JPS61161004A - Manufacture of reflecting plate for circularly polarized wave antenna - Google Patents

Abstract

PURPOSE:To eliminate the cut-off of a metallic layer after forming by applying injection-molding of a thermoplastic resin contg. an inorganic packing agent to a thermoplastic resin layer of a laminated metallic layer to a prescribed thickness. CONSTITUTION:The thermoplastic resin layer of the laminated metallic layer 3 to a male metallic die 1 is mounted to the moving part of the metallic die. After the metallic die is closed, a thermoplastic resin contg. an inorganic packing agent undergoes injection molding from a gate 4. The resin is formed so as to be made thin sequentially so that the thickness of the peripheral part is 1/6-5/6 to the thickness of the center part. In forming a reflecting plate in this way, the cut-off of the metallic layer after forming is avoided.

Description

[Detailed Description of the Invention] CI) Purpose of the Invention (Industrial Field of Application) The present invention is directed to the manufacture of a reflector for a circularly polarized antenna, in which the thickness of the circumference is thinner than the thickness of the center of the reflector. Regarding the method. More specifically,
To manufacture a reflector for a circularly polarized antenna, which is formed by sequentially laminating a thermoplastic resin layer with excellent weather resistance, a metal layer that reflects radio waves, and a thermoplastic resin layer containing an inorganic filler.

A metal foil thermoplastic resin laminated with a thermoplastic resin with excellent weather resistance is attached in advance to the moving side of the injection mold, and after the mold is closed, the inorganic filler-containing fJ%i+) plasticity The reflector for circularly polarized antenna is characterized by being injection molded and molded so that the thickness of the circumferential part becomes 176 to 5/6 of the thickness of the center part of the reflector plate for circularly polarized antenna. The present invention relates to a method for manufacturing a reflector for a circularly polarized antenna, and its purpose is to provide a reflector for a circularly polarized antenna that solves the problem of cutting the metal layer after molding and has improved strength against external pressure. It is something.

(II) Background of the invention (prior art and problems to be solved by the invention) High-definition television broadcasting using geostationary satellites, still W-picture broadcasting, text multiplex broadcasting, PCM (pulse code modulation) audio broadcasting, facsimile r Satellite broadcasting, such as Broadcasting, is planned to be put into practical use in the near future in Europe, the United States, Japan, and other countries around the world, and some of it has already been put into practical use.

In a satellite broadcasting system, plans are being made to use circularly polarized waves for broadcasting satellite radio waves when receiving radio waves from broadcasting satellites. On the other hand, conventional circularly polarized antennas include those using a conical horn, two dipoles combined 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 waveguide extends in the axial direction from the center of a parabolic reflector, and its tip is curved so that the opening end face is located at the focal point of the parabolic reflector. There is a so-called Hehat-type parabolic antenna which is arranged to face a parabolic reflector and is combined with a -order radiator. This antenna is widely used in microwave antennas for mobile relays, etc., but all conventional Heehat-type parabolic antennas use the waveguide described above to transmit and receive linearly polarized waves. , cannot be used for circularly polarized waves.

Generally, 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, with anti-corrosion coatings, it is necessary to repeat the coating several times to achieve complete corrosion protection, which is not only expensive but also
There is a problem in that the painted material deteriorates after being used for many years. In addition, even if a parabolic antenna with a predetermined shape is molded, it cannot be said to be fixed after molding.Furthermore, glass fibers or carbon fibers whose surfaces are metalized as a radio wave reflective layer on thermosetting resin such as unsaturated polyester resin. Attempts have been made to manufacture a radio wave reflecting plate made of laminated fibers, but the manufacturing method is complicated and it is extremely difficult to maintain the radio wave reflecting layer at a constant thickness and without unevenness. Furthermore, the radio wave reflection characteristics are inferior.

In addition, a parabolic antenna has been proposed in which an aluminum plate is used as a radio wave reflection layer and an olefin resin containing glass mat is formed as a base layer by compression molding. It is difficult to insert mold bosses etc.

Based on these facts, the inventors conducted various searches to obtain a reflector for circularly polarized antennas that has a simple manufacturing process, has radio wave reflecting ability, and can maintain its performance for a long period of time. , a laminate consisting of at least (A) a thermoplastic resin layer with good weather resistance, (B) a metal layer, and (C) a thermoplastic resin layer containing an inorganic filler in mM, and the thickness of the thermoplastic resin layer The diameter is 5 microns to 5+ am.

