CN115810912A - Manufacturing process of window type radome - Google Patents
Manufacturing process of window type radome Download PDFInfo
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- CN115810912A CN115810912A CN202211562896.3A CN202211562896A CN115810912A CN 115810912 A CN115810912 A CN 115810912A CN 202211562896 A CN202211562896 A CN 202211562896A CN 115810912 A CN115810912 A CN 115810912A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 28
- 238000000034 method Methods 0.000 claims abstract description 17
- 239000011265 semifinished product Substances 0.000 claims abstract description 17
- 239000003973 paint Substances 0.000 claims abstract description 14
- 238000005507 spraying Methods 0.000 claims abstract description 11
- 238000012545 processing Methods 0.000 claims abstract description 10
- 239000000047 product Substances 0.000 claims abstract description 9
- 239000011347 resin Substances 0.000 claims description 64
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- 239000003795 chemical substances by application Substances 0.000 claims description 14
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- 229920003235 aromatic polyamide Polymers 0.000 claims description 7
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Abstract
The invention relates to the technical field of antenna housing manufacturing, in particular to a manufacturing process of a window type antenna housing. The method comprises the following steps: a presetting step: attaching a high-wave-transmission plate into the antenna housing mould, wherein the attaching position corresponds to the microwave output position; skin processing: laying skin according to the antenna housing mould, and attaching the skin to the periphery of the high-wave-transmission plate to form a semi-finished product; demoulding: separating the radome mold from the semi-finished product; and (3) paint spraying: and spraying a paint surface to the surface of the semi-finished product to obtain a finished product. In the prior art, the whole antenna housing is made of high-wave-transmission materials, and the cost of a single antenna housing is high. Compared with the prior art, the area of the antenna housing, which is only output by microwaves, is made of high-wave-transparent materials, so that the production cost of the antenna housing is effectively reduced.
Description
Technical Field
The invention relates to the technical field of antenna housing manufacturing, in particular to a manufacturing process of a window type antenna housing.
Background
With the continuous development of communication technology, a wired transmission network mainly based on optical fiber communication dominates, but in some special application scenarios, a microwave communication mode is still adopted. For example: in remote areas, microwave communication is used when the difficulty of wired transmission is too high or the cost is too high. For private network communication users such as power grids, railways and the like, microwave communication is also adopted as a communication means between remote isolated sites. In addition, microwave communication has strong disaster resistance, and is often used for emergency communication in an emergency. As can be seen, microwave communications are often used for outdoor long-range wireless communications. Therefore, in order to enable the microwave communication device to work normally in different environments, a corresponding antenna cover needs to be covered on the microwave communication device to protect the antenna of the microwave communication device from being affected by environmental factors. Therefore, the antenna housing not only plays a role in shielding and protecting, but also needs to be normally transparent to microwaves. This places special demands on the material of the radome. Generally, in order to secure the wave-transmitting rate, the radome is manufactured using a high wave-transmitting material such as cyanate ester resin and quartz fiber. Due to the existing manufacturing process, the radome can only be integrally formed by adopting high-wave-transmission materials, so that the manufacturing cost of the large radome is extremely high. The manufacturing cost of a single radome can be as high as 20 ten thousand dollars, subject to size requirements.
Disclosure of Invention
Aiming at the technical problems in the prior art, the invention provides a manufacturing process of a window type radome.
In order to solve the technical problems, the invention provides the following technical scheme:
a manufacturing process of a window type antenna housing comprises the following steps: a presetting step: attaching a high-wave-transmission plate into the antenna housing mould, wherein the attaching position corresponds to the microwave output position;
skin processing: laying skin according to the antenna housing mould, and attaching the skin to the periphery of the high-wave-transmission plate to form a semi-finished product;
demoulding: separating the radome mold from the semi-finished product;
a paint spraying step: and spraying a paint surface to the surface of the semi-finished product to obtain a finished product.
