Radome, laminated plate and composite plate used in radome, and manufacturing method thereof

Abstract

The present invention provides a radome, a laminate and a composite plate used in the radome, and a manufacturing method. The radome is manufactured by performing a softening treatment and a hot roll press treatment on the composite plate. The laminate constituting the composite plate has a first layer, a second layer, and a third layer laminated in order. The first layer and the third layer have the same structure and are made of the same material. The first layer and the third layer are each formed by compounding a continuous fiber fabric and a thermoplastic resin. The second layer is made of a foam material.

Description

[Technical Field]

[0001] This application relates to the field of polymeric materials, and in particular to radomes, laminates and composite plates used in radomes, and methods for their manufacture. [Background technology]

[0002] A radome is a structure that protects an antenna system from external environmental influences. As passive antennas evolve from single-band and multi-band to full-band, passive multi-band or full-band antennas are integrated with MM active antennas. As a result, the antenna Na The overall weight has increased significantly, reaching over 50 kg. Summary of the Invention [Problem to be solved by the invention]

[0003] Such a heavy antenna is susceptible to shocks such as vibration and drop impacts during transportation or handling of the bare antenna, and may be stepped on at the installation site or may collide with the tower due to swinging during installation and lifting. To protect the antenna from external shocks, a radome 10 must be placed on the outside of the antenna 1, as shown in Figure 1, to ensure it can withstand shocks. [Means for solving the problem]

[0004] Therefore, in order to solve the above-mentioned technical problems, the present application provides a radome, a laminated plate and a composite plate used in the radome, and a manufacturing method thereof. The technical solutions are as follows:

[0005] In a first aspect, the present application provides a composite plate for use in a radome, the composite plate comprising an intermediate layer and a surface layer combined with the intermediate layer, the surface layer comprising first fibers and a thermoplastic resin filled between the first fibers, the surface layer and the intermediate layer being arranged in a first direction, the first direction being the thickness direction of the composite plate. The thickness direction can be understood as the direction in which the inner surface of a radome made of the composite plate points toward the outer surface of the radome, or the direction in which the outer surface of the radome points toward the inner surface of the radome. By filling the thermoplastic resin between the first fibers, the density of the surface layer can be increased, and the impact resistance of the surface layer can be improved. This allows the manufacture of a radome with even higher impact resistance.

[0006]

[0013] Referring to the first aspect and contemplated embodiments, in a contemplated embodiment of the first aspect, the composite plate has a sandwich structure, and the sandwich structure is an A-type sandwich structure or a C-type sandwich structure. In particular, in a contemplated embodiment, the composite plate has an intermediate layer, a first surface layer, and a second surface layer, which are combined with the intermediate layer, and the first surface layer, intermediate layer, and second surface layer are sequentially arranged based on an A-type sandwich structure, and the first surface layer and second surface layer are made of the same material and have the same structure. In another contemplated embodiment, the composite plate has a first surface layer, a third layer, an intermediate layer, a fourth layer, and a second surface layer, which are sequentially arranged based on a C-type sandwich structure, and the intermediate layer is combined with the third layer and fourth layer, and the first surface layer, the third layer, the fourth layer, and second surface layer are made of the same material and have the same structure.

[0007] Referring to the first aspect, in a contemplated embodiment of the first aspect, the melting point of the first fibers is higher than the melting point of the thermoplastic resin. This allows the thermoplastic resin to be melted by heat while the first fibers are not melted when the laminated plates constituting the composite plate are hot-pressed. Therefore, the molten thermoplastic resin can be filled between the first fibers. In a contemplated embodiment, the first fibers are understood to be high-melting-point fibers. The high-melting-point fibers are different from the low-melting-point fibers. The specific temperature value of the high-melting-point fibers is related to the manufacturing process of the composite plate. However, regardless of the manufacturing process used, when the composite plate is formed through heating, it is understood that the temperature reached through heating must be such that the high-melting-point fibers are not melted.

[0008] It should also be noted that the melting point of low-melting-point fibers generally ranges from 110°C to 150°C. Therefore, the melting point of high-melting-point fibers only needs to be higher than the melting point of low-melting-point fibers. In other contemplated embodiments, the melting point range of the low-melting-point fibers may alternatively be another temperature range. Correspondingly, the melting point range of the first fibers may alternatively be another temperature range. For example, the melting point of some inorganic fibers may reach over 1000°C. It is understood that the specific value of the melting point of the first fibers is not limited in this application.

[0009] With reference to the first aspect and contemplated embodiments, in a contemplated embodiment of the first aspect, the thermoplastic resin of the surface layer is made of the same material as the intermediate layer. In this case, no additional adhesive is required to bond the surface layer and the intermediate layer, and the surface layer can be better combined with the intermediate layer. This saves some material, improves the combination rate of the surface layer and the intermediate layer, and further improves the impact resistance of the final composite plate. In another contemplated embodiment, it can be understood that the material of the intermediate layer may alternatively be a material whose properties and melting point are close to those of the thermoplastic resin in the surface layer. This is not particularly limited in the present application. This also leads to the combination of the surface layer and the intermediate layer.

[0010]

[0013] Referring to the first aspect and contemplated embodiments, in a contemplated embodiment of the first aspect, the intermediate layer is made of a thermoplastic foam material, which can reduce the overall weight of the composite board, thereby further realizing a lightweight composite board.

[0011] Referring to the first aspect and contemplated embodiments, in a contemplated embodiment of the first aspect, the first fibers in the surface layer are a woven fiber structure, and the thermoplastic resin in the surface layer fills gaps in the woven fiber structure. It can be understood that a woven fiber structure can dissipate stress caused by an external impact. Therefore, by using a woven fiber structure for the first fibers in the surface layer, the impact resistance of the surface layer can be improved. By filling the gaps in the woven fiber structure with the thermoplastic resin, the density of the surface layer is further increased, and the impact resistance of the surface layer is further improved.

[0012] In some contemplated embodiments, the weaving style of the woven fiber structure includes any one of a plain weave, a square plain weave, a rib weave, a twill weave, and a satin weave. It is understood that the particular weave of the woven fiber structure is not limited herein.

[0013] Referring to the first aspect and contemplated embodiments, in a contemplated embodiment of the first aspect, the first fibers in the surface layer comprise inorganic fibers and / or organic fibers.

[0014]

[0013] Referring to the first aspect and contemplated embodiments, in a contemplated embodiment of the first aspect, the inorganic fibers in the surface layer are randomly arranged, which can better dissipate stress caused by external impacts than a structure formed by weaving according to a specific rule, thereby improving the impact resistance of the surface layer.

[0015] Referring to the first aspect and contemplated embodiments, in a contemplated embodiment of the first aspect, the inorganic fibers in the surface layer are glass fibers, and the glass fibers are randomly arranged to form a glass mat.

[0016]

[0013] Referring to the first aspect and contemplated embodiments, in contemplated embodiments of the first aspect, the inorganic fibers in the surface layer include at least one of glass fibers, basalt fibers, andesite fibers, aluminum silicate fibers, boron nitride fibers, aluminum oxide fibers, and quartz fibers. It is understood that the specific form and type of inorganic fibers are not limited herein.

[0017]

[0013] Referring to the first aspect and contemplated embodiments, in a contemplated embodiment of the first aspect, the organic fibers of the surface layer include at least one of polypropylene fibers, polybutylene terephthalate fibers, polyethylene fibers, polyethylene glycol terephthalate fibers, and polytrimethylene terephthalate fibers. It is understood that the specific form and type of organic fibers are not limited herein.

[0018] With reference to the first aspect and contemplated embodiments, in a contemplated embodiment of the first aspect, the first fibers in the surface layer include a plurality of fiber layers arranged in the first direction, and the included angle between the fibers in two of the plurality of fiber layers is a first preset angle. It is understood that the included angle between the fibers in the two fiber layers of the plurality of fiber layers is arranged based on the first preset angle, resulting in a staggered arrangement of the two fiber layers. This improves the impact resistance properties of the surface layer. Therefore, the value of the first preset angle is not limited herein, except in cases where the value of the first preset angle in this application does not allow the fibers in the two fiber layers to be parallel.

[0019] Referring to the first aspect and contemplated embodiments, in contemplated embodiments of the first aspect, the first preset angle includes at least one of 30°, 45°, and 60°. Also, in the present application, the value of the first preset angle may alternatively be another value other than 0. This is not particularly limited in the present application.

[0020]

[0013] Referring to the first aspect and contemplated embodiments, in a contemplated embodiment of the first aspect, the composite board further includes a weather-resistant coloring layer, the weather-resistant coloring layer being disposed on the surface layer away from the intermediate layer. It can be understood that the weather-resistant coloring layer may be disposed on the surface layer of the composite board to improve the aesthetics and weather resistance of the composite board.

[0021] Additionally, in some contemplated embodiments, the weather-resistant color layer and the surface layer may be integrally formed to conserve materials.

[0022]

[0013] Referring to the first aspect and contemplated embodiments, in contemplated embodiments of the first aspect, the thermoplastic resin comprises at least one of polypropylene, polyethylene, polyvinyl chloride, polybutylene terephthalate, polyethylene glycol terephthalate, polytrimethylene terephthalate, polycarbonate, and polyphenylene oxide. It is understood that the specific form and type of thermoplastic resin are not limited herein.

[0023] In a second aspect, the present application provides a laminate, which can be used to form a composite plate according to the first aspect and any one of the envisioned embodiments of the first aspect. The laminate includes at least two stacked first layers and at least one second layer, the first layer being formed by compounding the first fibers with a thermoplastic resin, and the at least two first layers and the at least one second layer being staggered in a second direction, the second direction being a thickness direction of the laminate and parallel to the first direction.

[0024] It should be noted that the thickness direction is the direction in which the inner surface of the radome made of laminated plates points to the outer surface of the radome, or the direction in which the outer surface of the radome points to the inner surface of the radome.

[0025] It should be noted that in the second embodiment, the beneficial effects of the same structures and materials as those in the first embodiment are referred to the relevant descriptions of the first embodiment, and will not be described in detail again in this application.

[0026] In a contemplated embodiment, the two first layers respectively form two surface layers: the upper surface layer and the lower surface layer of the laminate, i.e., the first layer and the third layer. The second layer also forms the middle layer of the laminate. In a contemplated embodiment, the second layer is made of foam board. The density of the second layer is 0.15 g / m 3 to 1.4 g / m 3 , preferably 0.4 to 1.0 g / m 3 The thickness of the second layer is in the range of 0.5 mm to 3 mm. Furthermore, in a contemplated embodiment, the density of the second layer of foam board is 0.4 g / cm 3 and the thickness of the second layer of foam board is 1 mm, thereby producing a radome that can better meet the requirements for weight reduction and impact resistance properties.

