A method of manufacturing an ice-proof acoustic array module

Abstract

The application discloses a manufacturing method of an anti-icing acoustic array module, and the module is manufactured by using an integrated forming process, and specifically comprises the following steps: S1, roughening treatment is performed on the inner and outer surfaces of a high-strength composite material layer to improve the surface bonding strength; S2, polyurea is sprayed on the front surface of the high-strength composite material layer, the thickness is uniform and controlled within the range of 0.5-2 mm; S3, an adhesive is coated on the back surface of the high-strength composite material layer, and a specific thickness of low-modulus polyurethane glue is poured after preheating; and S4, the anti-icing layer is completed by placing in an oven for heating and curing. The application has the advantages of simple process and uniform composite bonding of the anti-icing layer and the acoustic array main body, and can guarantee the acoustic performance of the acoustic array while obtaining the anti-icing capability.

Description

Technical fields:

[0001] This invention relates to the field of acoustic array technology, specifically a method for manufacturing an anti-icing acoustic array module. Background technology:

[0002] When polar scientific research icebreakers operate in polar environments, ice fragments can impact the hull. Since the multibeam acoustic array module is located at the hull, the problem of protecting the acoustic array module from ice fragment impacts needs to be addressed to ensure the deep-water multibeam measurement system can be used on polar scientific research icebreakers. One solution is to add a protective layer to the surface of the acoustic array. For example, ELAC's SeaBeam3020 system uses a polymer acoustically permeable plate filled with antifreeze integrated into the array. This technology requires a high-quality sealing structure and must eliminate air bubbles during antifreeze filling to avoid affecting acoustic performance, adding complexity to the manufacturing process.

[0003] How to achieve anti-icing capability while ensuring the acoustic performance of the acoustic array using a simple processing technique is a technical problem that urgently needs to be solved in this field. Summary of the Invention:

[0004] The technical problem to be solved by the present invention is to provide a manufacturing method for an anti-icing acoustic array module. The method is simple to implement and can ensure uniform bonding between the anti-icing layer and the acoustic array body, thus ensuring the acoustic performance of the acoustic array while obtaining anti-icing capability.

[0005] The technical solution of this invention is to provide a manufacturing method for an anti-icing acoustic array module. The module is manufactured using an integrated molding process, specifically including the following steps:

[0006] S1, roughen the inner and outer surfaces of the high-strength composite material layer to improve surface bonding strength;

[0007] S2, spray polyurea onto the front surface of the high-strength composite material layer, with uniform thickness and controlled within the range of 0.5 to 2 mm;

[0008] S3, an adhesive is coated on the back of a high-strength composite material layer, and a low-modulus polyurethane adhesive of a specific thickness is poured in after preheating;

[0009] S4, place in an oven and heat to cure to complete the anti-icing layer production;

[0010] S5, the acoustic array component and the anti-icing layer are loaded into the potting mold, wherein the anti-icing layer is attached and fixed to one side of the inner cavity of the mold. After preheating, potting glue is injected to encapsulate the acoustic array component inside the potting glue and to bond the working surface of the acoustic array component to the anti-icing layer as one piece.

[0011] S6. Place the mold in an oven and heat it to cure the potting compound, thus completing the manufacturing of the acoustic array module.

[0012] The module of this invention includes an acoustic array assembly and an anti-icing layer. The anti-icing layer has a three-layer structure. The three layers of polymer materials are first uniformly bonded together as a whole with a high-strength composite material layer (carbon fiber plate) as a substrate to form the anti-icing layer. Then, the anti-icing layer is integrated with the internal components of the acoustic array by potting adhesive on the outside of the acoustic array.

[0013] The anti-icing layer employs a multi-layer composite material technology. The inner layer serves as a buffer, the middle layer provides rigidity, and the outer layer enhances the anti-icing layer's toughness and wear resistance. The integrated molding technology first uses a high-strength composite material layer (carbon fiber plate) as a substrate to bond the three functional materials together to form the anti-icing layer. This anti-icing layer is then adhered and fixed to one side of the mold cavity. Finally, potting compound on the outside of the acoustic array integrates the anti-icing layer with the internal components of the acoustic array, ensuring a uniform and firm bond between the anti-icing layer and the main body of the acoustic array. This prevents defects such as air bubbles and voids at the bonding interface from affecting the acoustic performance of the array module.

[0014] Preferably, the strength composite layer is a carbon fiber plate.

[0015] Preferably, the thickness of the low-modulus polyurethane adhesive is 5–10 mm.

[0016] Preferably, the oven heating temperature in S4 is 50–60°C.

[0017] Preferably, the oven heating temperature in S6 is 50–70°C.

[0018] Preferably, the thickness of the carbon fiber plate is 3 to 8 mm.

[0019] Compared with the prior art, the beneficial effects of the present invention are:

[0020] The multi-layered composite anti-icing layer proposed in this invention possesses high strength, effectively dispersing impact force and preventing damage to the internal structural components of the acoustic array from excessive localized impact, thus giving the acoustic array module excellent resistance to ice breakage. Simultaneously, each layer of material exhibits good sound transmission properties, minimizing its impact on the acoustic performance of the acoustic array.

