EP0142180A1 - Method of making a moulded body of plastic material covered by a metallic layer, and plane antenna so realized - Google Patents

Method of making a moulded body of plastic material covered by a metallic layer, and plane antenna so realized Download PDF

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Publication number
EP0142180A1
EP0142180A1 EP84201264A EP84201264A EP0142180A1 EP 0142180 A1 EP0142180 A1 EP 0142180A1 EP 84201264 A EP84201264 A EP 84201264A EP 84201264 A EP84201264 A EP 84201264A EP 0142180 A1 EP0142180 A1 EP 0142180A1
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EP
European Patent Office
Prior art keywords
mold
plastic
metal
layer
demolding
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EP84201264A
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German (de)
French (fr)
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EP0142180B1 (en
Inventor
Michel Jean-Claude Monnier
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Laboratoires dElectronique Philips SAS
Koninklijke Philips NV
Original Assignee
Electronique & Physique
Laboratoires dElectronique Philips SAS
Laboratoires dElectronique et de Physique Appliquee
Philips Gloeilampenfabrieken NV
Koninklijke Philips Electronics NV
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Publication of EP0142180A1 publication Critical patent/EP0142180A1/en
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01P—WAVEGUIDES; RESONATORS, LINES, OR OTHER DEVICES OF THE WAVEGUIDE TYPE
    • H01P11/00—Apparatus or processes specially adapted for manufacturing waveguides or resonators, lines, or other devices of the waveguide type
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D1/00—Electroforming
    • C25D1/20—Separation of the formed objects from the electrodes with no destruction of said electrodes
    • C25D1/22—Separating compounds
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01Q—ANTENNAS, i.e. RADIO AERIALS
    • H01Q15/00—Devices for reflection, refraction, diffraction or polarisation of waves radiated from an antenna, e.g. quasi-optical devices
    • H01Q15/14—Reflecting surfaces; Equivalent structures
    • H01Q15/141—Apparatus or processes specially adapted for manufacturing reflecting surfaces
    • H01Q15/142—Apparatus or processes specially adapted for manufacturing reflecting surfaces using insulating material for supporting the reflecting surface