[0027]

[0013] Referring to the second aspect, in a contemplated embodiment of the second aspect, the thermoplastic resin includes second fibers, and the first layer includes a woven structure formed by weaving composite fibers formed by combining the first fibers and the second fibers, where the melting point of the first fibers is higher than the melting point of the second fibers. In this case, when the laminate is hot-pressed, the second fibers of the first layer melt and fill the gaps in the woven structure formed by the first fibers, thereby increasing the density of the first layer. This improves the impact resistance of the first layer.

[0028] Referring to the second aspect and contemplated embodiments, in contemplated embodiments of the second aspect, the first fibers comprise inorganic fibers and / or organic fibers.

[0029] With reference to the second aspect and contemplated embodiments, in a contemplated embodiment of the second aspect, the first layer includes a woven structure formed by weaving composite fibers. The composite fibers have a kernel structure made of a first organic material and a shell structure made of a second organic material disposed around the kernel structure. The melting point of the first organic material is higher than the melting point of the second organic material. It can be understood that in some contemplated embodiments, composite fibers may be used instead to form the woven structure. The composite fibers have a kernel structure made of a first organic material and a shell structure made of a second organic material, and the melting point of the first organic material is higher than the melting point of the second organic material. In this case, when the woven structure made of the composite fibers is hot-pressed, the shell structure made of the second organic material melts and fills the gaps in the woven structure, thereby increasing the density of the first layer. This improves the impact resistance properties of the first layer. In some contemplated embodiments, the surface density of the first layer formed by weaving the composite fibers is 450 g / m 2 is.

[0030] With reference to the second aspect and contemplated embodiments, in a contemplated embodiment of the second aspect, the first fiber in the first layer is a unidirectional continuous fiber, the first layer includes multiple layers of prepreg tape, and the prepreg tape is a unidirectional tape formed after the unidirectional continuous fiber is covered with a thermoplastic resin, and the included angle between two layers of the prepreg tape is a second preset angle. It can be understood that the length of the unidirectional continuous fiber is longer than the length of typical unidirectional fibers, and that the unidirectional continuous fiber used can exhibit good extensibility due to the prepreg tape formed from the unidirectional continuous fiber and the thermoplastic resin. However, this does not constitute a limitation on the type of the first fiber in this application. In other contemplated embodiments, unidirectional fibers of other lengths may alternatively be used. This is not a limitation in this application.

[0031] With reference to the second aspect and contemplated embodiments, in contemplated embodiments of the second aspect, the second preset angle includes at least one of 30°, 45°, and 60°. Also, in the present application, the value of the second preset angle may alternatively be another value other than 0. This is not particularly limited in the present application.

[0032] In a contemplated embodiment, the included angle between two prepreg tape layers of a multi-layer prepreg tape is a second preset angle, as follows: The included angle between two adjacent prepreg tape layers of a multi-layer prepreg tape is a second preset angle, or the included angle between any two prepreg tape layers of a multi-layer prepreg tape is a second preset angle. This is not a limitation of the present application. In another contemplated embodiment, the included angle between two prepreg tape layers of a multi-layer prepreg tape may be a second preset angle having a different value. For example, it is assumed that there are first, second, third, and fourth to sixth layers of prepreg tape, and the included angle between the first layer of prepreg tape and the second layer of prepreg tape is 45°, and the included angle between the third layer of prepreg tape and the fourth layer of prepreg tape is 60°, etc. Neither of these is a limitation of the present application.

[0033] With reference to the second aspect and contemplated embodiments, in contemplated embodiments of the second aspect, the thermoplastic resin includes a thermoplastic resin film and / or a thermoplastic resin powder. It is understood that in contemplated embodiments, the thermoplastic resin may be in the form of a film or a powder. When the thermoplastic resin is in the form of a film, the thermoplastic resin film may be a single layer, and the layer of thermoplastic resin film is disposed on the side of the first layer away from the second layer. When the laminate is hot-pressed, the thermoplastic resin film melts and is better combined with the first fiber, forming the first layer. In another contemplated embodiment, there may instead be two thermoplastic resin films, one layer laminated on the side of the first layer opposite the second layer and the other layer laminated on the side of the first layer closer to the second layer. It is understood that the relative positions of the thermoplastic resin film and the first layer are not limited herein.

[0034] In a third aspect, the present application provides a method for manufacturing a composite plate according to the first aspect and any one of the envisioned embodiments thereof. The method includes the step of sequentially hot-pressing a first ply and a second ply of a laminate according to the second aspect and any one of the envisioned embodiments thereof with a double steel tape or a double Teflon tape at a predetermined temperature to form a composite plate by conjugation. In a contemplated embodiment, the predetermined temperature range is 170°C to 240°C. In particular, the composite plate is formed by hot-pressing a first ply and a second ply of a laminate according to the second aspect and any one of the envisioned embodiments thereof with a double steel tape or a double Teflon tape at 170°C to 240°C.

[0035] It is understood that the preset temperature setting is related to a particular manufacturing process. The aforementioned 170°C to 240°C is merely an example. In other contemplated embodiments, the preset temperature range may be another range. This is not a limitation of the present application.

[0036] In a fourth aspect, the present application provides a method for manufacturing a composite plate according to the first aspect and any one of the contemplated embodiments thereof, the method comprising the steps of: hot-pressing a first layer of a laminate according to the second aspect and any one of the contemplated embodiments thereof with double steel tape or double Teflon tape at a predetermined temperature to form a third layer; laminating the third layer and the second layer in a staggered manner; and hot-pressing the staggered third layer and second layer in a staggered manner with double steel tape or double Teflon tape at a predetermined temperature to combine them to form a composite plate. In a contemplated embodiment, the predetermined temperature range is 170°C to 240°C. In particular, hot pressing is performed on the first layer of a laminate according to the second aspect and any one of the envisioned embodiments thereof at 170°C to 240°C using double steel tape or double Teflon tape to form a third layer, and then the third layer and the second layer are alternately laminated together. The second and third layers are hot pressed using double steel tape or double Teflon tape at 170°C to 240°C to form a composite plate. It is understood that the preset temperature setting is related to a specific manufacturing process. The aforementioned 170°C to 240°C is merely an example. In other envisioned embodiments, the preset temperature range may be different. This is not a limitation of the present application.

[0037] In a fifth aspect, the present application provides a radome. The radome is manufactured using the composite plate according to any one of the first aspect and the envisioned embodiments thereof, particularly by hot pressing or compression molding using the composite plate according to any one of the first aspect and the envisioned embodiments thereof. The radome has an intermediate layer and a surface layer bonded to the intermediate layer, the surface layer including first fibers and a thermoplastic resin filled between the first fibers. In one envisioned embodiment, the method includes continuously heating the composite plate according to any one of the first aspect and the envisioned embodiments thereof at 190°C to 240°C for 1 minute to 3 minutes to soften the composite plate, and performing roll pressing or compression molding on the composite plate to produce the radome.

[0038] Referring to the fifth aspect, in a contemplated embodiment of the fifth aspect, the thermoplastic resin of the surface layer is composed of the same material as the intermediate layer.

[0039] Referring to the fifth aspect and contemplated embodiments, in another contemplated embodiment of the fifth aspect, the intermediate layer is comprised of a thermoplastic foam material.

[0040] Referring to the fifth aspect and contemplated embodiments, in another contemplated embodiment of the fifth aspect, the radome uses a sandwich structure, and the sandwich structure is an A-type sandwich structure or a C-type sandwich structure.

[0041] In a sixth aspect, the present application provides a radome. The radome is manufactured by using the laminate according to the second aspect and any one of the envisioned embodiments of the second aspect. In particular, a method for manufacturing the radome includes the steps of: continuously hot-pressing the laminate according to the second aspect and any one of the envisioned embodiments of the second aspect with double steel tapes or double Teflon tapes at a predetermined temperature to form a composite plate through compounding; and hot-pressing or compression-molding the composite plate to manufacture a radome. The radome has an intermediate layer and a surface layer combined with the intermediate layer, and the surface layer has first fibers and a thermoplastic resin filled between the first fibers. [Brief explanation of the drawings]

[0042] [Figure 1] 1 is a schematic diagram of an example of an antenna and radome arrangement according to an embodiment. [Figure 2] 1 is a schematic diagram of an example antenna lifting scenario according to an embodiment. [Figure 3(A)] FIG. 1 is a schematic diagram of an example of an impact test according to an embodiment. [Figure 3(B)] 1 is a schematic diagram showing an example of the structure of an impact hammer according to an embodiment of the present invention. [Figure 4] 1 is a schematic diagram of an example of a layer structure of a fiberglass radome according to an embodiment. [Figure 5] 1 is a schematic flow chart of an example of a process for manufacturing a fiberglass radome in accordance with an embodiment. [Figure 6] 1 is a schematic diagram of an example of a layer structure of a fiberglass radome according to an embodiment. [Figure 7] FIG. 2 is a schematic diagram of an example of a layer structure of a radome according to an embodiment. [Figure 8(A)] FIG. 1 is a schematic diagram of a prepreg 101-1 forming a surface layer of a radome according to an embodiment. [Figure 8(B)]FIG. 10 is a schematic diagram of a prepreg 101-2 forming a surface layer of a radome according to another embodiment. [Figure 8(C)] FIG. 10 is a schematic diagram of a prepreg 101-3 forming a surface layer of a radome according to yet another embodiment. [Figure 9] 1 is a schematic diagram of a radome structure according to an embodiment. [Figure 10] 1 is a flowchart of an example process for manufacturing a radome in accordance with an embodiment. [Figure 11(A)] 1 is a schematic diagram of a fiber structure according to an embodiment. [Figure 11(B)] 9 is a partial enlarged view of the structure in the Pa region of FIG. 8 of a plate before molding for manufacturing a radome according to an embodiment. [Figure 11(C)] 9 is a partial enlarged view showing the structure of a plate in the Pb region of FIG. 8 before molding for manufacturing a radome according to an embodiment. [Figure 11(D)] 2 is a schematic diagram of another fiber structure according to an embodiment. [Figure 12] 1 is a flowchart of an example process for manufacturing a radome in accordance with an embodiment. [Figure 13] FIG. 2 is a schematic diagram illustrating an example of a layer structure of a radome according to an embodiment. [Figure 14] FIG. 13 is a schematic diagram of the surface state of the radome after the impact test in FIG. 12. [Figure 15] FIG. 2 is a schematic diagram of an example of a layer structure of a radome according to an embodiment. [Figure 16(A)] 3 is a schematic diagram of an example of a fiber structure according to another embodiment. [Figure 16(B)] 9 is a partial enlarged view of the structure in the Pa region of FIG. 8 of a plate before molding for manufacturing a radome according to another embodiment. [Figure 16(C)] 9 is a partial enlarged view of the structure in the Pb region of FIG. 8 of a plate before molding for manufacturing a radome according to another embodiment. [Figure 17(A)]11 is a partially enlarged view showing the structure of the Pa region of FIG. 10 of a plate before molding for manufacturing a radome according to an embodiment. [Figure 17(B)] 11 is a partially enlarged view showing the structure of the plate after molding in the Pb region of FIG. 10 for manufacturing a radome according to another embodiment. [Figure 17(C)] FIG. 11 is a partially enlarged view showing another structure of the Pa region in FIG. 10 of the plate before molding for manufacturing a radome according to yet another embodiment. [Figure 18(A)] 11 is a partial enlarged view of the structure of the first surface layer in the Pa region in FIG. 10 before molding according to yet another embodiment. [Figure 18(B)] 11 is a partial enlarged view of the structure of the first surface layer after preforming in the Pa region in FIG. 10 according to yet another embodiment. [Figure 18(C)] FIG. 11 is a partial enlarged view of the structure of the Pa region in FIG. 10 of a plate before molding for manufacturing a radome according to yet another embodiment. [Figure 18(D)] 11 is a partial enlarged view of the structure in the Pb region of FIG. 10 of a plate after molding for manufacturing a radome according to yet another embodiment. [Figure 19(A)] 11 is a partial enlarged view of the structure in the Pa region of FIG. 10 of a plate before molding for manufacturing a radome according to yet another embodiment. [Figure 19(B)] 11 is a partial enlarged view of the structure in the Pb region of FIG. 10 of a plate after molding for manufacturing a radome according to yet another embodiment. [Figure 20(A)] 11 is a partial enlarged view of the structure in the Pa region of FIG. 10 of a plate before molding for manufacturing a radome according to yet another embodiment. [Figure 20(B)] 11 is a partial enlarged view of the structure in the Pb region of FIG. 10 of a plate after molding for manufacturing a radome according to yet another embodiment. [Figure 21(A)] FIG. 11 is a partial enlarged view of the structure of the Pa region in FIG. 10 of a plate before molding for manufacturing a radome according to yet another embodiment. [Figure 21(B)]11 is a partial enlarged view of the structure in the Pb region of FIG. 10 of a plate after molding for manufacturing a radome according to yet another embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0043] In order to make the objectives, technical solutions and advantages of the present application clearer, the following describes the embodiments of the present application in more detail with reference to the accompanying drawings.

