Composite material reflecting surface and preparation method thereof

Abstract

The present invention discloses a composite material reflecting surface and a preparation method thereof. The composite material reflecting surface comprises: an outer skin, an aluminum honeycomb intermediate layer, an inner skin, and a metal layer, which are arranged in sequence from the outside to the inside. The metal layer comprises: a hollow ring net, a plurality of fan-shaped nets of the same shape, each fan-shaped net and the hollow ring net, as well as two adjacent fan-shaped nets, are overlapped at a predetermined distance, so that each fan-shaped net and the hollow ring net cooperate with each other to form a metal layer. The reflecting surface of the present invention has a low cost, which is 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 production process of the present invention does not require an autoclave or a metallization spraying step, thereby avoiding environmental pollution.

Description

Technical Field

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

[0002] Carbon fiber composite reflectors dominate the fields of satellite communications, aerospace, and more. Their superior overall performance meets the stringent requirements of modern technology for reflector materials. Most importantly, their excellent electromagnetic properties ensure efficient signal transmission. High-precision carbon fiber composite reflectors are typically metallized in the reflective area by spraying or coating, but this can pollute the environment and increase manufacturing costs. Summary of the Invention

[0003] The purpose of the present invention is to provide a composite material reflective surface and a preparation method thereof, so as to solve the problems of high cost and environmental pollution of carbon fiber composite material reflective surface.

[0004] The present invention adopts the following technical solution: a composite material reflective surface, comprising: an outer skin, an aluminum honeycomb middle layer, an inner skin, and a metal layer arranged in sequence from the outside to the inside;

[0005] The metal layer includes:

[0006] Hollow ring mesh is a hollow ring-shaped metal copper mesh, the center of which is the center point of the reflective surface;

[0007] Multiple fan-shaped nets of the same shape are all metal copper nets, and are arranged in a circular array with the center of the hollow ring net as the center point. Each fan-shaped net and the hollow ring net, as well as two adjacent fan-shaped nets, are overlapped by a predetermined distance, so that each fan-shaped net and the hollow ring net cooperate with each other to form a metal layer.

[0008] Further, the predetermined distance is 5 mm.

[0009] Furthermore, the metal copper meshes of the hollow ring mesh and the fan-shaped mesh are both 300 meshes.

[0010] Furthermore, both the inner skin and the outer skin are glass fiber layers.

[0011] A method for preparing a composite material reflective surface, comprising:

[0012] Step 1: Make the metal layer;

[0013] Step 2: Lay the inner skin, aluminum honeycomb middle layer, and outer skin on the outside of the metal layer in sequence to obtain the reflective surface;

[0014] Among them, step 1 includes: cutting the metal copper mesh according to the size of the reflective 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 of 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 reflective surface mold through the first adhesive film, and making the center of the hollow ring network coincide with the center point of the reflective surface.

[0015] Furthermore, step 1 also includes: cutting the metal copper mesh according to the size of the reflecting surface to obtain each fan-shaped mesh, and then cutting the adhesive film according to the size of each fan-shaped mesh to obtain a second adhesive film of the same size and the same number as the fan-shaped mesh, and adhering the second adhesive film to the inner wall of each fan-shaped mesh respectively; adhering each fan-shaped mesh to the reflecting surface mold through each second adhesive film, and making each fan-shaped mesh and the hollow ring mesh, as well as two adjacent fan-shaped meshes, overlap with each other, thereby obtaining a metal layer.

[0016] Furthermore, step 2 includes:

[0017] Step 201: Laying the inner skin on the outside of the metal layer, and then vacuuming and drying to obtain a first intermediate component;

[0018] Step 202: Laying a third adhesive film on the outer side of the first middle piece;

[0019] Step 203: Adhere the aluminum honeycomb middle layer to the outside of the third adhesive film, and then vacuum and dry it to obtain a second middle piece.

[0020] Step 204: Laying a fourth adhesive film on the outer side of the second middle piece;

[0021] Step 205: Adhere the outer skin to the outer side of the fourth adhesive film, and then evacuate and dry to obtain a reflective surface.

[0022] The beneficial effects of the present invention are:

[0023] The reflective surface of the present invention has a low cost, being only one-third of that of carbon fiber. The preparation method of the present invention is simple, has a short cycle, and can be mass-produced. The production process of the present invention does not require an autoclave or a metallization spraying step, thereby avoiding environmental pollution.

[0024] The preparation method of the present invention performs vacuuming and drying three times, thereby allowing the metal layer and the inner skin to be cured together, the aluminum honeycomb interlayer and the inner skin to be cured together, and the outer skin and the aluminum honeycomb interlayer to be cured together, thereby ensuring the fit and correspondence accuracy between the metal layer and the inner skin; the fit and correspondence accuracy between the aluminum honeycomb interlayer and the inner skin; and the fit and correspondence accuracy between the outer skin and the aluminum honeycomb interlayer.

