Luneberg lens production method
Through the method of half-shell vibration filling of particulate materials, the problem of long-term and high cost of production of Longbo lenses is solved, and the efficient and environmentally friendly production of Longbo lenses is achieved, and the lens indexes are stable.
Patent Information
- Application Number
- CN202510698157.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-05-28
- Publication Date
- 2025-07-29
AI Technical Summary
The existing Longbo lens production method is time-consuming, costly, and the adhesive affects the stability of the index.
The method of filling the particulate material with half-shell vibration is adopted, and the second half-shell is driven downward by vibration of the punch, so that the particles are evenly filled with the dielectric layer. The half-side core is formed by clamping the particles through the pressure plate, without the need for adhesives, and materials with low dielectric constant and reusable components are used.
Simplify production processes, improve efficiency, reduce costs, reduce environmental pollution, and create high-performance Longbo lenses with stable indexes.
Smart Images
Figure CN120382589A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of communication equipment, and particularly to a production method of a Luneburg lens. Background Art
[0002] The Luneburg lens technology was proposed by RK Luneberg in 1944 based on the geometric optics method and is used for applications such as antennas and scatterers, mainly for rapid scanning systems, satellite communication systems, automotive anti-collision radars, and radar reflectors.
[0003] Theoretically, the dielectric constant of the dielectric material used for the Luneburg lens should continuously change from 2 to 1 following a certain mathematical law from the center of the sphere to the outer diameter. However, such an ideal dielectric does not exist in nature, so in actual design, discrete spherical shells with a layered design are commonly used instead.
[0004] To make the actual performance of the Luneburg lens close to the theoretical performance, there are various production methods of Luneburg lenses on the market at present. For example, in the technical solution with the Chinese patent application number CN2019102251492 and the name "Production Method of Luneburg Lens", such a technical solution produces each dielectric layer by the method of applying glue to paste granular materials and then pressing with a punch. Such a production method takes a long time and has a high production cost. There is a large amount of adhesive doped in each dielectric layer. Since the dielectric constant of the adhesive itself is not zero, this affects the stability of the indicators of the produced Luneburg lens. Summary of the Invention
[0005] The purpose of the present invention is to provide a production method of a Luneburg lens. The production operation of this production method of Luneburg lens is simple, the production efficiency is high, no adhesive is required, the production cost can be reduced, and a high-performance Luneburg lens with stable indicators can be manufactured.
[0006] The technical solution of the present invention is realized as follows:
[0007] A production method of a Luneburg lens, in particular, includes the following steps:
[0008] Step a1): Prepare a first half-shell and a second half-shell. Both the first half-shell and the second half-shell are hemispherical or conical. The first half-shell is larger than the second half-shell, and both the first half-shell and the second half-shell are made of materials with as low a dielectric constant as possible;
[0009] Step a2): Fix the first half-shell with its opening facing upward;
[0010] Step a3): Pour a predetermined amount of the first type of particles prepared into the first half-shell, and cover a retaining ring for preventing the first type of particles from overflowing from the first half-shell at the opening of the first half-shell;
[0011] Step a4): Orient the opening of the second half-shell upward and fix it on the punch. Thereafter, while vibrating, the punch drives the second half-shell downward through the through-hole of the retaining ring and into the first half-shell. The first type of particles move dispersedly under the vibration of the punch until, when the second half-shell reaches a position concentric with the first half-shell, the chamber formed by the first half-shell, the second half-shell, and the retaining ring is evenly filled with the first type of particles, thereby forming a dielectric layer.
[0012] Step a5): The punch releases the second half-shell and withdraws from the through-hole of the retaining ring, and the second half-shell is left inside the first half-shell.
[0013] Step a6): Fill the second half-shell with prefabricated second type of particles, thereby forming a half-core; cover a pressing plate for preventing the second type of particles from overflowing from the second half-shell at the through-hole of the retaining ring; at this time, these half-shells, the dielectric layer, and the half-core form a half Luneburg lens.
[0014] Step a7): Insert a baffle between the half Luneburg lens and the pressing plate and the retaining ring, and this baffle covers the opening of the first half-shell.
[0015] Step a8): Remove the pressing plate and the retaining ring to obtain a half Luneburg lens with a baffle.
[0016] Step a9): Repeat steps a1) to a8) to obtain another half Luneburg lens with a baffle.
[0017] Step a10): Flip and attach a half Luneburg lens with a baffle to another half Luneburg lens with a baffle.
[0018] Step a11): Withdraw the two baffles between the two half Luneburg lenses.
[0019] Step a12): Connect the first half-shells of the two half Luneburg lenses together to form one Luneburg lens.
[0020] The inner and outer surface shapes of the first half-shell and the second half-shell are the same. When both the first half-shell and the second half-shell are hemispherical, the hemispherical shape can be a semi-regular spherical shape or a semi-elliptical spherical shape to make a spherical or ellipsoidal Luneburg lens. When both the first half-shell and the second half-shell are conical, the conical shape can be a regular quadrangular pyramid shape to make a cubic Luneburg lens. The concentricity mentioned in step a4) refers to the center of the Luneburg lens to be made.