[0044] As described above, an antenna is subjected to impacts during the lifting process. For example, as shown in Fig. 2, when lifting the antenna 1, the antenna 1 may collide with an obstacle X on a wall or a tower M. To withstand this impact, the antenna 1 is usually placed in a radome 10 shown in Fig. 1. To ensure that the radome 10 has good impact resistance, an impact test method shown in Fig. 3(A) is usually used in engineering to detect whether the radome 10 meets the impact resistance property requirements.

[0045] In particular, as shown in FIG. 3(A), a tester typically selects a 300 mm × 300 mm radome test sample plate 40, and then uses an impact hammer 3 shown in FIG. 3(B) to vertically impact the radome test sample plate 40 from a height of 1.3 m above the radome test sample plate 40 to detect whether the radome 10 satisfies the impact resistance characteristics. As shown in FIG. 3(B), the impact hammer 3 has an end 31 of the impact hammer and a detachable iron block 32 used as a counterweight. In some embodiments, the tester may choose to increase or decrease the amount of the iron block 32 to change the impact force of the impact hammer 3 and perform an impact resistance characteristic test on the radome at different forces. This is not a limitation in the present application.

[0046] Also, the size of the radome test sample plate 40 and the vertical impact height of the impact hammer 3 are merely examples. Instead, The radome test sample plate 40 may have a larger size, for example, 450 mm x 450 mm, or alternatively, a smaller size, for example, 200 mm x 200 mm, 400 mm x 200 mm, etc. The size and shape of the radome test sample plate 40 are not limited to this application. Similarly, the vertical impact height of the impact hammer 3 is also an example. In some other embodiments, the vertical impact height of the impact hammer 3 may alternatively be higher or lower. It can be understood that this is related to the particular test items that need to be performed on the radome test sample plate 40 to be evaluated. The vertical impact height of the impact hammer 3 is not limited to this application.

[0047] In one embodiment, a fiberglass radome is provided so that the radome 10 can have good impact resistance properties. As shown in Fig. 4, the fiberglass radome 10' has a first surface layer 100', an intermediate layer 200', and a second surface layer 300', which are laminated in this order. The first surface layer 100' and the second surface layer 300' are formed of glass mat, and the intermediate layer 200' is formed of unidirectional glass fiber yarn.

[0048] Specifically, in one embodiment, a method for manufacturing a fiberglass radome 10' is provided. Referring to Figures 4 and 5, the process for manufacturing the fiberglass radome 10' includes: The upper glass mat 101' passes through the upper first yarn wheel 21, The unidirectional glass fiber yarn 102' passes through the middle second yarn wheel 22, and the lower glass mat 103' passes through the lower first yarn wheel 21; The upper glass mat 101', the unidirectional glass fiber yarn 102' and the lower glass mat 103' are then immersed in an adhesive groove 23 containing unsaturated polyester resin. It is understood that this includes the following.

[0049] After being completely impregnated, the upper glass mat 101', the unidirectional glass fiber yarn 102', and the lower glass mat 103' are formed into a laminated structure by using a guide plate 24, in which the first layer 100' is a glass mat, the middle layer 200' is a unidirectional glass fiber yarn, and the second layer 300' is a glass mat, and then placed into a mold 25. In the mold 25, the glass mat, the unidirectional glass fiber yarn, and the unsaturated polyester resin are heated to a temperature required for the curing reaction of the unsaturated polyester resin (usually in the range of 150°C to 180°C). After the curing reaction at high temperature, the unsaturated polyester resin bonds the glass mat and the unidirectional yarn, and a composite cover is formed. The composite cover is then pulled and cut to obtain a fiberglass radome.

[0050] However, as shown in FIG. 6, in the fiberglass radome, the first layer 100' includes an upper glass mat 101', the middle layer 200' includes unidirectional glass fiber yarns 102', and the second layer 300' includes a lower glass mat 103'. The glass mats are formed by bonding continuous or short cut raw fibers in a non-directional manner using chemical adhesives or mechanical action. Therefore, the impact resistance of the first surface layer 100' of the fiberglass radome is not very good. Also, the middle layer 200' of the fiberglass radome is made of unidirectional yarns extending along d3, and the impact resistance of unidirectional yarns is not very good. As a result, the first layer 100', middle layer 200', and second layer 300' of the radome 10' are easily separated from each other in the direction d1 in FIG. 6, and then an impact force is applied to the middle layer 200'. When the unidirectional yarn as the intermediate layer 200' is subjected to an impact, the intermediate layer is easily separated in the direction d2 shown in Fig. 6. As a result, the radome 10' having the composite structure shown in Fig. 5 and Fig. 6 easily cracks when subjected to an impact, that is, the impact resistance property of the radome 10' is not good.

[0051] Also, the glass fiber content of the fiberglass radome 10' is high, typically greater than 80%. The density of the fiberglass is 2.7 g / cm3 The dielectric constant (dielectric constant, Dk) of the glass fiber is 6.13. As a result, the density of the glass fiber radome 10' made of glass fiber is high (>1.9 g / cm 3 ), Dk is also 4.0 to 4.8, and the dielectric loss (dielectric tangent, Df) value is in the range of 0.01 to 0.03. Details are shown in Table 1.

[0052] [Table 1] The dielectric constant represents the ratio of the capacitance of a capacitor constructed using an insulating material as the medium to the capacitance of a capacitor constructed using a vacuum as the medium, where the capacitors are the same size. The dielectric constant may represent the ability to polarize an electrolyte and store a charge. Dielectric loss represents energy loss in the form of internal heating (temperature rise) of a medium placed in an AC electric field. The dielectric constant and dielectric loss collectively represent the dielectric properties of a medium. The smaller the dielectric constant and dielectric loss, the better the dielectric properties of the medium. The larger the dielectric constant and dielectric loss, the worse the dielectric properties of the medium. Therefore, the dielectric properties and impact resistance properties of the fiberglass radome 10' are both not very good.

[0053] To overcome the aforementioned problems of the glass fiber radome 10', an embodiment of the present application provides a radome 10. As shown in FIG. 7, the laminate constituting the radome 10 has a first layer 101, a second layer 102, and a third layer 103 stacked in sequence. The first layer 101 and the third layer 103 have the same structure and are made of the same material. "Stacked" means that multiple layers of plates are arranged in sequence. The laminate forming the radome 10 refers to the state of the plates used in the radome 10 after they have been stacked; for example, hereinafter, it refers to a group of plates used to form a composite plate. The laminate refers to the material and structural properties of the raw plates before they are formed into a composite plate.

[0054] 7, in some embodiments, the laminate 1a forming the radome 10 may further include a weather-resistant coloring layer 104. The weather-resistant coloring layer 104 is laminated on the side of the first layer 101 farther from the second layer 102, or the weather-resistant coloring layer 104 is laminated on the side of the third layer 103 farther from the second layer 102. The weather-resistant coloring layer 104 is configured to improve the overall aesthetics and weather resistance of the radome 10. In some embodiments, the weather-resistant coloring layer 104, the first layer 101, the second layer 102, and the third layer 103 are laminated in sequence in the direction opposite to the direction d1.

[0055] It can be appreciated that in some embodiments, in order to reduce the number of layers in the board and the difficulty of hot pressing the laminated board 1a, the weather-resistant colored layer 104 and the first layer 101 are integrally formed. For example, some of the PP fibers in the first layer 101 form the weather-resistant colored layer 104. Alternatively, the weather-resistant colored layer 104 and the third layer 103 are integrally formed. For example, some of the PP fibers in the third layer 103 form the weather-resistant colored layer 104.

[0056] In one embodiment, the second layer 102 is an organic foam structure to reduce the mass of the radome 10. The organic foam structure is lighter than the glass fiber used in manufacturing the glass fiber radome 10', and can effectively reduce the mass of the radome 10. This further meets the requirement of reducing the weight of the radome 10.

