Composite material reflecting surface and preparation method thereof

Abstract

The invention discloses a composite material reflecting surface and a preparation method thereof. The composite material reflecting surface comprises an outer skin, an aluminum honeycomb middle interlayer, an inner skin and a metal layer which are sequentially arranged from outside to inside, the metal layer comprises a hollow ring net and a plurality of fan-shaped nets with the same shape, a preset distance is overlapped between each fan-shaped net and the hollow ring net as well as between every two adjacent fan-shaped nets, so that each fan-shaped net and the hollow ring net are matched with each other to form the metal layer; the cost of the reflecting surface is low and is only 1 / 3 of that of carbon fibers; the preparation method disclosed by the invention is simple, short in period and capable of realizing batch production; an autoclave is not needed in the manufacturing process, the metallization spraying step is not needed, and therefore environment pollution is avoided.

Description

Technical Field

[0001] The present invention belongs to the field of reflector surfaces and their preparation, and particularly relates to a composite material reflector surface and a preparation method thereof. Background Art

[0002] In the fields of satellite communication, aerospace, etc., carbon fiber composite material reflector surfaces dominate. Their excellent comprehensive performance meets the stringent requirements of modern technology for reflector surface materials. Most importantly, their excellent electromagnetic performance ensures efficient signal transmission. The metallization of the reflection area of high-precision carbon fiber composite material reflector surfaces is generally by spraying or coating, but this will cause environmental pollution and the manufacturing cost is relatively high. Summary of the Invention

[0003] The purpose of the present invention is to provide a composite material reflector surface and a preparation method thereof to solve the problems of high cost of carbon fiber composite material reflector surfaces and environmental pollution caused by spraying.

[0004] The present invention adopts the following technical solutions: A composite material reflector surface includes: an outer skin, an aluminum honeycomb intermediate sandwich, an inner skin, and a metal layer arranged in sequence from outside to inside; The metal layer includes: A hollow ring network, which is a hollow metal copper mesh ring, and its ring center is the center point of the reflector surface; A plurality of fan-shaped meshes with the same shape, all of which are metal copper meshes, are arranged in a circumferential array with the ring center of the hollow ring network as the center point. A predetermined distance is overlapped between each fan-shaped mesh and the hollow ring network and between two adjacent fan-shaped meshes, so that each fan-shaped mesh and the hollow ring network cooperate with each other to form a metal layer.

[0005] Further, the predetermined distance is 5 mm.

[0006] Further, the metal copper meshes of the hollow ring network and the fan-shaped meshes are both 300 meshes.

[0007] Further, both the inner skin and the outer skin are glass fiber layers.

[0008] A preparation method of a composite material reflector surface includes: Step 1: Fabricate the metal layer; Step 2: Lay the inner skin, the aluminum honeycomb intermediate sandwich, and the outer skin on the outside of the metal layer in sequence to obtain a reflector surface; Among them, Step 1 includes: cutting the metal copper mesh according to the size of the reflector surface to obtain a hollow ring network; then cutting the adhesive film according to the size of the hollow ring network to obtain a first adhesive film with the same size as the hollow ring network, and adhering the first adhesive film to the inner wall of the hollow ring network; adhering the hollow ring network to the reflector surface mold through the first adhesive film, and making the ring center of the hollow ring network coincide with the center point of the reflector surface.

[0009] Further, step 1 further includes: cutting the copper mesh according to the size of the reflecting surface to obtain each sector-shaped mesh, then cutting the adhesive film according to the size of each sector-shaped mesh to obtain the same number of second adhesive films with the same size as the sector-shaped mesh, and adhering the second adhesive films to the inner walls of the respective sector-shaped meshes; adhering the respective sector-shaped meshes to the reflecting surface mold through the respective second adhesive films, and making the respective sector-shaped meshes overlap with each other between the sector-shaped meshes and the hollow ring mesh, and between two adjacent sector-shaped meshes, thereby obtaining the metal layer.

[0010] Further, step 2 includes: Step 201: Lay the inner skin on the outside of the metal layer, then evacuate and dry it to form a first intermediate member; Step 202: Lay a third adhesive film on the outside of the first intermediate member; Step 203: Adhere the aluminum honeycomb intermediate sandwich to the outside of the third adhesive film, then evacuate and dry it to form a second intermediate member; Step 204: Lay a fourth adhesive film on the outside of the second intermediate member; Step 205: Adhere the outer skin to the outside of the fourth adhesive film, then evacuate and dry it to obtain the reflecting surface.

