EP1143561A1 - Electromagnetic wave reflector and associated manufactoring method - Google Patents

Electromagnetic wave reflector and associated manufactoring method Download PDF

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Publication number
EP1143561A1
EP1143561A1 EP01201226A EP01201226A EP1143561A1 EP 1143561 A1 EP1143561 A1 EP 1143561A1 EP 01201226 A EP01201226 A EP 01201226A EP 01201226 A EP01201226 A EP 01201226A EP 1143561 A1 EP1143561 A1 EP 1143561A1
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EP
European Patent Office
Prior art keywords
network
thermoplastic
wires
mold
electromagnetic wave
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.)
Granted
Application number
EP01201226A
Other languages
German (de)
French (fr)
Other versions
EP1143561B1 (en
Inventor
Jacques Trouillet
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Transformation Industrielle De Matieres Plastiques- Stimap Ste
Original Assignee
Transformation Industrielle De Matieres Plastiques- Stimap Ste
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Filing date
Publication date
Family has litigation
Priority to FR9813007 priority Critical
Priority to FR9813007A priority patent/FR2784804B1/en
Application filed by Transformation Industrielle De Matieres Plastiques- Stimap Ste filed Critical Transformation Industrielle De Matieres Plastiques- Stimap Ste
Priority to EP19990947544 priority patent/EP1119884A1/en
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=9531664&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=EP1143561(A1) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Publication of EP1143561A1 publication Critical patent/EP1143561A1/en
Publication of EP1143561B1 publication Critical patent/EP1143561B1/en
Application granted granted Critical
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01QANTENNAS, i.e. RADIO AERIALS
    • H01Q15/00Devices for reflection, refraction, diffraction or polarisation of waves radiated from an antenna, e.g. quasi-optical devices
    • H01Q15/14Reflecting surfaces; Equivalent structures
    • H01Q15/22Reflecting surfaces; Equivalent structures functioning also as polarisation filter
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01QANTENNAS, i.e. RADIO AERIALS
    • H01Q15/00Devices for reflection, refraction, diffraction or polarisation of waves radiated from an antenna, e.g. quasi-optical devices
    • H01Q15/14Reflecting surfaces; Equivalent structures
    • H01Q15/141Apparatus or processes specially adapted for manufacturing reflecting surfaces
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01QANTENNAS, i.e. RADIO AERIALS
    • H01Q15/00Devices for reflection, refraction, diffraction or polarisation of waves radiated from an antenna, e.g. quasi-optical devices
    • H01Q15/14Reflecting surfaces; Equivalent structures
    • H01Q15/141Apparatus or processes specially adapted for manufacturing reflecting surfaces
    • H01Q15/142Apparatus or processes specially adapted for manufacturing reflecting surfaces using insulating material for supporting the reflecting surface

Abstract

The embedded wires are arranged parallel or in the form of a grid, and are embedded in thermoplastic material. The structure acts as the reflector for a microwave antenna and focuses received signals onto a feed element. The aerial is constructed from electrically conducting wires (1) situated at a distance from each other, and embedded in the surface of a sheet of thermoplastic material. The wires may be parallel, or may form a grid, and the sheet of material forming the aerial may be concave. The wires lie nearer to one surface of the plastic than the other and have a separation between 0.003 mm and 1.5 cm, whilst the diameter of the wires lies in the range 0.005 - 5mm. The thickness of the plastic is between 0.5 mm and 1 cm and may be coloured or transparent.

Description

[001] The present invention relates to electromagnetic wave reflectors in an element made of an electrically conductive material, preferably having a convex face which defines a focusing home radio waves. They are most often antennas in the shape of a spherical or parabolic cap, but they can also have any other shape giving focus.

We already know a metal antenna manufactured in stamping, in one or more passes, a spherical cap allowing focusing signals from a satellite at one point. The surface metallic is radio opaque to frequencies transmitted by the satellite and allows a theoretical reflection rate of 100%. As the shape is obtained by stamping, the sheet must undergo several surface treatments in order to prevent corrosion. These treatments require repeats after stamping, including the application of a primer and paint.

