Mesh antenna metal mesh zero-constraint splicing method

Abstract

The application discloses a mesh antenna metal mesh zero-constraint splicing method, which comprises the following steps: laying and hanging metal meshes on a working tension applying device, applying working tension to the metal meshes in the transverse and longitudinal directions; sewing tension control belts along the length direction of the metal meshes on both sides in the working tension state; overlapping two metal meshes which need to be spliced and are sewn with the same tension control belts, and overlapping the cross sections in the overlapping position according to the order of 'belt-mesh-mesh-belt'; sewing the two layers of metal meshes along the two sides of the tension control belts by using composite sewing threads; and repeating the above steps to sew all the metal mesh pieces required by the whole antenna reflecting surface in sequence. The metal mesh splicing is performed by using the lock edge needle method, the tension control belts can be removed after the splicing is completed, the splicing joint formed is in a'mesh-mesh' structure, the thickness is only 0.07-0.08 mm, the elasticity keeps the original elasticity of the metal mesh, the mesh surface tension is more uniform, and the risk that the antenna unfolding resistance is increased due to the slight shrinkage of the tension control belts under high temperature is effectively eliminated.

Description

Technical Field

[0001] This invention belongs to the field of antenna technology, and specifically relates to a method for zero-constraint splicing of metal mesh in a mesh antenna. Background Technology

[0002] With the development and application of deployable antennas, the aperture of large mesh antennas has reached tens or hundreds of meters. Due to the limitations of metal mesh weaving equipment, the size of a single metal mesh cannot meet the size requirements of the reflective surface of a large-aperture antenna, so the metal mesh used for antennas needs to be spliced ​​together.

[0003] The metal mesh used in deployable mesh antennas is a fabric woven from ultra-fine alloy wires, possessing electromagnetic wave reflection properties. This type of fabric is a flexible material with a warp-knitted structure, which inherently gives the mesh a degree of elasticity. To ensure a smooth, wrinkle-free surface after assembly of the metal mesh and antenna, other low-elongation materials are needed to control and maintain tension during splicing.

[0004] The existing method for splicing metal mesh for antennas involves directly sewing two pieces of metal mesh together. A major problem with this method during antenna assembly is the uneven application of working tension, leading to an uneven mesh surface. A patent document with publication number CN103521661B discloses a "metal mesh splicing device under preset tension." This device uniformly applies pretension to the metal mesh in both length and width directions, then sews a composite material with low elongation onto the metal mesh along both length and width directions. The composite materials in different length directions are stretched to their natural lengths and overlapped before sewing. In the width direction, they are directly sewn together at the ends of the composite materials, achieving splicing of multiple metal meshes to meet the needs of large-aperture antennas. When assembling the metal mesh onto the antenna, stretching the existing composite material on the metal mesh to its natural length allows for the reapplication of pretension. However, the seams formed by this device lack elasticity. During the use of ultra-large antenna metal mesh assemblies, there is a risk of slight shrinkage of the tension control band at high temperatures, leading to increased deployment resistance. Summary of the Invention

[0005] The purpose of this invention is to provide a zero-constraint splicing method for metal mesh antennas. The metal mesh is spliced ​​using a locking pin method. After splicing, the tension control strip can be removed. The resulting splice has a "mesh-mesh" structure with a thickness of only 0.07-0.08mm. The elasticity of the metal mesh is maintained, which is beneficial for the laying of the reflective surface and makes the mesh tension more uniform. This effectively eliminates the risk of increased antenna deployment resistance due to slight shrinkage of the tension control strip at high temperatures.

[0006] The technical solution adopted in this invention is a zero-constraint splicing method for a mesh antenna metal mesh, comprising the following steps:

[0007] Step 1: Lay the metal mesh flat and suspend it on the working tension application device which is wider than its own width. Calculate the longitudinal and transverse working tension values ​​of the metal mesh according to the working tension requirements. Apply the transverse tension first and then the longitudinal tension to allow the metal mesh to expand naturally.

[0008] Step 2: Lay tension control strips at least 10mm from the edge on both sides along the length of the metal mesh. Stretch the tension control strips flat and make them fit the metal mesh surface. Initially fix both ends. Use composite material sutures and flat needle stitching to sew the tension control strips to the metal mesh.

[0009] Step 3: Remove the sewn metal mesh from the working tension application device and sew the next piece of metal mesh.