[0011] The beneficial effects of the present invention are: The reflecting surface of the present invention has a low cost, only 1 / 3 of that of carbon fiber; the preparation method of the present invention is simple, has a short cycle, and can be mass-produced; the manufacturing process of the present invention does not require an autoclave and does not require the step of metal spraying, thereby avoiding environmental pollution; In the preparation method of the present invention, evacuation and drying are carried out three times, so that the metal layer and the inner skin are cured together, the aluminum honeycomb intermediate sandwich and the inner skin are cured together, and the outer skin and the aluminum honeycomb intermediate sandwich are cured together, thereby ensuring the fit and corresponding accuracy between the metal layer and the inner skin; and the fit and corresponding accuracy between the aluminum honeycomb intermediate sandwich and the inner skin, and the fit and corresponding accuracy between the outer skin and the aluminum honeycomb intermediate sandwich; In the preparation process of the present invention, each sector-shaped mesh overlaps with the hollow ring mesh and between two adjacent sector-shaped meshes, and the thickness of the reflecting surface is made uniform by laying methods at different angles, avoiding the deformation problem caused by anisotropy, solving the warping and deformation of the reflecting surface, ensuring the required accuracy of the reflecting surface while improving the overall strength and stiffness of the reflecting surface, and the root mean square of the accuracy of the reflecting surface is 0.12 RMS to 0.14 RMS. Description of the Drawings

[0012] Figure 1 is a cross-sectional view of the present invention; Figure 2 is a detailed enlarged view of part A in the cross-sectional view of the present invention; Figure 3This is the layout diagram of the hollow ring network and the sector network in the present invention.

[0013] Among them: 10, inner skin; 11, aluminum honeycomb intermediate layer; 12, outer skin; 13, hollow ring network; 14, sector network. Specific embodiments

[0014] The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0015] In the description of the present invention, it should be understood that the orientation or positional relationship indicated by the terms "center", "longitudinal", "transverse", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. is based on the orientation or positional relationship shown in the accompanying drawings. It is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation to the present invention. In addition, the terms "first" and "second" are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly indicating the quantity of the indicated technical features. Thus, the features defined with "first" and "second" may explicitly or implicitly include one or more of such features. In the description of the present invention, unless otherwise specified, the meaning of "a plurality" is two or more. The "orientation" in the present invention is described based on the orientation of the present invention in the Figure 1 state.

[0016] The present invention discloses a composite material reflector surface, as Figures 1-3 shown, including: an outer skin 12, an aluminum honeycomb intermediate layer 11, an inner skin 10, and a metal layer arranged in sequence from outside to inside.

[0017] The metal layer includes: a hollow ring network 13 and a plurality of sector networks 14 of the same shape.

[0018] The hollow ring network 13 is a hollow ring-shaped copper mesh, and the center of the ring of the hollow ring network 13 is the center point of the reflector surface.

[0019] A plurality of sector networks 14 of the same shape are all copper meshes. A plurality of sector networks 14 are all arranged in a circular array with the center of the ring of the hollow ring network 13 as the center point. A predetermined distance is overlapped between each sector network 14 and the hollow ring network 13 and between two adjacent sector networks 14. Thus, each sector network 14 and the hollow ring network 13 cooperate with each other to form a metal layer.

[0020] Preferably, the predetermined distance is 5 mm.

[0021] Preferably, the copper meshes of the hollow ring network 13 and the sector network 14 are both 300 mesh.

[0022] Preferably, both the inner skin 10 and the outer skin 12 are glass fiber layers.

[0023] The present invention also discloses a method for preparing a composite material reflector surface, comprising: Step 1: fabricate a metal layer; Step 2: sequentially lay the inner skin 10, the aluminum honeycomb intermediate sandwich 11, and the outer skin 12 on the outside of the metal layer to obtain the reflector surface.

[0024] Among them, Step 1 includes: cutting the metal copper mesh according to the size of the reflector surface to obtain a hollow ring mesh 13; then cutting the adhesive film according to the size of the hollow ring mesh 13 to obtain a first adhesive film with the same size as the hollow ring mesh 13, and adhering the first adhesive film to the inner wall of the hollow ring mesh 13; adhering the hollow ring mesh 13 to the reflector surface mold through the first adhesive film, and making the center of the ring of the hollow ring mesh 13 coincide with the center point of the reflector surface.

