Precise knitting manufacturing method for antenna radiation array plane with any curved surface

Abstract

The invention relates to the technical field of antenna manufacturing, and particularly discloses a precise weaving manufacturing method for an antenna radiation array plane with any curved surface, which comprises the following steps of: S1, processing and manufacturing a weaving mold and a gum dipping curing tool; s2, weaving a radiation array surface matrix on the matching curved surface of the weaving mold; s3, weaving a circuit pattern and a feeder line on the radiation array surface substrate to obtain a first woven radiation surface blank; s4, weaving a resistance device on the circuit pattern to obtain a second woven radiating surface blank; s5, the second woven radiation surface blank is placed in a gum dipping and curing tool to be subjected to gum dipping and curing, and a shaped antenna woven radiation surface is obtained; and S6, demolding and cutting the woven radiating surface of the antenna. According to the invention, the antenna radiation array surface of any curved surface is manufactured, the obtained antenna radiation array surface is high in precision, small in thickness, dense in array element and firm in device, the antenna radiation array surface is attached to human skin, equipment appearance and the like in a shape following manner, and the purpose that the antenna radiation array surface of any curved surface plays an electromagnetic function is achieved.

Description

Technical Field

[0001] The present invention relates to the technical field of antenna manufacturing, and more specifically, to a precise weaving manufacturing method for an antenna radiation array surface with an arbitrary curved surface. Background Art

[0002] An antenna has the function of signal transmission, and its external radiation surface has various forms, making it an indispensable radio device in production and life.

[0003] To achieve conformal fitting of the antenna with the human skin, device shape, etc., an antenna with a radiation surface structure of an arbitrary curved surface is the future development direction; however, how to obtain a thin and light antenna radiation surface that can closely conform to an object with an arbitrary curved surface structure is a difficult problem in manufacturing.

[0004] For an antenna, the antenna radiation surface is located at the forefront, reflecting the external form of the antenna and realizing the function of receiving and transmitting electromagnetic waves of the antenna.

[0005] The antenna radiation surface includes a radiation curved surface substrate, a circuit pattern, components, etc. The curved surface substrate is prepared from high-strength, lightweight, and flexible materials, playing a role in support and weight reduction; the circuit pattern is located on the surface of the substrate and is the basis for receiving and transmitting electromagnetic waves; the electronic components are located above the pattern to match the impedance and further optimize signal transmission.

[0006] To ensure that the antenna can closely conform to the human body contour and device shape and exert the antenna performance on a special-shaped curved surface, the flexible radiation surface needs to be light in weight, high in strength, and have high three-dimensional contour accuracy and circuit pattern accuracy.

[0007] Currently, there are two technical methods in the prior art to realize the manufacturing of the curved surface antenna radiation surface: One is to use a flexible thin film material as the substrate, and the circuit pattern is combined with the substrate through printing, etching, printing, etc., and the connection of electronic components is realized through welding, mechanical connection, etc. However, the manufacturing process of this technology is complex, and the obtained curved surface radiation surface needs to be bent and bonded with the curved surface substrate, and complete fitting cannot be achieved. The bending process will cause damage to the circuit pattern and electronic components; The second is to use a fiber woven fabric as the substrate, and conductive fibers are woven into an antenna pattern on the substrate. Finally, the pattern and components are fixed on the substrate through printing, needle embroidery, bonding, sewing, etc. to prepare a flexible antenna radiation surface; this method has poor circuit pattern accuracy, large thickness (single-layer thickness > 5 mm), few array elements (single array element), and currently can only be realized in a planar state, and the preparation of an arbitrary curved surface radiation surface cannot be achieved.

[0008] Therefore, for an irregular curved surface array antenna with dense array elements, small devices, high pattern accuracy, and installation accuracy, the traditional radiation surface manufacturing technology can no longer be realized. Summary of the Invention

[0009] The technical problem to be solved by the present invention is to provide a precise weaving manufacturing method for an antenna radiation array surface with an arbitrary curved surface; the present invention realizes the manufacturing of an arbitrary curved surface of the antenna radiation array surface, obtains a radiation array surface with high precision, small thickness, dense array elements, and firm devices, realizes conformal fitting with the human skin, the shape of the device, etc., and achieves the purpose of the electromagnetic function of the antenna radiation array surface with an arbitrary curved surface.