[0010] Step 4: Overlap the two pieces of metal mesh sewn with the same tension control bands;

[0011] Step 5: Initially fix the suture starting point, and use composite material sutures to sew two layers of metal mesh along both sides of the tension control band edge, using the overlock stitch method for sewing;

[0012] Step 6: Repeat steps 1-5 to sew together all the metal meshes needed for the entire antenna reflector.

[0013] Furthermore, in step 1, after the metal mesh expands naturally, it is left to stand for at least 30 minutes to observe whether the surface of the metal mesh is flat and wrinkle-free and whether the mesh openings are uniform.

[0014] Furthermore, in step 2, the composite material suture is two parallel lines. To facilitate removal, the composite material suture is 1-2 mm away from the edge of the tension control band, and the stitch length is controlled at 15-20 mm. After suturing, the mesh surface is flat and wrinkle-free.

[0015] Furthermore, in step 4, the specific overlapping steps are as follows: when overlapping, the tension control bands of the two layers of metal mesh are aligned, and the cross-section of the overlap is overlapped in the order of "band-mesh-mesh-band", with the tension control bands distributed on the outer surface of the two layers of metal mesh.

[0016] Furthermore, in step 5, the overlock stitch is specifically as follows: the stitch length is controlled at 5-8mm, the stitching starts from the bottom and upwards, and three stitches form a loop.

[0017] The beneficial effects of this invention are as follows:

[0018] This invention employs a locking needle method for splicing metal mesh. After splicing, the tension control band can be removed, resulting in a "mesh-mesh" structure at the joint with a thickness of only 0.07-0.08mm. This maintains the original elasticity of the metal mesh, which is beneficial for laying the reflective surface and makes the mesh tension more uniform. It effectively eliminates the risk of increased antenna deployment resistance due to slight shrinkage of the tension control band at high temperatures. This invention can be widely applied to the development of ultra-large deployable antenna reflective surfaces. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the overall process of the method of the present invention;

[0020] Figure 2 This is a schematic diagram illustrating the metal mesh laying and working tension application of the present invention;

[0021] Figure 3 This is a schematic diagram of the auxiliary tension control band sewing of the present invention;

[0022] Figure 4 This is a schematic diagram of the joint structure of the present invention;

[0023] Figure 5 This is a schematic diagram of the stitching during assembly in this invention;

[0024] Figure 6 This is a schematic diagram of the seam formed after splicing according to the present invention;

[0025] Explanation of reference numerals in the attached drawings: 1. Tension application device; 2. Metal mesh; 3. Tension control band; 4. Composite material sewing thread; 5. Metal mesh 1; 6. Metal mesh 2; 7. Starting thread; 8. Sewing direction (where ①, ②, ③, and ④ are the sewing sequence); 9. Composite material sewing loop. Detailed Implementation

[0026] To make the objectives, technical solutions, and advantages of this invention clearer and more understandable, the technical solutions of this invention will be further described in detail below with reference to the accompanying drawings.

[0027] A method for zero-constraint splicing of metal mesh in a mesh antenna, such as Figure 1 As shown, the specific steps include:

[0028] Step 1, as follows Figure 2 As shown, the metal mesh 2 is laid flat and suspended on a special working tension application device 1 that is larger than its own width. The longitudinal and transverse working tension values ​​of the metal mesh 2 are calculated according to the working tension requirements. The transverse tension is applied first, followed by the longitudinal tension, so that the metal mesh 2 expands naturally. After standing still for at least 30 minutes, observe whether the surface of the metal mesh is flat and wrinkle-free and whether the mesh holes are uniform.

[0029] Step 2, as follows Figure 3As shown, a low-elongation auxiliary tension control strip 3 is laid at a distance of more than 10mm from the edge on both sides along the length of the metal mesh 2 (size A). The tension control strip 3 is naturally stretched flat and attached to the metal mesh surface. The two ends are initially fixed. The tension control strip 3 is sewn to the metal mesh 2 using composite material suture 4. The stitching method can be a flat stitch. The composite material suture 4 consists of two parallel lines. For easy removal, the composite material suture 4 is 1-2mm from the edge of the tension control strip 3 (size B). The stitch length can be controlled at 15-20mm (size C). After sewing, the mesh surface is flat and wrinkle-free.

