CN113540806B - Integrated terahertz corrugated horn antenna array based on 3D printing and manufacturing method thereof - Google Patents
Integrated terahertz corrugated horn antenna array based on 3D printing and manufacturing method thereof Download PDFInfo
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- CN113540806B CN113540806B CN202110826130.0A CN202110826130A CN113540806B CN 113540806 B CN113540806 B CN 113540806B CN 202110826130 A CN202110826130 A CN 202110826130A CN 113540806 B CN113540806 B CN 113540806B
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01Q—ANTENNAS, i.e. RADIO AERIALS
- H01Q13/00—Waveguide horns or mouths; Slot antennas; Leaky-waveguide antennas; Equivalent structures causing radiation along the transmission path of a guided wave
- H01Q13/02—Waveguide horns
- H01Q13/0208—Corrugated horns
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01Q—ANTENNAS, i.e. RADIO AERIALS
- H01Q1/00—Details of, or arrangements associated with, antennas
- H01Q1/12—Supports; Mounting means
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01Q—ANTENNAS, i.e. RADIO AERIALS
- H01Q21/00—Antenna arrays or systems
- H01Q21/0087—Apparatus or processes specially adapted for manufacturing antenna arrays
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01Q—ANTENNAS, i.e. RADIO AERIALS
- H01Q21/00—Antenna arrays or systems
- H01Q21/06—Arrays of individually energised antenna units similarly polarised and spaced apart
- H01Q21/061—Two dimensional planar arrays
- H01Q21/064—Two dimensional planar arrays using horn or slot aerials
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Abstract
The invention discloses an integrated terahertz corrugated horn antenna array based on 3D printing and a manufacturing method thereof, wherein the antenna array comprises a plurality of corrugated horn antenna units (101), a surface metal layer (102) and a main body supporting structure (103), the main body supporting structure (103) is made of photo-curing resin, the plurality of corrugated horn antenna units (101) are integrally formed on the main body supporting structure (103), the surface metal layer (102) is covered on the upper surface of the main body supporting structure (103), and a net-shaped supporting structure (104) integrated with the corrugated horn antenna units (101) is arranged between adjacent corrugated horn antenna units (101). The invention has the advantages that: the corrugated horn antenna array is integrally formed based on a photocuring 3D printing technology, does not need further assembly of antenna units, is good in structural strength, small in deformation in service period, light in weight, capable of being directly interconnected with a front feed source waveguide, and convenient to install and use, and adopts photocuring resin as a main material.
Description
Technical Field
The invention belongs to the field of 3D printing, and particularly relates to a corrugated horn antenna array based on a photo-curing 3D printing technology and a manufacturing method thereof.
Background
The terahertz radar works in the 0.1THz-10THz frequency band, can realize extremely narrow antenna beam and extremely large signal bandwidth, has high spatial resolution, thus obtaining fine target imaging, has the capability of penetrating cloud cover and smoke, is the development direction of the high-precision radar capable of coping with complex severe environmental conditions, and has important significance for national defense construction. The corrugated horn antenna is one of the most common antennas of the terahertz radar system, and is used as an improved horn antenna, and groove-shaped corrugations are designed on the side wall of the horn antenna to prevent surface current from flowing from the edge, so that the antenna pattern is improved. The corrugated horn antenna has the advantages of high gain, low side lobe, excellent radiation characteristic and standing wave characteristic, simple structure and the like. The traditional corrugated horn antenna is manufactured by machining a metal blank, is heavy in weight and difficult to machine, and the subsequent antenna array is high in assembly precision and complex in assembly process. The groove-shaped corrugation on the inner cavity surface of the corrugated horn antenna is a characteristic structure with the minimum key size and the maximum processing difficulty, the key size of the characteristic structure is positively correlated with the working frequency band of the antenna, when the working frequency band of the antenna goes deep into the millimeter wave or even the terahertz frequency band, the key size of the structure enters millimeter or even sub-millimeter magnitude, the structural complexity and the processing precision are close to or exceed the limit of the traditional mechanical processing means, and the further engineering application of the terahertz radar is restricted.