[0021] The Luneburg lens produced by the production method of the present Luneburg lens has no adhesive inside. The first half shell, the second half shell and the retaining ring form a chamber for making the dielectric layer. The second half shell and the pressing plate form a chamber for making half of the inner core. During production, the punch drives the second half shell to move downward while vibrating, causing the first type of particles to move dispersedly to form the dielectric layer. The half inner core is directly formed by clamping and pressing the second type of particles through the cooperation of the pressing plate and the second half shell. Such a method does not require an adhesive to make the dielectric layer and the half inner core, saving the production process, improving production efficiency, and reducing environmental pollution. The first half shell and the second half shell are both made of materials with as low a dielectric constant as possible, so that the presence of the first half shell and the second half shell does not affect the performance indicators of the Luneburg lens. In addition, components such as the punch, the first retaining ring, the pressing plate and the baffle used in the production process can be reused, greatly reducing the production cost.
[0022] Further, the punch adsorbs and fixes the second half shell through negative pressure.
[0023] Further, the punch is provided with a blowing channel; the second half shell is provided with an air passing hole, and the air passing hole of the second half shell is opposite to the air outlet of the blowing channel; the punch blows air during the downward pressing process to blow the first type of particles.
[0024] Further, the punch blows air intermittently during the working process; the punch presses downward during the air blowing period and retracts during the period of stopping air blowing, and the pressing distance of the punch is greater than the retracting distance.
[0025] Further, the second half shell is an elastic net-shaped hemisphere or cone.
[0026] Further, the dielectric constant of the first type of particles is less than the dielectric constant of the second type of particles, and the first type of particles and the second type of particles are preferably spherical or cubic.
[0027] Further, the dielectric constant of the first half shell is less than the dielectric constant of the dielectric layer, and the dielectric constant of the second half shell is between the dielectric constant of the dielectric layer and the dielectric constant of the half inner core.
[0028] The present invention also provides a technical solution in which the dielectric layer is multilayer. This technical solution is realized as follows:
[0029] A production method of a Luneburg lens, in particular, includes the following steps:
[0030] Step b1): Prepare N half shells of different sizes. All half shells are made of materials with as low a dielectric constant as possible; each half shell is a hemisphere or a cone, N is greater than 2, and all half shells are called the first half shell, the second half shell... the Nth half shell in order from large to small;
[0031] Step b2): Fix the first half shell with its opening facing upward;
[0032] Step b3): Pour a preset amount of the first type of particles into the first half shell, and cover the opening of the first half shell with a first retaining ring for preventing the first type of particles from overflowing out of the first half shell;
[0033] Step b4): Turn the opening of the second half shell upward and fix it on the punch. Thereafter, while vibrating, the punch drives the second half shell to move downward through the through hole of the first retaining ring and into the first half shell. The first type of particles move dispersedly under the vibration of the punch until when the second half shell reaches a position concentric with the first half shell, the chamber formed by the first half shell, the second half shell and the first retaining ring is evenly filled with the first type of particles and thus forms the first dielectric layer;
[0034] Step b5): The punch releases the second half shell and withdraws from the through hole of the first retaining ring, and the second half shell is left inside the first half shell;
[0035] Step b6): Pour a preset amount of the second type of particles into the second half shell, and cover the through hole of the first retaining ring with a second retaining ring for preventing the second type of particles from overflowing out of the second half shell;
[0036] Step b7): Turn the opening of the third half shell upward and fix it on the punch. Thereafter, while vibrating, the punch drives the third half shell to move downward through the through hole of the second retaining ring and into the second half shell. The second type of particles move dispersedly under the vibration of the punch until when the third half shell reaches a position concentric with the second half shell, the chamber formed by the second half shell, the third half shell and the second retaining ring is evenly filled with the second type of particles and thus forms the second dielectric layer;
[0037] Step b8): The punch releases the third half shell and withdraws from the through hole of the second retaining ring, and the third half shell is left inside the second half shell;
[0038] Step b9): By analogy with steps b6) to b8), analogously fabricate the remaining dielectric layers; after this step, the Nth half shell is left inside the (N - 1)th half shell, and an (N - 1)th retaining ring is provided at the opening of the (N - 1)th half shell;
[0039] Step b10): Fill the Nth half shell with the preset Nth type of particles to form a half core; cover the through hole of the (N - 1)th retaining ring with a pressing plate for preventing the Nth type of particles from overflowing out of the Nth half shell; at this time, these half shells, dielectric layers and half core form a half Luneburg lens;
[0040] Step b11): Insert a baffle between the half Luneburg lens and the pressing plate and each retaining ring, and this baffle covers the opening of the first half shell;
[0041] Step b12): Remove the pressing plate and each retaining ring to obtain a half Luneburg lens with a baffle;
[0042] Step b13): Repeat steps b1) to b12) to obtain another half Luneburg lens with a baffle;
[0043] Step b14): Flip and attach one half Luneburg lens with a baffle to the other half Luneburg lens with a baffle;
[0044] Step b15): Withdraw the two baffles located between the two half Luneburg lenses;
[0045] Step b16): Connect the first half shells of the two half Luneburg lenses together to form one Luneburg lens.