The thickness of the metal layer is 5 microns to 1 mm, and the thickness of the inorganic filler-containing thermoplastic resin layer is 500 microns to 15III, and the content of inorganic filler in this layer is 10 to 80% by weight. A reflector for circularly polarized antennas is characterized by:

We discovered that it not only has excellent durability, but also has good radio wave reflection characteristics, and also exhibits various effects, and has previously proposed (for example, Japanese Patent Application Nos. 59-8535, 59-9485, No. 59-9466, No. 59-14
No. 478, No. 59-2185fi, No. 59-2894
No. 5, No. 51a-66852).

However, in the obtained reflector for a circularly polarized antenna, wrinkles occur around the circumference of the radio wave reflecting surface, and unevenness due to sink marks occurs around the circumference. Furthermore, the metal layer may be cut.

Moreover, not only does the resulting molded product undergo harmful deformation such as twisting, but it is also necessary to increase the injection pressure during molding.

(m) Structure of the Invention (Means for Solving the Problems) Based on the above, the present inventors have found that the above-mentioned problems have been improved, the strength against external pressure is excellent, and the As a result of various searches to obtain a reflector for a circularly polarized antenna without cutting the metal layer (generally metal foil), we found a thermoplastic resin layer with excellent weather resistance, a metal layer that reflects radio waves, and an inorganic filler. In manufacturing a reflector for a circularly polarized antenna in which thermoplastic resin layers are sequentially laminated, metal foil laminated with a thermoplastic resin layer with excellent weather resistance, ``thermoplastic resin'' [hereinafter referred to as ``thermoplastic resin''] is used. The plastic resin (1) layer is attached in advance to the moving side of the mold for the injection molding machine.
After closing the mold, the inorganic filler-containing "thermoplastic resin"
A thermoplastic resin (II) J is injection molded and is gradually thinned so that the thickness of the circumferential part is 176 to 5/6 of the center of this circularly polarized antenna reflector. The method for manufacturing a reflector for a circularly polarized antenna, which is characterized by forming the reflector as shown in FIG. The present invention was achieved based on the discovery that

(IV) Detailed Description of the Invention (A) 8 Plastic Resin (I) The thermoplastic resin (I) 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 1
It is from 10,000 to 1,000,000. Typical thermoplastic resins (I) include monomers having double bonds such as ethylene, propylene, vinylidene fluoride, vinyl chloride, and styrene, which are the main components (50-ME
ffi% or more), styrene and acrylonitrile copolymer (AS resin), methitadiene copolymer rubber, acrylonitrile-butadiene copolymer rubber (N
BR), styrene-butadiene copolymer rubber (SBR)
, acrylic rubber, ethylene-propylene copolymer rubber (
Styrene alone or styrene and other vinyl compounds (
For example, acrylonitrile, methyl methacrylate)
Examples include graft copolymer resins, polyamide resins, polyester resins, polyphenylene oxide resins, and polycarbonate resins obtained by graft copolymerizing with. Furthermore, these thermoplastic resins contain organic compounds having at least one double bond (for example,
Even resins modified by grafting with unsaturated carboxylic acids and their anhydrides can be preferably used as long as they have excellent processability. Furthermore, in addition to the graft copolymer resins described above, 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, even with vinyl chloride-based resins, ethylene and/or propylene-based resins, the weather resistance of these formulations can be improved by adding UV absorbers. You can use it as you like. 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 polymerization of an unsaturated carboxylic acid and its anhydride (preferably an unsaturated carboxylic acid and its anhydride) because it has excellent adhesion to metals described below.

(B) Metal Further, 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, These metals do not need to be surface-treated, and may be pre-treated with chemical treatment or plating, and coated or printed metals are also preferable. It can be used with

(C) Thermoplastic resin (■) In addition, the thermoplastic resin (■) used to manufacture the inorganic filler-containing thermoplastic resin layer of the present invention is the same type as the above-mentioned thermoplastic resin (I). can do. Among these thermoplastic resins (II), acrylonitrile-butadiene terpolymerization obtained by graft copolymerizing 7-acrylonitrile and styrene onto propylene resin (pp), butadiene rubber, acrylonitrile-butadiene rubber, or styrene-butadiene rubber. resin (ABSI resin), ternary copolymer resin CAC3 resin obtained by graft copolymerizing chlorinated polyethylene with 7-crylonitrile and styrene), polyphenylene oxide resin (PPO resin), polyethylene terephthalate (PET), ;t 'Libutylene terephthalate (PBT) and polycarbonate resin (PC resin) are mentioned.