Definitions

  • the invention relates to a method for producing a molded plastic body coated with a metallic layer and finds its application in the manufacture of planar microwave antennas composed of radiating elements with microstrip lines associated with a dielectric substrate.
  • these antennas consist of two metal plates in which are made, on the one hand, openings directed towards the propagation medium, constituting the radiating elements, and on the other hand, a network of piping intended to receive central conductors.
  • the latter carried by a dielectric film sandwiched between the two plates metallic q ues, constitute, with the radiating elements and the grooves, the antenna feed network.
  • the total area of these antennas can range from a few square centimeters to several square meters.
  • Such antennas are of growing interest because they find their application in the reception of television programs relayed by satellites.
  • Many other planar antenna structures have been proposed in recent years, but these structures do not meet the conditions imposed by the specifications of the CCIR (International Radio Consultative Committee) whereas the planar antennas produced according to patent applications cited have low losses, high gain and wide bandwidth in the wavelength range concerned.
  • the present invention relates, more precisely, to a process for producing a molded plastic body coated with a metallic layer, according to which, an intermediate layer intended to facilitate demolding having been previously formed in the mold surface, the metal layer is deposited in the mold before the introduction of the plastic.
  • Such a method has the drawback, moreover cited in this document, of allowing the production of only a small number of parts.
  • the vinyl layer the aim of which is to avoid the adhesion of the metal layer to the mold, does not allow good precision to be obtained on the dimension of the details of the molded part. Indeed, it does not have a uniform thickness over the whole of a large area.
  • the method described in the cited document does not allow large parts to be produced;
  • the object of the present invention is therefore to remedy the disadvantages presented by the method described in the cited document by proposing a manufacturing process as defined in the preamble, remarkable in that, first, the mold is metallic and that the intermediate layer is formed by passivation of the metal, in that that then the metallic coating layer is deposited in the mold by electrolysis and the plastic material introduced into the mold thus prepared, and in that finally, after hardening of the plastic material, demolding is carried out by simultaneously practicing a heat treatment depending on the respective expansion coefficients of the materials constituting the mold and the plastic.
  • the mold is produced by machining a solid metal part, and its surface is electrolytically polished.
  • the mold is made of stamped sheet metal.
  • the plastic may be a thermosetting resin and be cast in the mold.
  • the plastic can also be a thermoplastic resin and be injected hot into the mold.
  • the mold is made of an iron-nickel-chromium alloy, it is chemically passivated, and the heat treatment used for demolding is cooling.
  • the mold is made of aluminum, passive with an oxide layer, and the heat treatment used for demolding is heating.
  • the metallic coating layer can be made of a copper, or silver, or gold, and nickel compound.
  • the polishing and metal deposition operations can be done by an electrolytic method, which makes it possible to on the one hand, manufacture large parts and on the other hand many parts at the same time.
  • the passivation layer of the metal of the mold does not change the dimensions of the latter and that, in this case, the precision on the dimensions of the details of the molded part is the same as the precision on the realization of the mold.
  • the layer formed by passivation of the metal of the mold does not constitute an intermediate layer added between the mold and the molding, but forms an integral part of the mold. Consequently, and particularly in the case of a machined mold, the precision obtained for the molded part can be extremely high, which may be required when making certain types of microwave antennas.
  • the moldings made from the same mold are extremely repetitive.
  • the quality of the parts is improved, and the manufacturing is simplified and accelerated.
  • the radiating element of the planar antenna is composed of two metal plates 40 and 50 in which the openings 41 and 51 are made facing one another. These two plates enclose the dielectric sheet 20 supporting the central conductor 30.
  • the flaring 61 is intended to improve the gain and the reflective plane 71 is intended to improve the adaptation.
  • the central conductors 30 progress towards the antenna outlet in the grooves 42 and 52 formed in the plates 40 and 50 respectively, and shown in section in FIG. 1b.
  • All antenna surfaces along which the signal to be transmitted or transmitted is propagated must be metallized.
  • the only surface which it is not essential to metallize is therefore the rear face of the antenna which is not turned towards the propagation medium.
  • the plate 40 for example, it is necessary to metallize the surfaces 14 and 16, while for the plate 50, it suffices to metallize the surface 15, as shown in FIGS. 2a and 2b.
  • the manufacture of the planar antenna using the method according to the invention is implemented in the manner illustrated by J T igures 3 and 4. This manufacture includes the production of two plates 40 and 50 using molds specifically provided for each of these parts.
  • Each of these molds can be obtained from a solid machined metal part, which is shown in Figure 3, or from a stamped sheet which is shown in Figure 4.
  • the use of a metallic material for the manufacture of the mold is made necessary because most of the operations carried out on the mold, according to the present invention, are preferably of the electrolytic type.
  • the mold is machined.
  • the plate 40 it comprises two parts 1 and 2 as shown on the Figure 3a. After machining, each of the parts constituting the mold is polished by a preferably electrolytic process. Then these parts 1 and 2 are passivated, so that the metal layer, which is deposited thereafter, cannot adhere to it.
  • the metal chosen to make the mold is steel, passivation is obtained by the action of hot nitric acid. If the metal chosen is aluminum, the passivation is done by anodic oxidation.
  • Each part of the mold thus prepared receives a metallic deposit, preferably by electrolysis, using a metal having electrolytic properties on the one hand and being compatible with the operation of a microwave antenna on the other hand. This is why a compound of copper, or silver, or gold with nickel is preferably chosen.
  • the metal layer produced by an electrolytic method is deposited both inside and outside the mold.
  • the electrolytic methods are used in preference to all others as giving the best results on the large areas presented by the antennas.
  • Electrolytic pickling allows on the one hand to obtain an excellent surface condition on very large parts, and electrolytic deposition on the other hand provides particularly uniform and homogeneous layers on these same parts.
  • these results are perfectly repetitive in the case of mass production.
  • many parts can be processed at the same time, which is also favorable for mass production.
  • a plastic or resin is then introduced between parts 1 and 2 of the mold.
  • This resin can be of the thermosetting or thermoplastic type, and depending on the case, it can be molded or injected. For the molding and / or hardening of such a resin, it is never necessary to raise the temperature of the mold to the melting point of the metallization, which therefore does not risk being deteriorated.
  • demolding takes place by separating parts 1, 40 and 2. If the metallic material constituting the mold has a lower coefficient of expansion than that of resin, demolding is obtained using a treaty- ; thermally consisting of cooling of the parts, and which causes the dimensions of the plastic body to shrink. The latter is ejected, causing metallization with it. This type of operation is used in the case where the metallic material used for the mold is for example an iron-nickel-chromium alloy of the INVAR type.
  • the metallic material constituting the mold has a coefficient of expansion greater than that of the resin, which is the case if the mold is made of aluminum for example, demolding is obtained using a consistent heat treatment in a heating which causes expansion of the mold, and the separation of the plastic body which is ejected causing metallization with it.
  • Another advantage of this method lies in the fact that the molds can be reused a large number of times.
  • the latter For the manufacture of the plate 50 using a machined mold, the latter comprises two parts 3 and 4, as shown in FIG. 3b.
  • the surface 15 of the body 50 having to be metallized alone, there is only the part 4 of the mold which receives the metallization.
  • the part 3 can be made of any material, metallic or not, such that its surface 17 does not adhere to the part 50 in resin. If this surface adhered to the resin, it could remain stuck on it and would in no way affect the functioning of the antenna. But one should then provide a part 3 of the new mold, for each antenna manufactured, which is not desired, so as not to increase the manufacturing cost.
  • the part 3 of the mold can therefore be provided in teflon for example, or else metallic and coated with a varnish.
  • the molding and demolding of the part 50 of the antenna is then carried out in the same way as has been described for the part 40.
  • the molds can be produced by stamping a sheet, as shown in FIGS. 4a and 4b.
  • the latter technique has a number of additional advantages. Firstly, less weight of metallic material is used to make the molds, which reduces the cost and makes it easier to use in the case of large parts, which are not easy to handle.
  • stamping is a simpler and less expensive operation than machining. Indeed, in the case of mass production, a large number of molds is necessary, and a low cost of manufacturing the molds is sought in the same way as a low cost of the parts themselves.
  • the stamped sheet has a sufficiently good surface condition to avoid the polishing operation. Finally the stamped sheet is flexible and facilitates demolding.
  • a stamped mold may be used in place of a more precise machined mold.
  • the precision lost on the stamped mold is gained on molding, since the intermediate layer intended to facilitate demolding has, in the process according to the invention, a negligible thickness, being a simple passivation layer.

