Assembly method, system and reflector of single-curved mesh reflector

Abstract

This invention provides an assembly method, system, and reflector for a single-curved mesh reflector, relating to the field of composite material technology. The method includes: Step S1: attaching a mesh panel onto a bonding assembly curved surface mold; Step S2: applying tensile prestress to the mesh panel; Step S3: drying the backing ribs; Step S4: stress-free bonding of the mesh panel and the dried backing ribs at room temperature; Step S5: measuring the profile of the mesh panel and recording the profile deviation; Step S6: attaching auxiliary ribs within the grid of the backing ribs and adjusting the carbon fiber position of the mesh panel to compensate for the profile deviation. This invention effectively improves the panel profile accuracy between the backing rib grids of the mesh reflector and enhances its resistance to temperature, humidity, and creep.

Description

Technical Field

[0001] This invention relates to the field of composite material technology, and more specifically, to an assembly method, system, and reflector for a single-curved mesh reflector. Background Technology

[0002] The reflector is the main functional component of an antenna, playing a crucial role in satellite reception and transmission of electromagnetic wave signals. Carbon fiber mesh antenna reflectors are characterized by their lightweight, high strength, and high rigidity.

[0003] Because the carbon fiber mesh panel is only 0.1–0.3 mm thick, the spacing between the carbon fiber composite back ribs in lightweight reflectors typically reaches 300–600 mm. It is difficult for the mesh panel within the back ribs to maintain its shape and achieve high-precision surface profiles. Furthermore, the mesh panel within the back ribs is prone to significant out-of-plane deformation due to temperature and humidity changes. These drawbacks severely limit the application of carbon fiber mesh antenna reflectors in high-precision satellite and ground antennas. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides an assembly method, system, and reflector for a single-curved mesh reflector.

[0005] According to the present invention, an assembly method, system, and reflector for a single-curved surface mesh reflector are provided, the solution of which is as follows:

[0006] Firstly, a method for assembling a single-curved surface mesh reflector is provided, the method comprising:

[0007] Step S1: Apply the mesh panel to the adhesive assembly curved surface mold;

[0008] Step S2: Apply tensile prestress to the grid panel;

[0009] Step S3: Dry the back tendons;

[0010] Step S4: Stress-free bonding of the mesh panel to the dried backing at room temperature;

[0011] Step S5: Measure the profile of the grid panel and record the profile deviation;

[0012] Step S6: Attach auxiliary ribs within the grid of the back ribs and adjust the position of the carbon fiber in the grid panel to compensate for surface deviations.

[0013] Preferably, step S1 includes: brushing a layer of adhesive onto the surface of the bonding assembly curved surface mold, then pressing the mesh panel onto the surface of the bonding assembly curved surface mold through a vacuum bag to ensure the fit between the mesh panel and the curved surface of the bonding assembly curved surface mold during assembly, placing the mesh panel on the mold for several days until the mesh panel surface is stable, and then demolding.

[0014] Preferably, when applying tensile prestress to the mesh panel, it is along the generatrix direction of the mesh panel.

[0015] Preferably, the tensile prestress applied to the mesh panel is 1 to 20 N / 100 mm.

[0016] Preferably, in step S3, the backing rib is dried so that the moisture content of the backing rib after drying is ≤0.1% and the moisture reabsorption before bonding is ≤50%.

[0017] Preferably, when attaching the auxiliary ribs, the spacing between the ribs along the generatrix of the grid panel is 30-150 mm.

[0018] Preferably, the auxiliary reinforcement includes carbon fiber composite mesh rods or T-shaped reinforcements.

[0019] Preferably, the amount of movement of the carbon fiber mesh in the profile compensation is -70% to -130% of the local deviation.

[0020] Secondly, an assembly system for a single-curved surface mesh reflector is provided, the system comprising:

[0021] Module M1: The mesh panel is attached to the adhesive assembly curved surface mold;

[0022] Module M2: Apply tensile prestress to the grid panel;

[0023] Module M3: Drying treatment for the back ribs;

[0024] Module M4: The mesh panel and the dried back rib are bonded together without stress at room temperature;

[0025] Module M5: Measure the profile of the grid panel and record the profile deviation;

[0026] Module M6: Attach auxiliary ribs within the grid of the back reinforcement to adjust the position of the carbon fiber in the grid panel to compensate for surface deviations.

[0027] The model M1 includes: brushing a layer of adhesive onto the surface of the bonding assembly curved surface mold, then pressing the mesh panel onto the surface of the bonding assembly curved surface mold through a vacuum bag to ensure the fit between the mesh panel and the curved surface of the bonding assembly curved surface mold during assembly, placing the mesh panel on the mold for several days until the mesh panel surface is stable, and then demolding.

