CN114300858B - Preparation method of Longber lens working in X wave band - Google Patents
Preparation method of Longber lens working in X wave band Download PDFInfo
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- CN114300858B CN114300858B CN202111500463.0A CN202111500463A CN114300858B CN 114300858 B CN114300858 B CN 114300858B CN 202111500463 A CN202111500463 A CN 202111500463A CN 114300858 B CN114300858 B CN 114300858B
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- 238000010146 3D printing Methods 0.000 claims abstract description 6
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- 238000002347 injection Methods 0.000 claims description 31
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- VEALVRVVWBQVSL-UHFFFAOYSA-N strontium titanate Chemical compound [Sr+2].[O-][Ti]([O-])=O VEALVRVVWBQVSL-UHFFFAOYSA-N 0.000 claims description 3
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Abstract
The invention provides a preparation method of a Robert lens working in an X-wave band, which comprises the steps of preparing a forming die, configuring a lens material and preparing the Robert lens; wherein: the preparation of the forming die comprises the steps of sequentially preparing a first forming die, a second forming die, a third forming die, a fourth forming die and a fifth forming die through a 3D printing technology according to a structural layer of a required Luneberg lens; the lens material is prepared by adopting silicon rubber, ceramic powder and curing agent, and respectively configuring an inner ellipsoidal structure (10), an outer ellipsoidal structure (20) and a spherical structure (30); the preparation of the luneberg lens comprises the steps of sequentially preparing an inner ellipsoidal structure (10), preparing an outer ellipsoidal structure (20) and preparing a spherical structure (30). The method has the advantages of simple preparation process, short preparation period, seamless molding at low temperature, difficult occurrence of interlayer air gaps between structural layers 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 Robert lens working in an X-band.
Background
The technology of the Robert lens is proposed by RKLuneberg in 1944 based on a geometrical optical 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; the luneberg lens is widely focused and used by people with its numerous characteristics 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 is continuously and smoothly changed from the core to the outer surface layer and from 2 to 1; however, dielectric materials having such ideal dielectric constants do not exist in nature. Therefore, a layered design or a layer-by-layer foaming method is generally adopted to prepare Long Bo lenses in the prior art, namely, each layer is prepared independently, and then the layers are bonded together, so that the continuously-changing dielectric constant is obtained, however, the process is complex, the yield is low, the cost is high, the production cost is extremely lost, the interfaces of the layers are obvious (due to precision errors in the processing process), interlayer air gaps are extremely easy to occur, the discontinuity of the dielectric constant is caused, the loss of the lenses is increased, and the radiation efficiency of the antenna is reduced; meanwhile, the prior art also has a method for preparing the Longber lens based on an aperture method, namely, the required equivalent dielectric constant is realized by controlling the density or shape of the aperture, however, the Longber lens prepared by the aperture method has the problems of insufficient mechanical strength, high processing difficulty and poor processing precision, and is very easy to cause great difference between simulation and actual measurement.
In addition, the low dielectric constant materials required for preparing the lober lens in the prior art are few in types, high in price and difficult to control the dielectric constant, so that the lober lens is prepared by adopting a high dielectric constant material foaming process and a layer-by-layer stacking mode in the prior art, for example: the polystyrene beads and the foaming agent are adopted to perform 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 Robert lens is realized, however, the consistency of the beads in the foaming process cannot be precisely 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 quality of the lens is high, the installation and the use are inconvenient, and the practical application field is narrow.
Disclosure of Invention
Aiming at the problems existing in the prior art, the invention aims to provide a preparation method of a Robert lens working in an X-band, which is used for preparing the Robert lens through high dielectric constant, so that the Robert lens has similar performance with the Robert 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 preparation method has the advantages of simple preparation process, short preparation period, seamless molding at low temperature, difficult occurrence of interlayer air gaps between structural layers and good radiation performance.
