High-low-temperature-resistant high-precision composite material terahertz reflector antenna and manufacturing method thereof

Abstract

The invention discloses a high-low-temperature-resistant high-precision composite material terahertz reflector antenna and a manufacturing method, and belongs to the technical field of structural composite material forming processes, the antenna comprises a carbon fiber inner skin, a carbon fiber outer skin, a honeycomb interlayer, a carbon fiber composite material embedded part and a titanium alloy flange; wherein the carbon fiber inner skin is arranged on the upper surface of the honeycomb interlayer; the carbon fiber outer skin is arranged on the lower surface of the honeycomb interlayer; the carbon fiber composite material embedded part is arranged in the groove of the honeycomb interlayer; the side wall of the titanium alloy flange is connected with the carbon fiber inner skin, the honeycomb interlayer and the carbon fiber outer skin. According to the invention, the requirements of extreme working conditions are met while light weight is realized.

Description

Technical Field

[0001] This invention belongs to the field of structural composite material molding technology, and particularly relates to a high-temperature and high-precision composite material terahertz reflector antenna and its manufacturing method. Background Technology

[0002] The high-orbit spacecraft on the far side of the moon can shield against the effects of low-frequency radiation from Earth and possesses a unique gravitational and electromagnetic environment. To reduce system load and improve transmission economics, the high-orbit reflector antenna product needs to use carbon fiber honeycomb sandwich composite material, operate in the 230GHz frequency band, which falls within the terahertz frequency range, and has high unit values, stringent performance requirements, and is extremely difficult to manufacture.

[0003] Existing antennas cannot meet the performance and accuracy requirements of high-orbit terahertz environments. Summary of the Invention

[0004] The technical problem solved by this invention is to overcome the shortcomings of the prior art and provide a high-temperature and high-precision composite material terahertz reflector antenna and its manufacturing method, which achieves lightweight design while meeting the requirements of extreme working conditions.

[0005] The objective of this invention is achieved through the following technical solution: a high-temperature and high-precision composite material terahertz reflector antenna, comprising: a carbon fiber inner skin, a carbon fiber outer skin, a honeycomb interlayer, a carbon fiber composite material embedded part, and a titanium alloy flange; wherein, the carbon fiber inner skin is disposed on the upper surface of the honeycomb interlayer; the carbon fiber outer skin is disposed on the lower surface of the honeycomb interlayer; the carbon fiber composite material embedded part is disposed in the groove of the honeycomb interlayer; and the sidewall of the titanium alloy flange is connected to the carbon fiber inner skin, the honeycomb interlayer, and the carbon fiber outer skin respectively.

[0006] In the aforementioned high-temperature and high-precision composite material terahertz reflector antenna, the surface of the carbon fiber inner skin is coated with a metal layer.

[0007] A method for manufacturing a high-temperature and high-precision composite material terahertz reflector antenna includes: designing a carbon fiber inner skin molding mold and a carbon fiber outer skin molding mold; laying carbon fiber prepreg in the carbon fiber inner skin molding mold to obtain a carbon fiber inner skin preform; laying carbon fiber prepreg in the carbon fiber outer skin molding mold to obtain a carbon fiber outer skin preform; curing the carbon fiber inner skin preform with the carbon fiber inner skin molding mold and the carbon fiber outer skin preform with the carbon fiber outer skin molding mold; demolding after curing to obtain the carbon fiber inner skin and the carbon fiber outer skin; and drilling positioning holes on the carbon fiber inner skin and the embedded part. The carbon fiber inner skin and embedded parts were trial-fitted with the honeycomb sandwich core. Structural adhesive film was applied to the bonding surfaces of the carbon fiber inner skin, outer carbon fiber skin, and embedded parts. The carbon fiber inner skin, titanium alloy flange, honeycomb sandwich core, embedded parts, and carbon fiber outer skin were assembled on the carbon fiber inner skin forming mold in the following order. The titanium alloy flange was connected to the inner skin forming mold by positioning process screws to obtain the assembled product. The assembled product was placed in an autoclave for curing. The cured product was demolded and cleaned to obtain the antenna, and then subjected to alternating hot and cold aging treatment. The shape of the aging-treated antenna was machined to the required dimensions to obtain the reflector antenna.

[0008] The above-mentioned method for manufacturing high-temperature and high-precision composite material terahertz reflector antennas also includes: depositing a metal film on the inner surface of the product; wherein the metal is aluminum or silver.

