A copper foil efficient bending device based on 3D printing technology

Abstract

This invention discloses a high-efficiency copper foil bending device based on 3D printing technology, relating to the technical field of TEM horn antennas. To address the problem, it specifically includes: two symmetrically arranged slot frames printed by a 3D printing device, each slot frame extending outward from its main body with a gradually changing curvature of different indices; and a mounting slot formed on one side of the slot frames for mounting the copper foil. The mounting slot is a channel structure with openings at both ends and longitudinal curvature, and the curvature change of the mounting slot is consistent with the curved edge of the slot frames. This invention provides a slot frame manufactured using 3D printing technology, which allows for precise bending of the copper foil to the required curvature, thereby achieving efficient bending of the copper foil. This effectively solves the problems existing in the prior art. By using 3D printing technology to manufacture the slot frame and mounting slot, this structure allows for precise bending of the copper foil to the required curvature.

Description

Technical Field

[0001] This invention relates to the field of TEM horn antenna technology, and in particular to a high-efficiency copper foil bending device based on 3D printing technology. Background Technology

[0002] In traditional TEM horn antenna design, the bending of the antenna's radiating portion typically requires conventional metalworking techniques such as mechanical bending, stamping, and milling. While these processes can achieve the desired bending shape, they have several significant drawbacks. First, they are costly and involve complex processes. Traditional metalworking techniques usually require high-precision machinery and result in significant material loss during processing, often necessitating multiple adjustments and repetitive operations, leading to high production costs. Furthermore, the manufacturing process is complex, involving multiple steps, from cutting and bending the copper foil to surface treatment, all requiring corresponding technical support and substantial manual labor. For applications requiring rapid iteration or low-volume production, the high cost and low efficiency of traditional processing methods often fail to meet the demands. Second, they lack manufacturing flexibility. In traditional manufacturing processes, the precision of metalworking is limited by equipment and technology, and the shape of the processed copper foil is often fixed, making flexible adjustments difficult. When design requirements or antenna specifications change, it is usually necessary to remake molds or adjust production processes, significantly increasing R&D cycles and manufacturing costs. Therefore, traditional methods lack sufficient flexibility and adaptability when facing complex or diverse design requirements. Simultaneously, issues with process accuracy and consistency also exist. Traditional metalworking methods rely on manual labor, resulting in significant errors in the manufacturing process, especially during large-scale production. Differences between products can affect the final antenna performance. In antenna designs requiring high precision, even minute manufacturing errors can lead to inconsistencies in electromagnetic wave propagation characteristics, thus impacting antenna performance and stability. Furthermore, traditional TEM horn antennas have long production cycles and slow response times. Traditional antenna designs often rely on multiple trials and modifications, each requiring the creation of new molds or adjustments to production equipment. This not only extends the product design cycle but also reduces responsiveness to market changes. In the rapidly evolving fields of modern communication technology and scientific research, traditional manufacturing methods cannot meet the demands of rapid iteration and flexible production.

[0003] In summary, while existing traditional metal processing technologies have solved the shape bending problem in antenna design to some extent, their high cost, low efficiency, poor flexibility, and unstable accuracy severely limit their application in complex, high-precision antenna designs. Therefore, there is an urgent need for a new, efficient, flexible, and cost-controllable manufacturing method to overcome the limitations of existing technologies. Summary of the Invention

[0004] The purpose of this invention is to address the shortcomings of existing technologies by proposing a high-efficiency copper foil bending device based on 3D printing technology.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A high-efficiency copper foil bending device based on 3D printing technology includes: two symmetrically arranged slots printed by a 3D printing device, each slot extending outward from its main body with a gradually changing curvature of different indices; a mounting slot formed on one side of the slot for mounting copper foil, the mounting slot being a channel structure with openings at both ends and longitudinally curved, and the curvature of the mounting slot being consistent with the arc edge of the slot; a fixing member for connecting and fixing one end of the two slots; and an auxiliary mechanism for facilitating the installation of copper foil in the mounting slot.

[0007] Preferably, the fixing member has a welding groove and a plug groove, one end of the groove frame is movably engaged in the plug groove, and a welding block is connected to one end of the groove frame, the welding block being movably engaged with the welding groove.

