JPS60158703A - Circular polarized antenna reflector - Google Patents

Abstract

PURPOSE:To obtain a circular polarized antenna reflector which can maintain the ratio wave reflecting performance for a long period of time with a simple manufacturing process, by laminating a thermoplastic resin layer, a metal layer and an anti-impact resing layer containing an inorganic filler successively. CONSTITUTION:A thermoplastic resin layer 3 has 10mum-1mm. thickness and excels in the weather resistance to prevent the errosion of a metallic layer 2. The layer 2 has 10-500mum thickness and reflects radio waves. While an anti-impact resin layer 1 containing an inorganic filler contains 10-70wt% inorganic fillr with 1-7mm. thickness. These layers 3, 2 and 1 are laminated successively.

Description

DETAILED DESCRIPTION OF THE INVENTION [I] Object of the Invention The present invention relates to a reflector for a circularly polarized antenna made of a laminate having a metal layer serving as a radio wave reflecting layer as an intermediate layer. More specifically, 1. A thermoplastic resin layer with excellent weather resistance, a metal layer that reflects radio waves, and an impact-resistant resin layer containing an inorganic filler are sequentially laminated, and the thickness of the thermoplastic resin layer is 5 microns to 5 mm. The thickness of the metal layer is 5 microns or more.
1m+n and the thickness of the inorganic filler-containing impact-resistant resin layer is 0.5 mm to 15 mm. The object of the present invention is to provide a reflector for a wave antenna.

[II] Background of the Invention Satellite broadcasting using geostationary satellites is planned to be put into practical use in Europe, America, Japan, and other countries around the world in the near future. However, since a geostationary satellite has only one orbit, there is a risk of interference between multiple broadcast radio waves. In order to avoid such mutual interference of broadcast waves,
It is necessary to utilize the cross-polarization identification of the satellite broadcasting antenna. In this way, when receiving terrestrial broadcast waves, the radio waves are linearly polarized horizontally or vertically, and the polarization plane of the receiving antenna is matched to the polarization plane of the broadcast waves, using cross-polarization discrimination. It's not that difficult to do, but
When receiving radio waves from a broadcasting satellite, the plane of polarization may shift due to disturbances such as the ionosphere in the radio wave propagation path and the angle of incidence of the radio wave at the receiving point, so it is not possible to align the planes of polarization as described above. Have difficulty.

Frequency allocation for multiple broadcasting satellites is
From the point of view of effective use of the frequency band used, it seems that the degree of polarization plane discrimination is taken into account, but for satellite broadcast waves with such frequency allocation, the quality of the polarization plane adjustment of the receiving antenna directly determines the broadcast channel. Therefore, if the broadcast satellite radio waves are linearly polarized waves, it cannot be expected to obtain a high degree of cross-polarization discrimination.

However, when broadcasting satellite radio waves are circularly polarized,
Irrespective of the shift in the plane of polarization as described above, it is easy to identify the direction of the circularly polarized wave. In addition to directing the receiving antenna, it is not necessary to adjust the plane of polarization, so it is much easier to adjust the receiving antenna than in the case of linearly polarized waves, and it is possible to obtain polarization discrimination as designed for the receiving antenna. I can do it.

For these reasons, plans are being made to use circularly polarized waves for broadcast satellite radio waves in future satellite broadcasting systems. In contrast, conventional circularly polarized antennas include those that use a conical horn, those that combine two Goupoles at right angles, and parabolic antennas that use these antennas as the primary radiator. The structure is complex and large, and manufacturing costs are high, so it is not suitable for general audience receiving antennas for receiving satellite broadcast radio waves using microwaves in the 12 gigahertz (G&) band. do not have.

On the other hand, the structure is extremely simple, and as a small and lightweight microwave antenna, a rectangular waveguide is extended in the axial direction from the center of a parabolic reflector, and its tip is curved so that the opening end surface becomes a parabolic shape. There is a so-called Hehat-type parabolic ann which faces a parabolic reflector at the focal position and uses this as a primary radiator. This antenna is widely used in microwave antennas for mobile relays, etc., but all conventional Heehat-type parabolic antennas use the aforementioned rectangular waveguide to transmit and receive linearly polarized waves. Therefore, it cannot be used for circularly polarized waves.

In 11Q, metal plates or metal nets have been used as parabolic antennas. However, since metals corrode, it is necessary to use anti-corrosion alloys or apply anti-corrosion coatings. If anti-corrosion alloys are used, they are expensive. On the other hand, anti-corrosion coating requires repeated application several times in order to achieve complete corrosion protection, which not only makes it expensive, but also causes the problem that the coated object deteriorates over many years of use. Furthermore, attempts have been made to manufacture radio wave reflecting plates in which glass fibers with metallized surfaces are laminated to thermosetting resins such as unsaturated polyester resins as radio wave reflecting layers, but the manufacturing method is complicated and It has been extremely difficult to maintain the radio wave reflective layer at a constant thickness and without unevenness.

