EP1143561B1 - Electromagnetic wave reflector and associated manufactoring method - Google Patents

Electromagnetic wave reflector and associated manufactoring method Download PDF

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Publication number
EP1143561B1
EP1143561B1 EP01201226A EP01201226A EP1143561B1 EP 1143561 B1 EP1143561 B1 EP 1143561B1 EP 01201226 A EP01201226 A EP 01201226A EP 01201226 A EP01201226 A EP 01201226A EP 1143561 B1 EP1143561 B1 EP 1143561B1
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EP
European Patent Office
Prior art keywords
lattice
wires
thermoplastic material
moulding tool
reflector
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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EP01201226A
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German (de)
French (fr)
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EP1143561A1 (en
Inventor
Jacques Trouillet
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Transformation Industrielle De Matieres Plastiques- Stimap Ste
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Transformation Industrielle De Matieres Plastiques- Stimap Ste
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Classifications

    • 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
    • H01Q15/22—Reflecting surfaces; Equivalent structures functioning also as polarisation filter
    • 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
    • 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 present invention relates to electromagnetic wave reflectors made of an element of an electrically conductive material, preferably having a convex face which defines a focal point for radio waves. They are most often antennas in the form of a spherical or parabolic cap, but they can also have any other shape giving focus.
  • DE 3911445 A also discloses antennas made of thermosetting material which require tools intended to obtain the desired shape, in particular parabolic.
  • a metal frame is shaped manually in the tooling.
  • a piece of material is then introduced into the tool above the frame.
  • the tool is locked.
  • Cooking is carried out in order to polymerize the material introduced.
  • the tool is opened and the part is extracted from the mold. Due to molding technology, deburring must be done followed by sanding, removing a primer, then painting on both sides.
  • an antenna comprising a metal fabric coated by injection molding with thermoplastic resin. We gives the desired shape to the wire mesh before molding. It is very difficult to conform a metallic canvas into a parabola with great accuracy.
  • Powder coating technologies do not allow for a large variation in color, without incurring disproportionate manufacturing costs due to the need to clean the manufacturing tool when switching from one color to another .
  • the invention overcomes these drawbacks and makes it possible to obtain an electromagnetic wave reflector protected from corrosion, which is much easier to manufacture and which, in particular, allows the possible use of a paint which is easier and less expensive to use. and therefore to dispense with any painting operation with dusting and the cleaning operations that this entails.
  • the subject of the invention is a method of manufacturing an electromagnetic wave reflector according to claim 1.
  • the network of electrically conductive material may include wires arranged at a distance, preferably constant, from each other.
  • the network is a canvas or a grid, in particular a plane.
  • the manufacture is carried out by injection molding of a thermoplastic material, preferably on a regular mesh grid of an electrically conductive material.
  • the injection is carried out under high pressure, in particular greater than 50 bar and most often between 150 and 450 bar.
  • the network is thus well maintained during molding and the curvatures of the network and of the coating are not offset, the whole being obtained automatically by the usual molding operation.
  • the coating of the wires is often almost complete and, in any case, takes place over more than 80% of the cross section of the wires.
  • the wire generally has a diameter of 0.005 to 0.5 mm, it being understood that the wires can also have a cross section other than circular and that then the values indicated above are understood for the largest dimension of the cross section .
  • thermoplastic material use may in particular be made of polyethylene, polypropylene or other polyolefins, ABS, polycarbonate, poly (methyl methacrylate) as well as any other injectable thermoplastic material.
  • the thickness of plastic material injected is generally between 0.5 mm and 1 cm.
  • the distance between the wires is between 0.003 mm and 1.5 cm.
  • the desired color for the antenna is given to it by the fact that the plastic is dyed in the mass.
  • the antenna can also be transparent.
  • a flat metallic fabric 1 is retained on one of the two half-molds 2, 3 of an injection mold for thermoplastic material.
  • 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
  • FIG. 3 represents the molded injected part 5 in which the fabric 1 is coated which protrudes by a part 6.
  • FIG. 4 shows that the part 6 has been cut in the form of a drop 6 leaving a parabolic antenna in the shape of the imprint 4 which is made up, as shown in FIGS. 5 and 6, of the fabric 1 coated with a layer 7 of thermoplastic plastic.
  • the antenna comprises a central part 8 in the form of a parabola and a peripheral border 9.
  • the fabric 1 appears punctually on one of the faces of the ply 7, while, on at least part of the border 9, the fabric 1 is embedded in the ply 7.
  • the antenna of the figure 5 was obtained when the direction of the injection current into the mold is directed vertically from bottom to top, while in FIG. 6, it was directed vertically from top to bottom.
  • Polyethylene is introduced beforehand brought to a temperature of 260 ° C., so that it can flow through an injection point, into the cavity 4 of the mold which is in the shape of the reflector to be obtained and in which puts a flat aluminum canvas which exceeds.
  • 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.