[0009] In the above-mentioned method for manufacturing a high-temperature and high-precision composite material terahertz reflector antenna, the carbon fiber inner skin molding mold includes a base, a convex arc mold, and a boss; wherein, the convex arc mold is connected to the base; the boss is disposed on the top of the convex arc mold; the profile of the convex arc mold is consistent with the inner profile of the reflector antenna.

[0010] In the above-mentioned method for manufacturing a high-temperature and high-precision composite material terahertz reflector antenna, the carbon fiber outer skin forming mold includes a second base and a concave arc surface mold; wherein, the concave arc surface mold is connected to the second base; and the shape of the concave arc surface mold is consistent with the outer shape of the reflector antenna.

[0011] In the above-mentioned method for manufacturing high-temperature and high-precision composite material terahertz reflector antenna, carbon fiber prepreg is laid in a carbon fiber inner skin forming mold according to the principle of symmetrical layup to obtain a carbon fiber inner skin preform, and carbon fiber prepreg is laid in a carbon fiber outer skin forming mold according to the principle of symmetrical layup to obtain a carbon fiber outer skin preform; wherein, carbon fiber prepreg includes carbon fiber and epoxy resin.

[0012] In the above-mentioned method for manufacturing high-temperature and high-precision composite material terahertz reflector antenna, a carbon fiber inner skin preform with a carbon fiber inner skin molding mold and a carbon fiber outer skin preform with a carbon fiber outer skin molding mold are placed in an autoclave for curing. The curing temperature is 120℃~180℃, the holding time is 2h~6h, and the pressure is 0.2MPa~0.8MPa. After the holding time is completed, the preform is removed from the autoclave after cooling to less than or equal to 50℃ and vacuuming is continued. After cooling to room temperature, the preform is demolded.

[0013] In the above-mentioned high-temperature and high-precision composite material terahertz reflector antenna manufacturing method, the titanium alloy flange is roughened by sandblasting or sandpaper grinding. Φ1-3mm positioning holes are drilled on the carbon fiber inner skin and the embedded part. The bonding surfaces of the carbon fiber inner skin, carbon fiber outer skin, and embedded part are sanded with 100-200 grit sandpaper. After cleaning, a trial fit is performed with the honeycomb core. Positions for the embedded part and titanium alloy flange are reserved in the honeycomb core, ensuring that the embedded part is not tilted or protruding. A structural adhesive film is pasted on the bonding surfaces of the carbon fiber inner skin, carbon fiber outer skin, and embedded part.

[0014] In the above-mentioned method for manufacturing high-temperature and high-precision composite material terahertz reflector antennas, the assembled product is placed in an autoclave for curing. The curing temperature is 120℃~180℃, the holding time is 2h~6h, and the pressure is 0.05MPa~0.3MPa. After the holding time is completed, the product is removed from the autoclave after cooling to room temperature. Foam is filled around the embedded parts and titanium alloy flange within a 5mm~10mm radius. The aging treatment with alternating hot and cold cycles includes: Step S1: Under vacuum conditions, the temperature is lowered from room temperature to -100℃~-70℃, held for 0.5~1h, then raised to 100~150℃, and held for 0.5~1h; Step S2: Step S1 is repeated three to five times.

[0015] Compared with the prior art, the present invention has the following advantages:

[0016] (1) This invention addresses the extreme working conditions and strict weight limitations on the far side of the moon, and proposes a lightweight structural design technology for all-composite materials, including carbon fiber skin and honeycomb sandwich, which can withstand high / low temperatures. The composite material structure accounts for more than 90% of the structure, which can meet the design and usage requirements.

[0017] (2) The present invention designs a low-expansion, high-precision reflective surface forming tooling, realizing the dual-purpose use of carbon fiber skin forming and reflective surface sandwich structure curing, ensuring the final product surface accuracy.

[0018] (3) This invention proposes a fine layup unfolding process for the skin of a large curvature reflector antenna and a layup angle deviation correction technology. By designing the layup sequence with equal stiffness, the curing deformation of the carbon fiber thin skin is effectively controlled.

