Cold press molded glass reflector and preparation method thereof
By employing cold pressing technology and vacuum adsorption process, the problems of long production cycles and high costs of glass reflectors have been solved, enabling the production of lightweight and high-precision glass reflectors suitable for stable use in complex environments.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-31
- Publication Date
- 2026-04-07
AI Technical Summary
Existing glass reflector manufacturing processes are characterized by long production cycles, high costs, and low mass production efficiency, making it difficult to meet the requirements of low-cost, short-cycle, and high-efficiency production for segmented optical systems. Furthermore, they are unstable in high-altitude or mountainous environments.
By combining cold pressing technology with vacuum adsorption process, using flat float glass and glass fiber composite materials, glass reflectors are prepared by vacuum die casting, achieving one-time molding and sealing, simplifying the process, reducing production costs and improving efficiency.
It has enabled the production of lightweight, high-precision glass reflectors, suitable for long-term stable use in complex environments, reducing production costs and improving production efficiency and product consistency.
Smart Images
Figure CN121806172A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to the technical field of optical element manufacturing, in particular to a cold-press forming glass reflector and a preparation method thereof. BACKGROUND
[0002] High mountain experiment is a ground detection means that can reduce the absorption effect of the atmosphere as much as possible in cosmic ray observation research, and has become an indispensable research means for very high energy and ultra-high energy gamma-ray astronomy and cosmic ray observation. To determine the nature of ultra-high energy gamma-ray sources and solve the century-old mystery of the origin of ultra-high energy cosmic rays, high angular resolution imaging observation research of these sources is needed. Under this background, it is urgent to develop a new type of atmospheric imaging Cherenkov telescope array, and to use space stereo imaging observation technology to greatly improve the angular resolution of the device. One of the key core components of the atmospheric imaging Cherenkov telescope is the optical glass reflector. In the face of growing construction needs, it is very urgent to improve the structure of the glass reflector and to improve the production process.
[0003] The segmented optical system similar to the Cherenkov telescope is more and more used in astronomy, and at present, such glass lenses are mostly made of quartz glass, which is first heated and bent into a mirror blank, then the mirror blank is roughly polished and processed, and finally coated and formed. This process route has long polishing and processing cycle, high manufacturing cost, low mass production efficiency, and the product has problems such as poor reliability, heavy weight, etc. Moreover, due to its high dependence on complex precision machining and operator's personal experience, its production rhythm is slow, the capacity is low, it is difficult to realize rapid and large-scale manufacturing, and it cannot meet the requirements of low cost, short cycle and efficient production of the required lenses for such segmented optical systems, and long-term stable use in highland or mountain environment. SUMMARY
[0004] To solve the above problems, the present application provides a cold-press forming glass reflector and a preparation method thereof. By using normal temperature or low temperature glue curing combined with precise vacuum adsorption forming technology, the planar glass can be once pasted and fixed without preheating and bending, the shape and size can be once clamped and molded, the process is simple, the manual operation is fast, and thus the lightweight glass reflector with high surface shape precision is prepared at low cost and high efficiency.
[0005] In order to achieve the above purpose, the technical scheme of the present application is as follows: a cold-press forming glass reflector, which comprises a front skin, a front skin glue transition layer, a honeycomb interlayer, an edge sealing strip, a rear skin glue transition layer and a rear skin; the front skin is the working surface and is made of planar float glass; the front skin glue transition layer and the rear skin glue transition layer are made of glass fiber fabric composite material; the honeycomb interlayer is made of aluminum honeycomb or aramid paper honeycomb; the edge sealing strip is made of glass steel composite material or PVC plate; and the rear skin is made of planar float glass or hot-bending float glass.
[0006] Further, the front skin is concave, and the concave curve is spherical; the plane float glass thickness of the front skin is 0.5mm-4mm.
