A pure carbon fiber reflector panel and a manufacturing process thereof

Abstract

The application discloses a pure carbon fiber reflecting panel and a manufacturing process thereof, and relates to the technical field of carbon fiber antenna panels. The main body of the pure carbon fiber reflecting panel is a fan-shaped curved surface. One end of the fan-shaped curved surface extends outward to form a center splicing disc. The other end of the fan-shaped curved surface is turned outward to form a turned edge. The cross-sectional thickness of the fan-shaped curved surface gradually increases from the middle part to the two ends. The structure adopts a hot press machine process method of long carbon fiber prepreg mold and a new mold. On the premise of ensuring the strength of the panel, the thickness of the product can be significantly reduced, and the overall weight can be reduced by more than 40%. The overall manufacturing process only needs a hot press forming machine. Compared with the existing RTM process and SMC process, the production efficiency is improved, and the production cost is effectively reduced.

Description

Technical Field

[0001] This invention relates to the field of carbon fiber antenna panel splicing technology, specifically to a pure carbon fiber reflective panel and its manufacturing process. Background Technology

[0002] Portable antennas are a common and widely used type of antenna in satellite communication. Because they are portable, they are required to be easy to carry and lightweight. In terms of design, the antenna reflector panel needs to be detachable for easy storage. When in use, the panels are connected to form a whole reflector.

[0003] Carbon fiber reflective panels serve the satellite communication industry with their excellent strength and lightweight characteristics, especially in portable satellite communication station equipment, where the requirements for lightweighting are even more stringent. As the integration of electronic and transmission components continues to increase, the weight of the reflective panel in the overall equipment needs to be further reduced.

[0004] The existing manufacturing processes for carbon fiber panels include the following:

[0005] 1) The main structure is carbon fiber skin with honeycomb foam sandwich structure. The process uses a single-sided mold and bag pressing method. The carbon fiber layer, inner sandwich (honeycomb / foam) and carbon fiber layer are laid on the single-sided mold. After sealing, it is placed in an autoclave for thermosetting. This type of carbon fiber panel is much lighter than the original metal panel. However, due to the presence of honeycomb / foam, its thickness cannot be further reduced.

[0006] 2) RTM process: This method uses a mold-forming method. After the dry fiber cloth and honeycomb are placed into the mold cavity, the mold is locked. Resin is introduced into the gaps of the material in the mold cavity through vacuum and pressure, and then heated and cured. It is heavier than the prepreg method and requires special equipment for glue injection. The equipment investment is relatively large, the process is more complicated, the mold cavity needs to be sealed well, and the operation requirements are also high.

[0007] 3) SMC process: short fiber material mixed with resin is placed into the mold cavity according to the model design after being supported. Then, the material is extruded and filled into the mold cavity by closing the upper and lower molds to make the product. The product of this process is heavy, and because it is short fiber, unlike carbon fiber prepreg which uses long fiber, it is not as strong and precise as long fiber prepreg products.

[0008] How to design a new process to manufacture pure carbon fiber reflective panels, and resolve the contradictions between weight, strength, precision, and equipment investment to meet the technological development requirements of portable antennas, and how to significantly reduce weight while improving the overall precision, appearance quality, and production efficiency of the product on the existing basis, has become a current technical challenge. Summary of the Invention

[0009] In view of this, the present invention proposes a pure carbon fiber reflective panel and its manufacturing process. It adopts a hot press process for molding long carbon fiber prepreg and a new type of mold. While ensuring the strength of the panel, it can significantly reduce the product thickness and reduce the overall weight by more than 40%. The entire manufacturing process only requires a hot press molding machine. Compared with the existing RTM and SMC processes, it not only improves production efficiency but also effectively reduces production costs.

[0010] To achieve the objectives of this invention, the following technical solution is adopted:

[0011] A pure carbon fiber reflective panel, characterized in that it comprises reflective panels, and multiple reflective panels can be spliced ​​together to form a circular reflective surface, wherein:

[0012] The main body of the reflective panel is a fan-shaped arc surface. One end of the fan-shaped arc surface extends outward to form a central splicing plate, and the other end of the fan-shaped arc surface flips outward to form a flange. The inner side of the reflective panel is smooth and forms a reflective surface. The outer side of the reflective panel is equipped with reinforcing ribs, and splicing latches are installed on both sides of the reflective panel.