We also know, from DE 3911445 A, antennas thermosetting material which requires tools intended to obtain the desired shape, particularly parabolic. A metallic frame is put in forms manually in the tooling. A piece of material is then introduced in the tool above the frame. The tool is locked. Cooking is carried out in order to polymerize the material introduced. After cooking, the tool is opened and the part is extracted from the mold. Due to molding technology, deburring must be carried out followed by sanding, removing a primer, then painting on both sides.

In EP-595 418, an antenna is described comprising a canvas metal coated by thermoplastic resin injection molding. We gives the desired shape to the wire mesh before molding. To conform a metallic fabric in parabola with great accuracy is a very difficult operation to perform.

[005] Powder coating painting technologies do not allow not to have a large shade variation, without incurring costs excessive manufacturing due to the need to clean the tool manufacturing when switching from one shade to another.

The invention overcomes these drawbacks and makes it possible to obtain a electromagnetic wave reflector protected against corrosion, much more easy to manufacture and which, in particular, allows the possible use of a painting easier and less expensive to implement and therefore to dispense with any painting operation with dusting and operations cleaning that it entails.

The invention relates to a method of manufacturing an electromagnetic wave reflector having a shape giving a focusing of electromagnetic waves, in which one puts an electrically conductive network in a molding tool, one puts thermoplastic plastic in the molding tool and a reflector is removed from the mold, characterized in that

  • the grating placed in the molding tool has a shape other than said shape giving focus of the electromagnetic waves, and
  • the thermoplastic material is injected into the molding tool under a pressure such that it brings the network to said shape giving focus.

We no longer have to conform the network regardless of the molding operation. This conformation is carried out by the operation of molding itself.

The network of electrically conductive material can include wires arranged at a distance, preferably constant, the each other. Preferably, the network is a canvas or a grid, especially flat.

The manufacturing is done by injection molding of a material thermoplastic, preferably on a regular mesh grid in one electrically conductive material. The injection is carried out under high pressure, especially above 50 bar and most often between 150 and 450 bar.

[011] Preferably, the method comprises

  • pinching a network of an electrically conductive material between the two half-molds of an injection mold of thermoplastic material, such that it exceeds the circumference of the mold footprint,
  • injecting thermoplastic material into the impression,
  • to unmold an injected part from the periphery of which exceeds the network, and
  • to cut the network flush with the room.

[012] The network is thus well maintained during molding and curvatures of the network and the coating are not offset, the whole being obtained automatically by the usual molding operation. The coating of the threads is often almost complete and, in any case, takes place on more than 80% of the cross section of the wires.

As an electrically conductive material, it is possible to use especially ferrous and non-ferrous metals as well as carbon fiber or their oxides and especially aluminum and stainless steel. The wire has generally a diameter of 0.005 to 0.5 mm, it being understood that the wires may also have a cross section other than circular and then the values indicated above are understood to mean the largest dimension of cross section.

As the thermoplastic material, use may in particular be made of polyethylene, polypropylene or other polyolefins, ABS, polycarbonate, poly (methyl methacrylate) as well as any other material injectable thermoplastic. The thickness of injected plastic is general between 0.5 mm and 1 cm.

Advantageously, the distance between the wires is between 0.003 mm and 1.5 cm.

According to a very particularly preferred embodiment, the the desired color for the antenna is given to it by the fact that the plastic in the mass. The antenna can also be transparent.

The invention also relates to a wave reflector electromagnetic including an array of conductive material electricity covered by a sheet of thermoplastic material having a portion central and border, characterized in that in the central part the network appears punctually on one of the faces of the tablecloth, while on part of the border it is embedded in the tablecloth.

[018] The network appears occasionally on one or both faces of the edge according to the injection direction.

