JP5606185B2 - Dual grid reflector and manufacturing method of dual grid reflector - Google Patents

Description

  The present invention relates to a dual grid reflector obtained by patterning a conductive material on a skin made of a dielectric material provided on an antenna for satellite installation or the like.

  Dual grid reflectors used in artificial satellites, etc., have a front reflector with a grid that reflects a specific polarized wave and transmits a polarized wave orthogonal to the polarized wave, and a rear surface that is a conductor surface without a grid. The reflecting mirror and a coupling member for coupling the front reflecting mirror and the rear reflecting mirror are configured.

  As a manufacturing method of a reflecting mirror provided with such a grid, for example, the following has been proposed (for example, see Patent Document 1). First, a film with a grid on which a grid having a predetermined pattern (including a curve) is formed is obtained by performing metal plating on a flexible film and etching the film.

  Next, the grid-attached film thus formed is closely adhered to a skin having a curved surface (for example, KFRP made of Kevlar (registered trademark) fiber (aramid fiber) and cyanate resin) with the grid side down, Heat and pressure mold. Thereafter, the reflector is manufactured by transferring the grid to the skin by peeling off the film.

  In addition, as a method of manufacturing a reflector having a carbon fiber grid, a method of forming a triaxial woven fabric using a conductive fiber such as carbon fiber and a dielectric fiber such as aramid fiber or glass fiber on a curved surface is proposed. (For example, refer to Patent Document 2).

JP-A-8-37418 JP 2003-347840 A

However, the prior art has the following problems.
When transferring a metal to a reflective surface as a grid, there are the following problems. In other words, in reflective mirrors with large curvatures and those with modified mirror surfaces where the curvature is not constant within the mirror surface and changes in a complicated manner, the grid connected in the axial direction does not follow the shape of the reflector and reflects. There was a problem of peeling from the surface.

  Similarly, when the carbon fiber is used as a grid to form a triaxial woven fabric, there are the following problems. That is, in a reflector having a large curvature or a mirror having a modified mirror surface in which the curvature is not constant within the mirror surface, the grid connected in the axial direction is adjacent to the dielectric fiber. The amount of deformation is limited by friction with the dielectric fiber. As a result, there is a problem that the grid does not follow the shape of the reflecting mirror and peels off from the reflecting surface.

  Eliminating such peeling from the reflective surface of the grid improves the mirror surface accuracy of the reflector, suppresses the defocus of the radio wave, prevents a decrease in communication accuracy, and improves the stability of communication. It is an important issue to be solved.

  The present invention has been made to solve the above-described problems, and provides a dual grid reflector capable of closely adhering a grid to a reflecting surface, preventing a decrease in specular accuracy, and improving communication stability. With the goal.

The dual grid reflector according to the present invention includes a front reflector having a grid so as to reflect a specific polarized wave and transmit a polarized wave orthogonal to the polarized wave, and a rear reflector that is a conductor surface without the grid. And a coupling member that couples the front reflector and the rear reflector, and a dual grid reflector having two reflectors, the grid provided on the front reflector is a grid-patterned conductive material. It is formed of a conductive material and is divided into three or more division numbers in the axial direction corresponding to the grid patterning direction.

In addition, the method of manufacturing the dual grid reflector according to the present invention includes a front reflector provided with a grid so as to reflect a specific polarization and transmit a polarization orthogonal to the polarization, and a conductor surface without the grid. A method of manufacturing a dual grid reflector, comprising a rear reflector and a coupling member for coupling the front reflector and the rear reflector, and comprising two reflectors, comprising a flexible film and a conductive film After integrally forming the conductive material, the grid formed by the grid-patterned conductive material is divided in an axial direction corresponding to the grid patterning direction by an etching process , and is laminated in advance on the mirror mold On the inner skin, a flexible film etched and then integrally formed so that the inner skin and the conductive material face each other A front reflector and a rear reflector made of an inner skin and a conductive material by transferring a conductive material, removing a flexible film, and applying pressure and heat for a predetermined time. Forming a dual-grid reflector having a grid that is integrally formed with a mirror and divided in the axial direction.

  According to the dual grid reflector and the manufacturing method of the dual grid reflector according to the present invention, the grid provided on the front reflector is formed of a conductive material and is divided in the axial direction of the grid. Can be brought into close contact with the reflecting surface to prevent a decrease in mirror surface accuracy and to improve the stability of communication, and a dual grid reflector and a method for manufacturing the dual grid reflector can be obtained.

It is a perspective view which shows the dual grid reflector in Embodiment 1 of this invention. It is an enlarged view of the grid part of the dual grid reflector in Embodiment 1 of this invention. The structure of the process of transfer-molding a flexible film and a conductive material integrally formed on the film on the inner skin previously laminated on the mirror mold in Embodiment 1 of the present invention is shown. It is sectional drawing. The structure of the process of transfer-molding a flexible film and a conductive material integrally formed on the film on the inner skin previously laminated on the mirror mold in Embodiment 1 of the present invention is shown. It is sectional drawing. It is sectional drawing which showed the structure of the process of integrally molding the inner skin and electroconductive material in Embodiment 1 of this invention.