[I11] Structure of the Invention From the above, the present inventors have obtained a reflector for a circularly polarized antenna, which has a simple manufacturing process, has radio wave reflecting ability, and can maintain its performance for a long period of time. As a result of various searches, we found that at least (A) a thermoplastic resin layer with good weather resistance, (B) a metal layer, and (C) an impact-resistant resin layer containing an inorganic filler are sequentially laminated. The thickness of the thermoplastic resin layer is 5 microns to 5 mm, the thickness of the metal layer is 5 microns to IIIl, and the thickness of the inorganic filler-containing impact-resistant resin layer is 500 microns to 15 mm.
! II, and the content of the inorganic filler in this layer is 10~
80% by weight, and the impact-resistant resin is chlorinated polyethylene, a graft copolymer obtained by graft polymerizing styrene and at least one other vinyl compound to chlorinated polyethylene, and styrene and at least one other vinyl compound. Impact-resistant resin containing at least one type of copolymer with a vinyl compound (provided that chlorinated polyethylene and styrene occupying the impact-resistant resin are graft copolymerized with at least one other vinyl compound) The reflector for circularly polarized antennas, which is characterized by having a total amount of chlorinated polyethylene of 5 to 40% by weight, not only has good durability but also has excellent radio wave reflection characteristics. This discovery led to the present invention.

[IV] Effects of the Invention The circularly polarized antenna reflector of the present invention exhibits the following effects (features) including its manufacturing process.

(1) Since it has excellent corrosion resistance, there is no change in radio wave reflection characteristics over a long period of time.

(2) Since the coefficient of linear expansion of the metal layer and the inorganic filler-containing impact-resistant resin layer is extremely small, peeling between the layers will not occur even if subjected to heat cycles (repetition of cold and heat) for a long period of time.

(3) The reflector for a circularly polarized antenna is lightweight and the manufacturing process is simple.

(4) The metal layer can be formed uniformly,
There is no uneven reflection of radio waves.

(5) Impact-resistant resins containing inorganic fillers can be easily formed into various complex shapes, and therefore have good appearance and functionality.

(8) The mechanical strength (especially rigidity) of the reflector for a circularly polarized antenna is excellent.

[V] Detailed description of the invention (A) Thermoplastic resin The thermoplastic resin used to manufacture the thermoplastic resin layer of the present invention is widely produced industrially and used in many fields. , their manufacturing methods and various physical properties are well known. Their molecular weight varies depending on the type, but generally ranges from 10,000 to 1,000,000. Typical thermoplastic resins include homopolymers of monomers having double bonds such as ethylene, propylene, vinylidene fluoride, vinyl chloride, and styrene, and copolymers containing these as the main component (50% by weight or more). Polymer, copolymer of styrene and 7-crylonitrile (AS resin), resin whose main component is methyl phthalate (H
MA resin) butadiene copolymer rubber, acrylonitrile-
Butadiene copolymer rubber CNBR) (styrene-butadiene copolymer rubber (SBR), acrylic rubber, ethylene-
Rubbers such as propylene copolymer rubber (EPR), ethylene-propylene-diene terpolymer rubber (EPDM), and chlorinated polyethylene are grafted with styrene alone or with styrene and other vinyl compounds (e.g., acrylonitrile, methyl methacrylate). Examples include graft copolymer resins obtained by copolymerization, polyamide resins, polyester resins, polyphenylene oxide resins, and polycarbonate resins. Furthermore, even if these thermoplastic resins are modified by grafting an organic compound having at least one double bond (for example, an unsaturated carboxylic acid or its anhydride), they have excellent processability. You can use it if you like. Furthermore, in addition to the graft copolymer resin,
Compositions obtained by blending the above-mentioned rubbers with these thermoplastic resins (the blending ratio of rubber is generally at most 40% by weight) can also be used. Among these thermoplastic resins, fluorine-containing resins such as polyvinylidene fluoride are preferred because of their excellent weather resistance. Furthermore, resins mainly composed of vinyl chloride, ethylene and/or
Alternatively, even if the resin has propylene as its main component, its weather resistance can be improved by adding an ultraviolet absorber, so blends of these can also be preferably used. . Furthermore, polyamide resins, polyester resins and polycarbonate resins can also be used.

Among these thermoplastic resins, organic compounds (especially, It is advantageous to use part or all of a modified resin obtained by graft polymerizing an unsaturated carboxylic acid and its anhydride (preferably an unsaturated carboxylic acid and its anhydride) because it has excellent adhesion to the metal layer described below.

(B) Metal layer Furthermore, typical examples of metals that are raw materials for the metal layer in the present invention include simple metals such as aluminum, iron, nickel, copper, and zinc, and alloys containing these metals as main components (for example, stainless steel). steel, brass). These metals do not need to be surface-treated, and may be previously subjected to surface treatment such as chemical treatment or plating treatment. Furthermore, those that have been painted or printed can also be preferably used.