[0028] Preferably, when applying tensile prestress to the mesh panel, it is along the generatrix direction of the mesh panel;

[0029] The tensile prestress applied to the grid panel is 1-20 N / 100 mm;

[0030] In module M3, the backing rib is dried so that the moisture content of the backing rib after drying is ≤0.1% and the moisture reabsorption before bonding is ≤50%.

[0031] When attaching the auxiliary ribs, the spacing between the ribs along the generatrix of the grid panel is 30-150mm.

[0032] The auxiliary reinforcement includes, but is not limited to, carbon fiber composite mesh rods or T-shaped reinforcements;

[0033] In the surface compensation, the movement of the carbon fiber mesh is -70% to -130% of the local deviation.

[0034] Thirdly, a reflector is provided, which is manufactured by using the assembly method of the single-curved mesh reflector described above.

[0035] Compared with the prior art, the present invention has the following beneficial effects:

[0036] This invention improves the panel profile accuracy between the back ribs of the mesh reflector by applying a fiber mesh panel to a curved assembly mold, applying tensile prestress, drying the carbon fiber back ribs, stress-free bonding, and compensating for profile deviations.

[0037] Other beneficial effects of the present invention will be explained in detail through the introduction of specific technical features and technical solutions in specific embodiments. Those skilled in the art should be able to understand the beneficial technical effects brought about by these technical features and technical solutions through the introduction of these technical features and technical solutions. Attached Figure Description

[0038] Other features, objects, and advantages of the present invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings:

[0039] Figure 1 This is a schematic diagram of the process of the present invention;

[0040] Figure 2 This is a schematic diagram of a high-precision single-curved surface mesh reflector.

[0041] Figure 3 This is a schematic diagram showing the state of auxiliary reinforcement bars being attached within the back reinforcement grid;

[0042] Figure 4 It is a carbon fiber mesh auxiliary reinforcement.

[0043] Reference numerals: 1. Grid panel; 2. Backing rib; 3. Auxiliary rib; 4. Adhesive assembly curved surface mold. Detailed Implementation

[0044] The present invention will now be described in detail with reference to specific embodiments. These embodiments will help those skilled in the art to further understand the present invention, but do not limit the invention in any way. It should be noted that those skilled in the art can make several changes and improvements without departing from the concept of the present invention. These all fall within the scope of protection of the present invention.

[0045] Example 1:

[0046] This invention provides an assembly method for a single-curved surface mesh reflector, referring to... Figure 1 and Figure 2 As shown, the method specifically includes the following:

[0047] Step S1: Apply the carbon fiber composite mesh panel 1 onto the adhesive assembly curved surface mold 4.

[0048] Specifically, a layer of adhesive is brushed onto the surface of the bonding assembly curved surface mold 4, and then the mesh panel 1 is pressed and shaped onto the surface of the bonding assembly curved surface mold 4 through a vacuum bag to ensure the fit between the mesh panel 1 and the curved surface of the bonding assembly curved surface mold 4 during assembly. The mesh panel 1 is placed on the mold for several days until the shape of the mesh panel 1 is stable and then demolded.

[0049] Step S2: Apply tensile prestress to the carbon fiber composite mesh panel 1. The tensile prestress is applied along the generatrix direction of the mesh panel 1, and the tensile prestress is 1~20N / 100mm.

[0050] Step S3: Dry the carbon fiber composite backing rib 2. Dry the backing rib 2 until its moisture content is ≤0.1% and its moisture reabsorption before bonding is ≤50%.

[0051] Step S4: The mesh panel 1 and the dried backing rib 2 are bonded together without stress at room temperature;

[0052] Step S5: Measure the profile of grid panel 1 and record the profile deviation;

[0053] Step S6: Refer to Figure 3 and Figure 4 As shown, auxiliary ribs 3 are pasted inside the grid of back rib 2, and the position of carbon fiber in the grid panel is adjusted to compensate for the surface deviation. Specifically, the amount of carbon fiber movement in the grid during surface compensation is -70% to -130% of the local deviation.

[0054] When attaching the auxiliary reinforcing bars 3, the spacing between the auxiliary reinforcing bars 3 along the generatrix direction of the grid panel 1 is 30-150mm. The auxiliary reinforcing bars 3 include carbon fiber composite mesh rods or T-shaped reinforcing bars.

[0055] This invention also provides an assembly system for a single-curved mesh reflector. This assembly system can be implemented by executing the steps of the assembly method for the single-curved mesh reflector. That is, those skilled in the art can understand the assembly method for the single-curved mesh reflector as a preferred embodiment of the assembly system. (Refer to...) Figure 1 and Figure 2 As shown, the system specifically includes the following:

[0056] Module M1: The carbon fiber composite mesh panel 1 is attached to the adhesive assembly curved surface mold 4.