(D) Inorganic filler Further, the inorganic filler used to produce the inorganic filler-containing thermoplastic 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 do not decompose during kneading and molding. The inorganic fillers include metals such as aluminum, copper, iron, lead and nickel, and these metals as well as magnesium, calcium, barium,
Oxides of metals such as zinc, zirconium, molybdenum, silicon, antimony, titanium, etc., and their hydrates (hydroxides)
It is broadly classified into compounds such as sulfates, carbonates, silicates, their double salts, and mixtures thereof. Typical examples of the inorganic filler include the above-mentioned metals, aluminum oxide (
alumina), its hydrates, calcium hydroxide, magnesium oxide (magnesia), magnesium hydroxide, zinc oxide (zinc oxide), lead oxides such as red lead and white lead, magnesium carbonate, calcium carbonate, basic carbonate. Magnesium, white carbon, asbestos, mica, talc, glass fiber, 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 mm or less (preferably 0.5 mm).
5+am or less) is preferable, and maa-like ones have a diameter of 1 to 500 microns (preferably 1 to 300 microns).
microns), and the length is preferably 0.1 to 8 mraC, preferably 0.1 to 5 mm).Furthermore, the flat plate-like diameter is preferably 2 mm or less (preferably laW or less). ) (E) Structure of each layer (1) Thermoplastic resin layer The thermoplastic resin layer of the present invention serves as a WA coating to prevent corrosion of the metal layer described later. For this reason, the thickness is usually 5 microns to 5 μl, preferably 10 microns to 5 m, particularly 10 microns to lsm.
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 51, 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 (metal foil) Furthermore, the metal layer of the present invention functions to reflect radio waves. The thickness of this metal layer is generally between 5 microns and lam, preferably between 5 and 500 microns, particularly between 10 and 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 10111, not only will the weight increase, but also the cost will increase, and furthermore, it will cause problems when bending or bending the laminate.

(3) Inorganic filler-containing thermoplastic resin layer The plasticity ratio of the inorganic filler in the inorganic filler-containing thermoplastic resin layer of the present invention is 10 to 80% by weight [i.e., the composition of thermoplastic resin (II)] The proportion is 80-20% by weight
], 10 to 70% by weight is preferred, particularly 10 to 80% by weight. If the composition ratio of the inorganic filler in the inorganic filler-containing thermoplastic resin layer is less than 10% by weight, the linear expansion coefficient of the inorganic filler-containing thermoplastic resin layer will be too different from that of the metal layer, and the metal will There is a problem that not only may peeling occur between the layer and the inorganic filler-containing thermoplastic resin layer, but also that the resulting laminate lacks rigidity. On the other hand, if it exceeds 80% by weight, it is difficult to produce a uniform composition, and even if a uniform composition is obtained, it is difficult to produce a laminate by sheet production or injection molding as described below. In this case, it is not possible to obtain a good product (laminate).

The thickness of this inorganic filler-containing thermoplastic resin layer will be explained in detail later.

In producing the thermoplastic resin layer with excellent weather resistance and the inorganic filler-containing thermoplastic resin layer, stabilizers against oxygen, heat and ultraviolet rays, metal deterioration inhibitors, and flame retardants commonly used in the respective fields are used. Additives such as additives, colorants, electrical property modifiers, antistatic agents, lubricants, processability modifiers, and tack modifiers are added to the compositions of the thermoplastic resin layer and inorganic filler-containing thermoplastic resin layer of the present invention. It may be added as long as it does not impair the properties of the compound.

When blending the above-mentioned additives into the thermoplastic resin with excellent weather resistance of the present invention, and when producing an inorganic filler-containing thermoplastic resin layer (including the case where the above-mentioned additives are blended), it is common practice in each industry. It may be triblended using a mixer such as a conventional Henschel mixer, or may be obtained by melt-kneading using a mixer such as a Banbury mixer, Niegoo, roll mill, or screw extruder. At this time, a homogeneous composition can be obtained by triblending in advance and melt-kneading the resulting composition (R compound).