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

La présente invention concerne des réflecteurs d'ondes électromagnétiques en un élément en un matériau conducteur de l'électricité, ayant de préférence une face convexe qui définit un foyer de focalisation des ondes radioélectriques. Ce sont le plus souvent des antennes en forme de calotte sphérique ou parabolique, mais elles peuvent aussi avoir toute autre forme donnant une focalisation.The present invention relates to electromagnetic wave reflectors made of an element of an electrically conductive material, preferably having a convex face which defines a focal point for radio waves. They are most often antennas in the form of a spherical or parabolic cap, but they can also have any other shape giving focus.

On connaît déjà une antenne métallique fabriquée en emboutissant, en une ou plusieurs passes, une calotte sphérique permettant la focalisation en un point des signaux issus d'un satellite. La surface métallique est radio opaque aux fréquences transmises par le satellite et permet un taux de réflexion théorique de 100 %. Comme la forme est obtenue par emboutissage, la tôle doit subir plusieurs traitements de surface afin de prévenir la corrosion. Ces traitements nécessitent des reprises après l'emboutissage, notamment l'application d'un apprêt et d'une peinture.There is already known a metal antenna manufactured by stamping, in one or more passes, a spherical cap allowing the focusing at a point of the signals coming from a satellite. The metal surface is radio opaque to the 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, in particular the application of a primer and a paint.

On connaît également, par le DE 3911445 A, des antennes en matériau thermodurcissable qui nécessitent un outillage destiné à obtenir la forme, notamment parabolique, souhaitée. Une trame métallique est mise en forme manuellement dans l'outillage. Un pâton de matière est ensuite introduit dans l'outillage au-dessus de la trame. L'outillage est verrouillé. Une cuisson est effectuée afin de polymériser la matière introduite. Après la cuisson, l'outillage est ouvert et la pièce est extraite du moule. En raison de la technologie du moulage, un ébavurage doit être effectué suivi d'un ponçage, d'une dépose d'un apprêt, puis d'une peinture sur les deux faces.DE 3911445 A also discloses antennas made of thermosetting material which require tools intended to obtain the desired shape, in particular parabolic. A metal frame is shaped manually in the tooling. A piece of material is then introduced into 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 done followed by sanding, removing a primer, then painting on both sides.

Au EP-595 418, on décrit une antenne comprenant une toile métallique enrobée par moulage par injection de résine thermoplastique. On donne la forme souhaitée à la toile métallique avant d'effectuer le moulage. Conformer une toile métallique en parabole avec une grande exactitude est une opération très difficile à réaliser.In EP-595 418, an antenna is described comprising a metal fabric coated by injection molding with thermoplastic resin. We gives the desired shape to the wire mesh before molding. It is very difficult to conform a metallic canvas into a parabola with great accuracy.

Les technologies de peinturage avec poudrage ne permettent pas d'avoir une grande variation de teinte, sans avoir à subir des coûts démesurés de fabrication en raison de la nécessité de nettoyer l'outil de fabrication lors du passage d'une teinte à l'autre.Powder coating technologies do not allow for a large variation in color, without incurring disproportionate manufacturing costs due to the need to clean the manufacturing tool when switching from one color to another .