[0019] (4) This invention proposes a curing process that satisfies the thermal matching of different materials in the reflective sandwich structure. By using a titanium alloy flange for precise positioning, the overall curing of carbon fiber thin panel-aluminum honeycomb sandwich-carbon fiber embedded part-metal embedded part and the precise installation of the embedded part are achieved, which meets the requirements of product surface accuracy. Attached Figure Description

[0020] Various other advantages and benefits will become apparent to those skilled in the art upon reading the following detailed description of preferred embodiments. The accompanying drawings are for illustrative purposes only and are not intended to limit the invention. Furthermore, the same reference numerals denote the same parts throughout the drawings. In the drawings:

[0021] Figure 1 This is a schematic diagram of a high-temperature and high-precision composite material terahertz reflector antenna provided in an embodiment of the present invention;

[0022] Figure 2 This is a cross-sectional view of the high-temperature and high-precision composite material terahertz reflector antenna provided in an embodiment of the present invention;

[0023] Figure 3 This is a schematic diagram of the carbon fiber inner skin molding die provided in an embodiment of the present invention;

[0024] Figure 4 This is a schematic diagram of the carbon fiber outer skin molding die provided in an embodiment of the present invention. Detailed Implementation

[0025] Exemplary embodiments of the present disclosure will now be described in more detail with reference to the accompanying drawings. While exemplary embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure may be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided to enable a more thorough understanding of the present disclosure and to fully convey the scope of the disclosure to those skilled in the art. It should be noted that, unless otherwise specified, the embodiments and features described herein can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0026] The terahertz band has a vast spectrum and strong directivity, and holds an important strategic position in fields such as next-generation backup anti-interference communication and Earth-Moon remote sensing.

[0027] The high-orbit terahertz environment places extremely high demands on the performance and accuracy of antennas:

[0028] (1) High and low temperature test - During the operation of the antenna, it is subjected to the alternating solar radiation day and night, resulting in extreme temperature differences. This requires materials with high mechanical properties in extreme environments, low stress release levels, and strong resistance to thermal deformation. The target operating environment temperature of the terahertz carbon fiber reflector antenna in this invention is -185℃ to +125℃.

[0029] (2) Surface Accuracy Requirements—As the antenna's operating frequency increases, the accuracy requirements for its element characteristic dimensions will also increase. The Ruze formula indicates that the root-mean-square (RMS) error of the antenna surface should be less than 2% to 0.5% of its operating wavelength. Terahertz waves refer to electromagnetic waves with operating frequencies between 100 GHz and 10 THz, corresponding to vacuum wavelengths of 3 mm to 30 μm, and corresponding to an RMS value requirement of 60 μm to 0.6 μm. The surface accuracy of reflector antennas is crucial for ensuring system performance, and there are numerous classic research results on this topic. As the antenna's operating frequency increases, the accuracy of its element characteristic dimensions will gradually improve.

[0030] Compared with metallic materials, carbon fiber composites possess characteristics such as low density, small coefficient of linear expansion, high specific strength and specific modulus, and designable physical and mechanical properties, making them ideal antenna structural materials. High-orbit terahertz reflector antennas impose a series of performance, precision, and quality requirements on carbon fiber composites. This embodiment enables high-precision molding of terahertz reflector antennas, achieving lightweight design while meeting the requirements of extreme operating conditions.

[0031] Figure 1 This is a schematic diagram of a high-temperature and high-precision composite material terahertz reflector antenna provided in an embodiment of the present invention; Figure 2 This is a cross-sectional view of the high-temperature and high-precision composite material terahertz reflector antenna provided in an embodiment of the present invention.

[0032] like Figure 1 and Figure 2 As shown, the high-temperature and low-temperature resistant, high-precision composite material terahertz reflector antenna includes: a carbon fiber inner skin 1, a carbon fiber outer skin 2, a honeycomb interlayer 3, a carbon fiber composite material embedded part 4, and a titanium alloy flange 5; wherein, the carbon fiber inner skin 1 is disposed on the upper surface of the honeycomb interlayer 3; the carbon fiber outer skin 2 is disposed on the lower surface of the honeycomb interlayer 3; the carbon fiber composite material embedded part 4 is disposed in the groove of the honeycomb interlayer 3; the sidewall of the titanium alloy flange 5 is connected to the carbon fiber inner skin 1, the honeycomb interlayer 3, and the carbon fiber outer skin 2 respectively.

[0033] The surface of the carbon fiber inner skin 1 is coated with a metal layer. The metal is aluminum or silver.

