WO2020191911A1

WO2020191911A1 - Method for producing luneburg lens

Info

Publication number: WO2020191911A1
Application number: PCT/CN2019/087968
Authority: WO
Inventors: 郑洪振; 芦永超; 窦英乾; 尚春辉
Original assignee: 佛山市粤海信通讯有限公司
Priority date: 2019-03-26
Filing date: 2019-05-22
Publication date: 2020-10-01
Also published as: CN109994837A

Abstract

Provided in the present invention is a novel method for producing a Luneburg lens, which may produce high-performance Luneburg lenses that have stable indexes under the conditions of room temperature, normal pressure and low costs. The method comprises the following steps: preparing a half housing as a lens half housing, spraying an adhesive on an inner wall surface of the lens half housing, coating a prefabricated first particulate material into the lens half housing, using a punch to press the first particulate material to form a first dielectric layer, spraying the adhesive on a surface of the first dielectric layer, coating a second particulate material on the surface of the first dielectric layer and pressing, and so on to produce a half Luneburg lens, and then bonding two half Luneburg lenses together to form a Luneburg lens. The described method for producing the Luneburg lens of the present invention has the advantages of a simple production process, low production costs, a light mass, easy control of lens characteristics, excellent lens performance indexes, etc.

Description

Lumber lens production method

Technical field

The present invention relates to the field of communication equipment production, and more specifically, to a method for producing Lumber lens.

Background technique

Lumber lens technology, proposed by RK Luneberg in 1944 based on geometric optics, is used as an antenna and scatterer application, mainly used in fast scanning systems, satellite communication systems, automotive collision avoidance radars, and radar reflectors.

Theoretically, the dielectric constant of the dielectric material used for the Lumber lens should change continuously from 2 to 1 from the center of the sphere to the outer diameter, following a certain mathematical law. However, such an ideal medium does not exist in nature, so discrete spherical shells of layered design are often used in actual design instead.

In order to make the actual performance of the Lumber lens close to the theoretical performance, a variety of Lumber lens production solutions exist, such as:

CN201510084764.8 A manufacturing method of a hemispherical Lumber lens antenna;

CN201510065135.0 A production method of Lumber lens with open structure;

CN201610015855.0 Very low profile cylindrical Lumbert lens antenna based on a new dielectric filling method;

CN201610393370.5 Lumber lens antenna manufacturing method;

CN201520112992.7 A Lumber lens antenna.

The above technical solutions include: drilling method, controlling the dielectric constant of the material through the proportion of the material volume occupied by the hole, but this method is difficult to control the density and precision of the drilling, the structure is complex, the manufacturing difficulty is high, and the weight is not suitable Mass production.

It also includes a layer-by-layer foaming method. Based on the middle core, it is wrapped layer by layer and foamed layer by layer. This is currently the most commonly used method to obtain a stepped dielectric constant foam material, but whether it is physical foaming, Chemical foaming requires strict temperature and pressure control, and is usually produced under high temperature and high pressure. Due to the low thermal conductivity of the foamed material, uneven foaming will occur. The process technology is complicated, special equipment is required, the yield is low, and the cost is very high.

It also includes a layered design method. The layers are made independently first, and then these layers are glued together. However, the interface between the layers is obvious. The discontinuity of the dielectric constant between the electromagnetic material layers will increase the lens. Electromagnetic loss reduces the radiation efficiency of the antenna.

Therefore, it is necessary to improve the existing Lumber lens production method.

technical problem

The technical problem to be solved by the present invention is to provide a new method for producing Lumber lens, which can manufacture Lumber lens with stable index and high performance under the conditions of room temperature, normal pressure and low cost.

