JP2006166109A - Reflection mirror and manufacturing method thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To prevent a reflection mirror from being curved toward the side of a radio non-reflecting surface. <P>SOLUTION: The manufacturing method of the reflection mirror having a surface plate 1a on the side of a radio reflecting surface, a surface plate 1b on the side of the radio non-reflecting surface and a honeycomb core 4 is provided with a step of laminating a prepreg 2 and molding it at a first curing temperature as the surface plate 1a on the side of the radio reflecting surface; a step of post-curing the surface plate 1a on the side of the radio reflecting surface at a second curing temperature; a step of laminating the prepreg 2 and molding it at the first curing temperature as the surface plate 1a on the side of the radio non-reflecting surface; a step of molding the honeycomb core 4; and a step of sandwiching and adhering the molded honeycomb core 4 between the surface plate 1a on the side of the radio reflecting surface and the surface plate 1b on the side of the radio non-reflecting surface, and molding this at a third curing temperature. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a method for manufacturing a reflecting mirror and a reflecting mirror, and more particularly to a method for manufacturing a reflecting mirror using a sandwich structure and a reflecting mirror.

  FIG. 2 is an external view (a) and a cross-sectional view (b) of the reflecting mirror 1 having a honeycomb sandwich structure. In the reflecting mirror 1, the surface plate 1 a on the radio wave reflecting surface side is bonded to one surface of the honeycomb core 4, and the surface plate 1 b on the non-radio wave reflecting surface side is bonded to the other surface of the honeycomb core 4. This reflecting mirror 1 is used as a lightweight and highly accurate reflecting mirror. A method of manufacturing the reflecting mirror 1 having a honeycomb sandwich structure will be described with reference to FIG. FIG. 3 is a view showing a conventional method for manufacturing a reflecting mirror (Non-Patent Document 1).

  First, a prepreg 2, that is, a semi-cured fiber reinforced plastic is laminated on the mold 3 (FIG. 3A), and thermoset in an autoclave 5, that is, a heating and pressurizing furnace (FIG. 3B). That is, the surface plate 1a on the radio wave reflecting surface side is thermally cured into a three-dimensional shape. The thermosetting here means that the semi-cured prepreg 2 is brought into a completely cured state (or a practically cured state). Next, the honeycomb core 4 is preformed using the mold 3 (FIG. 3C).

  Next, the honeycomb core 4 preformed on the mold 3 is placed on the mirror skin, that is, the surface plate 1a on the radio wave reflecting surface side, and the prepreg 2 is laminated outside the honeycomb core 4 (FIG. 3D )). The laminated prepreg 2 becomes the surface plate 1b on the radio wave non-reflecting surface side.

  A thermosetting film adhesive (not shown) is sandwiched between the surface plate 1a on the radio wave reflecting surface side, the surface plate 1b on the radio wave non-reflecting surface side (two surface plates 1a and 1b), and the honeycomb core 4. Glue. Then, in order to thermally cure the film adhesive and the surface plate 1b on the radio wave non-reflecting surface side, the film is again put in the autoclave 5 (FIG. 3 (e)).

  The reason why the prepreg 2 of the surface plate 1a on the radio wave reflecting surface side is previously cured in a heat-cured state, that is, completely cured will be described. If not completely cured, the surface plate is softened by heating when the honeycomb core 4 is bonded later, and a pattern of the honeycomb core 4, that is, a hammer tone (see FIG. 4) is generated on the radio wave reflecting surface. . When the hammer tone is generated, the surface plate 1a on the radio wave reflecting surface side is uneven, which reduces the efficiency of radio wave reflection.

  On the other hand, the reason why the prepreg 2 of the surface plate 1b on the radio wave non-reflecting surface side is not thermoset in advance will be described. If the two surface plates 1a and 1b are previously heat-cured, that is, completely cured with the same mold 3, only the surface plate 1b on the radio wave non-reflecting surface side is bonded to the honeycomb core 4 when the surface plate 1b is bonded to the honeycomb core 4 later. Is fixed at a position offset from the mold 3 by the thickness of the mold 3, so that it is forced into a shape different from that of the mold 3 (see FIG. 5). According to FIG. 5, a gap 1 c is generated between the surface plate 1 b on the radio wave non-reflecting surface side and the honeycomb core 4 that has been thermoset using the mold 3 in advance. If the surface plate 1b on the radio wave non-reflective surface side is forcibly fixed, the internal distortion caused by the force is released when the mold is removed, and as a result, the reflector 1 is deformed, and the accuracy of the radio wave reflective surface is problematic. Produce. If the surface plate 1b on the radio wave non-reflecting surface side is not heat-cured in advance, the prepreg 2 is in a semi-cured state, so that it is sufficiently softened by heating when the honeycomb core 4 is bonded later, and has a shape different from the mold 3 It is familiar and can be fixed in an unforced state.