[0007] Further, the front skin adhesive transition layer and the rear skin adhesive transition layer are both glass fiber fabric composites, the reinforcing body is satin or plain woven glass fiber fabric, the resin is single-component or multi-component liquid adhesive, and the adhesive can be cured at room temperature or with heating.
[0008] Further, the thickness of the front skin adhesive transition layer and the rear skin adhesive transition layer is 0.1mm-3mm.
[0009] Further, the honeycomb sandwich is processed to the theoretical curved surface of the glass mirror in a honeycomb sandwich pressure casting manner, and the thickness of the honeycomb sandwich is 20mm-80mm.
[0010] A preparation method of a cold-pressed formed glass mirror, based on the weight parts of any of the cold-pressed formed glass mirror raw materials, includes the following steps: S1, model establishment: establishing a mathematical model of the working curved surface of the glass mirror, and designing a vacuum adsorbable forming mold; S2, preparing the front skin: preparing plane float glass with a thickness of 0.5mm-4mm as the front skin base, processing to the required size and cleaning the surface impurities, at the same time, cleaning the surface dust of the forming mold, aligning the front skin with the contour line of the forming mold and placing it, deforming the plane float glass by high-pressure air with a vacuum degree of 0.05Mpa-0.1Mpa, and sticking it to the curved surface of the forming mold; S3, preparing the honeycomb sandwich and the rear skin: preparing aluminum honeycomb or aramid paper honeycomb as the sandwich material, processing the edges to the size of the glass mirror, processing to the theoretical curved surface of the glass mirror in a vacuum pressure casting manner, the thickness of the honeycomb is 20mm-80mm, preferably a honeycomb with holes to ensure air communication between the holes, the honeycomb with holes is transversely opened at the hole wall, and the holes are connected with each other; preparing plane float glass as the rear skin, processing and cleaning the surface impurities; S4, laying the transition layer: laying glass fiber fabric soaked with adhesive on the surface of the front skin and the rear skin to form the front skin adhesive transition layer and the rear skin adhesive transition layer, respectively; S5, assembling and demolding: after assembling the front skin, the rear skin and the honeycomb sandwich, vacuum packaging and overall vacuum curing are performed to form an integrated body, after demolding, the front skin and the rear skin are coated, and sealing is completed by using a sealant to bond the edge strip, and finally a cold-pressed formed glass mirror is obtained.
[0011] Furthermore, in S1, the specific preparation method of the forming mold is as follows: establish a mathematical model of the working surface of the glass reflector, design the forming mold according to the model, and use aluminum alloy or steel material to make the forming mold with good rigidity, surface smoothness and surface accuracy, so as to realize vacuum adsorption of the front skin and not deform under vacuum pressure.
[0012] Furthermore, in S4, the specific method of laying the transition layer is as follows: the glass fiber fabric is cut into the shape of a glass reflector, impregnated with a single-component or multi-component liquid adhesive, and then laid on the adhesive surfaces of the front skin and the prepared rear skin respectively, forming a front skin adhesive transition layer and a rear skin adhesive transition layer with a thickness of 0.1mm to 3mm. The adhesive can be cured at room temperature or by heating.
[0013] Furthermore, in S5, the assembly, curing, and demolding steps are as follows: the front and rear skins covered with the adhesive transition layer, as well as the processed honeycomb sandwich layer are assembled, and the demolding cloth, breathable felt, and vacuum bag are placed in sequence. The whole assembly is vacuumed and cured under a vacuum of 0.01Mpa~0.05Mpa. The demolding of the part is completed after the adhesive is completely cured.
[0014] Furthermore, in S5, the coating and edge sealing steps are as follows: after demolding, impurities, residual adhesive, and dust on the surface of the front and rear skins are cleaned to meet the coating requirements. Vacuum evaporation coating or magnetron sputtering coating processes are used to coat an aluminum layer and a silicon dioxide protective layer, wherein the aluminum layer thickness is 90nm~150nm and the silicon dioxide protective layer thickness is 50nm~150nm. A modified silane sealant or silicone rubber sealant with good UV resistance, thixotropic properties, and waterproof, mildew-proof, and moisture-proof properties is selected to bond the edge sealing strips made of fiberglass composite material or PVC board to the six thickness direction openings of the glass reflector to complete the overall sealing and curing.