(C) Impact-resistant resin The impact-resistant resin used to produce the inorganic filler-containing impact-resistant resin layer in the present invention can also be grafted with chlorinated polyethylene and styrene and at least one other vinyl compound. The total amount of copolymerized chlorinated polyethylene is 5 to 40% by weight (preferably 10 to 40% by weight, preferably 15 to 35% by weight). The impact resistant resin contains chlorinated polyethylene, styrene and at least one other vinyl compound (
For example, it consists of chlorinated polyethylene graft copolymerized with copolymers with acrylonitrile (methyl methacrylate) and/or styrene/with at least one other vinyl compound.

The impact-resistant resin of the present invention is a composition obtained by mixing chlorinated polyethylene with the above-mentioned copolymer, or a composition obtained by graft copolymerizing styrene and at least one other vinyl compound with chlorinated polyethylene. The graft copolymer obtained by graft copolymerizing a small amount of styrene and at least one other vinyl compound to chlorinated polyethylene in advance is further mixed with the above-mentioned copolymer. This is a composition obtained by. When using a composition among the impact-resistant resins of the present invention, a composition obtained by mixing the constituent components in advance may be used, and when producing the composition that is the final product of the present invention. These may be mixed. In the present invention, when any of the above-mentioned compositions or graph/ft copolymers is used as the impact-resistant resin, graft copolymerization in the impact-resistant resin of the composition that is the final product It is important to blend the chlorinated polyethylene so that the blending ratio is the above-mentioned composition ratio.

The chlorinated polyethylene used in the production of impact-resistant resins is obtained by chlorinating polyethylene powder or particles in an aqueous suspension or by chlorinating polyethylene dissolved in an organic solvent ( (preferably those obtained by chlorination in aqueous suspension)
. Generally, amorphous or crystalline chlorinated polyethylene with a chlorine content of 20 to 50% by weight is used, and amorphous chlorinated polyethylene with a chlorine content of 25 to 45% by weight is particularly preferred.

Said polyethylene is obtained by homopolymerizing ethylene or copolymerizing ethylene with at most 10% by weight of α-olefin (generally having at most 6 carbon atoms). Its density is generally between 0.910 and 0.910.
It is 870g/cc. In addition, its molecular weight is 50,000 to 7
It is 00,000.

Specific examples of impact-resistant resins used in the present invention include graft copolymerization of styrene and 7-crylonitrile onto chlorinated polyethylene, and graft copolymerization of styrene and methyl methacrylate onto chlorinated polyethylene. Examples include graft products obtained by chlorinated polyethylene and styrene, blends of copolymer resins with acrylonitrile, and blends of chlorinated polyethylene and acrylic resins. The acrylic resin is a polymer containing methacrylic ester or acrylic ester as a main component. Typical examples include polymers based on methyl acrylate, butyl acrylate and/or methyl methacrylate.

(D) Inorganic filler The inorganic filler used to produce the inorganic filler-containing impact-resistant resin layer is generally one widely used in the fields of synthetic resins and rubber. These inorganic fillers are preferably inorganic compounds that do not react with oxygen and water, and that do not decompose during crosstalk or molding. The inorganic fillers include metals such as aluminum, copper, iron, lead and nickel, and these metals as well as magnesium, calcium, barium, zinc, zirconium, molybdenum, silicon, antimony,
Oxides of metals such as titanium, their hydrates (hydroxides),
It is broadly classified into compounds such as sulfates, carbonates, and silicates, their double salts, and mixtures thereof. Typical examples of the collector filler include the metals mentioned above, aluminum oxide (alumina), its hydrates, calcium hydroxide, magnesium oxide (magnesia), magnesium hydroxide, zinc oxide (zinc white), red lead, and Lead oxides such as white lead, magnesium carbonate, calcium carbonate, basic magnesium carbonate, white carbon, asbestos, mica, talc,
Glass fiber 1, glass powder, glass peas, clay, diatomaceous earth, silica, wollastonite, iron oxide, antimony oxide, titanium oxide (titania), lithopone, pumice grains, aluminum sulfate (gypsum, etc.), zirconium silicate, zirconium oxide , barium carbonate, dolomite, molybdenum disulfide and iron sand. Among these inorganic fillers, those in powder form have a diameter of 1+ nm or less (preferably 0 nm or less).
, 5+am or less) is preferred. For m-cone shaped ones, the diameter is 1 to 500 microns (preferably 1 to 300 microns).
A length of 0.1 to 6 mm (preferably 0.1 to 5 mm) is desirable. Further, the diameter of the flat plate-like one is 2III11 or less (preferably 1 mm or less) (E) Structure of each layer (1) Thermoplastic resin layer The thermoplastic resin layer of the present invention has a diameter of 2III11 or less (preferably 1 mm or less). It works to prevent the occurrence of. From this, the thickness is 5 microns to 5 mm, and the thickness is 10 microns to 5 mm.
+n+a is preferred, especially 10 microns to lll
1 m is suitable. If the thickness of this thermoplastic resin layer is less than 5 microns, not only will the metal layer corrode, but also the metal layer will wear out and become exposed due to contact and friction with other articles during use. occurs and there is a problem.

On the other hand, if it exceeds 5IIIm, it is not preferable because it not only lowers the reflectance of radio waves but also increases the cost and weight of the laminate.