[0010] The solution adopted by the present invention to solve the technical problem is as follows: A precise weaving manufacturing method for an antenna radiation array surface with an arbitrary curved surface specifically includes the following steps: Step S1: Process and manufacture a weaving mold with a mating curved surface and an impregnating and curing tooling with a curing cavity; Step S2: Weave a radiation array surface substrate with a thickness of 0.5 mm to 1 mm on the mating curved surface of the weaving mold; Step S3: Weave a circuit pattern and a feeder on the radiation array surface substrate and connect the circuit pattern with the feeder to obtain a first rough woven radiation surface; Step S4: Weave a resistor device on the circuit pattern to obtain a second rough woven radiation surface; Step S5: Place the second rough woven radiation surface in the impregnating and curing tooling, impregnate it with a resin glue solution, and heat and press to cure it to obtain a shaped antenna woven radiation surface; Step S6: Demold and cut the antenna woven radiation surface to obtain an antenna radiation array surface with a curved surface.

[0011] In some possible implementation manners, the radiation array surface substrate includes a bottom fiber layer woven on the mating curved surface of the weaving mold by a three-dimensional weaving machine, an intermediate fiber layer woven on the bottom fiber layer, and a top fiber layer woven on the intermediate fiber layer; the intermediate fiber layer is at least one layer.

[0012] In some possible implementation manners, the bottom fiber layer, the intermediate fiber layer, and the top fiber layer are all made of fiber filaments, and the diameter of the fiber filaments is 0.1 μm to 20 μm; the fiber filaments are made of any one or more of carbon fiber, glass fiber, aramid fiber, and ultra-high molecular weight polyethylene fiber; when weaving the radiation array surface substrate, the offset accuracy of the fiber filaments is ±50 μm.

[0013] In some possible implementation manners, when performing circuit pattern weaving in step S3, a first wire fiber is used to weave the circuit pattern on the radiation array surface substrate by a three-dimensional weaving machine; The diameter of the first wire fiber is 0.1 μm to 20 μm, and the first wire fiber is made of any one or more of gold wire, silver wire, copper wire, and molybdenum wire; When weaving the circuit pattern, the offset accuracy of the first wire fiber is ±5 μm.

[0014] In some possible embodiments, when performing feeder weaving in step S3, a feeder fiber is used to weave a feeder connected to the circuit pattern on the radiation array substrate through a three-dimensional weaving machine, and the diameter of the feeder fiber is 5 μm to 20 μm; There are multiple groups of the feeders, and one end of each group of feeders away from the circuit pattern extends to the edge of the radiation array substrate; the feeder fiber is made of a metal wire.

[0015] In some possible embodiments, when weaving the resistor device in step S4, a second wire fiber is used to weave the resistor device on the circuit pattern through a three-dimensional weaving machine; The second wire fiber is made of any one or more of copper wire, chromium wire, tungsten wire, and non-metallic fiber.

[0016] In some possible embodiments, when the second woven radiation surface blank is impregnated and cured in the impregnation and curing tooling, the heating rate of curing is 0.5 to 5.0 °C / min, the curing temperature is 60 °C to 250 °C, and the curing pressure is 0.1 MPa to 6.0 MPa.

[0017] In some possible embodiments, the impregnation and curing tooling includes a male mold and a female mold that cooperates with the male mold to form a curing cavity and is provided with a glue injection port; a waste removal cavity is further provided on the female mold; the waste removal cavity and the glue injection port are respectively communicated with the curing cavity; When impregnating and curing, the second woven radiation surface blank will be located in the curing cavity.

[0018] In some possible embodiments, the weaving mold includes a weaving front-end transition part, a curved surface structure with a mating curved surface, and a weaving back-end transition part; the weaving front-end transition part, the curved surface structure, and the weaving back-end transition part are connected in sequence, the weaving front-end transition part and the curved surface structure form a starting point for cutting the antenna weaving radiation surface, and an end point for cutting the antenna weaving radiation surface is formed between the curved surface structure and the weaving back-end transition part.