Technical solutions

The following technical solutions are adopted:

The production method of Lumber lens includes the following steps:

Step 1): Prepare the half shell as the lens half shell, which is made of the material with the lowest dielectric constant as possible;

Step 2): Spray adhesive on the inner wall surface of the lens half shell, and spread the prefabricated first granular material into the lens half shell;

Step 3): Press the first granular material with a punch to make the first granular material adhere to the inner wall of the lens half-shell and thus form a layer with a certain thickness, which is called the first Dielectric layer

Step 4): Measure the thickness of the first dielectric layer at this time, if the thickness reaches the preset value, go to step 5); if the thickness does not reach the preset value, continue to spray adhesive on the surface of the first dielectric layer, and then continue to use The first kind of granular material is laid on it and pressed with a punch to make the thickness of the first medium layer reach the preset value;

Step 5) Spray adhesive on the surface of the first medium layer, and spread the prefabricated second granular material on the surface of the first medium layer;

Step 6): Press the second kind of granular material with a punch to make the second kind of granular material adhere to the first medium layer and thereby form another layer with a certain thickness. This layer is called the second Dielectric layer

Step 7): Measure the thickness of the second dielectric layer at this time, if the thickness reaches the preset value, go to step 8); if the thickness does not reach the preset value, continue to spray adhesive on the surface of the second dielectric layer, and then continue to use Lay the second kind of granular material and press with a punch to make the thickness of the second medium layer reach the preset value;

Step 8): Comparing steps 5) to 7), make the remaining dielectric layers by analogy;

Step 9): Spray adhesive on the surface of the final dielectric layer, fill the final prefabricated granular material into the cavity of the final dielectric layer, and then supplement it with several pressures, spray adhesives and refills Granular material to form a half core in the cavity of the final dielectric layer;

Step 10): So far, the lens half-shell is completely filled to become a half Lumber lens;

Step 11): Repeat step 1) to step 10) to obtain the other half of Lumbert lens;

Step 12): Glue the two halves of Lumber lens together to form a Lumber lens.

The Lumber lens production method adopts the method of adding prefabricated granular materials layer by layer from outside to inside.

Most of the existing technical solutions are to firstly fabricate materials with different dielectric constants into hemispherical shells, and then combine them into Lumbert lenses. Due to the sudden change of the dielectric constant of the adjacent housings, which causes electromagnetic wave reflection, the electromagnetic loss of such a Lumbert lens is very large. In the production method of the spherical Lumber lens of the present invention, the two-phase composite part is formed between the two dielectric layers due to the mutual interlocking of the particles. The dielectric constant of the two-phase composite part is between the dielectric constants of the two particulate materials. Between the dielectric constants, the dielectric constant between the dielectric layers of such a Lumber lens, and between the dielectric layer and the half core is smooth, thereby reducing the electromagnetic loss of the Lumber lens product.

The profile shape of the Lumber lens produced by this production method is preferably a three-dimensional shape that can be separated axisymmetrically. For example, the Lumber lens produced can be round or spheroid or spheroid or spheroid or cylindrical. In addition, when the Lumber lens produced is cylindrical, the contour shape of the half of the Lumber lens can be cylindrical (half of the two symmetrical halves along the lateral direction of the cylinder), or half. Cylindrical (half of the cylinder divided into two symmetrical halves along the longitudinal direction).

In this production method, the total number of dielectric layers is preferably between 3-20.

In the production method, the structure of the granular material used in each dielectric layer and half of the inner core is preferably: a granular or fibrous metal conductor is mixed into a non-metallic material.

In this production method, from the first dielectric layer to half of the core, the average diameter of the corresponding granular material is preferably getting smaller and smaller.

In this production method, from the first dielectric layer to the core half, the dielectric constant of the corresponding granular material is better to be larger and larger.

In this production method, from the first dielectric layer to half of the inner core, the shape of the corresponding granular material can be cubic or spherical.

In this production method, during step 1) to step 10), the lens half-shell is preferably always in a mold capable of stabilizing the shape of the lens half-shell.