[0008] Furthermore, the auxiliary mechanism includes a sliding rail connected to the side of the slot frame away from the mounting slot, a slider slidably connected to the sliding rail, a connecting frame connected to the slider, and a clamping assembly connected to the connecting frame for clamping the copper foil.

[0009] Based on the aforementioned solution: the slider includes two sliders slidably connected to the sliding track and the two sliders connected to the connecting plate, and both sliders are rotatably connected to the connecting plate, and the connecting plate is connected to a paddle for easy hand gripping.

[0010] As a further aspect of the present invention: the connecting frame includes a disassembly block connected to the connecting plate and a drive rod connected to the disassembly block via a buckle. A groove block is connected to the end of the drive rod away from the disassembly block, and a limiting groove with a certain depth is provided at the end of the groove block.

[0011] Meanwhile, the clamping assembly includes a plug plate that is movably inserted into a limiting groove at one end, an adjusting member connected to the other end of the plug plate, and two symmetrically arranged clamping plates connected to the adjusting member. The adjusting member can stably clamp the copper foil by adjusting the distance between the two clamping plates.

[0012] As a preferred embodiment of the present invention: a fixing bolt is provided on the limiting groove, one end of the fixing bolt extends through the top wall of the limiting groove into the limiting groove, and when the plug plate is inserted into the limiting groove, the plug plate is fixed by the fixing bolt.

[0013] Preferably, the adjusting component includes a frame plate fixedly connected to the plug-in plate, two symmetrically arranged threaded plates slidably connected within the frame plate, and a bidirectional threaded rod rotatably connected within the frame plate. The two ends of the bidirectional threaded rod are respectively threadedly connected to the two threaded plates, and the clamping plate is connected to the threaded plates. A stop pad is provided on the side of the frame plate near the clamping plate, and the stop pad is in active contact with the edge of the copper foil.

[0014] Preferably, the disassembly block has a sliding groove, and the fastener includes a pin block slidably connected in the sliding groove and a spring connecting the pin block to the sliding groove. The driving rod has a locking groove of a corresponding size to the pin block, and a pulling post is fixedly connected to the pin block. The pulling post is slidably connected to the disassembly block. A spring plate is provided on one side of the disassembly block, and a spring second connected to the spring plate. A push plate is connected to one end of the spring second. When the driving rod is locked in the disassembly block, the push plate abuts against one end of the driving rod.

[0015] Finally, an elastic sheet one is fixedly connected to one side of the disassembly block, and an elastic sheet two is connected to the fastener at a position corresponding to the elastic sheet one. The elastic sheet one and the elastic sheet two are movably engaged.

[0016] The beneficial effects of this invention are as follows:

[0017] 1. This invention provides a slot frame manufactured using 3D printing technology. This slot frame structure allows for the precise bending of copper foil into the required arc, thereby achieving efficient bending of copper foil. It effectively solves the problems of high cost, low efficiency, poor flexibility, and insufficient precision in existing technologies. By using 3D printing technology to manufacture the slot frame and mounting slot, and utilizing this structure to precisely bend copper foil into the required arc, the traditional antenna manufacturing process is simplified, production efficiency is improved, and costs are reduced. This overcomes the limitations of existing technologies and meets the needs of modern communication, radiation systems, electromagnetic compatibility testing, and other fields.

[0018] 2. In this invention, by setting an auxiliary mechanism on the slot frame, the sliding member can be slid onto the sliding track first, and then the clamping assembly is connected to the connecting frame to stably clamp the copper foil. When the sliding member is slid, the clamping assembly will be moved through the connecting frame, thereby moving the copper foil in the installation slot, avoiding the bending of the copper foil caused by manual installation.