In the appended drawing, given only by way of example:

  • FIG. 1 is a perspective view illustrating two half-molds according to the invention between which a wire mesh is inserted,
  • FIG. 2 shows the wire mesh at the stage where it is pinched between the two half-molds,
  • FIG. 3 is an elevation view of an antenna according to the invention before the fabric has been cut,
  • FIG. 4 represents the antenna with a drop of the canvas which has been cut out,
  • FIG. 5 is a partial sectional view of an antenna according to the invention, and
  • Figure 6 is a partial sectional view of a variant of an antenna according to the invention.
  • A flat metallic canvas 1 is retained on one of the two half-molds 2, 3 of a thermoplastic injection mold. Figure 2 shows that when the fabric 1 is pinched between the two half-molds 2, 3, it protrudes from the periphery of the mold cavity 4.

    [021] Figure 3 shows the injected part 5 demolded in which is coated with the fabric 1 which protrudes by a part 6. FIG. 4 shows that part 6 has been cut in the form of a drop 6 leaving an antenna parabolic to the shape of the imprint 4 which is formed, as shown Figures 5 and 6, of the canvas 1 coated with a ply 7 of plastic material thermoplastic. The antenna has a central part 8 in the form of parabola and a peripheral border 9. In the central part 8 the canvas 1 appears punctually on one of the faces of the web 7, while on at least part of the border 9, the fabric 1 is embedded in the sheet 7. The antenna of Figure 5 was obtained when the direction of the injection current in the mold is directed vertically from bottom to top, while in Figure 6 it was directed vertically from top to bottom.

    The following example illustrates the invention.

    [023] An autoclave was charged préalableme polyethylene heated to 260 ° C, so that it can flow through an injection point in the cavity 4 of the mold which is in the shape of the reflector to obtain and in which we put a flat aluminum canvas which protrudes. To fill the imprint, a pressure of 177 bar is applied to the plastic, the closing force of the two mold halves is 800 tonnes. 1.2 kg of polyethylene are injected into the imprint. The injection time is 7 seconds. The injection pressure is 117 bar. When the injection is complete, the mixture is allowed to cool for 50 seconds, the mold is opened and the fabric is cut into aluminum wire to obtain an electromagnetic wave reflector according to the invention.

    Claims (5)

    1. Method of manufacturing an electromagnetic wave reflector having a shape giving a focus of electromagnetic waves, in which an electrically conductive network (11) is placed in a molding tool (2, 3), thermoplastic plastic in the molding tool (2, 3) and a reflector is removed from the mold, characterized in that
      element (11) is a network, and
      the thermoplastic material, preferably transparent, is injected into the molding tool (2, 3) under a pressure such that it puts the network (11) in said shape giving focus.
    2. Method according to Claim 1, characterized in that the said form giving focus is the parabolic form.
    3. Method according to claim 1 or 2, characterized in that the network (11) is a preferably flat wire mesh.
    4. Method according to claim 2 or 3, characterized in that it consists
      pinching between the two half-molds (2, 3) of an injection mold of thermoplastic material a network (11) of an electrically conductive material of a size such that it exceeds the circumference of the mold imprint (4),
      injecting thermoplastic material into the impression (4),
      to unmold an injected part from the periphery of which protrudes the network (11),
      cutting the network (11) flush with the workpiece.
    5. Method according to one of claims 1 to 4, characterized in that the injection pressure of the thermoplastic plastic material is greater than 50 bar.
    EP01201226A 1998-10-16 1999-10-12 Electromagnetic wave reflector and associated manufactoring method Expired - Lifetime EP1143561B1 (en)

    Priority Applications (3)

    Application Number Priority Date Filing Date Title
    FR9813007 1998-10-16
    FR9813007A FR2784804B1 (en) 1998-10-16 1998-10-16 Antenna with wires coated with a layer of thermoplastic material
    EP19990947544 EP1119884A1 (en) 1998-10-16 1999-10-12 Electromagnetic wave reflector and method for making same