In particular, thermoplastic resin (I) and thermoplastic resin (I
It is preferable to use both of I) in the form of powder because it allows for more uniform mixing.

In this case, the mixture is generally melt-kneaded and then molded into a pellet-like material, which is then subjected to the molding described later.

In producing the inorganic filler-containing thermoplastic resin of the present invention, 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 It may be mixed with the remaining ingredients.

When melt-kneading is carried out in the production of the above blend, it must be carried out at a temperature higher than the melting point or softening point of the thermoplastic resin (I) or thermoplastic resin (■) used, but if carried out at a high temperature, Thermoplastic resin (I) and thermoplastic resin (■) are degraded by thermoplastic resin (■). Therefore, in general, the melting point or softening of each thermoplastic resin (I) or thermoplastic resin (II) is 2 than points
It is carried out at temperatures as high as 0"O (preferably above 50°C), but within a temperature range that does not cause deterioration.

(F) Method for manufacturing laminated metal foil In the present invention, the method for laminating the thermoplastic resin layer on the metal foil is the commonly practiced dry lamination method (
This can be achieved by applying an extrusion lamination 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. It is possible to take out. To produce laminated metal foil using the extrusion lamination method, a thermoplastic resin (I ) is extruded to the above-mentioned thickness and simultaneously bonded to the metal foil using a cooling pressure roll.

When using a thermoplastic resin (I) that has excellent adhesion to metal foil, a laminated metal foil can be produced as described above. However, if the thermoplastic resin (I) does not have sufficient adhesion to the metal foil, a primer (anchor coating agent) commonly used in the field of thermoplastic resins may be applied to the metal foil in advance. Coated on one side by gravure coating method or perspective coating method, 50~
Dry at 100°C. Next, a film or sheet of thermoplastic resin is applied on the primer surface of the metal foil for 50 to 10 minutes.
Pressure bonding is performed using a pressure bonding roll heated to 0°C.

The primer differs depending on the type of thermoplastic resin in the thermoplastic resin layer and the olefin polymer in the olefin polymer layer, but it is commonly used in various fields, and there are aqueous types and solvent types. Further, types include polyurethane adhesives, epoxy resins, polyester resins, acrylic resins, and cyanoacrylate resins. Among these adhesion agents,
In particular, polyurethane adhesives are preferred because they have good durability under cold/hot cycles and high temperature environments, and have high adhesive strength. Polyurethane adhesives are basically made of polyester polyol, polyether polyol, or polyurethane polyol, and diisocyanate. It is obtained by reacting. These adhesion-imparting agents are generally widely used, for example, in the Adhesive Handbook edited by the Japan Adhesive Association (
This is known from publications such as November 10, 1980, published by Nikkan Kogyo Shimbun.

The laminated metal foil (metal layer) manufactured in this manner will be explained with reference to FIG. 4. FIG. 4 is a partially enlarged sectional view of the laminated metal foil. In this drawing, A is a thermoplastic resin layer with excellent weather resistance,
B is a metal layer (metal foil). Furthermore, C1 and C2 are single-layer primers (in addition, if one or both of the primers is not used,
C1 and/or C2 are not present).

(G) Manufacture of reflector for circularly polarized antenna The thermoplastic resin layer of the laminated metal foil obtained in the above manner is attached to the mold surface on the moving side of the mold of an injection molding machine. Close the mold.

Next, the reflective plate for a circularly polarized antenna of the present invention can be manufactured by injection molding the inorganic filler-containing thermoplastic resin. At this time, the injection molding temperature is the resin temperature, which is the thermoplastic resin (II) of the inorganic filler-containing thermoplastic resin.
), but the temperature is higher than the melting point of the thermoplastic resin (II
) is lower than the thermal decomposition temperature of Therefore, the molding temperature varies depending on the type of thermoplastic resin 1) used. The range of molding temperatures for typical thermoplastic resins (II) is shown below.