[0046] The inner and outer surface shapes of all the half shells are the same. When all the half shells are hemispherical, the hemispherical shape can be a semi - regular spherical shape or a semi - elliptical spherical shape to make a spherical or ellipsoidal Luneburg lens. When all the half shells are conical, the conical shape can be a regular square pyramid shape to make a cubic - shaped Luneburg lens. The concentricity mentioned in steps b4) and b7) refers to the center of the Luneburg lens to be made.
[0047] For the Luneburg lens produced by this Luneburg lens production method, there is no adhesive inside it at all. Each adjacent two half shells and the corresponding retaining rings form a chamber for making the dielectric layer, and the Nth half shell and the pressing plate form a chamber for making the half core. During production, while vibrating, the punch drives the half shell downward, causing the corresponding granular materials to move dispersedly to fill the corresponding chambers to make the dielectric layer. The half core is directly formed by the pressing plate and the Nth half shell cooperating to clamp the Nth type of particles. Such a method does not require adhesives to make each dielectric layer and half core, saving production processes, improving production efficiency, and also reducing environmental pollution. Moreover, each half shell is made of a material with as low a dielectric constant as possible, so that the existence of each half shell does not affect the performance indicators of the Luneburg lens. In addition, components such as the punch, each retaining ring, the pressing plate, and the baffle used in the production process can be reused, greatly reducing the production cost.
[0048] Furthermore, N is preferably greater than 3 and less than 20.
[0049] Furthermore, replace the punch with a specification matching the preset specification of the next dielectric layer every time a dielectric layer is made; the punch adsorbs and fixes the half shell through negative pressure.
[0050] Furthermore, the punch is provided with a blowing channel; the second half shell to the Nth half shell are all provided with air passing holes; after each half shell is fixed on the punch, its air passing hole is aligned with the air outlet of the blowing channel; the punch blows air during the downward pressing process to blow the granular materials.
[0051] Furthermore, the punch blows air intermittently during the working process; the punch presses downward during the blowing period and retracts during the period when the blowing stops, and the downward pressing distance of the punch is greater than the retracting distance.
[0052] Further, the second half shell to the Nth half shell are all elastic, reticular, hemispherical or conical in shape.
[0053] Further, from the first dielectric layer to the half inner core, the dielectric constant of the corresponding granular material increases gradually, and the granular material is preferably spherical or cubic in shape.
[0054] Further, the dielectric constant of the first half shell is lower than that of the first dielectric layer, and the dielectric constants of the remaining half shells are between the dielectric layer or half inner core on their inner side and the dielectric layer on their outer side.
[0055] The beneficial effects of the present invention are as follows: it has the advantages of simple production operation, high production efficiency, no need for adhesives, which can reduce production costs and manufacture high-performance Luneburg lenses with stable indicators. BRIEF DESCRIPTION OF THE DRAWINGS
[0056] Figure 1 It is a schematic cross-sectional structure diagram of the target product in Example 1.
[0057] Figure 2 It is a schematic cross-sectional structure diagram of Example 1 after step a3).
[0058] Figure 3 It is a schematic cross-sectional structure diagram of Example 1 after step a4).
[0059] Figure 4 It is a schematic cross-sectional structure diagram of Example 1 after pouring the second kind of particles in step a6).
[0060] Figure 5 It is a schematic cross-sectional structure diagram of Example 1 after step a6).
[0061] Figure 6 It is a schematic cross-sectional structure diagram of Example 1 after step a7).
[0062] Figure 7 It is a schematic cross-sectional structure diagram of Example 1 after step a10).
[0063] Figure 8 It is a schematic structure diagram of the hemispherical die in Example 1.
[0064] Figure 9 It is a schematic cross-sectional structure diagram of the target product in Example 2.
[0065] Figure 10 It is a schematic cross-sectional structure diagram of Example 2 after step b3).
[0066] Figure 11 It is a schematic cross-sectional structure diagram of Example 2 after step b4).
[0067] Figure 12 Schematic cross-sectional structure diagram after step b6) of Example 2.
[0068] Figure 13 Schematic cross-sectional structure diagram after step b7) of Example 2.
[0069] Figure 14 Schematic cross-sectional structure diagram after step b9) of Example 2.
[0070] Figure 15 Schematic cross-sectional structure diagram after pouring the fifth kind of particles in step b10) of Example 2.
[0071] Figure 16 Schematic cross-sectional structure diagram after step b10) of Example 2.
[0072] Figure 17 Schematic cross-sectional structure diagram after step b11) of Example 2.
[0073] Figure 18 Schematic cross-sectional structure diagram after step b14) of Example 2.
[0074] Figure 19 Schematic structure diagram of the hemispherical female die in Example 2.
