Plastic-steel mixed plate for manufacturing laser-propelled satellites

Abstract

The invention relates to a plastic-steel mixed plate for manufacturing a laser-propelled satellite. The plate is a composite plate which takes an aluminum alloy base plate as an insert and is formed by injection molding of a PVC (Polyvinyl Chloride) material. On the premise of meeting the requirements of micro-nano satellite size, strength and structure lightweight, the device can be used for pushing the satellite to deorbit under the action of external laser in a specific direction, and working medium and structure integrated design is achieved. And standardization can be carried out according to micro-nano satellite design and manufacturing standards, and large-scale production and processing are facilitated. The material has the advantages of being low in cost, simple in structure, high in universality and short in production period, and meanwhile, satellite deorbit can be conveniently and remotely controlled through space-based laser irradiation.

Description

Technical Field

[0001] The present invention provides a plastic-steel hybrid plate material for manufacturing laser-propelled satellites, which involves utilizing PVC and aluminum alloy to manufacture a plate material capable of being laser-propelled while meeting the requirements of micro-nano satellite size, strength, and lightweight structure, and belongs to the field of multifunctional aerospace structural materials. Background Art

[0002] How to achieve satellite deorbiting and debris removal has become a hot issue in the aerospace field. According to the IADC Space Debris Mitigation Guidelines, low-orbit satellites must be deorbited within 25 years after their lifespan ends; and the EU Space Sustainability Regulation requires that newly launched satellites must be equipped with verifiable deorbiting devices.

[0003] Existing deorbiting technologies include active deorbiting and passive deorbiting. For active deorbiting spacecraft, if chemical fuel is used, the spacecraft needs to retain 5-10% of the fuel, which greatly increases the launch mass; if an electric propulsion system is used, not only will the deorbiting cycle be long, but the risk of failure will also be high. For passive deorbiting spacecraft, not only do they need to carry additional deorbiting sails, tethers, inflatable sails and other payloads, but they will also still face the problem of low success rate.

[0004] Research related to laser propulsion has shown that by irradiating solid materials with lasers, gas jets or plasma jets can be formed to generate thrust. Due to its advantages of high specific impulse, low cost, long-distance energy transmission, and strong maneuverability, the principle of laser propulsion has the potential to be applied to satellite deorbit. The research team of Professor Shen Ruiqi of Nanjing University of Science and Technology uses the inherent advantages of solid micro-propulsion systems such as high energy density, simple structure, no temporary refueling, and strong reliability. It uses miniaturized semiconductor continuous lasers to successfully control the combustion state and thrust of chemical propellants while ensuring low power consumption of the system, meeting the needs of micro-satellites for space propulsion systems, thereby ensuring the long-term stable and reliable operation of micro-satellites. In addition to specific chemical propellants, some high-performance polymer materials can also produce thrust effects under laser irradiation. Research by Koizumi et al. at the University of Tokyo shows that PVC will produce a certain thrust by dehydrochlorination under laser ablation, and this effect will be significantly enhanced after the carbon content of PVC is increased to 5%.

[0005] At present, the research on laser propulsion focuses on the design of thrusters and the selection and deployment of propulsion materials, but there is little research on the application of laser propulsion materials in satellite deorbiting. How to design a new structure to apply laser propulsion materials to satellite deorbiting is an innovative direction with strong cross-cutting and practical significance. Summary of the invention

[0006] (I) Purpose of the invention The objective of the present invention is to provide a plastic-steel hybrid plate for laser propulsion satellite manufacturing. The plate is a composite plate formed by injecting PVC material with an aluminum alloy substrate as an insert. On the premise of meeting the requirements of micro-nano satellite size, strength, and structural lightweight, it can be used to push the satellite out of orbit under the action of an externally applied laser in a specific direction, realizing the integrated design of the working medium and the structure.