The patent applications related to the present invention are: (1) Patent document 201310505614.0 discloses a 0.5THz corrugated horn antenna and a method for manufacturing by using an MEMS technology; (2) Patent document with application number 200910093482.9 discloses a millimeter wave rectangular-circular transition integrated corrugated horn antenna and a processing method. 201310505614.0 redesigns the corrugated horn antenna based on the MEMS processing technology to obtain the on-chip corrugated horn antenna based on the MEMS processing technology, and the MEMS processing method has the advantages of high processing precision, easy on-chip array integration, but very limited processing capability of the complex three-dimensional structure, complex processing procedure and high cost. 200910093482.9 the integrated antenna inner core is firstly manufactured by a machining method to serve as a die, and then the horn antenna is manufactured by an electroforming process, so that the machining precision of the horn antenna is improved to a certain extent, the die corrosion and electroforming process have long machining periods, the die is still limited by the machining process of the die as a whole, and the subsequent array integration still faces a complex assembly link.
Disclosure of Invention
The invention aims to solve the technical problems of improving the processing precision of the terahertz corrugated horn antenna and facilitating the manufacture.
The invention solves the technical problems by the following technical means: the utility model provides an integrated terahertz wave horn antenna array based on 3D prints, includes a plurality of ripple horn antenna unit (101), surface metal layer (102) and main part bearing structure (103), main part bearing structure (103) are light curing resin, and a plurality of ripple horn antenna unit (101) integrated into one piece sets up on main part bearing structure (103), and main part bearing structure (103) upper surface cover surface metal layer (102), be netted bearing structure (104) with ripple horn antenna unit (101) integration between adjacent ripple horn antenna unit (101).
The invention has the advantages that: aiming at the problems of small characteristic size, complex key structure, difficult processing, complex array surface assembly and the like of the traditional terahertz corrugated horn antenna array, the invention provides the integrally formed corrugated horn antenna array and the processing technology based on photocuring 3D printing thereof. The corrugated horn antenna array provided by the invention is mainly made of light-cured resin, has light weight, can be directly interconnected with the front feed source waveguide, and is convenient to install and use.
As an optimized technical solution, the mesh-shaped supporting structure (104) is a uniform mesh-shaped structure.
As an optimized technical scheme, the mesh support structure (104) is an uneven mesh structure, and has dense areas and sparse areas.
As an optimized technical scheme, the corrugated horn antenna units (101) are arranged according to the needs, including orthogonal and triangular arrangement modes.
As an optimized technical scheme, the surface metal layer (102) is copper or gold.
As an optimized technical scheme, the single corrugated horn antenna unit (101) is an integrated structure comprising five parts, namely a rectangular waveguide (1011), a waveguide transition section (1012), a circular waveguide (1013), a mode conversion section (1014) and a radiation section (1015);
the rectangular waveguide (1011) is a rectangular waveguide structure directly interconnected with an external input rectangular waveguide; the waveguide transition section (1012) is a smooth transition structure from rectangular to circular, and realizes transition from the rectangular waveguide (1011) to the circular waveguide (1013); the circular waveguide (1013) is a circular waveguide directly connected to the mode conversion section (1014); the mode conversion section (1014) is formed by a circular horn with a plurality of annular grooves; the radiation section (1015) is formed by a circular horn with a plurality of annular grooves;
the mesh support structure (104) is located between adjacent corrugated horn antenna units (101), and the mesh support structure (104) and the corrugated horn antenna units (101) are of an integral structure.
The invention also provides a preparation method of the integrated terahertz corrugated horn antenna array based on 3D printing, which comprises the following steps:
step S1, carrying out detailed design of the terahertz wave horn antenna array according to the working frequency of the terahertz wave horn antenna array to obtain a three-dimensional structure diagram of the terahertz wave horn antenna array;
step S2, optimizing the three-dimensional structure of the terahertz corrugated horn antenna array obtained in the step S1 according to the process constraint of 3D printing to obtain a three-dimensional structure diagram capable of being directly printed in 3D;
s3, based on a photocuring 3D printing technology, carrying out integral 3D printing of the terahertz corrugated horn antenna array from the end part, wherein the 3D printing is made of photocuring resin, the thickness of a single-layer printing layer is 10-100 micrometers in the photocuring 3D printing process, the optical imaging precision is 10-100 micrometers, and the vertical printing speed is 1-10 millimeters/min;
step S4, cleaning, coarsening, activating and electroless plating are sequentially carried out on the surface of the structure based on the electroless plating process, and a surface metal layer (102) with the thickness of 1-10um is deposited on all surfaces of the antenna array structure;
and S4, manufacturing annular or rectangular isolation areas (105) around the circular horn openings of the radiation sections (1015) of the corrugated horn antenna units (101) and the rectangular openings of the rectangular waveguides (1011) by utilizing a laser ablation process, and isolating the metal layers on the surfaces of the corrugated horn antenna units (101) from the metal layers (102) on the other surfaces.
