CN114300858A - Preparation method of luneberg lens working in X waveband - Google Patents
Preparation method of luneberg lens working in X waveband Download PDFInfo
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Abstract
The invention provides a preparation method of a Luneberg lens working in an X waveband, which comprises the steps of preparation of a forming mould, configuration of a lens material and preparation of the Luneberg lens; wherein: the preparation of the forming mold is to prepare a first forming mold, a second forming mold, a third forming mold, a fourth forming mold and a fifth forming mold in sequence by a 3D printing technology according to a structural layer of the required luneberg lens; the lens material is specifically prepared by respectively preparing a lens material with an inner-layer ellipsoid structure (10), an outer-layer ellipsoid structure (20) and a spherical ball structure (30) by adopting silicon rubber, ceramic powder and a curing agent; the preparation of the luneberg lens specifically comprises the steps of preparing an inner-layer ellipsoid structure (10), preparing an outer-layer ellipsoid structure (20) and preparing a spherical ball structure (30) in sequence. The method has the advantages of simple preparation process, short preparation period, seamless molding at low temperature, no air gap between layers of the prepared lens, and good radiation performance.
Description
Technical Field
The invention relates to the technical field of communication equipment production, in particular to a preparation method of a Luneberg lens working in an X wave band.
Background
The Luneberg lens technology is proposed by RKLuneberg in 1944 based on a geometric optics method, is used as an antenna and a scatterer and is mainly used in the fields of a rapid scanning system, a satellite communication system, an automobile anti-collision radar, a radar reflector and the like; luneberg lenses are widely used and spotlighted by many of their advantages over parabolic antennas.
Theoretically, in order to realize the ideal working performance of the luneberg lens antenna, the dielectric constant of the luneberg lens should be an ideal change rule, namely, the dielectric constant changes smoothly from 2 to 1 from the core to the outer surface layer; however, dielectric materials having such ideal dielectric constants do not exist in nature. Therefore, in the prior art, the dragon wave lens is usually prepared by adopting a layered design or layer-by-layer foaming method, namely, each layer is independently prepared firstly, and then the layers are bonded together, so that a continuously-changing dielectric constant is obtained, however, the process is complex, the yield is low, the cost is high, the production cost is extremely reduced no matter the dragon wave lens is designed in a layered manner or foamed in a layer-by-layer manner, interfaces of the layers are obvious (due to precision errors in the processing process), and air gaps between the layers are easily generated, so that the discontinuity of the dielectric constant, the loss of the lens and the radiation efficiency of the antenna are caused; meanwhile, in the prior art, a method for preparing a luneberg lens based on a hole opening method exists, namely, the required equivalent dielectric constant is realized by controlling the density or the shape and the size of holes, however, the luneberg lens prepared by the hole opening method has the problems of insufficient mechanical strength, large processing difficulty and poor processing precision, and great difference exists between simulation and actual measurement.
In addition, in the prior art, the low dielectric constant materials required for manufacturing the luneberg lens are few in types, expensive and not easy to control the dielectric constant, so the conventional production usually adopts a foaming process of the high dielectric constant material and a layer-by-layer stacking manner to manufacture the luneberg lens, for example: polystyrene beads and a foaming agent are adopted for high-temperature foaming molding in a mold, the dielectric constant is controlled by controlling the size and the density of the beads, and the preparation of the luneberg lens is realized, however, the consistency of the beads in the foaming process cannot be accurately controlled by adopting the mode and the material, so that the dielectric constant is difficult to control in the foaming process, the yield is low, the preparation time is long, the foaming process is complex, the lens quality is large, the lens is inconvenient to install and use, and the practical application field is narrow.
Disclosure of Invention
Aiming at the problems in the prior art, the invention aims to provide a preparation method of a luneberg lens working in an X wave band, the luneberg lens is prepared by high dielectric constant, the luneberg lens has similar performance with the luneberg lens prepared by a low dielectric constant material, and meanwhile, the method does not need a foaming process, and the obtained lens has small quality and stable dielectric constant; in addition, the method has the advantages of simple preparation process, short preparation period, seamless molding at low temperature, difficult occurrence of interlayer air gaps among structural layers of the prepared lens and good radiation performance.