The aim of the invention is achieved by the following technical scheme:
A preparation method of a Robert lens working in an X wave band is characterized by comprising the following steps: the preparation method comprises the steps of preparing a forming die, preparing a lens material and preparing a Robert lens; the method comprises the following steps:
S100, preparing a forming die: according to the structural layer of the required Robert lens, sequentially preparing a first forming die, a second forming die, a third forming die, a fourth forming die and a fifth forming die by a 3D printing technology;
The structural layer of the Long Bo lens is an inner ellipsoidal structure, an outer ellipsoidal structure and a spherical structure from the inner core to the outer in sequence; the outer layer ellipsoidal structure wraps the inner layer ellipsoidal structure and the spherical structure wraps the outer layer ellipsoidal structure, and the centers of the inner layer ellipsoidal structure and the outer layer ellipsoidal structure and the spherical center of the spherical 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 all comprise an upper half shell and a lower half shell; the upper half shell cavity and the lower half shell cavity of the first forming die are corresponding to the inner layer ellipsoid structure shape (namely, the cavities of the upper half shell and the lower half shell of the first forming die form a complete ellipsoid), the upper half shell cavity and the outer layer ellipsoid structure shape of the second forming die are corresponding to the outer layer ellipsoid structure shape, the lower half shell cavity and the inner layer ellipsoid structure shape of the second forming die are corresponding to each other (namely, the upper half shell is a big half ellipsoid shape, the lower half shell is a small half ellipsoid shape), the upper half shell cavity and the lower half shell cavity of the third forming die are corresponding to the outer layer ellipsoid structure shape (namely, the cavities of the third forming die form a complete ellipsoid), the upper half shell cavity and the lower half shell cavity of the fourth forming die are corresponding to the outer layer ellipsoid structure shape (namely, the upper half shell and the lower half shell are semi-ellipsoid shapes), and the upper half shell cavity and the lower half shell cavity of the fifth forming die are corresponding to the sphere structure shape (namely, the cavities of the fourth forming die form 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 curing agent, and an inner ellipsoidal structure, an outer ellipsoidal structure and a spherical structure lens material are respectively prepared; the method comprises the following steps:
s201, respectively configuring silicon rubber and ceramic powder which are prepared into materials according to the shapes and dielectric constants of an inner-layer ellipsoidal structure, an outer-layer ellipsoidal structure and a spherical structure, and respectively adding the silicon rubber and the ceramic powder into a planetary mixer to mix and degas the silicon rubber and the ceramic powder to obtain a mixed material of the inner-layer ellipsoidal structure, the outer-layer ellipsoidal structure and the spherical structure;
s202, respectively placing the mixed materials of the inner ellipsoidal structure, the outer ellipsoidal structure and the spherical structure 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 corresponding curing agents with an inner ellipsoidal structure, an outer ellipsoidal structure and a spherical structure into a stirrer respectively for uniform mixing, and transferring the mixed material into a syringe after the mixing is finished; then placing the injector in a vacuum furnace for defoaming treatment to obtain lens materials with an inner ellipsoidal structure, an outer ellipsoidal structure and a spherical structure;
S300, preparation of a Longber lens: the preparation of the inner ellipsoidal structure, the preparation of the outer ellipsoidal structure and the preparation of the spherical structure are sequentially carried out.
Further optimizing, wherein in the step S100, the radius of the long axis of the inner layer ellipsoid structure is 3.1cm, the radius of the short axis is 1.55cm, the volume is 23.665cm 3, and the dielectric constant is 3.44; the major axis radius of the outer layer ellipsoidal structure is 4.6cm, the minor axis radius is 2.3cm, the volume is 62.430cm 3, and the dielectric constant is 3.2; the radius of the sphere structure is 9.5cm, the volume is 3591.364cm 3, and the dielectric constant is 2.82.
And further optimizing, wherein in the step S100, the first forming die, the second forming die, the third forming die, the fourth forming die and the fifth forming die are formed by 3D printing of nylon and glass fibers.
Preferably, the glass fiber accounts for 30% of the nylon by weight.
And further optimizing, in the step S100, the first forming die, the second forming die, the third forming die, the fourth forming die and the upper half shell and the lower half shell of the fifth forming die are fastened and connected through screws and nuts.
And further optimizing, in the step S100, injection holes and exhaust holes 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, threads in sealing connection with the injector are arranged on the injection holes, the injection holes are formed in the middle part of the upper half shell of the die (namely, the first forming die, the second forming die, the third forming die, the fourth forming die and the fifth forming die, which are the same as each other) and are inclined upwards, so that the injector can conveniently inject from bottom to top, redundant bubbles caused by contact of materials with air in the injection process are avoided, and the exhaust holes are formed in the top end of the die, so that bubbles in the materials can be conveniently removed in the vacuum curing process.