[0019] 3. By utilizing the snap-fit ​​connection between the various structures on the auxiliary mechanism, after the copper foil is installed in the mounting slot, the corresponding structure can be disassembled without affecting signal transmission and radiation. Furthermore, these structures can adapt to slots with different bending angles, and copper foils on multiple slots can be installed using the same set of these structures, saving manufacturing costs and increasing practicality. Attached Figure Description

[0020] Figure 1 This is a three-dimensional structural diagram of a high-efficiency copper foil bending device based on 3D printing technology proposed in this invention;

[0021] Figure 2 This is a left view of a high-efficiency copper foil bending device based on 3D printing technology proposed in this invention;

[0022] Figure 3 This is a schematic diagram of the mounting groove structure of a high-efficiency copper foil bending device based on 3D printing technology proposed in this invention;

[0023] Figure 4 This is a partial structural diagram of a high-efficiency copper foil bending device based on 3D printing technology proposed in this invention. Figure 1 ;

[0024] Figure 5 This is a partial structural diagram of a high-efficiency copper foil bending device based on 3D printing technology proposed in this invention. Figure 2 ;

[0025] Figure 6 This is a schematic diagram of the fixing component and welding block structure of a high-efficiency copper foil bending device based on 3D printing technology proposed in this invention;

[0026] Figure 7 This is a three-dimensional structural diagram of the auxiliary mechanism of an efficient copper foil bending device based on 3D printing technology proposed in this invention.

[0027] Figure 8 This invention presents a schematic diagram of the three-dimensional structure of a connecting frame for a high-efficiency copper foil bending device based on 3D printing technology. Figure 1 ;

[0028] Figure 9 This is a schematic diagram of the clamping component structure of a high-efficiency copper foil bending device based on 3D printing technology proposed in this invention;

[0029] Figure 10 This invention presents a schematic diagram of the three-dimensional structure of a connecting frame for a high-efficiency copper foil bending device based on 3D printing technology. Figure 2 ;

[0030] Figure 11 This is a schematic diagram of the cross-sectional structure of the buckle component of a high-efficiency copper foil bending device based on 3D printing technology proposed in this invention;

[0031] Figure 12 CST simulation test diagram of a high-efficiency copper foil bending device based on 3D printing technology proposed in this invention. Figure 1 ;

[0032] Figure 13 CST simulation test diagram of a high-efficiency copper foil bending device based on 3D printing technology proposed in this invention. Figure 2 .

[0033] In the diagram: 1. Slot frame; 2. Mounting slot; 3. Fixing component; 30. Welding slot; 31. Insertion slot; 32. Welding block; 4. Sliding rail; 5. Sliding component; 501. Slider; 502. Connecting plate; 503. Paddle; 6. Connecting frame; 601. Disassembly block; 602. Driving rod; 603. Slot block; 604. Limiting slot; 7. Clamping assembly; 701. Insertion plate; 702. Clamping plate; 703. Frame plate; 704. Threaded plate; 705. Two-way threaded rod; 706. Backing pad; 8. Fixing bolt one; 9. Sliding slot; 10. Pin block; 11. Spring one; 12. Snap-fit ​​slot; 13. Pulling column; 14. Spring plate; 15. Spring two; 16. Push plate; 17. Elastic sheet one; 1803. Elastic sheet two; 19. Coaxial balun; 20. Loading medium. Detailed Implementation

[0034] The technical solution of the present invention will be further described in detail below with reference to specific embodiments.

[0035] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0036] Example 1:

[0037] A high-efficiency copper foil bending device based on 3D printing technology, such as Figures 1-13 As shown, the device includes two symmetrically arranged slot frames 1 printed by a 3D printer, an installation slot 2 opened on one side of the slot frame 1 for mounting copper foil, a fixing member 3 for connecting and fixing one end of the two slot frames 1, and an auxiliary mechanism. Specifically, one end of the slot frame 1 bends outward from the body and the curvature is a gradually changing curve with different indices; the installation slot 2 is a channel structure with openings at both ends and longitudinal curvature, with both ends of the installation slot 2 connected to the outside, and the curvature change of the installation slot 2 is consistent with the arc edge of the slot frame 1; the auxiliary mechanism is used to facilitate the installation of copper foil in the installation slot 2.

[0038] The 3D printing equipment mentioned is an existing technology structure. When printing the printing slot 1, it is operated based on existing 3D printing technology. The materials used are selected according to the actual use and are not limited.