[0021] Meanwhile, this invention employs an integrated molding technology, which simplifies the molding process and allows for the uniform bonding of all material layers and the acoustic array into a single unit. Compared to the molding process of attaching a protective layer to the outside of the acoustic array, this avoids air bubbles and voids at the bonding interface. Referring to the process of spraying an anti-icing coating onto the surface of the acoustic array, if the acoustic array is prepared first and then a multi-layered anti-icing layer is attached to the outside, the high rigidity of the anti-icing layer makes it difficult to evenly cover the bonding surface, easily leading to air bubbles and voids at the bonding interface. The integrated molding process effectively avoids this situation, resulting in high process reliability. During preparation, the anti-icing layer is attached and fixed to one side of the mold cavity, resulting in a uniformly sized and smooth-surfaced array module after molding. Attached image description:

[0022] Figure 1 This is a schematic diagram of the anti-icing acoustic array module according to an embodiment of the present invention.

[0023] In the figure, 1 is the acoustic array assembly; 2 is the buffer layer; 3 is the carbon fiber plate; and 4 is the wear-resistant coating. Detailed implementation method:

[0024] The present invention will be further described below with reference to the accompanying drawings and specific embodiments:

[0025] This invention discloses a method for manufacturing an anti-icing acoustic array module, such as... Figure 1 As shown, the anti-icing acoustic array module consists of an acoustic array component 1 and an anti-icing layer. The anti-icing layer is composed of three composite material layers: an inner buffer layer 2, which in this embodiment uses low-modulus polyurethane adhesive with a thickness of 5-10 mm; a middle high-strength composite material layer, made of 5 mm thick carbon fiber plate 3, which possesses extremely high impact resistance and rigidity; and an outer high-strength wear-resistant coating 4, made of polyurea, to improve the overall toughness and wear resistance of the module's anti-icing layer. All three composite material layers are polymeric materials, resulting in low sound propagation loss.

[0026] The module is made using an integrated molding process. Three layers of polymer materials are first bonded together with a carbon fiber plate as the substrate to form an anti-icing layer. Then, the anti-icing layer is integrated with the internal components of the acoustic array by applying potting compound to the outside of the acoustic array.

[0027] The process specifically includes the following steps.

[0028] S1, roughen the inner and outer surfaces of the high-strength composite material layer to improve surface bonding strength;

[0029] S2, spray polyurea onto the front surface of the high-strength composite material layer, with uniform thickness and controlled within 1mm;

[0030] S3, apply adhesive to the back of the high-strength composite material layer, and pour an 8mm thick low-modulus polyurethane adhesive after preheating;

[0031] S4, place in an oven and heat to 58℃ to solidify and complete the anti-icing layer production;

[0032] S5, the acoustic array component and the anti-icing layer are loaded into the potting mold, wherein the anti-icing layer is attached and fixed to one side of the inner cavity of the mold. After preheating, potting glue is injected to encapsulate the acoustic array component inside the potting glue and to bond the working surface of the acoustic array component to the anti-icing layer as one piece.

[0033] S6. Place the mold in an oven and heat it to 63°C to cure the potting compound, thus completing the manufacturing of the acoustic array module.

[0034] The anti-icing layer of this invention adopts multi-layer material composite technology, which enables multi-beams to have excellent anti-icing capabilities. Through an integrated molding method, the process is simple, and the anti-icing layer is uniformly bonded to the acoustic array body, avoiding defects such as bubbles and voids at the bonding interface, thus ensuring the acoustic performance of the acoustic array.

[0035] Meanwhile, the multi-layered composite anti-icing layer of this invention possesses high strength, effectively dispersing impact force and preventing damage to the internal structural components of the acoustic array from excessive localized impact, thus giving the acoustic array module excellent resistance to ice breakage. Furthermore, each layer of material has good sound transmission properties, minimizing its impact on the acoustic performance of the acoustic array.

[0036] The above description only illustrates preferred embodiments of the present invention and should not be construed as limiting the scope of the claims. Any equivalent structural or procedural modifications made using this specification are included within the patent protection scope of the present invention.

Claims

1. A method for manufacturing an anti-icing acoustic array module, characterized in that: The module is manufactured using a one-piece molding process, which includes the following steps: S1, roughen the inner and outer surfaces of the high-strength composite material layer to improve surface bonding strength; S2, spray polyurea onto the front surface of the high-strength composite material layer, with uniform thickness and controlled within the range of 0.5 to 2 mm; S3, apply adhesive to the back of the high-strength composite material layer, and pour low-modulus polyurethane adhesive with a thickness of 5-10mm after preheating; S4, place in an oven and heat to cure to complete the anti-icing layer production; S5, the acoustic array component and the anti-icing layer are loaded into the potting mold, wherein the anti-icing layer is attached and fixed to one side of the inner cavity of the mold. After preheating, potting glue is injected to encapsulate the acoustic array component inside the potting glue and to bond the working surface of the acoustic array component to the anti-icing layer as one piece. S6. Place the mold in an oven and heat it to cure the potting compound, thus completing the manufacturing of the acoustic array module; The high-strength composite material layer is made of carbon fiber.

2. The manufacturing method of the anti-icing acoustic array module according to claim 1, characterized in that: The oven temperature in S4 is 50-60℃.

3. The manufacturing method of the anti-icing acoustic array module according to claim 1, characterized in that: The oven temperature in S6 is 50–70℃.

4. The manufacturing method of the anti-icing acoustic array module according to claim 1, characterized in that: The thickness of the carbon fiber plate is 3-8mm.

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