CN114122709A - Manufacturing method of conformal radome - Google Patents
Manufacturing method of conformal radome Download PDFInfo
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- CN114122709A CN114122709A CN202111422587.1A CN202111422587A CN114122709A CN 114122709 A CN114122709 A CN 114122709A CN 202111422587 A CN202111422587 A CN 202111422587A CN 114122709 A CN114122709 A CN 114122709A
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- layer
- flange
- paving
- curing
- radome
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01Q—ANTENNAS, i.e. RADIO AERIALS
- H01Q1/00—Details of, or arrangements associated with, antennas
- H01Q1/42—Housings not intimately mechanically associated with radiating elements, e.g. radome
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01Q—ANTENNAS, i.e. RADIO AERIALS
- H01Q1/00—Details of, or arrangements associated with, antennas
- H01Q1/42—Housings not intimately mechanically associated with radiating elements, e.g. radome
- H01Q1/422—Housings not intimately mechanically associated with radiating elements, e.g. radome comprising two or more layers of dielectric material
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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
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Aerials With Secondary Devices (AREA)
Abstract
The invention discloses a manufacturing method of a conformal antenna housing, and belongs to the technical field of composite material processing. The method is suitable for preparing the complex conformal antenna capable of transmitting and receiving the directional beams, and realizes the integrated design and processing of the antenna and the cover body. According to the requirements of electric conduction and reflection indexes, the antenna housing can be prepared by secondary curing molding after metal aluminum is thermally sprayed or primary co-curing molding by paving and pasting a nickel-plated carbon felt. Through laying the layer design, combine frock design and use, can better confirm the position and the shape of metal aluminium layer or nickel plating carbon felt, adopt resin or glued membrane that bonding strength is good to carry out compound co-curing between hot spraying metal aluminium layer, nickel plating carbon felt and the preimpregnation material. Compared with the traditional radome manufacturing method, the radome and the manufacturing method have the advantages that the conductive layer and the reflecting layer are accurately formed in the radome, so that the antenna and the radome are integrally designed and processed; the conducting layer and the reflecting layer are not easy to scratch or peel, the quality is stable, and the reliability is strong.
Description
Technical Field
The invention relates to the technical field of composite material processing, in particular to a manufacturing method of a conformal antenna housing.
Background
With the development of wireless communication technology, the application of multifunctional communication systems is more and more extensive, and simultaneously, higher requirements are put forward on the design of antenna covers. In order to meet specific electrical performance requirements, the antenna and the cover are sometimes designed integrally to simplify the system structure, improve the system reliability, and meet the electrical performance design requirements.
The conventional antenna housing only has the effect of protecting the antenna from environmental factors such as rain, snow, wind, sand and the like, the antenna and the antenna housing are designed in a split mode usually, and then are connected together through machinery, the design is simple, the reliability of the whole system is poor, and the reliability of a communication system is seriously affected. Along with the continuous improvement of system integration, the problem of poor system reliability has been solved well to conformal antenna house, practices thrift the space, has realized multi-functional set. The conformal antenna housing requires an antenna shape curved surface to be conformal with an inner side wall, an outer side wall or an interlayer curved surface of the housing in terms of structure; in terms of electrical performance, conformal structures may enable transmission and reception of signals. Meanwhile, in the aspect of protection, the influence and damage of severe environments such as strong wind, salt fog, heavy rain and the like on the system can be effectively prevented, and the purposes of prolonging the service life of the antenna, improving the reliability of the system and ensuring the all-weather work of the antenna are achieved.
Disclosure of Invention
In view of the above, the present invention provides a method for manufacturing a conformal radome. The conductive layer and the reflecting layer are not easy to scratch or peel, and the conductive layer and the reflecting layer have stable quality and strong reliability.
In order to achieve the purpose, the technical scheme adopted by the invention is as follows:
a manufacturing method of a conformal radome specifically comprises the following steps:
fixing an electric conductivity material on the core mold, laying high-strength glass fiber prepreg layer by layer, folding the electric conductivity material to the outer surface of the prepreg after laying, winding a thermal contraction belt on the outer surface, vacuumizing, and pre-compacting for 30min at the temperature of 60 ℃;
step 5, impregnating the aluminum layer with resin glue solution or paving a glue film on the surface of the aluminum layer, and then paving high-strength glass fiber prepreg layer by layer; lay and paste glass fiber prepreg of high strength includes: flange paving, transition arc paving at the flange and integral wrapping paving; after paving, installing a flange pressing plate, and adjusting the flange to compact the flange;
and 7, taking out the molded part cured and molded in the step 6, demolding, sequentially removing the adjusting flange, the flange pressing plate and the bottom plate, removing the core mold through a demolding tool, removing the flash and finishing the preparation of the conformal radome.