[0039] In this invention, the slot frame 1 for copper foil mounting can be quickly manufactured directly by 3D printing. The slot frame 1 structure with pre-set mounting slots 2 is manufactured by 3D printing. The deformation of the copper foil is controlled by utilizing the geometric characteristics of the mounting slots 2, such as depth, spacing, angle, etc. Moreover, by using 3D printing technology, the bending angle tolerance of the mounting slots 2 on the slot frame 1 can reach ±0.2°, and the surface smoothness Ra<1.6μm, which meets the radiation accuracy requirements of 5G millimeter wave antennas.

[0040] A coaxial balun 19 is provided on one side of the slot 1 to connect to the end of the copper foil, and a loading medium 20 is provided between the two slots 1. The coaxial balun 19 is used for balance conversion, while the loading medium 20 optimizes impedance gradient. The two work together to improve the bandwidth and efficiency of the overall antenna. The two have a synergistic effect in electromagnetic performance regulation and signal transmission, and also play different functional roles. When connecting with the coaxial balun 19, the connection is reliably connected by a soldering machine.

[0041] Specifically, two slot frames 1 printed by the 3D printing equipment are symmetrically fixed, and then copper foil is inserted into the mounting slot 2 through one end opening. Under the action of mechanical force, the copper foil undergoes plastic deformation along the bending structure of the mounting slot 2. Since the thickness of the mounting slot 2 is basically the same as the thickness of the copper foil, the mounting slot 2 can also support the copper foil and reduce the vibration amplitude of the copper foil. During the installation process, the copper foil can be guided to slide in the mounting slot 2 using an auxiliary mechanism to avoid bending of the copper foil caused by manual installation.

[0042] The design of the depth, spacing, and angle of the mounting slot 2 allows for precise control of stress concentration points, achieving millimeter-level bending accuracy. Using this method, the installation of copper foil allows the coaxial cable's characteristic impedance to smoothly transition from 50 ohms to 377 ohms in free space, reducing antenna return loss. Before mass production, existing technologies such as finite element analysis can be used to parametrically model the slot frame 1 structure, ensuring a balance between material ductility and structural strength during bending. This information and drawings are then transferred to a 3D printing machine, and the slot frame 1 with a certain degree of bending is printed. Furthermore, for TEM horn plates modified with different exponential gradient curves, replacement can be achieved by adjusting the slot frame 1, reducing cost and time. Therefore, the 3D-printed TEM horn bracket features rapid processing and high manufacturing precision, making it widely applicable to simple antenna fabrication.

[0043] To solve the problem of fixing the two slotted brackets 1; such as Figure 6As shown, the fixing member 3 has a welding groove 30 and a plug groove 31. One end of the slot frame 1 is movably engaged in the plug groove 31. A welding block 32 is connected to one end of the slot frame 1. The welding block 32 is movably engaged with the welding groove 30. After the slot frame 1 is installed on the fixing member 3, the welding block 32 is connected to the welding groove 30 by welding.

[0044] To solve the problem of convenient and accurate installation of copper foil in mounting slot 2; such as Figures 7-11 As shown, the auxiliary mechanism includes a sliding rail 4 connected to the side of the slot frame 1 away from the mounting slot 2, a sliding member 5 slidably connected to the sliding rail 4, a connecting frame 6 connected to the sliding member 5, and a clamping assembly 7 connected to the connecting frame 6 for clamping the copper foil. In use, the sliding member 5 is first slid onto the sliding rail 4, and then the clamping assembly 7 is connected to the connecting frame 6 to stably clamp the copper foil. When the sliding member 5 is slid, the clamping assembly 7 will move through the connecting frame 6, thereby moving the copper foil within the mounting slot 2.

[0045] To solve the problem of ensuring stable sliding of the slider 5 on the curved sliding track 4; such as Figure 7 As shown, the slider 5 includes two sliders 501 slidably connected to the sliding rail 4 and a connecting plate 502 connecting the two sliders 501. The sliding rail 4 is printed together with the slot frame 1 by the 3D printing equipment to keep the curvature of the two consistent. The two sliders sliding on the sliding rail 4 are more stable than the single slider sliding on the sliding rail 4. Both sliders 501 are rotatably connected to the connecting plate 502, so they will bend adaptively when passing through a curved path. The connecting plate 502 is connected to a paddle 503 for easy hand holding.

