Composite structure, lens, preparation method, communication module and vehicle

Abstract

The invention relates to the technical field of electromagnetism, and discloses a composite structure, a lens, a preparation method, an integrated communication module and a vehicle. The composite structure comprises a base body with a slotted hole and an electroplating plastic block filled with non-solid air, the base body and the electroplating plastic block are embedded into a unit, and the preset effective refractive index is achieved by adjusting the size of the plastic block or the air filling proportion; the lens is formed by three-dimensionally arranging the units according to the gradient refractive index, and can be spherical or hemispherical (matched with a metal back plate, and works in the Sub-6GHz frequency band. The preparation method comprises the steps of 3D printing of the plastic blocks, foaming forming of the base body and assembling of the arrangement units. The communication module is integrated with the lens, can adjust the distance between the lens and the signal transceiving unit, and comprises a 10-30dB adjustable gain amplification unit; a vehicle carries the module to realize signal transceiving or radar detection. The system is light in weight, accurate in refractive index regulation and control, low in cost, good in integration and suitable for scenes such as 5G Internet of Vehicles and automatic driving radars.

Description

Technical Field

[0001] This application relates to the field of electromagnetic technology, and in particular to a composite structure, a lens, a manufacturing method, a communication module, and a vehicle. Background Technology

[0002] Variable refractive index lenses, as electromagnetic control devices with spatially gradient refractive indices, are crucial in applications such as 5G vehicle-to-everything (V2X) communication, autonomous driving radar, and outdoor emergency communication in the Sub-6GHz band. However, existing technologies face significant bottlenecks: lenses made from traditional high-dielectric materials such as ceramics are heavy and costly; 3D printing technology for large-size lenses is prone to weight increase due to material accumulation and incurs high equipment and material costs; foamed dielectric materials require the addition of composite additives to adjust the dielectric constant, but the complex process leads to difficulty in refractive index control and large performance fluctuations. Furthermore, existing lenses also suffer from issues such as excessive volume when integrated with communication modules and high load or cost when adapted for automotive applications, making it difficult to simultaneously meet the requirements of lightweight, low cost, high precision, and integration with downstream applications. Therefore, developing novel lens-related technologies that can solve these problems has become an urgent breakthrough direction in this field. Summary of the Invention

[0003] The technical problem to be solved by this invention is that existing lens-related technologies suffer from the following drawbacks: at the material level, materials such as ceramics are heavy and costly; 3D printing materials add significant weight in large-size applications; and foaming media rely on composite additives and have difficulty in precisely controlling the refractive index. At the manufacturing level, there are problems such as complex processes (e.g., ceramic sintering, foamed bead molding), long cycles, and high costs. At the downstream integration level, there are shortcomings such as exceeding volume limits when integrated with communication modules, and excessive load or cost when adapted to automotive applications. It is difficult to simultaneously meet the requirements of lightweight lenses, high-precision refractive index control, low-cost manufacturing, and efficient integration with communication modules and vehicles.

[0004] To solve the above-mentioned technical problems, on the one hand, a composite structure is provided, characterized in that it is used for a lens and includes: at least a portion of a substrate, the substrate having at least one slot; an electroplated plastic block having a non-solid air-filled structure inside; the electroplated plastic block being embedded in the slot of the substrate to form a composite unit; the composite unit achieving a preset equivalent refractive index by adjusting the size of the electroplated plastic block or the proportion of the air-filled structure.

[0005] As an optional technical solution of the present invention, the outer surface of the electroplated plastic block is subjected to metallization electroplating treatment, and or, the air-filling structure of the electroplated plastic block is a mesh structure, and the pore size of the mesh structure is 0.5-5mm.

[0006] As an optional technical solution of the present invention, the matrix is ​​expanded foam, and the material of the expanded foam is expandable polystyrene (EPS) or expandable polyethylene (EPE).

[0007] On the other hand, as an optional technical solution of the present invention, this disclosure also provides a lens, including: the above-mentioned composite unit; at least one of the composite units is arranged in three dimensions according to the gradient refractive index distribution law required by the lens to form a lens body; the lens body can focus or beamform electromagnetic waves through gradient refractive index.

[0008] As an optional technical solution of the present invention, the lens body is spherical or hemispherical; if it is hemispherical, the flat end of the lens body is provided with a metal back plate.

[0009] As an optional technical solution of the present invention, the three-dimensional arrangement of the composite units is a layered stacking, each layer is composed of several composite unit arrays, and adjacent layers are fixed by an adhesive layer.

[0010] As an optional technical solution of the present invention, the operating frequency band of the lens body is the Sub-6GHz band or a lower microwave band.

[0011] On the other hand, as an optional technical solution of the present invention, this disclosure also provides a method for preparing a lens, comprising the following steps: S1. Preparing an electroplated plastic block: using 3D printing technology to form a plastic block with an internal air-filled structure, pre-treating the surface of the plastic block, and then treating its outer surface by a metallization electroplating process to obtain an electroplated plastic block; S2. Preparing a substrate: using a foaming molding process to prepare a substrate with slots, the size of which is adapted to the electroplated plastic block in step S1; S3. Assembly and molding: embedding the electroplated plastic block in step S1 into the slots of the substrate in step S2 to form a composite unit; arranging and fixing several composite units in three dimensions according to the gradient refractive index distribution requirements of the lens to obtain a lens.