(2) Metal layer Furthermore, the metal layer of the present invention serves to reflect radio waves. The thickness of this metal layer is 5 microns or less.
111, preferably from 5 to 500 microns, particularly preferably from 10 to 500 microns. If the thickness of the metal layer is less than 5 microns, the metal layer is likely to wrinkle or fold during the production of a laminate, resulting in problems in terms of appearance and performance.

On the other hand, if it exceeds 1flI11, it not only increases IT, but also increases cost, and also causes problems when bending or bending the laminate.

(3) Inorganic filler-containing impact-resistant resin layer The composition ratio of the inorganic filler in the inorganic filler-containing impact-resistant resin layer of the present invention is 10 to 80% by weight (i.e., the composition of the impact-resistant resin The proportion is 90-20% by weight), 10
-70% by weight is preferred, particularly 10-60% by weight. If the composition ratio of the inorganic filler in the inorganic filler-containing impact-resistant resin layer is less than 10% by weight, the linear expansion coefficient of the inorganic filler-containing impact-resistant resin layer will be too different from that of the metal layer, and the heat cycle Therefore, there is a problem that not only peeling may occur between the gold H layer and the impact-resistant resin layer containing an inorganic filler, but also that the resulting laminate lacks rigidity. On the other hand, if it exceeds 80% by weight, the
It is difficult to produce a uniform composition, and even if a uniform composition is obtained, it is difficult to obtain a good product (laminate) when producing sheets or laminates by injection molding, etc. described below. I can't.

The thickness of this inorganic filler-containing impact-resistant resin layer is 500 microns to 1! lvm, preferably 1 to 110n1, particularly preferably 1 to 7 mm. If the thickness of the inorganic filler-containing impact-resistant resin layer is less than 500 microns, it is undesirable because the rigidity is insufficient and the layer is deformed and damaged by external force. On the other hand, if it exceeds 15 mm, it will take time to cool down during molding, and not only will sink marks be more likely to occur on the surface, but the weight will increase, causing problems in use.

In producing the thermoplastic resin layer and the inorganic filler-containing impact-resistant resin layer, stabilizers against oxygen, heat and ultraviolet rays, metal deterioration inhibitors, flame retardants, and colorants commonly used in the respective fields are used. , electrical property improver,
Additives such as antistatic agents, lubricants, processability improvers, and tackiness improvers are added to the extent that they do not impair the properties of the compositions of the thermoplastic resin layer and inorganic filler-containing impact-resistant resin layer of the present invention. You may.

When blending the above-mentioned additives into the thermoplastic resin of the present invention and when producing impact-resistant resins containing inorganic fillers (including cases where the above-mentioned additives are blended), Henschel Tri-blending may be performed using a mixer such as a mixer, or it may be obtained by melt-kneading using a mixer such as a Banbury mixer, kneader, roll mill, or screw extruder. At this time, a homogeneous composition can be obtained by triblending in advance and melt-kneading the resulting composition (mixture).

In particular, it is preferable to use the impact resin in the form of a powder because it can be mixed more evenly.

In this case, the mixture is generally melt-kneaded and then molded into pellets, which are then subjected to the molding described later.

Inorganic filler-containing resistance of the present invention! In producing the 7-stroke resin, all the ingredients may be mixed at the same time, or some of the ingredients may be mixed in advance to produce a so-called masterbatch, and the resulting masterbatch and the remaining ingredients may be mixed together. May be mixed.

When melt-kneading is used to produce blends, it must be carried out above the melting point or softening point of the thermoplastic resin or impact-resistant resin used; however, if carried out at high temperatures, the thermoplastic resin and The impact-resistant resin deteriorates.

For these reasons, it is generally 20°C higher than the melting point or softening point of the respective thermoplastic resin or impact-resistant resin.
It is carried out at high temperatures (preferably above 50° C.), but within a temperature range that does not cause deterioration.

(F) Reflector for Circularly Polarized Antenna The reflector for circularly polarized antenna of the present invention will be explained below with reference to FIGS. 1 to 3. FIG. 1 is a partial perspective view of an antenna to which a reflector for a circularly polarized antenna is attached. FIG. 2 is a sectional view of the reflector for the circularly polarized antenna. Also, the third
The figure is a partially enlarged view of the sectional view. In FIG. 1, A is a reflector for a circularly polarized antenna of the present invention, B is a converter, C is a converter support rod, and D is a reflector support rod. Further, E is a wiring. Further, in FIGS. 2 and 3, 1 is an impact-resistant resin layer containing an S machine filler, and 2 is a metal layer (metal foil). Further, 3 is a thermoplastic resin layer with excellent weather resistance. Furthermore, 2
a and 2b are single primer layers. As is clear from these drawings, the feature of the reflector for a circularly polarized antenna of the present invention is that it has a structure consisting of at least three layers. In addition, the reflector for a circularly polarized antenna of the present invention is designed to strengthen the adhesion between the thermoplastic resin layer, which has excellent weather resistance, and the metal layer, and between the metal layer and the impact-resistant resin layer containing an inorganic filler. You can also use a primer. moreover,
In order to attach the reflector for a circularly polarized antenna of the present invention to a support, ribs may be attached to the impact-resistant resin layer containing an inorganic filler to enable attachment, and the reflector may be reinforced. It is also possible to add reinforcing ribs for this purpose. Furthermore, it is also possible to drill holes in the circularly polarized antenna support obtained by the present invention and attach various support attachment parts using bolts, nuts, etc. In addition, the diameter of the reflector for the circularly polarized antenna is usually θGcm to 1
It is 20cm.