The purpose of the invention is realized by the following technical scheme:
a preparation method of a Luneberg lens working in an X waveband is characterized by comprising the following steps: the method comprises the steps of preparing a forming mould, configuring a lens material and preparing a Luneberg lens; the method specifically comprises the following steps:
s100, preparing a forming die: preparing a first forming die, a second forming die, a third forming die, a fourth forming die and a fifth forming die in sequence by a 3D printing technology according to a structural layer of the required luneberg lens;
the structural layer of the dragon wave lens is sequentially provided with an inner-layer ellipsoid structure, an outer-layer ellipsoid structure and a spherical structure from the inner core to the outer layer; the outer layer ellipsoid structure wraps the inner layer ellipsoid structure, the spherical ball structure wraps the outer layer ellipsoid structure, and the centers of the inner layer ellipsoid structure and the outer layer ellipsoid structure and the spherical center of the spherical ball structure are the same point;
the first forming die, the second forming die, the third forming die, the fourth forming die and the fifth forming die comprise upper half shells and lower half shells; the inner cavities of the upper half shell and the lower half shell of the first forming die correspond to the structural shape of the inner ellipsoidal layer (namely the inner cavity of the first forming die forms a complete ellipsoid), the upper half shell cavity of the second forming die corresponds to the outer layer ellipsoid structural shape, the lower half shell cavity corresponds to the inner layer ellipsoid structural shape (namely the upper half shell is a large semi-ellipsoid shape, and the lower half shell is a smaller semi-ellipsoid shape), the inner cavities of the upper half shell and the lower half shell of the third forming die correspond to the structural shape of the outer layer ellipsoid (namely the inner cavity of the third forming die forms a complete ellipsoid), the inner cavity of the upper half shell of the fourth forming die corresponds to the spherical structural shape, the inner cavity of the lower half shell corresponds to the ellipsoidal structural shape of the outer layer (namely the upper half shell is hemispherical and the lower half shell is semi-ellipsoidal), the inner cavities of the upper half shell and the lower half shell of the fifth forming die correspond to the structural shape of the sphere (namely the inner cavity of the fifth forming die forms a complete sphere);
s200, configuration of lens materials: the preparation materials of each structural layer of the luneberg lens are prepared from silicon rubber, ceramic powder and a curing agent, and the materials of the lens with the inner-layer ellipsoid structure, the outer-layer ellipsoid structure and the spherical structure are respectively prepared; the method specifically comprises the following steps:
s201, respectively preparing silicon rubber and ceramic powder of correspondingly prepared materials according to the shapes and dielectric constants of an inner-layer ellipsoid structure, an outer-layer ellipsoid structure and a spherical structure, and respectively adding the silicon rubber and the ceramic powder into a planetary mixer for mixing and degassing to obtain a mixed material of the inner-layer ellipsoid structure, the outer-layer ellipsoid structure and the spherical structure;
s202, respectively placing the mixed material of the inner-layer ellipsoid structure, the outer-layer ellipsoid structure and the spherical ball structure in a vacuum furnace for secondary defoaming treatment until no bubbles are generated on the surface of the mixed material;
s203, adding the mixed material subjected to secondary defoaming treatment in the step S202 and the curing agents of the corresponding inner-layer ellipsoid structure, outer-layer ellipsoid structure and spherical structure into a stirrer in proportion respectively for uniform mixing, and transferring the mixed material into an injector after mixing; then placing the injector in a vacuum furnace for defoaming treatment to obtain lens materials with an inner-layer ellipsoid structure, an outer-layer ellipsoid structure and a spherical structure;
s300, preparing a Luneberg lens: and sequentially preparing an inner-layer ellipsoid structure, an outer-layer ellipsoid structure and a spherical ball structure.
For further optimization, in the step S100, the major axis radius of the inner-layer ellipsoid structure is 3.1cm, the minor axis radius is 1.55cm, and the volume is 23.665cm3A dielectric constant of 3.44; the outer partThe major axis radius of the lamellar ellipsoid structure is 4.6cm, the minor axis radius is 2.3cm, and the volume is 62.430cm3A dielectric constant of 3.2; the radius of the spherical ball structure is 9.5cm, and the volume is 3591.364cm3The dielectric constant was 2.82.
For further optimization, in the step S100, the first forming mold, the second forming mold, the third forming mold, the fourth forming mold and the fifth forming mold are all formed by 3D printing of nylon and glass fiber.
Preferably, the weight of the glass fiber accounts for 30% of the weight of the nylon.
Further optimization is performed, in the step S100, the upper half shell and the lower half shell of the first forming mold, the second forming mold, the third forming mold, the fourth forming mold and the fifth forming mold are fastened and connected through screws and nuts.
Further optimization is performed, in the step S100, an injection hole and an exhaust hole are formed in upper half shells of the first forming mold, the second forming mold, the third forming mold, the fourth forming mold and the fifth forming mold, a thread hermetically connected with the injector is formed in the injection hole, the injection hole is formed in the middle of an upper half shell of the molds (i.e., the first forming mold, the second forming mold, the third forming mold, the fourth forming mold and the fifth forming mold, the same applies to the same), the injection hole is inclined upwards, the injector can conveniently inject from bottom to top, redundant bubbles generated by contact between materials and air in the injection process are avoided, and the exhaust hole is formed in the top end of the mold, so that the bubbles in the materials can be removed in the vacuum curing process.
For further optimization, the silicone rubber is polydimethylsiloxane (U.S. Dow Corning, Sylgard 184); the ceramic powder adopts strontium titanate (the molecular formula is SrTiO)3）。
Preferably, the curing agent is the curing agent matched with the silicone rubber in the American Dow Corning 184 silicone rubber.
Preferably, the ceramic powder has an average particle diameter of 5 μm and a density of 4.81 g/ml.
