A multi-layer foam composite sandwich structure fan-shaped reflective surface and its forming method

Abstract

The invention discloses a multi-layer foam composite sandwich structure fan-shaped reflective surface and a molding method thereof, belonging to the field of antenna technology; the sandwich structure is specially designed, a composite foam sandwich is used as the sandwich material of the fan-shaped reflective surface, the skin is made of fiber-reinforced resin composite material, the working surface is metallized, and the front and rear skins wrap the composite foam sandwich to form a fan-shaped reflective surface in one piece, thereby solving the shortcomings of low precision, poor molding quality, poor rigidity and stability of the fan-shaped reflective surface. At the same time, the manufacturing method has a simple processing technology, which is conducive to improving production efficiency and realizing mass production.

Description

Technical Field

[0001] The present invention relates to the field of antenna technology, and in particular to a fan-shaped reflective surface sandwich structure and a preparation method thereof. Background Art

[0002] Portable satellite communication stations play an important role in more and more satellite communications due to their advantages such as portability, ease of operation, and suitability for outdoor working environments. As an important component of portable antennas, the typical fan-shaped reflector directly affects the overall performance of the entire portable antenna. With the development of radio communication technology, the demand for high-quality and high-data-volume satellite communications is increasing, and the requirements for the surface accuracy of the reflector are getting higher and higher.

[0003] At present, the method to improve the forming accuracy of the fan-shaped reflective surface is mainly to cut the sandwich structure into pieces, process stress relief grooves, etc. However, whether the skin is formed as a whole in one step or the skins are formed separately and then assembled, the improvement in the forming accuracy of the reflective surface is very limited. At the same time, due to the disconnection of the sandwich material, the appearance quality of the product after molding deteriorates, and usually careful grinding is required, which affects production efficiency and increases costs.

[0004] In view of the above problems, the present invention designs a fan-shaped reflective surface with a multi-layer foam composite sandwich structure. This structure significantly improves the molding accuracy of the reflective surface, enhances the rigidity and stability of the reflective surface, and improves the appearance of the product. Summary of the invention

[0005] The purpose of the present invention is to solve the problems of low precision of sector-shaped reflective surfaces, poor demoulding appearance quality and many process steps, and proposes a multi-layer foam composite sandwich structure and a manufacturing method suitable for one-step molding of sector-shaped reflective surfaces, which can improve the effectiveness efficiency, surface precision, structural stability and demoulding appearance of the sector-shaped reflective surfaces.

[0006] In order to solve the above technical problems, the technical solution adopted by the present invention is:

[0007] A multi-layer foam composite sandwich structure fan-shaped reflective surface, comprising a front skin 1, a rear skin 2 and a composite foam sandwich 6; the front skin 1 and the rear skin are respectively connected to the front and rear surfaces of the composite foam sandwich 6 by gluing; the composite foam sandwich 6 has internal reinforcing ribs 8;

[0008] Both sides of the sector-shaped reflective surface are provided with assembly interfaces Ⅰ3 for the assembly of two adjacent sector-shaped reflective surfaces; the assembly interface Ⅱ4 is located at the inner end of the sector-shaped reflective surface and is used for the assembly of the sector-shaped panel and the central panel.

[0009] Furthermore, the working surfaces of the front skin and the rear skin are metallized, and the metal layer 5 of the working surface is a current continuous conduction surface or a metal arrangement specific pattern surface, and the surface is smooth and flat.

[0010] Furthermore, the composite foam interlayer is a structure with multiple foam interlayers stacked in layers; the foam material is one or a combination of PMI foam, PET foam, and VC foam.

[0011] Furthermore, a reinforcement rib reserved groove is provided on the corresponding layer of the foam interlayer; the reinforcement rib reserved groove may be cross-shaped, X-shaped, pentagonal or hexagonal.

[0012] Furthermore, the reinforcement rib reserved groove is filled with high-density foam or resin.

[0013] Furthermore, the foam layers of the composite foam sandwich are bonded together to form a whole, and the bonding is performed using one or more combinations of liquid adhesives or adhesive films.

[0014] Furthermore, the metal layer 5 of the working surface is prepared by flame spraying, electroplating, chemical plating, etching or bonding of metal layers.