(G) Method for manufacturing a reflector for a circularly polarized antenna The reflector for a circularly polarized antenna of the present invention is produced by manufacturing a laminated metal foil in advance, and using this laminated metal shape, vacuum forming and stamping are performed. It can be manufactured by molding using a molding method such as a molding method or an injection molding method.

Manufacturing methods using these molding methods will be explained in more detail.

(I) Manufacturing method of laminated metal foil In the present invention, the method of laminating the thermoplastic resin on the metal foil (metal layer) can be achieved by applying a commonly practiced method. The method will be explained in detail below.

The method of laminating (adhering) the thermoplastic resin layer with excellent weather resistance and the metal foil, which is the metal layer, can generally be carried out by a dry lamination method, but it is possible to perform the method by pressing the thermoplastic resin layer at high temperature. For olein-based polymers that can be produced, a thermoplastic resin layer and a metal foil can be laminated (adhered) by an extrusion lamination method.To produce a laminated metal foil using an extrusion lamination method Using a T-gui film molding machine, extrude the resin to the above thickness at a temperature in the range of 240 to 370''C, and at the same time bond it to the metal foil (metal layer) using a cooling pressure roll. That's fine.

When using a thermoplastic resin that has excellent adhesion to metal foil, a laminated metal foil can be produced as described above.

However, when using thermoplastic resin whose adhesion to metal foil is not fully satisfactory, apply a primer (anchor coating agent) commonly used in the field of thermoplastic resin to one side of the metal foil in advance. It is applied by gravure coating method or perspective coating method and dried at 50 to 100°C. Next, a thermoplastic resin film or sheet is pressed onto the surface of the metal foil primer using a pressure roll heated to 50 to 100°C. The primer varies depending on the type of thermoplastic resin used to form the thermoplastic resin layer, but it is commonly used in various fields,
Available in water-based and solvent-based forms.

Further, types include vinyl type, acrylic type, impact resistant type, epoxy type, rubber type, urethane type and titanium type.

(2) Manufacturing by vacuum forming method To manufacture by this method, a primer is applied to one side of the metal layer on which the thermoplastic resin layer obtained as described above is laminated, and then an impact-resistant resin containing an inorganic filler is applied. When extruded into a sheet using the T-Guy molding method, a laminate is created in which a thermoplastic resin layer with excellent weather resistance, a metal layer, and an impact-resistant resin layer containing an inorganic filler are sequentially laminated by laminating on one side. can get. The laminate (sheet) obtained in this way is fixed with iron cotton or claw-like objects, and placed in a jig that is easy to handle.
This is drawn into a device that can be heated using ceramic heaters arranged vertically or sheathed wire heaters, and heated.

When the sheet is heated, it begins to melt, but at that time, the sheet sag once, and then as the heating continues, it becomes stretched inside the wafer that holds the sheet. When this stretching phenomenon is observed, the best timing for sheet molding is when the molded product is in a good heating state without wrinkles or uneven thickness. At this time, the desired molded product is obtained by pulling out the sheet work, placing it on the upper part of the mold, and performing vacuum forming from the mold side under a reduced pressure of one atmosphere. Then, the product is cooled by wind or water spray and released from the mold.

On the other hand, in compressed air forming, the sheet that is easier to mold is pulled out to the top of the mold, a chamber (box) for compressed air is placed over the sheet, and the sheet is pressed against the mold side with a pressure of 3 to 5 atm. A molded product can be obtained by pushing up the mold together with the mold.

In addition, in any molding method, the surface temperature of the sheet is 110
~200°C is the optimum temperature.

(3) Manufacturing by stamping molding method To manufacture the circularly polarized antenna reflector of the present invention by this method, the weather-resistant A laminate sheet in which a superior thermoplastic resin layer, a metal layer, and an inorganic filler-containing impact-resistant resin layer are laminated in sequence is introduced into a drawing die attached to a vertical press, and the sheet is drawn to a size of 5 to 50 kg/cm. (
The desired molded product is preferably obtained by heating and pressing under a pressure of 10 to 20 kg/crn'. The product is then obtained by cooling with air or water spray and g&molding. Pressure time during molding is usually 15 seconds or more, and 15 to 40 seconds.
Seconds are common. Further, in order to improve surface properties, it is preferable to perform molding under two-stage pressure conditions. In this case, in the first stage, under a pressure of 10 to 20 kg/am',
After applying pressure for 0 seconds, a molded product with excellent surface smoothness can be obtained by applying pressure for 5 seconds or more under a pressure of 40 to 50 kg/crn' in the second stage. This two-stage molding method is particularly desirable when using an impact-resistant resin layer containing an inorganic filler with poor fluidity. Note that the suitable molding temperature in the stamping molding method is a sheet surface temperature of 110 to 180°C.

