Forming device for filling layer in antenna and process using method

Abstract

The invention discloses a forming device for an antenna internal filling layer and a process using method, and belongs to the technical field of mold manufacturing. The forming device of the antenna internal filling layer is composed of a mold body and a structural part, the mold body is mainly composed of an upper cover plate, a lower bottom plate, a base plate, locking screws, supporting feet, hinges and lock catches, and the surfaces of the upper cover plate, the lower bottom plate and the base plate are coated with Teflon non-stick coatings; the structural member is composed of a base, a pressing block, a microstrip board and a connector. Through the mold body mainly composed of the upper cover plate, the lower bottom plate, the base plate, the locking screws, the supporting feet, the hinges and the lock catches and the structural member composed of the base, the pressing block, the microstrip plate and the connector, the filling layer forming process is optimized according to the process using method, the manufacturing difficulty is greatly reduced, the sealing performance and the protection performance are good, the stability of the antenna is improved, and the production efficiency is high. The problems that according to an original forming process method, a polyurethane foam filling layer is large in deformation, large in assembly difficulty, poor in sealing performance and protection performance, long in production time consumption and low in efficiency are solved.

Description

Technical Field

[0001] The present invention relates to a forming device and a process usage method for an internal filling layer of an antenna, belonging to the technical field of mold manufacturing. Background Art

[0002] An antenna is an important component of a radar system. A radar antenna consists of a structural member, a filling layer, and a fiberglass outer cover. The structural member is mainly composed of a base, a pressing block, a microstrip board, and a connector. The filling layer is composed of a polyurethane foam material, which plays a role in heat insulation and protection for the structural member to ensure the normal operation of the structural member. The fiberglass outer cover plays a role in protection and sealing for the structural member and the filling layer. The three complement each other and are indispensable. At present, the forming process of the filling layer is to first foam the polyurethane foam material into two semi-face foam boards, and then assemble them with the structural member and the fiberglass outer cover to form an antenna. However, it is found in actual production that the foam board is greatly deformed after being formed alone, is not easy to assemble, and there are gaps inside the antenna after assembly, resulting in poor heat insulation, sealing, and protection performance, and it is difficult to ensure the production process quality of the radar antenna. Therefore, it is very necessary to develop a forming device and a process usage method for the internal filling layer of an antenna with simple assembly operation, greatly improved sealing and protection performance of the antenna, high production efficiency, and good process quality. Summary of the Invention

[0003] The invention purpose of the present invention is, aiming at the deficiencies of the above-mentioned prior art, to provide a forming device and a process usage method for the internal filling layer of an antenna. By using the forming die body and the structural body according to the method steps of the present invention, the difficulty of antenna manufacturing is greatly reduced, the process sealing and protection performance of the antenna are effectively ensured, the working stability of the antenna is improved, the operation method is simple, the process method is excellent, and the production efficiency is effectively improved. To solve the problems of large deformation, many gaps, poor sealing and protection performance of the existing filling layer process method.

[0004] The present invention realizes the above invention purpose through the following technical solutions: A forming device and a process usage method for the internal filling layer of an antenna, characterized in that: the forming device for the internal filling layer of the antenna is composed of a die body and a structural member. The die body is mainly composed of an upper cover plate, a lower bottom plate, a backing plate, locking screws, support feet, hinges, and a lock. Among them, the surfaces of the upper cover plate, the lower bottom plate, and the backing plate are sprayed with a Teflon non-stick coating; the structural member is composed of a base, a pressing block, a microstrip board, and a connector.