[0057] In one embodiment, as shown in FIG. 8(A), the first layer 101 may be a prepreg layer 101-1 obtained by compounding a continuous fiber fabric with a thermoplastic resin. In this case, when the prepreg layer 101-1 is hot-pressed, it is possible to ensure that the continuous fibers remain in a woven structure even after the thermoplastic resin material is melted. This improves the impact resistance of the radome 10. The prepreg layer 101-1 is, for example, a woven fabric formed by weaving composite fibers composed of inorganic fibers and organic fibers. As another example, the prepreg layer 101-1 is a woven fabric formed by weaving fibers composed of high-melting-point organic fibers and low-melting-point organic fibers. In yet another example, the prepreg layer 101-1 is a woven fabric formed by knitting core-shell fibers formed by compounding a high-melting-point organic material and a low-melting-point organic material. Alternatively, in yet another example, the prepreg layer 101-1 may be formed by compounding an inorganic fiber-woven fabric with a thermoplastic resin. Core-shell fibers have a core and a peripheral portion surrounding the core. The core is made of a high-melting-point material, and the peripheral portion is made of a low-melting-point material. For example, the core is made of a high-melting-point organic material, and the peripheral portion is made of a low-melting-point organic material. In another example, the core is made of an inorganic material, and the ring is made of an organic material.

[0058] In another embodiment, as shown in FIG. 8(B), the first layer 101 may be a prepreg layer 101-2 obtained by combining prepreg tape obtained by compounding unidirectional continuous fibers and a thermoplastic resin. The prepreg tape is a unidirectional tape having a predetermined thickness, and is formed by arranging fibers in one direction, impregnating them with an organic resin, and winding them. The material of the unidirectional continuous fibers in the prepreg tape may be the same as the high-melting-point material or high-melting-point fiber material in FIG. 8(A), and the material of the thermoplastic resin in the prepreg tape may be the same as the low-melting-point fiber or low-melting-point material material in FIG. 8(A). The prepreg layer 101-2 is formed by stacking and compounding several layers of prepreg tape at a 0° / 90° angle. Compared to FIG. 8(A), the arrangement of the prepreg tape in the prepreg layer 101-2 is different from that in the prepreg layer 101-1. Prepreg layer 101-1 uses a weaving method, while prepreg layer 101-2 uses a lamination and conjugation method at 0° and 90° angles. It should be understood that 0° and 90° are merely examples. In another embodiment, prepreg tapes obtained by conjugating unidirectional continuous inorganic fibers with thermoplastic resins may be alternately laminated and conjugated at other angles, such as 30°, 45°, or 60°. The specific angles are not limited in this application. Lamination and conjugation can be understood as follows: Assume there are two layers of prepreg tape, with the prepreg tape on the first layer aligned in a first direction and the prepreg tape on the second layer aligned in a second direction, with the first direction not parallel to the second direction but parallel to the second layer. Alternatively, it can be understood that the inorganic fibers in FIG. 8(B) may be organic fibers with a relatively high melting point.

[0059] In yet another embodiment, as shown in Figure 8(C), the first layer 101 may be a prepreg layer 101-3 obtained by compounding random inorganic fibers with a thermoplastic resin. Compared to the regular arrangement of the inorganic fibers in the prepreg layers 101-1 and 101-2 shown in Figures 8(A) and 8(B) (e.g., a woven structure or a 0° and 90° laminated structure), the arrangement of the inorganic fibers in the prepreg layer 101-3 is random (e.g., a glass mat), which enhances the ability of the first surface layer to dissipate stress caused by an external impact. This improves the impact resistance of the radome made of the prepreg layer 101-3.

[0060] The high melting point fibers in the prepreg layers of Figures 8(A) to 8(C) have a mesh structure arranged in different directions. Compared with the structural defects of the unidirectional yarns in the intermediate layer 200' of the glass fiber radome 10', the radome 10 of the present application can fully transmit and dissipate the stress caused by an external impact. Therefore, the radome has better impact resistance properties.

[0061] After describing the surface layer structure of the radome before molding in an embodiment, the following will continue to describe the structure after molding, the molding method, and the raw materials required for the radome. The raw materials are the materials required to form the radome.

[0062] 9, the radome 10 has a structure including a first surface layer 100X, an intermediate layer 200X, and a second surface layer 300X, which are laminated in this order. The first surface layer 100X is formed by combining fibers 110 arranged in a mesh structure with a thermoplastic resin 120, the intermediate layer 200X has an organic foam structure, and the second surface layer 300X and the first surface layer 100X have the same structure and are made of the same material. In one embodiment, the fibers may be organic or inorganic.

[0063] In one embodiment, the inorganic fibers include at least one of glass fibers, basalt fibers, andesite fibers, aluminum silicate fibers, boron nitride fibers, aluminum oxide fibers, and quartz fibers. The type of inorganic fibers is not particularly limited in this application.

[0064] In one embodiment, the organic fiber includes at least one of PP fiber, PE fiber, PBT fiber, PET fiber, and PTT fiber. The type of organic fiber is not particularly limited in the present application.

[0065] In some embodiments, the weave of the fibers may be any one of plain weave, square plain weave, rib weave, twill weave, and satin weave. The weave of the fibers is not particularly limited in the present application. Preferably, the weave of the fibers is plain weave.

[0066] In some embodiments, the thermoplastic resin includes at least one of polypropylene (polypropylene fiber, PP), polyethylene (polyethylene, PE), polyvinyl chloride (polyvinyl chloride, PVC), polybutylene terephthalate (polybutylene terephthalate, PBT), polyethylene glycol terephthalate (polyethylene glycol terephthalate, PET), polytrimethylene terephthalate (polytrimethylene terephthalate, PTT), polycarbonate (polycarbonate, PC), and polyphenylene oxide (polyphenylene oxide, PPO). The type of thermoplastic resin is not particularly limited in this application.

[0067] In one embodiment, the material of the organic foam structure of the intermediate layer 200X is the same as the material of the thermoplastic resin, which improves the fusion between the first surface layer 100X and the intermediate layer 200X and between the second surface layer 300X and the intermediate layer 200X, and improves the mechanical properties of the radome 10.

[0068] Specifically, as shown in FIG. 10, the molding process of the radome 10 includes the following steps:

[0069] S1001: Layers are stacked in order from top to bottom.

[0070] As shown in the figure, in one embodiment, a prepreg layer 101 forming a first surface layer 100, an organic foam material layer 102 forming an intermediate layer 200, and a prepreg layer 103 forming a second surface layer 300 are sequentially stacked from top to bottom based on an A-type sandwich structure to form a layer architecture 1a for manufacturing a radome.

[0071] In another alternative embodiment, the prepreg layers and the organic foam material layers are sequentially stacked from top to bottom based on a C-type sandwich structure to form a composite plate 1b for manufacturing the radome 10. The C-type sandwich structure is similar to the A-type sandwich structure, and therefore will not be further described here.

[0072] Since the radome is exposed to the external environment for a long time, it can be understood that in an embodiment, in order to improve the weather resistance of the radome, a weather-resistant colored layer 104 may be further added on the prepreg layer 101 forming the first surface layer 100. This can improve the weather resistance of the radome and also improve the appearance of the radome.

[0073] The specific material selection for each layer will be specifically described in the following embodiments, and will not be described in detail here.

[0074] S1002: The layer architecture obtained through lamination is subjected to hot pressing to form a composite plate.

[0075] After layers 101, 102, and 103 are stacked, laminate plate 1a is formed as shown in Figure 10. Laminate plate 1a is then hot pressed to form composite plate 1b. As can be seen in Figure 10, composite plate 1b has first surface layer 100, middle layer 200, and second surface layer 300 stacked in sequence.

[0076] It should be noted that for different compositions and composition ratios of the prepreg layers, the layer architecture obtained by lamination is subjected to different temperatures for hot pressing. The specific temperatures for hot pressing will be described in detail in the following embodiments, and will not be described in detail here.

[0077] In some embodiments, the size of the composite plate 1b is a predetermined size, which is equivalent to the size of the radome, i.e., it can be understood that one radome is formed using one composite plate 1b. In another alternative embodiment, the composite plate 1b is a continuous plate, and the pre-composite plate 1b needs to be further cut to an appropriate size before the radome is formed.

[0078] S1003: The composite plate 1b is heated to soften it and then molded to obtain a radome.

[0079] The molding may be roll press molding or compression molding. For example, after obtaining the composite plate 1b, the composite plate 1b is heated for a predetermined time to soften it, and then the softened composite plate 1b is roll pressed or compression molded to produce a radome. It should be noted that if the composition and composition ratio of the composite plate 1b are different, the temperature and time for hot pressing the composite plate 1b will also be different. This will be described in detail in the following embodiments. Details will not be described here.

[0080] It can be understood that in the above-mentioned molding step, the molding step of the composite plate 1b may further be integrated with the molding step of the radome, i.e., hot pressing and molding are performed on the layer architecture obtained by lamination to obtain the radome.

[0081] In particular, Figures 11(A), 11(B), and 11(C) show schematic diagrams of the aforementioned plate structure before and after molding according to an embodiment of the present application, where Figure 11(A) is a cross-sectional view of the fiber, Figure 11(B) is a magnified view of the Pa region in Figure 10, and Figure 11(C) is a magnified view of the Pb region in Figure 10.

[0082] In one embodiment, the fiber is a bicomponent fiber formed by combining a high melting point fiber and a low melting point fiber. The high melting point fiber may be an inorganic fiber or a high melting point organic fiber. The low melting point fiber is an organic fiber.

[0083] For example, as shown in FIG. 11(A), a composite fiber is formed by combining inorganic fiber i and organic fiber ii. The inorganic fiber i is a glass fiber, and the organic fiber ii is a PP fiber. In FIG. 11(A), the white circle indicates the cross-sectional shape of the glass fiber, the black circle indicates the cross-sectional shape of the PP fiber, and the area surrounded by the dashed line L indicates the boundary of the composite fiber composed of the glass fiber and the PP fiber. This is for illustrative purposes only. It can be understood that in an actual structure, the boundary represented by the dashed line L does not exist.

[0084] In another embodiment, as shown in Figure 11(D), the composite fiber may have a core-shell structure containing fibers of different materials, and the core portion of the core-shell structure may be made of high-melting point PP fiber and the outer portion of the core-shell structure may be made of low-melting point PP fiber.

[0085] This point will be explained in detail below.

[0086] 11(B), it can be seen that the pre-molded laminate 1a has a first layer 101a, a second layer 102a, and a third layer 103a, which are arranged from top to bottom based on an A-type sandwich structure.

[0087] The first layer 101a is made of composite fiber (see FIG. 11(A)) by mixing glass fiber and PP fiber in a predetermined weight ratio, and the composite fiber is woven into the first layer 101a using a plain weave method. The second layer 102a is made of PP foam material. The structure and materials of the third layer 103a are the same as those of the first layer 101a. Details will not be described again here. The aforementioned materials are stacked based on an A-type sandwich structure to form a laminate 1a. The thickness of the laminate 1a is S1.

[0088] In one embodiment, the basis weight of the first layer 101a is 200 g / m 2 to 1500g / m 2 Preferably, the basis weight of the first layer 101a is in the range of 400 g / m 2 to 1000g / m 2 The range is.

[0089] In some embodiments, the PP fibers may instead be another organic fiber, such as at least one of PE fibers, PBT fibers, PET fibers, and PTT fibers.