  Hereinafter, preferred embodiments of a dual grid reflector and a method of manufacturing the dual grid reflector of the present invention will be described with reference to the drawings.

Embodiment 1 FIG.
FIG. 1 is a perspective view showing a dual grid reflector (antenna reflector) according to Embodiment 1 of the present invention. A dual grid reflector 1 shown in FIG. 1 includes an inner skin 6 (corresponding to a front reflector) that forms a reflecting mirror surface as a dielectric material, and a conductive material 2 (corresponding to a grid) that is grid-patterned on the inner skin 6. A honeycomb core 4 (corresponding to a coupling member) on the back surface of the inner skin 6 and an outer skin 5 (corresponding to a rear reflector) on the back surface of the honeycomb core 4 are provided.

  Here, as the conductive material 2, for example, a metal material such as a copper foil is used, and is divided in the grid axis direction. Further, as the conductive material 2, carbon fiber can be used, or a carbon fiber surface coated with metal can be used.

  FIG. 2 is an enlarged view of the grid portion of the dual grid reflector according to Embodiment 1 of the present invention. As shown in FIG. 2, the conductive material 2 is grid-patterned on the inner skin 6 that forms the reflecting mirror surface, and the conductive material 2 is divided in the grid axis direction corresponding to the horizontal direction in the figure. .

  Thus, when the conductive material 2 is divided, the length of the conductive material 2 in the grid axis direction is shortened. As a result, the conductive material 2 having low flexibility can follow a reflecting mirror having a large curvature and a reflecting mirror having a modified mirror surface in which the curvature is not constant in the mirror surface but changes in a complicated manner. Become. Therefore, by using a configuration in which the conductive material is divided in the axial direction of the grid, the mirror surface accuracy of the reflecting mirror is improved, the radio wave defocus is suppressed, the communication accuracy is prevented from being lowered, and the communication stability is improved. It becomes possible.

  If the gap between adjacent conductive materials 2 is large, the reflection surface decreases. For this reason, the size of the gap is preferably about 1 to 2 mm, and more preferably not more than the width of the conductive material 2 in the direction perpendicular to the grid axis. Also, from the viewpoint of PIM (PASSIVE INTERMODULATON), it is desirable that the conductive material 2 does not overlap. The division | segmentation of the electroconductive material 2 can raise the suppression effect of peeling of the electroconductive material 2 by concentrating on the site | part with a large curvature.

  In the configuration shown in FIG. 1, the inner skin 6, the honeycomb core 4, and the outer skin 5 are reinforced composite materials obtained by impregnating and curing a resin in a fiber fabric, and are made of the same material. Here, as the reinforced composite material, for example, a dielectric such as Kevlar is used.

  Next, a method for manufacturing the dual grid reflector in the first embodiment will be specifically described with reference to the drawings. FIG. 3 shows a flexible film 8 and a conductive material 2 integrally formed on the film 8 on the inner skin 6 previously laminated on the mirror mold 3 in the first embodiment of the present invention. It is sectional drawing which showed the structure of the process of carrying out transfer molding, and has shown sectional drawing seen from the grid axis orthogonal direction.

  FIG. 4 shows a flexible film 8 on the inner skin 6 previously laminated on the mirror mold 3 in Embodiment 1 of the present invention, and a conductive material integrally formed with the film 8. It is sectional drawing which showed the structure of the process of carrying out transfer molding of 2, and has shown sectional drawing seen from the grid-axis direction. Further, FIG. 5 is a cross-sectional view showing a configuration of a process of integrally molding inner skin 6 and conductive material 2 in Embodiment 1 of the present invention, and shows a cross-sectional view seen from the direction perpendicular to the grid axis. Yes.

As an example, the manufacturing process of a dual grid reflector can be made into the following four stages.
[First Stage] The flexible film 8 and the conductive material 2 are integrally formed.
[Second Stage] The flexible film 8 and the conductive material 2 integrated with the film are transferred onto the inner skin 6 previously laminated on the mirror mold (see FIG. 3 above). (See FIG. 4).
[Third stage] Only the flexible film 8 is removed.
[Fourth Stage] The inner skin 6 and the conductive material 2 are integrally formed (see FIG. 5 above).

  As shown in FIGS. 3 and 4, the flexible film 8 is divided so as to have an area smaller than that of the inner skin 6. When dividing the film 8 having flexibility, the conductive material 2 integrated in the subsequent process is not continuous in the grid axis orthogonal direction, so that the flexibility is high, The number of divisions in the grid axis orthogonal direction is small, and it is desirable to increase the number of divisions in the grid axis direction.

