EP0142180B1 - Verfahren zur Herstellung von kunststoffgepresstem Material mit einer metallischen Schicht und Flachantenne nach diesem Verfahren - Google Patents
Verfahren zur Herstellung von kunststoffgepresstem Material mit einer metallischen Schicht und Flachantenne nach diesem Verfahren Download PDFInfo
- Publication number
- EP0142180B1 EP0142180B1 EP84201264A EP84201264A EP0142180B1 EP 0142180 B1 EP0142180 B1 EP 0142180B1 EP 84201264 A EP84201264 A EP 84201264A EP 84201264 A EP84201264 A EP 84201264A EP 0142180 B1 EP0142180 B1 EP 0142180B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- mould
- plastic material
- layer
- metallic
- mold
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
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Classifications
-
- 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 process 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 splines intended to receive central conductors.
- the latter carried by a dielectric film sandwiched between the two metal plates, constitute with the radiating elements and the grooves, the antenna supply 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 the patent application cited have low losses, high gain and wide bandwidth in the wavelength range concerned.
- 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 aim of the present production method is therefore to remedy the drawbacks presented by the methods described in the cited documents by proposing 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 on the surface of the mold, the metal layer is deposited in the mold before the introduction of the plastic, and according to which first, the mold is metallic and the intermediate layer is formed by passivation mold metal, then the metal coating layer is deposited by electrolysis and the plastic material introduced into the mold thus prepared and, finally, after hardening of the plastic material, demolding is carried out by practicing a heat treatment.
- 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 can be a thermosetting resin and can be poured into molds.
- 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, passivated by an oxide layer, and the heat treatment used for demolding is heating.
- the metallic coating layer may 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 manufacture, on the one hand, large parts and on the other hand many pieces at once.
- 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 in FIGS. 3 and 4.
- This manufacture includes the production of the 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 For the production of the plate 40, it comprises two parts 1 and 2 as shown in FIG. 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 there subsequently filed, cannot join.
- the metal chosen to make the mold is steel, passivation is obtained by the action of hot nitric acid. If the chosen metal 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.
- the electrolytic pickling allows on the one hand to obtain an excellent surface condition on very large parts, and the 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 temperature 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 heat treatment consisting of cooling of the parts, 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 an expansion of the mold, and the separation of the plastic body which is ejected causing the 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.
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Electrochemistry (AREA)
- Electromagnetism (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Physics & Mathematics (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
- Electroplating Methods And Accessories (AREA)
Claims (9)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
FR8314254 | 1983-09-07 | ||
FR8314254A FR2551587B1 (fr) | 1983-09-07 | 1983-09-07 | Procede de realisation d'un corps moule en matiere plastique revetu d'une couche metallique, et antenne plane ainsi realisee |
Publications (2)
Publication Number | Publication Date |
---|---|
EP0142180A1 EP0142180A1 (de) | 1985-05-22 |
EP0142180B1 true EP0142180B1 (de) | 1990-04-25 |
Family
ID=9292036
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP84201264A Expired - Lifetime EP0142180B1 (de) | 1983-09-07 | 1984-09-04 | Verfahren zur Herstellung von kunststoffgepresstem Material mit einer metallischen Schicht und Flachantenne nach diesem Verfahren |
Country Status (5)
Country | Link |
---|---|
US (1) | US4627894A (de) |
EP (1) | EP0142180B1 (de) |
JP (1) | JPS6099623A (de) |
DE (1) | DE3482080D1 (de) |
FR (1) | FR2551587B1 (de) |
Families Citing this family (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE3750205T2 (de) * | 1986-08-29 | 1994-12-08 | Hitachi Chemical Co Ltd | Substrat für Hochfrequenzschaltung und Verfahren zur Herstellung desselben. |
US5160421A (en) * | 1991-12-02 | 1992-11-03 | Xerox Corporation | Electroforms with high dimensional stability |
US6004447A (en) * | 1995-05-22 | 1999-12-21 | Xerox Corporation | Electroforming process |
US6052889A (en) * | 1996-11-21 | 2000-04-25 | Raytheon Company | Radio frequency antenna and its fabrication |
Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0108463A1 (de) * | 1982-11-08 | 1984-05-16 | Laboratoires D'electronique Et De Physique Appliquee L.E.P. | Strahlelement für orthogonal polarisierte Signale und flache Antennengruppe mit solchen nebeneinandergestellten Elementen |
Family Cites Families (12)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2646396A (en) * | 1949-03-17 | 1953-07-21 | Reginald S Dean | Method of making electroformed articles |
FR1107396A (fr) * | 1953-09-18 | 1955-12-30 | Thomson Houston Comp Francaise | Procédé perfectionné de construction des guides d'ondes |
NL112255C (de) * | 1956-05-17 | |||
NL6517040A (de) * | 1965-12-28 | 1967-06-29 | ||
US3536800A (en) * | 1966-02-25 | 1970-10-27 | Montecatini Edison Ellettronic | Method of forming radio frequency devices employing a destructible mold |
GB1167690A (en) * | 1968-09-30 | 1969-10-22 | Ford Motor Co | A Method of Making a Metal Coated Article |
US3954568A (en) * | 1970-01-30 | 1976-05-04 | Xerox Corporation | Electroforming an endless flexible seamless xerographic belt |
DE2335206A1 (de) * | 1973-07-11 | 1975-01-30 | Kabel Metallwerke Ghh | Verfahren zur herstellung eines weitverkehrsrundhohlleiters |
US4067782A (en) * | 1977-05-09 | 1978-01-10 | Xerox Corporation | Method of forming an electroforming mandrel |
JPS5952715B2 (ja) * | 1977-09-05 | 1984-12-21 | ソニー株式会社 | メツキ方法 |
GB2044543B (en) * | 1979-03-14 | 1983-03-09 | Marconi Co Ltd | Electrically conductive bodies |
US4363705A (en) * | 1981-07-16 | 1982-12-14 | Capitol Records, Inc. | Passivating and silver removal method |
-
1983
- 1983-09-07 FR FR8314254A patent/FR2551587B1/fr not_active Expired
-
1984
- 1984-08-31 US US06/645,896 patent/US4627894A/en not_active Expired - Fee Related
- 1984-09-04 DE DE8484201264T patent/DE3482080D1/de not_active Expired - Lifetime
- 1984-09-04 EP EP84201264A patent/EP0142180B1/de not_active Expired - Lifetime
- 1984-09-05 JP JP59184704A patent/JPS6099623A/ja active Pending
Patent Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0108463A1 (de) * | 1982-11-08 | 1984-05-16 | Laboratoires D'electronique Et De Physique Appliquee L.E.P. | Strahlelement für orthogonal polarisierte Signale und flache Antennengruppe mit solchen nebeneinandergestellten Elementen |
Also Published As
Publication number | Publication date |
---|---|
DE3482080D1 (de) | 1990-05-31 |
FR2551587A1 (fr) | 1985-03-08 |
JPS6099623A (ja) | 1985-06-03 |
EP0142180A1 (de) | 1985-05-22 |
US4627894A (en) | 1986-12-09 |
FR2551587B1 (fr) | 1988-04-29 |
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