A mesh antenna reflector and its manufacturing method

Abstract

This invention discloses a mesh antenna reflector and its manufacturing method, belonging to the field of satellite communication technology. It includes a mesh surface, a rib frame, and a pressure plate. The rib frame is the main supporting structure for the reflector. The mesh surface is laid on the concave surface of the rib frame, and the pressure plate is located above the mesh surface and fixed along the rib frame. The rib frame includes Z-shaped ring ribs, Z-shaped longitudinal ribs, L-shaped bends, and a connecting plate. The L-shaped bend is the inner edge of the rib frame. Multiple Z-shaped ring ribs are arranged along the extension direction of the Z-shaped longitudinal ribs, which connect the Z-shaped ring ribs and the L-shaped bend. The connecting plate is located at the connection point of the Z-shaped ring ribs and the Z-shaped longitudinal ribs and is used to fix the Z-shaped ring ribs and the Z-shaped longitudinal ribs. This invention aims to provide a low-cost, mass-producible, and highly consistent mesh antenna reflector design and manufacturing method.

Description

Technical Field

[0001] This invention belongs to the field of satellite communication technology, and particularly relates to a mesh antenna reflector and its manufacturing method. Background Technology

[0002] Antenna reflectors are primarily used to reflect and receive electromagnetic signals and are crucial components of antenna systems. Based on their structure, reflectors are mainly classified as solid reflectors, perforated metal plates, mesh reflectors, and grid reflectors. Mesh reflectors are typically used for wavelengths greater than 10 cm. Mesh reflectors offer advantages such as low wind resistance, light weight, and low cost, making them suitable for sites exposed to strong winds, sandstorms, rain, and snow.

[0003] The typical process for forming a mesh reflector involves first creating a rigid support frame, then laying a metal mesh on the frame and fixing the mesh using welding or riveting. For example, the article "Manufacturing Technology of Mesh Reflectors" introduces a mesh reflector antenna composed of an aluminum mesh, reinforcing ribs, a support frame, and a skeleton. The reinforcing ribs are of three types: "L"-shaped ribs, "["-shaped folded ribs, and edge rib tubes. The reflector mesh is welded to the folded ribs and edge ribs. The reflector mesh has a small diameter and is easily melted; to ensure the rigidity of the reflector mesh, the weld points are dense, which can easily cause welding deformation. The folded ribs and edge rib tubes connected to the reflector mesh require high spatial precision, making processing and forming difficult, and the panel manufacturing precision is 1.5 mm.

[0004] The mesh reflector formed by the above method has a complex process, low mesh tension, poor precision, and poor antenna electrical performance. Summary of the Invention

[0005] The purpose of this invention is to overcome the above-mentioned technical deficiencies and to manufacture a mesh antenna reflector with high precision and simple molding process.

[0006] The objective of this invention is achieved through the following technical solution:

[0007] A mesh antenna reflector includes multiple unit panels. Each unit panel includes a mesh surface 1, a stiffening beam frame 2, and a pressure plate 3. The stiffening beam frame 2 is the main support for the mesh surface. The mesh surface 1 is laid on the concave surface of the stiffening beam frame 2. The pressure plate 3 is located above the mesh surface 1 and is fixed along the stiffening beam frame.

[0008] The stiffening beam frame 2 includes Z-shaped ring bars 2-1, Z-shaped longitudinal bars 2-2, L-shaped corner pieces 2-3, and connecting plates 2-4; the L-shaped corner pieces 2-3 are the inner edge of the stiffening beam frame 2, and multiple Z-shaped ring bars 2-1 are arranged along the extension direction of the Z-shaped longitudinal bars 2-2. The Z-shaped longitudinal bars 2-2 are used to connect the Z-shaped ring bars 2-1 and the L-shaped corner pieces 2-3 or to connect adjacent Z-shaped ring bars 2-1; the connecting plate is located at the connection position of the Z-shaped ring bars 2-1 and the Z-shaped longitudinal bars 2-2, and is used to fix the Z-shaped ring bars 2-1 and the Z-shaped longitudinal bars 2-2.

[0009] Furthermore, the mesh surface 1 is a welded stainless steel wire mesh.

[0010] Furthermore, the connecting plate 2-4 of the stiffening beam frame 2 is provided with elongated holes that serve as adjustment points for the connection of the reflective surface.