(4) Manufacture by injection molding method In order to manufacture the reflector plate for a circularly polarized antenna of the present invention by injection molding method, a thermoplastic resin layer with excellent weather resistance is laminated on one side in advance, and a primer layer is placed on the other side. The metal layer coated or not coated is subjected to insert injection molding when forming a reflector for a circularly polarized antenna. To carry out insert injection molding, the metal layer is inserted between the male and female molds of the injection molding machine, and the thermoplastic resin layer with excellent weather resistance is placed on the male mold side.) , close the mold. After that, an impact-resistant resin containing an inorganic filler is filled into the mold from the gate part of the mold, and after cooling,
By opening the mold, a desired reflector for a circularly polarized antenna can be obtained. For insert injection molding, the resin temperature is above the melting point of the impact resin of the inorganic filled impact resin, but below the thermal decomposition temperature of the impact resin. Insert injection molding is therefore carried out at a temperature range tm of 160-240°C. In addition, if the injection pressure is 40 kg/cm' or more at the gauge pressure at the nozzle part of the cylinder of the injection molding machine, it is possible to form the impact-resistant resin containing inorganic filler into a shape almost similar to the shape of the mold. Not only is it possible to produce a product, but also a product with good appearance can be obtained. Injection pressure is generally 40 to 140
kg/cm', especially 70-120 kg7
cm' is desirable.

[]Examples and Comparative Examples The present invention will be explained in more detail with reference to Examples below.

In the Examples and Comparative Examples, the radio wave reflectance was measured as a microwave reflection coefficient based on the voltage standing wave ratio when a rectangular waveguide was used and the tip of the waveguide was short-circuited. In addition, weather resistance tests were conducted using a Sunshine Carbon Weather Meter, with a black panel temperature of 83°C and a due cycle of 12 minutes/60 minutes of irradiation. Gloss change, crazing,
Swelling.

Detrimental changes such as peeling and cracking of the metal foil were evaluated. Furthermore, in the to-cycle test, the sample was exposed to 80°C for 2 hours, then gradually cooled to -45°C over 4 hours, exposed to this temperature for 2 hours, and then gradually heated to 80°C over 4 hours.
After heating to .degree. C. and repeating this cycle 100 times, the surface appearance of the sample was evaluated in the same manner as in the weather resistance test. In addition, the peel strength was measured by cutting a test piece with a width of 15 mm (7) from the manufactured reflector for a circularly polarized antenna.
The strength was evaluated when the metal layer was peeled off at 180 degrees at a peeling speed of 50 mm/min using TM D-903 foam. Additionally, bending stiffness was measured according to ASTlt D-790 and coefficient of thermal expansion was measured according to ASTM D-888.

The types and physical properties of the thermoplastic resin, impact-resistant resin, inorganic filler, and metallic shape of the thermoplastic resin layer used in Examples and Comparative Examples are shown below.

[(A) Thermoplastic resin as a thermoplastic resin, melt flowray) (ASTM
D-1238, 0.4 weight of polyvinylidene fluoride (hereinafter referred to as PVdFJ), a benzotriazole-based ultraviolet absorber, with a weight of 8.1g (measured at a temperature of 250°C and a load of 10kg) for 710 minutes. % and 0.5% by weight of carbon black [melt flow index (JIS
Measured according to K-8758 at a temperature of 230°C and a load of 2.18 kg, hereinafter referred to as r MFIJ)
is 0.5g710min, hereinafter referred to as rPP(A)J],
High-density polyethylene containing 0.4% by weight of a benzotriazole-based ultraviolet absorber and 0.5% by weight of carbon black [density 0.858 g/cm'', melt index (according to JIS K-[1780, Measured at a temperature of IEIO ℃ and a load of 2.113 kg, hereinafter referred to as rM, 1.J) is 0.8 g / 1
0 minutes, hereinafter referred to as ``HDPE (1)''] As a mixture, chlorinated polyethylene (chlorine content 3.15% by weight, amorphous, molecular weight of raw material polyethylene approximately 200,000) has a Mooney viscosity (ML1+4) of 108. 20 parts by weight and 8
0 parts by weight of an acrylonitrile-styrene copolymer resin (acrylonitrile content 23% by weight) and 2 parts by weight of a dibutyl tin malate stabilizer [manufactured by Sankyoki Gosei Co., Ltd., trade name: Stann BM] as a stabilizer. Mixing was carried out for 10 minutes using a roll (surface temperature 180°C), and the resulting composition (hereinafter referred to as rACSJ), 20 parts by weight of dioctyl phthalate (as a plasticizer) and 5.0 parts by weight of dibutyltin. A mixture in which malate (as a dehydrochlorination inhibitor) was blended with 100 parts by weight of vinyl chloride homopolymer (degree of polymerization 1100, hereinafter referred to as r, PVCJ) was used.

[(B) Impact-resistant resin] As the impact-resistant resin, AC manufactured as follows
S (1) and AGS (2) and mixture (1) and mixture (2) were used.