[0005] The process usage method of the forming device for the internal filling layer of the antenna includes the following steps: Step 1, manufacturing the structural member, splicing and installing the base, the pressing block, the microstrip board, and the connector into the structural member according to the design drawing; Step 2, forming the filling layer, 2.1) Place a backing plate on the lower bottom plate of the mold body. Place the structural member from Step 1 face up on the backing plate. After adjusting and fixing the structural member with locking screws, close the upper cover plate. Do not tighten the lock catches. Put it into an oven. Raise the oven temperature to 50 - 55 °C and keep it warm for 20 minutes to make the mold body and the structural member reach the optimal temperature for the chemical reaction of the foaming material; 2.2) Mix the foaming material stored at room temperature: the black material and the white material according to the parameter ratio in the instruction manual. Pour them into a cup and stir for 10s - 15s to make the black material and the white material fully contact and reach a slightly foaming state; 2.3) Open the upper cover plate. Pour the prepared foaming material onto the front of the structural member, quickly close the upper cover plate, lock the lock catches, and keep it warm at 50 - 55 °C for 15 minutes to ensure that the chemical reaction of the foaming material is sufficient, completely fill the inner cavity, and closely adhere to the front of the structural member; 2.4) Loosen the lock catches, open the upper cover plate, loosen the locking screws, take out the structural member and the backing plate after half of the front side is formed, and remove the foaming residue overflowing around the mold body to make the structural member after half of the front side is formed; 2.5) Place the structural member after half of the front side is formed into the cavity of the lower bottom plate, with the unformed reverse side up and the formed front side down. Adjust the locking screws to fix the structural member; 2.6) Mix the foaming material stored at room temperature: the black material and the white material according to the parameter ratio in the instruction manual. Pour them into a cup and stir for 10s - 15s to make the black material and the white material fully contact and reach a slightly foaming state; 2.7) Pour the prepared foaming material onto the structural member with the reverse side up, quickly close the upper cover plate, lock the lock catches, and keep it warm at 50 - 55 °C for 15 minutes to ensure that the chemical reaction of the foaming material is sufficient, completely fill the inner cavity, and closely adhere to the reverse side of the structural member; 2.8) Loosen the lock catches, open the upper cover plate, loosen the locking screws, take out the combined component made of the structural member and the filling layer, and remove the foaming residue overflowing around the mold body and the filling layer to form the outer shape of the filling layer; 2.9) For the first combined component made by combining the structural member and the outer shape of the filling layer, check through quality inspection whether the appearance, overall sealing performance, and protection performance of the filling layer are qualified; 2.10) Assemble the combined component made of the structural member and the outer shape of the filling layer with the fiberglass outer cover into a radar antenna component; 2.11) For the first radar antenna component, check through quality inspection whether the electrical indicators, overall sealing performance, and protection performance are qualified. If the inspection is qualified, the radar antenna components can be mass-produced according to the process usage methods in Step 1 and Step 2, effectively ensuring the sealing performance and protection performance of the radar antenna.

[0006] The beneficial effects of the present invention compared with the prior art are: The forming device and process usage method for the internal filling layer of the antenna, through the mold body mainly composed of an upper cover plate, a lower bottom plate, a backing plate, locking screws, support feet, hinges, and latches, and the structural components composed of a base, a pressing block, a microstrip board, and a connector, optimize the filling layer forming process according to the process usage method of the present invention, greatly reducing the manufacturing difficulty, improving the stability of the antenna, having a simple operation method, and effectively improving the production efficiency. It solves the problems of large deformation of the polyurethane foam filling layer, great assembly difficulty, poor sealing and protection performance, long production time, and low efficiency in the original forming process method. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1 FIG. is an overall structural schematic diagram of a forming device and process usage method for the internal filling layer of an antenna according to the present invention; Figure 2 FIG. is a structural schematic diagram of the mold body of a forming device and process usage method for the internal filling layer of an antenna according to the present invention; Figure 3 FIG. is a structural schematic diagram of the structural components of a forming device and process usage method for the internal filling layer of an antenna according to the present invention; Figure 4 FIG. is a structural schematic diagram of a radar antenna component produced by a forming device and process usage method for the internal filling layer of an antenna according to the present invention.

[0008] In the figure: 1. Mold body, 2. Structural components, 3. Filling layer, 4. Fiberglass outer cover; 101. Upper cover plate, 102. Lower bottom plate, 103. Backing plate, 104. Locking screw, 105. Support foot, 106. Hinge, 107. Latch; 201. Base, 202. Pressing block, 203. Microstrip board, 204. Connector. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0009] The design concept of the present invention is that the antenna is an important part of the radar system. The antenna mainly consists of a base, a pressing block, a microstrip board, a filling layer, a fiberglass outer cover, and a connector. The material of the filling layer is polyurethane foam, which is formed by mixing and foaming polyurethane white foaming material (combined polyether 100-HL) and polyurethane black foaming material (modified MDIGWF-40'), and plays a certain role in heat insulation and protection. During the previous trial production process, the polyurethane foam was first foamed into two semi-finished foaming boards, and then assembled with other parts to form the antenna. However, it was found in actual production that the deformation of the foaming board after separate molding was relatively large, making it difficult to assemble, and there were gaps inside the antenna, resulting in poor sealing and protection performance. Therefore, the idea of optimizing the antenna manufacturing process was generated. First, the base, the pressing block, the microstrip board, and the connector were assembled into a structural part, and then the filling layer was made through a mold. The operation steps and methods were simple, but achieved remarkable results with half the effort. It not only solved the problem of difficult antenna assembly, but also effectively improved the sealing performance, protection performance, and production efficiency of the antenna, fully meeting the structural quality requirements of the antenna design.