[0090] In some embodiments, the glass fibers may be replaced with other inorganic fibers, such as at least one of basalt fibers, andesite fibers, aluminum silicate fibers, boron nitride fibers, aluminum oxide fibers, and quartz fibers. The type of inorganic fiber is not particularly limited in this application.

[0091] In one embodiment, the second layer 102a of the radome 10 in this embodiment of the present application is primarily composed of a lightweight filler material to reduce the weight of the radome 10. For example, the second layer 102a may be composed of at least one of a PP board, a PE board, a PBT board, a PET board, a PTT board, a PC board, a PPO board, and a lightweight PP glass mat reinforced thermoplastics (GMT) composite board. The type of lightweight filler material is not limited in the present application.

[0092] To further reduce the mass of the second layer 102a, the second layer 102a may alternatively use a lighter foam material. For example, the second layer 102a may be made of at least one of a PP foam board, a PE foam board, a PVC foam board, a PBT foam board, a PET foam board, a PTT foam board, a PC foam board, and a PPO foam board. In one embodiment, the density of the second layer 102a is 0.15 g / cm 3 to 1.4 g / cm 3 in the range of 0.4 g / cm 3 to 1.0 g / cm 3 The thickness of the second layer 102a is in the range of 0.5 mm to 3 mm.

[0093] In one embodiment, the material of the second layer 102a is a PP foam board, so that the radome 10 can meet the lightweight requirement. Furthermore, after several tests according to the present application have been carried out, it has been found that the density of the PP foam board is 0.4 g / cm 3 When the thickness of the PP foam board is 1 mm, the weight reduction effect of the radome 10 becomes better.

[0094] Next, the first layer 101a, the second layer 102a, and the third layer 103a, arranged based on the structure shown in FIG. 11(B), are successively hot-pressed and composited using double-layered steel or double-layered Teflon tape at temperatures ranging from 170°C to 240°C, followed by room temperature cooling, resulting in the composite board 1b shown in FIG. 11(C). The PP fibers in the first surface layer 100a and the second surface layer 300a of the composite board 1b melt into a liquid, while the glass fibers remain interwoven. The liquid PP obtained through the melting fills the gaps between the glass fibers in the first surface layer 100a and the second surface layer 300a, forming the composite board 1b after solidification. In this case, the thickness of the composite board 1b is S2, and it is easy to understand that S2 is smaller than S1.

[0095] Next, the composite plate 1b is heated and roll-pressed or compression-molded. Specifically, the composite plate 1b is continuously heated at 190 to 240°C for 1 to 3 minutes to be softened, and then roll-pressed or compression-molded to obtain the radome 10 shown in Fig. 10.

[0096] In some embodiments, the composite fiber may alternatively be woven in a manner such as plain weave, rib weave, twill weave, satin weave, etc. The weave of the composite fiber is not limited herein. Preferably, the composite fiber is woven in a plain weave.

[0097] In an embodiment, in order to enhance the impact resistance property of the radome 10, the composite fiber may be a composite fiber obtained by mixing glass fiber and PP fiber based on a weight ratio of 60:40, and the basis weight of the first layer 101a obtained after the composite fiber is woven is 600 g / m 2 It can be understood that in some other embodiments, the weight ratio of glass fiber to PP fiber in the composite fiber may range from (90:10) to (50:50). It should be noted that basis weight is the weight of a material in grams per square meter. The first layer 101a is used as an example. Basis weight is the weight of a composite material formed by glass fiber and PP fiber in grams per square meter.

[0098] Table 2 below shows the properties of the radome manufactured using the composite plate 1b.

[0099] [Table 2] A comparison of Table 2 with Table 1 reveals that the impact resistance of the radome of the present application is significantly improved. This can meet the requirements for a radome weighing approximately 90 kg. Compared with the dielectric constant and dielectric loss of a radome manufactured using the materials in Table 1, the dielectric constant is reduced by 2 and the dielectric loss is reduced by 0.0244. The dielectric constant represents the ratio of the capacitance of a capacitor manufactured using an insulating material as the medium to the capacitance of a capacitor manufactured using a vacuum as the medium, where the capacitors are the same size. The dielectric constant also represents the ability to polarize an electrolyte and store charge. The dielectric loss represents energy loss in the form of internal heating (temperature rise) of a medium placed in an AC electric field. The dielectric constant and dielectric loss collectively represent the dielectric properties of a medium. The smaller the dielectric constant and dielectric loss, the better the dielectric properties of the medium. The larger the dielectric constant and dielectric loss, the worse the dielectric properties of the medium. Therefore, the radome of the present application has better dielectric properties than the radome manufactured using the materials in Table 1.

[0100] Furthermore, the first surface layer 100a and the second surface layer 300a are woven fiber mesh structures, which may increase the withstandable dropping hammer impact to more than 2.2 kg (for example, 3 kg, 4 kg, etc.). Compared to the glass fiber radome 10', which can only withstand a dropping hammer impact of 1.3 kg, the dropping hammer impact resistance characteristics are also greatly improved.

[0101] In addition, in the above-mentioned embodiment, the intermediate layer 200a is a foam structure. Compared with the case where the fiberglass radome 10' uses a completely fiberglass structure, the weight is reduced by 0.6A. That is, the radome 10 in this application is lighter.

[0102] Furthermore, from the above, it can be seen that the first surface layer 100a and the second surface layer 300a of the radome in this application use a composite material obtained by mixing inorganic fibers and a thermoplastic resin material. A radome made using only an organic material such as a thermoplastic resin has better dielectric properties, but the impact resistance of the thermoplastic resin is significantly reduced. Compared to a radome made using only a thermoplastic resin in another embodiment, the radome 10 in this application uses a composite material of inorganic fibers and a thermoplastic resin material. Therefore, a balance between impact resistance properties and dielectric properties is achieved.

[0103] For example, the plastic radome 10' shown in FIG. 12 is manufactured using the extrusion molding process shown in FIG. 12. Specifically, the plastic radome 10' is obtained by extruding thermoplastic particles in a thermoplastic extruder 30, then extruding the thermoplastic particles into a mold, cooling, drawing, and cutting. From FIG. 13, it can be seen that the plastic radome 10' has only one layer 101', which is also made of a thermoplastic material. Because the effective length of the glass fibers in the thermoplastic particles is usually less than 2 mm, the length of the glass fibers in the layer 101' made of thermoplastic particles is shorter. Therefore, it can be seen that the impact resistance property of the plastic radome 10' is not good. In the impact test shown in FIG. 2, the plastic radome 10' is prone to holes. For example, a hole Y is generated after the impact test shown in FIG. 2 is performed on the plastic radome 10' shown in FIG. 14.

[0104] Furthermore, in the radome 10 of this embodiment, the first surface layer 100a, the intermediate layer 200a, and the second surface layer 300a are all made of the same thermoplastic resin material to improve adhesion between them. For example, the PP fiber is the same thermoplastic material as the intermediate layer. When manufacturing the composite plate 1b based on this design, only the PP fiber needs to be heated and melted, and then hot-pressed to more firmly bond the first surface layer 100a, the intermediate layer 200a, and the second surface layer 300a. Compared to other embodiments in which the radome layers are made of different materials and therefore require the use of adhesives to create a more robust structure in which the radome layers are firmly bonded, this embodiment has better impact resistance, saves materials, and is more environmentally friendly.

[0105] In one embodiment, for example, in Figure 15, an adhesive radome 10' is provided. The adhesive radome 10' has a first layer 100', a second layer 400', a third layer 200', a fourth layer 400', and a fifth layer 300'. The first layer 100' is an upper surface layer, the second layer 400' is an adhesive, the third layer 200' is a core layer (or middle layer), the fourth layer 400' is also an adhesive, and the fifth layer 300' is a lower surface layer. The upper surface layer 100', the lower surface layer 300', and the core layer 200' are bonded together using a polyurethane-based adhesive or a phenolic resin-based adhesive. The upper surface layer 100' and the lower surface layer 300' are made of a fiber-reinforced thermoplastic composite material (long fiber-reinforced thermoplastic composite material or continuous fiber-reinforced thermoplastic composite material), or a laminate material of a fiber-reinforced thermoplastic composite material and a transition material (the transition material is a fiber mat or a nonwoven fabric). The foam material used for the core layer 200' is a thermosetting material, such as a polyurethane foam material, a phenolic resin foam material, an epoxy resin foam material, etc.

[0106] From the analysis of the above structure, we can see that the upper and lower surface layers 300' of the bonded radome 10' are made of fiber-reinforced thermoplastic composite material. The glass fibers in the long-fiber-reinforced thermoplastic composite material are short, resulting in low impact resistance. Furthermore, the core layer 200' of the bonded radome 10' is made of a thermosetting foam material. Therefore, the upper and lower surface layers must be bonded (or bonded) to the core layer using an adhesive. To ensure adhesive bonding quality, the surface layer, adhesive layer, core layer, adhesive layer, and surface layer must first be laminated (as shown in Figure 15), followed by removal of air bubbles and subsequent high-temperature curing and bonding. The processing process involves many steps, which is complex and costly. Furthermore, since the thermosetting foam material does not have thermoplastic properties, the composite plate obtained based on the above structure does not have plasticity and cannot be processed a second time. Therefore, the composite plate can only be fabricated into flat radomes. For this reason, it is not possible to mold a radome with a complex structure such as that shown in Figure 10.

[0107] The process of forming composite fibers from PP fibers and glass fibers and weaving the composite fibers into prepreg layer 101-1 has been described above. It should be understood that in some embodiments, the composite fibers may alternatively be core-shell fibers formed by combining a low-melting-point material and a high-melting-point material. The core-shell fibers have a core portion and a peripheral portion. The core portion extends in the extension direction of the composite fibers, and the peripheral portion is disposed around the core portion and extends in the extension direction of the composite fibers.

[0108] In particular, Figures 16(A), 16(B), and 16(C) show schematic diagrams of the aforementioned plate structure before and after molding according to one embodiment of the present application, where Figure 16(A) is a cross-sectional view of the fiber, Figure 16(B) is a magnified view of the Pa region in Figure 10, and Figure 16(C) is a magnified view of the Pb region in Figure 10.

[0109] As shown in Figure 16(A), the core portion i (i.e., kernel portion) of the composite fiber is made of a high-melting point PP material, and the peripheral portion ii (i.e., shell portion) of the composite fiber is made of a low-melting point PP material.

[0110] It is understood that the core portion of the composite fiber may alternatively be composed of high-melting-point inorganic fibers and / or high-melting-point organic fibers. Details will not be described here. Hereinafter, the molding process of the composite fiber and the properties of the molded composite fiber will be described using an example in which the core portion of the composite fiber is composed of a high-melting-point PP material and the peripheral portion of the composite fiber is composed of a low-melting-point PP material.