[0046] To address the issue of connecting the clamping assembly 7, which stably holds the copper foil, to the sliding member 5; as... Figures 8-11 As shown, firstly, the connecting frame 6 is connected to the connecting plate 502 on the sliding member 5. Therefore, the connecting frame 6 includes a disassembly block 601 connected to the connecting plate 502 and a driving rod 602 connected to the disassembly block 601 through a buckle. A groove block 603 is connected to the end of the driving rod 602 away from the disassembly block 601. A limiting groove 604 with a certain depth is opened at the end of the groove block 603.

[0047] The clamping assembly 7 includes a plug-in plate 701 that is movably plugged into the limiting groove 604 at one end, an adjusting member connected to the other end of the plug-in plate 701, and two symmetrically arranged clamping plates 702 connected to the adjusting member. The adjusting member adjusts the distance between the two clamping plates 702 to stably clamp the copper foil. The side of the clamping plate 702 facing the copper foil has a certain curvature to avoid damage to the copper foil when it passes through a curved path.

[0048] In order to make the plug plate 701 stable and effective in the limiting groove 604, a fixing bolt 8 is provided on the limiting groove 604. One end of the fixing bolt 8 extends through the top wall of the limiting groove 604 into the limiting groove 604. When the plug plate 701 is inserted into the limiting groove 604, the fixing bolt 8 is used to hold and fix the plug plate 701 in place.

[0049] The adjusting component includes a frame plate 703 fixedly connected to the plug-in plate 701, two symmetrically arranged threaded plates 704 slidably connected within the frame plate 703, and a bidirectional threaded rod 705 rotatably connected within the frame plate 703. The two ends of the bidirectional threaded rod 705 are threadedly connected to the two threaded plates 704 respectively, and the clamping plate 702 is connected to the threaded plates 704. A stop pad 706 is provided on the side of the frame plate 703 near the clamping plate 702. The stop pad 706 is in active contact with the edge of the copper foil. When the copper foil contacts the stop pad 706, the plug-in plate 701 is stopped from being further inserted into the limiting groove 604, thus avoiding damage to the edge of the copper foil.

[0050] The disassembly block 601 has a sliding groove 9. The fastener includes a pin 10 that is slidably connected in the sliding groove 9 and a spring 11 that connects the pin 10 to the sliding groove 9. The drive rod 602 has a snap-fit ​​groove 12 of the same size as the pin 10. A pull post 13 is fixedly connected to the pin 10 and is slidably connected to the disassembly block 601.

[0051] A spring plate 14 and a second spring 15 connected to the spring plate 14 are provided on one side of the disassembly block 601. A push plate 16 is connected to one end of the second spring 15. When the driving rod 602 is engaged in the disassembly block 601, the push plate 16 abuts against one end of the driving rod 602.

[0052] When in use, all the above structures are connected by snap-fit. Therefore, after the copper foil is installed in the mounting slot 2, the corresponding structure can be disassembled in order not to affect the signal transmission and radiation. Moreover, these structures can adapt to slot frames 1 with different bending angles. The same set of these structures can be used to install copper foil on multiple slot frames 1, which saves manufacturing costs and increases practicality.

[0053] Finally, an elastic sheet 17 is fixedly connected to one side of the disassembly block 601, and an elastic sheet 1803 is connected to the fixing part 3 at the position corresponding to the elastic sheet 17. The elastic sheet 17 and the elastic sheet 1803 are respectively provided with protrusions and grooves. The elastic sheet 17 and the elastic sheet 1803 are movably engaged to facilitate stabilization after the sliding part 5 finishes sliding.

[0054] in, Figure 11 as well as Figure 12Through CST simulation, it was found that the VSWR of this antenna structure is less than 2.5 in the 1-4 GHz frequency band, and the maximum gain is greater than 10 dBi at each frequency.