The high-wave-transmission plate is made of high-wave-transmission materials. The high wave-transparent material is arc-shaped, and the size of the high wave-transparent material is adapted to the microwave output area of the microwave communication equipment antenna. In will highly pass through ripples plate laminating to the mould of antenna house, the position of laminating is corresponding with the microwave output position of antenna to establish back on the antenna with finished product antenna house cover, the antenna can normally pass through highly pass through ripples plate output microwave. And after the high-wave-transmission plate is attached, laying a skin according to the antenna housing mould, and attaching the skin around the high-wave-transmission plate. At this point, a semi-finished product has been formed, the shape of which corresponds to the desired radome shape. The high-wave-transparent plate is embedded in the skin. And after the semi-finished product is formed, separating the antenna housing mould from the semi-finished product, and spraying a paint surface on the separated semi-finished product to obtain a finished product. Therefore, the antenna housing produced by the process is only made of the high-wave-transparent material in the area corresponding to the antenna, so that the overall cost of the antenna housing is effectively reduced.
Further, the presetting step further comprises the following steps:
a positioning step: marking an installation position in the antenna housing mould according to the microwave output position;
brushing: and brushing resin to one side of the high-wave-transmission plate and the antenna housing mould, and attaching the high-wave-transmission plate to the mounting position so as to fully contact the resin with the antenna housing mould.
Further, the brushing step further comprises the following steps:
brushing a release agent to one side of the high-wave-transparent plate, which is attached to the antenna housing mold;
paving electronic cloth to one side of the high-wave-transparent plate, which is attached to the radome mold;
brushing resin to enable the resin to be soaked into the electronic cloth;
and (5) attaching the high-wave-transmission plate to a mounting position so as to enable the resin to be fully contacted with the antenna housing.
Further, the presetting step further comprises the following steps:
and (3) curing:
when the resin is in contact with the radome mold, laying a vacuum film into the radome mold so as to enable the high-wave-transmission plate to be arranged between the vacuum film and the radome mold;
pumping out gas between the vacuum film and the antenna housing mold;
standing the high-wave-transmission plate until the resin is cured;
when the resin is cured, the vacuum film is peeled off.
Further, the skin processing step further comprises the following steps:
laying an outer skin: brushing resin on the inner wall of the antenna housing mould to form outer layer resin, paving glass fiber cloth on the outer layer resin to form an outer skin;
a core material laying step: laying aramid honeycombs on the outer skin;
laying an inner skin: resin is brushed on the aramid fiber honeycomb and high-wave-permeability plate to form inner-layer resin, and glass fiber cloth is laid on the inner-layer resin to form the inner skin.
Furthermore, the high-wave-transmission plate comprises a setting plate and an extension plate;
the extension plate is surrounded on the periphery of the high-wave-transparent plate;
the step of laying the inner skin further comprises the following steps:
marking a setting plate and an extending plate;
and brushing resin on the aramid fiber honeycomb and the extending plate to form inner layer resin.
Furthermore, the glass fiber cloth comprises a 01 cloth layer and a 02 cloth layer.
Compared with the prior art, the invention has the following advantages:
by utilizing the manufacturing process, only the area of the finished antenna cover corresponding to the microwave output area of the antenna is made of high-wave-transparent materials, and other areas are made of materials with relatively low wave-transparent rate. Therefore, the manufacturing process of the antenna housing finished product is effectively reduced. The cost of the antenna housing can be reduced from 20 thousands to 5 thousands under the condition of the same size.
The invention can effectively embed the high-wave-transparent plates and the skin which are made of different materials together, and can effectively avoid the phenomenon that the gap is formed between the high-wave-transparent plates and the skin or the high-wave-transparent plates are separated from the skin in the use process so as to influence the integral use effect.
According to the manufacturing process, the atmospheric pressure is effectively utilized, on one hand, the gap between the high-wave-transmitting material and the antenna housing mould is effectively reduced, the manufacturing error is reduced, and the uncontrollable offset of the relative position of the high-wave-transmitting plate and the antenna housing mould under the influence of gravity before the resin is cured is effectively prevented. On the other hand for the whole configuration of aramid honeycomb and antenna house mould looks adaptation to manufacturing error has further been reduced. Meanwhile, the adverse effects of the adhesion of other materials and the contact of other objects on the wave transmission rate and the overall configuration are effectively avoided.