[0111] Before this, it should be noted that the difference between the following embodiment and the previous embodiment in Fig. 11 is the different fiber morphology. Specifically, in the following embodiment, the fibers used to weave into the fabric are core-shell type monofilaments, while in Fig. 11, the fibers used to weave into the fabric are fiber bundles after multiple types of fibers are mixed. For other similar steps and weaving methods, please refer to the relevant descriptions in Fig. 10 and Fig. 11, and no further description is provided here.

[0112] Specifically, as shown in Figure 16(B), the pre-molded laminate 1a has a first layer 101b, a second layer 102b, and a third layer 103b laminated in this order. The light circles represent high-melting-point PP materials, and the dark rings represent low-melting-point PP materials. It can be seen that the first layer 101b is formed by plain-weaving composite fibers formed by combining low-melting-point PP materials with high-melting-point PP materials, while the second layer 102b is still composed of a PP foam material. In this case, the thickness of the laminate 1a is S3.

[0113] In some embodiments, the composite fibers may alternatively be woven in a square weave, rib weave, twill weave, satin weave, etc. The weave of the composite fibers is not limited herein.

[0114] In one embodiment, in order to improve the impact resistance property of the radome 10, the first layer 101b is formed by weaving composite material fibers formed by compounding a low melting point PP material and a high melting point PP material, and has an areal density of 450 g / m 2 is.

[0115] In one embodiment, the material of the second layer 102b is a PP foam board, which allows the radome 10 to meet the requirement of light weight. Furthermore, after multiple tests conducted by the inventors, it was found that the density of the PP foam board is 0.4 g / cm 3 and when the thickness of the PP foam board is 1 mm, the manufactured radome can better meet the requirement of weight reduction and also has better impact resistance properties.

[0116] Next, the first layer 101b, the second layer 102b, and the third layer 103b, arranged according to the structure shown in Figure 16(B), are hot-pressed and composited using double-layered steel tape or double-layered Teflon tape at a temperature ranging from 160°C to 170°C. Then, the composite board 1b shown in Figure 16(C) is obtained by cooling at room temperature. From Figure 16(C), it can be seen that the low-melting-point PP material in the first layer 100b melts and becomes liquid, while the high-melting-point PP material in the inner layer remains fibrous and interwoven. The low-melting-point liquid PP material obtained through melting fills the spaces between the high-melting-point PP fiber material in the first layer 100b. Furthermore, because the hot-pressing process was performed, it is easy to see that the thickness of the composite board 1b is S4, which is smaller than S3.

[0117] Finally, the composite plate 1b is heated and roll-pressed or compression-molded. Specifically, the composite plate 1b is continuously heated at 160 to 170°C for 1 to 3 minutes to soften it, and then roll-pressed or compression-molded to obtain the radome 10 shown in Fig. 10.

[0118] Table 3 below shows the properties of the radome manufactured using composite plate 1b.

[0119] [Table 3] A comparison between Table 3 and Table 1 reveals that the first layer 101b of the radome in this embodiment is formed by weaving composite fiber formed by combining a high-melting-point PP material and a low-melting-point PP material, i.e., the PP material content is increased. Therefore, the impact resistance of the radome is significantly improved, and the drop hammer impact resistance can be increased, even reaching more than 3.1 kg (e.g., 4 kg, 5 kg, etc.). Furthermore, the radome in this application is made of PP fiber material. PP material is lighter than glass fiber, has low dielectric loss, and a low dielectric constant. Therefore, compared with the weight of the radome manufactured using glass fiber in Table 1, the weight of the radome in this embodiment can be reduced by 73%, and the dielectric loss and dielectric constant are lower, resulting in better dielectric properties.

[0120] A comparison of Table 3 and Table 2 reveals that the first layer 101b of the radome 10 manufactured in this embodiment is formed by weaving composite fibers composed of low-melting-point PP material and high-melting-point PP material, whereas the radome corresponding to Table 2 is formed by weaving composite fibers obtained by using glass fiber and PP fiber based on a specific weight ratio, and the dielectric constant of the PP fiber (2.3) is lower than the dielectric constant of the glass fiber (6.13). Therefore, the dielectric properties of the PP fiber are better than those of the glass fiber. Furthermore, the PP fiber has larger elastic deformation and higher shock absorption capacity. Therefore, the impact resistance properties of the PP fiber are better than those of the glass fiber. Thus, compared to the radome corresponding to Table 2, the radome corresponding to Table 3 can have better dielectric properties and impact resistance properties.

[0121] As described above, the laminate 1a shown in the previous drawings is obtained by forming prepreg layers using composite fibers or composite material fibers in a weaving manner. Then, hot pressing is performed using double steel tape or double Teflon tape to obtain the composite plate 1b. The prepreg composite plate 1b is heated to soften it and then hot roll pressed to obtain the radome shown in FIG. 10. Each of the first and third layers of the laminate 1a is composed of a woven fabric obtained by weaving composite fibers and composite material fibers. In another alternative embodiment, each of the first and third layers of the laminate 1a may be a composite layer formed by combining a woven fabric of high-melting-point fibers with a PP film. It can be understood that the weaving method for the high-melting-point fiber fabric may be the same as the weaving method in the previous embodiment. Details will not be described again in this application.

[0122] In particular, Figure 17(A) is an enlarged view of the Pa region in Figure 10, and Figure 17(B) is an enlarged view of the Pb region in Figure 10. As shown in Figure 17(A), the laminate 1a before molding has a first layer 101c, a second layer 102c, and a third layer 103c. The first layer 101c, the second layer 102c, and the third layer 103c are arranged from top to bottom based on an A-type sandwich structure, and the first layer 101c includes a first sublayer 101c1 and a second sublayer 101c2. The open circles represent glass fibers. The first sublayer 101c1 is made of a PP film layer, the second sublayer 101c2 is made of a glass fiber fabric obtained by weaving, and the second layer 102c is made of a PP foam material. In this case, the thickness of the laminate 1a is S5. The third layer 103c is similar to the first layer 101c, and the details will not be described again here.

[0123] In one embodiment, the first sub-layer 101c1 and the second sub-layer 101c2 form the first layer 101c based on a weight ratio of 40:60, and the basis weight of the second sub-layer 101c2 is 400 g / m 2 is.

[0124] In one embodiment, the density of the second layer 102c is 0.4 g / cm 3 and the thickness of the second layer 102c is 1 mm.

[0125] Next, the first sublayer 101c1, the second sublayer 101c2, the second layer 102c, and the third layer 103c, arranged according to the structure shown in FIG. 17(A), are hot-pressed and composited using a double-layer steel tape at temperatures ranging from 170°C to 240°C. Then, the composite board 1b shown in FIG. 17(B) is obtained by cooling at room temperature. As can be seen from FIG. 17(B), the PP film in the first sublayer 101c1 melts and becomes liquid, while the glass fibers in the second layer 101c2 remain interwoven. The liquid PP material obtained through melting fills the gaps between the glass fibers of the glass fiber fabric in the second sublayer 101c2. Furthermore, as the first sublayer 101c1 melts and becomes liquid during hot-pressing, the thickness of the composite board 1b becomes S6. It is easy to see that S6 is smaller than S5.

[0126] Next, the composite plate 1b is heated and roll-pressed or compression-molded. Specifically, the composite plate 1b is continuously heated at 190 to 240°C for 1 to 3 minutes to soften it, and then roll-pressed or compression-molded to obtain the radome 10 shown in Fig. 10.

[0127] Table 4 below shows the properties of the radome manufactured using composite plate 1b.

[0128] [Table 4] The first layer 101c of the radome of this embodiment is formed of a glass fiber fabric and a PP film. After being melted by hot pressing, the PP film fills between the glass fibers of the glass fiber fabric, forming a denser first surface layer 100c. Therefore, the impact resistance of the radome of this embodiment is better than that of radomes manufactured using the materials corresponding to Tables 1 and 2.

[0129] From a comparison of Table 4 and Table 1, the following can be understood. First, the surface layer of the radome of this embodiment is composed of a glass fiber fabric and a PP film. For the same surface layer thickness, the glass fiber content of the surface layer of the radome of this embodiment is lower than that of the glass fiber in Table 1, and the dielectric constant (2.3) and dielectric loss (0.002) of the PP resin are lower than the dielectric constant (4.8) and dielectric loss (0.03) of the glass fiber in Table 1. Therefore, the radome of this embodiment has better dielectric properties. Second, the glass fiber in the first surface layer 100c of the radome of this embodiment is in a woven state. As described above, compared with the unidirectional glass fiber yarn used in the glass fiber radome of Table 1, a woven structure can transmit and dissipate stress better than a unidirectional structure. Therefore, the surface layer of the radome of this embodiment has better impact resistance properties and can withstand a falling hammer impact of more than 2.65 kg (for example, 3 kg, 4 kg, etc.).

[0130] 17(A) and 17(B), it can be seen that there may be two layers of PP film, one layer disposed on the side of the first layer facing away from the second layer, and the other layer disposed on the side of the third layer facing away from the second layer. In another alternative embodiment, there may be four layers of PP film, two layers disposed on two sides each: one side facing away from the second layer of the first layer and one side facing the second layer of the first layer. The other two layers disposed on two sides each: one side facing away from the second layer of the third layer and one side facing the second layer of the third layer.

[0131] Specifically, Figure 17(C) is another enlarged view of the Pa region in Figure 10. As shown in Figure 17(C), the laminate 1a before molding has a first layer 101c, a second layer 102c, and a third layer 103c. The first layer 101c includes a first sublayer 101c1, a second sublayer 101c2, and a third sublayer 101c1, which are laminated in order. The first sublayer 101c1 and the third sublayer 101c1 are made of PP film, and the second sublayer 101c2 is made of glass fiber fabric.

[0132] Compared to the structure shown in Figure 17(A), Figure 17(C) differs only in the number and materials of the sub-layers that make up the first layer 101c. Specifically, in Figure 17(C), there are three sub-layers that make up the first layer 101c, with the first sub-layer made of PP film being added below the second sub-layer 101c2.

[0133] Furthermore, to improve the impact resistance properties of the radome 10, in one embodiment, inorganic fibers may be woven into a fabric, and then a layer of thermoplastic resin film may be added on top of the layer formed by weaving the inorganic fibers to form a prepreg layer. When the prepreg layer is hot-pressed, the thermoplastic resin film in the prepreg layer melts and becomes liquid, and then impregnates the thin layer of fabric formed by weaving the inorganic fibers to form the first surface layer 100d. It can be seen that such a design not only more closely combines the inorganic fibers and the thermoplastic resin, but also improves the impact resistance properties of the surface layer of the radome.

[0134] In another alternative embodiment, the prepreg layers may instead be pre-formed by using PP film and high melting point fiber fabric.