[0025] Step 1 further includes: cutting the metal copper mesh according to the size of the reflector surface to obtain each sector mesh 14, then cutting the adhesive film according to the size of each sector mesh 14 to obtain the same number of second adhesive films with the same size as the sector mesh 14, and respectively adhering the second adhesive films to the inner walls of each sector mesh 14; adhering each sector mesh 14 to the reflector surface mold through each second adhesive film, and making each sector mesh 14 overlap with the hollow ring mesh 13 and also overlap between two adjacent sector meshes 14, thereby obtaining the metal layer.

[0026] Step 2 includes: Step 201: lay the inner skin 10 on the outside of the metal layer, then evacuate and dry it to form a first intermediate member; Step 202: lay a third adhesive film on the outside of the first intermediate member; Step 203: adhere the aluminum honeycomb intermediate sandwich 11 to the outside of the third adhesive film, then evacuate and dry it to form a second intermediate member; Step 204: lay a fourth adhesive film on the outside of the second intermediate member; Step 205: adhere the outer skin 12 to the outside of the fourth adhesive film, then evacuate and dry it to form the reflector surface.

[0027] The metal layer of the present invention can provide electromagnetic reflection characteristics equivalent to those of carbon fiber and ensure sufficient mechanical strength. The signal transmission efficiency of the reflector surface of the present invention is equivalent to that of a carbon fiber reflector surface, and the material cost is only 1 / 3 of that of carbon fiber, thereby reducing the cost by more than 60%.

[0028] Example 1: In this example, a parabolic reflector surface with a diameter of 1800 mm needs to be fabricated, and a total of 12 sector meshes 14 and 1 hollow ring mesh 13 are used to fabricate the metal layer.

[0029] The diameter of the reflector mold is 1800 mm, and the surface arch height of the reflector mold is 335 mm.

[0030] The metal copper meshes of the hollow ring net 13 and the sector net 14 are both 300 - mesh plain - woven copper meshes.

[0031] The outer - circle diameter of the hollow ring net 13 is 500 mm, and the inner - circle diameter is 130 mm.

[0032] The aluminum honeycomb of the aluminum honeycomb intermediate sandwich 11 is hexagonal, and the hexagonal wall thickness of the aluminum honeycomb intermediate sandwich 11 is 0.05 mm.

[0033] The radius of the sector net 14 is 1070 mm, and the arc length is 560 mm.

[0034] The first adhesive film, the second adhesive film, the third adhesive film, and the fourth adhesive film all select adhesive films with a curing temperature of 120 °C, and the model of the adhesive film is LJM - 300.

[0035] Each sector net 14 and the hollow ring net 13, as well as between two adjacent sector nets 14, overlap each other by 5 mm.

[0036] Before manufacturing the reflector, clean the reflector mold and heat it to 40 °C - 50 °C, and apply a release agent on the surface of the reflector mold.

[0037] The specific steps include: Step 1: Manufacture the metal layer; Step 2: Lay the inner skin 10, the aluminum honeycomb intermediate sandwich 11, and the outer skin 12 on the outside of the metal layer in sequence to obtain the reflector; Among them, Step 1 includes: Adhere the first adhesive film to the inner wall of the hollow ring net 13; through the first adhesive film, adhere the hollow ring net 13 to the reflector mold, and make the center of the ring of the hollow ring net 13 coincide with the center point of the reflector; Adhere each second adhesive film to the inner wall of each sector net 14; through each second adhesive film, adhere each sector net 14 to the reflector mold, and make each sector net 14 and the hollow ring net 13, as well as between two adjacent sector nets 14, overlap each other, thereby obtaining the metal layer.

[0038] Among them, Step 2 includes: Step 201: Lay the inner skin 10 on the outside of the metal layer, then evacuate and dry it to form the first intermediate piece; among them, the vacuum pressure ≤ - 0.093 Mpa, and it remains without pressure drop for 5 minutes; drying conditions: first keep warm at 70 °C for 100 min, then keep warm at 130 °C for 200 min.

[0039] Step 202: Lay the third adhesive film on the outside of the first intermediate piece; Step 203: Adhere the aluminum honeycomb middle interlayer 11 to the outside of the third adhesive film, then evacuate and dry it to form the second intermediate part; wherein, the vacuum pressure ≤ -0.093 Mpa, and it keeps the pressure stable for 5 minutes; drying conditions: first keep warm at 70 °C for 100 min, and then keep warm at 130 °C for 200 min.

[0040] Step 204: Lay the fourth adhesive film on the outside of the second intermediate part; Step 205: Adhere the outer skin 12 to the outside of the fourth adhesive film, then evacuate and dry it to form the reflecting surface. wherein, the vacuum pressure ≤ -0.093 Mpa, and it keeps the pressure stable for 5 minutes; drying conditions: first keep warm at 70 °C for 100 min, and then keep warm at 130 °C for 200 min.