Type Molding temperature range (”O) P P
170~290ABS resin 200
~280 AC3 resin 160~240 PPO resin 220~300 PET 250~300P
B T 230-280P
C250-300 In addition, if the injection pressure is 40Kg/crn' or higher at the nozzle part of the cylinder of the injection molding machine, the thermoplastic resin containing the inorganic filler will be shaped into a shape almost similar to the shape of the mold. Not only can it be used, but also a product with good appearance can be obtained. Injection pressure is generally 40 to 14
0 Kg/c rn', especially TO~120
Kg/cm'' is desirable.

The above injection molding will be explained in an easy-to-understand manner using drawings.

FIG. 5 is a sectional view before injection molding, and FIG. 6 is a sectional view after injection molding. In these drawings, 1 is the male mold and 2 is the female mold. Further, 3 is a laminated metal foil, and 4 is a female gate. moreover,
5 is a thermoplastic resin layer containing an inorganic filler. First, the fifth
The thermoplastic resin layer of the metal foil laminated on the male die 1 of the die shown in the figure is attached to the male die of the die so that it is on the moving side of the die. Then, after closing the mold, a thermoplastic resin containing an inorganic filler is injection molded through the gate 4 under the conditions of the resin temperature and injection pressure (the state at this time is shown in FIG. 6). Note that the injection molding machine used is not unique to the present invention, but may be one used in the field of general thermoplastic resins, and the operating conditions are also the same as in the usual case.

(H) Reflector for Circularly Polarized Antenna The reflector for circularly polarized antenna of the present invention obtained in the following manner will be explained 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. Moreover, FIG. 3 is a partially enlarged view of the cross-sectional view. In FIG. 1, numeral 1 is a reflector for a circularly polarized antenna of the present invention, II is a converter, ▪ is a converter support rod, and lV is a reflector support rod. Also,
■ is the wiring. In addition, in Figures 2 and 3,
A is a laminated metal foil, and b is a thermoplastic resin layer containing an inorganic filler. Furthermore, A is a thermoplastic resin layer with excellent weather resistance, and B is a metal foil. Also, D
is an inorganic filler-containing thermoplastic resin layer consisting of an inorganic filler and a thermoplastic resin (II). Furthermore, although C1 and C2 are primer layers, one or both may be absent. Furthermore, in order to attach the circularly polarized antenna reflector obtained in this way to a support, ribs may be provided to enable attachment to the inorganic filler-containing thermoplastic resin layer. You can also add reinforcing ribs to strengthen the board. 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. , and the diameter of the reflector for the circularly polarized antenna is usually 80 cm to 120 cm.
It is.

The thickness of the inorganic filler-containing thermoplastic resin layer of this circularly polarized antenna reflector is usually 3 to 10 a+m at the center,
Especially desirable is 3~8■, and 2~8Ilf in the peripheral area.
fl, and particularly preferably 2 to 6 ■. However, the thickness of the peripheral part is 1/6 to 5/6 of the thickness of the center part.
In particular, 1/4 to 5/6 is preferable. If the thickness of the peripheral part is less than 176% of the thickness of the center part, the thickness of the peripheral part becomes very thin, and the strength against external pressure only decreases. However, the moldability deteriorates. On the other hand, if it exceeds 5/6, the peripheral part becomes thicker than the center part, which not only makes the circularly polarized antenna reflector heavier, but also makes the metal layer (metal foil) easier to cut, and the molded product Harmful deformations such as twisting occur. The thickness of this inorganic filler-containing thermoplastic resin layer does not necessarily have to become thinner linearly from the center toward the periphery, but may be made thinner sequentially.

(V) Effects of the Invention The circularly polarized antenna reflector manufactured by the present invention exhibits the following effects (features) including its manufacturing process.

(1) Due to its 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 olefin polymer layer is extremely small, peeling does not occur in the living room even when 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) Olefinic polymers containing inorganic fillers can be easily formed into various complex shapes, and therefore have good appearance and functionality.

(6) The laminated metal foil is easy to handle;
For example, it is possible to store it in a roll.

(7) When setting the laminated metal foil in the mold during injection molding, the laminated metal foil can be used in the form of a roll, so it can be continuously supplied, increasing productivity. is significantly improved.

(8) It can be easily molded even when the injection molding pressure is low.

(8) When attaching a boss to be inserted into the back surface, the thickness of the center part is thick, so unevenness due to sink marks etc. does not occur on the reflective surface.