[0135] FIG. 18(A) is a partial enlarged view of the structure of the Pa region in FIG. 10 of the first surface layer 100d before molding, and FIG. 18(B) is a partial enlarged view of the structure of the Pa region in FIG. 10 of the first surface layer 100d after pre-molding. As shown in FIGS. 18(A) and 18(B), the structure of the first surface layer 100d before molding includes a first sublayer 101d1, a second sublayer 101d2, and a third sublayer 101d1 stacked in order. Before the composite board 1b is manufactured, the first sublayer 101d1, the second sublayer 101d2, and the third sublayer 101d1 stacked in order are first manufactured to form the first layer 101d. The third layer 103d is similar to the first layer 101d. Details will not be described again in this application.

[0136] Figure 18(C) is an enlarged view of the Pa region in Figure 10, and Figure 18(D) is an enlarged view of the Pb region in Figure 10. As shown in Figure 18(C), the laminate 1a before molding has a first layer 101d, a second layer 102d, and a third layer 103d. The first layer 101d, the second layer 102d, and the third layer 103d are arranged from top to bottom based on a type A sandwich structure. In this case, the thickness of the laminate 1a is S7.

[0137] Next, the first layer 101d, the second layer 102d, and the third layer 103d arranged based on the structure shown in Figure 18(C) are hot-pressed and composited using double-layer steel tape at a temperature range of 170°C to 240°C, and then cooled at room temperature to obtain the composite plate 1b shown in Figure 18(D). The thickness of the composite plate 1b is S8. It can be understood that S8 is approximately equal to S7 because the first layer 101d and the third layer 103d are pre-formed.

[0138] Next, the composite plate 1b is heated and roll-pressed or compression-molded. Specifically, the composite plate 1b is continuously heated at 190 to 240°C for 1 to 3 minutes to soften it, and then roll-pressed or compression-molded to obtain the radome 10 shown in Fig. 10.

[0139] From the above description, it is easy to understand that composite fibers or composite material fibers are woven into the prepreg layers to obtain the laminate 1a shown in the above figures. Then, hot pressing is performed using double steel tape or double Teflon tape to obtain the thermoplastic prepreg composite plate 1b. For the laminate 1a, the prepreg composite plate 1b is heated to soften and molded to obtain the radome shown in FIG. 10. The high melting point fibers in the composite plate 1b are woven in. In another alternative embodiment, the high melting point fibers in the composite plate 1b may be arranged in a staggered pattern.

[0140] It can be understood that in some embodiments, prepreg tapes can be arranged in a 0° and 90° stacking manner to form prepreg layers (as shown in FIG. 8(B)). 0° can be understood to mean that the fiber direction in the prepreg tape is the same as the fiber direction in the composite plate, and 90° can be understood to mean that the fiber direction in the prepreg tape is perpendicular to the fiber direction in the composite plate.

[0141] This point will be explained in detail below. Figure 19(A) is an enlarged view of the Pa region in Figure 10, and Figure 19(B) is an enlarged view of the Pb region in Figure 10.

[0142] Specifically, as shown in FIG. 19(A), the pre-molded laminate 1a includes a first layer 101e, a second layer 102e, and a third layer 103e. The first layer 101e, the second layer 102e, and the third layer 103e are arranged from top to bottom based on an A-type sandwich structure. The first layer 101e includes, from top to bottom, a first sublayer 101e1 and a second sublayer 101e2. The fibers of the first sublayer 101e1 are arranged at a 90° angle, and the fibers of the second sublayer 101e2 are arranged at a 0° angle. The fibers of the second layer 102e are made of PP foam material. The third layer 103e includes, from top to bottom, a second sublayer 103e2 and a first sublayer 103e1. The fibers of the first sub-layer 103e1 are oriented at 90°, and the fibers of the second sub-layer 103e2 are oriented at 0°, so that the thickness of the laminate 1a is S9.

[0143] In another alternative implementation, the first layer 101e includes, from top to bottom, a first sublayer 101e1 and a second sublayer 101e2. The fibers of the first sublayer 101e1 are oriented at 0°, and the fibers of the second sublayer 101e2 are oriented at 90°. The second layer 102e is made of PP foam. The third layer 103e includes, from top to bottom, a second sublayer 103e2 and a first sublayer 103e1. The fibers of the first sublayer 103e1 are oriented at 0°, and the fibers of the second sublayer 103e2 are oriented at 90°.

[0144] After the composite plate 1b is obtained by any one of the above methods, the thickness of the composite plate 1b is 10 where S 10 is equal to S9. The composite plate 1b is heated and roll-pressed or compression-molded. Specifically, the composite plate 1b is continuously heated at 190 to 240°C for 1 to 3 minutes to soften, and then roll-pressed or compression-molded to obtain the radome 10 shown in Fig. 10.

[0145] Table 5 below shows the properties of the radome manufactured using composite plate 1b.

[0146] [Table 5] The materials and structure used for the radome 10 of this embodiment are similar to those of the radome 10 of the previous embodiment. A comparison of Table 5 with Table 1 reveals that the impact resistance of the radome 10 of this embodiment is significantly improved, withstanding an impact greater than 3 kg (e.g., 4 kg, 5 kg, etc.), which is greater than the 1.3 kg impact of a dropping hammer on the glass fiber radome 10'. The dielectric constant is lower than that of a radome manufactured using the materials in Table 1, and the dielectric loss is significantly reduced. Therefore, the radome of this embodiment has better dielectric properties than the glass fiber radome 10'. Furthermore, because the intermediate layer 200e uses an organic foam structure, the light weight of the radome of this embodiment is lower than that of the glass fiber radome 10' and significantly lower than that of the plastic radome 10' that uses pure plastic.

[0147] A comparison of Table 5 and Table 2 shows that the first surface layer 100e in this embodiment is formed by arranging multiple layers of prepreg tape at a specific angle, and therefore, compared to the radome 10 corresponding to Table 2, the radome 10 in this embodiment of the present application has better impact resistance properties than the fabric formed by weaving composite fibers in Table 2.

[0148] In some embodiments, the bicomponent or composite fibers may alternatively be arranged in 0° and 90° stacks to form a prepreg layer (not shown) with staggered fibers.

[0149] Before this, it is noted that the difference between the embodiment shown in Figures 20(A) and 20(B) and the embodiment shown in Figures 19(A) and 19(B) is in the method of forming the prepreg layers. Specifically, the prepreg layers in Figures 19(A) and 19(B) are formed by laying out staggered prepreg tapes, whereas the prepreg layers in Figures 20(A) and 20(B) are formed by weaving staggered composite fibers or composite material fibers.

[0150] This point will be explained in detail below. Figure 20(A) is an enlarged view of the Pa region in Figure 10, and Figure 20(B) is an enlarged view of the Pb region in Figure 10. Before this, it should be noted that the difference between the following embodiment and the previous embodiment in Figure 11 lies in the arrangement method when forming the first surface layer 100a. In Figure 11, a regular woven structure is adopted for composite fibers composed of PP fibers and glass fibers. In this embodiment, a regular laminated structure is adopted for the composite fibers, and the orientation of the composite fibers in each layer is unidirectional. For example, assume that a two-layer laminated structure is used. In this case, the orientation direction of the composite fibers in the first layer is a first direction (e.g., 0°), and the orientation direction of the composite fibers in the second layer is a second direction (e.g., 90°).

[0151] It can be understood that in some embodiments, the composite fiber may be formed by combining PP fiber and glass fiber in Table 2, or may be formed by combining a low-melting point PP material and a high-melting point PP material in Table 3, or may be a prepreg tape formed by combining unidirectional glass fiber yarn and a thermoplastic resin. The method of forming the composite fiber is not limited in this application.

[0152] Specifically, as shown in FIG. 20(A), the pre-molded laminate 1a includes a first layer 101f, a second layer 102f, and a third layer 103f. The first layer 101f, the second layer 102f, and the third layer 103f are arranged from top to bottom based on an A-type sandwich structure. The first layer 101f includes, from top to bottom, a first sublayer 101f1 and a second sublayer 101f2. The composite fibers in the first sublayer 101f1 are arranged at a 90° angle, and the composite fibers in the second sublayer 101f2 are arranged at a 0° angle. The composite fibers in the second layer 102f are made of PP foam material. The third layer 103f includes, from top to bottom, a second sublayer 103f2 and a first sublayer 103f1. The composite fibers of the first sub-layer 103f1 are oriented at 90°, and the composite fibers of the second sub-layer 103f2 are oriented at 0°.

[0153] In another alternative implementation, the first layer 101f includes, from top to bottom, a first sub-layer 101f1 and a second sub-layer 101f2. The composite fibers in the first sub-layer 101f1 are oriented at 0°, and the composite fibers in the second sub-layer 101f2 are oriented at 90°. The second layer 102f is made of a PP foam material. The third layer 103f includes, from top to bottom, a second sub-layer 103f2 and a first sub-layer 103f1. The composite fibers in the first sub-layer 103f1 are oriented at 0°, and the composite fibers in the second sub-layer 103f2 are oriented at 90°.

[0154] The above materials are laminated based on an A-type sandwich structure to obtain a laminate 1a. The thickness of the laminate 1a is S 11 In one embodiment, the basis weight of the first layer 101f is 750 g / m 2 and the thickness of the first layer 101f is 0.5 mm.

[0155] In some embodiments, the PP fibers may alternatively be another organic fiber, such as at least one of PE, PBT, PET, and PTT.

[0156] In one embodiment, the second layer 102f of the radome 10 in this embodiment of the present application is primarily composed of a lightweight filler material to reduce the weight of the radome 10. For example, the second layer 102f may be composed of at least one of a PP board, a PE board, a PBT board, a PET board, a PTT board, a PF board, a PPO board, and a lightweight PP glass mat reinforced thermoplastics (GMT) composite board. The type of lightweight filler material is not limited to this application.

[0157] To further reduce the mass of the second layer 102f, the second layer 102f may alternatively use a lighter foam material. For example, the second layer 102f may be formed of at least one of a PP foam board, a PE foam board, a PVF foam board, a PBT foam board, a PET foam board, a PTT foam board, a PF foam board, and a PPO foam board. In one embodiment, the density of the second layer 102f is 0.15 g / m 3to 1.4 g / m 3 , preferably 0.4 g / m 3 to 1.0 g / m 3 The thickness of the second layer 102f ranges from 0.5 mm to 3 mm.

[0158] In one embodiment, the second layer 102f is made of a PP foam board, so that the radome 10 can meet the requirement of weight reduction. After several tests have been carried out by the inventors, it has been found that the density of the PP foam board is 0.4 g / m 3 It was found that when the thickness of the PP foam board is 1 mm, the weight reduction effect of the radome 10 is more excellent.