[0075] Description of reference numerals: 11 - first half shell; 12 - dielectric layer; 13 - second half shell; 14 - half core; 2 - hemispherical female die; 21 - screw; 22 - notch; 3 - first kind of particles; 4 - retaining ring; 41 - exhaust hole; 42 - annular groove; 5 - punch; 51 - adsorption channel; 52 - blowing channel; 6 - second kind of particles; 7 - pressing plate; 8 - half Luneburg lens; 9 - baffle; 10 - tape; 15 - first dielectric layer; 16 - second dielectric layer; 17 - third half shell; 18 - third dielectric layer; 19 - fourth half shell; 110 - fourth dielectric layer; 120 - fifth half shell; 20 - first retaining ring; 30 - second retaining ring; 40 - fourth retaining ring; 50 - fifth kind of particles. Detailed implementation manners
[0076] Example 1
[0077] As Figure 1 shown, in this example, a 2-layer spherical Luneburg lens is taken as an example. Such a Luneburg lens from the outside to the inside is successively the first half shell 11, the dielectric layer 12, the second half shell 13 and the half core 14.
[0078] Its processing method is as follows:
[0079] Step a1): Prepare the first half shell 11 and the second half shell 13. Both the first half shell 11 and the second half shell 13 are semi-spherical. The first half shell 11 is larger than the second half shell 13. The first half shell 11 is an EPS foam material shell with a thickness of about 8 mm, and the second half shell 13 is an elastic net-like semi-spherical shape with a thickness of about 0.5 mm. Moreover, both the first half shell 11 and the second half shell 13 are made of materials with as low a dielectric constant as possible.
[0080] Step a2): Fix the first half shell 11 with its opening facing upward; as Figures 2 to 7 shown, the first half shell 11 is placed into a hemispherical concave die 2. The outer wall of the first half shell 11 contacts the hemispherical concave die 2. This hemispherical concave die 2 is used to fix the first half shell 11 and to bear the acting force of the punch 5, thereby preventing the first half shell 11 from deforming under force.
[0081] Step a3): Pour a pre-determined amount of the first type of particles 3 into the first half shell 11, and cover a retaining ring 4 for preventing the first type of particles 3 from overflowing from the first half shell 11 at the opening of the first half shell 11; in this step, the first type of particles 3 are generally leveled. The retaining ring 4 is fixed to the top surface of the hemispherical concave die 2 by screws 21, as Figure 2 shown.
[0082] Step a4): Fix the second half shell 13 with its opening facing upward on the punch 5. The punch 5 is a mold with a spherical movement. In contrast, the hemispherical concave die 2 belongs to a fixed mold. The punch 5 is provided with an adsorption channel 51, and the punch 5 adsorbs and fixes the second half shell 13 through negative pressure; thereafter, the punch 5 drives the second half shell 13 to move downward while vibrating and passes through the through hole of the retaining ring 4 into the first half shell 11. The first type of particles 3 move dispersedly under the vibration of the punch 5. When the second half shell 13 reaches a position concentric with the first half shell 11, the chamber formed by the first half shell 11, the second half shell 13, and the retaining ring 4 is evenly filled with the first type of particles 3 and thus forms a dielectric layer 12, as Figure 3 shown; in this step, the punch 5 is provided with a blowing channel 52; an air passing hole is provided at the lowest part of the second half shell 13, and the diameter of this air passing hole is smaller than the diameter of the first type of particles 3. The air passing hole of the second half shell 13 is directly opposite to the air outlet of the blowing channel 52; the punch 5 blows air during the downward pressing process to blow the first type of particles 3. For exhaust, exhaust holes 41 are arranged on the retaining ring 4; in addition, in order to further improve production efficiency, the punch 5 blows air intermittently during the working process; the punch 5 presses downward during the air blowing period and retracts during the period of stopping air blowing, and the pressing distance of the punch 5 is greater than the retracting distance.
[0083] Step a5): The punch 5 releases the second half shell 13 and withdraws from the through hole of the retaining ring 4, leaving the second half shell 13 inside the first half shell 11. The diameter of the through hole of the retaining ring 4 is slightly smaller than the diameter of the opening of the second half shell 13. After the second half shell 13 is fixed on the punch 5, the punch 5 is close to the bottom of the shell cavity of the second half shell 13, leaving a certain gap between the opening edge of the second half shell 13 and the top surface of the punch 5. In this way, when the punch 5 drives the second half shell 13 to move to be concentric with the first half shell 11, the opening of the second half shell 13 is reset after squeezing through the through hole of the retaining ring 4. Then, after the punch 5 withdraws, the second half shell 13 can be positioned between the dielectric layer 12 and the retaining ring 4 and thus remain inside the first half shell 11.
[0084] Step a6): As Figure 4 shown, fill the second half shell 13 with the prefabricated second type of particles 6, and level the second type of particles 6 in this step, thus forming a half core 14; cover a pressing plate 7 for preventing the second type of particles from overflowing from the second half shell 13 at the through hole of the retaining ring 4; at this time, these half shells, the dielectric layer 12 and the half core 14 form a half Luneburg lens, as Figure 5 shown. The pressing plate 7 presses down and positions and embeds the second type of particles 6 in the retaining ring 4. The structure of the pressing plate 7 positioned and embedded on the retaining ring 4 is: as Figure 2 、 Figure 3 、 Figure 4 、 Figure 5 shown, a supporting ring is formed on the outer circumferential surface of the pressing plate 7, and a ring groove 42 for supporting the supporting ring is formed on the inner hole wall of the retaining ring 4. The pressing plate 7 has a certain weight to prevent the second type of particles 6 from lifting the pressing plate 7.