[0030] Step 3, as follows Figure 4 As shown, the sewn mesh fabric 5 (i.e. Figure 4 The metal mesh 1) is removed from the dedicated working tension application device 1, and the next piece of mesh 6 (i.e.) is then processed. Figure 4 The sewing of the metal mesh 2).

[0031] Step 4: Overlap the two metal meshes 2 with the same tension control bands 3 sewn on them. The specific overlapping steps are as follows: when overlapping, align the tension control bands 3 of the two metal meshes 2, and overlap the cross-section of the overlap in the order of "band-mesh-mesh-band". The tension control bands 3 are distributed on the outer surface of the two metal meshes 2, which makes it easy to remove them during or after installation with the antenna mechanism.

[0032] Step 5: Initially fix the suture starting point, and use composite material suture 4 to sew two layers of metal mesh 2 along both sides of the tension control band 3. Use the overlock stitch method for sewing. The overlock stitch method is as follows:

[0033] like Figure 5 As shown, the stitch length is controlled at 5-8mm (size D), and the stitch pattern is to start from the bottom and work upwards, forming a loop with three stitches (as shown). Figure 5 The starting point 7 and the sewing direction 8 are shown in the diagram, where ①, ②, ③, and ④ indicate the sewing sequence.

[0034] Step 6: Repeat steps 1-5 to sew together all the metal meshes needed for the entire antenna reflector.

[0035] When assembling the metal mesh assembly with the antenna mechanism, the auxiliary tension control band 3 can be removed. The joint state of the two metal meshes (metal mesh 1 and metal mesh 2) after removal is as follows: Figure 6 As shown, the formed stitch line is composed of two composite material stitching coils 9. The composite material stitching coils 9 have high elasticity, which can achieve zero constraint on the metal mesh 2, maintain the elasticity of the metal mesh 2 at the stitch line, facilitate the laying of the reflective surface, make the mesh tension more uniform, and effectively eliminate the risk of increased antenna deployment resistance due to slight shrinkage of the tension control band at high temperature.

[0036] Any content not described in detail in this specification belongs to the prior art in this technical field.

Claims

1. A method for zero-constraint splicing of a mesh antenna metal mesh, characterized in that, Includes the following steps: Step 1: Lay the metal mesh flat and suspend it on the working tension application device which is wider than its own width. Calculate the longitudinal and transverse working tension values ​​of the metal mesh according to the working tension requirements. Apply the transverse tension first and then the longitudinal tension to allow the metal mesh to expand naturally. Step 2: Lay tension control strips at least 10mm from the edge on both sides along the length of the metal mesh. Stretch the tension control strips flat and make them fit the metal mesh surface. Initially fix both ends. Use composite material sutures and flat needle stitching to sew the tension control strips to the metal mesh. Step 3: Remove the sewn metal mesh from the working tension application device and sew the next piece of metal mesh. Step 4: Overlap the two pieces of metal mesh sewn with the same tension control bands; Step 5: Initially fix the suture starting point, and use composite material sutures to sew two layers of metal mesh along both sides of the tension control band edge, using the overlock stitch method for sewing; Step 6: Repeat steps 1-5 to sew together all the metal meshes needed for the entire antenna reflector.

2. The method for zero-constraint splicing of metal mesh for mesh antennas according to claim 1, characterized in that, In step 1, after the metal mesh expands naturally, it is left to stand for at least 30 minutes to observe whether the surface of the metal mesh is flat and wrinkle-free and whether the mesh holes are uniform.

3. The method for zero-constraint splicing of metal mesh for mesh antennas according to claim 1, characterized in that, In step 2, the composite material suture is two parallel lines. To facilitate removal, the composite material suture is 1-2 mm away from the edge of the tension control band, and the stitch length is controlled at 15-20 mm. After suturing, the mesh surface is flat and wrinkle-free.

4. The method for zero-constraint splicing of metal mesh for mesh antennas according to claim 1, characterized in that, In step 4, the specific overlapping steps are as follows: when overlapping, the tension control bands of the two layers of metal mesh are aligned, and the cross-section of the overlap is overlapped in the order of "band-mesh-mesh-band". The tension control bands are distributed on the outer surface of the two layers of metal mesh.

5. The method for zero-constraint splicing of metal mesh for mesh antennas according to claim 1, characterized in that, In step 5, the overlock stitch is specifically as follows: the stitch length is controlled at 5-8mm, the stitching starts from the bottom and moves upward, and three stitches form a loop.

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