[0012] On the other hand, as an optional technical solution of the present invention, this disclosure also provides a communication module, including: a communication module body, the communication module body being provided with a signal transceiver unit; a lens as described above; the lens being correspondingly arranged with the signal transceiver unit of the communication module body, and the two being electrically connected or signal-coupled, for enhancing the electromagnetic wave focusing or beam control capability of the signal transceiver unit.

[0013] As an optional technical solution of the present invention, the lens is fixed to the communication module body through a connector with a position adjustment structure, and the relative distance between the lens and the signal transceiver unit can be adjusted in the horizontal or vertical direction.

[0014] As an optional technical solution of the present invention, the communication module body further includes a signal amplification unit, which is connected in series between the signal transceiver unit and the lens, and the gain of the signal amplification unit is adjustable in the range of 10-30dB.

[0015] On the other hand, as an optional technical solution of the present invention, this disclosure also provides a vehicle, including: a vehicle body, the vehicle body being provided with a power supply system and a control module; a communication module with an integrated lens as described above; the communication module is installed at a preset position on the vehicle body and is electrically connected to the vehicle's power supply system and control module respectively, for realizing the vehicle's signal transmission and reception or radar detection functions.

[0016] The beneficial effects of this disclosure are as follows: the composite unit composed of electroplated plastic blocks and foamed foam matrix not only significantly reduces the weight of the lens, but also allows for precise control of the equivalent refractive index by adjusting the size of the plastic blocks or the air filling ratio, solving the problem of difficulty in balancing lightweighting and refractive index control in traditional materials; the manufacturing process adopts 3D printing + foaming molding + layered assembly technology, which simplifies the process and avoids complex process bottlenecks; at the same time, the lens can be flexibly made into spherical / hemispherical shapes, reducing the volume by 30% and improving signal performance when adapted to communication modules, and is lightweight and vibration resistant when integrated into vehicles, achieving efficient adaptation of the lens to communication modules and vehicles, taking into account lightweighting, high precision, low cost and high integration, and meeting the needs of multiple scenarios in the Sub-6GHz frequency band.

[0017] Other features and advantages of this application will be described in detail in the following detailed description section. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] To gain a more complete understanding of this application and its beneficial effects, the following description will be provided in conjunction with the accompanying drawings, wherein the same reference numerals in the following description denote the same parts.

[0020] Figure 1 This is one embodiment of some embodiments of the present invention. Figure 1 (Figure (a) is a schematic diagram of the composite unit structure of electroplated plastic block and foamed foam; Figure (b) is a schematic diagram of the equivalent refractive index of the composite unit structure when h is kept equal and w is changed).

[0021] Figure 2 This is one embodiment of some embodiments of the present invention. Figure 2 (Figures (a) and (b) are schematic diagrams of the equivalent permittivity and equivalent permeability of the composite unit structure while keeping h constant and changing w, respectively.)

[0022] Figure 3 This is one embodiment of some embodiments of the present invention. Figure 3 (Figure (a) is a schematic diagram of a continuous spherical lens layering in this invention; Figure (b) is a schematic diagram of the corresponding layered discretization layout.)

[0023] Figure 4 This is one embodiment of some embodiments of the present invention. Figure 4 (This is a schematic diagram of an embodiment of the present invention that forms a spherical lens based on the spatial stacking of pixel cubes).

[0024] Figure 5 This is one embodiment of some embodiments of the present invention. Figure 5 (This is a schematic diagram of the intermediate layer of an embodiment of the present invention based on the spatial stacking of pixel cubes to form a spherical lens).

[0025] Figure 6 This is one embodiment of some embodiments of the present invention. Figure 6 (This is an exploded view of the intermediate layer and a schematic diagram of the electroplating process on the plastic surface of an embodiment of the present invention based on the spatial stacking of pixel cubes to form a spherical lens.)

[0026] Figure 7 This is one embodiment of some embodiments of the present invention. Figure 7 (This is an embodiment of the present invention based on the spatial stacking of pixel cubes to form a spherical lens under plane wave excitation, wherein Figures (a) and (b) are cross-sectional electric field distribution diagrams of the lower layer 4 at a design frequency of 5.8 GHz and a non-design frequency of 7 GHz, respectively.)

[0027] Figure 8 This is one embodiment of some embodiments of the present invention. Figure 8 (This is an embodiment of the present invention based on the spatial stacking of pixel cubes to form a spherical lens under waveguide excitation at 5.8 GHz. Figure (a) is the 3D radiation pattern; Figure (b) is the E-plane pattern; and Figure (c) is the H-plane pattern.)

[0028] Figure 9 This is one embodiment of some embodiments of the present invention. Figure 9 (This is an embodiment of the present invention based on the spatial stacking of pixel cubes to form a spherical lens. When rotated 45 degrees at 5.8 GHz, Figure (a) is the radiation pattern of the D plane; Figure (b) is the radiation pattern of the E plane; and Figure (c) is the radiation pattern of the H plane.)

[0029] Figure 10 This is one embodiment of some embodiments of the present invention. Figure 10(This is an embodiment of the present invention based on the spatial stacking of pixel cubes to form a spherical lens, with the feed waveguide located at the top left, center, top right, bottom left, and bottom right, respectively, in 3D radiation patterns.)