In this production method, various granular materials can be spread by using a fixed paddle to poke the granular material when the lens half-shell is in a rotating state, or use a rotating paddle when the lens half-shell is in a fixed state The granular material is moved for covering, or when the lens half-shell is in a rotating state, a rotating paddle is used to move the granular material for covering. In this way, various granular materials can be evenly distributed.

In this production method, it is best to replace a punch that matches the preset specifications of the next dielectric layer every time the production of a dielectric layer is completed.

Beneficial effect

The production method of the Lumber lens of the present invention has the advantages of simple production process, low production cost, light weight, easy control of lens characteristics, and excellent lens performance indicators.

Description of the drawings

Figure 1 is a schematic diagram of the structure of the target product of Example 1;

2 is a schematic diagram of the structure in which the first dielectric layer and the second dielectric layer of the embodiment 1 are embedded with each other;

FIG. 3 is a schematic diagram of the structure of the half Lumber lens of embodiment 1;

4 is a schematic diagram of the structure of the target product of Embodiment 2.

Description of reference signs: 10-lens half shell; 11-first dielectric layer, 12-second dielectric layer, 13-third dielectric layer; 14-fourth dielectric layer; 15-fifth dielectric layer; 16-half side Kernel. To

Embodiments of the invention

The content of the utility model will be further explained below in conjunction with embodiments.

Example 1

As shown in FIG. 1, this embodiment takes the production of a spherical Lumbert lens with 5 dielectric layers as an example. Such a Lumber lens is, from the outside to the inside, the lens half shell 10, the first dielectric layer 11, the second dielectric layer 12, the third dielectric layer 13, the fourth dielectric layer 14, the fifth dielectric layer 15, and the half core 16 .

The processing method is as follows:

Step 1): Prepare a hemispherical shell as the lens half shell 10.

Step 2): Put the lens half-shell 10 into a hemispherical concave mold, the outer wall of the lens half-shell 10 is in contact with the hemispherical concave mold, this hemispherical concave mold is used to fix the lens half-shell 10 and bear the punch In order to prevent the lens half-shell 10 from being deformed by force. Spray adhesive on the inner wall surface of the lens half-shell 10, pour the prefabricated first granular material into the lens half-shell 10, and use a paddle rotating along a fixed axis to dial the first granular material to make The first granular material is uniformly distributed in the lens half-shell 10. A circular arc side is formed on the pick as its working side, and the center of the circle corresponding to the circular arc side is concentric with the center of the lens half shell 10. The first type of particulate material is used to make the first dielectric layer 11, the second type of particulate material is used to make the second dielectric layer 12, and so on. The sixth type of granular material is used to make half of the core 16. In this embodiment, the granular material of each dielectric layer and the granular material of the half core 16 are all spherical.

Step 3): The punch is a mold with a spherical movement. In contrast, the hemispherical die is a fixed mold. Use a punch to press and hold the first granular material so that the first granular material adheres to the inner wall of the lens half shell 10 and thereby forms a hemispherical shell-shaped layer with a certain thickness. It is called the first dielectric layer 11. The pressure exerted by the punch is not very strong, and it cannot cause excessive deformation of the granular material.

Step 4): Measure the thickness of the first dielectric layer 11 at this time. If the thickness reaches the preset value, go to step 5); if the thickness does not reach the preset value, continue to spray adhesive on the surface of the first dielectric layer 11, and then Continue to cover it with the first granular material, and press with a punch to make the thickness of the first dielectric layer 11 reach the preset value.

Step 5): Spray adhesive on the surface of the first medium layer 11, pour the prefabricated second granular material into the lens half-shell 10, and use a pick to move the second granular material to make the second The particulate material is uniformly distributed on the surface of the first dielectric layer 11. The diameter of the second kind of granular material can be equal to or smaller than the diameter of the first kind of granular material. The pursuit is that the depth of mutual embedding between the first kind of granular material and the second kind of granular material is as deep as possible. The more uniform the fit, the better, as shown in Figure 2.