[0015] The above approach has the following beneficial effects: 1. Float glass is used as the front and rear skins, glass fiber composite material is used as the transition layer, and aluminum honeycomb or aramid honeycomb is used as the interlayer material. The materials have similar coefficients of thermal expansion, the structure has good thermal stability, and it can maintain good optical performance in a wide temperature range.
[0016] 2. The glass fiber composite transition layer can not only suppress the micro-deformation of the glass skin, improve the surface accuracy and control the uniformity of the adhesive layer, but also fix the fragments when the glass breaks accidentally, improve the safety of use and reduce secondary damage.
[0017] 3. The use of planar float glass combined with cold pressing and vacuum adsorption processes replaces traditional hot bending and grinding, significantly shortening the processing cycle, reducing production costs, facilitating standardized and serialized mass production, and ensuring good product consistency and high precision.
[0018] 4. The glass reflector uses fiberglass composite material or PVC board and sealant to completely seal the lens, which isolates the aluminum honeycomb metal material inside the reflector from the air. It has excellent weather resistance, is not easy to corrode, and can be used for a long time in various complex outdoor environments.
[0019] 5. The honeycomb interlayer adopts a perforated design with horizontal openings in the pore walls and interconnected pores, so as to balance the internal air pressure with the external environment, effectively resist the air pressure difference deformation caused by the low air pressure environment at high altitudes, and ensure that the reflector can maintain the surface accuracy in both high and low altitude regions. 6. This solution, relying on high-precision molds and vacuum die-casting technology, enables the front skin to be directly adsorbed and shaped without pre-bending, and the honeycomb sandwich and the overall structure to be clamped and cured in one go, which greatly reduces the pre-processing steps, reduces the dependence on operator skills, and improves process stability and production efficiency. The sandwich composite structure has high specific stiffness and lightweight characteristics while ensuring optical surface precision, which facilitates transportation, installation and long-term use. It is especially suitable for large telescope arrays, aerospace optical systems and other occasions with high requirements for weight and stability. Attached Figure Description
[0020] Figure 1 This is an isometric schematic diagram of an embodiment of the cold-pressed glass reflector of the present invention; Figure 2 This is a schematic diagram of the structure of an embodiment of the cold-pressed glass reflector of the present invention; Figure 3 This is a schematic diagram of the molding die for an embodiment of the cold-pressed glass reflector of the present invention; Figure 4 This is a schematic diagram of the method steps in an embodiment of the cold-pressed glass reflector manufacturing method of the present invention.
[0021] The reference numerals in the accompanying drawings of the instruction manual include: 1. Glass reflector; 2. Front skin; 3. Front skin adhesive transition layer; 4. Honeycomb interlayer; 5. Edge sealing strip; 6. Rear skin adhesive transition layer; 7. Rear skin; 8. Molding mold. Detailed Implementation
[0022] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.
[0023] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., 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 the invention and for simplifying the description, and do not 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 the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.
[0024] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; 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; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.
[0025] The following detailed description illustrates the specific implementation method: Example 1: As attached Figure 1 As shown: A cold-pressed glass reflector comprises a front skin 2, a front skin adhesive transition layer 3, a honeycomb interlayer 4, an edge sealing strip 5, a rear skin adhesive transition layer 6, and a rear skin 7, which together form a composite structure. Figure 2 The structure shown is composed of the following components: the front skin 2 is the working surface, made of flat float glass, the front skin 2 is concave, and the concave curve is spherical; the thickness of the flat float glass in the front skin 2 is 0.5mm~4mm.