[0030] Figure 11 This is one embodiment of some embodiments of the present invention. Figure 10 (Figure (a) shows an embodiment of a hemispherical Luneburg lens achieved by cutting a spherical Luneburg lens based on the spatial stacking of pixel cubes according to the present invention; Figure (b) shows the 3D radiation pattern at 5.8 GHz under feed waveguide excitation.)

[0031] Figure 12 This is one embodiment of some embodiments of the present invention. Figure 10 (2. This invention provides a lens embodiment suitable for planar microstrip feed integration, achieved by cutting a spherical Luneburg lens based on pixel cube spatial stacking.)

[0032] The reference numerals in the accompanying drawings are as follows:

[0033] 1. Composite structure; 11. Substrate; 12. Electroplated plastic block; 13. Upper middle layer; 131. Upper adhesive layer of the upper middle layer; 132. Multi-slot layer of the upper middle layer; 133. Lower adhesive layer of the upper middle layer; 14. Lower middle layer; 141. Upper adhesive layer of the lower middle layer; 142. Multi-slot layer of the lower middle layer; 143. Lower adhesive layer of the lower middle layer; 144. Electroplated plastic block embedded in the lower middle layer; 2. Metal backplate; 3. Cut lens structure; 4. Planar microstrip array antenna feed. Detailed Implementation

[0034] To make the objectives, technical solutions, and advantages of the embodiments of this disclosure clearer, the technical solutions of this disclosure will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this disclosure, not all embodiments. Based on the embodiments of this disclosure, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this disclosure.

[0035] The following details a composite structure, lens, preparation method, communication module, and vehicle according to the present disclosure.

[0036] In optional embodiments of this disclosure, such as Figure 1-12The composite structure 1 is used for a lens and includes at least a portion of a substrate 11 and an electroplated plastic block 12. The substrate 11 has at least one slot, and the electroplated plastic block 12 has a non-solid air-filled structure inside, which is embedded in the slot to form the composite structure 1. The preset equivalent refractive index can be achieved by adjusting the size of the electroplated plastic block 12 or the proportion of the air-filled structure. The substrate 11 is made of expandable polystyrene (EPS) and manufactured using a molding process. Its dimensions are 20mm × 20mm × 10mm, with a rectangular slot (length × width × depth = 15mm × 15mm × 10mm) formed on it. The inner wall roughness of the slot is ≤ Ra1.6μm to ensure seamless insertion of the electroplated plastic block 12. The electroplated plastic block 12 is manufactured using FDM 3D printing (printing material: ABS plastic, printing speed: 60mm / s, layer thickness: 0.2mm). It features a honeycomb-like air-filled structure, with the air-fill ratio adjustable from 30% to 70%. When an equivalent refractive index of 1.4 is required, the plastic block size is set to 15mm × 15mm × 10mm, and the air-fill ratio is 40%. When an equivalent refractive index of 1.2 is required, the size remains the same, but the air-fill ratio is adjusted to 60%. The electroplated plastic block 12 is then embedded into the substrate 11. Within the slot, a complete composite structure 1 is formed (see Figure 1(a)). Full-wave simulation verification shows that the equivalent refractive index of the composite structure 1 can be adjusted within the range of 1.1-1.5. Lightweight: The non-solid air-filled structure reduces the weight of the composite structure 1 by 60% compared to the solid ceramic unit (of the same size) (composite structure 1 weight ≈ 8g, ceramic unit ≈ 20g), solving the weight load problem of large-size lenses; Adjustable refractive index: Without relying on additives, continuous adjustment of the equivalent refractive index can be achieved simply by adjusting the size of the plastic block or the air-filling ratio, with an adjustment accuracy ≤ ±0.02, adapting to the refractive index requirements of different radial layers in Luneburg lenses and avoiding the shortcomings of traditional foamed media with a single refractive index.

[0037] In optional embodiments of this disclosure, such as Figure 1-12The outer surface of the electroplated plastic block 12 is metallized by electroplating, and / or the air-filling structure of the electroplated plastic block 12 is a mesh structure with a pore size of 0.5-5mm. Metallization electroplating treatment: The surface of the electroplated plastic block 12 is cleaned sequentially (wiped twice with ethanol, 30s each time), roughened by sanding (sanded with 800-grit sandpaper in the same direction, roughness Ra 3.2μm), and activated (immersed in 10% dilute hydrochloric acid for 15 minutes); chemical nickel plating process is adopted (plating solution composition: nickel sulfate 25g / L, sodium hypophosphite 30g / L, sodium citrate 15g / L, pH=5.5, temperature 80℃, plating time 30 minutes), the plating thickness is 5μm, and the surface resistivity is ≤1Ω・cm (see the schematic diagram of the plastic surface electroplating process in Figure 6); mesh-like air-filled structure: the inside of the electroplated plastic block 12 is equipped with a square mesh (pore size 2mm, within the range of 0.5-5mm), the mesh rib width is 1mm, and the rib spacing is 2mm. It is integrally formed by 3D printing to ensure that the structure is unbroken. Electromagnetic performance enhancement: Metallization electroplating treatment enhances the conductivity of the plastic block surface, increasing electromagnetic wave reflection efficiency by 20% (reflectivity increased from 65% to 85% when tested at 5.8GHz), and improving the electromagnetic control precision of composite structure 1 by 15%; Structural stability: The mesh-like air-filled structure, while lightweight, enables composite structure 1 to have a compressive strength ≥5MPa (far exceeding the 3MPa of the honeycomb structure), and can withstand vibration and impact of 10-2000Hz in automotive scenarios without the risk of breakage.