[0034] This embodiment also provides a method for manufacturing a high-temperature and low-temperature resistant, high-precision composite material terahertz reflector antenna, which includes the following steps:

[0035] Design carbon fiber inner skin molding mold and carbon fiber outer skin molding mold;

[0036] Carbon fiber prepreg is laid up in a carbon fiber inner skin molding die according to the principle of symmetrical layup to obtain a carbon fiber inner skin preform, and carbon fiber prepreg is laid up in a carbon fiber outer skin molding die according to the principle of symmetrical layup to obtain a carbon fiber outer skin preform; wherein, carbon fiber prepreg includes carbon fiber and epoxy resin.

[0037] The carbon fiber inner skin preform with a carbon fiber inner skin molding mold and the carbon fiber outer skin preform with a carbon fiber outer skin molding mold are cured. After curing, they are demolded to obtain the carbon fiber inner skin and the carbon fiber outer skin. The curing temperature is 120℃~180℃, the holding time is 2h~6h, and the pressure is 0.2MPa~0.8MPa. After the holding time is completed, the preform is removed from the container after cooling to less than or equal to 50℃ and vacuum is continued. After cooling to room temperature, it is demolded.

[0038] Positioning holes are made on the carbon fiber inner skin and the embedded parts. The carbon fiber inner skin and the embedded parts are tested with the honeycomb sandwich core. Structural adhesive film is pasted on the bonding surfaces of the carbon fiber inner skin, the outer carbon fiber skin and the embedded parts.

[0039] The carbon fiber inner skin, titanium alloy flange, honeycomb sandwich, embedded parts, and carbon fiber outer skin are assembled on the carbon fiber inner skin forming mold in that order. The titanium alloy flange is connected to the inner skin forming mold by positioning process screws to obtain the assembled product. Foam is used to fill the 5-10mm area around the embedded parts and titanium alloy flange.

[0040] The assembled product is placed in an autoclave for curing; the curing temperature is 120℃~180℃, the holding time is 2h~6h, and the pressure is 0.05MPa~0.3MPa. After the holding time is completed, the product is removed from the autoclave after cooling to room temperature.

[0041] The cured product is demolded and cleaned to obtain the antenna, and then subjected to an aging treatment involving alternating hot and cold cycles. The alternating hot and cold cycle aging treatment includes: Step S1: Under vacuum conditions, the temperature is lowered from room temperature to -100℃ to -70℃, held for 0.5 to 1 hour, then raised to 100 to 150℃, and held for 0.5 to 1 hour; Step S2: Step S1 is repeated three to five times.

[0042] The antenna, after aging treatment, is machined to the required dimensions to obtain a reflector antenna.

[0043] like Figure 3As shown, the carbon fiber inner skin molding die includes a base 31, a convex arc mold 32, and a boss 33; wherein, the convex arc mold 32 is connected to the base 31; the boss 33 is disposed on the top of the convex arc mold 32; the profile of the convex arc mold 32 is consistent with the inner profile of the reflector antenna.

[0044] like Figure 4 As shown, the carbon fiber outer skin molding die includes a second base 41 and a concave arc mold 42; wherein, the concave arc mold 42 is connected to the second base 41; the shape of the concave arc mold 42 is consistent with the outer shape of the reflector antenna.

[0045] The reflector antenna comprises a carbon fiber inner skin 1, a carbon fiber outer skin 2, a honeycomb interlayer 3, a carbon fiber composite embedded part 4, and a titanium alloy flange 5. The entire assembly is bonded and assembled using high / low temperature resistant structural adhesive film and foam adhesive, and then co-cured. The inner and outer carbon fiber skins are made of high-strength, high-modulus carbon fiber / low-temperature resistant, tough epoxy resin prepreg, with a single layer thickness ≤0.10mm. The honeycomb interlayer is made of aluminum honeycomb, fiberglass honeycomb, or aramid paper honeycomb. The carbon fiber composite embedded part is a composite material structural component with the same thickness as the honeycomb interlayer. After curing, the reflector antenna shape is machined, and a metal plating layer is applied to the surface of the carbon fiber inner skin. The final overall surface accuracy of the reflector is required to be RMS ≤0.03mm. The manufacturing steps are as follows:

[0046] 1) Mold design and manufacturing: Based on the shaping surface of the main reflector, select mold materials with low thermal expansion coefficients to process the molding molds for the inner and outer carbon fiber skins. The shape of the inner carbon fiber skin molding mold is consistent with the inner shape of the reflector antenna, and the surface accuracy requirement is RMS better than 0.02mm; the shape of the outer carbon fiber skin molding mold is consistent with the outer shape of the reflector antenna, and the surface accuracy requirement is RMS better than 0.03mm.