With further optimization, the silicone rubber is polydimethylsiloxane (Dow Corning, sylgard184, U.S.); the ceramic powder adopts strontium titanate (the molecular formula is SrTiO 3).
Preferably, the curing agent is a curing agent matched with silicone rubber in the American Conning 184 silicone rubber.
Preferably, the ceramic powder has an average particle diameter of 5 μm and a density of 4.81g/ml.
Further optimized, in the step S200, the volume percentage of the ceramic powder with the inner-layer ellipsoidal 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 ellipsoidal structure to the silicon rubber is 3.815 percent, 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. the dielectric constant which is not used is obtained by regulating and controlling different volume ratios of the ceramic powder and the silicon rubber, and the dielectric constant which is continuously changed is finally obtained; meanwhile, by regulating and controlling different volume ratios of the ceramic powder and the silicon rubber, lower loss tangent is obtained, and serious loss of the Robert lens in the use process is avoided.
Preferably, in the step S200, a luer syringe is used as the syringe.
And further optimizing, wherein the mixing time in the step S201 is 1.5-3 min, and the degassing time is 7-10 min.
Further preferably, the stirring and mixing time in the step S203 is 1.5-3 min.
And (3) further optimizing, 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.
Further preferably, the step S300 specifically includes:
S301, preparing an inner layer ellipsoid structure: injecting the lens material with the inner ellipsoidal structure configured in the step S200 into a first molding die; then, defoaming treatment is carried out in a vacuum furnace, and solidification is carried out in the vacuum furnace after the defoaming is finished; taking out a cured sample from the first forming die after curing is finished, and carrying out smooth polishing on the surface of the cured sample (so as to remove burrs generated by surface injection holes and ventilation holes in the injection process) to obtain an inner ellipsoidal structure;
S302, preparing an outer ellipsoid structure: firstly, putting the obtained inner layer ellipsoid structure into a second forming die, keeping the outer wall of the lower part of the inner layer ellipsoid structure tightly attached to the cavity wall of the cavity of the lower half shell of the second forming die, and then injecting the lens material of the outer layer ellipsoid structure configured in the step S200 into the upper half shell of the second forming die; then, defoaming treatment is carried out in a vacuum furnace, and solidification is carried out in the vacuum furnace after the defoaming is finished; taking out a cured sample from the second forming die after curing is finished, and carrying out smooth polishing on the surface of the cured sample (so as to remove burrs generated by surface injection holes and ventilation holes in the injection process) to obtain a half-side outer-layer ellipsoidal 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 cavity of the lower half shell of the third forming die, and then injecting the lens material of the outer layer ellipsoid structure, which is configured in the step S200, into the upper half shell of the third forming die; then, defoaming treatment is carried out in a vacuum furnace, and solidification is carried out in the vacuum furnace after the defoaming is finished; taking out a cured sample from the third forming die after curing is finished, and carrying out smooth polishing on the surface of the cured sample (so as to remove burrs generated by surface injection holes and ventilation holes in the injection process) to obtain the whole outer ellipsoidal structure;
S303, preparing a sphere structure: firstly, putting 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 cavity of the lower half shell of the fourth forming die, and then injecting the lens material of the spherical structure, which is configured in the step S200, into the upper half shell of the fourth forming die; then, defoaming treatment is carried out in a vacuum furnace, and solidification is carried out in the vacuum furnace after the defoaming is finished; taking out a cured sample from the fourth forming die after curing is finished, and carrying out smooth polishing on the surface of the cured sample (so as to remove burrs generated by a surface injection hole and an air hole in the injection process) to obtain a hemispherical structure;
Placing the semi-sphere structure into a fifth forming die, keeping the outer wall of the semi-sphere structure tightly attached to the cavity wall of the cavity of the lower half shell of the fifth forming die, and then injecting the lens material of the sphere structure, which is configured in the step S200, into the upper half shell of the fifth forming die; then, defoaming treatment is carried out in a vacuum furnace, and solidification is carried out in the vacuum furnace after the defoaming is finished; and taking out a cured sample from the fifth forming die after curing is finished, and polishing the surface of the cured sample smoothly (so as to remove burrs generated by surface injection holes and ventilation holes in the injection process) to obtain the whole spherical structure, namely the special-shaped Robert lens.