[0085] Step a7): Insert a baffle 9 between the half Luneburg lens 8, the pressing plate 7 and the retaining ring 4. The baffle 9 covers the opening of the first half shell 11, as Figure 6 shown; before inserting the baffle 9 in this step, first remove the screw 21 that fixes the retaining ring 4 on the hemispherical concave die 2. The baffle 9 is equivalent to a lid to prevent the granular material from pouring out.
[0086] Step a8): Remove the pressing plate 7 and the retaining ring 4 to obtain a half Luneburg lens 8 with a baffle 9; to facilitate the removal of the half Luneburg lens 8 with a baffle 9, as Figure 8 shown, a notch 22 for the worker's finger to pass through is formed on the hemispherical concave die 2.
[0087] Step a9): Repeat steps a1) to a8) to obtain another half Luneburg lens 8 with a baffle 9.
[0088] Step a10): Flip and attach a half Luneburg lens 8 with a baffle 9 to another half Luneburg lens 8 with a baffle 9. In this step, one half Luneburg lens 8 with a baffle 9 can still be installed on the hemispherical concave die 2, while the other half Luneburg lens 8 with a baffle 9 has been removed from the hemispherical concave die 2, as shown in Figure 7 shown.
[0089] Step a11): Withdraw the two baffles 9 between the two half Luneburg lenses 8.
[0090] Step a12): Connect the first half shells 11 of the two half Luneburg lenses 8 together to form one Luneburg lens. Before connecting the first half shells 11 of the two half Luneburg lenses 8 in this step, the hemispherical concave die 2 is removed. In this embodiment, the two first half shells 11 are connected together by winding the tape 10.
[0091] In order to make the Luneburg lens produced by this Luneburg lens production method meet the requirements, the dielectric constant of the first type of particles 3 is less than that of the second type of particles 6, and the particulate material poured into each half shell is a spherical structure formed by mixing fibrous metal conductors in a non-metal foamed material; the diameter of the second type of particles 6 can be equal to or smaller than the diameter of the first type of particles 3. In order to make the indexes of the produced Luneburg lens better, the dielectric constant of the first half shell 11 is lower than that of the dielectric layer 12, and the dielectric constant of the second half shell 13 is between the dielectric constant of the dielectric layer 12 and the dielectric constant of the half inner core 14. During production, the total volume of the particulate material poured into each half shell is predetermined, and the total volume of the particulate material poured is usually 2% - 8% larger than the volume of the chamber corresponding to the dielectric layer 12 or the half inner core 14 to be made, so that the particulate material in the produced dielectric layer 12 and half inner core 14 can be closely attached, so that the particulate material in the produced Luneburg lens will not shift, and the structural stability is good; in addition, a measuring cup or a prefabricated container can be used as the container for holding the particulate material during the production process to speed up the pouring speed of the particulate material and further improve the production efficiency.
[0092] Embodiment 2
[0093] As Figure 9 shown, this embodiment takes the production of a 5-layer spherical Luneburg lens as an example. Such a Luneburg lens from the outside to the inside is successively the first half shell 11, the first dielectric layer 15, the second half shell 13, the second dielectric layer 16, the third half shell 17, the third dielectric layer 18, the fourth half shell 19, the fourth dielectric layer 110, the fifth half shell 120 and the half inner core 14.
[0094] Its processing method is as follows:
[0095] Step b1): Prepare five half - shells of different sizes. All half - shells are made of materials with as low a dielectric constant as possible. Each half - shell is semi - spherical. All half - shells are successively called the first half - shell 11, the second half - shell 13, the third half - shell 17, the fourth half - shell 19, and the fifth half - shell 120 from large to small. The first half - shell 11 is an EPS foam material shell with a thickness of about 8 mm, and the remaining half - shells are elastic and reticular semi - spherical with a thickness of about 0.5 mm.
[0096] Step b2): Fix the first half - shell 11 with its opening facing upward. As Figures 10 to 18 shown, the first half - shell 11 is placed into a hemispherical concave die 2. The outer wall of the first half - shell 11 contacts the hemispherical concave die 2. This hemispherical concave die 2 is used to fix the first half - shell 11 and bear the force of the punch 5 to prevent the first half - shell 11 from deforming under force.
[0097] Step b3): Pour a predetermined amount of the first kind of particles 3 into the first half - shell 11, and cover the opening of the first half - shell 11 with a first retaining ring 20 for preventing the first kind of particles from overflowing from the first half - shell 11. In this step, the first kind of particles 3 are generally leveled. The first retaining ring 20 is fixed on the top surface of the hemispherical concave die 2 by screws 21, as Figure 10 shown.
