CN111864403A - High-precision reflecting surface forming method - Google Patents
High-precision reflecting surface forming method Download PDFInfo
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- CN111864403A CN111864403A CN202010617162.5A CN202010617162A CN111864403A CN 111864403 A CN111864403 A CN 111864403A CN 202010617162 A CN202010617162 A CN 202010617162A CN 111864403 A CN111864403 A CN 111864403A
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- precision
- reflecting surface
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- metal layer
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01Q—ANTENNAS, i.e. RADIO AERIALS
- H01Q15/00—Devices for reflection, refraction, diffraction or polarisation of waves radiated from an antenna, e.g. quasi-optical devices
- H01Q15/14—Reflecting surfaces; Equivalent structures
- H01Q15/141—Apparatus or processes specially adapted for manufacturing reflecting surfaces
- H01Q15/142—Apparatus or processes specially adapted for manufacturing reflecting surfaces using insulating material for supporting the reflecting surface
- H01Q15/144—Apparatus or processes specially adapted for manufacturing reflecting surfaces using insulating material for supporting the reflecting surface with a honeycomb, cellular or foamed sandwich structure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/02—Processes for applying liquids or other fluent materials performed by spraying
- B05D1/04—Processes for applying liquids or other fluent materials performed by spraying involving the use of an electrostatic field
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/02—Processes for applying liquids or other fluent materials performed by spraying
- B05D1/08—Flame spraying
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/24—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials for applying particular liquids or other fluent materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/50—Multilayers
- B05D7/56—Three layers or more
- B05D7/58—No clear coat specified
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D129/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an alcohol, ether, aldehydo, ketonic, acetal, or ketal radical; Coating compositions based on hydrolysed polymers of esters of unsaturated alcohols with saturated carboxylic acids; Coating compositions based on derivatives of such polymers
- C09D129/02—Homopolymers or copolymers of unsaturated alcohols
- C09D129/04—Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
- C09D7/40—Additives
- C09D7/60—Additives non-macromolecular
- C09D7/63—Additives non-macromolecular organic
Abstract
The invention discloses a high-precision reflecting surface forming method, which belongs to the technical field of antenna panel manufacturing, and comprises the steps of firstly coating a release agent for 5-6 times on the surface of a high-precision reflecting surface forming die, and uniformly coating a metal transfer film for 2-3 times after drying; then spraying a metal layer on the prepared die to obtain a metal layer skin; then uniformly coating an epoxy resin adhesive on the sprayed metal layer skin for hole sealing; and placing the aluminum honeycomb on a mold to prepare a vacuum bag, heating and pressing the vacuum bag in an autoclave, and demolding to obtain the high-precision reflecting surface. According to the invention, the metal skin is directly bonded and formed with the aluminum honeycomb by using a metal transfer method, so that the process period is shortened, and the requirement of batch preparation of high-precision reflecting surfaces is met; the metal transfer film has better coating property, and the electrical property of the metal skin is improved, so that the requirement of a reflecting surface is met.
Description
Technical Field
The invention belongs to the technical field of antenna panel manufacturing, particularly relates to a forming method of a reflecting surface, and particularly relates to a forming method of a high-precision reflecting surface.
Background
With the continuous development of space exploration technology and the improvement of technical requirements, the antenna reflecting surface is taken as a typical representative of structural function integration, and the requirement on the profile precision is higher and higher. However, for domestic large-caliber millimeter wave submillimeter wave astronomical telescopes, the caliber requirement of a main reflecting surface reaches 60-120 m, the precision requirement of a single panel reaches 15-100 microns, the forming process of the traditional metallic aluminum material (GBT, TM65) or electroformed nickel (LMT) reflecting surface is complex, the cost is high, the forming mode is limited by processing equipment and quantity, and the requirement of batch copy forming cannot be realized.
The Chinese patent with publication number CN110474153A discloses a flexible high-precision parabolic antenna, which comprises a flexible sealing film layer, a flexible hot melt adhesive film layer, a flexible parabolic antenna layer, a flexible hot melt adhesive film layer and a flexible sealing film layer from bottom to top in sequence. The invention further provides a preparation method of the flexible high-precision parabolic antenna, and 1) an invar mould is processed and manufactured; 2) selecting materials of a flexible sealing film layer, a flexible hot melt adhesive film layer and a flexible parabolic antenna layer for standby; 3) placing the mold into an oven for preheating; 4) laying layers on the surface of the preheated mould; 5) after the layering is finished, vacuumizing, simultaneously putting the mould into an oven, and preserving heat for 30 minutes after the temperature of the mould is raised to 140 ℃; 6) and continuously vacuumizing and cooling to room temperature, demoulding, and finally trimming the edge to prepare the high-precision parabolic antenna. The invention solves the problems of poor reflecting surface precision and difficult control of the traditional flexible parabolic antenna after the traditional flexible parabolic antenna passes through a plane fitting curved surface, and has the advantages of integrated forming, one-step curing, low cost and capability of forming large-size flexible reflecting surface products. The elastic cloth woven by the metal-plated fibers is used in the patent, and the requirements are difficult to meet for some reflecting surfaces with high electrical property requirements (the electrical property is more than or equal to 99 percent); a preparation process which can realize high precision of the reflecting surface and can realize batch copy molding is urgently needed, so that the requirement of shortening the construction period of the national millimeter wave submillimeter wave astronomical observation station is met.