L'invention pallie ces inconvénients et permet d'obtenir un réflecteur d'ondes électromagnétiques protégé de la corrosion, bien plus facile à fabriquer et qui, notamment, permet l'utilisation éventuelle d'une peinture plus facile et moins onéreuse à mettre en oeuvre et donc de se dispenser de toute opération de peinturage avec poudrage et des opérations de nettoyage que cela entraîne.The invention overcomes these drawbacks and makes it possible to obtain an electromagnetic wave reflector protected from corrosion, which is much easier to manufacture and which, in particular, allows the possible use of a paint which is easier and less expensive to use. and therefore to dispense with any painting operation with dusting and the cleaning operations that this entails.

L'invention a pour objet un procédé de fabrication d'un réflecteur d'ondes électromagnétiques suivant la revendication 1.The subject of the invention is a method of manufacturing an electromagnetic wave reflector according to claim 1.

On n'a plus à conformer le réseau indépendamment de l'opération de moulage. Cette conformation s'effectue par l'opération de moulage elle-même.We no longer have to conform the network independently of the molding operation. This conformation is carried out by the molding operation itself.

Le réseau en matériau conducteur de l'électricité peut comprendre des fils disposés à une distance, de préférence constante, les uns des autres. De préférence, le réseau est une toile ou une grille, notamment plane.The network of electrically conductive material may include wires arranged at a distance, preferably constant, from each other. Preferably, the network is a canvas or a grid, in particular a plane.

La fabrication se fait par moulage par injection d'une matière thermoplastique, de préférence sur une grille à maille régulière en un matériau conducteur de l'électricité. L'injection s'effectue sous haute pression, notamment supérieure à 50 bar et le plus souvent comprise entre 150 et 450 bar.The manufacture is carried out by injection molding of a thermoplastic material, preferably on a regular mesh grid of an electrically conductive material. The injection is carried out under high pressure, in particular greater than 50 bar and most often between 150 and 450 bar.

De préférence, le procédé consiste

  • à pincer entre les deux demi-moules d'un moule d'injection de matière thermoplastique un réseau en un matériau conducteur de l'électricité d'une dimension telle qu'il dépasse du pourtour de l'empreinte du moule,
  • à injecter de la matière thermoplastique dans l'empreinte,
  • à démouler une pièce injectée du pourtour de laquelle dépasse le réseau, et
  • à découper le réseau au ras de la pièce.
Preferably, the method consists
  • pinching a network of an electrically conductive material between the two half-molds of an injection mold for thermoplastic material, of a size such that it exceeds the circumference of the mold footprint,
  • injecting thermoplastic material into the impression,
  • to unmold an injected part from the circumference of which exceeds the network, and
  • to cut the network flush with the room.

Le réseau est ainsi bien maintenu pendant le moulage et les courbures du réseau et de l'enrobage ne sont pas décentrées, le tout étant obtenu automatiquement par l'opération de moulage habituelle. L'enrobage des fils est souvent presque complet et, en tout cas, a lieu sur plus de 80% de la section transversale des fils.The network is thus well maintained during molding and the curvatures of the network and of the coating are not offset, the whole being obtained automatically by the usual molding operation. The coating of the wires is often almost complete and, in any case, takes place over more than 80% of the cross section of the wires.

Comme matériau conducteur de l'électricité, on peut utiliser notamment des métaux ferreux et non ferreux ainsi que la fibre de carbone ou leurs oxydes et tout particulièrement l'aluminium et l'inox. Le fil a généralement un diamètre de 0,005 à 0,5 mm, étant entendu que les fils peuvent avoir aussi une section transversale autre que circulaire et qu'alors les valeurs indiquées ci-dessus s'entendent pour la plus grande dimension de la section transversale.As electrically conductive material, it is possible in particular to use ferrous and non-ferrous metals as well as carbon fiber or their oxides and very particularly aluminum and stainless steel. The wire generally has a diameter of 0.005 to 0.5 mm, it being understood that the wires can also have a cross section other than circular and that then the values indicated above are understood for the largest dimension of the cross section .