[0055] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A high-efficiency copper foil bending device based on 3D printing technology, characterized in that, include: Two symmetrically arranged slots (1) are printed by a 3D printing device. One end of each slot (1) extends outward from the body and the curvature is a gradual curve with different indices. An installation groove (2) is formed on one side of the slot frame (1) for installing copper foil. The installation groove (2) is a channel structure with openings at both ends and longitudinal curvature, and the curvature of the installation groove (2) is consistent with the arc edge of the slot frame (1). A fastener (3) for connecting and fixing one end of the two slot frames (1); An auxiliary mechanism is provided to facilitate the installation of copper foil in the mounting slot (2); The auxiliary mechanism includes a sliding rail (4) connected to the side of the slot frame (1) away from the mounting slot (2), a sliding member (5) slidably connected to the sliding rail (4), a connecting frame (6) connected to the sliding member (5), and a clamping assembly (7) connected to the connecting frame (6) for clamping the copper foil. The slider (5) includes two sliders (501) slidably connected to the sliding rail (4) and a connecting plate (502) connecting the two sliders (501). Both sliders (501) are rotatably connected to the connecting plate (502). A paddle (503) for easy hand grip is connected to the connecting plate (502).

2. The high-efficiency copper foil bending device based on 3D printing technology according to claim 1, characterized in that, The fastener (3) has a welding groove (30) and a plug groove (31). One end of the slot frame (1) is movably engaged in the plug groove (31). A welding block (32) is connected to one end of the slot frame (1). The welding block (32) is movably engaged with the welding groove (30).

3. The high-efficiency copper foil bending device based on 3D printing technology according to claim 1, characterized in that, The connecting frame (6) includes a disassembly block (601) connected to the connecting plate (502) and a drive rod (602) connected to the disassembly block (601) by a buckle. A groove block (603) is connected to one end of the drive rod (602) away from the disassembly block (601). A limiting groove (604) with a certain depth is opened at the end of the groove block (603).

4. The high-efficiency copper foil bending device based on 3D printing technology according to claim 3, characterized in that, The clamping assembly (7) includes a plug plate (701) that is movably plugged into a limiting groove (604) at one end, an adjusting member connected to the other end of the plug plate (701), and two symmetrically arranged clamping plates (702) connected to the adjusting member. The adjusting member adjusts the distance between the two clamping plates (702) to stably clamp the copper foil.

5. The high-efficiency copper foil bending device based on 3D printing technology according to claim 4, characterized in that, The limiting groove (604) is provided with a fixing bolt (8). One end of the fixing bolt (8) extends through the top wall of the limiting groove (604) into the limiting groove (604). When the plug plate (701) is inserted into the limiting groove (604), the plug plate (701) is fixed by the fixing bolt (8).

6. The high-efficiency copper foil bending device based on 3D printing technology according to claim 5, characterized in that, The adjusting component includes a frame plate (703) fixedly connected to the plug plate (701), two symmetrically arranged threaded plates (704) slidably connected within the frame plate (703), and a bidirectional threaded rod (705) rotatably connected within the frame plate (703). The two ends of the bidirectional threaded rod (705) are respectively threadedly connected to the two threaded plates (704), and the clamping plate (702) is connected to the threaded plates (704). The frame plate (703) is provided with a stop pad (706) on the side near the clamping plate (702), and the stop pad (706) is in active contact with the edge of the copper foil.

7. The high-efficiency copper foil bending device based on 3D printing technology according to claim 4, characterized in that, The disassembly block (601) has a sliding groove (9) inside. The fastener includes a pin (10) that is slidably connected in the sliding groove (9) and a spring (11) that connects the pin (10) to the sliding groove (9). The drive rod (602) has a snap-fit ​​groove (12) of the same size as the pin (10). A pull post (13) is fixedly connected to the pin (10). The pull post (13) is slidably connected to the disassembly block (601). The disassembly block (601) has a spring plate (14) on one side and a second spring (15) connected to the spring plate (14). A push plate (16) is connected to one end of the second spring (15). When the driving rod (602) is engaged in the disassembly block (601), the push plate (16) abuts against one end of the driving rod (602).

8. The high-efficiency copper foil bending device based on 3D printing technology according to claim 4, characterized in that, On one side of the disassembly block (601), an elastic sheet one (17) is fixedly connected, and on the fastener (3) at the position corresponding to the elastic sheet one (17), an elastic sheet two (1803) is connected, and the elastic sheet one (17) and the elastic sheet two (1803) are movably engaged.

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