(Vl) Examples and Comparative Examples The present invention will now be explained in more detail with reference to Examples.

In the Examples and Comparative Examples, the radio wave reflectance was measured as a microwave reflection coefficient from the voltage standing wave ratio when a waveguide was used and the tip of the waveguide was short-circuited. Weather resistance tests were conducted using a Sunshine Carbon Weather Meter with a black panel temperature of 83°C and a due cycle of 1.
Surface appearance after 2,000 hours under conditions of 2 minutes/(60 minutes irradiation) (discoloration, fading, gloss change, crazing, blistering,
Detrimental changes such as peeling and cracking of the metal foil were evaluated. Furthermore, a heat cycle test was performed in which 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 ℃ and repeating this cycle 100 times,
The appearance of the surface 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 15ffi from the manufactured reflector for circularly polarized antenna.
In accordance with STM D-i303, the strength was evaluated by peeling a laminated metal foil at a peeling rate of 50 cm/min at 180 degrees.

In this column of Table 1, "cohesive failure" refers to the fact that the adhesive strength between the laminated metal foil and the inorganic filler-containing olefin polymer layer is too strong, causing the metal foil to break. Additionally, bending stiffness was measured according to ASTM D-790, and coefficient of thermal expansion was measured according to ASTM [1-896.

In addition, thermoplastic resin (I) and thermoplastic resin (TI) of the thermoplastic resin layer used in Examples and Comparative Examples
, the types and physical properties of the inorganic filler and metal foil are shown below.

[(A) Thermoplastic resin (I)]

Melt 7 is a thermoplastic resin (I) with excellent weather resistance.
a-rate (measured according to ASTN D-1238 at a temperature of 250°C and a load of 10 kg) is 8
．． Polyvinylidene fluoride (hereinafter referred to as “P
VdFJ), propylene homopolymer C containing 0.4% by weight of a benzotriazole-based ultraviolet absorber and 0.5% by weight of Garpon black melt flow index (according to JIS K-8758), Measured at 230°C and a load of 2.16 kg, 0.5 g 710 minutes, hereinafter referred to as rPP(A) J), 0.4% by weight of hensitriazole ultraviolet absorber. and high-density polyethylene containing 0.5% by weight of carhon plaque [density 0.
J58g/c rn', Melt in Day, Kusu (JIS
According to K-137BO, measured at a temperature of 180°C and a load of 2.18 kg, hereinafter referred to as "ni,!") was 0-8 g / 10 minutes, hereinafter rHOPE (1) J
] as a mixture.

Chlorinated polyethylene with a Mooney viscosity (NLl, 4) of 108 (chlorine content 3.15% by weight, non-grade, raw material polyethylene molecular weight approximately 200,000) 20 parts by weight and 80 parts by weight of 7-crylonitrile-styrene. Polymer resin (acrylonitrile content 23% by weight) and as a stabilizer 2
Parts by weight of a dibutyltin malate stabilizer (manufactured by Sankyoki Gosei Co., Ltd., trade name: Stann) BNI was mixed for 10 minutes using a roll (surface temperature 180°C), and the resulting composition (rAC5J) ) and 20-layer it
part of dioctyl phthalate (as a plasticizer) and 5.
A mixture of 0 parts by weight of dibutyltin malate (as a dehydrochlorination inhibitor) and 100 parts by weight of vinyl chloride homopolymer (degree of polymerization 1100, hereinafter referred to as r rPVc J ) was used.

[(B) Thermoplastic resin (■)]

The following thermoplastic resin was used as the thermoplastic resin (II) used to produce the inorganic filler-containing thermoplastic resin.

(+) Olefin polymer As an olefin polymer, MFI is 2.0g/1
0 minute propylene homopolymer [rPP (B)
J], a propylene-ethylene block copolymer with an MFI of 15 g/10 min [ethylene content
Medium density polycarbonate resin (density 1.2/cm', MFI 4.5g) manufactured using 15-layer A as the main raw material
/ 10 minutes, using a computer (hereinafter referred to as "PC").

(3) Acrylonitrile-butadiene-styrene ternary copolymer resin (ABS resin) As the acrylonitrile-butadiene-styrene ternary copolymer resin, ABS resin (hereinafter rABs J
) was used.