[0047] 2) Lay ultra-thin carbon fiber prepreg with a single layer thickness ≤0.10mm on the mold according to the principle of symmetrical layup, and prepare carbon fiber inner and outer skin and embedded parts. The layup can be appropriately extended to 5-30mm beyond the working surface of the reflective surface. The resin is a high-toughness epoxy resin that can withstand -196℃ to 180℃.

[0048] 3) The inner and outer skins of the carbon fiber and the embedded parts are put into the autoclave for curing. The curing temperature is 120-180℃, the holding time is 2-6h, and the pressure is 0.2-0.8MPa. After the holding time is completed, the parts are taken out of the autoclave after cooling down to less than or equal to 50℃ and vacuuming is continued. After cooling down to room temperature, the parts are demolded and ready for use.

[0049] 4) The total height of the honeycomb core in the reflector antenna should be 2-10mm, with a height tolerance better than 0.1mm. The honeycomb core should have a 10-20mm margin around the product.

[0050] 5) The titanium alloy flange is roughened by sandblasting or sandpaper grinding. 1-3mm positioning holes are drilled on the carbon fiber inner skin and the embedded parts. The bonding surfaces of the carbon fiber inner and outer skin and the embedded parts are sanded with 100-200 grit sandpaper. After cleaning, they are tested with the honeycomb sandwich core. The position of the embedded parts and the titanium alloy flange should be reserved in the honeycomb sandwich core. It should be ensured that the embedded parts are not tilted or protruding. The structural adhesive film is pasted on the bonding surfaces of the carbon fiber inner and outer skin and the embedded parts. The adhesive film is tightly bonded to the skin without wrinkles or air bubbles.

[0051] 6) Place the carbon fiber inner skin, honeycomb sandwich, titanium alloy flange, embedded part, and carbon fiber outer skin in sequence on the carbon fiber inner skin forming mold for assembly. The titanium alloy flange is positioned with the forming mold by positioning process screws, and the carbon fiber embedded part is positioned with the carbon fiber inner skin by positioning holes. Foam is filled around the embedded part and the titanium alloy flange within a range of 5-10mm.

[0052] 7) After assembly, the product is placed in an autoclave for curing at a temperature of 120-180℃ for 2-6 hours and a pressure of 0.05-0.3MPa. After the curing is completed, the product is removed from the autoclave after cooling to room temperature.

[0053] 8) Demolding and cleaning the product, removing the positioning screws, and cleaning the excess adhesive from the product surface and surrounding area; performing surface accuracy testing on the product and developing an aging treatment plan;

[0054] 9) Perform aging treatment on the product by alternating hot and cold cycles: Under vacuum conditions, lower the temperature from room temperature to -100℃ to -70℃, keep it at that temperature for 0.5 to 1 hour, then raise the temperature to 100 to 150℃, keep it at that temperature for 0.5 to 1 hour, and repeat the cycle 3 to 5 times.

[0055] 10) Process the product's shape to the required dimensions;

[0056] 11) The inner surface of the product is coated with a thin metal film, which can be aluminum or silver;

[0057] 12) Perform surface accuracy testing on the product, requiring RMS to be better than 0.03mm.

[0058] The diameter of the reflector antenna is 300–500 mm. The thickness of the inner and outer carbon fiber skins of the reflector antenna is 0.4–1 mm, and the thickness of the honeycomb sandwich layer is 2–10 mm. The inner and outer carbon fiber skins use ultra-thin unidirectional carbon fiber prepreg with a single layer thickness of 0.06–0.08 mm, a resin content of 34–50%, and a temperature resistance range of -196–180℃. The inner and outer carbon fiber skins adopt quasi-isotropic symmetrical layup, with a layup angle deviation ≤1°. The curing and heating of the inner and outer carbon fiber skins begins with pressurization to 0.2–0.8 MPa, and the cooling rate after the heat preservation is 10–30℃ / h. The honeycomb sandwich core has 0.1–0.3 mm ventilation holes on its cell walls. The curing and cooling rate of the reflector antenna sandwich structure assembly is 10–20℃ / h. The molding molds for the inner and outer carbon fiber skins are made of Invar steel or composite materials with a low coefficient of thermal expansion. After the reflector antenna is shaped, 10–30 1–2 mm vent holes are uniformly drilled on the outer ring of the interlayer. The aging treatment temperature range for the reflector antenna is -70℃ to 120℃, with a heating / cooling rate of 10–30℃ / h, and the heat preservation time of the heat preservation step is 10–60 min. The thickness of the metal film coated on the reflector surface of the reflector antenna is 0.5–3 μm.