Further, the curing and forming process in the step 3 and the step 6 comprises the following steps: the pressure in the forming process is more than or equal to 0.1MPa, the curing is firstly carried out for 30min at 90 ℃, and then the curing is carried out for 3h at 130 ℃.
A manufacturing method of a conformal radome specifically comprises the following steps:
fixing an electric conductivity material on the core mold, laying high-strength glass fiber prepreg layer by layer, folding the electric conductivity material to the outer surface of the prepreg after laying, winding a thermal contraction belt on the outer surface, vacuumizing, and pre-compacting for 30min at the temperature of 60 ℃;
and 5, taking out the molded part cured and molded in the step 4, demolding, sequentially removing the adjusting flange, the flange pressing plate and the bottom plate, removing the core mold through a demolding tool, removing the flash and finishing the preparation of the conformal radome.
Further, the curing and forming process in the step 4 comprises the following steps: the pressure in the forming process is more than or equal to 0.1MPa, the curing is firstly carried out for 30min at 90 ℃, and then the curing is carried out for 3h at 130 ℃.
The invention adopts the technical scheme to produce the beneficial effects that:
1. the invention can form the electric conduction layer and the reflecting layer which are positioned at any position between the layers, realizes the communication between the electric conduction layer and the inner cavity equipment, has better designability, and has the advantages of difficult scratch and peeling of the electric conduction layer and the reflecting layer, stable quality and strong reliability compared with the traditional surface metallization.
2. According to the requirements of electric conduction and reflection indexes, the conformal radome can be prepared by a secondary curing molding technology of thermal spraying of metal aluminum or a primary co-curing molding technology of paving and pasting of a nickel-plated carbon felt. The requirement on electric conduction is high, a hot spraying metal aluminum secondary curing molding technology is selected, the requirement on electric conduction is not high, the production efficiency is considered, and a one-time co-curing molding technology of paving and pasting the nickel-plated carbon felt is selected.
3. According to the invention, through the laying design and the combination of tool design and use, the position and the shape of the metal aluminum layer or the nickel-plated carbon felt can be better determined through thermal spraying, and the resin or the glue film with good bonding strength is adopted between the metal aluminum layer or the nickel-plated carbon felt and the prepreg for composite co-curing.
Drawings
FIG. 1 is a schematic diagram of an integrated structure of a conformal antenna and a cover;
fig. 2 is a schematic view of a first stage bonding and mold assembly for a radome;
fig. 3 is a schematic view of a second stage of radome placement and mold assembly.
In the figure: 1. the antenna housing comprises an antenna housing main body, 2 an electric conduction layer, 3 an reflection layer, 4 a conduction connecting hole, 5 a metal bottom plate, 6 a core mold, 7 a reflection layer setting and positioning tool, 8 an electric conduction layer setting and positioning tool, 9 a first-stage laying and pasting preformed body, 10 an adjusting flange, 11 a flange pressing plate, 12 a second-stage laying and pasting preformed body.
Detailed Description
The present invention will be further described with reference to the accompanying drawings and specific embodiments.
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings of 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 that other drawings can be obtained according to these drawings without creative efforts.
By adopting the processing and manufacturing technology, the complex conformal antenna capable of transmitting and receiving directional beams can be prepared by accurately forming the conductive layer and the reflecting layer in the antenna housing, and the integrated design and processing of the antenna and the housing body are realized. The concrete forming steps are as follows:
the forming die for the radome is built according to a model of a product, the radome is built into a needed die, the die comprises a metal bottom plate 5, a core die 6, a reflecting layer shaping and positioning tool 7, a conducting layer shaping and positioning tool 8, an adjusting flange 10, a flange pressing plate 11 and the like, the rigid metal bottom plate and the core die are built according to the inner surface of the radome model, the shaping and positioning tools 7 and 8 are designed according to the position and the shape of the conducting layer and the reflecting layer of electrical design, and the blocked rigid metal flange pressing plate 11 is built according to the outer surface of the radome flange.
And secondly, coating a release agent on the surface of the mold for 3-4 times in a first stage, in order to conduct with inner cavity equipment, firstly, fixing materials with good conductivity, such as strip-shaped aluminum foils, nickel-plated carbon felts and the like, on the core mold, paving the high-strength glass fiber prepreg on the core mold 5 layer by layer according to the paving design, circularly paving and pasting the surplus aluminum foils or nickel-plated carbon felts and the like to the outer surface of the prepreg at a paving angle of 0 degree and 90 degrees, winding a thermal contraction belt on the outer surface, vacuumizing at 60 ℃ and pre-compacting for 30 min.