[0019] In some possible embodiments, the roughness of the mating curved surface ≤ Ra3.2.

[0020] Compared with the prior art, the beneficial effects of the present invention: The present invention can realize the processing of a radiation array surface with an arbitrary curved surface, high precision, small thickness, dense array elements, and firm devices, so as to realize conformal fitting with the human skin, device shape, etc., and achieve the purpose of the electromagnetic function of the radiation array surface of the arbitrary curved surface antenna; The present invention provides a curved surface shape and dimensional accuracy for the radiation array substrate through a weaving mold, and adopts three-dimensional weaving technology to ensure the shape and accuracy of the radiation array substrate, circuit pattern, resistor device, and feeder; the dipping and curing tooling manufactured by machining ensures the structure and accuracy of the dipping and curing tooling, and the weaving radiation surface blank II is fixed and the circuit pattern, resistor device, and feeder are protected by dipping and curing in the dipping tooling. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 is the flowchart of the operation of the present invention; Figure 2 is the structural schematic diagram of the weaving mold in the present invention; Figure 3 is the schematic diagram when the weaving radiation surface blank II is processed by using the dipping and fixing tooling in the present invention; Figure 4 is the structural schematic diagram of the weaving radiation surface blank II in the present invention; Figure 5 is the structural schematic diagram of the antenna radiation array prepared by using the present invention; Wherein: 1. Weaving front-end transition part; 2. Curved surface structure; 3. Weaving rear-end transition part; 4. Starting point; 5. End point; 6. Male mold; 7. Female mold; 8. Glue injection port; 9. Excess removal cavity; 10. Weaving radiation surface blank II; 101. Bottom fiber layer; 102. Intermediate fiber layer; 103. Top fiber layer; 104. Circuit pattern; 105. Feeder; 106. Resistor device. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0022] In the present invention, unless otherwise clearly defined and limited, terms such as "installation", "connection", "connection", "fixation", etc. should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or integrated; it can be directly connected, or indirectly connected through an intermediate medium, and can be the internal communication of two components or the interaction relationship between two components. The "first", "second" and similar terms mentioned in this application do not represent any order, quantity or importance, but are only used to distinguish different components. Similarly, terms such as "one" or "a" do not represent a quantity limit, but represent the existence of at least one. In the implementation of this application, "and / or" describes the association relationship of associated objects, indicating that three relationships can exist. For example, A and / or B can represent: A exists alone, A and B exist simultaneously, and B exists alone. In the description of the embodiments of this application, unless otherwise stated, the meaning of "multiple" is two or more. For example, multiple positioning posts refer to two or more positioning posts. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0023] The present invention will be described in detail below.

[0024] As Figures 1 to 5 shown: A precise weaving manufacturing method for an antenna radiation array surface with an arbitrary curved surface, specifically including the following steps: Step S1: Process and manufacture a weaving mold with a mating curved surface and an impregnating and curing tooling with a curing cavity, where the curing cavity is consistent with the shape of the antenna radiation array surface; Specifically, according to the three-dimensional model of the antenna radiation array surface, a mold blank with a mating curved surface is manufactured using 3D printing technology; the mold blank is processed using five-axis finishing technology to obtain a weaving mold; through this weaving mold, the curved surface shape and dimensional accuracy of the antenna radiation array surface are provided; The impregnating and curing tooling is also processed using 3D printing technology and five-axis finishing technology; Furthermore, as Figure 2 shown, the weaving mold includes a weaving front-end transition part 1, a curved surface structure 2 with a mating curved surface, and a weaving rear-end transition part 3; the weaving front-end transition part 1, the curved surface structure 2, and the weaving rear-end transition part 3 are connected in sequence, and the weaving front-end transition part 1 and the curved surface structure 2 form a starting point 4 for later cutting, and an end point 5 for later cutting is formed between the curved surface structure 2 and the weaving rear-end transition part 3; the roughness of the mating curved surface ≤ Ra3.2; the accuracy of the mating curved surface contour is ±0.05 mm; It should be noted that when weaving on the weaving mold, the weaving equipment performs weaving traction according to the set requirements, and weaves layer by layer along the fiber winding direction on the surface of the weaving mold. Among them, the weaving front-end transition part 1 and the weaving rear-end transition part 3 are respectively weaving process edges, and the starting point 4 and the end point 5 of the curved surface structure 2 are cutting positions; specifically, the weaving equipment is a three-dimensional weaving machine.