Only the surface of the high-wave-transparent plate is coated with a release agent and a spray paint. The influence of the material on the wave transmission rate of the high-wave-transmission plate is in a controllable range. Thereby effectively avoiding the adverse effect of other materials on the wave-transmitting rate.
The core material of covering adopts the aramid fiber honeycomb to make, the effectual whole weight that reduces the antenna house finished product.
Drawings
FIG. 1: the whole process flow chart.
Detailed Description
The following are specific embodiments of the present invention and are further described with reference to the accompanying drawings, but the present invention is not limited to these embodiments.
A manufacturing process of a window type antenna housing comprises the following steps: the method comprises the steps of presetting, skin processing, demolding and paint spraying.
In practical implementation, the high-wave-transparent plate needs to be produced in advance. The high wave-transmitting plate is integrally formed by adopting a corresponding die. The high wave-transmitting plate is an arc plate with the radian of 240 degrees. The high wave-transparent plate comprises a setting plate and an extending plate. The setting plate and the extension plate are all cyanate prepreg plates. Wherein the coverage area of the plate is set to correspond to the microwave output range of the antenna. The extension plate surrounds the periphery of the setting plate. That is, the coverage area of the high-wave-transparent plate member is larger than the microwave output range of the antenna. After the high-wave-transmission plate is taken out of the mold, the surface is polished to be smooth and bright by using 1000-mesh sand paper, and then a layer of wax is applied to the surface.
Meanwhile, the radome mold needs to be treated in advance. And (4) cleaning the combined radome mold, and polishing and waxing the inner surface of the radome mold. And after waxing is finished, brushing a release agent on the inner surface of the antenna housing mould twice.
Specifically, the presetting step further comprises the following steps:
a positioning step:
according to the microwave output position of the antenna, the mounting position of the high-wave-transmission plate is marked on the inner surface of the antenna housing mould.
Brushing:
the release agent is brushed twice on one side of the high-wave-transmission plate attached to the antenna housing mold, so that on one hand, the amount of the release agent attached to the high-wave-transmission plate can meet follow-up requirements. On the other hand, the release agent is made to sufficiently cover the highly wave-transparent plate member to avoid that some areas are not brushed with the release agent. And after the release agent is brushed, paving a layer of electronic cloth on one side of the high-wave-transparent plate, which is attached to the antenna housing mould. The area of the electronic cloth is slightly larger than the surface area of the attaching side, so that the electronic cloth can fully cover the high-wave-transmission plate. The surface of the electronic cloth is coated with a layer of SW-901 resin (hereinafter referred to as resin) so that the resin can be fully immersed into the electronic cloth. Meanwhile, the curing time is controlled to be more than 1 hour. At this time, the redundant electronic cloth is cut off, so that the outer edge of the electronic cloth is consistent with the high-wave-transparent plate. After the electronic cloth is processed, the high-wave-transmission plate is attached to the mounting position, so that the electronic cloth soaked with resin is in full contact with the inner surface of the antenna housing mould.
And (3) curing:
after the high wave-transmitting plate is attached to the antenna housing mould. And laying a layer of vacuum film into the antenna housing mould. The area of vacuum membrane should make after the vacuum membrane covers high ripples plate of passing through completely, can also laminate to the inner wall of antenna house mould on to make high ripples plate of passing through be located between vacuum membrane and the antenna house mould. After laying, air between the vacuum film and the antenna housing mold is extracted, and the vacuum degree is 0.09. Therefore, the vacuum film can continuously extrude the high-wave-transmission plate by utilizing the atmospheric pressure. On the one hand, the high-wave-transmission plate can be effectively prevented from sliding downwards gradually under the influence of gravity and separating from the installation position. On the other hand, the gap between sustainable compression high wave-transparent plate and the antenna house mould, compress the thickness of electron cloth self promptly for the gap is close to 0, thereby effectual installation error that has reduced. And standing the high-wave-transmission plate, removing the vacuum film after the resin is completely cured, and cleaning the resin overflowing from the space between the high-wave-transmission plate and the antenna housing die due to the extrusion of the vacuum film.