[0038] In optional embodiments of this disclosure, such as Figure 1-12 The metallization electroplating process is selected from any one of electroless nickel plating, spraying silver-based conductive coating, or vacuum evaporation aluminum plating. Similar to the metallization electroplating steps in claim 2, it is suitable for scenarios requiring high coating adhesion (such as long-term outdoor communication), with a coating adhesion ≥ 5 MPa (cross-cut test, no peeling); a pneumatic spray gun is used (spraying pressure 0.4 MPa, spraying distance 20 cm, spraying speed 100 mm / s), sprayed in two coats (dry film thickness 10 μm), using DuPont 7160 coating (65% solids content), suitable for low-cost, rapid preparation scenarios (such as prototype development); under a vacuum of 1×10⁻ 4Under conditions of Pa and a deposition temperature of 1200℃, aluminum wire (99.99% purity) is evaporated and deposited on the surface of a plastic block, with a coating thickness of 8μm and a reflectivity of ≥95% at 5.8GHz, suitable for high-precision radar scenarios. Three processes cover different scenario requirements: electroless nickel plating is suitable for long-term durability scenarios, conductive coating spraying is suitable for low-cost and rapid scenarios, and vacuum aluminum evaporation is suitable for high-reflectivity scenarios, improving the applicability of the invention; the unit area cost of all three processes is lower than that of ceramic sintering (electroless nickel plating reduces cost by 30%, and conductive coating spraying reduces cost by 50%).

[0039] In optional embodiments of this disclosure, such as Figure 1-12 The matrix 11 is a foam, and the foam material is expandable polystyrene (EPS) or expandable polyethylene (EPE). EPS matrix: BASF PS 3030 beads (0.5mm particle size) are used, pre-foamed (90℃, 30 minutes, 50x expansion ratio), cured (25℃ for 24 hours), and molded (100℃, 0.3MPa, 5 minutes) to form matrix 11. After molding, the density is 0.03g / cm³, the dielectric constant at 1GHz is 1.05, and the dielectric loss tangent is ≤0.005. EPE matrix: Low-density EPE raw material (0.02g / cm³) is used, with butane as the foaming agent (5% addition). It is produced by extrusion foaming (85℃, screw speed 60r / min). After molding, the elongation at break is ≥150%, and the flexibility is superior to EPS. Lightweight and low dielectric loss: The density of EPS / EPE material is ≤0.03g / cm³, which is 98.8% lower than that of ceramic material (2.5g / cm³), significantly reducing the overall weight of the lens; the dielectric constant is ≤1.05, which reduces the loss of electromagnetic waves in the substrate and improves the focusing efficiency of the lens (focusing error is reduced from 5% to 3%); easy to process: EPS / EPE can be quickly prepared into a grooved substrate 11 through molding or extrusion processes, shortening the processing cycle by 80% compared to ceramic (which requires 24 hours of sintering), and no secondary processing is required after molding.

[0040] In optional embodiments of this disclosure, such as Figure 1-12A lens is provided, comprising at least the aforementioned composite structure 1; at least one composite structure 1 is arranged in three dimensions according to the gradient refractive index distribution required by the lens to form the lens body; the lens body can focus or beamform electromagnetic waves through the gradient refractive index. Composite Structure 1 Selection: The above-mentioned composite structure 1 (EPS substrate 11 + electroless nickel-plated plastic block 12) is selected, with an equivalent refractive index control range of 1.1-1.4; Gradient refractive index distribution: According to the Luneburg lens refractive index formula \(n(r)=\sqrt{2-(r / R)^2}\) (\(R=150mm\) is the lens radius, r is the distance from the center of the sphere), the lens is divided into 7 layers (L1-L7, see Figure 3(a)) along the radial direction. The equivalent refractive index of layer L1 (r=0-20mm) is 1.4, layer L2 (r=20-40mm) is 1.38, layer L3 is 1.35, layer L4 is 1.3, layer L5 is 1.25, layer L6 is 1.2, and layer L7 is 1.1; Three-dimensional arrangement: Each layer consists of an array of composite structure 1 (see Figure 3(b)), with 9 composite structures 1 (3×3) in layer L1. The L7 layer contains 121 composite structures 1 (11×11 array), stacked in the order of "L1-L2-L3-L4-L5-L6-L7-L7-L6-L5-L4-L3-L2-L1" to form a spherical lens body with a diameter of 300mm (see Figure 4). The lens body includes an upper middle layer 13 and a lower middle layer 14 (the lower middle layer 14 contains an embedded electroplated plastic block 144). The gradient refractive index arrangement ensures that the lens has a plane wave focusing error of ≤3% at 5.8GHz and a sidelobe suppression of ≤-13dB after beamforming (see Figure 8(b)(c)), which is better than traditional foamed lenses (sidelobe suppression ≤-8dB). It can realize electromagnetic wave focusing (such as communication) or beamforming (such as radar), and is suitable for multiple scenarios such as 5G vehicle networking and autonomous driving radar. There is no need to design lenses separately for different scenarios, reducing equipment redundancy costs.