Comme matière thermoplastique, on peut utiliser notamment du polyéthylène, du polypropylène ou d'autres polyoléfines, de l'ABS, du polycarbonate, du poly(méthacrylate de méthyle) ainsi que toute autre matière thermoplastique injectable. L'épaisseur de matière plastique injectée est en général comprise entre 0,5 mm et 1 cm.As thermoplastic material, use may in particular be made of polyethylene, polypropylene or other polyolefins, ABS, polycarbonate, poly (methyl methacrylate) as well as any other injectable thermoplastic material. The thickness of plastic material injected is generally between 0.5 mm and 1 cm.

Avantageusement, la distance entre les fils est comprise entre 0,003 mm et 1,5 cm.Advantageously, the distance between the wires is between 0.003 mm and 1.5 cm.

Suivant un mode de réalisation tout particulièrement préféré, la couleur souhaitée pour l'antenne lui est conférée par le fait que l'on teint la matière plastique dans la masse. L'antenne peut être aussi transparente.According to a very particularly preferred embodiment, the desired color for the antenna is given to it by the fact that the plastic is dyed in the mass. The antenna can also be transparent.

Au dessin annexé, donné uniquement à titre d'exemple :

  • la figure 1 est une vue en perspective illustrant deux demi-moules suivant l'invention entre lesquels est insérée une toile métallique,
  • la figure 2 montre la toile métallique au stade où elle est pincée entre les deux demi-moules,
  • la figure 3 est une vue en élévation d'une antenne suivant l'invention avant que la toile n'ait été découpée,
  • la figure 4 représente l'antenne avec une chute de la toile qui a été découpée,
  • la figure 5 est une partielle en coupe d'une antenne suivant l'invention, et
  • la figure 6 est une vue partielle en coupe d'une variante d'une antenne suivant l'invention.
In the attached drawing, given solely 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,
  • 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.

Une toile 1 métallique plane est retenue sur l'un des deux demi-moules 2, 3 d'un moule d'injection de matière thermoplastique. La figure 2 montre que, lorsque la toile 1 est pincée entre les deux demi-moules 2, 3, elle dépasse du pourtour de l'empreinte 4 du mouleA flat metallic fabric 1 is retained on one of the two half-molds 2, 3 of an injection mold for thermoplastic material. 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

La figure 3 représente la pièce 5 injectée démoulée dans laquelle est enrobée la toile 1 qui dépasse par une partie 6. La figure 4 montre que la partie 6 a été découpée sous forme de chute 6 laissant une antenne parabolique à la forme de l'empreinte 4 qui est constituée, comme le montre les figures 5 et 6, de la toile 1 nappée par une nappe 7 de matière plastique thermoplastique. L'antenne comporte une partie 8 centrale en forme de parabole et une bordure 9 périphérique. Dans la partie 8 centrale la toile 1 apparaît ponctuellement sur l'une des faces de la nappe 7, tandis que, sur au moins une partie de la bordure 9, la toile 1 est noyée dans la nappe 7. L'antenne de la figure 5 a été obtenue lorsque le sens du courant d'injection dans le moule est dirigé verticalement de bas en haut, tandis qu'à la figure 6, il était dirigé verticalement de haut en bas.FIG. 3 represents the molded injected part 5 in which the fabric 1 is coated which protrudes by a part 6. FIG. 4 shows that the part 6 has been cut in the form of a drop 6 leaving a parabolic antenna in the shape of the imprint 4 which is made up, as shown in FIGS. 5 and 6, of the fabric 1 coated with a layer 7 of thermoplastic plastic. The antenna comprises a central part 8 in the form of a parabola and a peripheral border 9. In the central part 8 the fabric 1 appears punctually on one of the faces of the ply 7, while, on at least part of the border 9, the fabric 1 is embedded in the ply 7. The antenna of the figure 5 was obtained when the direction of the injection current into the mold is directed vertically from bottom to top, while in FIG. 6, it was directed vertically from top to bottom.

L'exemple suivant illustre l'invention.The following example illustrates the invention.

