JP6482493B2 - Grid reflector and grid reflector manufacturing method - Google Patents

Description

  The present invention relates to a grid reflector subjected to conductive grid patterning and a method of manufacturing a grid reflector. In particular, the present invention relates to a grid reflector used for an antenna mounted on an artificial satellite.

  Many reflectors mounted on artificial satellites are usually made of a composite material using fibers as reinforcing materials in order to achieve high rigidity and light weight. Conventionally, various structures such as a sandwich panel system, a dual reflector system, a membrane reflector system, and a mesh system are known as reflector structures.

The dual reflector system is an antenna composed of a front reflector and a rear reflector. The front reflector reflects a specific polarization. On the other hand, the rear reflector has a structure that reflects the polarized light transmitted through the front reflector. In order to reflect a specific polarized wave by the front reflector, there is a method of applying grid pattern having conductivity such as copper on the reflector surface.
Patent Document 1 discloses a technique for obtaining a film with a grid in which a grid having a predetermined pattern is formed by performing metal plating on a flexible film and performing etching. Then, the formed film with a grid is brought into close contact with a skin having a curved surface with the grid side down, and is heated and pressure-molded. Thereafter, the reflector is manufactured by transferring the grid to the skin by peeling off the film. However, in the technique of Patent Document 1, there is a problem that the grid connected in the axial direction peels off from the reflecting surface without following the shape of the reflector.
In contrast to such a problem of Patent Document 1, Patent Document 2 discloses a technique for patterning by suppressing the wrinkles and bending of a curved surface by dividing the grid in the axial direction. However, in the technique of Patent Document 2, the method itself of pasting a patterned copper foil on a film on a curved reflector is the same as that of Patent Document 1. Therefore, it is difficult to completely follow the reflector having a curved surface shape when transferring from a flat surface to a curved surface. In particular, those having a small curvature and having a complicated modified curved surface generate wrinkles and bends, and it has been difficult to completely solve the problem of peeling.

Japanese Unexamined Patent Publication No. 08-037418 JP 2012-015861 A

  In the conventional technology, it is difficult to accurately transfer flat grid patterning to a curved reflector without wrinkles or bends, and there is a problem that grid pattern peeling occurs due to wrinkles or bends. there were. If peeling occurs, the reflection performance of the reflector is affected, and thus correction is required. However, the peeling correction work is largely dependent on the skill level of the operator.

  An object of this invention is to prevent peeling of a grid by modeling a three-dimensional grid pattern.

The grid reflector according to the present invention is a grid reflector in which a conductor grid is formed on the reflector.
The grid is
It has a grid surface that reflects radio waves and a grid back surface that is the back surface of the grid surface, and includes a convex portion that protrudes from the grid back surface toward the reflector and has an end portion joined to the reflector. It was.

  According to the grid reflector according to the present invention, the grid is a convex portion protruding toward the reflector from the back surface of the grid, and the end portion includes a convex portion joined to the reflector. Are firmly joined to each other, and it is possible to prevent the peeling of the grid.

1 is a configuration diagram of a grid 100 according to Embodiment 1. FIG. 1 is a configuration diagram of a grid reflector 10 according to Embodiment 1. FIG. FIG. 3 is a partially enlarged configuration diagram of the grid reflector 10 according to the first embodiment. FIG. 3 is a flowchart showing a grid reflector manufacturing method S100 according to the first embodiment. The flowchart which shows the grid reflector manufacturing method S100a which is a modification of Embodiment 1. FIG.

Embodiment 1 FIG.
*** Explanation of configuration ***
FIG. 1 is a diagram illustrating a configuration of a grid 100 according to the present embodiment.
FIG. 2 is a diagram illustrating a configuration of the grid reflector 10 according to the present embodiment.
FIG. 3 is a partially enlarged configuration diagram of the grid reflector 10 of FIG.
The configuration of the grid 100 and the grid reflector 10 according to the present embodiment will be described with reference to FIGS. 1 to 3.
As shown in FIG. 2, in the grid reflector 10 according to the present embodiment, a conductive grid 100 is formed on the surface of a reflector 200 that transmits radio waves. Thereby, the grid reflector 10 can transmit only polarized waves in a certain direction, and can selectively reflect radio waves. The grid reflector 10 according to the present embodiment can be applied to, for example, a reflector for artificial satellite mounting, particularly a dual reflector type antenna. The grid reflector 10 is also referred to as an antenna reflector.
The grid 100 has a predetermined pattern. The grid 100 is also referred to as grid patterning or conductive patterning.

As shown in FIGS. 1 and 3, the grid 100 includes a grid surface 110 that reflects radio waves and a grid back surface 120 that is the back surface of the grid surface 110. The grid surface 110 is also referred to as a radio wave reflecting mirror surface. In addition, the grid 100 includes a convex portion 130 that protrudes from the grid back surface 120 toward the reflector 200, and includes a convex portion 130 whose end portion is joined to the reflector 200. The convex part 130 has a joint surface 131 joined to the reflector 200 at the end part. Since the grid 100 has the convex portion 130 on the grid back surface 120, the grid 100 has irregularities on the grid back surface 120 side.
As shown in FIG. 3, the reflector 200 is in contact with the joint surface 131, the side surface 132, and the grid back surface 120. That is, the reflector 200 is joined to the joining surface 131 and enters a recessed portion formed between the convex portion 130 and the convex portion 130.