[0041] In optional embodiments of this disclosure, such as Figure 1-12The lens body is spherical or hemispherical; if hemispherical, a metal back plate 2 is provided at the flat end of the lens body. Spherical lens: In the same three-dimensional arrangement as in claim 5, a spherical lens with a diameter of 300mm is made to adapt to omnidirectional communication scenarios (such as base station communication), and the lens weight is ≤1.5kg; Hemispherical lens: The spherical lens is cut along a plane passing through the center of the sphere (cutting accuracy ±0.5mm) to obtain a cut lens structure 3 with a radius of 150mm (see Figure 11(a)); a brass metal back plate 2 with a thickness of 2mm (size 300mm×300mm, surface nickel-plated for rust prevention) is pasted on the flat end, and the metal back plate 2 is fixed to the cut lens structure 3 by 4 M3 screws with a screw spacing of 200mm. The spherical lens is suitable for omnidirectional signal coverage, while the hemispherical lens (cut lens structure 3 + metal backplate 2) is suitable for directional scenarios (such as vehicle radar), expanding the application range of the lens. The metal backplate 2 can reflect leakage waves, which improves the lens energy utilization rate by 15% (under the same excitation, the detection distance is extended from 160m to 192m), and the volume of the hemispherical structure is reduced by 50% compared with the spherical structure (the volume is reduced from 14.1L to 7.05L), making it easier to integrate into vehicles.

[0042] In optional embodiments of this disclosure, such as Figure 1-12The three-dimensional arrangement of the composite structure 1 is a layered stacking, with each layer consisting of several arrays of composite structures 1, and adjacent layers are fixed together by an adhesive layer. Layered structure: Each layer of the lens (such as the upper middle layer 13 and the lower middle layer 14, see Figure 5) includes an adhesive layer and a multi-slot layer. The upper middle layer 13 consists of an upper adhesive layer 131 (epoxy resin: Loctite E-44, thickness 0.5mm), a multi-slot layer 132 (EPS substrate 11, with arrayed slots), and a lower adhesive layer 133 (same as 131). The lower middle layer 14 consists of an upper adhesive layer 141, a multi-slot layer 142, and a lower adhesive layer 143. The multi-slot layer 142 of the lower middle layer embeds an electroplated plastic block 144 embedded in the lower middle layer. Fixing method: Align and bond the lower adhesive layer 133 of the upper middle layer 13 with the upper adhesive layer 141 of the lower middle layer 14, and cure in a 50℃ oven for 1 hour. After curing, the interlayer peel strength is ≥2MPa. Each layer has a composite structure 1 The array is positioned via slots, ensuring that the unit spacing deviation is ≤0.1mm (see exploded view of the middle layer in Figure 6). Layered stacking and adhesive layer fixation ensure interlayer positioning accuracy is ≤0.1mm, avoiding abrupt changes in refractive index caused by misalignment of composite structure 1, and improving the consistency of lens electrical performance by 30% (batch-to-batch gain deviation reduced from ±1.5dB to ±1.05dB). The layered structure facilitates the replacement of individual composite structures 1; if a unit in a certain layer is damaged, only the corresponding adhesive layer needs to be peeled off and replaced, reducing maintenance costs by 50%.

[0043] In optional embodiments of this disclosure, such as Figure 1-12The lens body operates in the Sub-6GHz band or lower microwave bands. Sub-6GHz band (5.8GHz): Composite structure 1 has an equivalent refractive index of 1.1-1.4, a lens radius of 150mm, and a beamwidth of 13.7° (see Figure 8), suitable for 5G NR bands; Lower microwave band (2.4GHz, IoT band): Increase the size of composite structure 1 (substrate 11 with slots of 20mm×20mm×10mm, electroplated plastic block 12 with dimensions of 15mm×15mm×10mm), lens radius of 300mm, equivalent refractive index of 1.1-1.3, tested at 2.4GHz, beamwidth ≤15°, gain increased by 6dBi (from 12dBi to 18dBi). Wide-band compatibility: Covers Sub-6GHz and lower frequency bands (2.4GHz, 5.8GHz, etc.), compatible with multiple systems such as 5G, IoT, and radar. No need to design lenses separately for different frequency bands, reducing equipment costs (a single lens can adapt to multiple frequency bands, reducing costs by 40%). Superior low-frequency performance: In the 2.4GHz band, the lens gain is 6dBi higher than that of traditional antennas, solving the problems of insufficient gain and narrow signal coverage of traditional low-frequency lenses (the coverage range is expanded from 120° to 180°).

[0044] In optional embodiments of this disclosure, such as Figure 1-12 The process includes: S1 preparing an electroplated plastic block 12; S2 preparing a substrate 11; and S3 assembling and molding. S1 uses 3D printing to form a plastic block with an internal air-filled structure, followed by pretreatment and metallization electroplating. S2 uses a foaming molding process to prepare a slotted substrate 11. S3 embeds the plastic block into the slots of the substrate 11 to form a composite structure 1, arranged and fixed according to a gradient refractive index. S1 prepares the electroplated plastic block 12: using a Creality Ender-3 S1 3D printer, an ABS plastic block (15mm × 15mm × 10mm in size, with an internal mesh-like air-filled structure and 2mm pore diameter) is printed; after pretreatment (cleaning-roughening-activation), it is electrolessly nickel-plated (as in claim 2) to obtain the electroplated plastic block 12.

[0045] S2 Preparation of substrate 11: EPS beads are pre-foamed (90℃ / 30 minutes), cured (25℃ / 24 hours), and molded (100℃ / 0.3MPa) to form substrate 11 with 15mm×15mm×10mm slots. The slot array is designed according to the lens layering requirements.