[0013] Preferably, the shapes of adjacent splicing latches are matched and they are locked together by snap rings.

[0014] Preferably, it also includes a regular polygonal chuck for mounting the central splicing plate, the regular polygonal chuck being arranged at the center of the circular reflective surface.

[0015] Preferably, the cross-sectional thickness of the fan-shaped arc surface gradually increases from the middle to both ends.

[0016] A manufacturing process for a pure carbon fiber reflective panel, characterized by the following steps:

[0017] 1) Preheat the upper and lower molds and apply release agent. After the release agent dries, wipe the molds clean.

[0018] 2) Lay carbon fiber prepreg on the cavity surface of the upper mold and lay carbon fiber prepreg on the cavity surface of the lower mold;

[0019] 3) Place the rib preformed carbon fiber part and the reinforcing rib carbon fiber preformed part into the reserved groove between the upper carbon fiber prepreg and the lower carbon fiber prepreg;

[0020] 4) Fill the gap between the preform and the carbon fiber prepreg with expanding foam;

[0021] 5) Close the upper and lower molds together and place them on the hot press. Heat and cure them. After the curing time is reached, stop heating the hot press and maintain the pressure value. At this time, circulate cooling water through the mold to cool it down quickly.

[0022] 6) When the mold temperature drops to 60℃, remove the product from the mold and perform the deburring process.

[0023] Preferably, the upper mold has a recessed upper cavity in the middle, and multiple upper positioning through holes are provided around the upper mold. A guide post and a positioning block are provided on the side of the upper mold near the lower mold, and an upper cooling water channel is provided on the top of the upper mold.

[0024] Preferably, the lower mold has a central protrusion forming a lower cavity, and multiple lower positioning through holes are provided around the lower mold. The lower positioning through holes are in the same position and size as the upper positioning through holes. A positioning post is installed between the lower positioning through holes and the upper positioning through holes. A guide hole for installing the guide post and a positioning groove for installing the positioning block are provided on the side of the lower mold close to the upper mold. A lower cooling water channel is provided at the bottom of the lower mold.

[0025] Preferably, the cavity of the lower mold has a circumferential groove on its mold-closing surface. The groove is used for venting and overflowing adhesive, and a support groove for connecting to the outside is provided on the groove.

[0026] Preferably, the rib preformed carbon fiber component includes a side rib preformed component, a top rib preformed component, and a center rib preformed component.

[0027] The pure carbon fiber reflective panel and its manufacturing process of the present invention have the following beneficial effects:

[0028] 1) The main body of the pure carbon fiber reflective panel is a fan-shaped arc surface. One end of the fan-shaped arc surface extends outward to form a central splicing plate, and the other end of the fan-shaped arc surface flips outward to form a flange. The cross-sectional thickness of the fan-shaped arc surface gradually increases from the middle to both ends. This structure can significantly reduce the product thickness and reduce the overall weight by more than 40% while ensuring the strength of the panel.

[0029] 2) This method adopts a novel hot press molding process for long carbon fiber prepregs. Rib preformed carbon fiber parts and reinforcing rib carbon fiber preformed parts are placed in the reserved groove between the upper and lower carbon fiber prepregs. The entire manufacturing process only requires a hot press molding machine. Compared with the existing RTM and SMC processes, it not only improves production efficiency but also effectively reduces production costs.

[0030] 3) The mold involved in this method is equipped with a long groove. The long groove is set at the mold parting surface of the cavity. The long groove is used for venting and overflowing glue. On the one hand, it helps to remove the air trapped inside the cavity and between the carbon fiber layers, thereby obtaining better interlayer bonding strength. On the other hand, it can also remove excess resin from the carbon fiber prepreg during molding. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the reflective panel splicing.