(4) Acrylonitrile-chlorinated polyethylene-styrene ternary copolymer resin (CACB resin) Acrylo and tolyl-chlorinated polyethylene-styrene ternary copolymer resin used in the examples and comparative examples of JP-A-58-191751. A grafted product (hereinafter referred to as rAcsJ) was produced in the same manner as ACS (1), and this ACS was
Similar to No.-191751, a dibutylmalate stabilizer was mixed and used.

Further, in the same manner as the mixture (2) used in the Example of No. 58-191751, chlorinated polyethylene, acrylonitrile-styrene copolymer resin, and a stabilizer were mixed, and the resulting mixture was used.

(5) As an aromatic polyester, the intrinsic viscosity is 0.65
polyethylene terephthalate (rPET J)
) and polybutylene terephthalate (hereinafter referred to as rPBT) having an intrinsic viscosity of 0.85 were used.

(6) Modified PPO (grafted product) Modified PPO produced as follows was used.

First, 2,8-xylenol was polycondensed by an oxidative coupling method, and poly-2,6-dimethylphenylene-1.
4-ether [intrinsic viscosity (measured in chloroform at 3oC, unit dl/g) 0.53, hereinafter referred to as rPPo J] was produced. 100 parts by weight of PPO, 25 parts by weight of styrene monomer, 10 parts by weight of styrene homopolymer [melt flow index (measured according to JIS K-8870, at a temperature of 2.18 kg and a load of IOK) 13.0 g 710 minutes] and 2.1 parts by weight of di-tertiary-butyl peroxide were mixed for 10 minutes using a Henschel mixer, and then mixed using a twin screw extruder (diameter 30
a+m, resin temperature 270° C.) to produce a styrene-grafted PPO alloy [hereinafter referred to as “modified PPOJ”].

[(C) Inorganic filler j As an 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 Calcium carbonate (hereinafter referred to as rcacOsJ) having an average particle size of 11 microns and a cut length of 3 mm (hereinafter referred to as rGFJ) and an average particle size of 50.8 microns were used.

[(D) Metal foil]

Aluminum (each approximately 20 microns thick)
(hereinafter referred to as rAiJ), copper and brass foils were used.

Examples 1-6, Comparative Examples 1-9 The above pva'! ' [as thermoplastic resin (I)] was molded to form a film with a thickness of 100 microns.

In addition, an acrylic primer (manufactured by Showa Kobunshi Co., Ltd., trade name: Vinyroll 82T) was applied to one side of the An foil to a thickness of 20 microns.

A urethane primer (manufactured by Toyo Morton Co., Ltd., trade name: Atocoat 335) was applied to the other surface to a thickness of 20 microns and dried.

Furthermore, 30 parts by weight of GF (as an inorganic filler) and P
70 parts by weight of P(C) [as thermoplastic resin (II)] were triblended for 5 minutes each using a Henschel mixer. Pellets (composition) were produced from the resulting mixture using a vented extruder at a resin temperature of 230°C.

The laminated metal foil produced as described above was placed on the male mold surface (
A thermoplastic resin layer with excellent weather resistance was inserted on the moving side of the mold. Table 1 shows the thickness distribution at the center (the ratio of the thickness at the circumference to the thickness at the center).

In Table 1, "AM cutting" was evaluated by visually observing the appearance. In this section, "o" means that there was no breakage cut, and "x" means that there was cut of the Al foil. ′°Deformation of reflector°°
After the obtained molded product (reflector plate) was laid down on a horizontal surface, it was determined by the deviation of the entire circumference from the horizontal surface. In this section, "O" means that there was no deviation from the horizontal plane, "Δ" means that there was a slight deviation from the horizontal plane, and "×" means that there was a considerable deviation from the horizontal plane. . In addition, "°Moldability was determined by the amount of inorganic filler-containing thermoplastic resin wrapped around the circumference of the obtained molded product. In this section, rOJ means that it was wrapped around the entire surface of the mold, "Δ" means that it did not go around the circumference a little, and "x" means that it did not go around the entire inner circumference. Furthermore, "sink marks" were judged based on the presence or absence of unevenness at the center and circumference. In this section, "Q" means that there was no unevenness at the center or circumference, and "× ” means that unevenness occurred. Table 1 shows the evaluation results of the obtained molded product (reflection plate).