Step 6): Use a punch to press the second type of granular material to make the second type of granular material adhere to the first dielectric layer 11 and thereby form a hemispherical shell-shaped layer with a certain thickness, which is called It is the second dielectric layer 12. It should be noted that the spherical diameter of the working surface of the punch used at this time is smaller than that of the punch used in step 3). That is, before this step, there may be a step of replacing the punch, or there may be a step of transferring the hemispherical die to another station where a punch with a smaller spherical diameter is arranged on the other station.

Step 7): Measure the thickness of the second dielectric layer 12 at this time. If the thickness reaches the preset value, go to step 8); if the thickness does not reach the preset value, continue to spray adhesive on the surface of the second dielectric layer 12, and then Continue to cover it with the second granular material, and press with a punch to make the thickness of the second dielectric layer 12 reach the preset value;

Step 9): The final dielectric layer is the fifth dielectric layer 15. The adhesive is sprayed on the surface of the fifth dielectric layer 15, and the final prefabricated particulate material, that is, the sixth particulate material, is filled into the fifth dielectric layer 15. In the cavity, it is then supplemented with several times of pressure, supplemental spraying of the adhesive and supplement of the sixth particulate material, so that a hemispherical half core 16 is finally formed in the cavity of the fifth medium layer 15.

Step 10): So far, the lens half-shell 10 is completely filled to become a half Lumber lens, and the half Lumber lens is hemispherical, as shown in FIG. 3. At this time, it is desirable that the exposed surfaces of all the dielectric layers and the half inner core 16 are sufficiently flush with the hemispherical bottom surface of the lens half shell 10.

Step 11): Repeat step 1) to step 10) to obtain the other half of Lumbert lens;

Step 12): Glue two halves of Lumber lens together to form a spherical Lumber lens. In the process of bonding, the pursuit is that the depth of the inter-engaging between the granular materials is as deep as possible, and the uniformity of inter-engaging is as uniform as possible.

So far, the production of spherical Lumber lens is completed.

In this embodiment, the granular materials used for each dielectric layer and the half-core core 16 are all prepared in advance, and their structure is: a non-metal foamed material is mixed with a fibrous metal conductor. As long as the number or diameter of the metal conductors mixed in a single particle is controlled, the dielectric constant of these particle materials can be controlled. For example, if more metal conductors are mixed, the dielectric constant will increase; if more metal conductors are mixed, the dielectric constant will be greater. One of the granular materials can be referred to as "AN ARTIFICIAL DIELECTRIC MATERIAL AND A METHOD OF MANUFACTURING THE SAME", the publication number is WO2009078807, and the publication date is the patent document on June 25, 2009.

When the dielectric constant and size of each granular material are well set, the Lumber lens produced by the production method of this embodiment has the advantages of light weight, easy control of lens characteristics, and excellent lens performance indicators.

Example 2

In this embodiment, the production of a rotating ellipsoidal Lumber lens with 5 dielectric layers is taken as an example.

A rotating ellipsoid can be understood as a three-dimensional shape formed by rotating an ellipse along its long axis. As shown in Figure 4, such a three-dimensional shape is a three-dimensional shape that can be separated axisymmetrically. There are two ways to separate it axisymmetrically. One kind is to divide the three-dimensional shape into two axisymmetric halves by the plane passing the long axis of the ellipse, for example, the plane A in Figure 4 is used to separate; the other is the plane passing the short axis of the ellipse and perpendicular to the long axis The three-dimensional shape is divided into two axially symmetric halves, for example, in the B plane of FIG. 4.

In the two halves obtained by the previous method, none of the halves are rotating bodies. Therefore, when making half of the Lumber lens, the difference from Embodiment 1 is that you cannot use a paddle rotating along a fixed axis to move the media. Layer of granular material for uniform spreading. In the two halves obtained by the latter method of separation, any half is a rotating body. Therefore, when making half of the Lumber lens, you can use a paddle rotating along a fixed axis to move the media as in Example 1. Layer of granular material for uniform spreading. In theory, the latter separation method is more preferable.

