JP5693290B2 - Method for manufacturing antenna reflector - Google Patents

Description

The present invention relates to the production how the antenna reflector.

The antenna reflector is required to have surface mirror accuracy and conductivity in order to reflect radio waves. Therefore, it is often manufactured using sheet metal processing or drawing processing of a metal plate.
Since fiber reinforced plastic (FRP) has high specific strength, it may be used for the purpose of weight reduction. Regarding an antenna reflector using a fiber reinforced plastic, Patent Document 1 describes a fiber reinforced plastic reflector antenna in which a conductive woven fabric (6) is formed on a reflecting surface. Moreover, it is described in patent document 2 regarding the fiber reinforced plastic molding using a prepreg.

JP 61-205005 JP-A-6-8240

However, in the FRP reflector antenna described in Patent Document 1 described above, three conductive layers coated with a conductive layer on the reflective surface side, an intermediate radio wave absorber, a conductive paint on the opposite side of the reflective surface, and the like. There is a problem that the number of manufacturing steps is increased, for example, the surface opposite to the reflecting surface is composed of layers and requires coating with a conductive paint.
Further, the fiber reinforced plastic molded article described in Patent Document 2 is manufactured such as a prepreg manufacturing process, a prepreg attaching process, a heat curing process in a mold, a deburring process, a polishing process, and a clear coating process. There was a problem that the number of processes increased.

The present invention has been made to solve the above problems, and an object thereof is to provide a manufacturing how the manufacturing process is small antenna reflector.

  The method of manufacturing an antenna reflector according to the present invention includes a metal film forming step for forming a metal film on a fiber in a yarn or cloth state, a first fiber having a metal film formed in the metal film forming step, and a metal film. Molded second fibers that are not formed, a release sheet that is permeable to the resin and has a releasability to the cured resin, a diffusion net that has voids to promote the flow of the resin, and a non-breathable film Step of installing on the mold in sequence, Adhesion step of sealing other than the through hole of the tube by sandwiching the tube and bonding the mold and film without gaps, and molding the film through the through hole An exhaust step for discharging the air in the space surrounded by the mold to the outside, and an injection step for injecting resin into the space from which air has been discharged in the exhaust step through the through hole And removing the film, the diffusion net, the release sheet, and the tube after the resin injected in the injection step is cured, and removing the cured first fiber and second fiber from the mold. It is characterized by including.

According to this invention, without using a prepreg, the first fiber on which the metal film is formed in the state of yarn (yarn) or cloth, the second fiber on which the metal film is not formed, and the auxiliary material installed, for doing injection and curing of the resin, it is possible to provide a manufacturing how the less manufacturing steps antenna reflector.

FIG. 3 is a diagram illustrating a layer configuration of the antenna reflector according to the first embodiment. It is a figure for demonstrating the manufacturing method of the antenna reflector of this invention. 6 is a diagram illustrating a layer configuration of an antenna reflector according to a second embodiment. FIG. 6 is a diagram illustrating a layer configuration of an antenna reflector according to Embodiment 3. FIG.

Embodiment 1 FIG.
Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a diagram showing a layer structure of an antenna reflector 10 according to the present invention.
As shown in this figure, the antenna reflector 10 of this embodiment has a resin infiltrated into a metal vapor-deposited cloth (first fiber) 1 and a glass cloth 2 (second fiber), and the permeated resin is used. It is an antenna reflector of an antenna used by the frequency up to 40 GHz manufactured by hardening with the metal vapor deposition cloth 1 and the glass cloth 2. FIG.

  The metal vapor-deposited cloth 1 is a reinforcing member having a metal film using Cu-Ni metal vapor deposition, metal plating, or both metal vapor deposition and metal plating in a yarn (thread) state or a cloth (woven fabric) state. It is a cloth as (fiber). The metal vapor deposition cloth 1 constitutes at least one layer of the reflecting surface side surface of the antenna reflector 10. The thickness of the metal film is preferably 0.1 μm or more and 30 μm or less. Specifically, at least one of aluminum, chromium, zinc, gold, silver, platinum, and nickel can be used for the metal film.

The main raw material of the metal vapor deposition cloth 1 can be glass, a resin material, or a carbon fiber material. Examples of the resin material include PET (Polyethylene terephthalate), polyethylene (polyethylene), and polyester (polyester). The metal vapor deposition cloth 1 is preferably in a woven (cross) state, but may be in a mat state.
The metal vapor-deposited cloth 1 may be laminated in such a state that the optimal number of sheets is electrically shifted if necessary, that is, the fiber directions are different from each other (independent of the fiber direction). With respect to the configuration of the reflective surface, the number of the metal vapor deposition cloths 1 is increased and the angle is further shifted to increase the reflection efficiency, so that the manufacturing process can be reduced.

  The glass cloth 2 is a cloth or a mat that is laminated on the opposite side of the reflective surface of the metal vapor deposition cloth 1 and is not subjected to metal vapor deposition and metal plating. The main raw material of the glass cloth 2 can be glass, a resin material, or a carbon fiber material. Examples of the resin material include PET (Polyethylene terephthalate), polyethylene (polyethylene), and polyester (polyester).

  A plurality of glass cloths 2 may be layered. The number of glass cloths 2 can be determined based on the strength required for the antenna reflector 10.

Next, a method for manufacturing the antenna reflector 10 using the VaRTM method according to the first embodiment will be described with reference to FIG.
Metal vapor deposition cloth 1 by forming a metal film by performing metal vapor deposition, metal plating, or both metal vapor deposition and metal plating in a yarn or cloth state on a fiber made mainly of glass or resin material. (Metal film forming step).