[0046] S3 Assembly and Molding: Electroplated plastic blocks 12 are embedded in the slots of the substrate 11 to form a composite structure 1; according to the discrete layout in Figure 3(b), the composite structure 1 is stacked in layers, each layer is coated with an epoxy resin adhesive layer (thickness 0.5mm), and cured at 50℃ for 1 hour to finally produce a spherical lens body (see Figure 4). The three-step method reduces the number of steps by 40% compared to 3D printing a full-size lens (requiring 7 steps), shortening the production cycle from 72 hours to 24 hours and improving the preparation efficiency; the equipment cost of 3D printing + foam molding is 60% lower than that of ceramic sintering equipment (requiring a high-temperature furnace), and the raw material cost is reduced by 50%, making it suitable for small-to-medium batch prototype development and large-scale production.

[0047] In optional embodiments of this disclosure, such as Figure 1-12 A communication module is provided, including a communication module body (with a signal transceiver unit) and a lens; the lens is correspondingly arranged with the signal transceiver unit, electrically connected or signal coupled, to enhance the electromagnetic wave focusing or beam control capability. The communication module body uses the Huawei MH5000 5G vehicle-to-everything (V2X) communication module, and the signal transceiver unit is a microstrip antenna (8dBi gain, operating frequency band 3.3-5.8GHz); the lens integration uses the hemispherical lens described in claim 6 (cut lens structure 3 + metal backplate 2, radius 100mm), fixed above the communication module body by an aluminum alloy bracket, the distance between the lens center and the signal transceiver unit is 120mm (optimal distance optimized by simulation), and the two are signal coupled (no physical electrical connection); the bracket height is 50mm, and the planar microstrip array antenna feed 4 is integrated on one side of the communication module body (see...). Figure 12 The lens expands the signal coverage of the communication module from 120° to 180%, and improves the receiving sensitivity from -95dBm to -105dBm, solving the problems of narrow coverage and weak anti-interference of traditional communication modules (the disconnection rate in weak signal scenarios is reduced from 15% to 3%). The lens is small in size (radius 100mm), and after compact integration with the module body, the overall size is only 200mm×150mm×80mm, which is 30% smaller than the traditional "antenna + amplifier" solution.

[0048] In optional embodiments of this disclosure, such as Figure 1-12The lens is fixed to the communication module body via a connector with a position adjustment structure, allowing adjustment of the relative distance between the lens and the signal transceiver unit in either horizontal or vertical directions. Connector: A THK SSR15 aluminum alloy slide rail (100mm in length) is used, fixed to the top of the communication module body with four M2 screws. The lens is connected to the slide rail via a slider equipped with an M3 locking screw; loosening the screw allows for horizontal movement along the slide rail (adjustment range 0-100mm). Vertical adjustment: A lifting column (8mm in diameter, 50mm stroke) is mounted on the slider. The top of the lifting column connects to the lens bracket, allowing for vertical adjustment of the lens height (adjustment range 80-130mm) with an adjustment accuracy of ±0.5mm by rotating the lifting column knob. The distance can be adjusted according to different frequency bands—120mm for 5.8GHz and 180mm for 2.4GHz, without the need to redesign the module, reducing debugging time by 60% (from 2 hours to 48 minutes); the matching degree between the lens and the signal transceiver unit is improved in each frequency band, with gain deviation ≤1dB (from ±1.5dB to ±1.0dB), ensuring stable performance across the entire frequency band and avoiding signal attenuation due to distance deviation.

[0049] In optional embodiments of this disclosure, such as Figure 1-12 The communication module also includes a signal amplification unit, which is connected in series between the signal transceiver unit and the lens. The gain of the signal amplification unit is adjustable from 10 to 30 dB. The signal amplification unit uses an ADI ADL5565 low-noise amplifier (operating frequency band 0.1-6 GHz, noise figure ≤ 1.5 dB), with an adjustable gain range of 10-30 dB (adjusted via a 3-position DIP switch on the module body in 5 dB increments). The circuit connection is as follows: the amplification unit is connected in series between the signal transceiver unit (microstrip antenna) and the lens via an SMA connector. The signal flow is: during transmission, "signal transceiver unit → amplification unit → lens"; during reception, "lens → amplification unit → signal transceiver unit". The amplification unit is powered by 5V and has a current ≤ 50mA, supplied by the communication module itself. The 10-30dB adjustable gain extends the communication distance of the communication module by 50%-100% (from 1km to 1.5-2km). In weak signal scenarios (such as underground parking garages), normal communication is still possible when the gain is adjusted to 30dB, solving the problem of weak signal disconnection. The amplification unit is compatible with the entire frequency band from 0.1-6GHz and can be paired with different types of signal transceiver units and lenses, improving compatibility by 40% compared to fixed gain amplifiers.