Disclosure of Invention
In order to overcome the defects in the prior art, the invention aims to provide a high-precision reflecting surface forming method.
The purpose of the invention is realized by the following technical scheme: a high-precision reflecting surface forming method comprises the following steps:
A. coating a release agent on the surface of a forming die for manufacturing the high-precision reflecting surface of the antenna, and airing for later use;
B. uniformly coating a metal transfer film on the surface of a high-precision reflecting surface forming die for manufacturing the antenna;
C. spraying a metal layer on the surface of a metal transfer film of a high-precision reflector forming die for manufacturing the antenna to obtain a metal layer skin;
D. uniformly coating an epoxy resin adhesive on a high-precision reflecting surface forming die for manufacturing the antenna with the metal layer skin sprayed, and carrying out hole sealing treatment;
E. placing the aluminum honeycomb on a hole-sealing processed high-precision antenna-manufacturing reflecting surface forming die, and attaching the aluminum honeycomb to a metal layer skin of the high-precision antenna-manufacturing reflecting surface forming die through an adhesive
Preferably, the release agent is coated for 5-6 times in the step A, and the metal transfer film is coated for 2-3 times in the step B.
Preferably, the metal transfer film in the step B comprises the following components in parts by weight:
preferably, the spraying of the metal layer in step C specifically includes the following steps: and spraying metal on the surface of the metal transfer film of the high-precision antenna reflecting surface forming die by using an electric arc spraying or flame spraying method to obtain a metal layer skin.
Preferably, the metal comprises one or more of aluminum, nickel. The metal layers of aluminum and nickel have good sprayability and lower cost, and are better choices.
Preferably, the diameter of the metal particles of the metal layer skin formed by arc spraying or flame spraying is 20-50 μm.
Preferably, the thickness of the metal layer skin is 1.5-3 mm. If the thickness of the metal layer skin is less than or equal to 1.5mm, the skin is insufficient in rigidity and easy to crack; if the thickness of the metal layer skin is more than or equal to 3mm, residual thermal stress can exist in the skin, and the profile precision of the reflecting surface is influenced.
Preferably, the coating amount of the epoxy resin adhesive uniformly coated on the metal layer skin in the step D is 150g/m2～350g/m2。
Preferably, the step E specifically includes the following steps: placing the aluminum honeycomb on a hole-sealing processed high-precision antenna-manufacturing reflecting surface forming die, placing a vacuum bag, placing the aluminum honeycomb into an autoclave, vacuumizing and pressurizing, wherein the heating temperature of the autoclave is 80-130 ℃, the pressure is 0.1-0.3 MPa, the aluminum honeycomb is attached to a metal layer skin through an adhesive, and after pressurizing is finished, the die is demoulded after the temperature is reduced to normal temperature.
Preferably, the precision of the mould for manufacturing the high-precision reflecting surface of the antenna is more than 3 times of that of the high-precision reflecting surface of the antenna. The precision of the prepared high-precision reflecting surface is 15-100 micrometers, and more preferably, the precision of the prepared high-precision reflecting surface is 20-35 micrometers
In summary, compared with the prior art, the invention has the following beneficial effects:
(1) according to the invention, the metal skin is directly bonded and formed with the aluminum honeycomb by using a metal transfer method, so that the process period is shortened, and the requirement of batch preparation of high-precision reflecting surfaces is met;
(2) the metal transfer film has better coating property, and the electrical property of the metal skin is improved, so that the requirement of a reflecting surface is met.
