成型后增强层具有较好的柔韧性。
为了保证增强层与PI膜之间具有较好的结合强度，所述胶黏剂采用牌号为JN02的聚酰亚胺改性环氧树脂类胶黏剂，同时其具有较好的耐空间环境性能，能够满足长期在轨±100℃温度环境的使用要求。
适用于低轨环境的柔性基板，为了对低轨原子氧进行防护，在聚酰亚胺薄膜外表面还有一层原子氧防护层。原子氧防护层可以采用在柔性基板制备好后，在聚酰亚胺薄膜表面刷涂防原子氧有机硅胶，也可在聚酰亚胺薄膜表面采用物理或化学的方法生长一层原子氧防护层，或采用体材改性的具有原子氧防护能力的聚酰亚胺薄膜。
在本实施例中，结合图2和图3，柔性基板成型工艺方法包括：
步骤一、将增强层用树脂SP120N按配方混合配制好后，采用上胶工艺将纤维布浸渍在树脂中，然后在上胶机内进行烘干固化，形成粘结片后收卷待用，此步骤主要将纤维布与树脂进行复合并半固化；
步骤二、在本实施案例中，将半固化的粘结片裁切成2.5m×0.52m大小的片状材料，将这些片材材料与钢板、离型材料、缓冲材料等按照一定的顺序堆叠起来，称作“叠book”，“叠book”示意图见图3所示，再由输送装置将“book”送入真空层压机进行压合，压合温度为160℃/180min、压合压力为10kg/cm2，压合固化而成增强层。此步骤通过真空平面模压工艺，保证增强层固化后平整、无气泡；
步骤三、将各层粘接用胶黏剂按照配方混合配制好后，采用涂覆工艺制作PI覆盖膜。在涂覆机上通过在聚酰亚胺薄膜上连续化涂覆胶黏剂层，并将胶黏剂层用离型纸保护起来，生产出来的成品即为PI覆盖膜，收卷后待用；
步骤四、将卷状PI覆盖膜裁切成一定尺寸规格的片状材料，将片状PI覆盖膜、片状增强层材料与钢板、离型材料、缓冲材料等按照一定的顺序“叠book”起来，然后再将“叠book”后结构采用真空平面模压工艺进行压合固化，压合温度为190℃/50min、压合压力为30kg/cm2，；
步骤五、采用激光加工的方式对基板外形和其上的孔位进行制作，采用菲林定位技术保证大尺寸柔性基板的孔位精度和外形尺寸精度。
本实施例中，成型后的柔性基板厚度为0.3mm，加工好后的尺寸为2424mm×438mm，重量约为440g。
本实施例中，所述柔性基板应用于低轨环境的空间站太阳翼上，且在轨寿命长，需要面临剂量较大的原子氧侵蚀，因此需对柔性基板采取原子氧防护措施。本实施例中，采用在柔性基板两面刷涂防原子氧有机硅胶进行原子氧防护，有机硅胶层厚度为30微米。
结合图4，所述柔性基板两面均可用于电池片的粘贴。
本实施例中所涉及的柔性基板成功应用到空间站柔性太阳翼产品中，参考本发明设计的柔性基板也可以应用于如扇形翼等柔性的太阳翼产品中。
本发明虽然已以较佳实施例公开如上，但其并不是用来限定本发明，任何本领域技术人员在不脱离本发明的精神和范围内，都可以利用上述揭示的方法和技术内容对本发明技术方案做出可能的变动和修改，因此，凡是未脱离本发明技术方案的内容，依据本发明的技术实质对以上实施例所作的任何简单修改、等同变化及修饰，均属于本发明技术方案的保护范围。
本发明未详细说明部分属于本领域技术人员的公知常识。

Claims (8)

1.一种柔性的太阳翼基板结构，其特征在于：所述的基板结构为柔性平面结构，从截面看为对称结构，其中中间为增强层，靠近增强层的上下两层为胶黏剂层，胶黏剂层的外侧为聚酰亚胺薄膜层，胶黏剂层将增强层和聚酰亚胺薄膜层粘贴成整体。
2.依据权利要求1所述的太阳翼基板结构，其特征在于，在聚酰亚胺薄膜外表面还有一层原子氧防护层。
3.依据权利要求2所述的太阳翼基板结构，其特征在于，所述的原子氧防护层采用在太阳翼基板结构制备好后，在聚酰亚胺薄膜表面刷涂防原子氧有机硅胶，或者在聚酰亚胺薄膜表面采用物理或化学的方法生长一层原子氧防护层，或采用体材改性的具有原子氧防护能力的聚酰亚胺薄膜。
4.依据权利要求1所述的太阳翼基板结构，其特征在于，所述增强层为纤维增强环氧树脂基体的复合材料，其中增强材料采用SW110C-100a高强玻璃纤维布，树脂为SP120N环氧树脂。
5.依据权利要求1所述的太阳翼基板结构，其特征在于，所述胶黏剂采用牌号为JN02的聚酰亚胺改性环氧树脂类胶黏剂。
6.一种适用于柔性太阳翼的基板结构成型方法，其特征在于包括如下步骤：
步骤一、配置增强层用SP120N树脂，采用上胶工艺将纤维布浸渍在所述树脂中，然后在上胶机内进行烘干半固化，形成粘结片后收卷待用；
步骤二、将半固化的粘结片裁切成片状材料，将片材材料与钢板、离型材料、缓冲材料按顺序堆叠起来，称作“叠book”，再由输送装置将“book”送入真空层压机进行压合，压合温度为160℃±10℃/180min±20min、压合压力为10±5kg/cm2，压合固化而成增强层；
步骤三、在涂覆机上通过在聚酰亚胺薄膜上连续化涂覆胶黏剂层，并将胶黏剂层用离型纸进行保护，生产出来的成品即为PI覆盖膜；
步骤四、将PI覆盖膜裁切成片状材料，将片状PI覆盖膜、片状增强层材料与钢板、离型材料、缓冲材料按顺序堆叠，然后再将堆叠后结构采用真空平面模压工艺进行压合固化，压合温度为190℃±10/50min±10min、压合压力为30±5kg/cm2；
步骤五、采用激光加工的方式对基板外形和其上的孔位进行制作。
7.依据权利要求6所述的方法，其特征在于：步骤五中采用菲林定位技术保证大尺寸柔性基板的孔位精度和外形尺寸精度。
8.依据权利要求6或7所述的成型方法，其特征在于：得到的基板结构绝缘性能大于20MΩ，电池电路粘帖在基板结构的正面或者反面。
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