[0050] In optional embodiments of this disclosure, such as Figure 1-12This invention provides a vehicle comprising a vehicle body (with a power supply system and a control module) and a communication module for the aforementioned integrated lens. The communication module is installed at a preset position on the vehicle body and is electrically connected to the power supply system and the control module, enabling the vehicle to transmit and receive signals or perform radar detection functions. The vehicle body is a BYD Han EV new energy vehicle, with a 12V low-voltage power supply (converted to 5V via a DC-DC converter to power the communication module), and a Bosch ESP 9.3 vehicle ECU. The communication module is installed in the center of the vehicle roof via a detachable silicone bracket (avoiding the sunroof, with an installation position deviation ≤10mm). The bracket has a 3mm thick shock-absorbing pad (hardness 50 Shore A) to reduce the impact of vehicle vibrations on the lens. The communication module connects to the power supply system via an XT60 interface and communicates with the control module via Ethernet (100Mbps speed), transmitting real-time signal strength (sampling rate 1Hz) and operating temperature (range -40℃ to 85℃) data. The lightweight lens (weight ≤500g) will not add extra load to the vehicle, and the shock absorber bracket can withstand vibrations of 10-2000Hz, adapting to the vehicle's driving environment (the lens did not loosen or become damaged after vibration testing); the communication module of the integrated lens can simultaneously support V2X communication (vehicle-to-vehicle, vehicle-to-roadside equipment) and millimeter-wave radar detection, improving the integration of vehicle intelligent driving functions by 50% (reducing hardware costs by 30%) and increasing the detection range to 200m.

[0051] Taking the "Sub-6GHz band 5.8GHz hemispherical lens and vehicle communication module" as an example, the fabrication and integration process is explained in detail:

[0052] Preparation of composite structure 1:

[0053] 3D printed ABS plastic blocks (15mm×15mm×10mm in size, with internal mesh-like air filling and 2mm pore diameter) were cleaned, roughened, and activated before being chemically nickel-plated (5μm coating) to produce electroplated plastic blocks 12;

[0054] EPS beads are pre-foamed (90℃ / 30 minutes), cured (25℃ / 24 hours), and molded (100℃ / 0.3MPa) to form a substrate 11 with 15mm×15mm×10mm slots;

[0055] An electroplated plastic block 12 is embedded into a slot in a substrate 11 to form a composite structure 1 with an equivalent refractive index of 1.3.

[0056] Preparation of hemispherical lenses:

[0057] As shown in Figures 3(a) and (b), the composite structure 1 is divided into 7 layers (L1-L7), with an equivalent refractive index of 1.4 for layer L1 and 1.1 for layer L7. Each layer is bonded and fixed by the upper adhesive layer 131 of the middle and upper layers and the upper adhesive layer 141 of the middle and lower layers to form a spherical lens with a diameter of 300 mm.

[0058] Cut the spherical lens along the plane of the center of the sphere to obtain the cut lens structure 3. Attach the brass metal back plate 2 to make a hemispherical lens (see Figure 11(a)).

[0059] Communication module integration:

[0060] Select the Huawei MH5000 communication module, connect the ADI ADL5565 amplifier unit in series (gain set to 20dB), fix the hemispherical lens on top of the module with a bracket with a slide rail, adjust the distance between the lens and the signal transceiver unit to 120mm, and integrate the planar microstrip array antenna feed 4 (see Figure 12).

[0061] Vehicle installation:

[0062] The communication module was installed in the middle of the roof of the BYD Han EV using a silicone shock-absorbing bracket, and then connected to the vehicle ECU via a 12V to 5V DC-DC converter to complete the integration.

[0063] Simulation Experiment

[0064] Simulation conditions

[0065] Simulation software: ANSYS HFSS 2023 R1;

[0066] Lens parameters: Spherical lens based on composite structure 1 (diameter 300mm, 7-layer composite structure 1, equivalent refractive index 1.1-1.4), hemispherical lens (radius 150mm, with metal back plate 2).

[0067] Operating frequency bands: 5.8GHz (design frequency), 7GHz (non-design frequency), 2.4GHz (lower frequency bands);

[0068] Excitation methods: plane wave excitation (Figure 7), waveguide excitation (Figures 8-10, waveguide model WR-187, adapted for 5.8GHz).

[0069] Test parameters: electric field distribution, radiation pattern (gain, beamwidth, sidelobe suppression), angular stability (45° rotation), multi-beam performance (5 feed positions), and hemispherical lens performance.

[0070] Simulation results

[0071] Frequency-selective verification (Figure 7)

[0072] 5.8GHz (design frequency): The plane wave is focused on the rear surface after passing through the lens. The electric field intensity at the focal point is 8 times that of the incident field, and the focusing error is ≤3%, which meets the design requirements.

[0073] 7GHz (non-design frequency): The plane wave has no obvious focusing, only twice the incident field intensity, and mainly diffraction occurs, proving that the lens has good frequency selectivity.

[0074] Radiation performance verification (Figure 8)

[0075] Gain: Under waveguide excitation at 5.8 GHz, the maximum gain of the lens reaches 20.6 dBi, which is 8.6 dBi higher than that of the waveguide antenna without a lens (gain of 12 dBi).

[0076] Beamwidth: 3dB. The beamwidth is 13.7°, with E-plane sidelobe suppression of -13.5dB and H-plane sidelobe suppression of -19dB, both of which are better than the industry standard (sidelobe suppression ≤-10dB), which can reduce adjacent channel interference.

[0077] Angular stability verification (Figure 9)

[0078] After rotating the lens by 45°, the maximum gain still reached 20.3dBi (a decrease of only 0.3dBi), the sidelobe suppression of the E-plane was -14.8dB, and the sidelobe suppression of the H-plane was -20.7dB, proving that the lens has stable performance under different installation angles and is suitable for the dynamic environment of vehicle scenarios.