[0032] Figure 2 This is a schematic diagram of the front of the reflective panel;

[0033] Figure 3 This is a schematic diagram of the cross-section of the reflective panel;

[0034] Figure 4 This is a schematic diagram showing the connection between the splicing latch and the snap ring;

[0035] Figure 5 This is a schematic diagram of the upper mold structure;

[0036] Figure 6 This is a schematic diagram of the lower mold structure;

[0037] Figure 7 This is a schematic diagram of the layout of carbon fiber prepreg.

[0038] Figure 8 This is a schematic diagram of the forming process of a reflective panel product.

[0039] In the diagram, 1-reflective panel, 101-fan-shaped arc surface, 102-center splicing plate, 103-flanged edge, 104-reinforcing rib, 105-splicing latch, 106-ring clip, 2-upper mold, 201-upper positioning through hole, 202-guide post, 203-positioning block, 204-upper cooling water channel, 3-lower mold, 301-lower positioning through hole, 302-guide hole, 303-positioning groove, 304-lower cooling water channel, 305-long groove, 4-upper carbon fiber prepreg, 5-ribbed preformed carbon fiber part, 6-reinforcing rib carbon fiber preformed part, 7-lower carbon fiber prepreg. Detailed Implementation

[0040] In the description of this invention, it should be understood that the terms "center," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. The terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0041] Example 1

[0042] like Figures 1 to 4 As shown, the pure carbon fiber reflective panel includes a reflective panel 1. Multiple reflective panels 1 can be spliced ​​together to form a circular reflective surface. In the figure, the main body of the reflective panel 1 is a fan-shaped arc surface 101. One end of the fan-shaped arc surface 101 extends outward to form a central splicing plate 102, and the other end of the fan-shaped arc surface 101 flips outward to form a flange 103. The inner side of the reflective panel 1 is smooth and forms a reflective surface. The outer side of the reflective panel 1 is provided with reinforcing ribs 104, and splicing latches 105 are installed on both sides of the reflective panel 1.

[0043] It should be noted that adjacent splicing latches 105 are shaped to match each other and are locked together by snap rings 106. For example, the splicing latches 105 include right-angled trapezoidal latches for mutual positioning, and the snap rings 106 are swayable. Utilizing the deformation of the snap rings 106, they simultaneously engage with adjacent splicing latches 105 to achieve positioning interlocking. It also includes a regular polygonal chuck for mounting the central splicing plate 102, which is positioned at the center of the circular reflective surface. Figure 1 In the middle, the regular polygonal chuck has a regular octagonal structure, and the central splicing disks 102 of the eight reflective panels 1 are respectively and symmetrically installed in the regular polygonal chuck to form a complete pattern.

[0044] It should be noted that the cross-sectional thickness of the fan-shaped arc surface 101 gradually increases from the middle to both ends, with reinforced flanges around the perimeter of the panel. The front section of the panel features a gradual thickness transition to a thinner surface to ensure sufficient product strength. This product is made of pure carbon fiber, and the panel thickness is significantly reduced compared to a sandwich structure. To achieve sufficient structural strength, a reinforcing rib structure is added to the back, and the latch is also made of lightweight materials. Furthermore, the metal embedded parts for internal latch installation have been eliminated.

[0045] Example 2

[0046] A manufacturing process for a pure carbon fiber reflective panel, characterized by the following steps:

[0047] 1) Preheat the upper mold 2 and the lower mold 3, and apply the release agent. After the release agent dries, wipe the mold clean to ensure a good and clean mold surface.

[0048] 2) Lay carbon fiber prepreg 4 on the cavity surface of the upper mold 2, and lay carbon fiber prepreg 7 on the cavity surface of the lower mold 3;

[0049] 3) Place the rib preformed carbon fiber part 5 and the reinforcing rib carbon fiber preformed part 6 into the reserved groove between the upper carbon fiber prepreg 4 and the lower carbon fiber prepreg 7. In the figure, the rib preformed carbon fiber part 5 includes the side rib preformed part, the top rib preformed part and the center rib preformed part. The upper carbon fiber prepreg 4 is the main frame and is designed with reinforcing rib grooves, locking grooves, center connecting pieces, etc. The bottom of the lower carbon fiber prepreg 7 is the reflective surface and its top is connected to the reinforcing rib carbon fiber preformed part 6.