[0041] The surface accuracy of the reflecting surface prepared in the embodiment was detected by a photogrammetry instrument, and the detection results are shown in Table 1.

[0042] Table 1 Detection Results

[0043] In Table 1, dX represents the deviation of the vector in the X direction, dY represents the deviation of the vector in the Y direction, dZ represents the deviation of the vector in the Z direction, the length Mag represents the length of the vector, the minimum value represents the minimum value of the deviations in each direction and the vector length, the maximum value is the maximum value of the deviations in each direction and the vector length, and the average value represents the average value of the deviations in each direction and the vector length.

[0044] It can be seen from the tolerance analysis in Table 1 that the tolerance range is ±0.76 mm, all 189 data points are within the tolerance range, and 0 data points exceed the tolerance range. The displacement change is relatively small, the maximum displacement in all directions does not exceed 0.23 mm, all measurement results are within the specified tolerance range, and the root mean square RMS of the overall accuracy of the product is 0.1 mm, which indicates that the performance of the reflecting surface is good.

[0045] The above are only the preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A composite material reflective surface, characterized in that: include: An outer skin (12), an aluminum honeycomb intermediate layer (11), an inner skin (10), and a metal layer are sequentially arranged from the outside to the inside; The metal layer comprises: The hollow ring mesh (13) is a hollow ring-shaped metal copper mesh, the center of which is the center point of the reflection surface; A plurality of fan-shaped nets (14) of the same shape, all of which are metal copper nets, are arranged in a circular array with the center of the hollow ring net (13) as the center point, and each fan-shaped net (14) and the hollow ring net (13) as well as two adjacent fan-shaped nets (14) are overlapped by a predetermined distance, so that each fan-shaped net (14) and the hollow ring net (13) cooperate with each other to form a metal layer.

2. A composite material reflective surface according to claim 1, characterized in that: The predetermined distance is 5 mm.

3. The composite material reflective surface according to claim 1, characterized in that: The metal copper meshes of the hollow ring mesh (13) and the fan-shaped mesh (14) are both 300 meshes.

4. The composite material reflective surface according to claim 1, characterized in that: The inner skin (10) and the outer skin (12) are both glass fiber layers.

5. A method for preparing a composite material reflective surface according to any one of claims 1 to 4, characterized in that: include: Step 1: Make the metal layer; Step 2: laying an inner skin (10), an aluminum honeycomb middle layer (11), and an outer skin (12) in sequence on the outer side of the metal layer to obtain a reflective surface; Wherein, step 1 comprises: cutting the metal copper mesh according to the size of the reflective surface to obtain the hollow ring net (13); then cutting the adhesive film according to the size of the hollow ring net (13) to obtain a first adhesive film of the same size as the hollow ring net (13), and adhering the first adhesive film to the inner wall of the hollow ring net (13); and adhering the hollow ring net (13) to the reflective surface mold through the first adhesive film, so that the center of the hollow ring net (13) coincides with the center point of the reflective surface.

6. The method for preparing a composite material reflective surface according to claim 5, characterized in that: The step 1 further comprises: cutting the metal copper mesh according to the size of the reflective surface to obtain each of the fan-shaped meshes (14), then cutting the adhesive film according to the size of each of the fan-shaped meshes (14) to obtain a second adhesive film of the same size and number as the fan-shaped mesh (14), and respectively adhering the second adhesive film to the inner wall of each of the fan-shaped meshes (14); adhering each of the fan-shaped meshes (14) to the reflective surface mold through each of the second adhesive films, and making each of the fan-shaped meshes (14) and the hollow ring mesh (13) and two adjacent fan-shaped meshes (14) overlap each other, thereby obtaining a metal layer.

7. The method for preparing a composite material reflective surface according to claim 6, characterized in that: The step 2 comprises: Step 201: laying the inner skin (10) on the outer side of the metal layer, and then vacuuming and drying to obtain a first intermediate component; Step 202: laying a third adhesive film on the outer side of the first middle piece; Step 203: adhering the aluminum honeycomb intermediate interlayer (11) to the outer side of the third adhesive film, and then vacuumizing and drying to obtain a second intermediate component; Step 204: laying a fourth adhesive film on the outer side of the second middle piece; Step 205: Adhere the outer skin (12) to the outer side of the fourth adhesive film, and then evacuate and dry to obtain a reflective surface.

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