[0079] Multibeam performance verification (Figure 10)

[0080] When the feed waveguide is located at five positions: upper left, center, upper right, lower left, and lower right, the lens can form a directional pencil beam with a gain of approximately 20 dBi and a sidelobe suppression of ≤-13 dB.

[0081] With a multi-beam switching response time of ≤1ms, it can support multi-directional signal transmission and reception for vehicle V2X communication or multi-target detection for radar.

[0082] Performance verification of the hemispherical lens (Figure 11(b))

[0083] The hemispherical lens (cut lens structure 3 + metal backplate 2) has a maximum gain of 20.5 dBi at 5.8 GHz, which is close to that of the complete spherical lens (20.6 dBi), with H-plane sidelobe suppression of -17.6 dB and E-plane sidelobe suppression of -12.8 dB.

[0084] It is 50% smaller in volume than a spherical lens, weighs only 0.75kg, is easier to integrate into vehicles, and has no significant performance degradation.

[0085] Simulation conclusions

[0086] The lens and composite structure 1 of the present invention have the characteristics of precise focusing, high gain, excellent sidelobe suppression, and stable multi-beam performance in the Sub-6GHz frequency band (especially 5.8GHz); the hemispherical structure is suitable for vehicle-mounted scenarios, and has significant advantages in lightweight and integration. Simulation results fully verify the feasibility and superiority of the technical solution.

[0087] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

[0088] In the description of this disclosure, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this disclosure and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this disclosure.

[0089] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this disclosure, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0090] In this disclosure, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this disclosure according to the specific circumstances.

[0091] In this disclosure, unless otherwise expressly specified and limited, "above" or "below" the second feature can mean that the first and second features are in direct contact, or that the first and second features are in indirect contact through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0092] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this disclosure. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0093] Although embodiments of the present disclosure have been shown and described above, it is to be understood that the above embodiments are exemplary and should not be construed as limiting the present disclosure. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present disclosure.

Claims

1. A composite structure, characterized by, A lens comprises: at least a base body provided with at least one slot; and a galvanic plastic block with an air-filled structure inside, wherein the galvanic plastic block is embedded in the slot of the base body to form a composite unit, and the composite unit has a preset equivalent refractive index by adjusting the size of the galvanic plastic block or the proportion of the air-filled structure.

2. The composite structure of claim 1, wherein, The outer surface of the galvanic plastic block is subjected to a metallization galvanization treatment, and / or the air-filled structure of the galvanic plastic block is a grid structure with a pore size of 0.5-5 mm.

3. The composite structure of claim 1, wherein, The metallization galvanization treatment is selected from any one of chemical nickel plating, spraying silver-based conductive paint, or vacuum evaporation of aluminum.

4. The composite structure of claim 1, wherein, The base body is a foamed foam, and the material of the foamed foam is expandable polystyrene (EPS) or expandable polyethylene (EPE).

5. A lens characterized by The lens comprises: at least one composite unit according to any one of claims 1-4; at least one composite unit is arranged in three dimensions according to the gradient refractive index distribution required by the lens to form a lens body, and the lens body can focus or beam shape electromagnetic waves through the gradient refractive index.

6. The lens of claim 5, wherein, The lens body is in the form of a sphere or a hemisphere; if it is a hemisphere, the flat end of the lens body is provided with a metal back plate.

7. The lens of claim 5, wherein The three-dimensional arrangement of the composite unit is layer-by-layer stacking, and each layer is composed of a plurality of composite unit arrays, and adjacent layers are fixed through an adhesive layer.

8. The lens of claim 5, wherein, The working frequency band of the lens body is a Sub-6GHz frequency band or a lower microwave frequency band.

9. A method for producing a lens, characterized by, The lens comprises the following steps: S1. Preparing a galvanic plastic block: using a 3D printing process to form a plastic block with an air-filled structure inside, pretreating the surface of the plastic block, and then treating the outer surface of the plastic block through a metallization galvanization process to obtain a galvanic plastic block; S2. Preparing a base body: using a foaming molding process to prepare a base body with a slot, and the size of the slot is matched with the galvanic plastic block in step S1; S3. Assembling and forming: embedding the galvanic plastic block in step S1 into the slot of the base body in step S2 to form a composite unit; arranging and fixing a plurality of composite units in three dimensions according to the gradient refractive index distribution required by the lens to obtain a lens.

10. A communication module, characterized by The lens comprises: a communication module body provided with a signal transceiver unit; the lens according to any one of claims 5-8; the lens is arranged correspondingly with the signal transceiver unit of the communication module body, and the two are electrically connected or signal coupled to enhance the electromagnetic wave focusing or beam control ability of the signal transceiver unit.

11. The communication module of claim 10, wherein, The lens is fixed to the communication module body through a connecting piece with a position adjusting structure, and the relative distance between the lens and the signal transceiver unit can be adjusted in the horizontal or vertical direction.

12. The communication module of claim 11, wherein, The communication module body further comprises a signal amplification unit connected in series between the signal transceiver unit and the lens, and the gain of the signal amplification unit can be adjusted in the range of 10-30 dB.

13. A vehicle characterized by comprising: The lens comprises: a vehicle body provided with a power supply system and a control module; The integrated lens communication module according to any one of claims 11-12, wherein the integrated lens communication module is installed at a predetermined position of a vehicle body and electrically connected to a power supply system and a control module of the vehicle, so as to realize a signal transceiving or radar detection function of the vehicle.

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