[0059] Example 1: High / Low Temperature Resistant High-Precision Composite Material Terahertz Reflector Antenna

[0060] The reflector antenna has a diameter of 300mm and is composed of a carbon fiber upper skin, a carbon fiber lower skin, a honeycomb core, carbon fiber embedded parts, and a titanium alloy flange. The upper and lower carbon fiber skins are 0.4-1mm thick. The honeycomb core is made of aluminum honeycomb with an aluminum foil thickness of 0.05mm, a side length of 3mm, and a honeycomb height of 3mm. The embedded parts are made of carbon fiber composite material with a thickness of 1.5-3mm. The inner surface has a metal coating thickness of 2-3μm. The fabrication method of this carbon fiber foam sandwich frame is as follows:

[0061] (1) Design and manufacture of molding dies:

[0062] Based on the shaping surface of the main reflector, Invar steel with a low coefficient of thermal expansion is selected to process the molding molds for the inner and outer carbon fiber skins. The inner surface of the inner skin is consistent with the surface of the reflector antenna and can be used for the assembly of the reflector antenna sandwich structure. The surface accuracy RMS of the carbon fiber inner skin molding mold is 0.02mm.

[0063] (2) Layup of carbon fiber parts:

[0064] The inner and outer carbon fiber skins and embedded parts are formed by laying up a high-toughness epoxy resin / high-modulus carbon fiber composite material system. The thickness of the prepreg is 0.08-0.1mm, and a quasi-isotropic symmetrical layup is adopted with a layup angle deviation of no more than 1°. The layup can be appropriately extended beyond the working surface of the reflective surface by 5-30mm. After the layup is completed, it is placed in an autoclave for curing at a curing temperature of 160-180℃ for 2-6 hours and a pressure of 0.4-0.8MPa. After the curing is completed, it is removed from the autoclave after cooling to below 50℃ and vacuuming is continued. After cooling to room temperature, it is demolded for use.

[0065] (3) Trial breeding of honeycomb:

[0066] The sandwich structure uses aluminum honeycomb core, with a honeycomb core strip height requirement of (2.8~3.0)±0.1mm. The honeycomb core wall has a 0.2mm ventilation hole, and a 10~20mm allowance is reserved around the honeycomb core. The honeycomb core is used as a whole piece without splicing.

[0067] (4) Installation of carbon fiber embedded parts and metal parts:

[0068] Trial fit the carbon fiber inner skin with the carbon fiber embedded parts and titanium alloy flanges. If necessary, drill Φ1-2mm holes for positioning. After the trial fit is suitable, perform surface sandblasting treatment on the adhesive surface of the titanium alloy. Reserve the position of the carbon fiber embedded parts and titanium alloy flanges in the honeycomb core and fill the surrounding 10-20mm range with expanding foam. After grinding and cleaning the surface of the upper and lower carbon fiber skins and embedded parts, apply primer and apply adhesive film.

[0069] (5) Assembly of reflector antenna:

[0070] The carbon fiber inner skin, honeycomb core, titanium alloy flange, embedded part, and carbon fiber outer skin are sequentially placed on the carbon fiber inner skin forming mold for assembly. The titanium alloy flange is positioned with the forming mold by positioning process screws, and the carbon fiber embedded part is positioned with the carbon fiber inner skin by positioning holes. The sandblasted titanium alloy flange is fixed to the forming mold by positioning process screws. After confirming that the installation position of the carbon fiber embedded part is correct, foam is filled around the embedded part and the titanium alloy flange within a range of 5-10mm. The lower carbon fiber skin is then installed on the honeycomb core. If necessary, a hair dryer can be used for assistance.

[0071] (6) Mold assembly, coating and curing:

[0072] The product is coated and cured at 160-180℃ for 2-6 hours under pressure of 0.05-0.3MPa. After curing, the product is cooled at a rate of 10-15℃ / h and removed from the can after cooling to room temperature.