[0098] Step b4): Fix the second half - shell 13 with its opening facing upward on the punch 5. Then, while vibrating, the punch 5 drives the second half - shell 13 to move downward through the through - hole of the first retaining ring 20 into the first half - shell 11. The first kind of particles 3 move dispersedly under the vibration of the punch 5. When the second half - shell 13 reaches a concentric position with the first half - shell 11, the cavity formed by the first half - shell 11, the second half - shell 13, and the first retaining ring 20 is evenly filled with the first kind of particles 3, thus forming the first dielectric layer 15, as Figure 11 shown.
[0099] Step b5): The punch 5 releases the second half - shell 13 and withdraws from the through - hole of the first retaining ring 20, and the second half - shell 13 is left inside the first half - shell 11. The diameter of the through - hole of the first retaining ring 20 is slightly smaller than the diameter of the opening of the second half - shell 13. After the second half - shell 13 is fixed on the punch 5, the punch 5 is close to the bottom of the cavity of the second half - shell 13, leaving a certain gap between the opening edge of the second half - shell 13 and the top surface of the punch 5. In this way, when the punch 5 drives the second half - shell 13 to move to a concentric position with the first half - shell 11, the opening of the second half - shell 13 resets after squeezing through the through - hole of the first retaining ring 20. Furthermore, after the punch 5 withdraws, the second half - shell 13 can be positioned between the first dielectric layer 15 and the first retaining ring 20 and thus remains inside the first half - shell 11.
[0100] Step b6): Pour a pre-determined amount of the second type of particles 6 into the second half-shell 13. In this step, the second type of particles 6 are also leveled, and a second retaining ring 30 for preventing the second type of particles from overflowing from the second half-shell 13 is placed over the through-hole of the first retaining ring 20, as Figure 12 shown. The structure of the second retaining ring 30 disposed within the through-hole of the first retaining ring 20 is: as Figure 10 , Figure 11 , Figure 12 shown, a supporting ring is formed on the outer circumferential surface of the second retaining ring 30, and a ring groove 42 for supporting the supporting ring is formed on the inner hole wall of the first retaining ring 20. The second retaining ring 30 has a certain weight to prevent the second type of particles 6 from lifting the second retaining ring 30.
[0101] Step b7): Turn the opening of the third half-shell 17 upward and fix it on the punch 5. Thereafter, while vibrating, the punch 5 drives the third half-shell 17 downward to pass through the through-hole of the second retaining ring 30 and enter the second half-shell 13. The second type of particles 6 move dispersedly under the vibration of the punch until when the third half-shell 17 reaches a position concentric with the second half-shell 13, the chamber formed by the second half-shell 13, the third half-shell 17, and the second retaining ring 30 is evenly filled with the second type of particles 6, thereby forming the second dielectric layer 16, as Figure 13 shown. It should be noted that the spherical diameter of the working surface of the punch 5 used at this time is smaller than that of the punch 5 used in step b4). That is, before this step, there may be a step of replacing the punch 5, or there may be a step of transferring the hemispherical female die 2 to another station, and a punch 5 with a smaller spherical diameter is configured at that other station; as Figure 11 , Figure 13 shown, and each punch 5 is provided with an adsorption channel 51. The punch 5 adsorbs and fixes the half-shell through negative pressure, and the half-shell refers to the second half-shell 13 to the fifth half-shell 120; in addition, a blowing channel 52 is provided on the punch 5; air passing holes are provided at the lowest positions of the second half-shell 13 to the fifth half-shell 120 respectively, and the diameter of the air passing holes on the half-shell is smaller than the diameter of the granular material it pushes. The air passing holes on the half-shell mounted on the punch 5 are aligned with the air outlet of the blowing channel 52; each punch 5 blows air during the downward pressing process to blow the granular material. For exhaust, exhaust holes 41 are evenly distributed on each retaining ring; in addition, to further improve production efficiency, the punch 5 blows air intermittently during the working process; the punch 5 presses down during the air blowing period and retracts during the period of stopping air blowing, and the pressing-down distance of the punch 5 is greater than the retracting distance.
[0102] Step b8): The punch 5 releases the third half-shell 17 and withdraws from the through-hole of the second retaining ring 30, and the third half-shell 17 is left in the second half-shell 13; the structural principle of the third half-shell 17 being left in the second half-shell 13 is the same as the structural principle of the second half-shell 13 being left in the first half-shell 11 in step b5), and will not be elaborated here.
[0103] Step b9): By analogy with steps b6) to b8), the remaining third dielectric layer 18 and fourth dielectric layer 110 are fabricated. At this time, the fifth half-shell 120 is left inside the fourth half-shell 19, and a fourth retaining ring 40 is provided at the opening of the fourth half-shell 19, as Figure 14 shown.