As an optimized technical scheme, the 3D printing method comprises a DLP photo-curing 3D printing or LCD photo-curing 3D printing technology.
The invention has the advantages that: aiming at the problems of small characteristic size, complex key structure, difficult processing, complex array surface assembly and the like of the traditional terahertz corrugated horn antenna array, the invention provides the corrugated horn antenna array which is based on the photocuring 3D printing technology, is a surface molding 3D printing technology, has high printing precision and high speed, is integrally formed, does not need further assembly of an antenna unit, has good structural strength and small deformation in the service period. The corrugated horn antenna array provided by the invention is mainly made of light-cured resin, has light weight, can be directly interconnected with the front feed source waveguide, and is convenient to install and use.
The terahertz corrugated horn antenna array based on the photocuring 3D printing technology is provided by combining with the surface metallization technology, and lays a foundation for engineering application of terahertz radars.
Drawings
Shown in fig. 1 is a horn antenna array schematic.
Shown in fig. 2 is a schematic cross-sectional structure of a feedhorn array.
Illustrated in fig. 3 is a cross-sectional view of one half of a single corrugated feedhorn unit structure.
Shown in fig. 4a is a top view of one half of one side of a radiating section of a single corrugated horn antenna element structure.
Shown in fig. 4b is a top view of one half of one side of a rectangular waveguide of a single corrugated feedhorn unit structure.
Shown in fig. 5 is a process flow for manufacturing a corrugated horn antenna array.
Detailed Description
For the purpose of making the objects, technical solutions and advantages of the embodiments of the present invention more apparent, the technical solutions in the embodiments of the present invention will be clearly and completely described in the following in conjunction with the embodiments of the present invention, and it is apparent that the described embodiments are some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
The invention provides an integrated terahertz wave horn antenna array based on 3D printing, which is shown in fig. 1 and comprises a plurality of corrugated horn antenna units 101, a surface metal layer 102 and a main body supporting structure 103.
The body support structure 103 is a photocurable resin. The corrugated horn antennas 101 are integrally formed on the main body supporting structure 103, and the surfaces of the corrugated horn antennas 101 and the main body supporting structure 103 are covered with a surface metal layer 102, and the surface metal layer 102 is made of copper, gold and other metals.
As shown in fig. 2, which is a middle cross-sectional view of the corrugated horn antenna array in fig. 1, it can be seen that, between adjacent corrugated horn antenna units 101, there is a mesh support structure 104 integrated with the corrugated horn antenna units 101, where the mesh support structure 104 may be a uniform mesh structure or an uneven mesh structure, that is, some areas are dense and some areas are sparse, so as to ensure that the rigidity of the whole array structure is maximized and the weight is minimized.
The corrugated horn antenna units 101 may be arranged according to needs, including various arrangements such as orthogonal, triangular, etc. As shown in fig. 3, the single corrugated horn antenna unit 101 is a unitary structure including five parts, namely a rectangular waveguide 1011, a waveguide transition section 1012, a circular waveguide 1013, a mode transforming section 1014, and a radiating section 1015.
The rectangular waveguide 1011 is a rectangular waveguide structure directly interconnected with an external input rectangular waveguide; the waveguide transition section 1012 is a smooth transition structure from rectangular to circular, and realizes transition from the rectangular waveguide 1011 to the circular waveguide 1013; the circular waveguide 1013 is a circular waveguide directly connected to the mode conversion section 1014; mode conversion section 1014 is formed by a circular horn with a plurality of annular grooves on the surface, and is used for realizing conversion from TEM wave to HE wave; the radiation section 1015 is formed by a circular horn with a plurality of annular grooves on the surface, and functions to realize external radiation of HE waves. The mesh support structure 104 is located between adjacent corrugated horn antenna units 101. And the mesh support structure 104 is an integral structure with the corrugated horn antenna unit 101.