[0015] A method for manufacturing a multi-layer foam composite sandwich structure fan-shaped reflective surface, used for manufacturing the above-mentioned composite foam sandwich structure fan-shaped reflective surface, comprises the following steps:

[0016] Step 1, establishing a three-dimensional model of a multi-layer foam composite sandwich structure fan-shaped reflective surface, and designing and processing a mold of the composite foam sandwich structure fan-shaped reflective surface according to the model, including a front skin mold 9 and a rear skin mold 11, and the front skin mold 9 and the rear skin mold 11 can be assembled into a closed cavity;

[0017] Step 2, applying a mold release agent on the surface of the molding area 10 of the fan-shaped reflective surface molding mold of the composite foam sandwich structure, and then laying nickel-plated carbon felt impregnated with resin to prepare a metal reflective layer;

[0018] Step 3, laying a fiber fabric impregnated with resin on the metal reflective layer as a front skin;

[0019] Step 4, cutting a foam interlayer with a thickness of 1 to 3 mm according to the shape of the front skin;

[0020] Step 5, according to the shape of the foam cut in step 4, cut another foam interlayer, the thickness of which is freely selected according to the thickness and number of layers of the reflective surface interlayer;

[0021] Step 6, processing a built-in reinforcement rib reserved groove 8 on one side of the foam sandwich surface prepared in step 5;

[0022] Step 7, filling the reserved groove of the foam interlayer prepared in step 6 with the filling material;

[0023] Step 8, repeating steps 5 to 7 according to the number of layers of the designed foam interlayer to prepare the remaining interlayers;

[0024] Step 9, wrapping each foam interlayer in steps 4 to 8 with a film, with the slotted side of the slotted foam interlayer facing the foam prepared in step 4, and bonding them as a whole to form a composite foam interlayer foam, with the slotted area placed inside the composite foam;

[0025] Step 10, placing the composite foam sandwich foam on the front skin laid in step 3, and focusing on strengthening the assembly interface I and assembly interface II;

[0026] Step 11, laying a fiber fabric impregnated with resin on the composite foam as a rear skin;

[0027] Step 12, closing the mold, heating and curing, and demoulding to complete the molding of the fan-shaped reflective surface of the composite foam sandwich structure.

[0028] Compared with the prior art, the present invention has the following advantages:

[0029] 1. The present invention simplifies the molding steps of the sandwich structure fan-shaped reflective surface. The product adopts upper and lower molds and is molded in one step, thereby improving production efficiency.

[0030] 2. The multi-layer foam composite sandwich structure of the present invention improves the appearance quality of the product after molding. Through structural design, the sandwich slot part is hidden inside the composite sandwich, avoiding defects such as lattice marks on the product appearance caused by the discontinuity of the slots in the traditional sandwich structure.

[0031] 3. The multi-layer foam composite sandwich structure of the present invention improves the surface accuracy of the product. Compared with the traditional single-layer sandwich reflective surface, the composite sandwich reduces the thickness of the sandwich, releases the bending stress of the sandwich in the vertical direction, and also reduces the bending stress of the sandwich in the horizontal direction. The foam sandwich is more conformable to the molding surface, so that the surface accuracy of the reflective surface is improved.

[0032] 4. The multi-layer foam composite sandwich structure of the present invention enhances the structural rigidity and stability of the product. The internal reinforcement rib reserved groove hidden in the composite foam sandwich can be filled with hard foam or resin and other materials to form a reinforcement rib network structure inside the reflective surface, thereby enhancing the overall rigidity and stability of the product. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 : Schematic diagram of the fan-shaped reflective surface structure of the present invention;

[0034] Figure 2 : Schematic diagram of the cross-sectional structure of the fan-shaped reflecting surface of the present invention.

[0035] Figure 3 : Schematic diagram of multi-layer foam composite sandwich structure;

[0036] Figure 4 : Schematic diagram of the front skin mold of the fan-shaped reflector of the present invention;

[0037] Figure 5 : Schematic diagram of the rear skin mold of the sector-shaped reflective surface of the present invention;

[0038] Figure 6 : Schematic diagram of the fan-shaped reflective surface sandwich foam of the present invention;

[0039] Figure 7 : Schematic diagram of the reserved groove structure of the sandwich foam reinforcement rib of the fan-shaped reflective surface of the present invention;

[0040] Explanation of the reference numerals: front skin 1, rear skin 2, assembly interface I 3, assembly interface II 4, working surface metal layer 5, composite foam interlayer 6, composite foam interlayer bonding layer 7, composite foam interlayer built-in reinforcement rib 8, skin mold 9, molding area 10, rear skin mold 11. DETAILED DESCRIPTION

[0041] The present invention will be further described below in conjunction with the accompanying drawings and specific embodiments.