[0104] Step b10): As Figure 15 shown, the prefabricated fifth type of particles 50 are filled into the fifth half-shell 120, and the fifth type of particles 50 are leveled, thereby forming a half-core 14; a pressing plate 7 for preventing the fifth type of particles from overflowing out of the fifth half-shell 120 is covered at the through-hole of the fourth retaining ring 40; at this time, these half-shells, dielectric layers, and half-core 14 form a half Luneburg lens 8, as Figure 16 shown. The structure of the pressing plate 7 disposed on the fourth retaining ring 40 is similar to the structure of the pressing plate disposed on the retaining ring in Embodiment 1, and will not be elaborated herein.
[0105] Step b11): A baffle 9 is inserted between the half Luneburg lens 8 and the pressing plate 7 and each retaining ring, and the baffle 9 covers the opening of the first half-shell 11, as Figure 17 shown; before inserting the baffle 9 in this step, the screw 21 that fixes the first retaining ring 20 on the hemispherical concave die 2 is removed first. The baffle 9 is equivalent to a lid to prevent the granular material from pouring out.
[0106] Step b12): The pressing plate 7 and each retaining ring are removed to obtain a half Luneburg lens 8 with a baffle 9; in order to facilitate the removal of the half Luneburg lens 8 with a baffle 9, as Figure 19 shown, a notch 22 for the worker's finger to pass through is formed on the hemispherical concave die 2.
[0107] Step b13): Steps b1) to b12) are repeated to obtain another half Luneburg lens 8 with a baffle 9.
[0108] Step b14): One half Luneburg lens 8 with a baffle 9 is flipped and attached to another half Luneburg lens 8 with a baffle 9; in this step, one half Luneburg lens 8 with a baffle 9 can still be installed on the hemispherical concave die 2, and the other half Luneburg lens 8 with a baffle 9 has been removed from the hemispherical concave die 2, as Figure 18 shown.
[0109] Step b15): The two baffles 9 between the two half Luneburg lenses 8 are removed.
[0110] Step b16): The first half-shells 11 of the two half Luneburg lenses 8 are connected together to form one Luneburg lens. Before connecting the first half-shells 11 of the two half Luneburg lenses 8 in this step, the hemispherical concave die 2 is removed. In this embodiment, the two first half-shells 11 are connected together by winding a tape 10.
[0111] In order to make the Luneburg lens produced by this Luneburg lens production method meet the requirements, from the first dielectric layer 15 to the half core 14, the dielectric constant of the corresponding particulate material increases gradually, and the particulate material poured into each half shell is a spherical structure formed by mixing fibrous metal conductors in a non-metallic foamed material; from the first dielectric layer 15 to the half core 14, the diameters of the corresponding particulate materials can be equal or gradually decrease. In order to make the Luneburg lens have better performance indicators, the dielectric constant of the first half shell 11 is lower than that of the first dielectric layer 15, and the dielectric constants of the remaining half shells are between the dielectric layer or half core 14 on their inner side and the dielectric layer on their outer side. During production, the total volume of the particulate material poured into each half shell is predetermined, and the total volume of the particulate material poured is usually 2% - 8% larger than the volume of the chamber corresponding to the dielectric layer or half core 14 to be made, so that the particulate materials in the made dielectric layer and half core 14 can be closely attached, so that the particulate materials in the made Luneburg lens will not shift, and the structural stability is good; in addition, during the production process, a measuring cup or a prefabricated container can be used as the container for holding the particulate material to speed up the pouring speed of the particulate material, further improving the production efficiency.
Claims
1. A Luneburg lens production method, characterized in that: Comprising the following steps: Step a1): Prepare a first half shell and a second half shell. Both the first half shell and the second half shell are hemispherical or conical in shape. The first half shell is larger than the second half shell, and both the first half shell and the second half shell are made of materials with as low a dielectric constant as possible; Step a2): Fix the first half shell with its opening facing upwards; Step a3): Pour a predetermined amount of the first type of particles into the first half shell, and cover the opening of the first half shell with a retaining ring for preventing the first type of particles from overflowing out of the first half shell; Step a4): Orient the opening of the second half shell upwards and fix it on the punch. Thereafter, while vibrating, the punch drives the second half shell to move downwards through the through hole of the retaining ring and into the first half shell. The first type of particles move dispersedly under the vibration of the punch until when the second half shell reaches a position concentric with the first half shell, the chamber formed by the first half shell, the second half shell and the retaining ring is evenly filled with the first type of particles and thus a dielectric layer is formed; Step a5): The punch releases the second half shell and withdraws from the through hole of the retaining ring, and the second half shell is left inside the first half shell; Step a6): Fill the second half shell with a predetermined amount of the second type of particles to form a half core; cover the through hole of the retaining ring with a pressing plate for preventing the second type of particles from overflowing out of the second half shell; at this time, these half shells, the dielectric layer and the half core form a half Luneburg lens; Step a7): Insert a baffle plate between the half Luneburg lens and the pressing plate and the retaining ring. The baffle plate covers the opening of the first half shell; Step a8): Remove the pressing plate and the retaining ring to obtain a half Luneburg lens with a baffle plate; Step a9): Repeat steps a1) to a8) to obtain another half Luneburg lens with a baffle plate; Step a10): Flip and fit a half Luneburg lens with a baffle plate onto another half Luneburg lens with a baffle plate; Step a11): Withdraw the two baffle plates between the two half Luneburg lenses; Step a12): Connect the first half shells of the two half Luneburg lenses together to form one Luneburg lens.