  A technique for heating and softening a material to form is known as described above. However, if all the surface plates are simply softened, a hammer tone is generated on the surface plate 1a on the radio wave reflecting surface side, which may cause a problem in the characteristics of the reflecting mirror 1.

Mikiro Morita, edited by Hiroshi Iwamoto, “Composite Materials for Electronic Engineering”, 102 pages, IEICE, October 15, 1986

  In the manufacturing method of the reflecting mirror 1, the prepreg 2 of the surface plate 1b on the radio wave non-reflecting surface side is simultaneously thermoset by heating when bonding the two surface plates 1a, 1b and the honeycomb core 4. The prepreg 2 has a problem of causing the reflecting mirror 1 to warp toward the radio wave non-reflecting surface because the resin undergoes curing shrinkage when thermosetting is performed (see FIG. 6).

  The present invention has been made in view of the above circumstances, and it is an object of the present invention to provide a method of manufacturing a reflecting mirror and a reflecting mirror capable of reducing the warp of the reflecting mirror 1 and realizing high-precision manufacturing accuracy. .

  A manufacturing method of a reflecting mirror according to the present invention is a manufacturing method of a reflecting mirror having a sandwich structure in which a first surface plate is bonded to one surface of a honeycomb core and a second surface plate is bonded to the other surface, The curing temperature for curing the first surface plate is different from the curing temperature for curing the second surface plate.

  The method of manufacturing a reflecting mirror according to the present invention is characterized in that the first surface plate is a radio wave reflecting surface and the second surface plate is a radio wave non-reflecting surface.

  The manufacturing method of the reflecting mirror according to the present invention is characterized in that a curing temperature for curing the first surface plate is higher than a curing temperature for curing the second surface plate.

  In the method of manufacturing a reflecting mirror according to the present invention, the curing temperature for curing the first surface plate is 30 ° C. or more with respect to the curing temperature for curing the second surface plate. .

  A manufacturing method of a reflecting mirror according to the present invention is a manufacturing method of a reflecting mirror having a first surface plate, a second surface plate, and a honeycomb core, wherein a prepreg is laminated as the first surface plate, Forming the prepreg as the second surface plate, forming the prepreg at the first curing temperature, forming the honeycomb core, the first surface plate, A step of bonding the second surface plate to the formed honeycomb core in a sandwich manner, and forming at a third curing temperature.

  A manufacturing method of a reflecting mirror according to the present invention is a manufacturing method of a reflecting mirror having a first surface plate, a second surface plate, and a honeycomb core, wherein a prepreg is laminated as the first surface plate. Forming at the curing temperature, post-curing the first surface plate at the second curing temperature, and laminating the prepreg as the second surface plate and molding at the first curing temperature. And forming the honeycomb core, and bonding the first surface plate and the second surface plate to the formed honeycomb core as a sandwich, and forming at a third curing temperature. And a step.

  The manufacturing method of the reflecting mirror according to the present invention is characterized in that the second curing temperature is higher than the first curing temperature, and the third curing temperature is higher than the first curing temperature.

  In the reflector manufacturing method according to the present invention, the first surface plate is a radio wave reflection surface, the second surface plate is a radio wave non-reflection surface, and the second curing temperature is higher than the first curing temperature. Is 30 ° C. or higher, and the third curing temperature is 30 ° C. or higher than the first curing temperature.

  The reflector manufacturing method according to the present invention is characterized in that a fiber reinforced plastic thermoset at the first curing temperature is adopted as the honeycomb core, and the step of forming the honeycomb core is omitted.

  The reflecting mirror according to the present invention is manufactured by using the reflecting mirror manufacturing method according to any one of claims 1 to 9.