For further optimization, in the step S200, the volume percentage of the ceramic powder with the inner layer ellipsoid structure to the silicone rubber is 5.736%, and the weight ratio of the silicone rubber to the curing agent is 10: 1, the volume percentage of the ceramic powder with the outer layer ellipsoid structure to the silicon rubber is 3.815%, and the weight ratio of the silicon rubber to the curing agent is 10: 1, the volume percentage of the ceramic powder with the spherical structure to the silicon rubber is 1.108 percent, and the weight ratio of the silicon rubber to the curing agent is 10: 1. different dielectric constants are obtained by regulating and controlling different volume ratios of the ceramic powder and the silicon rubber, and the dielectric constant with continuous change is finally obtained; meanwhile, by regulating and controlling different volume ratios of the ceramic powder and the silicon rubber, a lower loss tangent is obtained, and serious loss of the luneberg lens in the using process is avoided.
Preferably, the syringe in step S200 is a luer syringe.
Further optimization is carried out, the mixing time in the step S201 is 1.5-3 min, and the degassing time is 7-10 min.
Further optimization is carried out, and the stirring and mixing time in the step S203 is 1.5-3 min.
Further optimization is carried out, the defoaming treatment in the steps S202 and S203 adopts a vacuum furnace of 27 in-Hg, and the defoaming time is 30-35 min.
For further optimization, the step S300 specifically includes:
s301, preparing an inner-layer ellipsoid structure: injecting the lens material with the inner layer ellipsoid structure configured in the step S200 into a first molding die; then carrying out defoaming treatment in a vacuum furnace, and curing in the vacuum furnace after defoaming; taking out the solidified sample from the first forming die after solidification, and smoothly polishing the surface of the solidified sample (so as to remove burrs generated by surface injection holes and air holes in the injection process) to obtain an inner-layer ellipsoid structure;
s302, preparing an outer layer ellipsoid structure: firstly, placing the obtained inner-layer ellipsoidal structure into a second forming die, keeping the outer wall of the lower part of the inner-layer ellipsoidal structure tightly attached to the cavity wall of the inner cavity of the lower half shell of the second forming die, and then injecting the lens material with the outer-layer ellipsoidal structure, which is prepared in the step S200, into the upper half shell of the second forming die; then carrying out defoaming treatment in a vacuum furnace, and curing in the vacuum furnace after defoaming; taking out the cured sample from the second molding die after the curing is finished, and smoothly polishing the surface of the cured sample (so as to remove burrs generated by surface injection holes and air holes in the injection process) to obtain a half edge outer layer ellipsoid structure;
placing the half outer layer ellipsoid structure into a third forming die, keeping the outer wall of the half outer layer ellipsoid structure tightly attached to the cavity wall of the inner cavity of the lower half shell of the third forming die, and injecting the lens material with the outer layer ellipsoid structure configured in the step S200 into the upper half shell of the third forming die; then carrying out defoaming treatment in a vacuum furnace, and curing in the vacuum furnace after defoaming; taking out the solidified sample from the third forming die after solidification, and smoothly polishing the surface of the solidified sample (so as to remove burrs generated by surface injection holes and air holes in the injection process), thereby obtaining the whole outer-layer ellipsoid structure;
s303, preparing a spherical ball structure: firstly, placing the obtained outer layer ellipsoid structure into a fourth forming die, keeping the outer wall of the lower part of the outer layer ellipsoid structure tightly attached to the cavity wall of the inner cavity of the lower half shell of the fourth forming die, and then injecting the lens material with the spherical ball structure configured in the step S200 into the upper half shell of the fourth forming die; then carrying out defoaming treatment in a vacuum furnace, and curing in the vacuum furnace after defoaming; taking out the cured sample from the fourth molding die after the curing is finished, and smoothly polishing the surface of the cured sample (so as to remove burrs generated by surface injection holes and air holes in the injection process) to obtain a semi-edge spherical structure;
placing the hemispherical ball structure into a fifth forming die, keeping the outer wall of the hemispherical ball structure tightly attached to the cavity wall of the inner cavity of the lower half shell of the fifth forming die, and injecting the lens material with the spherical ball structure prepared in the step S200 into the upper half shell of the fifth forming die; then carrying out defoaming treatment in a vacuum furnace, and curing in the vacuum furnace after defoaming; and after the solidification is finished, taking out the solidified sample from the fifth forming die, and smoothly polishing the surface of the solidified sample (so as to remove burrs generated by surface injection holes and air holes in the injection process) to obtain the whole spherical structure, namely the special-shaped luneberg lens.
Further optimization is carried out, the defoaming treatment in the steps S301 to S303 adopts a vacuum furnace of 27 in-Hg, and the defoaming time is 30-35 min.
Further optimization is carried out, the curing temperature of the vacuum furnace in the steps S301-S303 is 58-62 ℃, and the curing time is 2.5-3.5 h.
For further optimization, in order to facilitate testing, the method further comprises the step of preparing an antenna base of the luneberg lens after the step S300, wherein the antenna base is processed by adopting 0.5 density methacrylimide foam, and the dielectric constant of the antenna base in the X waveband is 1.07.
The invention has the following technical effects:
the preparation process is simple, materials are easy to process, the Luneberg lens antenna working in the X wave band is obtained by the method, and the Luneberg lens antenna is made of high dielectric constant materials and achieves performance similar to the Luneberg lens antenna with low dielectric constant; meanwhile, the luneberg lens obtained by the method is low in specific gravity, excellent in compatibility with additive manufacturing materials and wide in application range. In addition, the dielectric constant of the Luneberg lens prepared by the method is stable and easy to control in the whole X-band (8.2-12.4 GHz), the dielectric loss is low, and the use performance and the scanning capability of the Luneberg lens are effectively ensured.