Skin processing:
laying an outer skin:
and brushing a layer of resin on the inner wall of the antenna housing mould, so that the resin covers other areas except the high-wave-transmission plate to form outer layer resin. A layer of 01 cloth (0.1 mm glass fiber cloth) is laid on the outer layer resin, and then two layers of 02 cloth (0.2 mm glass fiber cloth) are laid. Wherein, each layer of glass fiber cloth is coated with a layer of resin, and the glass fiber cloth is completely soaked by the other resin. After the resin is cured, the resin and the glass fiber cloth form an outer skin together.
A core material laying step:
cutting out a plurality of aramid fiber honeycombs for later use. And (3) brushing resin on the outer skin, and paving the aramid fiber honeycombs on the outer skin one by one to enable the aramid fiber honeycombs to completely cover the outer skin and fully contact with the resin. At this moment, a certain gap may exist between two adjacent aramid honeycombs due to the laying precision and the shape of the radome mold. Meanwhile, the aramid fiber honeycomb is aligned with the outer edge of the high-wave-transmission plate. After the aramid fiber honeycomb is laid, a vacuum film is laid in the antenna housing mould, and the aramid fiber honeycomb is fully covered by the vacuum film. Air between vacuum film and the antenna house mould is taken out to utilize atmospheric pressure, make the vacuum film continuously extrude the aramid fiber honeycomb, thereby make aramid fiber honeycomb and outer covering fully laminate and fully contact with resin. From this for the whole appearance of aramid fiber honeycomb can keep unanimous with the antenna house mould, avoids the part region to influence off-the-shelf wholeness ability because of the laminating untight results in the whole shape of aramid fiber honeycomb to appear uncontrollable change. After the resin is cured, the vacuum film is removed. Cutting off redundant aramid fiber honeycombs, and enabling the coverage area of the aramid fiber honeycombs to be consistent with a set area. Gaps among the aramid fiber honeycombs are filled with gap filling glue, burrs on the surfaces of the aramid fiber honeycombs are polished, and the surfaces of the aramid fiber honeycombs are flat. Thus, the aramid honeycomb is laid. In conclusion, the whole weight of the radome is effectively reduced by the aramid fiber honeycombs.
Laying an inner skin:
and marking a setting plate on the high-wave-transparent plate so as to separate the setting plate from the extension plate through the mark. And brushing resin on the aramid fiber honeycombs and the extending plates of the high-wave-permeability plates to form inner-layer resin. Two layers of 02 cloth and one layer of 01 cloth are laid on the inner layer resin. Wherein, each layer of glass fiber cloth is paved with a layer of resin by brush coating, and the resin is fully soaked in the glass fiber cloth. After the resin is cured, the resin and the glass fiber cloth form the inner skin together. Thereby, the outer skin is combined with the inner skin as one body (the body is hereinafter referred to as skin). The high-wave-transparent plate is embedded into the skin and is stably connected with the skin through the inner skin, so that the separation of the high-wave-transparent plate from the skin in the subsequent use process is effectively avoided. In conclusion, the invention effectively combines the components of two different materials together stably.
And finishing the machining of the semi-finished product of the antenna housing.
Demoulding:
because the internal standard surface of the antenna housing mould is coated with the release agent, the semi-finished product can be easily released from the antenna housing mould. And (4) properly processing the joint between the high-wave-transparent plate and the inner skin so as to enable the high-wave-transparent plate and the outer skin to smoothly transit on the same curved surface. On the other hand, the high-wave-transparent plate is coated with the release agent in advance, so that the electronic cloth mixed with the resin can be easily cleaned from the high-wave-transparent plate. After the electronic cloth is removed, the outer skin is properly polished. And repairing the joint between the outer skin and the high-wave-transmission plate by using atomic ash so that the outer skin can be smoothly transited to the high-wave-transmission plate. It should be noted that the atomic ash cannot be attached to the high-wave-transparent plate, so as not to affect the wave-transparent performance of the high-wave-transparent plate.