[0073] (7) Product demolding:

[0074] Remove the covering material from the outer surface of the product, remove the process screws, take the product off the mold, clean up any excess adhesive, and perform surface accuracy testing on the product.

[0075] (8) Product aging treatment: The product is subjected to alternating hot and cold aging treatment. The treatment process is as follows: Under vacuum environment, the temperature is lowered from room temperature to -70℃, kept at the temperature for 0.5h, then raised to 120℃, kept at the temperature for 0.5h, and the cycle is repeated 3 to 5 times.

[0076] (9) Product processing: Process the outer surface of the reflector antenna and the titanium alloy flange to the required dimensions, and drill 10 to 30 φ1 to 2mm ventilation holes evenly on the outer ring of the interlayer.

[0077] (10) Product coating: A metal aluminum film with a thickness of 2-3 μm is deposited on the inner surface of the product by vacuum sputtering.

[0078] (11) Product surface inspection: Perform surface accuracy inspection on the product, with RMS not less than 0.03mm.

[0079] This embodiment designs a low expansion rate and ultra-high precision reflector molding fixture. It uses high-modulus ultra-thin carbon fiber prepreg to form the inner and outer carbon fiber skin, which is integrally cured and formed with aluminum honeycomb sandwich, carbon fiber composite embedded parts and titanium alloy flange. This achieves high-precision molding of high / low temperature terahertz composite material reflector antenna, meeting the requirements of extreme working conditions while achieving lightweight design.

[0080] This embodiment addresses the extreme working conditions and strict weight limitations on the far side of the moon, proposing a lightweight all-composite material structure design technology for carbon fiber skin and honeycomb sandwich layers, capable of withstanding high / low temperatures. The composite material content exceeds 90%, meeting design requirements. This embodiment also features a low-expansion, high-precision reflector molding fixture, enabling dual-purpose molding for both carbon fiber skin forming and reflector sandwich structure curing, ensuring the final product's surface accuracy. Furthermore, this embodiment proposes a fine-layout process for the skin of large-curvature reflector antennas and a layup angle deviation correction technology. By coordinating the layup sequence with equal stiffness, the curing deformation of the thin carbon fiber skin is effectively controlled. Finally, this embodiment proposes a curing process that meets the thermal matching requirements of different materials in the reflector sandwich structure. Precise positioning using titanium alloy flanges achieves overall curing of the thin carbon fiber panel, aluminum honeycomb sandwich core, carbon fiber embedded parts, and metal embedded parts, as well as precise installation of the embedded parts, meeting the product's surface accuracy requirements.

[0081] Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make possible changes and modifications to the technical solutions of the present invention by utilizing the methods and techniques disclosed above without departing from the spirit and scope of the present invention. Therefore, any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solutions of the present invention shall fall within the protection scope of the technical solutions of the present invention.

Claims

1. A high-temperature and low-temperature resistant, high-precision composite material terahertz reflector antenna, characterized in that... include: Carbon fiber inner skin (1), carbon fiber outer skin (2), honeycomb sandwich (3), carbon fiber composite embedded parts (4), and titanium alloy flange (5); among which, The carbon fiber inner skin (1) is disposed on the upper surface of the honeycomb interlayer (3); The carbon fiber outer skin (2) is disposed on the lower surface of the honeycomb interlayer (3); The carbon fiber composite material embedded part (4) is disposed in the groove of the honeycomb sandwich layer (3); The sidewalls of the titanium alloy flange (5) are respectively connected to the carbon fiber inner skin (1), the honeycomb sandwich (3) and the carbon fiber outer skin (2).

2. The high-temperature and low-temperature resistant, high-precision composite material terahertz reflector antenna according to claim 1, characterized in that: The surface of the carbon fiber inner skin (1) is coated with a metal layer.