[0026] Both the front skin adhesive transition layer 3 and the rear skin adhesive transition layer 6 are made of glass fiber fabric composite material. The reinforcement is satin or plain weave glass fiber fabric, and the resin is a single-component or multi-component liquid adhesive. The adhesive can be cured at room temperature or with heating. The thickness of both the front skin adhesive transition layer 3 and the rear skin adhesive transition layer 6 is 0.1mm~3mm.
[0027] The honeycomb interlayer 4 is made of aluminum honeycomb or aramid paper honeycomb. The honeycomb interlayer 4 is processed to the theoretical curved surface of the glass reflector 1 by vacuum die casting. The thickness of the honeycomb interlayer 4 is 20mm~80mm.
[0028] The edge banding strip 5 is made of fiberglass composite material or PVC board.
[0029] The rear skin 7 is made of flat float glass or hot-bent float glass. When the radius of curvature of the working surface of the rear skin 7 is greater than 16m, it does not need to be hot-bent. When the radius of curvature is less than or equal to 16m, the flat float glass needs to be heated and softened and pre-formed by hot bending on a specific mold.
[0030] Example 2: As attached Figure 4 As shown, the difference from Example 4 is that a method for preparing a cold-pressed glass reflector 1, based on the weight parts of the raw material for the cold-pressed glass reflector 1 described in Example 1, includes the following steps: S1, Model Establishment: Establish a mathematical model of the working surface of the glass reflector 1, and design a vacuum-adsorption-capable forming mold 8. The forming mold 8 is as follows: Figure 3 As shown; the specific preparation method of the forming mold 8 is as follows: establish a mathematical model of the working surface of the glass reflector 1, design the forming mold 8 according to the model, the forming mold 8 is made of aluminum alloy or steel, has good rigidity, surface smoothness and surface accuracy, can realize vacuum adsorption of the front skin 2 and not deform under vacuum pressure, the mold surface accuracy is better than 1μm, the surface roughness is better than 80nm, and it has the function of vacuum adsorption of the front skin 2 glass.
[0031] S2, Preparation of front skin 2: Prepare a flat float glass with a thickness of 0.5mm~4mm as the substrate of front skin 2. Taking this scheme as an example, prepare a flat float glass with a thickness of 2.5mm, process it to the required size and clean the surface impurities. At the same time, clean the dust on the surface of the forming mold 8, align the front skin 2 with the outline of the forming mold 8 and place it. Use high-pressure air with a vacuum degree of 0.05Mpa~0.1Mpa to deform the flat float glass and attach it to the curved surface of the forming mold 8. S3, Preparation of the honeycomb interlayer 4 and the back skin 7: Prepare aluminum honeycomb or aramid paper honeycomb as the interlayer material, process the edges to the outer dimensions of the glass reflector 1, and the honeycomb thickness is 30mm; process it to the theoretical curved surface of the glass reflector 1 using vacuum die casting, with a honeycomb thickness of 20mm~80mm. Perforated honeycomb is preferred to ensure airflow between the cells. All perforated honeycomb cells have transverse openings at the cell walls, and the pores are interconnected to balance the micro-deformation of the glass surface caused by pressure changes in high-altitude, low-pressure environments; prepare flat float glass as the back skin 7. When the working surface curvature radius of the glass reflector 1 is >16m, hot bending is not required. When the curvature radius is ≤16m, the flat float glass is heated and softened, and then pre-formed by hot bending on a specific forming mold 8. Specifically, prepare a piece of flat float glass for making the back skin 7. Since the working surface curvature radius of the reflector in this embodiment is 16m, this piece of flat float glass needs to be heated and softened, and then pre-formed by hot bending on a specific mold. Clean surface impurities after processing.