[0007] (I) Technical solution

[0008] The present invention uses aluminum alloy material as the substrate and coats hard PVC material on both sides of the aluminum alloy substrate by injection molding. 6061-T6 aluminum alloy is used as the aluminum alloy substrate material, and a precision-stamped aluminum alloy substrate with a thickness of 1 mm and a length and width of 100 mm is made. Except for the threaded hole part and the "X" - shaped area passing through the center and the four-corner threaded holes on the substrate, the rest of the area is hollowed out into a honeycomb structure. The inner diameter of the honeycomb structure unit is 4 mm, the outer diameter is 4.61 mm, and a 0.3 mm rounded corner is made to avoid stress concentration. There is 1 M4 threaded hole at each of the four corners of the substrate for structural connection. The PVC injection layer is coated on both sides of the surface of the aluminum alloy substrate, with a thickness of 1.0 mm each.

[0009] The aluminum alloy substrate is used as an insert and is formed in one step in the PVC injection mold. The PVC injection layer and the aluminum alloy substrate form a mechanical interlock through sandblasting the threaded hole area and the honeycomb-shaped injection fitting structure. Among them, the aluminum alloy undergoes anodic oxidation treatment to generate a 10 - 15 μm porous oxide layer to enhance the bonding effect.

[0010] In order to improve the adaptability of PVC to the orbital space environment, an appropriate amount of DINP plasticizer is added before the material is injection-molded to optimize the performance of the material in a low-temperature environment, and nano-titanium dioxide is added to improve the anti-ultraviolet ability and heat distortion temperature of the material. In order to improve the laser propulsion efficiency, 5 phr of carbon black (N550) is added before the material is injection-molded to promote the absorption of energy and improve the thermal decomposition efficiency.

[0011] A customized three-plate mold is used for injection molding.

[0012] (II) Advantages

[0013] The advantages of a plastic-steel hybrid plate for laser propulsion satellite manufacturing according to the present invention are as follows:

[0014] ① A new composite material applicable to micro-nano satellite manufacturing is proposed in the present invention.

[0015] ②A plastic-steel hybrid plate for laser propulsion satellite manufacturing proposed in the present invention is composed of an aluminum alloy insert and a PVC outer envelope structure, which can be standardized according to the design and manufacturing standards of microsatellites, facilitating mass production and processing. This makes the material have the advantages of low cost, simple structure, strong versatility, and short production cycle.

[0016] ③A plastic-steel hybrid plate for laser propulsion satellite manufacturing proposed in the present invention reduces the usage of aluminum alloy, eliminates the need for the satellite to carry a deorbiting device, reduces the overall mass of the structure, and enables the satellite to carry more payloads.

[0017] ④A plastic-steel hybrid plate for laser propulsion satellite manufacturing proposed in the present invention realizes the integrated design of the working medium and the structure, facilitating the remote control of satellite deorbiting through convenient space-based laser irradiation. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a schematic diagram of the aluminum alloy substrate of the present invention.

[0019] Figure 2 It is a schematic diagram of the whole of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0020] The present invention will be further described in detail below with reference to the accompanying drawings.

[0021] The following is a detailed description of the embodiments of the present invention with reference to the accompanying drawings. Taking the manufacture of a plastic-steel hybrid plate with dimensions of 100mm × 100mm × 2mm as an example, the specific steps are as follows:

[0022] 1. Preparation of the aluminum alloy substrate

[0023] Step 1.1: Material selection and pretreatment

[0024] Select 6061-T6 aluminum alloy plate (thickness 1mm), after surface degreasing (ultrasonic cleaning with acetone for 10 minutes), perform anodic oxidation treatment: oxidation solution: sulfuric acid solution (concentration 15%, temperature 20°C); voltage: 15V, time: 30 minutes; generate a porous alumina layer with a thickness of 10–15μm (pore diameter 1–3μm).