The method has the advantages that the three-layer structure is formed from the inner core to the outer core through injection molding of the mold, a multi-layer spherical shell assembling mode is not needed, and the influence of interlayer air gaps on the radiation performance of the lens is effectively avoided; and the three-layer structure is easy to manufacture and process, the manufacturing period is short, seamless molding can be realized at low temperature, the final scanning performance and radiation performance of the luneberg lens are prevented from being influenced by the precision of the multilayer spherical shell processing or bonding process, the production manufacturing efficiency is effectively improved, the production cost is reduced, and the yield is improved. The luneberg lens obtained by the method has small mass (only 3.5 kg) and is easy to install.
Drawings
Fig. 1 is a schematic structural diagram of a special-shaped luneberg lens in an embodiment of the present invention.
FIG. 2 is a schematic diagram of the structures of the layers of a sample of a profiled Luneberg lens according to an embodiment of the present invention; fig. 2 (a) is a schematic diagram of a sample structure after injection molding of an inner-layer ellipsoid structure, fig. 2 (b) is a schematic diagram of a sample structure after injection molding of an outer-layer ellipsoid structure, fig. 2 (c) is a schematic diagram of a sample structure after first injection molding of a spherical structure, and fig. 2 (d) is a schematic diagram of a sample structure after second injection molding of a spherical structure, namely a schematic diagram of a final sample structure of a luneberg lens.
Fig. 3 is a schematic structural diagram of a first molding die in an embodiment of the present invention.
Fig. 4 is a schematic structural diagram of a second molding die in the embodiment of the present invention.
Fig. 5 is a schematic structural diagram of a third molding die in the embodiment of the present invention.
Fig. 6 is a schematic structural view of a fourth molding die in the embodiment of the present invention.
Fig. 7 is a schematic structural view of a fifth molding die in the embodiment of the present invention.
FIG. 8 is a simulated and actually tested radiation pattern of the special-shaped Luneberg lens manufactured in the embodiment of the present invention in the X-band; fig. 8 (a) shows a radiation pattern at S11 in the X band, fig. 8 (b) shows a radiation pattern at 8.5GHz, fig. 8 (c) shows a radiation pattern at 10GHz, and fig. 8 (d) shows a radiation pattern at 12 GHz.
Fig. 9 shows the simulated and actually tested scanning patterns of the special-shaped luneberg lens manufactured in the embodiment of the present invention at 10 GHz.
Wherein, 10, inner layer ellipsoid structure; 20. an outer layer ellipsoid structure; 30. a spherical structure.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Example (b):
as shown in fig. 1 to 7, a method for preparing a luneberg lens operating in an X band is characterized in that: the method comprises the steps of preparing a forming mould, configuring a lens material and preparing a Luneberg lens; the method specifically comprises the following steps:
s100, preparing a forming die: preparing a first forming die, a second forming die, a third forming die, a fourth forming die and a fifth forming die in sequence by a 3D printing technology according to a structural layer of the required luneberg lens;
the structural layer of the dragon wave lens is provided with an inner-layer ellipsoid structure 10, an outer-layer ellipsoid structure 20 and a spherical ball structure 30 from the inner core to the outer layer in sequence; the outer-layer ellipsoid structure 20 wraps the inner-layer ellipsoid structure 10, the spherical structure 30 wraps the outer-layer ellipsoid structure 20, and the centers of the inner-layer ellipsoid structure 10 and the outer-layer ellipsoid structure 20 are the same as the spherical center of the spherical structure 30; the major axis radius of the inner ellipsoidal structure 10 is 3.1cm, the minor axis radius is 1.55cm, and the volume is 23.665cm3A dielectric constant of 3.44; the outer ellipsoidal structure 20 has a major axis radius of 4.6cm, a minor axis radius of 2.3cm, and a volume of 62.430cm3A dielectric constant of 3.2; the spherical structure 30 has a radius of 9.5cm and a volume of 3591.364cm3A dielectric constant of 2.82;
the first forming die, the second forming die, the third forming die, the fourth forming die and the fifth forming die are all formed by 3D printing of nylon and glass fibers, wherein the weight of the glass fibers accounts for 30% of the weight of the nylon;
the first forming die, the second forming die, the third forming die, the fourth forming die and the fifth forming die comprise an upper half shell and a lower half shell; the upper and lower half-shell cavities of the first forming mold correspond to the inner ellipsoidal structure 10 in shape (i.e., the cavities form a complete ellipsoid), the upper half-shell cavity of the second forming mold corresponds to the outer ellipsoidal structure 20 in shape, the lower half-shell cavity corresponds to the inner ellipsoidal structure 10 in shape (i.e., the upper half-shell is a large semi-ellipsoidal shape, the lower half-shell is a small semi-ellipsoidal shape), and on the third forming mold, the inner cavities of the lower half shells correspond to the outer-layer ellipsoidal structure 20 in shape (namely the inner cavities of the lower half shells form a complete ellipsoid), the inner cavities of the upper half shells of the fourth forming dies correspond to the spherical ball structure 30 in shape, the inner cavities of the lower half shells correspond to the outer-layer ellipsoidal structure 20 in shape (namely the upper half shells are hemispherical and the lower half shells are hemispherical), and the inner cavities of the upper half shells and the lower half shells of the fifth forming dies correspond to the spherical ball structure 30 in shape (namely the inner cavities of the upper half shells and the lower half shells form a complete sphere);
the upper half shell and the lower half shell of the first forming die, the second forming die, the third forming die, the fourth forming die and the fifth forming die are fixedly connected through screws and nuts; the injection hole and the exhaust hole are arranged on the upper half shells of the first forming die, the second forming die, the third forming die, the fourth forming die and the fifth forming die, the injection hole is provided with threads which are hermetically connected with the injector (namely a Ruhr injector), the injection hole is arranged in the middle of the upper half shells of the dies (namely the first forming die, the second forming die, the third forming die, the fourth forming die and the fifth forming die, the lower half shells are the same) and is inclined upwards, so that the injector can conveniently inject from bottom to top, the phenomenon that materials are contacted with air in the injection process to generate redundant air bubbles is avoided, and the exhaust hole is arranged at the top end of the dies, so that the air bubbles in the materials can be removed in the vacuum curing process.