[0011] Furthermore, the groove spacing, groove width, and groove depth of the ring ribs 2-1 and longitudinal ribs 2-2 are set by the curvature of the reflective surface.

[0012] Furthermore, the outer contour of the pressure plate 3 is consistent with the outer contour of the reflective surface.

[0013] A method for manufacturing a mesh antenna reflector, comprising the following steps:

[0014] Step 1: Establish a mathematical model of the antenna reflector surface and design the unit panel mold based on the mathematical model;

[0015] Step 2: Cut the stainless steel mesh according to the outline dimensions of the reflective surface to form mesh surface 1. Mesh surface 1 is a spliced ​​mesh surface, and the splice is set at the position of longitudinal rib 2-2.

[0016] Step 3: Design Z-shaped ring ribs 2-1 and Z-shaped longitudinal ribs 2-2, using aluminum alloy profiles that are cut and slotted.

[0017] Step 4: On the unit panel mold, the Z-shaped ring rib 2-1 and Z-shaped longitudinal rib 2-2 are fitted onto the mold through machining process.

[0018] Step 5: First, fix the Z-shaped ring rib 2-1 and Z-shaped longitudinal rib 2-2 on the mold. Apply an adhesive layer to the surface of the connecting plate 2-4 and the corner piece 2-3. Adhede the Z-shaped ring rib 2-1 and Z-shaped longitudinal rib 2-2. The adhesive cures to form the reflective rib beam frame 2.

[0019] Step 6: Establish the unfolded material model based on the mathematical model of the reflective surface, and process the pad. The pad is laid inside the pressure plate 3. The thickness of the pad is the same as that of the pressure plate 3. According to the curvature of the reflective surface, a groove can be opened on the pad to ensure that the pad fits the unit panel mold.

[0020] Step 7: Place the pressure plate 3 on the unit panel mold and fix it to the unit panel mold with tape;

[0021] Step 8: Lay the mesh on the pressure plate 3 and the pad, and use a tool to pull the mesh tight along the four sides to make the mesh fit with the pad and the pressure plate 3;

[0022] Step 9: Apply adhesive along the concave surface of the reinforcing beam frame 2 to ensure even distribution of the adhesive.

[0023] Step 10: Fit the reinforcing beam frame 2 with the pressure plate 3, and place a heavy object on the reinforcing beam frame 2 to apply pressure;

[0024] Step 11: After the adhesive has cured, cut off the excess mesh 1 along the outer contour of the pressure plate 3; demold, leaving the backing plate on the surface of the unit panel mold.

[0025] Step 12: Evenly distribute rivets along the pressure plate 3 to reinforce the mesh surface 1, the reinforcing beam frame 2, and the pressure plate 3, thus completing the manufacturing of the mesh panel.

[0026] Furthermore, in step 3, the Z-shaped ring rib 2-1 and the Z-shaped longitudinal rib 2-2 are grooved from the edge inward at the end that contacts the mesh surface 1 for bending.

[0027] The beneficial effects achieved by adopting the above scheme are:

[0028] 1. Compared with the prior art, the present invention uses adhesive bonding and curing on the mold to form the mesh panel, which ensures the forming accuracy;

[0029] 2. The mesh surface and the backing frame are connected by adhesive, resulting in low structural stress and minimal deformation;

[0030] 3. Using slotted Z-shaped reinforcing bars, the forming process is simple and the fitting accuracy of the curved surface of the reinforcing bar and beam is high;

[0031] 4. The pressure plate is bonded to the mesh panel and the stiffening beam frame to form a whole, which improves the rigidity of the reflective surface;

[0032] 5. The reflective panel molding process of the present invention is simple and is a low-cost, mass-production manufacturing technology.

[0033] In summary, this invention is ingeniously conceived, easy to implement, applicable to the manufacturing of mesh antenna reflectors, and has high forming precision, representing a significant improvement over existing technologies. Attached Figure Description

[0034] Figure 1 This is a schematic diagram of the overall assembly structure according to an embodiment of the present invention;

[0035] Figure 2 yes Figure 1 Side view.