2. The production method of a Luneburg lens according to claim 1, characterized in that: The punch adsorbs and fixes the second half shell through negative pressure.
3. A Luneburg lens production method according to claim 1, characterized in that: The punch is provided with a blowing channel; the second half shell is provided with an air through hole, and the air through hole of the second half shell is directly opposite to the air outlet of the blowing channel; the punch blows air during the downward pressing process to blow the first type of particles.
4. A Luneburg lens production method according to claim 3, characterized in that: The punch blows air intermittently during the working process; the punch presses down during the air blowing period and retracts during the period of stopping blowing, and the pressing down distance of the punch is greater than the retracting distance.
5. A Luneburg lens production method according to claim 1, characterized in that: The second half shell is an elastic net-shaped hemisphere or cone.
6. A Luneburg lens production method, characterized in that: Comprising the following steps: Step b1): Prepare N half shells of different sizes. All the half shells are made of materials with as low a dielectric constant as possible; each half shell is hemispherical or conical in shape, N is greater than 2, and all the half shells are successively called the first half shell, the second half shell... the Nth half shell from large to small; Step b2): Fix the first half shell with its opening facing upwards; Step b3): Pour a predetermined amount of the first type of particles into the first half shell, and cover the opening of the first half shell with a first retaining ring for preventing the first type of particles from overflowing out of the first half shell; Step b4): Orient the opening of the second half-shell upward and fix it on the punch. Thereafter, while vibrating, the punch drives the second half-shell downward to pass through the through-hole of the first retaining ring and enter the first half-shell. The first type of particles move dispersedly under the vibration of the punch until, when the second half-shell reaches a position concentric with the first half-shell, the chamber formed by the first half-shell, the second half-shell, and the first retaining ring is evenly filled with the first type of particles, thereby forming the first dielectric layer. Step b5): The punch releases the second half-shell and withdraws from the through-hole of the first retaining ring, and the second half-shell is left inside the first half-shell. Step b6): Pour a pre-determined amount of the second type of prefabricated particles into the second half-shell, and cover the through-hole of the first retaining ring with a second retaining ring for preventing the second type of particles from overflowing from the second half-shell. Step b7): Orient the opening of the third half-shell upward and fix it on the punch. Thereafter, while vibrating, the punch drives the third half-shell downward to pass through the through-hole of the second retaining ring and enter the second half-shell. The second type of particles move dispersedly under the vibration of the punch until, when the third half-shell reaches a position concentric with the second half-shell, the chamber formed by the second half-shell, the third half-shell, and the second retaining ring is evenly filled with the second type of particles, thereby forming the second dielectric layer. Step b8): The punch releases the third half-shell and withdraws from the through-hole of the second retaining ring, and the third half-shell is left inside the second half-shell. Step b9): By analogy with steps b6) to b8), make the remaining dielectric layers. After this step, the Nth half-shell is left inside the (N - 1)th half-shell, and an (N - 1)th retaining ring is provided at the opening of the (N - 1)th half-shell. Step b10): Fill the Nth half-shell with the prefabricated Nth type of particles, thereby forming a half-core. Cover the through-hole of the (N - 1)th retaining ring with a pressing plate for preventing the Nth type of particles from overflowing from the Nth half-shell. At this time, these half-shells, dielectric layers, and half-core form a half Luneburg lens. Step b11): Insert a baffle between the half Luneburg lens and the pressing plate and each retaining ring, and this baffle covers the opening of the first half-shell. Step b12): Remove the pressing plate and each retaining ring to obtain a half Luneburg lens with a baffle. Step b13): Repeat steps b1) to b12) to obtain another half Luneburg lens with a baffle. Step b14): Flip and fit a half Luneburg lens with a baffle to another half Luneburg lens with a baffle. Step b15): Withdraw the two baffles between the two half Luneburg lenses. Step b16): Connect the first half-shells of the two half Luneburg lenses together to form one Luneburg lens.
7. A Luneburg lens production method according to claim 6, characterized in that: Replace the punch with one matching the preset specifications of the next dielectric layer every time a dielectric layer is made; the punch adsorbs and fixes the half-shell by negative pressure.
8. A Luneburg lens production method according to claim 6 or 7, characterized in that: The punch is provided with a blowing channel; the second half-shell to the Nth half-shell are all provided with air through-holes; after each half-shell is fixed on the punch, its air through-hole is aligned with the air outlet of the blowing channel; the punch blows air during the downward pressing process to blow the particulate material.
9. A Luneburg lens production method according to claim 8, characterized in that: The punch blows air intermittently during the working process; the punch presses downward during the blowing period and retracts during the period of stopping blowing, and the downward pressing distance of the punch is greater than the retracting distance.
10. A Luneburg lens production method according to claim 6, characterized in that: The second half-shell to the Nth half-shell are all elastic, net-shaped hemispherical or conical.