S200, configuration of lens materials: the preparation materials of each structural layer of the luneberg lens are all prepared by silicon rubber, ceramic powder and curing agent, and the lens materials of the inner-layer ellipsoid structure 10, the outer-layer ellipsoid structure 20 and the spherical structure 30 are respectively configured; the silicone rubber is polydimethylsiloxane (Dow Corning, Sylgard184, USA), and the ceramic powder is strontium titanate (Sigma-Aldrich, molecular formula is SrTiO)3) The curing agent is the curing agent matched with the silicon rubber in the American Dow Corning 184 silicon rubber, the average grain diameter of the ceramic powder is 5 mu m, and the density is 4.81 g/ml.
The method specifically comprises the following steps:
s201, firstly, according to the shapes and dielectric constants of the inner-layer ellipsoid structure 10, the outer-layer ellipsoid structure 20 and the spherical ball structure 30, respectively configuring silicon rubber and ceramic powder of correspondingly prepared materials,
the method specifically comprises the following steps: the volume percentage of the ceramic powder and the silicon rubber of the inner-layer ellipsoidal structure 10 is 5.736%, and the weight ratio of the silicon rubber to the curing agent is 10: 1, the volume percentage of the ceramic powder and the silicon rubber of the outer-layer ellipsoidal structure 20 is 3.815%, and the weight ratio of the silicon rubber to the curing agent is 10: 1, the volume percentage of the ceramic powder and the silicon rubber of the spherical structure 30 is 1.108 percent, and the weight ratio of the silicon rubber to the curing agent is 10: 1.
then respectively adding the mixture into a planetary mixer to mix for 1.5-3 min (preferably 2 min) and degassing for 7-10 min (preferably 8 min) to respectively obtain mixed materials of an inner-layer ellipsoid structure 10, an outer-layer ellipsoid structure 20 and a spherical ball structure 30;
s202, respectively placing the mixed materials of the inner-layer ellipsoid structure 10, the outer-layer ellipsoid structure 20 and the spherical ball structure 30 in a 27-Hg vacuum furnace for secondary defoaming treatment, wherein the defoaming time is 30-35 min (preferably 30 min) until no bubbles are generated on the surface of the mixed materials;
s203, adding the mixed materials subjected to the secondary defoaming treatment in the step S202 and the curing agents of the corresponding inner-layer ellipsoid structure 10, outer-layer ellipsoid structure 20 and spherical ball structure 30 in proportion (namely the proportion) into a stirrer for uniform mixing for 1.5-3 min (preferably 2 min), and transferring the mixed materials into a luer syringe after the mixing is finished; then placing the injector in a 27 in-Hg vacuum furnace for defoaming for 30-35 min (preferably 30 min) to obtain lens materials of the inner-layer ellipsoid structure 10, the outer-layer ellipsoid structure 20 and the spherical ball structure 30 respectively;
s300, preparing a Luneberg lens: the preparation of the inner-layer ellipsoid structure 10, the preparation of the outer-layer ellipsoid structure 20 and the preparation of the spherical ball structure 30 are sequentially carried out, and specifically:
s301, preparing an inner-layer ellipsoid structure 10: injecting the lens material of the inner-layer ellipsoidal structure 10 configured in the step S200 into a first molding die; then, defoaming in a vacuum furnace of 27 in-Hg for 30-35 min (preferably 30 min), curing in the vacuum furnace after defoaming, wherein the curing temperature is 58-62 ℃ (preferably 60 ℃), and the curing time is 2.5-3.5 h (preferably 3 h); taking out the solidified sample from the first forming die after solidification, and smoothly polishing the surface of the solidified sample (so as to remove burrs generated by surface injection holes and air holes in the injection process), thereby obtaining an inner-layer ellipsoidal structure 10;
s302, preparing an outer-layer ellipsoid structure 20: firstly, placing the obtained inner-layer ellipsoidal structure 10 into a second forming mold, keeping the outer wall of the lower part of the inner-layer ellipsoidal structure 10 tightly attached to the cavity wall of the inner cavity of the lower half shell of the second forming mold, and then injecting the lens material of the outer-layer ellipsoidal structure 20 configured in the step S200 into the upper half shell of the second forming mold; then carrying out defoaming treatment in a vacuum furnace for 30-35 min (preferably 30 min), curing in the vacuum furnace after defoaming, wherein the curing temperature is 58-62 ℃ (preferably 60 ℃), and the curing time is 2.5-3.5 h (preferably 3 h); taking out the cured sample from the second molding die after the curing is finished, and smoothly polishing the surface of the cured sample (so as to remove burrs generated by surface injection holes and air holes in the injection process) to obtain a half edge outer layer ellipsoid structure 20;
