Composite all-welded aluminum honeycomb core waveguide window and production process thereof

[0041] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments.

[0042] plan 1

[0043] Reference figure 1 , 2 , 3, 4, 5, the production process steps of a composite fully welded aluminum honeycomb core waveguide window:

[0044] S1. Calculate the waveguide depth according to the electromagnetic field shielding performance requirements required by the customer, select the side length of the honeycomb core 4, the height of the honeycomb core 4, and the aluminum foil thickness of the aluminum honeycomb core. The selected aluminum foil is an aluminum composite material, and the brazing filler metal Laminated on the surface of aluminum foil;

[0045] S2. According to the requirements of the multi-cell structure of the regular hexagonal metal honeycomb core, the coil is cut according to the required aluminum foil height, and then calculated according to the sheet area required by the customer to cut a certain number of aluminum foil strips;

[0046] S3. The cut aluminum foil is rolled into a corrugated structure;

[0047] S4. Clean and dry the surface of the cut corrugated aluminum foil;

[0048] S5. First arrange the semi-regular hexagonal honeycomb strips according to the law, and then perform spot welding to simply relatively fix them into a regular hexagonal metal honeycomb core;

[0049] S6. The upper skin aluminum plate 1 and the flange plate 6 made of multilayer composite materials of the upper brazing filler metal are firstly opened 2 and then the upper and lower skins and the side to be connected to the honeycomb core 4 are sprayed with solder respectively. At the same time, spray flux on the woven regular hexagonal aluminum honeycomb core 4; then assemble skin aluminum plates 1 and flanges 6 on the upper and lower sides of the regular hexagonal aluminum honeycomb core to form a hexagonal metal aluminum honeycomb panel structure. Clamp and fix with fixtures;

[0050] S7. Put the assembled hexagonal aluminum honeycomb structure into the brazing furnace for brazing. Before welding, tighten the tooling to ensure that the honeycomb core 4 and the honeycomb core 4, the honeycomb core 4 and the upper skin aluminum plate 1, the flange plate The welding between 6 is 100% wire connection;

[0051] S8. Perform cooling and aging treatment on the welded aluminum honeycomb panel;

[0052] S9. Cut the welded aluminum honeycomb panel from the middle of the honeycomb core into two honeycomb cores 4 with the same height. The cut honeycomb core 4 is equipped with the two accessories of the skin aluminum plate 1 and the flange 6;

[0053] S10. Take a piece of stainless steel plate 7, whose area is the same as the cross-sectional area of ​​honeycomb core 4. Punch holes on the surface of stainless steel plate 7. The punching is a hexagonal pattern. The side length and spacing of the hexagonal holes are based on the actual shielding effectiveness. It is required to calculate that the area of ​​the punched part corresponds to the area of ​​the milled window, and the hole is punched to remove burrs;

[0054] S11. Place the welded honeycomb panel fittings with flanges and windows on the bottom layer, and place a stamped hexagonal stainless steel plate 7 above this. The openings 2 of the block fittings are aligned and pressed with tooling so that the honeycomb core 4 and the stainless steel plate 7 are in a tight fit;

[0055] S12. Next, wrap the first window frame 3 and the second window frame 5 with the same size and size around the three compressed fittings, and then apply the first window frame 3, the second window frame 5 and the first window frame 3. The connecting part of the second window frame 5 and the flange plate 6 is seamlessly welded, and the connecting part of the first window frame 3, the second window frame 5 and the upper skin aluminum plate 1 is seamlessly welded;

[0056] S13. Polish the surface after welding;

[0057] S14. In order to ensure 100% conduction between the stainless steel plate and the honeycomb core, apply shielding glue to the connecting part of the stainless steel plate and the honeycomb core as needed;

[0058] S15. Finally, spray conductive paint according to the customer's color requirements.

[0059] Scenario 2

[0060] Reference Figure 4 , 6 , 7, 8, 11, the production process steps of a composite fully welded aluminum honeycomb core waveguide window:

[0061] S1. Calculate the waveguide depth according to the electromagnetic field shielding performance requirements required by the customer, select the side length of the honeycomb core 4, the height of the honeycomb core 4, and the aluminum foil thickness of the aluminum honeycomb core. The selected aluminum foil is an aluminum composite material, and the brazing filler metal Laminated on the surface of aluminum foil;

[0062] S2. According to the requirements of the multi-cell structure of the regular hexagonal metal honeycomb core, the coil is cut according to the required aluminum foil height, and then calculated according to the sheet area required by the customer to cut a certain number of aluminum foil strips;

[0063] S3. Lay the cut aluminum foil layer by layer, and cut out micro-holes with a diameter of 1-1.5mm at the calculated aluminum foil position. The position is to be punched on the same horizontal line at the center of each corrugated three sides to be pressed. ;

[0064] S4. The aluminum foil that has been punched after cutting is made into a corrugated structure by rolling;