A paint spraying step:
and spraying milky Y11 matt paint on the outer surface of the semi-finished product, and standing for 24 hours until the paint film is completely dried. And (5) inspecting the semi-finished product, and finishing the manufacture of the finished product if the inspection result is qualified.
In summary, by using the manufacturing process of the present invention, only the region of the finished antenna cover corresponding to the microwave output region of the antenna is made of a high wave-transparent material, and the other regions are made of materials with relatively low wave-transparent rate. Therefore, the manufacturing cost of the antenna housing finished product is effectively reduced under the condition that the normal microwave output can be maintained. The cost of the antenna housing can be reduced from 20 ten thousand to 5 ten thousand under the same size. Meanwhile, the high-wave-transparent plate and the skin can be stably connected, and gaps or separation between the high-wave-transparent plate and the skin in the using process is effectively avoided. On the other hand, the aramid honeycomb is adopted in the covering part, so that the overall weight of the finished antenna housing is effectively reduced.
Meanwhile, in the manufacturing process, the surface of the plate is only set to be coated with the release agent and sprayed with paint. The influence of the release agent and the paint spraying on the wave transmission rate of the set plate is in a controllable range, and the adverse influence of other materials on the wave transmission rate is effectively avoided.
The method also comprises a flange processing step, and specifically comprises the following flange processing steps:
and (4) preprocessing the steel ring matched with the inner diameter of the flange. The method specifically comprises the following steps: and (4) polishing and waxing after surface derusting, and brushing the release agent twice. Brushing white gel coat once, and after curing, paving two layers of 02 cloth and two layers of 04 cloth (0.4 mm glass fiber cloth) on the surface of the steel circular ring. And brushing a layer of resin on each layer of glass fiber cloth. And after the resin is cured, removing surface burrs for later use. Therefore, the white gel coat, the glass fiber cloth and the resin are combined together to form the inner layer flange. At this time, the inner flange is attached to the steel ring.
In the laying process of the outer skin, the outer layer flange is synchronously laid out by adopting the laying mode of the outer skin according to the antenna housing mould and the outer skin.
And after the aramid fiber honeycomb is laid, laying eight layers of alkali-free fiber cloth with the thickness of 0.4mm on the outer layer flange so as to be in butt joint with the aramid fiber honeycomb.
And the inner-layer flange is properly corrected, so that the steel ring can be placed in the position, corresponding to the flange, in the antenna housing mould. Two layers of alkali-free cloth are laid at the outer layer flange, and glass putty prepared from 901 resin is brushed on the alkali-free cloth. Put into the steel ring in the antenna house mould, adjust the position of steel ring and antenna house mould for concentric back, fasten steel ring and antenna house mould together in order to extrude glass putty for the clearance between inner flange and the outer flange is fully filled to glass putty. And after the glass putty is cured, the steel ring is removed. Thus, the flange is attached.
It should be noted that, the present embodiment does not strictly limit the operation sequence of the foregoing steps, and in an actual state, the operation sequence of the foregoing steps may be adjusted according to an actual situation to meet an actual requirement.
The specific embodiments described herein are merely illustrative of the spirit of the invention. Various modifications or additions may be made to the described embodiments or alternatives may be employed by those skilled in the art without departing from the spirit or ambit of the invention as defined in the appended claims.
Claims (7)
1. A manufacturing process of a window type radome is characterized in that: the method comprises the following steps:
a presetting step: attaching a high-wave-transmission plate into the antenna housing mould, wherein the attaching position corresponds to the microwave output position;
skin processing: laying skin according to the antenna housing mould, wherein the skin is attached to the periphery of the high-wave-transmission plate to form a semi-finished product;
demoulding: separating the radome mold from the semi-finished product;
a paint spraying step: and spraying a paint surface on the surface of the semi-finished product to obtain a finished product.
2. A process according to claim 1 for manufacturing a window-type radome, wherein: the presetting step further comprises the following steps:
a positioning step: marking an installation position in the antenna housing mould according to the microwave output position; brushing: brush resin extremely high wave-transparent plate with one side of laminating mutually of antenna house mould, the laminating high wave-transparent plate extremely the mounted position, so that the resin with the antenna house mould fully contacts.