And (3) further optimizing, wherein the defoaming treatment in the steps S301-S303 adopts a vacuum furnace of 27 in-Hg, and the defoaming time is 30-35 min.
And further optimizing, wherein the curing temperature of the vacuum furnace in the steps S301 to S303 is 58 to 62 ℃ and the curing time is 2.5 to 3.5 hours.
Further optimized, for the convenience of testing, the step S300 further includes preparing an antenna base of the luneberg lens, where the antenna base is processed by using a methacryloimide foam with a density of 0.5, and a dielectric constant of 1.07 in the X-band.
The invention has the following technical effects:
The preparation process is simple, the materials are easy to process, the Robert lens antenna working in the X wave band is obtained by the method, and the Robert lens antenna is made of a high dielectric constant material, so that the performance similar to that of the low dielectric constant Robert lens antenna is realized; meanwhile, the Robert lens obtained by the method has low specific gravity, excellent compatibility with additive manufacturing materials and wide application range. In addition, the dielectric constant of the Lobster lens prepared by the method is stable, easy to control and low in dielectric loss on the whole X-wave band (8.2-12.4 GHz), and the usability and scanning capability of the Lobster lens are effectively ensured.
According to the method, the inner core is in a three-layer structure outwards through injection molding by a mold, a multi-layer spherical shell assembling mode is not needed, and the influence of an interlayer air gap 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, the seamless forming can be realized at low temperature, the influence of the precision of the processing or bonding process of the multi-layer spherical shell on the final scanning performance and the radiation performance of the Longber lens is avoided, the production and manufacturing efficiency is effectively improved, the production cost is reduced, and the yield is improved. The Roberts 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 according to an embodiment of the present invention.
Fig. 2 is a schematic diagram of the structure of each layer of a special-shaped luneberg lens sample 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 ellipsoidal structure, fig. 2 (b) is a schematic diagram of a sample structure after injection molding of an outer ellipsoidal 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 sample structure of a final luneberg lens.
Fig. 3 is a schematic structural diagram of a first molding die according to an embodiment of the invention.
Fig. 4 is a schematic structural diagram of a second molding die according to an embodiment of the invention.
Fig. 5 is a schematic structural diagram of a third molding die according to an embodiment of the invention.
Fig. 6 is a schematic structural diagram of a fourth molding die according to an embodiment of the invention.
Fig. 7 is a schematic structural diagram of a fifth molding die according to an embodiment of the invention.
FIG. 8 is a radiation pattern of simulation and actual test of a shaped Robert lens in an X-band, which is prepared in an embodiment of the present invention; 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 is a scan pattern of simulation and actual test of the shaped luneberg lens at 10GHz prepared in the examples of the present invention.
Wherein, 10, an inner layer ellipsoid structure; 20. an outer ellipsoidal structure; 30. a ball structure.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only 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.
Examples:
as shown in fig. 1 to 7, a method for preparing a luneberg lens operating in the X-band is characterized by: the preparation method comprises the steps of preparing a forming die, preparing a lens material and preparing a Robert lens; the method comprises the following steps:
S100, preparing a forming die: according to the structural layer of the required Robert lens, sequentially preparing a first forming die, a second forming die, a third forming die, a fourth forming die and a fifth forming die by a 3D printing technology;
The structural layer of Long Bo lens is composed of an inner ellipsoidal structure 10, an outer ellipsoidal structure 20 and a spherical structure 30 from the inner core to the outer; the outer layer ellipsoidal structure 20 wraps the inner layer ellipsoidal structure 10, the spherical structure 30 wraps the outer layer ellipsoidal structure 20, and the centers of the inner layer ellipsoidal structure 10 and the outer layer ellipsoidal structure 20 and the spherical center of the spherical structure 30 are the same point; the major axis radius of the inner ellipsoidal structure 10 is 3.1cm, the minor axis radius is 1.55cm, the volume is 23.665cm 3, and the dielectric constant is 3.44; the outer ellipsoidal structure 20 has a major axis radius of 4.6cm, a minor axis radius of 2.3cm, a volume of 62.430cm 3, and a dielectric constant of 3.2; the radius of the sphere structure 30 is 9.5cm, the volume is 3591.364cm 3, and the dielectric constant is 2.82;