[0010] The following further details the specific implementation of a forming device and a process usage method for the internal filling layer of an antenna in conjunction with the accompanying drawings (see Figures 1 to 4 ): A forming device and a process usage method for the internal filling layer of an antenna are characterized in that the forming device for the internal filling layer of the antenna is composed of a mold body 1 and a structural part 2. The mold body 1 mainly consists of an upper cover plate 101, a lower bottom plate 102, a backing plate 103, locking screws 104, support feet 105, hinges 106, and a lock 107. The surfaces of the upper cover plate 101, the lower bottom plate 102, and the backing plate 103 are sprayed with a Teflon non-stick coating. The structural part 2 is composed of a base 201, a pressing block 202, a microstrip board 203, and a connector 204.

[0011] The process usage method of the forming device for the internal filling layer of the antenna is characterized in that it is realized through the following steps: The mold body 1 mainly consists of an upper cover plate 101, a lower bottom plate 102, a backing plate 103, locking screws 104, support feet 105, hinges 106, and a lock 107. The surfaces of the upper cover plate 101, the lower bottom plate 102, and the backing plate 103 are sprayed with a Teflon non-stick coating. The structural part 2 is composed of a base 201, a pressing block 202, a microstrip board 203, and a connector 204. Step 1: Fabricate the structural part 2, and assemble and install the base 201, the pressing block 202, the microstrip board 203, and the connector 204 into the structural part 2 according to the design drawing. Step 2: Form the filling layer 3. 2.1) Place a backing plate 103 on the lower base plate 102 of the mold body 1. Place the structural member 2 from step one face up on the backing plate 103. After adjusting and fixing the structural member 2 with locking screws 104, close the upper cover plate 101. Do not tighten the lock catch 107. Place it in an oven, raise the oven temperature to 50 - 55 °C and keep it warm for 20 minutes to make the mold body 1 and the structural member 2 reach the optimal temperature for the chemical reaction of the foaming material; 2.2) Mix the foaming materials stored at room temperature: the black material and the white material according to the parameter ratio in the instruction manual. Pour them into a cup and stir for 10 s - 15 s to make the black material and the white material fully contact and reach a slightly foaming state; 2.3) Open the upper cover plate 101, pour the prepared foaming material onto the front of the structural member 2, quickly close the upper cover plate 101, lock the lock catch 107, and keep it warm at 50 - 55 °C for 15 minutes to ensure that the chemical reaction of the foaming material is sufficient, completely fill the inner cavity, and tightly adhere to the front of the structural member 2; 2.4) Loosen the lock catch 107, open the upper cover plate 101, loosen the locking screws 104, take out the structural member 2 and the backing plate 103 after half of the front side is formed, and remove the foaming residue overflowing around the mold body 1 to make the structural member 2 after half of the front side is formed; 2.5) Place the structural member 2 after half of the front side is formed into the cavity of the lower base plate 102, with the unformed reverse side up and the formed front side down. Adjust the locking screws 104 to fix the structural member 2; 2.6) Mix the foaming materials stored at room temperature: the black material and the white material according to the parameter ratio in the instruction manual. Pour them into a cup and stir for 10 s - 15 s to make the black material and the white material fully contact and reach a slightly foaming state; 2.7) Pour the prepared foaming material onto the structural member 2 with the reverse side up, quickly close the upper cover plate 101, lock the lock catch 107, and keep it warm at 50 - 55 °C for 15 minutes to ensure that the chemical reaction of the foaming material is sufficient, completely fill the inner cavity, and tightly adhere to the reverse side of the structural member 2; 2.8) Loosen the lock catch 107, open the upper cover plate 101, loosen the locking screws 104, take out the combined component made of the structural member 2 and the filling layer 3, and remove the foaming residue overflowing around the mold body 1 and the filling layer 3 to make the outer shape of the filling layer 3; 2.9) For the combined component made by combining the first structural member 2 and the outer shape of the filling layer 3, check through quality inspection whether the appearance of the filling layer, the overall sealing performance and the protection performance are qualified; 2.10) Assemble the combined component made of the structural member 2 and the outer shape of the filling layer 3 and the fiberglass outer cover 4 into a radar antenna component; 2.11) For the first radar antenna component, check through quality inspection whether the electrical indicators, the overall sealing performance and the protection performance are qualified. If the inspection is qualified, the radar antenna components can be mass-produced according to the process usage methods in step one and step two, effectively ensuring the sealing performance and the protection performance of the radar antenna.

[0012] The above are only the preferred embodiments of the present invention. The above examples do not impose any formal restrictions on the essence of the present invention. Any simple modification or variation made by those of ordinary skill in the art to the above specific embodiments based on the technical essence of the present invention after reading this specification, and any equivalent embodiments that may be changed or modified by using the disclosed technical content into equivalent variations, still fall within the scope of the technical solution of the present invention without departing from the essence and scope of the present invention.