On introduit du polyéthylène préalablement porté à une température de 260°C, en sorte qu'il peut s'écouler par un point d'injection, dans l'empreinte 4 du moule qui est à la forme du réflecteur à obtenir et dans laquelle on met une toile d'aluminium plane qui en dépasse. Pour remplir l'empreinte, on applique à la matière plastique une pression de 177 bar, la force de fermeture des deux moitiés de moule est de 800 tonne. On injecte dans l'empreinte 1,2 kg de polyéthylène. La durée d'injection est de 7 secondes. La pression d'injection est de 117 bar. L'injection terminée, on laisse refroidir pendant 50 secondes, on ouvre le moule et l'on découpe la toile en fil d'aluminium pour obtenir un réflecteur d'ondes électromagnétiques suivant l'invention.Polyethylene is introduced beforehand brought to a temperature of 260 ° C., so that it can flow through an injection point, into the cavity 4 of the mold which is in the shape of the reflector to be obtained and in which puts a flat aluminum canvas which exceeds. 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 (4)

  1. Process for manufacturing a reflector of electromagnetic waves having a parabolic shape in which an electrically conductive lattice (1) is placed in a moulding tool (2, 3), thermoplastic plastic material is placed in the moulding tool (2, 3) and a reflector is demoulded, characterised in that
    - the lattice (1) placed in the moulding tool (2, 3) has a different shape from the parabolic shape and
    - the preferably transparent thermoplastic material is injected into the moulding tool (2, 3) under a pressure which imparts to the lattice (1) said parabolic shape in a coating (7) having a parabolic central portion and a peripheral border, the lattice appearing on one of the faces of the coating and on a portion of the peripheral border, the lattice (1) is buried in the coating.
  2. Process according to claim 1, characterised in that the lattice (1) is a preferably plane metallic gauze.
  3. Process according to claim 2, characterised in that it comprises
    - gripping between the two mould halves (2, 3) of a thermoplastic material injection mould the electrically conductive lattice (1) of a dimension such that it overhangs the periphery of the mould die (4),
    - injecting a thermoplastic material into the die (4),
    - demoulding an injected portion from the periphery of that which overhangs the lattice (1),
    - cutting off the lattice (1) level with the portion.
  4. Process according to one of claims 1 to 3, characterised in that the injection pressure of the thermoplastic plastic material exceeds 5 bar.
EP01201226A 1998-10-16 1999-10-12 Electromagnetic wave reflector and associated manufactoring method Expired - Lifetime EP1143561B1 (en)

Applications Claiming Priority (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
EP99947544A 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
EP99947544A Division EP1119884A1 (en) 1998-10-16 1999-10-12 Electromagnetic wave reflector and method for making same

Publications (2)

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

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EP01201226A Expired - Lifetime EP1143561B1 (en) 1998-10-16 1999-10-12 Electromagnetic wave reflector and associated manufactoring method
EP99947544A Pending EP1119884A1 (en) 1998-10-16 1999-10-12 Electromagnetic wave reflector and method for making same

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EP99947544A Pending EP1119884A1 (en) 1998-10-16 1999-10-12 Electromagnetic wave reflector and method for making same

Country Status (10)

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US (1) US6486854B1 (en)
EP (2) EP1143561B1 (en)
JP (1) JP2002528937A (en)
AT (1) ATE286309T1 (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)

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Publication number Priority date Publication date Assignee Title
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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

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FR2784804B1 (en) 2001-06-29
EP1143561A1 (en) 2001-10-10
FR2784804A1 (en) 2000-04-21
ATE286309T1 (en) 2005-01-15
DE69923001D1 (en) 2005-02-03
WO2000024086A1 (en) 2000-04-27
DE69923001T2 (en) 2005-07-21
US6486854B1 (en) 2002-11-26
BR9912233A (en) 2001-04-10
CA2337810A1 (en) 2000-04-27
AU6095299A (en) 2000-05-08
EP1119884A1 (en) 2001-08-01
JP2002528937A (en) 2002-09-03

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