Abstract

Procédé de réalisation d'un corps moulé en matière plastique revêtu d'une couche métallique, selon lequel, une couche intermédiaire detinée à faciliter le démoulage ayant été préalablement formée à la surface du moule, la couche métallique est déposée dans le moule avant l'introduction de la matière plastique, caractérisé en ce que d'abord, le moule (3 et 4) est métallique et la couche intermédiaire est formée par passivation du métal, en ce que ensuite la couche métallique (15) de revêtement est déposée par électrolyse et la matière plastique (50) introiduite dans le moule ainsi préparé et en ce que, enfin, après durcissement de la matière plastique, le démoulage est effectué en pratiquant un traitement thermique. Une antenne plane du type à lignes microrubans associées à un support diélectrique caractérisé en ce que les parties destinées à former les cavités des éléments rayonnants ou celles des lignes d'alimentation sont réalisées par ce procédé.Method for producing a plastic molded body coated with a metal layer, according to which, an intermediate layer intended to facilitate demolding having been previously formed on the surface of the mold, the metal layer is deposited in the mold before introduction of the plastic, characterized in that first, the mold (3 and 4) is metallic and the intermediate layer is formed by passivation of the metal, in that then the metallic coating layer (15) is deposited by electrolysis and the plastic material (50) introiduit in the mold thus prepared and in that, finally, after hardening of the plastic material, the release is carried out by practicing a heat treatment. A flat antenna of the microstrip line type associated with a dielectric support, characterized in that the parts intended to form the cavities of the radiating elements or those of the supply lines are produced by this process.

Description

L'invention concerne un procédé de réalisation d'un corps moulé en matière plastique revêtu d'une couche métallique et trouve son application dans la fabrication d'antennes planes hyperfréquences composées d'éléments rayonnants à lignes microrubans associées à un substrat diélectrique.The invention relates to a method for producing a molded plastic body coated with a metallic layer and finds its application in the manufacture of planar microwave antennas composed of radiating elements with microstrip lines associated with a dielectric substrate.

De telles antennes sont décrites dans les demandes de brevet français N° 82 18 700 et N° 83 06 650 déposées par la Demanderesse respectivement le 8 Novembre 1982 et le 22 Avril 1983.Such antennas are described in French patent applications No. 82 18 700 and No. 83 06 650 filed by the Applicant on November 8, 1982 and April 22, 1983.

Pour la réception ou la transmission d'un signal présentant une seule polarisation, ces antennes sont constituées de deux plaques métalliques dans lesquelles sont pratiquées, d'une part, des ouvertures dirigées vers le milieu de propagation, constituant les éléments rayonnants, et d'autre part, un réseau de connelures destiné à recevoir des conducteurs centraux. Ces derniers, portés par un film diélectrique enserré entre les deux plaques métalli- ques, constituent avec les éléments rayonnants et les cannelures, le réseau d'alimentation de l'antenne. La surface totale de ces antennes peut aller de quelques centimètres carrés à plusieurs mètres carrés.For the reception or transmission of a signal having a single polarization, these antennas consist of two metal plates in which are made, on the one hand, openings directed towards the propagation medium, constituting the radiating elements, and on the other hand, a network of piping intended to receive central conductors. The latter, carried by a dielectric film sandwiched between the two plates metallic q ues, constitute, with the radiating elements and the grooves, the antenna feed network. The total area of these antennas can range from a few square centimeters to several square meters.

De telles antennes présentent un intérêt grandissant du fait qu'elles trouvent leur application dans la réception d'émissions de télévision relayées par satellites. De nombreuses autres structures d'antennes planes ont été proposées au cours de ces dernières années, mais ces structures ne répondent pas aux conditions imposées par les spécifications du C.C.I.R (Comité Consultatif International de Radio) alors que les antennes planes réalisées selon les demandes de brevet citées présentent des faibles pertes, un gain élevé et une large bande passante dans le domaine de longueur d'onde concerné.Such antennas are of growing interest because they find their application in the reception of television programs relayed by satellites. Many other planar antenna structures have been proposed in recent years, but these structures do not meet the conditions imposed by the specifications of the CCIR (International Radio Consultative Committee) whereas the planar antennas produced according to patent applications cited have low losses, high gain and wide bandwidth in the wavelength range concerned.

Dans ces conditions, il est impératif de mettre au point un procédé de fabrication permettant la réalisation de telles antennes, en grande quantité, avec un faible coût. En effet, les applications dans le domaine de la réception de télévision impliquent toujours des fabrications en grande série pour une gamme de produits présentant un rapport satisfaisant entre la qualité et le prix.In these conditions, it is imperative to point a manufacturing process allowing the realization of such antennas, in large quantities, at low cost. In fact, applications in the field of television reception always involve mass production for a range of products having a satisfactory relationship between quality and price.

C'est pourquoi, il est intéressant de remplacer,' dans la fabrication de ces antennes, les plaques métalliques par des plaques en plastique métallisé, tout en imposant à l'ensemble une grande résistance à l'usage et aux intempéries.This is why, it is advantageous to replace, ' in the manufacture of these antennas, the metal plates with metallic plastic plates, while imposing on the whole a great resistance to use and to bad weather.

A cet effet, la présente invention concerne, de façon plus précise, un procédé de réalisation d'un corps moulé en matière plastique revêtu d'une couche métallique, selon lequel, une couche intermédiaire destinée à faciliter le démoulage ayant été préalablement formée à la surface du moule, la couche métallique est déposée dans le moule avant l'introduction de la matière plastique.To this end, the present invention relates, more precisely, to a process for producing a molded plastic body coated with a metallic layer, according to which, an intermediate layer intended to facilitate demolding having been previously formed in the mold surface, the metal layer is deposited in the mold before the introduction of the plastic.