  In the grid 100, an angle θ formed by the side surface 132 of the convex portion 130 and the grid back surface 120 is an acute angle. By setting the angle θ to an acute angle, when a peeling force is applied to the reflector 200 and the grid 100, the anchor effect is activated and the strength of the bonding can be increased.

  As for the grid 100, it is preferable that thickness L1 from the grid surface 110 to the grid back surface 120 is 5 micrometers-200 micrometers. If the thickness L1 of the grid 100 is less than 5 μm, it is difficult to form the shape. If the thickness L1 is greater than 200 μm, satisfactory electrical characteristics cannot be obtained due to thermal deformation in a heat cycle at high and low temperatures. Note that the thickness L1 of the grid 100 is more preferably 10 μm to 80 μm because both the manufacturability and functionality can be satisfied.

  Moreover, it is preferable that the convex part 130 is 5-100 micrometers in height L2 from the grid back surface 120. FIG. If the height L2 of the convex portion 130 is smaller than 5 μm, the effect of developing the mechanical joint strength with the reflector 200 is small. If the height L2 is larger than 100 μm, the volume of the grid 100 is increased, which increases the weight. The height L2 of the convex portion 130 is particularly preferably in the height range of 10 μm to 80 μm because the mechanical strength and the lightening effect can be balanced.

The reflector 200 is a material having radio wave permeability. Specifically, it is an aramid fiber prepreg.
For the grid 100, it is preferable to use copper having high electrical conductivity or a fiber-reinforced composite material including carbon fiber, which has a large lightening effect and a low linear expansion coefficient.

*** Explanation of manufacturing method ***
A grid reflector manufacturing method S100 according to the present embodiment will be described with reference to FIG.
The grid reflector manufacturing method S100 includes a support jig manufacturing step S110, a grid forming step S120, a reflector forming step S130, and a grid reflector demolding step S140.

<Support jig manufacturing step S110>
First, a support jig 300 for supporting the reflector 200 and the grid 100 is manufactured using a three-dimensional modeling method (also referred to as a three-dimensional modeling apparatus). Since the mirror surface accuracy of the grid reflector 10 is determined by the shape of the support jig 300, the surface accuracy is important, and it is preferable that the support jig 300 is manufactured by an ink jet method or a powder sintering lamination method in which the surface accuracy is easily obtained. In addition, since it is necessary to remove the grid reflector 10 from the support jig 300, a material having releasability is used for the surface of the support jig 300, or a release agent or the like is used on the surface of the support jig 300. It is preferred to apply the components.

<Grid forming step S120>
In the grid forming step S <b> 120, the grid 100 having the convex portion 130 that protrudes from the grid back surface 120 facing the reflector 200 toward the reflector 200 and includes the joint surface 131 that joins the reflector 200 is formed. The grid 100 is integrally formed.
Here, a three-dimensional modeling method (three-dimensional modeling apparatus) for forming the grid 100 and the reflector 200 will be described. In the present embodiment, there is no particular limitation on the three-dimensional modeling method, for example, a 3D printer, and an optical modeling method, a powder sintering lamination method, a heat melting lamination method, and an inkjet method can be employed. In particular, the patterning of the grid 100 requires highly accurate modeling, and it is preferable to use a powder sintering lamination method or a heat melting lamination method.

In the grid forming step S <b> 120, the grid 100 is formed on the support jig 300. As the conductive material, a metal powder or a resin containing a conductive material can be used.
In the grid forming step S120, the grid 100 is formed so that the angle θ formed by the side surface 132 of the convex portion 130 and the grid back surface 120 is an acute angle. In the grid forming step S120, the grid 100 is formed so that the thickness L1 is 5 μm to 200 μm. Further, the grid 100 is formed so that the height L2 of the convex portion 130 is 5 μm to 100 μm.

<Reflector forming step S130>
In the reflector forming step S130, the reflector 200 is formed on the joint surface 131 of the grid 100. In the grid reflector manufacturing method S100 according to the present embodiment, the reflector 200 can also be manufactured by a three-dimensional modeling method (three-dimensional modeling apparatus). In particular, since the reflector 200 is required to be lightweight and have radio wave transmission characteristics, it is preferable to use an ink jet method or a heat melting lamination method.
Specifically, after the grid 100 is formed, the reflector 200 is manufactured by stacking prepreg or the like on the joining surface 131 side of the grid 100.

<Grid reflector demolding step S140>
In the grid reflector demolding step S <b> 140, the grid reflector 10 is demolded from the support jig 300. As described above, the grid reflector 10 can be easily demolded by using a material having releasability on the surface of the support jig 300 or by applying a component such as a mold release agent to the surface of the support jig 300. It becomes.

  This is the end of the description of the grid reflector manufacturing method.