  In the present invention, since the prepreg of the surface plate on the radio wave non-reflective surface side is preliminarily cured at the first curing temperature, curing shrinkage of the prepreg due to heating when bonding the surface plate and the honeycomb core is suppressed. There is an effect of reducing the warp of the reflecting mirror.

  Further, in the present invention, since the prepreg of the surface plate on the radio wave reflecting surface side is thermally cured in advance at the second curing temperature, it is difficult to be softened even if heated at the third curing temperature later, resulting in a hammer tone. It has the effect of being difficult.

  Next, the best mode for carrying out the present invention will be described in detail with reference to the drawings.

  In this method of manufacturing a reflecting mirror 1 having a honeycomb sandwich structure, a surface plate 1b on the radio wave non-reflecting surface side made of fiber reinforced plastic is thermoset to obtain a surface plate 1a on the radio wave reflecting surface side made of fiber reinforced plastic. Heat curing is performed at a temperature 30 ° C. higher than the radio wave non-reflecting surface side, and then the two surface plates 1a and 1b are sandwiched and bonded to the honeycomb core 4.

  Next, the operation of the best mode for carrying out the present invention will be described with reference to the drawings. FIG. 1 is a diagram showing a manufacturing method of a reflecting mirror according to an embodiment of the present invention.

  The prepreg 2 is laminated on the mold 3 (FIG. 1 (a)), and is heated and pressurized and cured in the autoclave 5 (FIG. 1 (b)) as a surface plate 1b (second surface plate). . The prepreg 2 has, for example, a thickness of 0.1 mm, and may be used by being laminated, or may contain carbon. The curing temperature at this time is 120 ° C. (first curing temperature). The prepreg 2 is laminated on the mold 3 (FIG. 1 (c)), and is heated and pressurized and cured in the autoclave 5 (FIG. 1 (d)) as the surface plate 1a (first surface plate). . The curing temperature at this time is 120 ° C. (first curing temperature).

  Next, only the surface plate 1a is post-cured, that is, post-cured (heated and pressure-cured) at 180 ° C. (second curing temperature) (FIG. 1 (e)). The curing temperature can be increased by this post cure. If the surface plate 1a is not post-cured, it will soften when heated later at 180 ° C., resulting in a hammer tone, which tends to cause problems with the characteristics of the reflector.

  On the other hand, the honeycomb core 4 is preformed by using the molding die 3 (FIG. 1 (f)).

  Next, the surface plate 1a and the surface plate 1b are sandwiched and bonded to the honeycomb core 4 (layup in FIG. 1 (g)), and heated and pressure cured in an autoclave 5 at 180 ° C. (third curing temperature). (FIG. 1 (h)). A film adhesive (not shown) is used for this adhesion. As a resin of fiber reinforced plastic, for example, in the characteristic value of the material, it can be thermally cured at 120 ° C. (first curing temperature), and post-cured, that is, post-cured at 180 ° C. (second curing temperature) as necessary. Use materials that can be used.

  Resins such as fiber reinforced plastics can be sufficiently softened by exposure to a temperature higher than the curing temperature of the resin (for example, 30 ° C. or higher). That is, the surface plate 1b preliminarily heat-cured at 120 ° C. is sufficiently softened at a heat-curing temperature of 180 ° C. when bonded to the honeycomb core 4 and fixed at a position offset from the mold 3 by the thickness of the honeycomb core 4. Can be fixed in an unforced state.

  In the above description, since the curing temperature of the surface plate 1b is 120 ° C. and the curing temperature of the surface plate 1a is 180 ° C., the temperature difference is 60 ° C. This temperature difference is not limited to 60 ° C. If there is a temperature difference, the effect of the invention can be obtained. This temperature difference may be 30 ° C., for example.

  In the above embodiment, the surface plate 1a is thermally cured at 120 ° C. (FIG. 1 (d)) and then post-cured at 180 ° C., that is, post-cured (FIG. 1 (e)). The same effect can be obtained by omitting d) and thermosetting at 180 ° C. from the beginning.