And a curing molding step (iv) adopting thermal spraying of metal aluminum, placing the intermediate preform (namely the first-stage spread preform 9), the metal bottom plate 5, the core mold 6, the simple flange and the like in an oven, an autoclave or a hot press and other devices capable of heating and pressurizing, heating the mold to 90 ℃ and keeping the temperature for 30min, then heating to 130 ℃ and keeping the temperature for 180min to perform curing molding, wherein the whole process pressure in the molding process is not less than 0.1MPa, and the performance requirement is selected according to the use environment of the product. And fourthly, paving and pasting the nickel-plated carbon felt, omitting the step and directly carrying out the step IV.
Spraying metal aluminum (or paving and pasting a nickel-plated carbon felt), forming an electric conduction layer and a reflection layer by thermally spraying the metal aluminum, polishing and cleaning the outer surface of the product after the step (III), removing a release agent, exposing electric conduction materials such as aluminum foil or nickel-plated carbon felt and the like folded to the outer surface, thermally spraying a metal aluminum layer through an electric conduction layer shaping and positioning tool 8, communicating the aluminum layer with the electric conduction materials in the step (II), and further communicating with inner cavity equipment to form the electric conduction layer; and spraying a metal aluminum layer through the reflecting layer shaping and positioning tool 7 to form a reflecting layer which is not communicated with the equipment. And (4) paving and pasting a nickel-plated carbon felt to form the electric conduction layer and the reflecting layer, directly paving and pasting the nickel-plated carbon felt on the prepreg in the step two, cutting the shape and determining the position by a shaping and positioning tool.
Thermally spraying metal aluminum, impregnating the aluminum layer with resin glue solution or paving adhesive films on the surface of the aluminum layer, and paving high-strength glass fiber prepreg layer by layer according to the paving design; paving and pasting the nickel-plated carbon felt, paving and pasting an adhesive film on the surface of the nickel-plated carbon felt, paving and pasting high-strength glass fiber prepreg layer by layer according to a paving design, stacking and paving the flange plane after blanking by a blanking machine, sequentially winding and covering the arc part of the flange by using strip prepreg with gradual width, integrally paving and pasting the rest prepreg according to the designed layers, circularly paving and pasting according to the paving angle of 0 degree and 90 degrees, installing a flange pressing plate 11 and adjusting a flange 10 to compact the flange after paving and pasting is completed, and winding a thermal contraction belt on the rest outer surface.
Sixthly, curing and forming, namely placing the preformed body 12 laid and pasted in the second stage and the die assembly in the fifth step on equipment which can be heated and pressurized, such as an oven, an autoclave or a hot press, heating the die to 90 ℃, preserving heat for 30min, then heating to 130 ℃, preserving heat for 180min, and curing and forming, wherein the pressure in the whole forming process is not less than 0.1MPa, and the proper pressure value is selected according to the performance requirements of the product use environment, wherein the thermal spraying metal aluminum method is used for secondary curing and forming, and the laying nickel-plated carbon felt method is used for primary curing and forming.
And seventhly, demoulding, taking out the solidified and molded part, demoulding, sequentially removing the adjusting flange 10, the flange pressing plate 11 and the metal bottom plate 5, removing the core mould 6 through a demoulding tool, and removing the flash of the product to finish the preparation of the integrated conformal antenna and the mask body.
And eighthly, detecting the conducting position after forming, machining a conducting connecting hole 4 according to a model machine, inlaying a steel wire screw sleeve, connecting equipment, and detecting the electric conduction condition of the product.
The method realizes the integrated design and processing of a certain type of complex conformal antenna and the cover body, simplifies the system structure and improves the system reliability.
Compared with the traditional forming method, the processing and manufacturing technology can more accurately form the electric conduction layer (namely the conformal antenna) and the reflecting layer by layer laying design and combining tool design and use, so that the position, shape and thickness uniformity of the electric conduction layer and the reflecting layer are more consistent with the theoretical requirements, the design index can be better realized, the electrical performance of the antenna housing is improved, and the transmission and the reception of the directional beam are realized.
The method can form the electric conduction layer and the reflecting layer which are positioned at any positions between the layers, realizes the communication between the electric conduction layer and the inner cavity equipment, has better designability, and has the advantages of difficult scratch and peeling of the electric conduction layer and the reflecting layer, stable quality and strong reliability compared with the traditional surface metallization.