Detailed Description
The following examples will assist those skilled in the art in further understanding the invention, but are not intended to limit the invention in any way. It will be apparent to those skilled in the art that various changes and modifications can be made without departing from the spirit and scope of the invention. The endpoints of the ranges and any values disclosed herein are not limited to the precise range or value, and such ranges or values should be understood to encompass values close to those ranges or values. For ranges of values, between the endpoints of each of the ranges and the individual points, and between the individual points may be combined with each other to give one or more new ranges of values, which ranges of values are to be considered as specifically disclosed herein, the invention is described in detail below with reference to specific examples:
Example 1:
a method for forming a high-precision reflecting surface comprises the following steps:
A. coating a release agent for 5 times on the surface of a forming die for manufacturing the high-precision reflecting surface of the antenna, and airing for later use;
B. uniformly coating a metal transfer film for 2 times on the surface of a high-precision reflecting surface forming die for manufacturing the antenna;
the metal transfer film comprises the following components in parts by weight:
C. spraying aluminum and nickel metal layers on the surface of a metal transfer film for manufacturing an antenna high-precision reflecting surface forming die by using an arc spraying or flame spraying method to obtain a metal layer skin, wherein the surface precision of the antenna high-precision reflecting surface forming die is 8.8 mu m;
the diameter of the metal particles of the metal layer skin is 20-50 mu m; the thickness of the metal layer skin is 1.5-3 mm;
D. uniformly coating an epoxy resin adhesive on a high-precision reflector forming die for manufacturing an antenna, which is coated with a metal layer skin, for hole sealing treatment, wherein the coating amount is 250g/m2；
E. Placing the aluminum honeycomb on a hole-sealing processed high-precision antenna-manufacturing reflecting surface forming die, placing a vacuum bag, placing the aluminum honeycomb into an autoclave, vacuumizing and pressing, wherein the heating temperature of the autoclave is 90 ℃, the pressure is 0.2MPa, the aluminum honeycomb is attached to a metal layer skin through an adhesive, and after pressing, reducing the temperature of the die to normal temperature and then demoulding.
The precision of the prepared high-precision reflecting surface is 27 microns.
Example 2:
a method for forming a high-precision reflecting surface comprises the following steps:
A. coating a release agent for 6 times on the surface of a forming die for manufacturing the high-precision reflecting surface of the antenna, and airing for later use;
B. uniformly coating a metal transfer film for 2 times on the surface of a high-precision reflecting surface forming die for manufacturing the antenna;
the metal transfer film comprises the following components in parts by weight:
C. spraying aluminum and nickel metal layers on the surface of a metal transfer film for manufacturing an antenna high-precision reflecting surface forming die by using an arc spraying or flame spraying method to obtain a metal layer skin, wherein the surface precision of the antenna high-precision reflecting surface forming die is 8.8 mu m;
the diameter of the metal particles of the metal layer skin is 20-50 mu m; the thickness of the metal layer skin is 1.5-3 mm;
D. uniformly coating an epoxy resin adhesive on a high-precision reflector forming die for manufacturing the antenna with the metal layer skin sprayed on for hole sealing treatment, wherein the coating amount is 150g/m2；
E. Placing the aluminum honeycomb on a hole-sealing processed high-precision antenna-manufacturing reflecting surface forming die, placing a vacuum bag, placing the aluminum honeycomb into an autoclave, vacuumizing and pressing, wherein the heating temperature of the autoclave is 130 ℃, the pressure is 0.1MPa, the aluminum honeycomb is attached to a metal layer skin through an adhesive, and after pressing, reducing the temperature of the die to normal temperature and then demoulding.
The precision of the prepared high-precision reflecting surface is 20 mu m.
Example 3:
a method for forming a high-precision reflecting surface comprises the following steps:
A. coating a release agent for 5 times on the surface of a forming die for manufacturing the high-precision reflecting surface of the antenna, and airing for later use;
B. uniformly coating a metal transfer film for 3 times on the surface of a high-precision reflecting surface forming die for manufacturing the antenna;
the metal transfer film comprises the following components in parts by weight:
C. spraying aluminum and nickel metal layers on the surface of a metal transfer film for manufacturing an antenna high-precision reflecting surface forming die by using an arc spraying or flame spraying method to obtain a metal layer skin, wherein the surface precision of the antenna high-precision reflecting surface forming die is 8.8 mu m;
the diameter of the metal particles of the metal layer skin is 20-50 mu m; the thickness of the metal layer skin is 1.5-3 mm;
D. uniformly coating an epoxy resin adhesive on a high-precision reflector forming die for manufacturing an antenna, which is coated with a metal layer skin, for hole sealing treatment, wherein the coating amount is 350g/m2；
E. Placing the aluminum honeycomb on a hole-sealing processed high-precision antenna-manufacturing reflecting surface forming die, placing a vacuum bag, placing the aluminum honeycomb into an autoclave, vacuumizing and pressing, wherein the heating temperature of the autoclave is 80 ℃, the pressure is 0.3MPa, the aluminum honeycomb is attached to a metal layer skin through an adhesive, and after pressing, reducing the temperature of the die to normal temperature and then demoulding.
The precision of the prepared high-precision reflecting surface is 35 mu m.
Comparative example 1
A method of forming a reflecting surface, which is different from embodiment 1 in that: the metal transfer film in the step B comprises the following components in parts by weight:
the rest operation steps are the same, partial areas of the prepared reflecting surface metal skin are cracked, sodium dodecyl benzene sulfonate is used as a surfactant, the film forming quality of the metal transfer film can be improved, and the metal transfer film is not mixed to form uneven films and partial areas are thin, so that the metal skin is cracked.