Or il est connu par le brevet anglais N° 11 67 690, publié le 22 Octobre 1969, de fabriquer de tels corps en plastique métallisé. La méthode proposée par ce document consiste à revêtir un moule en bois d'une première couche de vinyle destinée à favoriser le démoulage et qui sera éliminée lors de cette opération. Puis une couche métallique est pluvérisée sur le vinyle dans le moule ainsi préparé et le corps plastique est moulé par injection. Il suffit ensuite de dissoudre la couche de vinyle pour obtenir le corps en plastique revêtu de la couche métallique.However, it is known from English Patent No. 11 67 690, published on October 22, 1969, to manufacture such metallized plastic bodies. The method proposed by this document consists in coating a wooden mold with a first layer of vinyl intended to promote release from the mold and which will be eliminated during this operation. Then a metal layer is sprayed onto the vinyl in the mold thus prepared and the plastic body is injection molded. It then suffices to dissolve the vinyl layer to obtain the plastic body coated with the metal layer.

Une telle méthode présente l'inconvénient, d'ailleurs cité dans ce document, de ne permettre la réalisation que d'un petit nombre de pièces. En outre, la couche de vinyle, dont le but est d'éviter l'adhérence de la couche métallique sur le moule, ne permet pas d'obtenir une bonne précision sur la dimension des détails de la pièce moulée. En effet, elle ne présente pas une épaisseur uniforme sur l'ensemble d'une grande surface. Enfin la méthode décrite dans le document cité ne permet pas de réaliser des pièces de grandes dimensions;Such a method has the drawback, moreover cited in this document, of allowing the production of only a small number of parts. In addition, the vinyl layer, the aim of which is to avoid the adhesion of the metal layer to the mold, does not allow good precision to be obtained on the dimension of the details of the molded part. Indeed, it does not have a uniform thickness over the whole of a large area. Finally, the method described in the cited document does not allow large parts to be produced;

Le but de la présente invention est donc de remédier aux inconvénients présentés par la méthode décrite dans le document cité en proposant un procédé de fabrication tel que défini dans le préambule, remarquable en ce que, d'abord, le moule est métallique et que la couche intermédiaire est formée par passivation du métal, en ce que ensuite la couche métallique de revêtement est déposée dans le moule par électrolyse et la matière plastique introduite dans le moule ainsi préparé, et en ce que enfin, après durcissement de la matière plastique, le démoulage est effectué en pratiquant simultanément un traitement thermique fonction des coefficients de dilatation respectifs des matériaux constituant le moule et la matière plastique.The object of the present invention is therefore to remedy the disadvantages presented by the method described in the cited document by proposing a manufacturing process as defined in the preamble, remarkable in that, first, the mold is metallic and that the intermediate layer is formed by passivation of the metal, in that that then the metallic coating layer is deposited in the mold by electrolysis and the plastic material introduced into the mold thus prepared, and in that finally, after hardening of the plastic material, demolding is carried out by simultaneously practicing a heat treatment depending on the respective expansion coefficients of the materials constituting the mold and the plastic.

Dans une mise en oeuvre du procédé selon l'invention, le moule est réalisé par usinage d'une pièce métallique massive, et sa surface est polie électrolytiquement.In an implementation of the method according to the invention, the mold is produced by machining a solid metal part, and its surface is electrolytically polished.

Dans une autre mise en oeuvre du procédé selon l'invention le moule est réalisé en tôle emboutie.In another implementation of the method according to the invention the mold is made of stamped sheet metal.

Dans l'une ou l'autre de ces mises en oeuvre du procédé selon l'invention le plastique peut être une résine thermodurcissable et être coulé dans le moule. Le plastique peut également être une résine thermoplastique et être injecté à chaud dans le moule.In one or other of these implementations of the method according to the invention, the plastic may be a thermosetting resin and be cast in the mold. The plastic can also be a thermoplastic resin and be injected hot into the mold.

Dans une mise en oeuvre du procédé selon l'invention le moule est fait en un alliage fer-nickel-chrome, il est passivé chimiquement, et le traitement thermique employé pour le démoulage est un refroidissement.In an implementation of the method according to the invention, the mold is made of an iron-nickel-chromium alloy, it is chemically passivated, and the heat treatment used for demolding is cooling.

Dans une autre mise en oeuvre du procédé selon l'invention, le moule est en aluminium, passive par une couche d'oxyde, et le traitement thermique employé pour le démoulage est un réchauffement.In another implementation of the method according to the invention, the mold is made of aluminum, passive with an oxide layer, and the heat treatment used for demolding is heating.

- Dans chacune de ces mises en oeuvre du procédé selon l'invention, la couche métallique de revêtement peut être en un composé de cuivre, ou argent, ou or, et de nickel.- In each of these implementations of the method according to the invention, the metallic coating layer can be made of a copper, or silver, or gold, and nickel compound.

Dans ces conditions, du fait de l'emploi d'un moule conducteur, les opérations de polissage et de dépôt métallique peuvent être faites par une méthode électrolytique, ce qui permet de fabriquer d'une part, des pièces de grandes dimensions et d'autre part de nombreuses pièces à la fois.Under these conditions, due to the use of a conductive mold, the polishing and metal deposition operations can be done by an electrolytic method, which makes it possible to on the one hand, manufacture large parts and on the other hand many parts at the same time.