[0050] It should be noted that the small molds of the preforms mentioned above can be used to preform some scraps into the required shapes, which can further reduce material waste. Carbon fiber scrap preforms are used as fillers for uneven thickness parts because the strength of foam material is insufficient, and the foam will deform and expand after molding, which will cause poor precision. The above products can maintain good strength and precision in the range of -40 to 80 degrees. The preforms are placed in the grooves after the carbon fiber prepreg is laid. A gap is left between the preforms and the carbon fiber prepreg laid in the upper and lower molds to facilitate the placement of the preforms, making the operation easier and reducing the operation time and difficulty.

[0051] In actual work, during the layup process, a layer of carbon fiber material is first laid on each of the upper and lower molds to cover the front and rear curved surfaces. Then, the areas with uneven thickness (ribs and thickened parts) in the shape are filled with pre-formed carbon fiber parts, and then carbon fiber material is laid on top until the designed thickness is achieved (the thickness is determined according to the product strength simulation value). After the material is placed, the upper and lower molds can be closed by mold guide pillars. After the molds are closed, they are placed on a hot press machine for pressure curing.

[0052] 4) Fill the gap between the preform and the carbon fiber prepreg with expanding foam, and strictly control the weight of the expanding foam to achieve a small product weight deviation.

[0053] 5) Close the upper mold 2 and the lower mold 3 together and place them on the hot press. Heat and cure them. After the curing time is reached, stop heating the hot press and maintain the pressure value. At this time, cool water is circulated into the mold to cool it down quickly.

[0054] It should be noted that circulating cooling water into the mold cools it down. Due to the large volume of circulating water, the cooling time of the mold is significantly shortened, thus improving production efficiency.

[0055] 6) When the mold temperature drops to 60℃, remove the product from the mold and perform the deburring process.

[0056] It should be noted that the mold can be disassembled when it cools down to 60 degrees Celsius, and the product can be removed from the mold for deburring. Due to the strict control over the product's shape caused by the precision of the mold processing, the burrs are minimal and can be cleaned quickly, which is a major advantage of this process compared to the original bag pressing process. Furthermore, since the final product requires the installation of snap fasteners, after cleaning, the product is placed on a snap fastener bonding fixture for fastener bonding, thus completing the first stage of production for this part. The subsequent surface painting process can then proceed.

[0057] Example 3

[0058] like Figures 5 to 8 As shown, in order to make a pure carbon fiber reflective panel, a new type of upper mold 2 and lower mold 3 are required. The mold structure is a mold-matching structure. The upper and lower molds are the curved surfaces of the front and back of the product, respectively. After the upper and lower molds are closed, the mold cavity is the shape of the product.

[0059] In the figure, the upper mold 2 has a concave center forming an upper cavity. Multiple upper positioning through holes 201 are provided around the upper mold 2. A guide post 202 and a positioning block 203 are provided on the side of the upper mold 2 closest to the lower mold 3. An upper cooling water channel 204 is provided on the top of the upper mold 2. The lower mold 3 has a convex center forming a lower cavity. Multiple lower positioning through holes 301 are provided around the lower mold 3. The lower positioning through holes 301 are in the same position and size as the upper positioning through holes 201. A positioning post is installed between the lower positioning through holes 301 and the upper positioning through holes 201. A guide hole 302 for installing the guide post 202 and a positioning groove 303 for installing the positioning block 203 are provided on the side of the lower mold 3 closest to the upper mold 2. A lower cooling water channel 304 is provided at the bottom of the lower mold 3. It should be noted that the openings of the lower cooling water channel 304 or the upper cooling water channel 204 are directly connected with pressure-resistant water pipes. During the mold cooling process, as long as the machine heating is turned off and the cooling water is turned on, the mold can be cooled down. At the same time, the pressure inside the mold cavity can be maintained to avoid stress deformation of the product. This improves production efficiency and product precision.