[0042] A fan-shaped reflective surface of a composite foam sandwich structure, characterized by comprising: a front skin 1, a rear skin 2, a composite foam sandwich 6, a composite foam sandwich adhesive layer 7, a composite foam sandwich built-in reinforcing rib 8, an assembly interface I3, and an assembly interface II4;

[0043] The front and rear skins of the reflector are made of fiber-reinforced resin composite materials, the working surface of the front skin is metallized, and the front and rear skins are integrally formed; each layer in the composite foam sandwich can be processed and grooved according to needs; the grooves in the composite foam sandwich can be filled with materials to form built-in reinforcement ribs; the layers in the composite foam sandwich are bonded to form a composite foam sandwich; the composite foam sandwich is connected to the front skin and the rear skin at the same time by gluing to form a whole sandwich structure;

[0044] Among them, assembly interface I is located on both sides of the fan-shaped reflective surface, and is used for splicing two adjacent fan-shaped reflective surfaces; assembly interface II is located at the top of the fan-shaped reflective surface, and is used for splicing the fan-shaped panel and the central panel.

[0045] Furthermore: the thickness d of the front and rear skins is 0.15-1.5 mm, the working surface is metallized, the working surface metal layer 5 is a current continuous conduction surface or a metal arrangement specific pattern surface, and the surface is smooth and flat.

[0046] Furthermore: the composite foam interlayer is divided into 2 to 5 interlayer areas of different thicknesses according to the overall thickness D of the reflective surface. The thickness of each layer can be freely combined, and the thickness of each layer is not less than 1 mm and not more than Dd-1 mm.

[0047] Furthermore: the composite foam interlayer may be made of one or a combination of PMI foam, PET foam, PVC foam, etc.

[0048] Further: Each layer of the composite foam sandwich can be processed or not processed with the built-in reinforcement rib reserved groove 8 according to demand. The shape of the built-in reinforcement rib reserved groove can be cross-shaped, X-shaped, pentagonal, hexagonal, etc.; the width of the built-in reinforcement rib reserved groove is 0.1-5mm; the depth of the built-in reinforcement rib reserved groove does not exceed the thickness of the layered foam minus 0.1mm; the interval between adjacent built-in reinforcement rib reserved grooves is 5-100mm; the built-in reinforcement rib reserved groove can be processed on one side or on both sides;

[0049] Further: the reserved grooves for built-in reinforcement ribs in each layer of the composite foam sandwich can be filled with high-density foam glue, various resins, etc., and solidified during the molding process to form a built-in reinforcement rib network;

[0050] Further: the composite foam sandwich layers are bonded to form a whole, and the bonding can be carried out by using one or more combinations of liquid adhesives and adhesive films, and the thickness of the adhesive layer is 0.05-0.5 mm;

[0051] Further: the working surface metal layer 5 is prepared by flame spraying, electroplating, chemical plating, etching, bonding metal layer, etc., and its thickness is 0.05 to 0.5 mm.

[0052] Further: the assembly interface I and the assembly interface II are connected in any manner, such as by screw connection, mechanical mortise and tenon connection, magnetic connection, etc.;

[0053] A method for manufacturing a multi-layer foam composite sandwich structure fan-shaped reflective surface, used for manufacturing a multi-layer foam composite sandwich structure fan-shaped reflective surface as claimed in any one of claims 1 to 9, comprising the following steps:

[0054] Step 1, establishing a three-dimensional model of a multi-layer foam composite sandwich structure fan-shaped reflective surface, and designing and processing a mold of the multi-layer foam composite sandwich structure fan-shaped reflective surface according to the model, including a front skin mold 9 and a rear skin mold 11, which can be assembled into a closed cavity;

[0055] Step 2, applying a mold release agent on the surface of the molding area 10 of the multi-layer foam composite sandwich structure fan-shaped reflective surface molding mold, and then laying nickel-plated carbon felt impregnated with resin to prepare a metal reflective layer;

[0056] Step 3, laying a fiber fabric impregnated with resin on the metal reflective layer as a front skin;

[0057] Step 4, cutting a piece of foam 12 with a thickness of 1 to 3 mm according to the shape of the front skin;

[0058] Step 5, according to the shape of the foam cut in step 4, cut another piece of foam 13, the thickness of which is freely selected according to the thickness and number of layers of the reflective surface interlayer;