[Manufacture of AC3 (1)] Mooney viscosity (MSI + 41
00) is 76 salt/chlorinated polyethylene (chlorine content 40
゜6% by weight, the molecular weight of the raw material polyethylene is approximately 200,000, 11,800g, hereinafter referred to as rai-pE(a)J, 32.0g of polyvinyl alcohol (saponification degree 85%) and 8.0 grams of water (ion exchange water). I prepared it. This was then vigorously stirred at room temperature (approximately 23°C). Add 4560 g of styrene and 1520 g of acrylonitrile as monomers, 320 g of liquid paraffin as a lubricant, and Ifl as a polymerization initiator to this dispersion while stirring at room temperature.
, og of tertiary-natyl peracetate and te, og of tertiary-dodecyl mercaptan as a chain transfer agent were added. After replacing the upper part of the suspension of this reaction system with nitrogen gas, the temperature was raised to 105°C. After polymerization was conducted at this temperature for 4 hours with stirring, polymerization was further conducted at a temperature of 145° C. for 2 hours. After this reaction system was allowed to cool to room temperature, the obtained polymer (graft material) was filtered and thoroughly washed with water. The obtained graft material was dried under reduced pressure at 50° C. all day and night. The polymerization conversion rate (based on the monomer used in the polymerization) was 85.4%, and the product was in the form of a slightly coarse powder. The content of the rubbery material in this graft product [hereinafter referred to as rAcs(1)J] was 20.3% by weight.

To the obtained ACS (1), 2% by weight of a dibutyltin malate stabilizer E (manufactured by Sankyoki Gosei Co., Ltd., trade name: Stann BM) was added, and the surface of the roll was heated to 18% by weight.
Crosstalk was performed for 10 minutes using a roll set at 0°C. The resulting mixture was pressed for 5 minutes under a pressure of 100 kg/c rf using a press set at 200 °C, and then pressed at 100 kg/c rf using a water-cooled press.
Pressing was carried out for 2 minutes under RF pressure. The izot impact strength (with notches) of the obtained pressed plate was 8.0 kg.
Cll1/Cff1, and the tensile strength is 325 kg/
cr'. In addition, the Vicat softening point is 83.8
It was ℃.

[Production of AC3 (2) I The amount of C1-PE (a) used in the production of ACS (1) is e, O kg, and the amount of styrene is 1280 g.
Polymerization was carried out under exactly the same conditions as in the case of ACS (1), except that the amount of acrylonitrile used was changed to 320 g. After the polymerization was completed, filtration, washing with water, and drying were performed in the same manner as in the case of Ac5(i) to produce a polymer (grafted product). The polymerization conversion rate of this graft product (hereinafter referred to as rAC3(2)J) was 85.3%, and it was in the form of a slightly coarse powder. The content of rubbery substances in this ACS (2) is 78
．． It was 6%.

[Production of mixture (1)] Instead of AC3 (1), AC8 (2) and acrylonitrile-styrene copolymer resin [acrylonitrile content: 23% by weight, hereinafter referred to as r ASJ, the mixing ratio of j: Melt-kneading was carried out under the same conditions as in the case of AC8(1) so that the resultant composition was 3. A press plate was produced from the obtained mixture [hereinafter referred to as [mixture (1)]] in the same manner as in the case of Ac5(1). The obtained press plate had an Izo impact strength (notched) of 7.8 kg·cm'/cm, and a tensile strength of 330 kg/cm'. Moreover, the Vicat softening point was 83.7°C.

[Production of mixture (2) I: 100 parts by weight and 400 parts by weight of chlorinated polyethylene (chlorine content 38.2% by weight, amorphous, molecular weight of raw material polyethylene approximately 250,000) having a Mooney viscosity (MS!+4100) of 75 A used in preparing the mixture of
As S and a stabilizer, 2 parts by weight of the dibutyltin malate stabilizer were melt-kneaded in the same manner as in the case of AC8(1). The resulting mixture [hereinafter referred to as "mixture (2)"]
A pressed plate was produced in the same manner as in the case of ACS (1). The obtained press plate had an izot impact strength (notch strength) of 8.0 kg/cm/cm and a tensile strength of 340 kg/cm'. Moreover, the Vicat softening point was 94.5°C.

[(C) Inorganic filler] As the inorganic filler, talc with an average particle size of 3 microns (aspect ratio of about 7), mica with an average particle size of 3 microns (aspect ratio of about 8), glass fiber (
Single fiber diameter 11 microns, cut length 3III11,
(hereinafter referred to as rGFJ), the average grain size is 0.8
Micron calcium carbonate (r CaC03J
) was used.

[(D) Metal foil] Aluminum foil each having a thickness of about 20 microns (
(hereinafter referred to as rAIJ), copper, brass, and silver foils were used.