Mais il est surtout notable que la couche de passivation du métal du moule ne change pas les dimensions de ce dernier et que, dans ce cas, la précision sur les dimensions des détails de la pièce moulée est la même que la précision sur la réalisation du moule. En effet, la couche formée par passivation du métal du moule, ne constitue pas une couche intermédiaire ajoutée entre le moule et le moulage, mais fait partie intégrante du moule. Par conséquent, et particulièrement dans le cas d'un moule usiné, la précision obtenue pour la pièce moulée peut être extrêmement grande, ce qui peut être demandé lors de la réalisation de certains types d'antennes hyperfréquences. Enfin, les moulages réalisés à partir d'un même moule sont extrêmement répétitifs.But it is especially notable that the passivation layer of the metal of the mold does not change the dimensions of the latter and that, in this case, the precision on the dimensions of the details of the molded part is the same as the precision on the realization of the mold. Indeed, the layer formed by passivation of the metal of the mold, does not constitute an intermediate layer added between the mold and the molding, but forms an integral part of the mold. Consequently, and particularly in the case of a machined mold, the precision obtained for the molded part can be extremely high, which may be required when making certain types of microwave antennas. Finally, the moldings made from the same mold are extremely repetitive.

Ainsi, par le procédé selon l'invention, la qualité des pièces est améliorée, et la fabrication en est simplifiée et accélérée.Thus, by the method according to the invention, the quality of the parts is improved, and the manufacturing is simplified and accelerated.

L'invention sera mieux comprise à l'aide de la description détaillée de ces modes de réalisation, appliqués à la fabrication d'une antenne plane hyperfréquence, prise comme exemple non limitatif, et illustrés schématiquement par les figures ci-après annexées.

  • La figure 1a représente en coupe schématique un élément rayonnant d'antenne plane tel que décrit dans la demande de brevet N° 82 18 700 déposée par la Demanderesse le 8 Novembre 1982.
  • La figure 1b représente en coupe schématique une ligne d'alimentation d'une telle antenne.
  • La figure 1c représente, vue de dessus, une partie d'une telle antenne.
  • Les figures 2a et 2b représentent en coupe schématique les plaques d'antenne obtenues par le procédé selon l'invention.
  • Les figures 3a et 3b représentent, en coupe schématique, le moulage de ces plaques d'antenne dans le cas où le moule utilisé est en métal usiné.
  • Les figures 4a et 4b représentent, en coupe schématique, le moulage de ces plaques d'antenne dans le cas où le moule utilisé est en tôle emboutie.
The invention will be better understood using the detailed description of these embodiments, applied to the manufacture of a planar microwave antenna, taken as a non-limiting example, and illustrated schematically by the figures below appended.
  • FIG. 1a represents in diagrammatic section a radiating element of planar antenna as described in the patent application N ° 82 18 700 filed by the Applicant on November 8, 1982.
  • Figure 1b shows in schematic section a feed line of such an antenna.
  • FIG. 1c represents, seen from above, part of such an antenna.
  • Figures 2a and 2b show in schematic section the antenna plates obtained by the method according to the invention.
  • Figures 3a and 3b show, in schematic section, the molding of these antenna plates in the case where the mold used is of machined metal.
  • FIGS. 4a and 4b represent, in schematic section, the molding of these antenna plates in the case where the mold used is stamped sheet metal.

Tel que représenté sur les figures 1a et 1c, l'élément rayonnant d'antenne plane est composé de deux plaques métalliques 40 et 50 dans lesquelles sont pratiquées les ouvertures 41 et 51 en regard l'une de l'autre. Ces deux plaques enserrent la feuille de diélectrique 20 supportant le conducteur central 30. L'évasement 61 est destiné à améliorer le gain et le plan réflecteur 71 est destiné à améliorer l'adaptation. Les conducteurs centraux 30 progressent vers la sortie d'antenne dans les cannelures 42 et 52 pratiquées dans les plaques 40 et 50 respectivement, et représentées en coupe sur la figure 1b.As shown in FIGS. 1a and 1c, the radiating element of the planar antenna is composed of two metal plates 40 and 50 in which the openings 41 and 51 are made facing one another. These two plates enclose the dielectric sheet 20 supporting the central conductor 30. The flaring 61 is intended to improve the gain and the reflective plane 71 is intended to improve the adaptation. The central conductors 30 progress towards the antenna outlet in the grooves 42 and 52 formed in the plates 40 and 50 respectively, and shown in section in FIG. 1b.

Toutes les surfaces de l'antenne le long desquelles se propage le signal à transmettre ou à émettre doivent être métallisées. La seule surface qu'il n'est pas indispensable de métalliser est donc la face postérieure de l'antenne qui n'est pas tournée vers le milieu de propagation. Pour la plaque 40 par exemple, il est nécessaire de métalliser les surfaces 14 et 16, alors que pour la plaque 50, il suffit de métalliser la surface 15, comme il est montré sur les figures 2a et 2b.All antenna surfaces along which the signal to be transmitted or transmitted is propagated must be metallized. The only surface which it is not essential to metallize is therefore the rear face of the antenna which is not turned towards the propagation medium. For the plate 40 for example, it is necessary to metallize the surfaces 14 and 16, while for the plate 50, it suffices to metallize the surface 15, as shown in FIGS. 2a and 2b.