Claims (4)
1. A manufacturing method of a conformal radome is characterized by comprising the following steps:
step 1, establishing an antenna housing forming mold; the mold comprises a metal floor, a core mold, a reflecting layer setting and positioning tool, an electric conduction layer setting and positioning tool, an adjusting baffle and a flange pressing plate;
fixing an electric conductivity material on the core mold, laying high-strength glass fiber prepreg layer by layer, folding the electric conductivity material to the outer surface of the prepreg after laying, winding a thermal contraction belt on the outer surface, vacuumizing, and pre-compacting for 30min at the temperature of 60 ℃;
step 3, putting the preformed body and the die assembly in the step 2 into an oven, a hot pressing tank or a hot pressing machine for heating, pressurizing, curing and molding;
step 4, polishing and cleaning the outer surface of the product cured and molded in the step 3, exposing the electric conductive material turned to the outer surface in the step 2, spraying a metal aluminum layer through a conductive layer shaping and positioning tool, communicating the aluminum layer with the electric conductive material in the step 2, and further communicating with an inner cavity device to form an electric conductive layer; spraying a metal aluminum layer through a reflecting layer shaping and positioning tool to form a reflecting layer which is not communicated with the inner cavity equipment;
step 5, impregnating the aluminum layer with resin glue solution or paving a glue film on the surface of the aluminum layer, and then paving high-strength glass fiber prepreg layer by layer; lay and paste glass fiber prepreg of high strength includes: flange paving, transition arc paving at the flange and integral wrapping paving; after paving, installing a flange pressing plate, and adjusting the flange to compact the flange;
step 6, placing the preformed body and the die assembly in the step 5 in an oven, an autoclave or a hot press for heating, pressurizing, curing and molding;
and 7, taking out the molded part cured and molded in the step 6, demolding, sequentially removing the adjusting flange, the flange pressing plate and the bottom plate, removing the core mold through a demolding tool, removing the flash and finishing the preparation of the conformal radome.
2. The method for manufacturing a conformal radome according to claim 1, wherein the curing and forming processes in the steps 3 and 6 are as follows: the pressure in the forming process is more than or equal to 0.1MPa, the curing is firstly carried out for 30min at 90 ℃, and then the curing is carried out for 3h at 130 ℃.
3. A manufacturing method of a conformal radome is characterized by comprising the following steps:
step 1, establishing an antenna housing forming mold; the mold comprises a metal floor, a core mold, a reflecting layer setting and positioning tool, an electric conduction layer setting and positioning tool, an adjusting baffle and a flange pressing plate;
fixing an electric conductivity material on the core mold, laying high-strength glass fiber prepreg layer by layer, folding the electric conductivity material to the outer surface of the prepreg after laying, winding a thermal contraction belt on the outer surface, vacuumizing, and pre-compacting for 30min at the temperature of 60 ℃;
step 3, paving and pasting a nickel-plated carbon felt on the high-strength glass fiber prepreg in the step 2, cutting the nickel-plated carbon felt into a shape by a shaping and positioning tool, and determining the position; after the nickel-plated carbon felt is paved, an adhesive film is paved on the surface of the nickel-plated carbon felt, and high-strength glass fiber prepreg is paved layer by layer; lay and paste glass fiber prepreg of high strength includes: flange paving, transition arc paving at the flange and integral wrapping paving; after paving, installing a flange pressing plate, and adjusting the flange to compact the flange;
step 4, putting the preformed body and the die assembly in the step 3 into an oven, an autoclave or a hot press for heating, pressurizing, curing and molding;
and 5, taking out the molded part cured and molded in the step 4, demolding, sequentially removing the adjusting flange, the flange pressing plate and the bottom plate, removing the core mold through a demolding tool, removing the flash and finishing the preparation of the conformal radome.
4. The method for manufacturing a conformal radome according to claim 3, wherein the curing and molding process in the step 4 is as follows: the pressure in the forming process is more than or equal to 0.1MPa, the curing is firstly carried out for 30min at 90 ℃, and then the curing is carried out for 3h at 130 ℃.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202111422587.1A CN114122709A (en) | 2021-11-26 | 2021-11-26 | Manufacturing method of conformal radome |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202111422587.1A CN114122709A (en) | 2021-11-26 | 2021-11-26 | Manufacturing method of conformal radome |
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| CN114122709A true CN114122709A (en) | 2022-03-01 |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115709577A (en) * | 2022-11-26 | 2023-02-24 | 零八一电子集团四川天源机械有限公司 | Manufacturing method of surface local metallization radome |
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2021
- 2021-11-26 CN CN202111422587.1A patent/CN114122709A/en active Pending
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115709577A (en) * | 2022-11-26 | 2023-02-24 | 零八一电子集团四川天源机械有限公司 | Manufacturing method of surface local metallization radome |
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