If the Lumber lens that you want to make is cylindrical, you will also face the same problem of selecting the cutting position.

This specification enumerates only the preferred embodiments of the present utility model, and all equivalent technical transformations made under the working principles and ideas of the present utility model shall be regarded as the protection scope of the present utility model.

Claims

The production method of Lumber lens is characterized by the following steps:

Step 1): Prepare the half shell as the lens half shell, which is made of the material with the lowest dielectric constant as possible;

Step 2): Spray adhesive on the inner wall surface of the lens half shell, and spread the prefabricated first granular material into the lens half shell;

Step 3): Press the first granular material with a punch to make the first granular material adhere to the inner wall of the lens half-shell and thus form a layer with a certain thickness, which is called the first Dielectric layer

Step 4): Measure the thickness of the first dielectric layer at this time, if the thickness reaches the preset value, go to step 5); if the thickness does not reach the preset value, continue to spray adhesive on the surface of the first dielectric layer, and then continue to use The first kind of granular material is laid on it and pressed with a punch to make the thickness of the first medium layer reach the preset value;

Step 5) Spray adhesive on the surface of the first medium layer, and spread the prefabricated second granular material on the surface of the first medium layer;

Step 6): Press the second kind of granular material with a punch to make the second kind of granular material adhere to the first medium layer and thereby form another layer with a certain thickness. This layer is called the second Dielectric layer

Step 7): Measure the thickness of the second dielectric layer at this time, if the thickness reaches the preset value, go to step 8); if the thickness does not reach the preset value, continue to spray adhesive on the surface of the second dielectric layer, and then continue to use Lay the second kind of granular material and press with a punch to make the thickness of the second medium layer reach the preset value;

Step 8): Comparing steps 5) to 7), make the remaining dielectric layers by analogy;

Step 9): Spray adhesive on the surface of the final dielectric layer, fill the final prefabricated granular material into the cavity of the final dielectric layer, and then supplement it with several pressures, spray adhesives and refills Granular material to form a half core in the cavity of the final dielectric layer;

Step 10): So far, the lens half-shell is completely filled to become a half Lumber lens;

Step 11): Repeat step 1) to step 10) to obtain the other half of Lumbert lens;

Step 12): Glue two halves of Lumber lens together to form a Lumber lens.
The method for producing the Lumber lens according to claim 1, wherein the profile shape of the Lumber lens is a three-dimensional shape that can be separated axisymmetrically.
The method for producing Lumbert lens according to claim 1, characterized in that the total number of dielectric layers is between 3-20.
The method for producing Lumbert lens according to claim 1, characterized in that the structure of the granular material used in each dielectric layer and half of the inner core is: mixing granular or fibrous metal conductors in non-metallic materials.
The method for producing Lumbert lens according to claim 1, characterized in that: from the first dielectric layer to the half core, the average diameter of the corresponding granular material becomes smaller and smaller.
The method for producing Lumbert lens according to claim 1, characterized in that: from the first dielectric layer to the half core, the dielectric constant of the corresponding granular material becomes larger and larger.
The method for producing Lumbert lens according to claim 1, characterized in that: from the first dielectric layer to half of the inner core, the shape of the corresponding granular material is cubic or spherical.
The method for producing a Lumbert lens according to claim 1, wherein the lens half-shell is always in a mold capable of stabilizing the shape of the lens half-shell during steps 1) to 10).
The method of producing Lumbert lens according to claim 1, characterized in that: when the lens half-shell is in a rotating state, a fixed pick is used to move the granular material for covering, or the lens When the half-shell is in a fixed state, a rotating paddle is used to dial the granular material for covering, or when the lens half-shell is in a rotating state, a rotating paddle is used to dial the granular material for covering.
The method for producing Lumbert lens according to claim 1, characterized in that: each time the production of one dielectric layer is completed, a punch that matches the preset specifications of the next dielectric layer is replaced.