La fabrication de l'antenne plane à l'aide du procédé selon l'invention est mise en oeuvre de la façon illustrée par les JTigures 3 et 4. Cette fabrication comprend la réalisation des deux -plaques 40 et 50 à l'aide de moules spécifiquement prévus pour chacune de ces pièces.The manufacture of the planar antenna using the method according to the invention is implemented in the manner illustrated by J T igures 3 and 4. This manufacture includes the production of two plates 40 and 50 using molds specifically provided for each of these parts.

Chacun de ces moules peut être obtenu à partir d'une pièce métallique massive usinée, ce qui est montré sur la figure 3, ou bien à partir d'une tôle emboutie ce qui est montré sur la figure 4. L'emploi d'un matériau métallique pour la fabrication du moule est rendu nécessaire du fait que la plupart des opérations effectuées sur le moule, selon la présente invention, sont préférentiellement du type électrolytique.Each of these molds can be obtained from a solid machined metal part, which is shown in Figure 3, or from a stamped sheet which is shown in Figure 4. The use of a metallic material for the manufacture of the mold is made necessary because most of the operations carried out on the mold, according to the present invention, are preferably of the electrolytic type.

Dans une première mise en oeuvre du procédé selon l'invention, le moule est usiné. Pour la réalisation de la plaque 40, il comprend deux parties 1 et 2 comme il est montré sur la figure 3a. Après usinage, chacune des parties constituant le moule est polie par un procédé de préférence électrolytique. Puis ces parties 1 et 2 sont passivées, en sorte que la couche métallique, qui y est déposée ultérieurement, ne peut y adhérer. A titre d'exemple, si le métal choisi pour réaliser le moule est un acier, la passivation est obtenue par l'action de l'acide nitrique chaud. Si le métal choisi est l'aluminium, la passivation est faite par oxydation anodique.In a first implementation of the method according to the invention, the mold is machined. For the realization of the plate 40, it comprises two parts 1 and 2 as shown on the Figure 3a. After machining, each of the parts constituting the mold is polished by a preferably electrolytic process. Then these parts 1 and 2 are passivated, so that the metal layer, which is deposited thereafter, cannot adhere to it. For example, if the metal chosen to make the mold is steel, passivation is obtained by the action of hot nitric acid. If the metal chosen is aluminum, the passivation is done by anodic oxidation.

Chaque partie du moule ainsi préparée reçoit un dépôt métallique, de préférence par électrolyse, à l'aide d'un métal possédant des propriétés électrolytiques d'une part et étant compatible avec le fonctionnement d'une antenne hyperfréquence d'autre part. C'est pourquoi un composé de cuivre, ou argent, ou or avec le nickel est choisi de préférence.Each part of the mold thus prepared receives a metallic deposit, preferably by electrolysis, using a metal having electrolytic properties on the one hand and being compatible with the operation of a microwave antenna on the other hand. This is why a compound of copper, or silver, or gold with nickel is preferably chosen.

On notera que la couche métallique réalisée par une méthode électrolytique se dépose aussi bien à l'intérieur qu'à l'extérieur du moule. Afin de diminuer l'usure du bain électrolytique, il est préférable de recouvrir l'extérieur du moule d'une couche de vernis par exemple, permettant d'éviter ce dépôt.It will be noted that the metal layer produced by an electrolytic method is deposited both inside and outside the mold. In order to reduce the wear of the electrolytic bath, it is preferable to cover the outside of the mold with a layer of varnish for example, making it possible to avoid this deposit.

Dans chacune des mises en oeuvre du procédé selon l'invention, les méthodes électrolytiques sont employées de préférence à toutes autres comme donnant les meilleurs résultats sur les grandes surfaces présentées par les antennes. Le décapage électrolytique permet d'une part d'obtenir un excellent état de surface sur de très grandes pièces, et le dépôt électrolytique d'autre part fournit des couches particulièrement uniformes et homogènes, sur ces mêmes pièces. De plus ces résultats sont parfaitement répétitifs dans le cas d'une fabrication en grande série. Enfin de nombreuses pièces peuvent être traitées à la fois, ce qui est également favorable à une fabrication en série.In each implementation of the method according to the invention, the electrolytic methods are used in preference to all others as giving the best results on the large areas presented by the antennas. Electrolytic pickling allows on the one hand to obtain an excellent surface condition on very large parts, and electrolytic deposition on the other hand provides particularly uniform and homogeneous layers on these same parts. In addition, these results are perfectly repetitive in the case of mass production. Finally, many parts can be processed at the same time, which is also favorable for mass production.

Une matière plastique ou résine est ensuite introduite entre les pièces 1 et 2 du moule. Cette résine peut être du type thermodurcissable ou thermoplastique, et suivant le cas, elle peut être moulée ou injectée. Pour le moulage et/ou le durcissement d'une telle résine, il n'est jamais nécessaire d'élever la température du moule jusqu'à la température de fusion de la métallisation, laquelle ne risque donc pas d'être détériorée.A plastic or resin is then introduced between parts 1 and 2 of the mold. This resin can be of the thermosetting or thermoplastic type, and depending on the case, it can be molded or injected. For the molding and / or hardening of such a resin, it is never necessary to raise the temperature of the mold to the melting point of the metallization, which therefore does not risk being deteriorated.