[0025] During the preparation process, the present invention overlaps each sector-shaped net and the hollow ring net, as well as two adjacent sector-shaped nets, and the thickness of the reflecting surface is made uniform through laying methods at different angles, thereby avoiding the deformation problem caused by anisotropy and solving the warping and deformation of the reflecting surface. While improving the overall strength and rigidity of the reflecting surface, the required accuracy of the reflecting surface is ensured, and the root mean square accuracy of the reflecting surface is between 0.12RMS and 0.14RMS. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 is a cross-sectional view of the present invention;

[0027] Figure 2 It is an enlarged view of the details at A in the cross-sectional view of the present invention;

[0028] Figure 3 This is the layout diagram of the hollow ring network and fan-shaped network in the present invention.

[0029] Among them: 10, inner skin; 11, aluminum honeycomb middle layer; 12, outer skin; 13, hollow ring network; 14, fan-shaped network. DETAILED DESCRIPTION

[0030] The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0031] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are 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 cannot be understood as limiting the present invention. In addition, the terms "first" and "second" are used for descriptive purposes only, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the features. In the description of the present invention, unless otherwise specified, "multiple" means two or more. The "direction" in the present invention is based on the direction of the present invention. Figure 1 Description of the direction of the state.

[0032] The present invention discloses a composite material reflecting surface, such as Figure 1-3 As shown, it includes: an outer skin 12, an aluminum honeycomb middle layer 11, an inner skin 10, and a metal layer, which are arranged in sequence from the outside to the inside.

[0033] The metal layer includes: a hollow ring mesh 13 and a plurality of fan-shaped meshes 14 of the same shape.

[0034] The hollow ring mesh 13 is a hollow ring-shaped metal copper mesh, and the center of the hollow ring mesh 13 is the center point of the reflection surface.

[0035] Multiple fan-shaped nets 14 of the same shape are all metal copper nets. Multiple fan-shaped nets 14 are arranged in a circular array with the center of the hollow ring net 13 as the center point. Each fan-shaped net 14 and the hollow ring net 13 and the two adjacent fan-shaped nets 14 are overlapped at 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.

[0036] Preferably, the predetermined distance is 5 mm.

[0037] Preferably, the metal copper meshes of the hollow ring mesh 13 and the fan-shaped mesh 14 are both 300 meshes.

[0038] Preferably, both the inner skin 10 and the outer skin 12 are fiberglass layers.

[0039] The present invention also discloses a method for preparing a composite material reflective surface, comprising:

[0040] Step 1: Make the metal layer;

[0041] Step 2: Lay the inner skin 10, the aluminum honeycomb middle layer 11, and the outer skin 12 on the outside of the metal layer in sequence to obtain a reflective surface.

[0042] Among them, step 1 includes: cutting the metal copper mesh according to the size of the reflective 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 of 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 reflective surface mold through the first adhesive film, and making the center of the hollow ring mesh 13 coincide with the center point of the reflective surface.

[0043] Step 1 also includes: cutting the metal copper mesh according to the size of the reflective surface to obtain each fan-shaped mesh 14, then cutting the adhesive film according to the size of each fan-shaped mesh 14 to obtain a second adhesive film of the same size and the same number as the fan-shaped mesh 14, and adhering the second adhesive film to the inner wall of each fan-shaped mesh 14; adhering each fan-shaped mesh 14 to the reflective surface mold through each second adhesive film, and making each fan-shaped mesh 14 and the hollow ring mesh 13, as well as two adjacent fan-shaped meshes 14, overlap with each other to obtain a metal layer.

[0044] Step 2 includes:

[0045] Step 201: Laying the inner skin 10 on the outside of the metal layer, and then vacuuming and drying to obtain a first intermediate component;

[0046] Step 202: Laying a third adhesive film on the outer side of the first middle piece;

[0047] Step 203: Adhere the aluminum honeycomb interlayer 11 to the outside of the third adhesive film, and then evacuate and dry to obtain a second intermediate component;

[0048] Step 204: Laying a fourth adhesive film on the outer side of the second middle piece;

[0049] Step 205: Adhere the outer skin 12 to the outer side of the fourth adhesive film, and then evacuate and dry it to obtain a reflective surface.

[0050] The metal layer of the present invention provides electromagnetic reflection properties comparable to carbon fiber while ensuring sufficient mechanical strength. The reflective surface of the present invention has comparable signal transmission efficiency to that of a carbon fiber reflective surface, while costing only one-third of that of carbon fiber, resulting in a cost reduction of over 60%.

[0051] Example 1: This example requires manufacturing a parabolic reflector with a diameter of 1800 mm, and a total of 12 fan-shaped meshes 14 and 1 hollow ring mesh 13 are used to prepare the metal layer.

[0052] The diameter of the reflective surface mold is 1800 mm, and the arch height of the reflective surface mold is 335 mm.

[0053] The metal copper meshes of the hollow ring mesh 13 and the fan-shaped mesh 14 are both 300-mesh plain-weave copper meshes.

[0054] The outer diameter of the hollow ring net 13 is 500 mm, and the inner diameter is 130 mm.