Claims

1. A forming device for an internal filling layer of an antenna, characterized in that: The forming device for the internal filling layer of the antenna is composed of a mold body (1) and a structural member (2). The mold body (1) mainly consists of an upper cover plate (101), a lower bottom plate (102), a backing plate (103), locking screws (104), support feet (105), hinges (106) and latches (107). The surfaces of the upper cover plate (101), the lower bottom plate (102) and the backing plate (103) are sprayed with a Teflon non-stick coating. The structural member (2) consists of a base (201), a pressing block (202), a microstrip board (203) and a connector (204).

2. Process usage method of a forming device for an internal filling layer of an antenna, characterized in that: The forming device for the internal filling layer of the antenna is composed of a mold body (1) and a structural member (2). The mold body (1) mainly consists of an upper cover plate (101), a lower bottom plate (102), a backing plate (103), locking screws (104), support feet (105), hinges (106) and latches (107). The surfaces of the upper cover plate (101), the lower bottom plate (102) and the backing plate (103) are sprayed with a Teflon non-stick coating. The structural member (2) consists of a base (201), a pressing block (202), a microstrip board (203) and a connector (204). Its process usage method is realized by including the following steps: Step 1: Fabricate the structural member (2): Assemble and install the base (201), the pressing block (202), the microstrip board (203) and the connector (204) into the structural member (2) according to the design drawing. Step 2: Form the filling layer (3): 2.1) Place the backing plate (103) on the lower bottom plate (102) of the mold body (1). Place the structural member (2) from Step 1 face up on the backing plate (103). After adjusting and fixing the structural member (2) with the locking screws (104), close the upper cover plate (101). Do not tighten the latch (107). Put it into the oven. Raise the oven temperature to 50 - 55 °C and keep it warm for 20 minutes to make the mold body (1) and the structural member (2) reach the optimal temperature for the chemical reaction of the foaming material. 2.2) Mix the foaming material stored at room temperature: the black material and the white material according to the parameter ratio in the instruction manual. Pour them into a cup and stir for 10s - 15s to make the black material and the white material fully contact and reach a slightly foaming state. 2.3) Open the upper cover plate (101), pour the prepared foaming material onto the front of the structural member (2), quickly close the upper cover plate (101), tighten the latch (107), and keep it warm at 50 - 55 °C for 15 minutes to ensure the full chemical reaction of the foaming material, completely fill the inner cavity, and closely adhere to the front of the structural member (2). 2.4) Loosen the latch (107), open the upper cover plate (101), loosen the locking screws (104), take out the structural member (2) and the backing plate (103) after half of the front side is formed, and remove the foaming residue overflowing from the periphery of the mold body (1) to make the structural member (2) after half of the front side is formed. 2.5) Place the structural member (2) after half of the front side is formed into the cavity of the lower bottom plate (102), with the unformed side facing up and the formed side facing down, and adjust the locking screws (104) to fix the structural member (2). 2.6) Take the foaming materials stored at room temperature: the black material and the white material, mix them according to the parameter ratio in the instruction manual, pour them into a cup and stir for 10 s to 15 s to make the black material and the white material fully contact and reach a slightly foaming state; 2.7) Pour the prepared foaming material onto the said structural member (2) with the reverse side facing up, quickly close the upper cover plate (101), lock the lock catch (107), and keep it warm at 50 - 55 °C for 15 minutes to ensure that the chemical reaction of the foaming material is sufficient, completely fill the inner cavity, and tightly adhere to the reverse side of the structural member (2); 2.8) Loosen the lock catch (107), open the upper cover plate (101), loosen the locking screw (104), take out the combined member made of the structural member (2) and the filling layer (3), and remove the foaming residual materials overflowing from the periphery of the mold body 1 and the filling layer (3), thus forming the outer shape of the filling layer (3); 2.9) For the combined member formed by combining the outer shape of the first structural member (2) and the filling layer (3), inspect through quality inspection whether the appearance, overall sealing performance, and protection performance of the filling layer are qualified; 2.10) Assemble the combined member made of the outer shape of the structural member (2) and the filling layer (3) and the fiberglass outer cover (4) into a radar antenna member; 2.11) For the first radar antenna member, inspect through quality inspection whether the electrical indicators, overall sealing performance, and protection performance are qualified. If the inspection is qualified, the radar antenna members can be mass-produced according to the process usage methods in Step 1 and Step 2, so as to effectively ensure the sealing performance and protection performance of the radar antenna.

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