[0057] Specifically, a layer of adhesive is brushed onto the surface of the bonding assembly curved surface mold 4, and then the mesh panel 1 is pressed and shaped onto the surface of the bonding assembly curved surface mold 4 through a vacuum bag to ensure the fit between the mesh panel 1 and the curved surface of the bonding assembly curved surface mold 4 during assembly. The mesh panel 1 is placed on the mold for several days until the shape of the mesh panel 1 is stable and then demolded.

[0058] Module M2: Apply tensile prestress to the carbon fiber composite mesh panel 1. The tensile prestress is applied along the generatrix direction of the mesh panel 1, and the tensile prestress is 1~20N / 100mm.

[0059] Module M3: Drying treatment of carbon fiber composite backing rib 2. The backing rib 2 is dried to ensure its moisture content is ≤0.1% after drying, and its moisture reabsorption before bonding is ≤50%.

[0060] Module M4: The mesh panel 1 and the dried back rib 2 are bonded together without stress at room temperature;

[0061] Module M5: Measure the profile of grid panel 1 and record the profile deviation;

[0062] Module M6: Reference Figure 3 and Figure 4 As shown, auxiliary ribs 3 are pasted inside the grid of back rib 2, and the position of carbon fiber in the grid panel is adjusted to compensate for the surface deviation. Specifically, the amount of carbon fiber movement in the grid during surface compensation is -70% to -130% of the local deviation.

[0063] When attaching the auxiliary reinforcing bars 3, the spacing between the auxiliary reinforcing bars 3 along the generatrix direction of the grid panel 1 is 30-150mm. The auxiliary reinforcing bars 3 include carbon fiber composite mesh rods or T-shaped reinforcing bars.

[0064] Example 2:

[0065] Example 2, based on Example 1, further provides a method for assembling a single-curved surface mesh reflector, specifically including:

[0066] Step 1: Apply the carbon fiber composite mesh panel onto the bonding assembly curved surface mold: Brush a layer of adhesive / acetone (1:1) solution onto the surface of the mold curved surface, then press the mesh panel onto the mold surface through a vacuum bag to ensure the mesh panel fits the mold curved surface during assembly. Place the mesh panel on the mold in a free state for 3-5 days to allow the surface to stabilize before demolding.

[0067] Step 2: Apply tensile prestress to the carbon fiber composite mesh panel by increasing humidity and hanging weights.

[0068] Step 3: Vacuum drying treatment is performed on the carbon fiber composite backing.

[0069] Step 4: Apply a layer of adhesive PTFE film between the mesh panel and the drying backing, leaving a 0.05mm gap for bonding. Before bonding, position the curved surface mold for bonding assembly to ensure there is no interference with the panel, and ensure that the mesh panel and the drying backing are bonded without stress at room temperature.

[0070] Step 5: Measure the grid panel by suspension to reduce the influence of gravity. The long side is the vertical direction of suspension. Attach a target to the grid panel and measure the actual spatial coordinates of the product's surface points. Calculate the deviation between the measured values ​​and the theoretical model. The difference between the actual product surface point coordinates and the theoretical coordinates is the surface deviation at that location.

[0071] Step 6: Place the mesh panel on the forming curved surface mold, and according to the surface deviation, attach auxiliary ribs inside the back rib grid to correct the deformation of the mesh panel that deviates from the mold surface;

[0072] The tensile prestress applied to the carbon fiber composite mesh panel is along the generatrix direction of the mesh panel. (The generatrix of the mesh panel is the sweep curve generatrix of the curved surface).

[0073] The tensile prestress applied to the carbon fiber composite mesh panel is 1 to 20 N / 100 mm.

[0074] Before bonding the backing ribs to the mesh panel, vacuum drying is performed to remove moisture absorbed by the composite material. (Moisture absorption is a property of composite materials, and it can lead to aging, so it must be removed.)

[0075] The carbon fiber composite backing was treated in a vacuum degassing chamber at 50℃ and a vacuum degree ≤6.5×10-3pa for 24 hours to remove moisture from the composite backing. The moisture reabsorption before bonding was ≤20%. (Based on weight: (weight at bonding - weight after vacuum) / weight after vacuum).

[0076] The auxiliary ribs are arranged along the generatrix of the reflector surface, with a spacing of 50mm between them (determined based on the spacing of the back ribs of the reflector).

[0077] The auxiliary ribs are carbon fiber composite mesh rods with a density of 10g / m (considering both weight reduction and performance).

[0078] The movement of the carbon fiber in the mesh panel during surface compensation is -90% to -110% of the local deviation. (The relative position of the carbon fiber in the mesh panel before and after compensation; the local deviation is the position of the corresponding carbon fiber in the mesh panel during compensation).

[0079] The single-curved grid reflector with dimensions of 4897mm×1672mm and a weight of 12.2Kg has an RMS (root mean square) of 0.26mm under a temperature of ±50℃.