Après durcissement de la résine, le démoulage a lieu par séparation des pièces 1, 40 et 2. Si le matériau métallique constituant le moule présente un coefficient de dilatation inférieur à celui de la résine, le démoulage est obtenu à l'aide d'un traite- ; ment thermique consistant en un refroidissement des pièces, et qui provoque un retrait des dimensions du corps plastique. Ce dernier est'éjecté, entraînant la métallisation avec lui. Ce type d'opération est employé dans le cas où le matériau métallique utilisé pour le moule est par exemple un alliage fer-nickel-chrome du type INVAR.After the resin has hardened, demolding takes place by separating parts 1, 40 and 2. If the metallic material constituting the mold has a lower coefficient of expansion than that of resin, demolding is obtained using a treaty- ; thermally consisting of cooling of the parts, and which causes the dimensions of the plastic body to shrink. The latter is ejected, causing metallization with it. This type of operation is used in the case where the metallic material used for the mold is for example an iron-nickel-chromium alloy of the INVAR type.

Au contraire, si le matériau métallique constituant le moule présente un coefficient de dilatation supérieur à celui de la résine, ce qui est le cas si le moule est en aluminium par exemple, le démoulage est obtenu à l'aide d'un traitement thermique consistant en un réchauffement qui provoque une dilatation du moule, et le décolement du corps plastique qui est éjecté entraînant la métallisation avec lui.On the contrary, if the metallic material constituting the mold has a coefficient of expansion greater than that of the resin, which is the case if the mold is made of aluminum for example, demolding is obtained using a consistent heat treatment in a heating which causes expansion of the mold, and the separation of the plastic body which is ejected causing metallization with it.

Un autre avantage de cette méthode réside dans le fait que l'on peut réutiliser les moules un grand nombre de fois.Another advantage of this method lies in the fact that the molds can be reused a large number of times.

Pour la fabrication de la plaque 50 à l'aide d'un moule usiné, ce dernier comprend deux parties 3 et 4, comme il est montré sur la figure 3b. La surface 15 du corps 50 devant seule être métallisée, il n'y a-que la pièce 4 du moule qui reçoive la métallisation. La pièce 3 peut être constituée par n'importe quel matériau, métallique ou non, tel que sa surface 17 n'adhère pas à la pièce 50 en résine. Si cette surface adhérait à la résine, elle pourrait y rester collée et ne nuirait en rien au fonctionnement de l'antenne. Mais on devrait alors prévoir une partie 3 du moule nouvelle, pour chaque antenne fabriquée, ce qui n'est pas souhaité, de manière à ne pas augmenter le coût de fabrication. La pièce 3 du moule peut donc être prévue en téflon par exemple, ou bien métallique et enduite d'un vernis.For the manufacture of the plate 50 using a machined mold, the latter comprises two parts 3 and 4, as shown in FIG. 3b. The surface 15 of the body 50 having to be metallized alone, there is only the part 4 of the mold which receives the metallization. The part 3 can be made of any material, metallic or not, such that its surface 17 does not adhere to the part 50 in resin. If this surface adhered to the resin, it could remain stuck on it and would in no way affect the functioning of the antenna. But one should then provide a part 3 of the new mold, for each antenna manufactured, which is not desired, so as not to increase the manufacturing cost. The part 3 of the mold can therefore be provided in teflon for example, or else metallic and coated with a varnish.

Le moulage et le démoulage de la pièce 50 de l'antenne sont ensuite conduits de la même façon qu'il a été décrit pour la pièce 40.The molding and demolding of the part 50 of the antenna is then carried out in the same way as has been described for the part 40.

Dans un second exemple de mise en oeuvre du procédé selon l'invention, les moules peuvent être réalisés par emboutissage d'une tôle, comme il est montré sur les figures 4a et 4b. Cette dernière technique présente un certain nombre d'avantages supplémentaires. En premier lieu, il est utilisé un poids moins grand de matériau métallique pour réaliser les moules, ce qui en réduit le coût et en facilite la mise en oeuvre dans le cas de grandes pièces, peu aisées à manipuler. D'autre part l'emboutissage est une opération plus simple et moins coûteuse que l'usinage. En effet, dans le cas d'une fabrication en grande série, un grand nombre de moules est nécessaire, et un faible coût de fabrication des moules est recherché au même titre qu'un faible coût des pièces elles-mêmes. De plus la tôle emboutie présente un état de surface suffisamment bon pour éviter l'opération de polissage. Enfin la tôle emboutie est souple et facilite le démoulage.In a second example of implementation of the method according to the invention, the molds can be produced by stamping a sheet, as shown in FIGS. 4a and 4b. The latter technique has a number of additional advantages. Firstly, less weight of metallic material is used to make the molds, which reduces the cost and makes it easier to use in the case of large parts, which are not easy to handle. On the other hand stamping is a simpler and less expensive operation than machining. Indeed, in the case of mass production, a large number of molds is necessary, and a low cost of manufacturing the molds is sought in the same way as a low cost of the parts themselves. In addition, the stamped sheet has a sufficiently good surface condition to avoid the polishing operation. Finally the stamped sheet is flexible and facilitates demolding.

En dehors des simplifications et des particularités exposées ci-dessus, la mise en oeuvre du procédé selon l'invention à l'aide de moules en tôle emboutie est conduite comme il a été décrit pour le moulage à l'aide de moules usinés.Apart from the simplifications and particularities set out above, the implementation of the method according to the invention using stamped sheet molds is carried out as has been described for molding using machined molds.

L'une ou l'autre méthode est choisie en fonction de la précision recherchée.Either method is chosen depending on the precision sought.