    Related Parent Applications (1)

    Application Number Title Priority Date Filing Date
    EP19990947544 Division EP1119884A1 (en) 1998-10-16 1999-10-12 Electromagnetic wave reflector and method for making same

    Publications (2)

    Publication Number Publication Date
    EP1143561A1 true EP1143561A1 (en) 2001-10-10
    EP1143561B1 EP1143561B1 (en) 2004-12-29

    Family

    ID=9531664

    Family Applications (2)

    Application Number Title Priority Date Filing Date
    EP19990947544 Pending EP1119884A1 (en) 1998-10-16 1999-10-12 Electromagnetic wave reflector and method for making same
    EP01201226A Expired - Lifetime EP1143561B1 (en) 1998-10-16 1999-10-12 Electromagnetic wave reflector and associated manufactoring method

    Family Applications Before (1)

    Application Number Title Priority Date Filing Date
    EP19990947544 Pending EP1119884A1 (en) 1998-10-16 1999-10-12 Electromagnetic wave reflector and method for making same

    Country Status (10)

    Country Link
    US (1) US6486854B1 (en)
    EP (2) EP1119884A1 (en)
    JP (1) JP2002528937A (en)
    AT (1) AT286309T (en)
    AU (1) AU6095299A (en)
    BR (1) BR9912233A (en)
    CA (1) CA2337810A1 (en)
    DE (1) DE69923001T2 (en)
    FR (1) FR2784804B1 (en)
    WO (1) WO2000024086A1 (en)

    Families Citing this family (3)

    * Cited by examiner, † Cited by third party
    Publication number Priority date Publication date Assignee Title
    FR2808382B1 (en) 2000-04-28 2003-07-25 Vector Ind France Parabolic antenna and manufacturing method thereof
    FR2819641A1 (en) * 2001-01-18 2002-07-19 Gilles Ribatto Thermoplastic conductor material antenna having conductor material thermoplastic material added with single operation injection moulding providing clear/dyed/natural look
    US20110221101A1 (en) * 2010-03-10 2011-09-15 Legare David J Resin-based molding of electrically conductive structures

    Citations (8)

    * Cited by examiner, † Cited by third party
    Publication number Priority date Publication date Assignee Title
    FR2244618A1 (en) * 1973-09-24 1975-04-18 Asea Ab Metal faced injection moulding for refrigerators or cars - with metal deformed to mould surface by injection of plastics
    US4030953A (en) * 1976-02-11 1977-06-21 Scala Radio Corporation Method of molding fiberglass reflecting antenna
    JPH01227505A (en) * 1988-03-07 1989-09-11 Mitsuboshi Belting Ltd Manufacture of reflector for parabolic antenna
    DE9001255U1 (en) * 1990-02-03 1990-04-05 Hagenbusch, Guenther, 7313 Reichenbach, De
    JPH03173618A (en) * 1989-12-01 1991-07-26 Dainippon Printing Co Ltd Manufacture of reflector for parabola antenna
    JPH0441216A (en) * 1990-06-07 1992-02-12 Azuma Seimitsu Kanagata Seisakusho:Kk Mold for injection-molding parabolic antenna
    EP0595418A1 (en) * 1992-10-28 1994-05-04 Di. W.S. PLASTIC S.r.l. Reflecting parabolic antenna for e.m. wave reception and related manufacturing method
    US5473111A (en) * 1992-10-07 1995-12-05 Mitsubishi Denki Kabushiki Kaisha Shielded enclosure for housing electronic components and manufacturing method thereof

    Family Cites Families (10)