The first forming die, the second forming die, the third forming die, the fourth forming die and the fifth forming die are formed by 3D printing of nylon and glass fiber, wherein the weight of the glass fiber 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 half shell cavity and the lower half shell cavity of the first forming die are corresponding to the shape of the inner layer ellipsoid structure 10 (namely, the cavities of the upper half shell and the lower half shell of the first forming die form a complete ellipsoid), the upper half shell cavity of the second forming die is corresponding to the shape of the outer layer ellipsoid structure 20, the lower half shell cavity of the second forming die is corresponding to the shape of the inner layer ellipsoid structure 10 (namely, the upper half shell is a big half ellipsoid, the lower half shell is a small half ellipsoid), the upper half shell cavity and the lower half shell cavity of the third forming die are corresponding to the shape of the outer layer ellipsoid structure 20 (namely, the cavities of the upper half shell and the lower half shell of the fourth forming die form a complete ellipsoid), the upper half shell cavity and the lower half shell cavity of the fourth forming die are corresponding to the shape of the spherical structure 30 (namely, the cavities of the fourth forming die 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 formed in the upper half shell of the first forming die, the second forming die, the third forming die, the fourth forming die and the fifth forming die, threads which are in sealing connection with the injector (namely the luer injector) are arranged on the injection hole, the injection hole is formed in the middle of the upper half shell of the die (namely the first forming die, the second forming die, the third forming die, the fourth forming die and the fifth forming die, which are the same below) and is inclined upwards, the injector is convenient to inject from bottom to top, redundant bubbles generated by contact of materials and air in the injection process are avoided, and the exhaust hole is formed in the top end of the die, so that 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 prepared from silicon rubber, ceramic powder and curing agent, and lens materials of an inner ellipsoidal structure 10, an outer ellipsoidal structure 20 and a spherical structure 30 are respectively prepared; the silicone rubber is made of polydimethylsiloxane (Dow Corning, sylgard184 in U.S.), the ceramic powder is made of strontium titanate (Sigma-Aldrich, molecular formula is SrTiO 3), the curing agent is made of the silicone rubber matched with the silicone rubber in the American Conning 184 silicone rubber, the average particle size of the ceramic powder is 5 mu m, and the density is 4.81g/ml.
The method comprises the following steps:
s201, firstly, respectively configuring silicon rubber and ceramic powder of corresponding preparation materials according to the shape and dielectric constants of the inner ellipsoidal structure 10, the outer ellipsoidal structure 20 and the spherical structure 30,
The method comprises the following steps: the volume percentage of the ceramic powder and the silicon rubber of the inner ellipsoidal structure 10 is 5.736 percent, and the weight ratio of the silicon rubber to the curing agent is 10:1, the volume percentage of ceramic powder and silicon rubber of the outer ellipsoidal structure 20 is 3.815%, and the weight ratio of silicon rubber to curing agent is 10:1, the volume percentage of the ceramic powder and the silicon rubber of the ball 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 materials 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 ellipsoidal structure 10, an outer ellipsoidal structure 20 and a spherical structure 30;
s202, respectively placing the mixed materials of the inner ellipsoidal structure 10, the outer ellipsoidal structure 20 and the spherical structure 30 in a vacuum furnace with the speed of 27 in-Hg for secondary defoaming treatment for 30-35 min (preferably 30 min) 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 corresponding proportions (namely the proportions) of the curing agents of the inner ellipsoidal structure 10, the outer ellipsoidal structure 20 and the spherical structure 30 into a stirrer for uniform mixing for 1.5-3 min (preferably 2 min), and transferring the mixed material into a luer syringe after mixing; then placing the injector in a vacuum furnace with the temperature of 27 in-Hg for defoaming treatment for 30-35 min (preferably 30 min) to respectively obtain lens materials of an inner ellipsoidal structure 10, an outer ellipsoidal structure 20 and a spherical structure 30;