As shown in fig. 4a and 4b, the circular horn opening of the radiating section 1015 of the corrugated horn antenna unit 101 and the rectangular opening of the rectangular waveguide 1011 are fabricated with annular or rectangular isolation regions 105 that isolate the metal layer of the surface of the corrugated horn antenna unit 101 from the remaining surface metal layer 102.
In detail, the manufacturing method of the corrugated horn antenna is shown in fig. 5, and comprises the following steps:
step S1, carrying out detailed design of the terahertz wave horn antenna array according to the working frequency of the terahertz wave horn antenna array to obtain a three-dimensional structure diagram of the terahertz wave horn antenna array;
step S2, properly optimizing the three-dimensional structure of the terahertz corrugated horn antenna array obtained in the step S1 according to the process constraint of 3D printing to obtain a three-dimensional structure diagram capable of being directly printed in 3D;
s3, carrying out integral 3D printing of the terahertz corrugated horn antenna array according to the direction indicated by an arrow in FIG. 1 based on a photocuring 3D printing technology, wherein the 3D printing method comprises a DLP (digital laser projection) photocuring 3D printing or LCD photocuring 3D printing and other surface forming 3D printing technology, the 3D printing is made of photocuring resin, and in the photocuring 3D printing process, the thickness of a single-layer printing layer is 10-100 micrometers, the optical imaging precision is 10-100 micrometers, and the vertical printing speed is 1-10 millimeters/min;
step S4, cleaning, coarsening, activating and electroless plating are sequentially carried out on the surface of the structure based on the electroless plating process, and a surface metal layer 102 with the thickness of 1-10um is deposited on all surfaces of the antenna array structure;
in step S5, an annular or rectangular isolation region 105 is fabricated on the circular horn opening of the radiation section 1015 of the corrugated horn antenna unit 101 and the rectangular opening of the rectangular waveguide 1011 by using a laser ablation process, so as to isolate the metal layer on the surface of the corrugated horn antenna unit 101 from the metal layer 102 on the other surface.
Aiming at the problems of small characteristic size, complex key structure, difficult processing, complex array surface assembly and the like of the traditional terahertz corrugated horn antenna array, the invention provides the corrugated horn antenna array which is based on the photocuring 3D printing technology, is a surface molding 3D printing technology, has high printing precision and high speed, is integrally formed, does not need further assembly of an antenna unit, has good structural strength and small deformation in the service period. The corrugated horn antenna array provided by the invention is mainly made of light-cured resin, has light weight, can be directly interconnected with the front feed source waveguide, and is convenient to install and use.
The above embodiments are only for illustrating the technical solution of the present invention, and are not limiting; although the invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit and scope of the technical solutions of the embodiments of the present invention.
Claims (10)
1. 3D printing-based integrated terahertz corrugated horn antenna array is characterized in that: including a plurality of ripple horn antenna unit (101), surface metal layer (102) and main part bearing structure (103), main part bearing structure (103) are light curing resin, and a plurality of ripple horn antenna unit (101) integrated into one piece sets up in main part bearing structure (103), and main part bearing structure (103) and ripple horn antenna unit (101) upper surface cover surface metal layer (102), are provided with the isolation zone between the metal layer on ripple horn antenna unit (101) surface and the remaining surface metal layer (102), are netted bearing structure (104) with ripple horn antenna unit (101) integration between adjacent ripple horn antenna unit (101).
2. The 3D printing-based integrated terahertz wave horn antenna array according to claim 1, wherein: the mesh support structure (104) is a uniform mesh structure.
3. The 3D printing-based integrated terahertz wave horn antenna array according to claim 1, wherein: the mesh support structure (104) is a non-uniform mesh structure with dense areas and sparse areas.
4. The 3D printing-based integrated terahertz wave horn antenna array according to claim 1, wherein: the corrugated horn antenna units (101) are arranged according to the needs, including orthogonal and triangular arrangement modes.
5. The 3D printing-based integrated terahertz wave horn antenna array according to claim 1, wherein: the surface metal layer (102) is copper or gold.