  In the above embodiment, a case where fiber reinforced plastic is used as the material of the honeycomb core 4 will be described. For example, the material of the honeycomb core 4 is a fiber reinforced plastic that is thermoset at 120 ° C., similar to the surface plate 1b. In this case, it becomes possible to soften at 180 ° C. when a film adhesive (not shown) is thermally cured. That is, when the substantially planar honeycomb core 4 is bonded to the surface plate 1a, it can be simultaneously softened and formed into a three-dimensional shape. Therefore, it is possible to save the trouble of preforming the honeycomb core 4.

  In the above embodiment, the second curing temperature in FIG. 1 (e) and the third curing temperature in FIG. 1 (h) are set to the same value (180 ° C.), but they are not the same value. Also good.

  When the honeycomb core 4 is preformed, when the preformed honeycomb core 4 is placed on the surface plate 1a, an error occurs in the placement position, and the positioning error adversely affects the mirror surface accuracy. That is, if the honeycomb core 4 is formed at the same time when the surface plate 1a and the honeycomb core 4 are bonded together, there is no need to worry about positioning errors, and the mirror surface accuracy can be improved.

  The present invention can be used, for example, as a light-weight and high-accuracy reflecting mirror suitable for mounting on a spacecraft such as an artificial satellite.

It is a figure which shows the manufacturing method of the reflective mirror which concerns on one Embodiment of this invention. It is the external view (a) and sectional drawing (b) of the reflecting mirror by a honeycomb sandwich structure. It is a figure which shows the manufacturing method of the conventional reflective mirror. It is a figure which shows a hammer tone. It is a figure which shows a deformation | transformation of a reflective mirror. It is a figure which shows the curvature of a reflecting mirror.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Reflective mirror 1a Surface plate by the side of a radio wave reflection surface 1b Surface plate by the side of a radio wave non-reflection surface 1c Crevice 2 Prepreg 3 Molding die 4 Honeycomb core 5 Autoclave

Claims (10)

A method for manufacturing a reflector having a sandwich structure in which a first surface plate is bonded to one surface of a honeycomb core and a second surface plate is bonded to the other surface,
A method for manufacturing a reflecting mirror, wherein a curing temperature for curing the first surface plate and a curing temperature for curing the second surface plate are different. The first surface plate is a radio wave reflecting surface;
The method of manufacturing a reflecting mirror according to claim 1, wherein the second surface plate is a radio wave non-reflecting surface. The method for manufacturing a reflecting mirror according to claim 1, wherein a curing temperature for curing the first surface plate is higher than a curing temperature for curing the second surface plate. The manufacturing temperature of the reflecting mirror according to claim 1, wherein the curing temperature for curing the first surface plate has a temperature difference of 30 ° C. or more with respect to the curing temperature for curing the second surface plate. Method. A method of manufacturing a reflector having a first surface plate, a second surface plate, and a honeycomb core,
As the first surface plate, laminating a prepreg and molding at a second curing temperature;
Laminating the prepreg as the second surface plate and molding at a first curing temperature;
Forming the honeycomb core;
A reflector comprising: a step of sandwiching and bonding the first surface plate and the second surface plate to the formed honeycomb core, and forming at a third curing temperature. Manufacturing method. A method of manufacturing a reflector having a first surface plate, a second surface plate, and a honeycomb core,
As the first surface plate, a step of laminating a prepreg and molding at a first curing temperature;
Post-curing the first face plate at a second curing temperature;
Laminating the prepreg as the second surface plate and molding at a first curing temperature;
Forming the honeycomb core;
A reflector comprising: a step of sandwiching and bonding the first surface plate and the second surface plate to the formed honeycomb core, and forming at a third curing temperature. Manufacturing method. The method of manufacturing a reflecting mirror according to claim 5, wherein the second curing temperature is higher than the first curing temperature, and the third curing temperature is higher than the first curing temperature. The first surface plate is a radio wave reflecting surface, and the second surface plate is a radio wave non-reflecting surface;
The second curing temperature is 30 ° C or higher than the first curing temperature, and the third curing temperature is 30 ° C or higher than the first curing temperature. A manufacturing method of a reflecting mirror. The method for manufacturing a reflecting mirror according to claim 5 or 6, wherein a fiber reinforced plastic thermoset at the first curing temperature is adopted as the honeycomb core, and the step of forming the honeycomb core is omitted. . A reflecting mirror manufactured using the reflecting mirror manufacturing method according to claim 1.

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