[0059] Step 6, processing a built-in reinforcement rib reserved groove 8 on one side of the foam surface prepared in step 5;

[0060] Step 7, filling the reserved groove of the foam prepared in step 6 with a filling material;

[0061] Step 8, repeating steps 5 to 7 according to the number of designed composite interlayer layers to prepare the remaining interlayers;

[0062] Step 9, wrapping the sandwich foams in steps 4 to 8 with adhesive film, with the slotted side of the slotted foam facing the foam prepared in step 4, and bonding them as a whole to form a composite foam sandwich foam, with the slotted area placed inside the composite foam;

[0063] Step 10, placing the composite foam sandwich foam on the front skin laid in step 3, and focusing on strengthening the assembly interface I and assembly interface II;

[0064] Step 11, laying a fiber fabric impregnated with resin on the composite foam as a rear skin;

[0065] Step 12, closing the mold, heating and curing, and demoulding to complete the molding of the fan-shaped reflective surface of the composite foam sandwich structure.

[0066] The following is a more specific embodiment:

[0067] like Figure 1 to Figure 7 Shown: a multi-layer foam composite sandwich structure fan-shaped reflective surface, which includes a front skin 1, a rear skin 2, an assembly interface I3, an assembly interface II4, a working surface metal layer 5, a composite foam interlayer 6, a composite foam interlayer adhesive layer 7, and a composite foam interlayer built-in reinforcement rib 8.

[0068] like Figure 1 and Figure 2 As shown, the front and rear skins of the reflector are made of carbon fiber composite materials with a thickness of 0.5 mm. The working surface is metallized by flame spraying aluminum. The metal layer of the working surface is a smooth and flat continuous electrical conductive surface with a thickness of 0.1 to 0.2 mm.

[0069] like Figure 2 and Figure 3 As shown, the reflective surface composite foam sandwich adopts a two-layer structure, and the total thickness is 1mm thinner than the product thickness. The reserved internal reinforcement groove of the thick foam is filled with high-density foam glue and then faces the thin foam. The two layers of foam are bonded as a whole as a composite sandwich foam.

[0070] like Figure 6 As shown, the thinner layer of foam is 1mm thick and is not grooved;

[0071] like Figure 7 As shown, the thicker layer of foam is cross-grooved on one side, with a groove width of 1mm, a spacing of 30mm, and a depth of the foam thickness minus 1mm;

[0072] like Figure 4 and Figure 5 As shown, the front and rear reflective skin molds are designed according to the model and are processed and formed separately. After the product is cured, it can be assembled and closed, and the working surface of the mold is continuous, flat and smooth.

[0073] A method for forming a fan-shaped reflective surface of a multi-layer foam composite sandwich structure according to the present invention is shown in the accompanying drawings and comprises the following steps:

[0074] a) establishing a three-dimensional model of a multi-layer foam composite sandwich structure fan-shaped reflective surface, and designing and processing a mold of the composite foam sandwich structure fan-shaped reflective surface according to the model, including a front skin mold 9 and a rear skin mold 11, which can be assembled into a closed cavity;

[0075] b) applying a release agent on the surface of the forming area 10 of the forming mold for the fan-shaped reflective surface of the composite foam sandwich structure, and then laying nickel-plated carbon felt impregnated with resin to prepare a metal reflective layer;

[0076] c) laying a fiber fabric impregnated with resin on the metal reflective layer as a front skin;

[0077] d) Cutting a piece of foam 12 with a thickness of 1 to 3 mm according to the shape of the front skin;

[0078] e) according to the shape of the foam cut in step d, cut another piece of foam 13, the thickness of which is freely selected according to the thickness and number of layers of the reflective surface interlayer;

[0079] f) processing a reserved groove 8 for built-in reinforcement ribs on one side of the foam surface prepared in step e;

[0080] g) filling the reserved groove of the foam prepared in step f with a filling material;

[0081] h) Repeat steps e to g according to the number of designed composite interlayers to prepare the remaining interlayers;

[0082] i), wrapping the sandwich foams in steps d to h with adhesive film, with the slotted side of the slotted foam facing the foam prepared in step d, and bonding them together to form a composite foam sandwich foam, with the slotted area placed inside the composite foam;

[0083] j) Place the composite foam sandwich foam on the front skin laid in step 3, and strengthen it at the assembly interface I and assembly interface II;

[0084] k) laying a fiber fabric impregnated with resin on the composite foam as a rear skin;

[0085] l) Closing the mold, heating and curing, and demoulding to complete the molding of the fan-shaped reflective surface of the composite foam sandwich structure.