6. The 3D printing-based integrated terahertz wave horn antenna array according to claim 1, wherein: a single corrugated feedhorn unit (101) is a unitary structure comprising five parts, namely a rectangular waveguide (1011), a waveguide transition section (1012), a circular waveguide (1013), a mode transforming section (1014) and a radiating section (1015);
the rectangular waveguide (1011) is a rectangular waveguide structure directly interconnected with an external input rectangular waveguide; the waveguide transition section (1012) is a smooth transition structure from rectangular to circular, and realizes transition from the rectangular waveguide (1011) to the circular waveguide (1013); the circular waveguide (1013) is a circular waveguide directly connected to the mode conversion section (1014); the mode conversion section (1014) is formed by a circular horn with a plurality of annular grooves; the radiation section (1015) is formed by a circular horn with a plurality of annular grooves;
the mesh support structure (104) is located between adjacent corrugated horn antenna units (101), and the mesh support structure (104) and the corrugated horn antenna units (101) are of an integral structure.
7. The integrated terahertz wave horn antenna array based on 3D printing of any one of claims 1 to 6, wherein: the preparation method of the integrated terahertz corrugated horn antenna array based on 3D printing comprises the following steps:
step S1, carrying out detailed design of the terahertz wave horn antenna array according to the working frequency of the terahertz wave horn antenna array to obtain a three-dimensional structure diagram of the terahertz wave horn antenna array;
step S2, optimizing the three-dimensional structure of the terahertz corrugated horn antenna array obtained in the step S1 according to the process constraint of 3D printing to obtain a three-dimensional structure diagram capable of being directly printed in 3D;
s3, based on a photocuring 3D printing technology, carrying out integral 3D printing of the terahertz corrugated horn antenna array from the end part, wherein the 3D printing is made of photocuring resin, the thickness of a single-layer printing layer is 10-100 micrometers in the photocuring 3D printing process, the optical imaging precision is 10-100 micrometers, and the vertical printing speed is 1-10 millimeters/min;
step S4, cleaning, coarsening, activating and electroless plating are sequentially carried out on the surface of the structure based on the electroless plating process, and a surface metal layer (102) with the thickness of 1-10um is deposited on all surfaces of the antenna array structure;
and S5, manufacturing an annular or rectangular isolation region (105) around the circular horn opening of the radiation section (1015) of the corrugated horn antenna unit (101) and the rectangular opening of the rectangular waveguide (1011) by utilizing a laser ablation process, and isolating the metal layer on the surface of the corrugated horn antenna unit (101) from the rest surface metal layers (102).
8. The 3D printing-based integrated terahertz wave horn antenna array of claim 7, wherein: the 3D printing method comprises a DLP photo-curing 3D printing or LCD photo-curing 3D printing technology.
9. A method for manufacturing the 3D printing-based integrated terahertz wave horn antenna array according to any one of claims 1 to 6, which is characterized in that: the method comprises the following steps:
step S1, carrying out detailed design of the terahertz wave horn antenna array according to the working frequency of the terahertz wave horn antenna array to obtain a three-dimensional structure diagram of the terahertz wave horn antenna array;
step S2, optimizing the three-dimensional structure of the terahertz corrugated horn antenna array obtained in the step S1 according to the process constraint of 3D printing to obtain a three-dimensional structure diagram capable of being directly printed in 3D;
s3, based on a photocuring 3D printing technology, carrying out integral 3D printing of the terahertz corrugated horn antenna array from the end part, wherein the 3D printing is made of photocuring resin, the thickness of a single-layer printing layer is 10-100 micrometers in the photocuring 3D printing process, the optical imaging precision is 10-100 micrometers, and the vertical printing speed is 1-10 millimeters/min;
step S4, cleaning, coarsening, activating and electroless plating are sequentially carried out on the surface of the structure based on the electroless plating process, and a surface metal layer (102) with the thickness of 1-10um is deposited on all surfaces of the antenna array structure;
and S4, manufacturing annular or rectangular isolation areas (105) around the circular horn openings of the radiation sections (1015) of the corrugated horn antenna units (101) and the rectangular openings of the rectangular waveguides (1011) by utilizing a laser ablation process, and isolating the metal layers on the surfaces of the corrugated horn antenna units (101) from the rest surface metal layers (102).
10. The method for manufacturing the integrated terahertz wave horn antenna array based on 3D printing as set forth in claim 9, wherein: the 3D printing method comprises a DLP photo-curing 3D printing or LCD photo-curing 3D printing technology.
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| US11909110B2 (en) * | 2020-09-30 | 2024-02-20 | The Boeing Company | Additively manufactured mesh horn antenna |
| CN116852054B (en) * | 2023-08-31 | 2023-12-05 | 河南工学院 | Terahertz conical corrugated horn layered casting and milling integrated manufacturing method |
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