[0032] S4, Laying the transition layer: Laying glass fiber fabric impregnated with adhesive onto the surfaces of the front skin 2 and the rear skin 7 to form the front skin adhesive transition layer 3 and the rear skin adhesive transition layer 6 respectively; The specific method of laying the transition layer is as follows: the glass fiber fabric is cut into the shape of the glass reflector 1, impregnated with a single-component or multi-component liquid adhesive, and then laid onto the adhesive surfaces of the adsorbed front skin 2 and the prepared rear skin 7 respectively, forming the front skin adhesive transition layer 3 and the rear skin adhesive transition layer 6 with a thickness of 0.1mm~3mm respectively. The adhesive can be cured at room temperature or by heating.
[0033] S5, Assembly and Demolding: After assembling the front skin 2, rear skin 7 and honeycomb sandwich 4, the parts are vacuum sealed and solidified as a whole. The assembly, solidification and demolding steps are as follows: the front skin 2 and rear skin 7 with the adhesive transition layer laid on them, as well as the processed honeycomb sandwich 4, are assembled. The demolding cloth, breathable felt and vacuum bag are placed in sequence. The whole part is solidified under the condition of vacuum degree of 0.01Mpa~0.05Mpa. After the adhesive is completely solidified, the part is demolded. After demolding, the front skin 2 and rear skin 7 are coated, and then the edge sealing strip 5 is bonded with sealant to complete the sealing. The coating and edge sealing steps are as follows: clean the impurities, residual adhesive and dust on the surface of the front skin 2 and rear skin 7 after demolding to meet the coating requirements; use vacuum evaporation coating or magnetron sputtering coating process to coat an aluminum layer and a silicon dioxide protective layer, wherein the thickness of the aluminum layer is 90nm~150nm and the thickness of the silicon dioxide protective layer is 50nm~150nm, wherein in this embodiment the thickness of the aluminum layer is 90nm and the thickness of the silicon dioxide protective layer is 60nm; select a modified silane sealant or silicone rubber sealant with good UV resistance, thixotropic properties and waterproof, mildew-proof and moisture-proof properties, and bond the edge sealing strip 5 of fiberglass composite material or PVC board material to the six thickness direction openings of the glass reflector 1 to complete the overall sealing and curing, and finally obtain the cold-pressed glass reflector 1.
[0034] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the scope of protection of this invention.
Claims
1. A cold-pressed glass reflector, characterized in that, It consists of a front skin (2), a front skin adhesive transition layer (3), a honeycomb interlayer (4), an edge sealing strip (5), a rear skin adhesive transition layer (6), and a rear skin (7). The front skin (2) is the working surface and is made of flat float glass. The front skin adhesive transition layer (3) and the rear skin adhesive transition layer (6) are both made of glass fiber fabric composite material. The honeycomb interlayer (4) is made of aluminum honeycomb or aramid paper honeycomb. The edge sealing strip (5) is made of fiberglass composite material or PVC board. The rear skin (7) is made of flat float glass or hot-bent float glass.
2. The cold-pressed glass reflector according to claim 1, characterized in that, The front skin (2) is concave, and the concave curve is spherical; the thickness of the flat float glass of the front skin (2) is 0.5mm~4mm.
3. The cold-pressed glass reflector according to claim 1, characterized in that, Both the front skin adhesive transition layer (3) and the rear skin adhesive transition layer (6) are glass fiber fabric composite materials. The reinforcement is satin or plain weave glass fiber fabric, and the resin is a single-component or multi-component liquid adhesive. The adhesive can be cured at room temperature or by heating.
4. The cold-pressed glass reflector according to claim 1, characterized in that, The thickness of the front skin adhesive transition layer (3) and the rear skin adhesive transition layer (6) is 0.1mm~3mm.
5. The cold-pressed glass reflector according to claim 1, characterized in that, The honeycomb interlayer (4) is processed to the theoretical curved surface of the glass reflector (1) by vacuum die casting. The thickness of the honeycomb interlayer (4) is 20mm~80mm.