3. A process according to claim 2, wherein: the brushing step further comprises the following steps:
brushing a release agent to one side of the high-wave-transmission plate, which is attached to the antenna housing mold;
laying electronic cloth to one side of the high-wave-transmission plate, which is attached to the antenna housing mould;
brushing the resin to enable the resin to be soaked into the electronic cloth;
and fitting the high-wave-transmission plate to the mounting position so as to enable the resin to be in full contact with the antenna housing.
4. A process for manufacturing a window-type radome as claimed in claim 2, wherein: the presetting step further comprises the following steps:
and (3) curing:
laying a vacuum film into the radome mold while the resin is in contact with the radome mold such that the high-wave-transmission plate is interposed between the vacuum film and the radome mold;
evacuating gas between the vacuum film and the radome mold;
standing the high-wave-transmission plate until the resin is cured;
when the resin is cured, the vacuum film is peeled off.
5. A process according to claim 1 for manufacturing a window-type radome, wherein: the skin processing step further comprises the following steps:
laying an outer skin: brushing resin on the inner wall of the antenna housing mould to form outer layer resin, paving glass fiber cloth on the outer layer resin to form the outer skin;
a core material laying step: laying aramid honeycombs on the outer skin;
laying an inner skin: and brushing resin on the aramid fiber honeycomb and the high-wave-transmission plate to form inner-layer resin, and paving glass fiber cloth on the inner-layer resin to form the inner skin.
6. A process for manufacturing a window-type radome as claimed in claim 5, wherein: the high-wave-transmission plate comprises a setting plate and an extension plate;
the extension plate is surrounded on the periphery of the high-wave-transmission plate;
the step of laying the inner skin further comprises the following steps:
marking the setting plate and the extending plate;
and brushing resin on the aramid honeycomb and the extension plate to form the inner-layer resin.
7. A process for manufacturing a window radome as claimed in any one of claims 5 to 6 wherein: the glass fiber cloth comprises a 01 cloth layer and a 02 cloth layer.
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| CN202211562896.3A CN115810912B (en) | 2022-12-07 | 2022-12-07 | Window type radome manufacturing process |
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| CN202211562896.3A CN115810912B (en) | 2022-12-07 | 2022-12-07 | Window type radome manufacturing process |
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| US4980696A (en) * | 1987-05-12 | 1990-12-25 | Sippican Ocean Systems, Inc. | Radome for enclosing a microwave antenna |
| CN105856589A (en) * | 2016-04-27 | 2016-08-17 | 航天材料及工艺研究所 | Integrated molding method for high-temperature-resistant heat-insulation wave-transmissive radome with honeycomb interlayer C |
| CN207381528U (en) * | 2017-03-23 | 2018-05-18 | 西安奥尔科航空科技有限公司 | A kind of high wave transmission rate motor-car satellite antenna kuppe |
| CN207602785U (en) * | 2017-07-13 | 2018-07-10 | 铱格斯曼航空科技集团有限公司 | One kind has high wave-penetrating composite material antenna radar cover |
| CN108274879A (en) * | 2018-02-26 | 2018-07-13 | 上海本哲科技有限公司 | A kind of preparation method of high frequency wave transparent sandwich structure composite material 5G antenna houses |
| CN108521016A (en) * | 2018-04-13 | 2018-09-11 | 哈尔滨哈玻拓普复合材料有限公司 | A kind of D shipborne radar cover and its manufacturing method |
| CN109638445A (en) * | 2018-10-26 | 2019-04-16 | 上海无线电设备研究所 | A kind of high temperature resistant foam A interlayer composite material antenna house and preparation method thereof |
| CN110429381A (en) * | 2019-07-26 | 2019-11-08 | 中国航空工业集团公司济南特种结构研究所 | A kind of sandwich antenna house |
| CN112271452A (en) * | 2020-10-26 | 2021-01-26 | 中国电子科技集团公司第五十四研究所 | Vacuum wave-transparent radome with multilayer structure |
| CN112590247A (en) * | 2020-11-30 | 2021-04-02 | 江苏新扬新材料股份有限公司 | Method for integrally forming C-sandwich flat radome |
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