placing the half outer layer ellipsoid structure 20 into a third forming die, keeping the outer wall of the half outer layer ellipsoid structure 20 tightly attached to the cavity wall of the inner cavity of the lower half shell of the third forming die, and then injecting the lens material of the outer layer ellipsoid structure 20 configured in the step S200 into the upper half shell of the third forming die; then carrying out defoaming treatment in a vacuum furnace for 30-35 min (preferably 30 min), curing in the vacuum furnace after defoaming, wherein the curing temperature is 58-62 ℃ (preferably 60 ℃), and the curing time is 2.5-3.5 h (preferably 3 h); taking out the solidified sample from the third forming die after solidification, and smoothly polishing the surface of the solidified sample (so as to remove burrs generated by surface injection holes and air holes in the injection process), thereby obtaining the whole outer-layer ellipsoidal structure 20;
s303, preparing a spherical ball structure 30: firstly, placing the obtained outer-layer ellipsoidal structure 20 into a fourth forming die, keeping the outer wall of the lower part of the outer-layer ellipsoidal structure 20 tightly attached to the cavity wall of the inner cavity of the lower half shell of the fourth forming die, and then injecting the lens material of the spherical ball structure 30 configured in the step S200 into the upper half shell of the fourth forming die; then carrying out defoaming treatment in a vacuum furnace for 30-35 min (preferably 30 min), curing in the vacuum furnace after defoaming, wherein the curing temperature is 58-62 ℃ (preferably 60 ℃), and the curing time is 2.5-3.5 h (preferably 3 h); taking out the cured sample from the fourth molding die after the curing is finished, and smoothly polishing the surface of the cured sample (so as to remove burrs generated by surface injection holes and air holes in the injection process) to obtain a semi-edge spherical structure 30;
placing the hemispherical spherical structure 30 into a fifth forming mold, keeping the outer wall of the hemispherical spherical structure 30 tightly attached to the cavity wall of the inner cavity of the lower half shell of the fifth forming mold, and injecting the lens material of the spherical structure 30 configured in the step S200 into the upper half shell of the fifth forming mold; then carrying out defoaming treatment in a vacuum furnace for 30-35 min (preferably 30 min), curing in the vacuum furnace after defoaming, wherein the curing temperature is 58-62 ℃ (preferably 60 ℃), and the curing time is 2.5-3.5 h (preferably 3 h); after the solidification is completed, the solidified sample is taken out from the fifth molding die, and the surface of the solidified sample is smoothly polished (to remove burrs generated by surface injection holes and air holes in the injection process), so that the whole spherical structure 30, namely the special-shaped luneberg lens, is obtained.
S400, in order to facilitate testing, the method further comprises the step of preparing an antenna base of the luneberg lens after the step S300, wherein the antenna base is processed by adopting 0.5 density methacrylimide foam, and the dielectric constant of the antenna base in the X wave band is 1.07.
As shown in FIG. 8, S11 of the Luneberg lens prepared in this embodiment is below-20 dB in the range of 8.2-12.4GHz, which meets the requirement of energy transfer. Meanwhile, the simulation gain values at 8.5GHz, 10GHz and 12GHz are respectively 21.1 dBi, 22.2 dBi and 22.8 dBi, the measured values are respectively 20.8 dBi, 22.4 dBi and 22.6 dBi, the side lobe electricity average is lower than-19 dB, and the test result is basically consistent with the simulation result.
As shown in fig. 9, the gain of the luneberg lens antenna manufactured in this embodiment is only reduced by 0.7 dBi when the luneberg lens antenna scans ± 54 ° on the azimuth plane, which indicates that the combined structure of the luneberg lens does not significantly affect the omni-directional scanning capability of the antenna.
Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (10)
1. A preparation method of a Luneberg lens working in an X waveband is characterized by comprising the following steps: the method comprises the steps of preparing a forming mould, configuring a lens material and preparing a Luneberg lens; the method specifically comprises the following steps:
s100, preparing a forming die: preparing a first forming die, a second forming die, a third forming die, a fourth forming die and a fifth forming die in sequence by a 3D printing technology according to a structural layer of the required luneberg lens;
the structural layer of the dragon wave lens is sequentially provided with an inner-layer ellipsoid structure (10), an outer-layer ellipsoid structure (20) and a spherical ball structure (30) from the inner core to the outer layer; the outer-layer ellipsoid structure (20) wraps the inner-layer ellipsoid structure (10), the spherical structure (30) wraps the outer-layer ellipsoid structure (20), and the centers of the inner-layer ellipsoid structure (10) and the outer-layer ellipsoid structure (20) and the spherical center of the spherical structure (30) are the same point;
the first forming die, the second forming die, the third forming die, the fourth forming die and the fifth forming die comprise upper half shells and lower half shells; the upper half shell inner cavity and the lower half shell inner cavity of the first forming die correspond to the shape of an inner-layer ellipsoid structure (10), the upper half shell inner cavity and the outer-layer ellipsoid structure (20) of the second forming die correspond to each other in shape, the lower half shell inner cavity and the inner-layer ellipsoid structure (10) of the second forming die correspond to each other in shape, the upper half shell inner cavity and the lower half shell inner cavity of the third forming die correspond to each other in shape of an outer-layer ellipsoid structure (20), the upper half shell inner cavity and the spherical ball structure (30) of the fourth forming die correspond to each other in shape, the lower half shell inner cavity and the outer-layer ellipsoid structure (20) of the fourth forming die correspond to each other in shape, and the upper half shell inner cavity and the lower half shell inner cavity of the fifth forming die correspond to each other in shape of the spherical ball structure (30);
s200, configuration of lens materials: the preparation materials of each structural layer of the luneberg lens are all prepared from silicon rubber, ceramic powder and a curing agent, and the lens materials of an inner-layer ellipsoid structure (10), an outer-layer ellipsoid structure (20) and a spherical structure (30) are respectively configured; the method specifically comprises the following steps:
s201, respectively preparing silicon rubber and ceramic powder of correspondingly prepared materials according to the shapes and dielectric constants of an inner-layer ellipsoid structure (10), an outer-layer ellipsoid structure (20) and a spherical structure (30), and respectively adding the silicon rubber and the ceramic powder into a planetary mixer for mixing and degassing to obtain a mixed material of the inner-layer ellipsoid structure (10), the outer-layer ellipsoid structure (20) and the spherical structure (30);
s202, respectively placing the mixed materials of the inner-layer ellipsoid structure (10), the outer-layer ellipsoid structure (20) and the spherical ball structure (30) in a vacuum furnace for secondary defoaming treatment until no bubbles are generated on the surfaces of the mixed materials;
s203, adding the mixed material subjected to the secondary defoaming treatment in the step S202 and the curing agents of the inner-layer ellipsoid structure (10), the outer-layer ellipsoid structure (20) and the spherical ball structure (30) in proportion into a stirrer for uniform mixing, and transferring the mixed material into an injector after the mixing is finished; then placing the injector in a vacuum furnace for defoaming treatment to obtain lens materials with an inner-layer ellipsoid structure (10), an outer-layer ellipsoid structure (20) and a spherical ball structure (30);
s300, preparing a Luneberg lens: the preparation of the inner-layer ellipsoid structure (10), the preparation of the outer-layer ellipsoid structure (20) and the preparation of the spherical ball structure (30) are sequentially carried out.
2. The method for manufacturing a luneberg lens operating in the X-band as claimed in claim 1, wherein: in the step S100, the major axis radius of the inner-layer ellipsoid structure (10) is 3.1cm, the minor axis radius is 1.55cm, and the volume is 23.665cm3A dielectric constant of 3.44; the major axis radius of the outer layer ellipsoid structure (20) is 4.6cm, the minor axis radius is 2.3cm, and the volume is 62.430cm3A dielectric constant of 3.2; the radius of the round ball structure (30) is 9.5cm, and the volume is 3591.364cm3The dielectric constant was 2.82.
3. A method for producing a luneberg lens operating in the X band according to claim 1 or 2, wherein: in the step S100, an injection hole and an exhaust hole are formed in the upper half shells of the first forming die, the second forming die, the third forming die, the fourth forming die and the fifth forming die, the injection hole is provided with a thread hermetically connected with the injector, the injection hole is formed in the middle of the upper half shell of the die and is inclined upwards, and the exhaust hole is formed in the top end of the die.
4. The method for preparing a luneberg lens operating in the X band according to any one of claims 1 to 3, wherein: the silicone rubber adopts polydimethylsiloxane; the ceramic powder is strontium titanate.
5. The method for manufacturing a luneberg lens operating in the X band as claimed in claim 4, wherein: in the step S200, the volume percentage of the ceramic powder and the silicone rubber of the inner layer ellipsoid structure (10) is 5.736%, and the weight ratio of the silicone rubber to the curing agent is 10: 1, the volume percentage of the ceramic powder and the silicon rubber of the outer-layer ellipsoidal structure (20) is 3.815%, and the weight ratio of the silicon rubber to the curing agent is 10: 1, the volume percentage of the ceramic powder and the silicon rubber of the spherical structure (30) is 1.108%, and the weight ratio of the silicon rubber to the curing agent is 10: 1.
6. the method for manufacturing a luneberg lens operating in the X-band as claimed in claim 1, wherein: in the step S201, the mixing time is 1.5-3 min, and the degassing time is 7-10 min.
7. The method for manufacturing a luneberg lens operating in the X-band as claimed in claim 1, wherein: and the stirring and mixing time in the step S203 is 1.5-3 min.
8. The method for manufacturing a luneberg lens operating in the X-band as claimed in claim 1, wherein: the defoaming treatment in the steps S202 and S203 adopts a vacuum furnace of 27 in-Hg, and the defoaming time is 30-35 min.