S300, preparation of a Longber lens: the preparation of the inner ellipsoidal structure 10, the preparation of the outer ellipsoidal structure 20 and the preparation of the spherical structure 30 are sequentially performed, specifically:
S301, preparing an inner-layer ellipsoid structure 10: injecting the lens material of the inner ellipsoidal structure 10 configured in step S200 into a first molding die; then, defoaming treatment is carried out in a vacuum furnace with the temperature of 27 in-Hg, the defoaming time is 30-35 min (preferably 30 min), and curing is carried out in the vacuum furnace after the defoaming is finished, the curing temperature is 58-62 ℃ (preferably 60 ℃), and the curing time is 2.5-3.5 h (preferably 3 h); taking out a cured sample from the first molding die after curing is finished, and carrying out smooth polishing on the surface of the cured sample (so as to remove burrs generated by surface injection holes and ventilation holes in the injection process) to obtain an inner ellipsoidal structure 10;
S302, preparing an outer ellipsoidal structure 20: firstly, putting the obtained inner layer ellipsoid structure 10 into a second forming die, keeping the outer wall of the lower part of the inner layer ellipsoid structure 10 tightly attached to the cavity wall of the cavity of the lower half shell of the second 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 second forming die; then defoaming treatment is carried out in a vacuum furnace for 30-35 min (preferably 30 min), curing is carried out in the vacuum furnace after the defoaming is finished, the curing temperature is 58-62 ℃ (preferably 60 ℃), and the curing time is 2.5-3.5 h (preferably 3 h); taking out a cured sample from the second molding die after curing is finished, and carrying out smooth polishing on the surface of the cured sample (so as to remove burrs generated by surface injection holes and ventilation holes in the injection process) to obtain a half-outer-layer ellipsoidal 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 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 defoaming treatment is carried out in a vacuum furnace for 30-35 min (preferably 30 min), curing is carried out in the vacuum furnace after the defoaming is finished, the curing temperature is 58-62 ℃ (preferably 60 ℃), and the curing time is 2.5-3.5 h (preferably 3 h); taking out a cured sample from the third molding die after curing is finished, and carrying out smooth polishing on the surface of the cured sample (so as to remove burrs generated by surface injection holes and ventilation holes in the injection process) to obtain the whole outer ellipsoidal structure 20;
S303, preparing a sphere structure 30: firstly, putting the obtained outer ellipsoidal structure 20 into a fourth forming die, keeping the outer wall of the lower part of the outer ellipsoidal structure 20 tightly attached to the cavity wall of the cavity of the lower half shell of the fourth forming die, and then injecting the lens material of the spherical structure 30, which is configured in the step S200, into the upper half shell of the fourth forming die; then defoaming treatment is carried out in a vacuum furnace for 30-35 min (preferably 30 min), curing is carried out in the vacuum furnace after the defoaming is finished, the curing temperature is 58-62 ℃ (preferably 60 ℃), and the curing time is 2.5-3.5 h (preferably 3 h); taking out a cured sample from the fourth forming die after curing is finished, and carrying out smooth polishing on the surface of the cured sample (so as to remove burrs generated by surface injection holes and ventilation holes in the injection process) to obtain a hemispherical structure 30;
Placing the semi-sphere structure 30 into a fifth forming die, keeping the outer wall of the semi-sphere structure 30 tightly attached to the cavity wall of the cavity of the lower half shell of the fifth forming die, and then injecting the lens material of the sphere structure 30, which is configured in the step S200, into the upper half shell of the fifth forming die; then defoaming treatment is carried out in a vacuum furnace for 30-35 min (preferably 30 min), curing is carried out in the vacuum furnace after the defoaming is finished, the curing temperature is 58-62 ℃ (preferably 60 ℃), and the curing time is 2.5-3.5 h (preferably 3 h); and taking out the cured sample from the fifth forming die after curing is finished, and polishing the surface of the cured sample smoothly (so as to remove burrs generated by the surface injection holes and the air holes in the injection process) to obtain the whole spherical structure 30, namely the special-shaped Robert lens.
S400, for convenience in testing, the method further comprises the step of preparing an antenna base of the Robert lens after the step S300, wherein the antenna base is processed by adopting methacryloimide foam with the density of 0.5, and the dielectric constant of the antenna base in an X wave band is 1.07.