[0055] The aluminum honeycomb of the aluminum honeycomb intermediate interlayer 11 is hexagonal, and the hexagonal wall thickness of the aluminum honeycomb intermediate interlayer 11 is 0.05 mm.

[0056] The radius of the fan-shaped net 14 is 1070 mm and the arc length is 560 mm.

[0057] The first adhesive film, the second adhesive film, the third adhesive film and the fourth adhesive film are all adhesive films with a curing temperature of 120° C., and the model of the adhesive film is LJM-300.

[0058] Each sector-shaped net 14 and the hollow ring net 13, as well as two adjacent sector-shaped nets 14, are overlapped by 5 mm.

[0059] Before making the reflective surface, clean the reflective surface mold, heat it to 40°C~50°C, and apply a release agent on the surface of the reflective surface mold.

[0060] The specific steps include:

[0061] Step 1: Make the metal layer;

[0062] Step 2: Lay the inner skin 10, the aluminum honeycomb middle layer 11, and the outer skin 12 on the outside of the metal layer in sequence to obtain a reflective surface;

[0063] Wherein, step 1 includes:

[0064] Adhere the first adhesive film to the inner wall of the hollow ring net 13; adhere the hollow ring net 13 to the reflective surface mold through the first adhesive film, and make the center of the hollow ring net 13 coincide with the center point of the reflective surface;

[0065] The second adhesive films are respectively adhered to the inner wall of each fan-shaped net 14; each fan-shaped net 14 is adhered to the reflective surface mold through each second adhesive film, and each fan-shaped net 14 and the hollow ring net 13, as well as two adjacent fan-shaped nets 14, are overlapped with each other to obtain a metal layer.

[0066] Wherein, step 2 includes:

[0067] Step 201: Lay the inner skin 10 on the outside of the metal layer, then evacuate and dry to obtain a first intermediate component; wherein, the vacuum pressure is ≤-0.093Mpa, and the pressure is maintained for 5 minutes without pressure drop; the drying conditions are: first keep warm at 70℃ for 100 minutes, then keep warm at 130℃ for 200 minutes.

[0068] Step 202: Laying a third adhesive film on the outer side of the first middle piece;

[0069] Step 203: Adhere the aluminum honeycomb interlayer 11 to the outside of the third adhesive film, then evacuate and dry to form a second intermediate component; wherein, the vacuum pressure is ≤-0.093Mpa, and the pressure is maintained for 5 minutes without pressure drop; the drying conditions are: first keep warm at 70°C for 100 minutes, then keep warm at 130°C for 200 minutes.

[0070] Step 204: Laying a fourth adhesive film on the outer side of the second middle piece;

[0071] Step 205: Adhere the outer skin 12 to the outside of the fourth adhesive film, then evacuate and dry to form the reflective surface. The vacuum pressure is ≤ -0.093 MPa and maintained for 5 minutes without pressure loss. Drying conditions: First, maintain at 70°C for 100 minutes, then at 130°C for 200 minutes.

[0072] The surface accuracy of the reflective surface prepared in the embodiment was tested using a photogrammetric instrument, and the test results are shown in Table 1.

[0073] Table 1 Test results

[0074]

[0075] 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, length Mag represents the length of the vector, minimum value represents the minimum value of the deviation in each direction and the vector length, maximum value represents the maximum value of the deviation in each direction and the vector length, and average value represents the average value of the deviation in each direction and the vector length.

[0076] The tolerance analysis in Table 1 shows a ±0.76 mm tolerance range, with 189 data points falling within the tolerance range and 0 points falling outside it. The displacement variation is relatively small, with the maximum displacement in all directions not exceeding 0.23 mm. All measurement results are within the specified tolerance range, while the overall RMS accuracy of the product is 0.1 mm, demonstrating the good performance of the reflective surface.

[0077] The above are only 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 principles of the present invention should be included in the scope of protection 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; The preparation method includes: 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 outside of the metal layer to obtain a reflective surface; Wherein, the 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); adhering the hollow ring net (13) to the reflective surface mold through the first adhesive film, and making the center of the hollow ring net (13) coincide with the center point of the reflective surface; Step 2 includes: Step 201: Laying the inner skin (10) on the outside of the metal layer, and then vacuuming and drying to obtain a first intermediate piece; Step 202: Laying a third adhesive film on the outer side of the first middle piece; Step 203: Adhere the aluminum honeycomb interlayer (11) to the outside of the third adhesive film, and then vacuumize and dry 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 outside of the fourth adhesive film, and then vacuumize and dry to obtain a reflective surface; The diameter of the reflecting surface is 1800 mm.

2. The 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. The composite material reflective surface according to claim 1, characterized in that: The step 1 further comprises: cutting the metal copper mesh according to the size of the reflecting 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 reflecting surface mold through each of the second adhesive films, and making each of the fan-shaped meshes (14) and the hollow ring mesh (13), as well as two adjacent fan-shaped meshes (14), overlap each other, thereby obtaining a metal layer.

Images