[0036] Figure 3 This is a schematic diagram of the mesh structure according to an embodiment of the present invention;

[0037] Figure 4 This is a schematic diagram of the stiffener-beam frame structure according to an embodiment of the present invention;

[0038] Figure 5 This is a schematic diagram of the pressure plate structure according to an embodiment of the present invention;

[0039] Figure 6 This is a schematic diagram of the Z-shaped profile structure according to an embodiment of the present invention;

[0040] The numbers in the attached diagram are explained as follows: 1 is the mesh surface; 2 is the reinforcing beam frame; 2-1 is the Z-shaped ring reinforcement; 2-2 is the Z-shaped longitudinal reinforcement; 2-3 is the L-shaped corner piece; 2-4 is the connecting plate; and 3 is the pressure plate. Detailed Implementation

[0041] Combination Figure 1-6 The present invention will now be further described. The following embodiments will help those skilled in the art to further understand the present invention. It should be noted that any applications and improvements made by those skilled in the art without departing from the concept of the present invention are within the scope of protection of the present invention.

[0042] like Figure 1-6 As shown, a mesh antenna reflector and its manufacturing method are disclosed. It consists of three parts: a mesh surface 1, a reinforcing beam frame 2, and a pressure plate 3. The mesh surface 1 is laid on the concave surface of the reinforcing beam frame, and the pressure plate 3 is located above the mesh surface and fixed along the reinforcing beam frame. The reinforcing beam frame 2 includes Z-shaped ring ribs 2-1, Z-shaped longitudinal ribs 2-2, L-shaped corner pieces 2-3, and connecting plates 2-4. Multiple slots are respectively formed at the ends of the Z-shaped ring ribs 2-1 and Z-shaped longitudinal ribs 2-2 that contact the mesh surface 1, extending inwards from the edge.

[0043] In this invention, the mesh surface 1 is a welded stainless steel wire mesh with a mesh size of 10×10 mm and a wire diameter of 0.8 mm.

[0044] In this invention, six reflective surface connection adjustment points are designed on the connecting plate 2-4 of the reinforcing beam frame 2.

[0045] In this invention, the groove spacing of the annular rib 2-1 and the longitudinal rib 2-2 is set with a reference to the curvature of the reflective surface, and the groove depth is 80 mm.

[0046] In this invention, the outer contour of the pressure plate 3 is consistent with the outer contour of the reflective surface.

[0047] The present invention discloses a method for manufacturing a mesh antenna reflector, which, as shown in the accompanying drawings, includes the following steps:

[0048] ① Establish a mathematical model of the antenna reflector surface, and design the reflector unit mold based on the mathematical model;

[0049] ② Cut the stainless steel mesh according to the outline dimensions of the reflective surface to form reflective mesh surface 1;

[0050] ③ Design Z-shaped ring ribs 2-1 and Z-shaped longitudinal ribs 2-2, using aluminum alloy profiles cut and formed;

[0051] ④ On the reflective surface unit mold, the Z-shaped ring rib 2-1 and Z-shaped longitudinal rib 2-2 are fitted onto the mold through machining process;

[0052] ⑤ First, fix the Z-shaped ring reinforcement 2-1 and Z-shaped longitudinal reinforcement 2-2 on the mold. Apply an adhesive layer to the surface of the connecting plate 2-4 and the corner piece 2-3. Adhede the Z-shaped ring reinforcement 2-1 and Z-shaped longitudinal reinforcement 2-2. The adhesive cures to form the reflective surface reinforcement beam frame 2.

[0053] ⑥ Establish the unfolded material model based on the mathematical model of the reflective surface, process the pad, the pad is laid inside the pressure plate, the thickness of the pad is the same as that of the pressure plate, and according to the curvature of the reflective surface, a groove can be opened on the pad to ensure that the pad fits the mold;

[0054] ⑦ Place the pressure plate 3 on the mold and secure it to the mold with tape;

[0055] ⑧ Lay the mesh on the pressure plate 3 and the pad, and use a tool to pull the mesh tight along the four sides to make the mesh fit with the pad and the pressure plate;

[0056] ⑨ Apply adhesive along the concave surface of the reinforcing beam frame 2 to ensure even distribution of the adhesive;

[0057] ⑩ Fit the reinforcing beam frame 2 with the pressure plate 3, and place a heavy object on the reinforcing beam frame to apply pressure;

[0058] ①1 After the adhesive has cured, cut off the excess mesh along the outer contour of the pressure plate 3;

[0059] ①2 Rivets are evenly distributed along the pressure plate 3 to reinforce the mesh surface 1, the reinforcing beam frame 2, and the pressure plate 3, thus completing the manufacturing of the mesh panel.