6. A method for preparing a cold-pressed glass reflector, based on the weight proportions of the cold-pressed glass reflector raw materials according to any one of claims 1-5, characterized in that, Includes the following steps: S1, Model Establishment: Establish a mathematical model of the working surface of the glass reflector (1) and design a molding mold that can be vacuum adsorbed; S2, Preparation of front skin (2): Prepare a flat float glass with a thickness of 0.5mm~4mm as the base of the front skin (2), process it to the required size and clean the surface impurities, and clean the dust on the surface of the forming mold at the same time. Align the front skin (2) with the outline of the forming mold and place it. Use high pressure air with a vacuum degree of 0.05Mpa~0.1Mpa to deform the flat float glass and attach it to the curved surface of the forming mold. S3, Prepare honeycomb interlayer (4) and back skin (7): Prepare aluminum honeycomb or aramid paper honeycomb as interlayer material, process the edge to the outer dimensions of the glass reflector (1), process to the theoretical curved surface of the glass reflector (1) by vacuum die casting, the honeycomb thickness is 20mm~80mm, preferably perforated honeycomb to ensure air passage between the cells, the perforated honeycomb is all transversely opened at the hole wall, and the pores are all interconnected; Prepare flat float glass as back skin (7), and clean the surface impurities after processing; S4, Laying transition layer: Laying glass fiber fabric impregnated with adhesive on the surface of the front skin (2) and the rear skin (7) to form front skin adhesive transition layer (3) and rear skin adhesive transition layer (6) respectively. S5, Assembly and Demolding: After assembling the front skin (2), rear skin (7) and honeycomb interlayer (4), the front skin (2) and rear skin (7) are vacuum sealed and solidified into a single unit. After demolding, the front skin (2) and rear skin (7) are coated, and the sealing strip (5) is then bonded with sealant to complete the sealing. Finally, a cold-pressed glass reflector (1) is obtained.
7. The method for preparing a cold-pressed glass reflector according to claim 6, characterized in that, In S1, the specific preparation method of the forming mold is as follows: establish a mathematical model of the working surface of the glass reflector (1), design the forming mold according to the model, the forming mold is made of aluminum alloy or steel, with good rigidity, surface smoothness and surface accuracy, and can realize vacuum adsorption of the front skin (2) and not deform under vacuum pressure.
8. The method for preparing a cold-pressed glass reflector according to claim 6, characterized in that, In S4, the specific method of laying the transition layer is as follows: cut the glass fiber fabric into the shape of the glass reflector (1), impregnate it with a single-component or multi-component liquid adhesive, and lay it on the adhesive surface of the front skin (2) and the prepared rear skin (7) respectively, forming a front skin adhesive transition layer (3) and a rear skin adhesive transition layer (6) with a thickness of 0.1mm~3mm. The adhesive can be cured at room temperature or by heating.
9. The method for preparing a cold-pressed glass reflector according to claim 6, characterized in that, In S5, the assembly, curing and demolding steps are as follows: the front skin (2) and rear skin (7) covered with adhesive transition layer, as well as the processed honeycomb sandwich (4) are assembled, and the demolding cloth, breathable felt and vacuum bag are placed in sequence. The whole is vacuumed and cured under the condition of vacuum degree of 0.01Mpa~0.05Mpa. After the adhesive is completely cured, the part is demolded.
10. The method for preparing a cold-pressed glass reflector according to claim 6, characterized in that, In S5, the coating and edge sealing steps are as follows: clean the impurities, residual glue and dust on the surface of the front skin (2) and the rear skin (7) after demolding until they meet the coating requirements. Use vacuum evaporation coating or magnetron sputtering coating process to coat an aluminum layer and a silicon dioxide protective layer, wherein the aluminum layer thickness is 90nm~150nm and the silicon dioxide protective layer thickness is 50nm~150nm. Select a modified silane sealant or silicone rubber sealant with good UV resistance, thixotropic properties and waterproof, mildew-proof and moisture-proof properties, and bond the edge sealing strip (5) of fiberglass composite material or PVC board material to the six thickness direction openings of the glass reflector (1) to complete the overall sealing and curing.