[0065] S5. Clean and dry the surface of the cut corrugated aluminum foil;

[0066] S6. After placing the semi-regular hexagonal honeycomb strips in a regular arrangement, select stainless steel wires with a diameter of less than 1mm to pass through the drilled honeycomb core 4 from the three corrugated sides, so that the stainless steel wires form a mesh on a horizontal line The structure is connected to each other and fixed, and then spot welding is performed to simply relatively fix it into a regular hexagonal metal honeycomb core. The part of the worn stainless steel wire extending out of the honeycomb core 4 is tightened and fixed in one direction to ensure that the cross section of the stainless steel wire can be fixed. connected together;

[0067] S7. The upper and lower skins made of multi-layer composite materials with upper brazing filler metal are first opened 2 and then the upper and lower skins and the side to be connected to the honeycomb core 4 are sprayed with brazing agent respectively. The honeycomb core 4 with stainless steel mesh structure is sprayed with flux; then cover plates are assembled on the upper and lower sides of the regular hexagonal metal honeycomb core to form a hexagonal metal honeycomb structure, which is clamped and fixed with a fixture;

[0068] S8. Put the assembled hexagonal metal honeycomb structure into the brazing furnace for brazing. Before welding, tighten the tooling to ensure the connection line between the honeycomb core 4 and the honeycomb core 4, which is between the honeycomb core 4 and the upper and lower skins. The connecting line and connecting surface between are 100% metallurgical connection;

[0069] S9. Perform cooling aging treatment on the welded honeycomb panel;

[0070] S10. Take one welded aluminum honeycomb panel and make another welded aluminum honeycomb panel. The flange and upper skin area of ​​the second welded aluminum honeycomb panel is the same as the upper skin area of ​​the first windowed honeycomb aluminum panel.

[0071] S11. Stack the two window honeycomb aluminum plates together, with the large flange at the bottom, and place a stainless steel plate with hexagonal punching in the middle of the two window honeycomb aluminum plates. Figure 4 Or copper plate, choose to place the honeycomb aluminum plate with the upper and lower windows out of place during the placement process;

[0072] S12. Seamlessly weld the connecting parts of the two welded aluminum honeycomb panels, while ensuring that the stainless steel plate 7 or copper plate with hexagonal punching in the middle is in close fit with the two connecting window frames;

[0073] S13. Next, use two first window frames 3 and second window frames 5 of the same size to wrap around the welded aluminum honeycomb panel, and then pair the first window frame 3, the second window frame 5 and the first window The connecting parts of the frame 3, the second window frame 5 and the flange plate 6 are seamlessly welded, and the connecting parts of the first window frame 3, the second window frame 5 and the upper skin aluminum plate 1 are seamlessly welded;

[0074] S14. Polish the surface after welding;

[0075] S15. In order to ensure 100% conduction between the stainless steel wires, apply shielding glue to the overlapping parts between the stainless steel wires as required;

[0076] S16. Finally, spray conductive paint according to the customer's color requirements.

[0077] In scheme 2, the number of layers of the stainless steel mesh is adjusted according to different electromagnetic field shielding efficiency requirements.

[0078] Reference Picture 9 , 10 , You can also select a window separately as a waveguide window.

[0079] In addition, all the above three technical solutions in the present invention can form independent waveguide window structures.

[0080] Electromagnetic shielding technology is divided into three categories: electric field shielding, magnetic field shielding, and electromagnetic field shielding. In addition to adjusting the shielding effect by adjusting the length of the honeycomb core and the depth of the waveguide, different field shielding technologies are essentially different, and the shielding materials used are also different. When the shielding effect is very demanding, single-layer shielding is often difficult to meet the requirements. Multi-layer combined shielding structure can be adopted, the outer layer of the shield is made of diamagnetic material, and the inner layer is made of strong magnetic material. When the shielding layer is a multi-layer shielding composed of ferromagnetic materials and conductive materials, there should be no gap between the shielding layers. In addition, in order to maintain the integrity of the shield, the transition point can be welded to ensure better shielding effectiveness. , Maintain the continuity of the contact surface. The present invention selects aluminum honeycomb cores with different waveguide depths, different side lengths and thicknesses according to different individual frequency bands or high and low frequency electric and magnetic shielding efficiency requirements, and can also adjust the side length, spacing and spacing of the punching plate hexagons according to different shielding efficiency The number of interlayers, at the same time, the shielding effectiveness can also be adjusted by changing the materials selected for the interlayer: it can be strong magnetic materials, ferromagnetic materials, such as iron, steel and other metals, or diamagnetic materials, such as copper and other metals. . Different combinations can flexibly adjust the overall high and low frequency magnetic field shielding effectiveness of the product, making the product application more and more extensive.

[0081] The above are only preferred specific embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Anyone familiar with the technical field within the technical scope disclosed in the present invention, according to the technical solutions of the present invention and its Equivalent replacements or changes to the inventive concept should all fall within the protection scope of the present invention.