[0025] Step S2: Based on the weaving mold processed in step S1, use a three-dimensional weaving machine to weave a radiation array matrix with a thickness of 0.5 mm to 1 mm and having an external interconnection interface on the mating curved surface of the weaving mold; As Figure 4 shown, the radiation array matrix includes a bottom fiber layer 101 woven on the mating curved surface of the weaving mold using a three-dimensional weaving machine, an intermediate fiber layer 102 woven on the bottom fiber layer 101, and a top fiber layer 103 woven on the intermediate fiber layer 102; the intermediate fiber layer 102 is at least one layer, that is, the radiation array matrix will be realized by weaving at least three fiber layers; The bottom fiber layer 101, the middle fiber layer 102, and the top fiber layer 103 are all made of fiber bundles, and the diameter of the fiber bundles is 0.1 micrometer to 20 micrometers; the fiber bundles are made of any one or more of carbon fiber, glass fiber, aramid fiber, and ultra-high molecular weight polyethylene fiber; When weaving the radiation front substrate, the offset accuracy of the fiber bundle is ±50 micrometers, and a process edge of 2 mm to 8 mm is reserved at the four peripheral edges of the radiation front substrate for cutting.

[0026] Step S3: Use a three-dimensional braiding machine to braid the circuit pattern 104 and the feeder 105 on the radiation front substrate, and connect the circuit pattern 104 and the feeder 105 to obtain a first rough woven radiation surface.

[0027] Specifically, when braiding the circuit pattern 104, use the first wire fiber to braid the circuit pattern 104 on the radiation front substrate through a three-dimensional braiding machine; The diameter of the first wire fiber is 0.1 micrometer to 20 micrometers, and the first wire fiber is made of any one or more of gold wire, silver wire, copper wire, and molybdenum wire; When braiding the circuit pattern 104, the offset accuracy of the first wire fiber is ±5 micrometers; It should be noted that for the circuit pattern 104 that will continue to braid the resistor device 106, a splicing interface needs to be left; to ensure the performance of the antenna radiation front, the circuit pattern 104 needs to meet the braiding forming accuracy ≤ 0.05 mm.

[0028] When braiding the feeder 105, use the feeder fiber to braid the feeder 105 connected to the circuit pattern 104 on the radiation front substrate through a three-dimensional braiding machine; The feeder 105 is in multiple groups, and one end of each group of the feeder 105 away from the circuit pattern 104 extends to the edge of the radiation front substrate; the diameter of the feeder fiber is 5 micrometers to 20 micrometers; The feeder fiber is made of a metal wire; Of course, the feeder fiber can also be made of a metal wire to form a metal inner core, and an outer core is sleeved outside the metal inner core, and the outer core is made of a non-metallic dielectric material.

[0029] Step S4: Use a three-dimensional braiding machine to braid the resistor device 106 on the corresponding circuit pattern 104 to obtain a second rough woven radiation surface 10; When braiding the resistor device 106, use the second wire fiber to braid the resistor device 106 on the circuit pattern 104 through a three-dimensional braiding machine; The second wire fiber is made of any one or more of copper wire, chromium wire, tungsten wire, and non-metallic fiber; the diameter of the second wire fiber is 5 micrometers to 200 micrometers; Further, the non-metallic fiber is any one of polyimide fiber, polyether ether ketone fiber, and polyethylene fiber.

[0030] By setting the diameters of the fiber tow, the first wire fiber, the feeding fiber, and the second wire fiber, the present invention effectively ensures that the thickness of the finally formed antenna radiation array surface < 5 mm.