9. The method for preparing a luneberg lens operating in the X band as claimed in claim 1 or 5, wherein: the step S300 specifically includes:
s301, preparing an inner-layer ellipsoid structure (10): injecting the lens material of the inner-layer ellipsoid structure (10) configured in the step S200 into a first molding die; then carrying out defoaming treatment in a vacuum furnace, and curing in the vacuum furnace after defoaming; taking out the cured sample from the first forming die after curing is finished, and smoothly polishing the surface of the cured sample to obtain an inner-layer ellipsoid structure (10);
s302, preparing an outer layer ellipsoid structure (20): firstly, placing the obtained inner-layer ellipsoidal structure (10) into a second molding die, keeping the outer wall of the lower part of the inner-layer ellipsoidal structure (10) tightly attached to the cavity wall of the inner cavity of the lower half shell of the second molding die, and then injecting the lens material of the outer-layer ellipsoidal structure (20) which is configured in the step S200 into the upper half shell of the second molding die; then carrying out defoaming treatment in a vacuum furnace, and curing in the vacuum furnace after defoaming; taking out the cured sample from the second molding die after the curing is finished, and smoothly polishing the surface of the cured sample to obtain a half outer layer ellipsoid structure (20);
placing the half outer layer ellipsoid structure (20) into a third forming die, keeping the outer wall of the half outer layer ellipsoid structure (20) tightly attached to the cavity wall of the inner cavity of the lower half shell of the third forming die, and injecting the lens material of the outer layer ellipsoid structure (20) which is configured in the step S200 into the upper half shell of the third forming die; then carrying out defoaming treatment in a vacuum furnace, and curing in the vacuum furnace after defoaming; taking out the cured sample from the third forming die after curing is finished, and smoothly polishing the surface of the cured sample to obtain a whole outer-layer ellipsoid structure (20);
s303, preparing a spherical ball structure (30): firstly, placing the obtained outer layer ellipsoid structure (20) into a fourth forming die, keeping the outer wall of the lower part of the outer layer ellipsoid structure (20) tightly attached to the cavity wall of the inner cavity of the lower half shell of the fourth forming die, and then injecting the lens material of the spherical ball structure (30) which is configured in the step S200 into the upper half shell of the fourth forming die; then carrying out defoaming treatment in a vacuum furnace, and curing in the vacuum furnace after defoaming; taking out the cured sample from the fourth forming die after curing is finished, and smoothly polishing the surface of the cured sample to obtain a semi-edge spherical structure (30);
placing the hemispherical ball structure (30) into a fifth forming die, keeping the outer wall of the hemispherical ball structure (30) tightly attached to the cavity wall of the inner cavity of the lower half shell of the fifth forming die, and injecting the lens material of the spherical ball structure (30) prepared in the step S200 into the upper half shell of the fifth forming die; then carrying out defoaming treatment in a vacuum furnace, and curing in the vacuum furnace after defoaming; and after the solidification is finished, taking out the solidified sample from the fifth forming die, and smoothly polishing the surface of the solidified sample to obtain the whole spherical structure (30), namely the special-shaped luneberg lens.
10. The method for manufacturing a luneberg lens operating in the X band according to claim 1 or 9, wherein: the defoaming treatment in the steps S301 to S303 adopts a vacuum furnace of 27 in-Hg, and the defoaming time is 30-35 min.
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| CN104659496A (en) * | 2015-02-16 | 2015-05-27 | 航天特种材料及工艺技术研究所 | Manufacture method of hemispherical luneberg lens antenna |
| CN106099382A (en) * | 2016-06-02 | 2016-11-09 | 深圳贝斯特网联通讯设备有限公司 | The manufacture method of Luneberg lens antenna |
| CN110401039A (en) * | 2019-07-29 | 2019-11-01 | 佛山市粤海信通讯有限公司 | A kind of production method of the primary lens of dragon |
| WO2020190331A1 (en) * | 2019-03-15 | 2020-09-24 | John Mezzalingua Associates, LLC | Spherical luneburg lens-enhanced compact multi-beam antenna |
| CN112350074A (en) * | 2020-10-28 | 2021-02-09 | 厦门华厦学院 | Luneberg lens reflector and passive radar reflecting ball comprising same |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN104659496A (en) * | 2015-02-16 | 2015-05-27 | 航天特种材料及工艺技术研究所 | Manufacture method of hemispherical luneberg lens antenna |
| CN106099382A (en) * | 2016-06-02 | 2016-11-09 | 深圳贝斯特网联通讯设备有限公司 | The manufacture method of Luneberg lens antenna |
| WO2020190331A1 (en) * | 2019-03-15 | 2020-09-24 | John Mezzalingua Associates, LLC | Spherical luneburg lens-enhanced compact multi-beam antenna |
| CN110401039A (en) * | 2019-07-29 | 2019-11-01 | 佛山市粤海信通讯有限公司 | A kind of production method of the primary lens of dragon |
| CN112350074A (en) * | 2020-10-28 | 2021-02-09 | 厦门华厦学院 | Luneberg lens reflector and passive radar reflecting ball comprising same |
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