[0025] Step 1.2: Processing of the honeycomb structure

[0026] Use a fiber laser cutting machine (IPG YLS-500, wavelength 1070nm) to process the honeycomb structure: laser power: 600W, pulse frequency 50kHz, cutting speed 1.2m / min; inner diameter of the honeycomb unit 4mm, outer diameter 4.61mm, fillet radius 0.3mm ( Figure 1); After processing, electro-polish (voltage 12V, time 3 minutes), with surface roughness Ra < 1μm.

[0027] Step 1.3: Threaded hole machining and sandblasting

[0028] Machine M4 threaded through-holes at the four corners of the substrate, with hole position tolerance of ±0.02mm; sandblast the area within 3mm around the threaded holes (Al2O3 abrasive grains, particle size 50μm, air pressure 0.5MPa), with surface roughness Ra = 1–2μm.

[0029] 2. Preparation of the PVC injection molding layer

[0030] Step 2.1: Material formulation

[0031] PVC resin (K value 67) 100 phr; plasticizer DINP: 20 phr (to improve low-temperature toughness); carbon black N550: 5 phr (to increase laser absorption rate to >95%); nano-titanium dioxide (TiO2): 3 phr (anti-ultraviolet, to increase heat distortion temperature to 120°C).

[0032] Step 2.2: Injection mold design

[0033] Use a customized three-plate mold, with cavity size 101mm × 101mm × 2.02mm (including 1.0% shrinkage compensation); threaded hole protection boss: diameter 3.9mm, height 0.5mm, to fit with the PEEK plug (M4 × 3); conformal cooling channels: diameter 6mm, 12mm away from the cavity surface, water temperature 20 ± 2°C.

[0034] Step 2.3: Injection molding

[0035] Melt temperature: 185°C, injection pressure: 90MPa, holding pressure: 70MPa; injection molding cycle: mold closing, injection (10s), holding pressure (15s), cooling (40s), demolding; immediately remove the PEEK plug after demolding and clean the flash in the threaded hole (trim with a 0.1mm inner diameter tap).

[0036] 4. Assembly and use. Use the plate as a satellite housing module ( Figure 2 ), connect it to the satellite frame through M4 titanium alloy bolts; irradiate the honeycomb area of the plate with an external laser, and the ablation gas production pushes the satellite out of orbit and into a decay orbit.

Claims

1. A plastic-steel hybrid plate for laser propulsion satellite manufacturing, characterized in that: It is a composite board used for cube satellite manufacturing, which is formed by injection molding of PVC material with an aluminum alloy substrate as an insert. The thickness of the aluminum alloy substrate is 1.2 mm, the length and width are both 100 mm, and there is 1 M4 threaded hole at each of the four corners of the substrate for structural connection; Except for the threaded hole part on the substrate and the "X" - shaped area passing through the center and the threaded holes at the four corners, the remaining areas are hollowed out into a honeycomb structure. The inner diameter of the unit of the honeycomb structure is 4 mm, the outer diameter is 4.61 mm, and there is a 0.3 - mm rounded corner; The aluminum alloy substrate, as an insert, is integrally formed in a PVC injection mold, and is coated on both sides of the surface of the aluminum alloy substrate, with a thickness of 0.5 mm each; The PVC injection layer and the aluminum alloy substrate form a mechanical interlock through sandblasting the threaded hole area and an injection - fitting structure.

2. The plastic-steel hybrid board according to claim 1, wherein: The substrate material is 6061 - T6 aluminum alloy, and a 10 - 15 - μm porous oxide layer is formed by anodizing treatment; the PVC injection layer is added with DINP plasticizer, nano - titanium dioxide, and 5% carbon black (N550).

3. A three - plate mold for manufacturing the plastic - steel hybrid board described in claim 1, characterized in that: The cavity is 101 mm long, 101 mm wide, and 2.02 mm high, and the gap with the aluminum alloy substrate is 0.5 - 0.6 mm; a threaded - hole protection boss is provided at the position of the cavity corresponding to the threaded hole, with a diameter of 3.9 mm and a height of 0.5 mm.

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