(Left below) Examples 7 to 28, Comparative Example 10.11 Thermoplastic resins CI) whose types are shown in Table 2 were molded to produce films each having a thickness of 100 microns. Further, on one side of each metal foil whose type is shown in Table 2, an acrylic primer was applied to one side and an urethane primer was applied to the other side in the same manner as in Example 2, and then dried (slicked, Examples 14 to 17). Now apply urethane primer on both sides)
In addition, in Examples 27 and 28, a modified propylene polymer (modification amount: 085% by weight) obtained by grafting maleic anhydride to pp(A) on both sides of the aluminum foil was coated to a thickness of 60 microns. It was extruded and laminated.

Furthermore, inorganic filler and thermoplastic resin (II) [respective inorganic filler and thermoplastic resin preparations were carried out. Compositions were produced using a vented extruder while kneading each of the obtained mixtures under the resin temperature conditions shown in Table 2.

The laminated metal foil obtained as described above was inserted into the mold of an injection molding machine in the same manner as in Example 2 so as to form the male surface of the mold. After closing the mold, the thermoplastic resin (II) containing an inorganic filler was injected at a pressure of 80K as in Example 2.
Insert injection molding was performed under the conditions shown in g/cm'$ and the resin temperature shown in Table 2 to produce a reflector for a circularly polarized antenna having the same shape as in Example 2.

Measurement of the peel strength of the metal foil from the inorganic filler-containing thermoplastic resin layer of each reflective plate obtained as described above, and measurement of the flexural modulus and linear expansion coefficient of each inorganic filler-containing thermoplastic resin composition. I did this. Those results in the third
Shown in the table.

(The following is a blank space) Note that in all of the circularly polarized antenna reflectors obtained in Examples 7 to 28, no cutting of the AIL foil could be observed. Also, regarding the deformation of the reflector,
There was no deviation from the horizontal plane, and regarding moldability, the inorganic filler-containing thermoplastic resin was evenly distributed over the entire surface of the mold. Furthermore, regarding sink marks, no unevenness could be observed at the center or circumference of the reflector.

When the radio wave reflectance of each of the circularly polarized antenna reflectors obtained as described above was measured, it was 98%. Furthermore, a weather resistance test and a heat cycle test 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 samples except for Comparative Example 11. . However, in Comparative Example 11, the aluminum foil on the surface corroded.

[Brief explanation of the drawing]

FIG. 1 is a partial perspective view of an antenna to which a reflector for a circularly polarized antenna is attached, and FIG. 2 is a sectional view of the reflector for a circularly polarized antenna. Moreover, FIG. 3 is a partially enlarged view of the cross-sectional view. Furthermore, FIG. 4 is a partially enlarged sectional view of the laminated metal foil. Moreover, FIG. 5 is a sectional view before injection molding, and FIG. 6 is a sectional view after injection molding. ■・・・Reflector plate II for circularly polarized antenna...
・Converter■・・・Converter support rod■・・・Reflector support rod■・・・Wiring A・・・Thermoplastic resin layer B with excellent weather resistance...
...Metal foils C1 and C2 ... Primer layer D ...
- Inorganic filler-containing thermoplastic resin layer a... Laminated metal foil b... Inorganic filler-containing thermoplastic resin layer l... Male mold 2 of the mold. ... Female mold 3 ... Laminated metal foil 4 ...
female gate

Claims (1)

[Claims] In manufacturing a reflector for a circularly polarized antenna, which is made up of a thermoplastic resin layer with excellent weather resistance, a metal layer that reflects radio waves, and a thermoplastic resin layer containing an inorganic filler, which are successively laminated, thermoplastic resin with excellent weather resistance is used. A thermoplastic resin layer of metal foil laminated with resin is attached in advance to the moving side of the injection mold, and after the mold is closed, a thermoplastic resin containing an inorganic filler is injection molded, and this circular deviation is A reflector for a circularly polarized wave antenna, characterized in that the reflector for a circularly polarized wave antenna is formed so that the thickness of the circumferential portion thereof becomes gradually thinner to 1/6 to 5/6 of the thickness of the center portion of the reflector for a circularly polarized wave antenna. Method of manufacturing the board.