[0031] It should be noted that the fibers in the weaving radiation surface blank two 10 exist separately in each weaving direction, and the first wire fiber, the feeding wire fiber, and the second wire fiber are connected to each other; the first wire fibers at the boundary between the top fiber layer 103 and the circuit pattern 104 of the radiation array substrate are interpenetrated with each other, so that the two have good connection strength. During the weaving process, by controlling the change of the types of fibers (fiber tow, the first wire fiber, the feeding wire fiber, the second wire fiber) on different spools and controlling the weaving path, the weaving of the radiation array substrate, the circuit pattern 104, the feeding wire 105, and the resistance device 106 is realized, so that the shape accuracy of the weaving radiation surface blank two 10 is ≤ 0.1 mm, and the pattern accuracy is ≤ 0.05 mm.

[0032] Step S5: Place the weaving radiation surface blank two 10 in an impregnation and curing tooling, impregnate it with a resin glue solution, and heat and pressurize it for curing and shaping to obtain a shaped antenna weaving radiation surface. Specifically, as Figure 3 shown, the impregnation and curing tooling includes a male mold 6 and a female mold 7 that cooperates with the male mold 6 to form a curing cavity and is provided with a glue injection port 8; a surplus removal cavity 9 is also provided on the female mold 7; the surplus removal cavity 9 and the glue injection port 8 are respectively communicated with the curing cavity. During impregnation and curing, the weaving radiation surface blank two 10 will be compacted and shaped and fixed in the curing cavity, and the resin glue solution is injected into the curing cavity through the glue injection port 8 and cured and formed; the resin glue solution is any one of epoxy resin, polyimide resin, and vinyl resin.

[0033] Specifically, when the weaving radiation surface blank two 10 is placed in the impregnation and curing tooling for impregnation and curing, the heating rate of curing is 0.5 - 5.0 °C / min, the curing temperature is 60 °C - 250 °C, and the curing pressure is 0.1 MPa - 6.0 MPa.

[0034] It should be noted that before impregnation and curing, the feeding wire 105 is protected in advance to prevent the end of the feeding wire 105 from being contaminated by the resin glue solution, which is convenient for the installation of subsequent connectors.

[0035] Step S6: Demold and cut the antenna weaving radiation surface to obtain a curved surface and as Figure 5The shown antenna radiation array surface is a single-layer structure and retains the external interconnection interface; the trimming includes surface treatment and edge trimming.

[0036] The present invention uses 3D printing and five-axis finishing technology to provide contour and roughness accuracy for the braiding mold; the braiding mold provides the curved surface shape and dimensional accuracy for the antenna radiation array surface, and the three-dimensional braiding machine is used for braiding each layer to ensure the shape and accuracy of the radiation array surface substrate, circuit pattern 104, feeder 105, and resistor device 106; so that the shape accuracy is ≤0.1 mm and the circuit pattern 104 accuracy is ≤0.05 mm. The present invention manufactures the impregnation and curing tooling through machining to ensure the structure and accuracy of the impregnation and curing tooling, and realizes the fixation of the braided radiation surface blank 10 and the protection of the circuit pattern 104, resistor device 106, and feeder 105 through the impregnation and curing tooling; finally, the braiding mold, impregnation and curing tooling, and three-dimensional braiding machine are used to complete the braiding manufacture of the arbitrary curved surface antenna radiation array surface in the present invention. The present invention embeds the circuit pattern 104, feeder 105, and resistor device 106 in the radiation array surface substrate with a thickness <1 mm to construct a high-array-density antenna element, where the element density >10000 elements / m 2 , and the element is a pattern on the radiation array surface substrate.

[0037] The present invention is not limited to the foregoing specific embodiments. The present invention extends to any new feature or any new combination disclosed in this specification, as well as any new method or process step or any new combination disclosed.

Claims

1. A precise weaving manufacturing method for an antenna radiation array surface with an arbitrary curved surface, characterized in that Specifically, it includes the following steps: Step S1: Process and manufacture a braiding mold with a mating surface and an impregnation and curing tooling with a curing cavity; Step S2: Braiding a radiation array substrate with a thickness of 0.5 mm to 1 mm on the mating surface of the braiding mold; Step S3: Braiding a circuit pattern and a feeder on the radiation array substrate, and connecting the circuit pattern to the feeder to obtain a first braided radiation surface blank; Step S4: Braiding a resistor device on the circuit pattern to obtain a second braided radiation surface blank; Step S5: Placing the second braided radiation surface blank in the impregnation and curing tooling, impregnating it with a resin adhesive, and heating and pressurizing it for curing to obtain a shaped antenna braided radiation surface; Step S6: Demolding and cutting the antenna braided radiation surface to obtain an antenna radiation array surface with a curved surface.