Claims

1. A multi-layer foam composite sandwich structure fan-shaped reflective surface, characterized in that: The invention comprises a front skin (1), a rear skin (2) and a composite foam sandwich (6); the front skin (1) and the rear skin are respectively connected to the front and rear surfaces of the composite foam sandwich (6) by gluing; the composite foam sandwich (6) has a built-in reinforcing rib (8); Both sides of the sector-shaped reflective surface are provided with assembly interfaces I (3) for assembling two adjacent sector-shaped reflective surfaces; assembly interface II (4) is located at the inner end of the sector-shaped reflective surface and is used for assembling the sector-shaped panel and the central panel.

2. The multi-layer foam composite sandwich structure sector-shaped reflective surface according to claim 1, characterized in that: The working surfaces of the front skin and the rear skin are metallized, and the working surface metal layer (5) is a current continuous conduction surface or a metal arrangement specific pattern surface, and the surface is smooth and flat.

3. The multi-layer foam composite sandwich structure sector-shaped reflective surface according to claim 1, characterized in that: The composite foam interlayer is a structure with multiple foam interlayers stacked in layers; the foam material is one or a combination of multiple of PMI foam, PET foam, and VC foam.

4. The multi-layer foam composite sandwich structure sector-shaped reflective surface according to claim 3, characterized in that: A reinforcement rib reserved groove is arranged on the foam interlayer of the corresponding layer; the reinforcement rib reserved groove can be cross-shaped, X-shaped, pentagonal or hexagonal.

5. The multi-layer foam composite sandwich structure sector-shaped reflective surface according to claim 3, characterized in that: The reinforcement rib reserved groove is filled with high-density foam glue or resin.

6. The multi-layer foam composite sandwich structure sector-shaped reflective surface according to claim 3, characterized in that: The foam layers of the composite foam sandwich are bonded to form a whole, and the bonding is carried out using one or more combinations of liquid adhesives or adhesive films.

7. The multi-layer foam composite sandwich structure sector-shaped reflective surface according to claim 3, characterized in that: The metal layer (5) of the working surface is prepared by flame spraying, electroplating, chemical plating, etching or bonding metal layers.

8. A method for forming a multi-layer foam composite sandwich structure fan-shaped reflective surface, characterized in that: The method for manufacturing a composite foam sandwich structure fan-shaped reflective surface according to any one of claims 1 to 7 comprises the following steps: Step 1, establishing a three-dimensional model of a multi-layer foam composite sandwich structure fan-shaped reflective surface, and designing and processing a mold of the composite foam sandwich structure fan-shaped reflective surface according to the model, including a front skin mold (9) and a rear skin mold (11), and the front skin mold (9) and the rear skin mold (11) can be assembled into a closed cavity; Step 2, applying a mold release agent on the surface of the molding area (10) of the composite foam sandwich structure fan-shaped reflective surface molding mold, and then laying nickel-plated carbon felt impregnated with resin to prepare a metal reflective layer; Step 3, laying a fiber fabric impregnated with resin on the metal reflective layer as a front skin; Step 4, cutting a foam interlayer with a thickness of 1 to 3 mm according to the shape of the front skin; Step 5, according to the shape of the foam cut in step 4, cut another foam interlayer, the thickness of which is freely selected according to the thickness and number of layers of the reflective surface interlayer; Step 6, processing a built-in reinforcement rib reserved groove (8) on one side of the surface of the foam sandwich prepared in step 5; Step 7, filling the reserved groove of the foam interlayer prepared in step 6 with the filling material; Step 8, repeating steps 5 to 7 according to the number of layers of the designed foam interlayer to prepare the remaining interlayers; Step 9, wrapping each foam interlayer in steps 4 to 8 with a film, with the slotted side of the slotted foam interlayer facing the foam prepared in step 4, and bonding them as a whole to form a composite foam interlayer foam, with the slotted area placed inside the composite foam; Step 10, placing the composite foam sandwich foam on the front skin laid in step 3, and focusing on strengthening the assembly interface I and assembly interface II; Step 11, laying a fiber fabric impregnated with resin on the composite foam as a rear skin; Step 12, closing the mold, heating and curing, and demoulding to complete the molding of the fan-shaped reflective surface of the composite foam sandwich structure.

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