[0159] Next, the first layer 101f, the second layer 102f, and the third layer 103f arranged based on the structure shown in Figure 20(A) are successively hot-pressed and composited at a temperature range of 190°C to 240°C by using double steel tape or double Teflon tape, and then cooled to room temperature to obtain the composite plate 1b shown in Figure 20(B). In this case, the thickness of the composite plate 1b is S 12 and S 12 S 11 It is easy to see that it is smaller than

[0160] To improve the effect of hot pressing the laminate 1a to obtain the composite plate 1b and to prevent warping and deformation of the composite plate 1b, in one embodiment, the first surface layer 100f and the second surface layer 300f are symmetrical with respect to the intermediate layer 200f. As an example, FIG. 20(B) is used. The first surface layer 100f includes a first sub-surface layer 100f1 and a second sub-surface layer 100f2, where the first sub-surface layer 100f1 is disposed on the side of the second sub-surface layer 100f2 that is farther from the intermediate layer 200f. The second surface layer 300f includes a first sub-surface layer 300f1 and a second sub-surface layer 300f2, where the first sub-surface layer 300f1 is disposed on the side of the second sub-surface layer 300f2 that is farther from the intermediate layer 200f.

[0161] The orientation of the glass fibers in the first sub-surface layer 100f1 and the orientation of the glass fibers in the first sub-surface layer 300f1 are both 90°, and the orientation of the glass fibers in the second sub-surface layer 100f2 and the orientation of the glass fibers in the second sub-surface layer 300f2 are both 0°. Correspondingly, the first layer 101f and the third layer 103f are symmetrically distributed on two sides of the second layer 102f.

[0162] In one embodiment, the difference from the previous embodiment in which glass fiber, glass fiber and PP fiber composite fiber, or PP fiber is designed to be woven or laminated layer by layer is that the continuous fibers are arranged in a random manner and then a first layer 101g is formed with a PP film. Compared with prepreg fabrics formed by weaving in a specific order, the first layer 101g in this embodiment has a better effect in transmitting and dissipating stress.

[0163] Specifically, as shown in FIG. 21, FIG. 21(A) is an enlarged view of the Pa region in FIG. 10, and FIG. 21(B) is an enlarged view of the Pb region in FIG. 10. As shown in FIG. 21(A), the laminate 1a before molding includes a first layer 101g, a second layer 102g, and a third layer 103g. The first layer 101g, the second layer 102g, and the third layer 1013g are arranged from top to bottom based on an A-type sandwich structure. The first layer 101g is composed of a first sub-layer 101g1 and a second sub-layer 101g2. The first sub-layer 101g1 is composed of a PP film layer, the second sub-layer 101g2 is composed of a glass mat, and the second layer 102g is composed of a PP foam material. In this case, the thickness of the laminate 1a is S 13 This becomes:

[0164] To enhance the impact resistance properties of the radome 10, in one embodiment, the glass fiber content of the first layer 101g is 50% and the areal density is 450 g / cm 3 In one embodiment, the density of the second layer 102g is 0.4 g / cm 3 and the thickness of the second layer 102g is 1 mm.

[0165] Next, the first sublayer 101g1, the second sublayer 101g2, the second layer 102g, and the third layer 103g, arranged based on the structure shown in Figure 21(A), are hot-pressed and composited using a double-layer steel tape at a temperature range of 190°C to 240°C, followed by room temperature cooling, resulting in the composite board 1b shown in Figure 21(B). Figure 21(B) shows that the PP film of the first sublayer 101g1 melts and becomes liquid, while the glass fiber mat of the second sublayer 101g2 remains randomly distributed, and the liquid low-melting-point PP obtained by melting fills the gaps between the glass mats in the second sublayer 101g2. Furthermore, as the first sublayer 101g1 melts and becomes liquid during hot-pressing, the thickness of the composite board 1b increases to S. 14 Then, S 14 S 13 It is easy to see that it is smaller than

[0166] Next, the composite plate 1b is heated and roll-pressed or compression-molded. Specifically, the composite plate 1b is continuously heated at 190 to 240°C for 1 to 3 minutes to soften, and then roll-pressed or compression-molded to obtain the radome 10 shown in Fig. 10.

[0167] Table 6 below shows the properties of the radome manufactured using composite plate 1b.

[0168] [Table 6] A comparison of Table 6 with Table 1 reveals that the first layer 101g of the radome in this embodiment is formed of glass mat and PP film, and after being melted through a hot press, the PP film is filled between the glass mats, making the glass mats more compact. This improves the impact resistance of the first surface layer 100g, and increases the withstandable falling hammer impact to a maximum of more than 1.8 kg (e.g., 2 kg or 3 kg). Furthermore, because glass mat, PP film, and PP foam board are used, the weight of the radome manufactured in this embodiment of the present application is reduced by 62% compared to the weight of the radome manufactured using the materials listed in Table 1. Furthermore, Table 6 reveals that the dielectric constant (3.0) and dielectric loss (0.006) of the radome manufactured in this embodiment of the present application are lower than the dielectric constant (4.8) and dielectric loss (0.03) of the glass fiber in Table 1, and therefore the radome manufactured in this embodiment of the present application has better dielectric properties.

[0169] It can be understood that, since the radome 10 is exposed outdoors for a long period of time, there are also requirements for the weather resistance and aesthetic appeal of the radome 10. Therefore, in order to improve the aesthetic appeal of the radome, a weather-resistant colored layer 104 may be added to the first layer of the laminate plate 1a shown in FIGS. 2 to 10, thereby improving the aesthetic appeal of the radome and also improving the weather resistance of the surface layer of the radome. In addition, in an embodiment, the PP film or PP fiber and the weather-resistant colored layer 104 may be designed integrally. For example, in a first layer 101g formed of a plain-woven glass fiber fabric and a PP film, the PP film may be designed as a weather-resistant colored layer and may be laminated (tiled) on the plain-woven glass fiber fabric to jointly form the first layer 101g. This is not a limitation in the present application.

[0170] In the description of the embodiments of the present application, it should be noted that the terms "located," "connected to," and "connected" should be understood in a broad sense unless otherwise clearly stated and limited. For example, the connection may be a fixed connection, an indirect connection using an intermediate medium, or an internal communication or interaction relationship between two elements. Those skilled in the art can understand the specific meaning of the aforementioned terms in the embodiments of the present application based on the specific case.

[0171] In the specification, claims, and accompanying drawings of embodiments of this application, terms such as "first," "second," "third," "fourth," etc. (when present) are intended to distinguish between similar objects and do not necessarily indicate a particular order or sequence. Such terms, when used, are interchangeable under appropriate circumstances, and it will be understood that the described embodiments of this application may be performed in orders other than those illustrated or described. Additionally, the terms "comprise," "have," and any other variations thereof are intended to cover non-exclusive inclusions. For example, a process, method, system, product, or apparatus that includes a list of steps or units is not necessarily limited to the explicitly listed steps or units and may have other steps or units not explicitly listed or that are inherent to the process, method, product, or apparatus.

[0172] Finally, it should be noted that the above embodiments are merely intended to describe the technical solutions of the embodiments of the present application, and do not limit the technical solutions of the embodiments of the present application. Although the embodiments of the present application have been described in detail with reference to the above embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the above embodiments, or equivalent substitutions can be made to some or all of the technical features thereof, without departing from the scope of the technical solutions of the embodiments of the present application. [Explanation of symbols]

[0173] 1 antenna 1a Laminate 1b Composite board 3 Impact Hammer 10 Radome 21 First Yarn Wheel 22 Second Yarn Wheel 23 Adhesive groove 24 Guide plate 25 Molds 30 Thermoplastic Extruder 31 Impact hammer end 32 Iron Lump 40 Radome test sample plate 100 First surface layer 101 First Layer 102 Second Layer 103 Third Layer 104 Weather-resistant colored layer 200 Middle Class 300 Second surface layer x Obstacles Y vacancy M tower.

Claims

1. A composite plate used in a radome, an intermediate layer and a surface layer combined with the intermediate layer; the surface layer has first fibers and a thermoplastic resin filled between the first fibers, the surface layer and the intermediate layer are arranged in a first direction, the first direction being a thickness direction of the composite plate; the first fibers in the surface layer have a plurality of fiber layers arranged in the first direction, each fiber layer having unidirectional continuous fibers; The composite plate, wherein an included angle between fibers in two fiber layers of the plurality of fiber layers is a first preset angle.

2. 2. The composite board of claim 1, wherein the melting point of the first fibers is higher than the melting point of the thermoplastic resin.

3. The composite board according to claim 1 , wherein the thermoplastic resin of the surface layer is made of the same material as the intermediate layer.

4. 4. The composite board according to claim 1 or 3, wherein the intermediate layer is made of a thermoplastic foam material.

5. 4. The composite board according to claim 1, wherein the first fibers in the surface layer comprise inorganic fibers and / or organic fibers.

6. 6. The composite board according to claim 5, wherein the inorganic fibers in the surface layer are glass fibers.

7. 6. The composite board of claim 5, wherein the inorganic fibers in the surface layer include at least one of glass fibers, basalt fibers, andesite fibers, aluminum silicate fibers, boron nitride fibers, aluminum oxide fibers, and quartz fibers.

8. 6. The composite board of claim 5, wherein the organic fibers of the surface layer include at least one of polypropylene fibers, polybutylene terephthalate fibers, polyethylene fibers, polyethylene glycol terephthalate fibers, and polytrimethylene terephthalate fibers.

9. The composite plate of claim 1 , wherein the first preset angle comprises at least one of 30°, 45°, and 60°.

10. The composite plate further has a weather-resistant coloring layer, 4. The composite board according to claim 1, wherein the weather-resistant coloring layer is disposed on the surface layer on a side farther from the intermediate layer.

11. The composite plate further has a weather-resistant coloring layer, 4. The composite board according to claim 1, wherein the weather-resistant coloring layer and the surface layer are integrally formed.

12. 4. The composite plate according to claim 1, wherein the composite plate has a sandwich structure, and the sandwich structure is an A-type sandwich structure or a C-type sandwich structure.

13. 4. The composite board according to claim 1, wherein the thermoplastic resin comprises at least one of polypropylene, polyethylene, polyvinyl chloride, polybutylene terephthalate, polyethylene glycol terephthalate, polytrimethylene terephthalate, polycarbonate, and polyphenylene oxide.

14. A radome comprising the composite plate according to any one of claims 1 to 3.

15. The radome according to claim 14, wherein the thermoplastic resin in the surface layer is made of the same material as the intermediate layer.

16. The radome of claim 14 , wherein the intermediate layer is made of a thermoplastic foam material.

17. The composite plate has a sandwich structure, 15. The radome according to claim 14, wherein the sandwich structure is an A-type sandwich structure or a C-type sandwich structure.

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