2. The precision weaving manufacturing method of an antenna radiation array surface with an arbitrary curved surface according to claim 1, characterized in that, The radiation array substrate includes a bottom fiber layer braided on the mating surface of the braiding mold by a three-dimensional braiding machine, an intermediate fiber layer braided on the bottom fiber layer, and a top fiber layer braided on the intermediate fiber layer; the intermediate fiber layer is at least one layer.

3. A precise weaving manufacturing method for an antenna radiation array surface with an arbitrary curved surface according to claim 2, characterized in that The bottom fiber layer, the intermediate fiber layer, and the top fiber layer are all made of fiber filaments, and the diameter of the fiber filaments is 0.1 micron to 20 microns; the fiber filaments are made of any one or more of carbon fiber, glass fiber, aramid fiber, and ultra-high molecular weight polyethylene fiber; When braiding the radiation array substrate, the offset accuracy of the fiber filaments is ±50 microns.

4. The precision weaving manufacturing method of an antenna radiation array surface with an arbitrary curved surface according to claim 1, characterized in that When braiding the circuit pattern in Step S3, a first wire fiber is used to braid the circuit pattern on the radiation array substrate by a three-dimensional braiding machine; The diameter of the first wire fiber is 0.1 micron to 20 microns, and the first wire fiber is made of any one or more of gold wire, silver wire, copper wire, and molybdenum wire; When braiding the circuit pattern, the offset accuracy of the first wire fiber is ±5 microns.

5. The precision weaving manufacturing method of an antenna radiation array surface with an arbitrary curved surface according to claim 1, wherein, When braiding the feeder in Step S3, a feeder fiber is used to braid a feeder connected to the circuit pattern on the radiation array substrate by a three-dimensional braiding machine; the diameter of the feeder fiber is 5 microns to 20 microns; There are multiple groups of the feeders, and one end of each group of feeders away from the circuit pattern extends to the edge of the radiation array substrate; The feeder fiber is made of a metal wire.

6. The precision weaving manufacturing method of an antenna radiation array surface with an arbitrary curved surface according to claim 1, characterized in that, When braiding the resistor device in Step S4, a second wire fiber is used to braid the resistor device on the circuit pattern by a three-dimensional braiding machine; The second wire fiber is made of any one or more of copper wire, chromium wire, tungsten wire, and non-metallic fiber.

7. A precise weaving manufacturing method for an antenna radiation array surface with an arbitrary curved surface according to claim 1, characterized in that When the second braided radiation surface blank is placed in the impregnation and curing tooling for impregnation and curing, the heating rate of curing is 0.5 to 5.0 °C / min, the curing temperature is 60 °C to 250 °C, and the curing pressure is 0.1 MPa to 6.0 MPa.

8. A precision weaving manufacturing method for an antenna radiation array surface with an arbitrary curved surface according to claim 7, characterized in that, The impregnation and curing tooling includes a male mold and a female mold that cooperates with the male mold to form a curing cavity and is provided with a glue injection port; a waste removal cavity is also provided on the female mold; the waste removal cavity and the glue injection port are respectively communicated with the curing cavity; During impregnation and curing, the second braided radiation surface blank will be located in the curing cavity.

9. A precise weaving manufacturing method for an antenna radiation array surface with an arbitrary curved surface according to any one of claims 1 to 8, characterized in that, The weaving mold includes a front weaving transition part, a curved surface structure with a mating curved surface, and a rear weaving transition part; the front weaving transition part, the curved surface structure, and the rear weaving transition part are connected in sequence. The front weaving transition part and the curved surface structure form a starting point for cutting the antenna weaving radiation surface, and an end point for cutting the antenna weaving radiation surface is formed between the curved surface structure and the rear weaving transition part.

10. A method for precision weaving and manufacturing an antenna radiation array surface with an arbitrary curved surface according to claim 9, characterized in that, The roughness of the mating curved surface is ≤ Ra3.2.

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