Il est à noter que dans bien des cas, on pourra employer un moule embouti à la place d'un moule usiné plus précis. En effet, la précision perdue sur le moule embouti est gagnée sur le moulage, puisque la couche intermédiaire destinée à faciliter le démoulage a, dans le procédé selon l'invention, une épaisseur négligeable, étant une simple couche de passivation.It should be noted that in many cases, a stamped mold may be used in place of a more precise machined mold. In fact, the precision lost on the stamped mold is gained on molding, since the intermediate layer intended to facilitate demolding has, in the process according to the invention, a negligible thickness, being a simple passivation layer.

Il est manifeste que, d'une part l'application de l'invention à la fabrication de pièces d'antenne plane hyperfréquence n'est pas limitative et que l'invention peut s'appliquer à la fabrication d'autres types d'antenne ou à celle d'autres sortes de pièces en plastique moulées et métallisées, et que d'autre part de nombreuses variantes sont possibles notamment dans le choix des formes et des matériaux, sans sortir du cadre de la présente invention, tel que défini par les revendications ci-après annexées.It is obvious that, on the one hand, the application of the invention to the manufacture of flat microwave antenna parts is not limiting and that the invention can be applied to the manufacture of other types of antenna. or that of other kinds of molded and metallized plastic parts, and that, on the other hand, numerous variants are possible, in particular in the choice of shapes and materials, without departing from the scope of the present invention, as defined by the the following claims are appended.

Claims (9)

1. Procédé de réalisation d'un corps moulé en matière plastique revêtu d'une couche métallique, selon lequel, une couche intermédiaire destinée à faciliter le démoulage ayant été préalablement formée à la surface du moule, la couche métallique est déposée dans le moule avant l'introduction de la matière plastique, caractérisé en ce que d'abord, le moule est métallique et la couche in- tetmédiaire est formée par passivation du métal, en ce que ensuite la couche métallique de revêtement est déposée par électrolyse et la matière plastique introduite dans le moule ainsi préparé et en ce que, enfin, après durcissement de la matière plastique, le démoulage est effectué en pratiquant un traitement thermique.1. A method of producing a molded plastic body coated with a metal layer, according to which, an intermediate layer intended to facilitate demolding having been previously formed on the surface of the mold, the metal layer is deposited in the front mold the introduction of the plastic, characterized in that first, the mold is metallic and the intermediate layer is formed by passivation of the metal, in that then the metallic coating layer is deposited by electrolysis and the plastic introduced into the mold thus prepared and in that, finally, after hardening of the plastic, the release is carried out by practicing a heat treatment. 2. Procédé selon la revendication 1 caractérisé en ce que le moule métallique est réalisé par usinage d'une pièce métallique massive et sa surface polie électrolytiquement.2. Method according to claim 1 characterized in that the metal mold is produced by machining a solid metal part and its surface electropolished. 3. Procédé selon la revendication 1 caractérisé en ce que le moule est en tôle emboutie.3. Method according to claim 1 characterized in that the mold is in stamped sheet metal. 4. Procédé selon l'une des revendications 1 à 3 caractérisé en ce que le plastique est une résine thermodurcissable coulée dans le moule.4. Method according to one of claims 1 to 3 characterized in that the plastic is a thermosetting resin poured into the mold. 5. Procédé selon l'une des revendications 1 à 3 caractérisé en ce que le plastique est une résine thermoplastique injectée à chaud dans le moule.5. Method according to one of claims 1 to 3 characterized in that the plastic is a thermoplastic resin injected hot into the mold. 6. Procédé selon l'une des revendication 1 à 5 caractérisé en ce que le moule est en alliage fer-nickel-chrome passive chimiquement et en ce que le traitement thermique utilisé pour le démoulage est un refroidissement.6. Method according to one of claims 1 to 5 characterized in that the mold is chemically passive iron-nickel-chromium alloy and in that the heat treatment used for demolding is cooling. 7. Procédé selon l'une des revendications 1 à 5 caractérisé en ce que le moule est en aluminium passive par une couche d'oxyde et en ce que le traitement thermique utilisé pour le démoulage est un réchauffement.7. Method according to one of claims 1 to 5 characterized in that the mold is made of passive aluminum with an oxide layer and in that the heat treatment used for demolding is heating. 8. Procédé selon l'une des revendications 1 à 7 caractérisé en ce que la couche métallique est en un composé de cuivre, ou argent, ou or, et de nickel.8. Method according to one of claims 1 to 7 characterized in that the metal layer is made of a copper, or silver, or gold, and nickel compound. 9. Antenne plane hyperfréquence du type à lignes microrubans associées à un support diélectrique caractérisé en ce que les parties destinées à former les cavités des éléments rayonnants ou celles des lignes d'alimentation sont réalisées par un procédé selon l'une des revendications 1 à 8.9. Line type flat microwave antenna microstrips associated with a dielectric support, characterized in that the parts intended to form the cavities of the radiating elements or those of the supply lines are produced by a method according to one of claims 1 to 8.
EP84201264A 1983-09-07 1984-09-04 Method of making a moulded body of plastic material covered by a metallic layer, and plane antenna so realized Expired - Lifetime EP0142180B1 (en)

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FR8314254A FR2551587B1 (en) 1983-09-07 1983-09-07 PROCESS FOR PRODUCING A MOLDED BODY IN PLASTIC MATERIAL COATED WITH A METAL LAYER, AND FLAT ANTENNA THUS REALIZED
FR8314254 1983-09-07

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Also Published As

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US4627894A (en) 1986-12-09
EP0142180B1 (en) 1990-04-25
JPS6099623A (en) 1985-06-03
DE3482080D1 (en) 1990-05-31
FR2551587B1 (en) 1988-04-29
FR2551587A1 (en) 1985-03-08

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