    * Cited by examiner, † Cited by third party
    Publication number Priority date Publication date Assignee Title
    NL179527C (en) * 1977-05-20 1986-09-16 Philips Nv Method and apparatus for manufacturing a reflector with a plastic support body
    JPH027198B2 (en) * 1982-11-06 1990-02-15 Inax Corp
    JPS6146099A (en) * 1984-08-10 1986-03-06 Bridgestone Corp Electromagnetic wave reflector
    US4647329A (en) * 1984-09-27 1987-03-03 Toyo Kasei Kogyo Kabushiki Kaisha Manufacture of parabolic antennas
    SE463290B (en) * 1987-04-24 1990-11-05 Fibo Stoep As Foerfarande foer framstaellning of a product comprising aatminstone second up of metal components, and means foer genomfoerande THE PROCEEDING
    JPH0180783U (en) * 1987-11-18 1989-05-30
    DE3911445A1 (en) * 1989-04-07 1990-10-11 Ring Hans Georg Hollow mirror for focusing incident electromagnet waves
    DE19613541C1 (en) * 1996-04-03 1997-10-02 Deutsche Forsch Luft Raumfahrt Fibre reinforced antenna reflector manufacturing method
    DE19737566C2 (en) * 1997-08-28 2001-04-05 Ebel Gerlach Helga Process for the production of curved metal plates coated with plastic film
    WO1999028988A2 (en) * 1997-12-04 1999-06-10 Marconi Aerospace Defence Systems, Inc. Metallized fiber mat, and its use as reflective applique in antenna

    Patent Citations (8)

    * Cited by examiner, † Cited by third party
    Publication number Priority date Publication date Assignee Title
    FR2244618A1 (en) * 1973-09-24 1975-04-18 Asea Ab Metal faced injection moulding for refrigerators or cars - with metal deformed to mould surface by injection of plastics
    US4030953A (en) * 1976-02-11 1977-06-21 Scala Radio Corporation Method of molding fiberglass reflecting antenna
    JPH01227505A (en) * 1988-03-07 1989-09-11 Mitsuboshi Belting Ltd Manufacture of reflector for parabolic antenna
    JPH03173618A (en) * 1989-12-01 1991-07-26 Dainippon Printing Co Ltd Manufacture of reflector for parabola antenna
    DE9001255U1 (en) * 1990-02-03 1990-04-05 Hagenbusch, Guenther, 7313 Reichenbach, De
    JPH0441216A (en) * 1990-06-07 1992-02-12 Azuma Seimitsu Kanagata Seisakusho:Kk Mold for injection-molding parabolic antenna
    US5473111A (en) * 1992-10-07 1995-12-05 Mitsubishi Denki Kabushiki Kaisha Shielded enclosure for housing electronic components and manufacturing method thereof
    EP0595418A1 (en) * 1992-10-28 1994-05-04 Di. W.S. PLASTIC S.r.l. Reflecting parabolic antenna for e.m. wave reception and related manufacturing method

    Non-Patent Citations (3)

    * Cited by examiner, † Cited by third party
    Title
    PATENT ABSTRACTS OF JAPAN vol. 013, no. 548 (E - 856) 7 December 1989 (1989-12-07) *
    PATENT ABSTRACTS OF JAPAN vol. 015, no. 414 (M - 1171) 22 October 1991 (1991-10-22) *
    PATENT ABSTRACTS OF JAPAN vol. 016, no. 217 (M - 1252) 21 May 1992 (1992-05-21) *

    Also Published As

    Publication number Publication date
    AT286309T (en) 2005-01-15
    CA2337810A1 (en) 2000-04-27
    FR2784804A1 (en) 2000-04-21
    BR9912233A (en) 2001-04-10
    EP1143561B1 (en) 2004-12-29
    WO2000024086A1 (en) 2000-04-27
    DE69923001T2 (en) 2005-07-21
    JP2002528937A (en) 2002-09-03
    DE69923001D1 (en) 2005-02-03
    US6486854B1 (en) 2002-11-26
    EP1119884A1 (en) 2001-08-01
    FR2784804B1 (en) 2001-06-29
    AU6095299A (en) 2000-05-08

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