[0060] In the figure, the cavity of the lower mold 3 is provided with a long groove 305 around the perimeter. The long groove 305 is used for venting and overflowing resin. The long groove 305 is provided with a support groove connecting to the outside. This structure is conducive to removing the air trapped between the cavity and the carbon fiber layers, thereby obtaining better interlayer bonding strength. It also serves as an overflow groove to discharge excess resin from the carbon fiber prepreg during molding.

[0061] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A pure carbon fiber reflective panel, characterized in that, Including a reflective panel (1), multiple reflective panels (1) can be spliced ​​together to form a circular reflective surface, wherein: The main body of the reflective panel (1) is a fan-shaped arc surface (101). One end of the fan-shaped arc surface (101) extends outward to form a central splicing plate (102), and the other end of the fan-shaped arc surface (101) flips outward to form a flange (103). The inner side of the reflective panel (1) is smooth and forms a reflective surface. The outer side of the reflective panel (1) is provided with reinforcing ribs (104), and splicing latches (105) are installed on both sides of the reflective panel (1). The adjacent splicing latches (105) are matched in shape and locked by snap rings (106); It also includes a regular polygonal chuck for mounting the central splicing plate (102), the regular polygonal chuck being arranged at the center of the circular reflective surface; The cross-sectional thickness of the fan-shaped arc surface (101) gradually increases from the middle to both ends; The manufacturing process of the pure carbon fiber reflective panel includes the following steps: 1) Preheat the upper mold (2) and lower mold (3) and apply release agent. After the release agent dries, wipe the mold clean. 2) Lay carbon fiber prepreg (4) on the cavity surface of the upper mold (2) and lay carbon fiber prepreg (7) on the cavity surface of the lower mold (3). 3) Place the rib preformed carbon fiber part (5) and the reinforcing rib carbon fiber preformed part (6) into the reserved groove between the upper carbon fiber prepreg (4) and the lower carbon fiber prepreg (7). 4) Fill the gap between the preform and the carbon fiber prepreg with expanding foam; 5) Close the upper mold (2) and the lower mold (3) and place them on the hot press machine. Heat and cure them. After the curing time is reached, the hot press machine stops heating and maintains the pressure value. At this time, cooling circulating water is introduced into the mold to cool it down quickly. 6) When the mold temperature drops to 60℃, remove the product from the mold and perform the deburring process.

2. The manufacturing process of the pure carbon fiber reflective panel as described in claim 1, characterized in that, The upper mold (2) has an indentation in the middle to form an upper cavity. Multiple upper positioning through holes (201) are provided around the upper mold (2). A guide post (202) and a positioning block (203) are provided on the side of the upper mold (2) close to the lower mold (3). An upper cooling water channel (204) is provided on the top of the upper mold (2).

3. The manufacturing process of the pure carbon fiber reflective panel as described in claim 1, characterized in that, The lower mold (3) has a central protrusion forming a lower cavity. Multiple lower positioning through holes (301) are provided around the lower mold (3). The lower positioning through holes (301) and the upper positioning through holes (201) are in the same position and size. A positioning post is installed between the lower positioning through holes (301) and the upper positioning through holes (201). A guide hole (302) for installing a guide post (202) and a positioning groove (303) for installing a positioning block (203) are provided on the side of the lower mold (3) close to the upper mold (2). A lower cooling water channel (304) is provided at the bottom of the lower mold (3).

4. The manufacturing process of the pure carbon fiber reflective panel as described in claim 1, characterized in that, The cavity of the lower mold (3) is provided with a long groove (305) around its perimeter. The long groove (305) is used for venting and overflowing adhesive. A support groove for connecting to the outside is provided on the long groove (305).

5. The manufacturing process of the pure carbon fiber reflective panel as described in claim 1, characterized in that, The rib preformed carbon fiber part (5) includes a side rib preformed part, a top rib preformed part and a center rib preformed part.

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