Claims

1. A mesh antenna reflector, comprising multiple unit panels, characterized in that, Each unit panel includes a mesh surface (1), a reinforcing beam frame (2), and a pressure plate (3). The reinforcing beam frame (2) is the main support for the panel. The mesh surface (1) is laid on the concave surface of the reinforcing beam frame (2). The pressure plate (3) is located above the mesh surface (1) and is fixed along the reinforcing beam frame. The stiffening beam frame (2) includes Z-shaped ring bars (2-1), Z-shaped longitudinal bars (2-2), L-shaped corner pieces (2-3), and connecting plates (2-4); the L-shaped corner pieces (2-3) are the inner edge of the stiffening beam frame (2), and multiple Z-shaped ring bars (2-1) are arranged along the extension direction of the Z-shaped longitudinal bars (2-2). The Z-shaped longitudinal bars (2-2) are used to connect the Z-shaped ring bars (2-1) and the L-shaped corner pieces (2-3); the connecting plate is located at the connection position of the Z-shaped ring bars (2-1) and the Z-shaped longitudinal bars (2-2) and is used to fix the connection between the Z-shaped ring bars (2-1) and the Z-shaped longitudinal bars (2-2). The manufacturing method of the mesh antenna reflector specifically includes the following steps: Step 1: Establish a mathematical model of the antenna reflector surface and design the unit panel mold based on the mathematical model; Step 2: Cut stainless steel wire mesh according to the outline size of the reflective surface and leave a margin to form a mesh surface (1). Splice the mesh surface (1) and set the splice seam at the position of the longitudinal rib (2-2). Step 3: Design Z-shaped ring ribs (2-1) and Z-shaped longitudinal ribs (2-2), using aluminum alloy profiles that are cut and slotted. Step 4: On the unit panel mold, the Z-shaped ring ribs (2-1) and Z-shaped longitudinal ribs (2-2) are fitted onto the mold through machining process. Step 5: First, fix the Z-shaped ring reinforcement (2-1) and Z-shaped longitudinal reinforcement (2-2) on the mold. Apply an adhesive layer to the surface of the connecting plate (2-4) and the corner piece (2-3) to glue the Z-shaped ring reinforcement (2-1) and Z-shaped longitudinal reinforcement (2-2). The adhesive is cured to form a reflective surface reinforcement beam frame (2). Step 6: Establish the unfolded material model according to the mathematical model of the reflective surface, process the pad, the pad is laid inside the pressure plate (3), the thickness of the pad is consistent with the pressure plate (3), and according to the curvature of the reflective surface, open the groove on the pad to ensure that the pad fits the unit panel mold; Step 7: Place the pressure plate (3) on the unit panel mold and fix it to the unit panel mold with tape; Step 8: Lay the mesh on the pressure plate (3) and the pad, and use a tool to pull the mesh along the four sides so that the mesh is in contact with the pad and the pressure plate (3); Step 9: Apply adhesive along the concave surface of the reinforcing beam frame (2) to ensure even distribution of the adhesive. Step 10: Fit the reinforcing beam frame (2) with the pressure plate (3) and place a heavy object on the reinforcing beam frame (2) to apply pressure; Step 11: After the adhesive has cured, cut off the excess mesh (1) along the outer contour of the pressure plate (3); demold, leaving the pad on the surface of the unit panel mold; Step 12: Evenly distribute rivets along the pressure plate (3) to reinforce the mesh surface (1), the reinforcing beam frame (2), and the pressure plate (3), thus completing the manufacturing of the mesh panel.

2. The mesh antenna reflector according to claim 1, characterized in that, The mesh surface (1) is a welded stainless steel wire mesh.

3. The mesh antenna reflector according to claim 1, characterized in that, The connecting plate (2-4) of the stiffening beam frame (2) is provided with an elongated hole as a connection adjustment point for the reflective surface.

4. The mesh antenna reflector according to claim 1, characterized in that, The groove spacing, groove width, and groove depth of the ring ribs (2-1) and longitudinal ribs (2-2) are set by the curvature of the reflective surface.

5. The mesh antenna reflector according to claim 1, characterized in that, The outer contour of the pressure plate (3) is consistent with the outer contour of the reflective surface.

6. The mesh antenna reflector according to claim 1, characterized in that, In step 3, the Z-shaped ring rib (2-1) and Z-shaped longitudinal rib (2-2) are grooved from the edge inward at the end that contacts the mesh surface (1) for bending.

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