  From the viewpoint of workability, it is desirable that the length of the flexible film before division is about 300 mm to 500 mm. The cut flexible film 8 is integrated with the conductive material 2 having a thin film shape by, for example, an epoxy adhesive. As another means for integration, for example, an acrylic adhesive can be used instead of the epoxy adhesive.

  The conductive material 2 integrated with the flexible film 8 has a grid formed by etching. By this procedure, the flexible film 8 and the conductive material 2 on which the grid is formed can be integrally formed.

  Next, the inner skin 6 is disposed on the mirror mold 3. Furthermore, the integrated flexible film 8 and the conductive material 2 are arranged on the inner skin 6 so that the inner skin 6 and the conductive material 2 face each other. At this time, the gap between adjacent flexible films 8 (that is, the gap between the conductive materials 2) is desirably as small as about 1 to 2 mm from the viewpoint of deterioration of radio wave characteristics.

  In addition, it is desirable to apply pressure with a weight or the like so that the inner skin 6, the flexible film 8, and the conductive material 2 are in close contact with each other. The inner skin 6 is desirably in a state before being semi-cured having tackiness so as to be in close contact with the conductive material 2. By such a series of procedures, the flexible film 8 and the conductive material 2 can be transferred onto the inner skin 6 previously laminated on the mirror mold 3 (see FIGS. 3 and 4). ).

  Next, the conductive material 2 and the flexible film 8 are separated. When removing the flexible film 8, it is necessary to prevent the conductive material 2 and the inner skin 6 from peeling off. Therefore, it is desirable to roll the flexible film 8 from the end and hold the conductive material 2 by hand. By this procedure, only the flexible film 8 can be removed.

  Next, the core 4 and the outer skin 5, the release film 7 and the breather 9 are disposed on the inner skin 6 and the conductive material 2. Further, the bagging film 10 and the sealing material 11 are used to form a bag, and the internal air is extracted using a vacuum pump. In this state, for example, pressurization and heating are performed for a predetermined time at a predetermined temperature and pressure using an autoclave. By this procedure, the inner skin 6 and the conductive material 2 can be integrally formed.

  As a result, it is possible to obtain a dual grid reflector 1 in which a mirror surface can be formed and the grid formed by the conductive material 2 is divided in the axial direction of the grid.

  As described above, according to the first embodiment, the dual grid reflector includes an inner skin provided with a reflective surface, a conductive material attached to the inner skin, a honeycomb core on the back surface of the inner skin, And an outer skin on the back surface of the honeycomb core. The inner skin, honeycomb core, and outer skin are made of the same material. Furthermore, the grid formed by the conductive material is divided in the axial direction of the grid. By providing such a configuration, it is possible to realize a dual grid reflector capable of bringing the grid into close contact with the reflecting surface, preventing a decrease in mirror surface accuracy, and improving the stability of communication.

  DESCRIPTION OF SYMBOLS 1 Dual grid reflector, 2 Conductive material (grid), 3 Mirror surface shaping | molding die, 4 Honeycomb core (joining member), 5 Outer skin (rear surface reflection mirror), 6 Inner skin (front surface reflection mirror), 7 Release film, 8 Flexible film, 9 breather, 10 bagging film, 11 sealing material.

Claims (5)

A front reflecting mirror provided with a grid so as to reflect a specific polarization and transmit a polarization orthogonal to the polarization;
A rear reflector that is a conductor surface without the grid;
A dual grid reflector comprising: a coupling member that couples the front reflector and the rear reflector;
The dual grid characterized in that the grid provided on the front reflecting mirror is formed of a grid-patterned conductive material and is divided into three or more division numbers in an axial direction corresponding to the grid patterning direction. Grid reflector. The dual grid reflector according to claim 1,
The grid is made of metal, and is a dual grid reflector. The dual grid reflector according to claim 1,
The said grid is comprised with the carbon fiber, The dual grid reflector characterized by the above-mentioned. The dual grid reflector according to claim 3,
The grid is formed by coating the surface of the carbon fiber with a metal. A front reflecting mirror provided with a grid so as to reflect a specific polarization and transmit a polarization orthogonal to the polarization;
A rear reflector that is a conductor surface without the grid;
A manufacturing method of a dual grid reflector, comprising: a coupling member that couples the front reflector and the rear reflector;
After integrally molding the flexible film and the conductive material, dividing the grid formed by the grid patterned conductive material in an axial direction corresponding to the grid patterning direction by an etching process;
The flexible film and the conductive material that have been integrally molded and then etched so that the inner skin and the conductive material face each other on the inner skin previously laminated on the mirror mold are transferred. And steps to
Removing the flexible film;
By performing pressure treatment and heat treatment over a predetermined time, the front reflector and the rear reflector made of the inner skin and the conductive material are integrally molded, and the grid is divided in the axial direction. Forming a dual grid reflector comprising: a method of manufacturing a dual grid reflector.

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