As shown in FIG. 8, the S11 of the Robert lens manufactured in the embodiment is below-20 dB within the range of 8.2-12.4 GHz, and the energy transmission requirement is met. Meanwhile, simulation gain values at 8.5 GHz, 10 GHz and 12 GHz are respectively 21.1 dBi, 22.2 dBi and 22.8 dBi, actual measurement values are respectively 20.8 dBi, 22.4 dBi and 22.6 dBi, the side lobe level is lower than-19 dB, and the test result is basically consistent with the simulation result.
As shown in fig. 9, when the luneberg lens antenna manufactured in this embodiment scans to ±54° on the azimuth plane, the gain drop of the antenna is only 0.7 dBi, which indicates that the combined structure of the luneberg lens does not significantly affect the omnidirectional scanning capability of the antenna.
Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made therein 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 Robert lens working in an X wave band is characterized by comprising the following steps: the preparation method comprises the steps of preparing a forming die, preparing a lens material and preparing a Robert lens; the method comprises the following steps:
S100, preparing a forming die: according to the structural layer of the required Robert lens, sequentially preparing a first forming die, a second forming die, a third forming die, a fourth forming die and a fifth forming die by a 3D printing technology;
The structure layer of the Robert lens is an inner layer ellipsoidal structure (10), an outer layer ellipsoidal structure (20) and a spherical structure (30) from the inner core to the outer layer in sequence; the outer layer ellipsoidal structure (20) wraps the inner layer ellipsoidal structure (10), the spherical structure (30) wraps the outer layer ellipsoidal structure (20), and the centers of the inner layer ellipsoidal structure (10) and the outer layer ellipsoidal structure (20) are the same as the spherical center of the spherical structure (30);
The first forming die, the second forming die, the third forming die, the fourth forming die and the fifth forming die all comprise an upper half shell and a lower half shell; the upper half shell inner cavity and the lower half shell inner cavity of the first forming die correspond to the shape of the inner layer ellipsoidal structure (10), the upper half shell inner cavity of the second forming die corresponds to the shape of the outer layer ellipsoidal structure (20), the lower half shell inner cavity corresponds to the shape of the inner layer ellipsoidal structure (10), the upper half shell inner cavity and the lower half shell inner cavity of the third forming die correspond to the shape of the outer layer ellipsoidal structure (20), the upper half shell inner cavity of the fourth forming die corresponds to the shape of the spherical structure (30), the lower half shell inner cavity corresponds to the shape of the outer layer ellipsoidal structure (20), and the upper half shell inner cavity and the lower half shell inner cavity of the fifth forming die correspond to the shape of the spherical structure (30);
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 lens materials of an inner ellipsoidal structure (10), an outer ellipsoidal structure (20) and a spherical structure (30) are respectively prepared; the method comprises the following steps:
S201, respectively preparing silicon rubber and ceramic powder of corresponding preparation materials according to the shape and dielectric constants of an inner-layer ellipsoidal structure (10), an outer-layer ellipsoidal structure (20) and a spherical structure (30), and respectively adding the silicon rubber and ceramic powder into a planetary mixer to mix and degas to obtain a mixed material of the inner-layer ellipsoidal structure (10), the outer-layer ellipsoidal structure (20) and the spherical structure (30);
S202, respectively placing the mixed materials of the inner ellipsoidal structure (10), the outer ellipsoidal structure (20) and the spherical 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 curing agents of the corresponding inner ellipsoidal structure (10), the corresponding outer ellipsoidal structure (20) and the corresponding spherical structure (30) into a stirrer for uniform mixing, and transferring the mixed material into a syringe after mixing; then placing the injector in a vacuum furnace for defoaming treatment to obtain lens materials of an inner ellipsoidal structure (10), an outer ellipsoidal structure (20) and a spherical structure (30);
S300, preparation of a Longber lens: the preparation of the inner ellipsoidal structure (10), the preparation of the outer ellipsoidal structure (20) and the preparation of the spherical structure (30) are sequentially carried out.
2. The method for preparing the luneberg lens operating in the X-band according to claim 1, wherein: the major axis radius of the inner layer ellipsoidal structure (10) in the step S100 is 3.1cm, the minor axis radius is 1.55cm, the volume is 23.665cm 3, and the dielectric constant is 3.44; the major axis radius of the outer layer ellipsoidal structure (20) is 4.6cm, the minor axis radius is 2.3cm, the volume is 62.430cm 3, and the dielectric constant is 3.2; the radius of the sphere structure (30) is 9.5cm, the volume is 3591.364cm 3, and the dielectric constant is 2.82.