Comparative example 2
A method of forming a reflecting surface, which is different from embodiment 1 in that: the metal transfer film in the step B comprises the following components in parts by weight:
the rest operation steps are the same, most of the area of the prepared reflecting surface metal skin cracks, the glycerol can enhance the strength of the metal transfer film and does not mix in to reduce the strength of the metal transfer film, so that the metal transfer film cracks when the metal layer is sprayed, and finally most of the area of the metal skin cracks.
Comparative example 3
A method of forming a reflecting surface, which is different from embodiment 1 in that: the thickness of the metal layer skin in the step C is 4.5 mm; the other operation steps are the same, the precision of the prepared reflecting surface is 58 mu m, the thickness of the metal skin is too thick, the residual thermal stress is too high, and the profile precision of the reflecting surface is too low.
Comparative example 4
A method of forming a reflecting surface, which is different from embodiment 1 in that: the thickness of the metal layer skin in the step C is 1 mm; the rest operation steps are the same, and the prepared reflecting surface metal skin cracks in partial areas, the thickness of the metal skin is too thin, the rigidity is insufficient, the reflecting surface product is difficult to demould, and the metal skin cracks in partial areas.
The foregoing description of specific embodiments of the present invention has been presented. It is to be understood that the present invention is not limited to the specific embodiments described above, and that various changes or modifications may be made by one skilled in the art within the scope of the appended claims without departing from the spirit of the invention. The embodiments and features of the embodiments of the present application may be combined with each other arbitrarily without conflict.
Claims (10)
1. A high-precision reflecting surface forming method is characterized by comprising the following steps:
A. coating a release agent on the surface of a forming die for manufacturing the high-precision reflecting surface of the antenna, and airing for later use;
B. uniformly coating a metal transfer film on the surface of a high-precision reflecting surface forming die for manufacturing the antenna;
C. spraying a metal layer on the surface of a metal transfer film of a high-precision reflector forming die for manufacturing the antenna to obtain a metal layer skin;
D. Uniformly coating an epoxy resin adhesive on a high-precision reflecting surface forming die for manufacturing the antenna with the metal layer skin sprayed, and carrying out hole sealing treatment;
E. and placing the aluminum honeycomb on the hole-sealing processed high-precision antenna-manufacturing reflecting surface forming die, and attaching the aluminum honeycomb to a metal layer skin of the high-precision antenna-manufacturing reflecting surface forming die through an adhesive.
2. The method of claim 1, wherein the step A is performed 5 to 6 times by coating a release agent, and the step B is performed 2 to 3 times by coating a metal transfer film.
3. The method for forming a high-precision reflecting surface according to claim 1, wherein the metal transfer film in the step B comprises the following components in parts by weight:
4. the method for forming a high-precision reflecting surface according to claim 1, wherein the step C of spraying the metal layer specifically comprises the steps of: and spraying metal on the surface of the metal transfer film of the high-precision antenna reflecting surface forming die by using an electric arc spraying or flame spraying method to obtain a metal layer skin.
5. The method according to claim 4, wherein the metal comprises one or more of aluminum and nickel.
6. The method for forming the high-precision reflecting surface according to claim 4, wherein the metal particle diameter of the metal layer skin formed by arc spraying or flame spraying is 20-50 μm.
7. The method for forming the high-precision reflecting surface according to claim 4, wherein the thickness of the metal layer skin is 1.5-3 mm.
8. The method for forming a high-precision reflecting surface according to claim 1, wherein in the step D, the coating amount of the epoxy resin adhesive uniformly coated on the metal layer skin is 150g/m2～350g/m2。
9. The method for forming a high-precision reflecting surface according to claim 1, wherein the step E specifically comprises the steps of: placing the aluminum honeycomb on a hole-sealing processed high-precision antenna-manufacturing reflecting surface forming die, placing a vacuum bag, placing the aluminum honeycomb into an autoclave, vacuumizing and pressurizing, wherein the heating temperature of the autoclave is 80-130 ℃, the pressure is 0.1-0.3 MPa, the aluminum honeycomb is attached to a metal layer skin through an adhesive, and after pressurizing is finished, the die is demoulded after the temperature is reduced to normal temperature.
10. The method of claim 1, wherein the precision of the mold for manufacturing the high-precision reflecting surface of the antenna is 3 times or more the precision of the high-precision reflecting surface of the antenna.
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| CN202010617162.5A CN111864403B (en) | 2020-06-30 | 2020-06-30 | High-precision reflecting surface forming method |
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| CN202010617162.5A CN111864403B (en) | 2020-06-30 | 2020-06-30 | High-precision reflecting surface forming method |
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| CN111864403B (en) | 2022-05-03 |
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