Examples 1 to 12, Comparative Example 1.2 The thermoplastic resin was molded to produce films each having a thickness of 20 microns. In addition, an acrylic primer (manufactured by Showa Kobunshi Co., Ltd., trade name Vinylol 82) was applied to one side of each metal foil to a thickness of 20 microns, and a urethane primer (manufactured by Toyo Morton Co., Ltd.) was applied to the other side. , trade name Atcoat 335) was applied to a thickness of 20 microns on each surface and dried (in Example 7 and 1O, the urethane-based primer was applied on both sides). In addition, inorganic fillers and impact-resistant resins (
The types of each inorganic filler and impact-resistant resin and the content of the inorganic filler in the composition are shown in Table 1.6 Note that in Comparative Example 2, the inorganic filler was not blended.
Tri-blending was performed using a Henschel mixer for a minute, and each mixture was used to produce a composition using a vented extruder at a resin temperature of 200°C. A sheet having a thickness of 21 mm was manufactured from each of the obtained compositions (pellets) using a T-Guy molding machine.

The thermoplastic resin film produced in this way (not used in Comparative Example 1), the metal foil coated with primer on both sides, and the impact-resistant resin sheet containing an inorganic filler were dry laminated. The laminate was produced by gluing. The obtained laminate was heated to 140°C.
(Surface temperature of laminate)
A reflector for a circularly polarized antenna was manufactured by vacuum forming using a female mold having a shape of 80 mm in height (Example 1.2).

Laminate produced in the same manner as in Examples 1 and 2 (Table 1 shows the types of S filler and impact-resistant resin, the content of inorganic filler in the composition, and the type of metal foil) When the surface temperature is 130°C, the first stage is
30 seconds under pressure of 0 kg/cm' and second stage 5
Stamping was carried out in two stages by holding it under a pressure of 0 kg/cm'' for 29 seconds (the shape of the mold was the same as in Example 1), and a reflector for a circularly polarized antenna was manufactured (Example 3, 4).

After applying the above acrylic primer to one side of each metal foil whose type is shown in Table 1 to a dry thickness of 20 microns, a film of each thermoplastic resin whose type is shown in Table 1 is applied. (thickness 20 microns) was laminated. A urethane primer was applied to the other surface of the metal foil of the obtained laminate in the same manner as in Example 1. The resulting coated laminates were placed in an injection molding machine (clamping force 150α
The thermoplastic resin film was inserted into the mold so that it was in contact with the male surface of the mold. After closing the mold, the injection pressure is 80k.
g/cm' and a resin temperature of 200° C., the types of impact-resistant resin and inorganic filler and the content of the inorganic filler in the composition are shown in Table 1. was subjected to insert injection molding to produce a circularly polarized antenna reflector having the same shape as Example 1 (Example
5-12. Comparative Example 1.2).

The elastic modulus and linear expansion coefficient of the inorganic filler-containing impact-resistant resin layer of each circularly polarized antenna reflector obtained as described above, and the peel strength of the metal foil from the inorganic filler-containing impact-resistant resin layer. Measurements were made. those results first
Shown in the table.

(The following is a blank space) When the radio wave reflectance of each circularly polarized antenna reflector obtained as described above was measured, it was 88% in all cases. Furthermore, weather resistance tests and heat cycle tests were conducted, but no harmful changes such as discoloration, fading, change in gloss, crazing, blistering, peeling of metal foil, or cracks were observed on the surface of all cases except for Comparative Example 1. Ta. However, in Comparative Example 1, the aluminum foil on the surface corroded.

[Brief explanation of drawings]

FIG. 1 is a partial perspective view of an antenna to which a typical reflector for a circularly polarized antenna manufactured according to the present invention is attached. Moreover, FIG. 2 is a sectional view of the reflector for the circularly polarized antenna. Furthermore, FIG. 3 is a partially enlarged view of the cross-sectional view. A...Reflector for circularly polarized antenna, B...Converter, C...Converter support rod, D...Reflector support rod, E...Wiring, 1...Inorganic filler-containing resistance Impact resin layer, 2...metal layer (metal foil), 3...thermoplastic resin layer with excellent weather resistance, 2a...primer layer, 2b...primer layer Patent applicant Showa Denko K.K. Agent Patent Attorney Sei Kikuchi - Figure 1, Figure 2, Figure 3

Claims (1)

[Claims] A thermoplastic resin layer with excellent weather resistance, a metal layer that reflects radio waves, and an impact-resistant resin layer containing an inorganic filler are sequentially laminated, and the thickness of the thermoplastic resin layer is 5 microns to 5 m.
m, the thickness of the metal layer is 5 microns to 1 mm, and the thickness of the impact-resistant resin layer containing an inorganic filler is 0.5
mm to 15 mm, the content of inorganic filler in this layer is 10 to 80% by weight, and the impact resin is chlorinated polyethylene, chlorinated polyethylene with styrene and at least - other vinyl compounds. An impact-resistant resin containing at least one of a graft copolymer obtained by graft copolymerizing and a copolymer of styrene and at least one other vinyl compound (However, in the impact-resistant resin, A reflector plate for a circularly polarized antenna, characterized in that the total amount of chlorinated polyethylene and chlorinated polyethylene graft copolymerized with styrene and at least one other vinyl compound is 5 to 40% by weight. .