3. The method for preparing a luneberg lens operating in the X-band according to claim 1 or 2, characterized in that: in the step S100, injection holes and exhaust holes are formed in the upper half shells of the first molding die, the second molding die, the third molding die, the fourth molding die and the fifth molding die, threads in sealing connection with the injector are formed in the injection holes, the injection holes are formed in the middle of the upper half shells of the dies and are inclined upwards, and the exhaust holes are formed in the top ends of the dies.
4. A method of manufacturing a lober lens operating in the X-band of claim 3, wherein: the silicon rubber adopts polydimethylsiloxane; the ceramic powder adopts strontium titanate.
5. The method for preparing a luneberg lens operating in the X-band of claim 4, wherein: the ceramic powder and silicone rubber of the inner ellipsoidal structure (10) in the step S200 have the volume percentage of 5.736%, and the weight ratio of silicone rubber to curing agent is 10:1, the volume percentage of ceramic powder and silicone rubber of the outer ellipsoidal structure (20) is 3.815%, 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 ball structure (30) is 1.108 percent, and the weight ratio of the silicon rubber to the curing agent is 10:1.
6. The method for preparing the luneberg lens operating in the X-band according to claim 1, wherein: the mixing time in the step S201 is 1.5-3 min, and the degassing time is 7-10 min.
7. The method for preparing the luneberg lens operating in the X-band according to claim 1, wherein: the stirring and mixing time in the step S203 is 1.5-3 min.
8. The method for preparing the luneberg lens operating in the X-band according to 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 of claim 5, wherein: the step S300 specifically includes:
S301, preparing an inner layer ellipsoid structure (10): injecting the lens material of the inner ellipsoidal structure (10) configured in the step S200 into a first molding die; then, defoaming treatment is carried out in a vacuum furnace, and solidification is carried out in the vacuum furnace after the defoaming is finished; taking out a cured sample from the first forming die after curing is finished, and carrying out smooth polishing on the surface of the cured sample to obtain an inner-layer ellipsoidal structure (10);
s302, preparing an outer ellipsoidal structure (20): firstly, putting the obtained inner layer ellipsoid structure (10) into a second forming die, keeping the outer wall of the lower part of the inner layer ellipsoid structure (10) tightly attached to the cavity wall of the cavity of the lower half shell of the second 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 second forming die; then, defoaming treatment is carried out in a vacuum furnace, and solidification is carried out in the vacuum furnace after the defoaming is finished; taking out a cured sample from the second forming die after curing is finished, and carrying out smooth polishing on the surface of the cured sample to obtain a half outer layer ellipsoidal 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 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, defoaming treatment is carried out in a vacuum furnace, and solidification is carried out in the vacuum furnace after the defoaming is finished; taking out a cured sample from the third forming die after curing is finished, and carrying out smooth polishing on the surface of the cured sample to obtain a whole outer layer ellipsoidal structure (20);
S303, preparing a sphere structure (30): firstly, putting 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 cavity of the lower half shell of the fourth forming die, and then injecting the lens material of the spherical structure (30) which is configured in the step S200 into the upper half shell of the fourth forming die; then, defoaming treatment is carried out in a vacuum furnace, and solidification is carried out in the vacuum furnace after the defoaming is finished; taking out a cured sample from the fourth forming die after curing is finished, and carrying out smooth polishing on the surface of the cured sample to obtain a hemispherical structure (30);
Placing the semi-sphere structure (30) into a fifth forming die, keeping the outer wall of the semi-sphere structure (30) tightly attached to the cavity wall of the cavity of the lower half shell of the fifth forming die, and then injecting the lens material of the finished sphere structure (30) in the step S200 into the upper half shell of the fifth forming die; then, defoaming treatment is carried out in a vacuum furnace, and solidification is carried out in the vacuum furnace after the defoaming is finished; and taking out a cured sample from the fifth forming die after curing is finished, and carrying out smooth polishing on the surface of the cured sample to obtain the whole spherical structure (30), namely the special-shaped Robert lens.
10. The method for preparing a luneberg lens operating in the X-band of claim 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 to 35 minutes.
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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 |
| 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 |
|---|---|---|---|---|
| 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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