*** Other configurations ***
In the present embodiment, the reflector forming step S130 is performed after the grid forming step S120. However, the grid 100 and the reflector 200 may be simultaneously manufactured by the three-dimensional modeling apparatus.
FIG. 5 is a diagram showing a grid reflector manufacturing method S100a which is a modification of the present embodiment.
5 includes a reflector and grid forming step S150 instead of the grid forming step S120 and the reflector forming step S130 of FIG.
In the reflector and grid forming step S150, the grid 100 and the reflector 200 are simultaneously manufactured by the three-dimensional modeling apparatus. In the reflector and grid forming step S150, the grid forming step S120 and the reflector forming step S130 may be performed in parallel, or the grid 100 and the reflector 200 may be integrally formed.
Thus, the grid reflector 10 can be manufactured more efficiently by simultaneously manufacturing the grid 100 and the reflector 200 with the three-dimensional modeling apparatus.

  Moreover, in this Embodiment, although the convex part protrudes in one direction of the substantially perpendicular direction from the grid back surface 120, you may protrude in several directions, such as an oblique direction. Specifically, the uneven shape may be a shape that intersects not only in one direction but in the same plane. By using the intersecting shape, it is possible to effectively cope with the peeling force from each direction.

*** Explanation of effects of this embodiment ***
According to the grid reflector 10 according to the present embodiment, there are a step in which a grid having irregularities on the surface is formed by a three-dimensional modeling apparatus, and a step in which the reflector is formed and integrated on the formed grid. In this manner, by forming a three-dimensional grid pattern with the three-dimensional modeling apparatus, it is possible to perform strong bonding by the anchor effect, and prevent peeling of patterning. In addition, the three-dimensional modeling apparatus enables accurate patterning of a curved surface shape, and can improve the polarization reflection performance of the reflector.
Moreover, since the grid 100 is provided with a convex portion on the back surface of the grid, the grid patterning has irregularities on one side, and is mechanically joined to the reflector. In this way, peeling can be further prevented by mechanically joining the reflector and the grid.

As mentioned above, although embodiment of this invention was described, any one may be employ | adopted among what is demonstrated as a "process" in description of this embodiment, and some arbitrary combinations are employ | adopted. May be.
Moreover, although the grid reflector 10 which concerns on this Embodiment can be manufactured with the grid reflector manufacturing method mentioned above, if the structure of the grid reflector 10 can be created, it will not be limited to the said manufacturing method.
Moreover, you may implement combining several parts among this embodiment. Alternatively, this embodiment may be partially implemented. In addition, this embodiment may be implemented in any combination as a whole or in part.
In addition, said embodiment is an essentially preferable illustration, Comprising: It does not intend restrict | limiting the range of this invention, its application thing, or a use, A various change is possible as needed. .

  10 grid reflector, 100 grid, 110 grid surface, 120 grid back surface, 130 convex portion, 131 joint surface, 132 side surface, 200 reflector, 300 support jig, θ angle, L1 thickness, L2 height, S100, S100a Grid reflector manufacture Method, S110 support jig manufacturing step, S120 grid forming step, S130 reflector forming step, S140 grid reflector demolding step, S150 reflector and grid forming step.

Claims (11)

The surface of the reflector which is formed of a material having radio wave transmittance in a grid reflector grid is formed of a conductive material,
The grid is
It has a grid surface that reflects radio waves and a grid back surface that is the back surface of the grid surface, and includes a convex portion that protrudes from the grid back surface toward the reflector and has an end portion joined to the reflector. Grid reflector.   The grid reflector according to claim 1, wherein an angle formed between a side surface of the convex portion and the back surface of the grid is an acute angle.   The grid reflector according to claim 1, wherein the convex portion has a joint surface joined to the reflector at the end portion. The grid is
The grid reflector according to any one of claims 1 to 3, wherein a thickness from the grid surface to the grid back surface is 5 µm to 200 µm. The convex portion is
The grid reflector according to any one of claims 1 to 4, wherein a height from the back surface of the grid is 5 µm to 100 µm.   The grid reflector according to any one of claims 1 to 5, wherein the grid is a fiber-reinforced composite material including carbon fibers. In a grid reflector manufacturing method for manufacturing a grid reflector in which a grid of conductors is formed on the surface of a reflector formed of a material having radio wave permeability,
A grid forming step of forming a grid having a convex portion having a bonding surface to be bonded to the reflector a convex portion projecting from the grid back surface facing the reflector,
A reflector manufacturing method comprising: a reflector forming step of forming the reflector on the joint surface. The grid forming step
The grid reflector manufacturing method according to claim 7, wherein the grid is formed such that an angle formed between a side surface of the convex portion and the back surface of the grid is an acute angle. The grid forming step
The grid reflector manufacturing method according to claim 7 or 8, wherein the grid is formed so that a thickness from a grid surface reflecting radio waves to a back surface of the grid on the back surface of the grid surface is 5 µm to 200 µm. The grid forming step
The grid reflector manufacturing method according to any one of claims 7 to 9, wherein the grid is formed so that a height of the convex portion is 5 µm to 100 µm. The grid forming step
The grid reflector manufacturing method according to any one of claims 7 to 10, wherein the grid is formed of a fiber-reinforced composite material including carbon fibers.

Images