3. A method for manufacturing a high-temperature and low-temperature resistant, high-precision composite material terahertz reflector antenna, characterized in that... include: Design carbon fiber inner skin molding mold and carbon fiber outer skin molding mold; Carbon fiber prepreg is laid up in a carbon fiber inner skin molding die to obtain a carbon fiber inner skin preform, and carbon fiber prepreg is laid up in a carbon fiber outer skin molding die to obtain a carbon fiber outer skin preform. The carbon fiber inner skin preform with a carbon fiber inner skin molding mold and the carbon fiber outer skin preform with a carbon fiber outer skin molding mold are cured. After curing, the carbon fiber inner skin and the carbon fiber outer skin are demolded. Positioning holes are made on the carbon fiber inner skin and the embedded parts. The carbon fiber inner skin and the embedded parts are tested with the honeycomb sandwich core. Structural adhesive film is pasted on the bonding surfaces of the carbon fiber inner skin, the outer carbon fiber skin and the embedded parts. The carbon fiber inner skin, titanium alloy flange, honeycomb sandwich, embedded parts, and carbon fiber outer skin are assembled on the carbon fiber inner skin forming mold in that order. The titanium alloy flange is connected to the inner skin forming mold by positioning process screws to obtain the assembled product. The assembled product is placed in an autoclave for curing. The cured product is demolded and cleaned to obtain the antenna, and then subjected to an aging treatment with alternating hot and cold cycles. The antenna, after aging treatment, is machined to the required dimensions to obtain a reflector antenna.

4. The method for manufacturing a high-temperature and high-precision composite material terahertz reflector antenna according to claim 3, characterized in that... Also includes: The inner surface of the product is coated with a metal film; the metal is aluminum or silver.

5. The method for manufacturing a high-temperature and high-precision composite material terahertz reflector antenna according to claim 3, characterized in that: The carbon fiber inner skin molding die includes a base, a convex arc-shaped die, and a boss; wherein... The convex arc-shaped mold is connected to the base; The boss is disposed on the top of the convex arc surface mold; The convex arc surface of the model is consistent with the inner surface of the reflector antenna.

6. The method for manufacturing a high-temperature and high-precision composite material terahertz reflector antenna according to claim 3, characterized in that: The carbon fiber outer skin molding die includes a second base and a concave arc-shaped mold; wherein... The concave arc-shaped mold is connected to the second base; The concave arc surface of the model is consistent with the outer surface of the reflector antenna.

7. The method for manufacturing a high-temperature and high-precision composite material terahertz reflector antenna according to claim 3, characterized in that: Based on the principle of symmetrical layup, carbon fiber prepreg is laid up in a carbon fiber inner skin forming mold to obtain a carbon fiber inner skin preform, and based on the same principle, carbon fiber prepreg is laid up in a carbon fiber outer skin forming mold to obtain a carbon fiber outer skin preform; wherein... Carbon fiber prepregs consist of carbon fiber and epoxy resin.

8. The method for manufacturing a high-temperature and high-precision composite material terahertz reflector antenna according to claim 3, characterized in that: The carbon fiber inner skin preform with the carbon fiber inner skin molding mold and the carbon fiber outer skin preform with the carbon fiber outer skin molding mold are placed in an autoclave for curing. The curing temperature is 120℃~180℃, the holding time is 2h~6h, and the pressure is 0.2MPa~0.8MPa. After the holding time is completed, the preform is removed from the autoclave after cooling to less than or equal to 50℃ and vacuuming is continued. The preform is then demolded after cooling to room temperature.

9. The method for manufacturing a high-temperature and high-precision composite material terahertz reflector antenna according to claim 3, characterized in that: The titanium alloy flange is surface-treated by sandblasting or sanding. 1-3mm positioning holes are drilled on the carbon fiber inner skin and the embedded part. The bonding surfaces of the carbon fiber inner skin, carbon fiber outer skin and the embedded part are sanded with 100-200 grit sandpaper. After cleaning, it is trial-fitted with the honeycomb sandwich core. The positions of the embedded part and the titanium alloy flange are reserved in the honeycomb sandwich core. It is necessary to ensure that the embedded part is not tilted or protruding. Structural adhesive film is pasted on the bonding surfaces of the carbon fiber inner skin, carbon fiber outer skin and the embedded part.

10. The method for manufacturing a high-temperature and high-precision composite material terahertz reflector antenna according to claim 3, characterized in that: The assembled product is placed in an autoclave for curing at a temperature of 120℃~180℃ for 2h~6h and a pressure of 0.05MPa~0.3MPa. After the curing is completed, the product is removed from the autoclave after cooling to room temperature. Fill the area around the embedded parts and titanium alloy flanges with expanding foam within 5mm to 10mm. The aging treatment involving alternating hot and cold cycles includes: Step S1: Under vacuum conditions, the temperature is lowered from room temperature to -100℃ to -70℃, held for 0.5 to 1 hour, then raised to 100 to 150℃ and held for 0.5 to 1 hour; Step S2: Step S1 is repeated three to five times.

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