[0080] This invention provides an assembly method, system, and reflector for a single-curved mesh reflector, which effectively improves the surface accuracy of the panel between the back ribs of the mesh reflector.

[0081] Those skilled in the art will understand that, besides implementing the system and its various devices, modules, and units provided by this invention in the form of purely computer-readable program code, the same functions can be achieved entirely through logical programming of the method steps, making the system and its various devices, modules, and units of this invention function in the form of logic gates, switches, application-specific integrated circuits, programmable logic controllers, and embedded microcontrollers. Therefore, the system and its various devices, modules, and units provided by this invention can be considered as a hardware component, and the devices, modules, and units included therein for implementing various functions can also be considered as structures within the hardware component; alternatively, the devices, modules, and units for implementing various functions can be considered as both software modules implementing the method and structures within the hardware component.

[0082] Specific embodiments of the present invention have been described above. It should be understood that the present invention is not limited to the specific embodiments described above, and those skilled in the art can make various changes or modifications within the scope of the claims, which do not affect the essence of the present invention. Unless otherwise specified, the embodiments and features described in this application can be arbitrarily combined with each other.

Claims

1. A method for assembling a single-curved mesh reflector, characterized in that, include: Step S1: Cover the mesh panel (1) onto the adhesive assembly curved surface mold (4); Step S2: Apply tensile prestress to the grid panel (1); Step S3: Dry the back rib (2); Step S4: The mesh panel (1) and the dried backing (2) are bonded together without stress at room temperature; Step S5: Measure the profile of the grid panel (1) and record the profile deviation; Step S6: Paste auxiliary ribs (3) into the grid of the back rib (2) and adjust the position of the carbon fiber of the grid panel to compensate for the surface deviation; Step S1 includes: brushing a layer of adhesive on the surface of the bonding assembly curved surface mold (4), then pressing the mesh panel (1) onto the surface of the bonding assembly curved surface mold (4) through a vacuum bag to ensure the fit between the mesh panel (1) and the curved surface of the bonding assembly curved surface mold (4) during assembly, placing the mesh panel (1) on the mold for several days until the shape of the mesh panel (1) is stable and demolding. When applying tensile prestress to the grid panel (1), it is along the generatrix direction of the grid panel (1); The tensile prestress applied to the grid panel (1) is 1 to 20 N / 100 mm; In step S3, the backing rib (2) is dried so that the moisture content of the backing rib (2) after drying is ≤0.1% and the moisture reabsorption before bonding is ≤50%. When pasting the auxiliary ribs (3), the pasting spacing of the auxiliary ribs (3) along the generatrix direction of the grid panel (1) is 30-150mm; In the surface compensation, the movement of the carbon fiber mesh is -70% to -130% of the local deviation.

2. The assembly method of the single-curved surface mesh reflector according to claim 1, characterized in that, The auxiliary reinforcement (3) includes carbon fiber composite mesh rods or T-shaped reinforcements.

3. An assembly system for a single-curved mesh reflector, characterized in that, include: Module M1: Cover the mesh panel (1) onto the adhesive assembly curved surface mold (4); Module M2: Apply tensile prestress to the grid panel (1); Module M3: Dry the back rib (2); Module M4: The mesh panel (1) and the dried backing (2) are bonded together without stress at room temperature; Module M5: Measure the profile of the grid panel (1) and record the profile deviation; Module M6: Auxiliary ribs (3) are pasted inside the grid of the back rib (2), and the carbon fiber position of the grid panel is adjusted to compensate for the surface deviation; The module M1 includes: brushing a layer of adhesive on the surface of the bonding assembly curved surface mold (4), then pressing the mesh panel (1) onto the surface of the bonding assembly curved surface mold (4) through a vacuum bag to ensure the fit between the mesh panel (1) and the curved surface of the bonding assembly curved surface mold (4) during assembly, placing the mesh panel (1) on the mold for several days until the shape of the mesh panel (1) is stable and demolding; When applying tensile prestress to the grid panel (1), it is along the generatrix direction of the grid panel (1); The tensile prestress applied to the grid panel (1) is 1 to 20 N / 100 mm; In module M3, the back rib (2) is dried so that the moisture content of the back rib (2) after drying is ≤0.1% and the moisture reabsorption before bonding is ≤50%. When pasting the auxiliary ribs (3), the pasting spacing of the auxiliary ribs (3) along the generatrix direction of the grid panel (1) is 30-150mm; The auxiliary reinforcement (3) includes carbon fiber composite mesh rods or T-shaped reinforcements; In the surface compensation, the movement of the carbon fiber mesh is -70% to -130% of the local deviation.

4. A reflector, characterized in that, The reflector is manufactured using the assembly method of the single-curved mesh reflector according to any one of claims 1 to 2.

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