  On the convex mold 8, from the mold surface side, the metal vapor-deposited cloth 1 is placed at the bottom by shifting the angle, if necessary, by an electrically optimal number of sheets. On the metal vapor deposition cloth 1 that has been installed, a glass cloth 2 that has not been subjected to metal vapor deposition and metal plating to a thickness necessary for strength is installed. On the installed glass cloth 2, auxiliary materials such as peel ply (release sheet) 3, resin diffusion net (diffusion net) 4, bagging film (film) 5 are installed (installation step).

  The tube 6 is installed between the mold 8 and the bagging film 5, and the mold 8 and the bagging film 5 are bonded to each other with the seal tape 7 between the tubes 6 (adhesion step). Thereby, it becomes possible to seal other than the through-hole in the tube 6.

  The air in the space surrounded by the bagging film 5 and the mold 8 is discharged to the outside through the through hole of the tube 6 (exhaust step). As a result, the pressure around the metal vapor deposition cloth 1 and the glass cloth 2 and in the air gap is reduced. Accordingly, the resin can easily penetrate there.

Resin is injected into the space from which the air has been discharged through the through-hole of the tube 6 (injection step).
After the injected resin is cured, the bagging film 5, the resin diffusion net 4, the peel ply 3, and the tube 6 are removed, and the cured metal vapor deposition cloth 1 and glass cloth 2 (antenna reflector 10) are removed from the mold 8 (removal step). ).
After finishing the necessary outer periphery and mounting hole, etc., and painting if necessary, the product is completed.

  The peel ply 3 is permeable to resin and has peelability with respect to the cured resin. The peel ply 3 has a function of preventing the product and the auxiliary material from sticking with resin. Thereby, the effect that the resin and other auxiliary materials are easily peeled after the resin is cured is obtained. The peel ply 3 is preferably a soft cloth (woven fabric) using polyester. Representative product names include, for example, Econo Ply J (Air Tech). However, the present invention is not limited to this, and various applications are possible after confirming compatibility with a resin material such as a phenol resin. Since it becomes a mark at the time of peeling, a colored product or a product with a line is preferable.

  The resin diffusion net 4 is inserted between the peel ply 3 installed on the glass cloth 2 and the bagging film 5 and has a function of promoting the flow of the resin. The resin diffusion net 4 includes gaps in all directions. As a result, an effect of uniformly flowing the resin that permeates the cloth is obtained. The resin diffusion net 4 is preferably in the form of a soft sheet or mesh (woven fabric). For example, 35-FM-007 can be given as a typical product name.

  The bagging film 5 has the same function as the mold. Moreover, the bagging film 5 has a function of forming an appropriate gap when the resin is poured into the laminated metal vapor deposition cloth 1 and the glass cloth 2. The bagging film 5 also has a function of maintaining the degree of vacuum around the antenna reflector 10 being manufactured. That is, the bagging film 5 has no air permeability and blocks the air around the metal vapor deposition cloth 1 and the glass cloth 2 from the outside air.

  The bagging film 5 is preferably made of soft nylon (nylon film) as a material. The thickness of the bagging film 5 is preferably a sheet of about 38 micrometers. Representative product names include, for example, Econolon (Air Tech). However, the present invention is not limited to this, and various selections can be made based on heat resistance, styrene resistance (and other solvent) properties, gas barrier properties, elongation, and the like. Note that the bagging film 5 is generally used with wrinkles approached at the expense of elongation from the viewpoint of price.

  The tube 6 has a function as a resin passage when the resin is poured. The tube 6 has a function as a suction port when vacuum suction is performed. A general PE tube having a thickness of about 1.5 mm to 2 mm and using polyethylene as a material is suitable.

The seal tape 7 is a tape for bonding the bagging film 5 and the mold 8. The mold 8 can be a resin material.
The resin injected through the tube 6 may be a conductive resin or a non-conductive resin. Specifically, an epoxy resin, a vinyl ester resin, an unsaturated polyester resin, a phenol resin, or the like can be used. As typical trade names, there can be mentioned vinyl ester type lipoxy (registered trademark) R7070 (manufactured by Showa Denko KK).

  As described above, in the manufacturing method of the antenna reflector 10 according to the first embodiment, the metal film is formed on the fiber in the yarn or cloth state, and the metal vapor-deposited cloth 1 and the metal film are formed. Molded glass cloth 2, peel ply 3 through which resin can permeate and peel from cured resin, resin diffusion net 4 having voids to promote resin flow, and non-breathable bagging film 5 The mold 8 and the bagging film 5 are placed in order on the mold 8, and the tube 6 is sandwiched between them and bonded together without any gaps so that the holes other than the through hole of the tube 6 are sealed. Air in the space surrounded by the bagging film 5 and the mold 8 is discharged to the outside, and resin is injected into the space from which the air has been discharged through the through-hole of the tube 6. After curing of the resins, bagging film 5, resin distribution network 4, remove the peel ply 3 and the tube 6, and remove the metal deposition cloth 1 and glass cloth 2 after curing from mold 8. For this reason, the prepreg manufacturing process, the prepreg attaching process, the pressure heating process, the process of forming a conductive layer on the surface by applying paint, the process of depositing metal on the molded reflector, the middle of the reflector The step of forming the radio wave absorber layer and the post-processing steps such as deburring, polishing and clear coating can be omitted. Therefore, there is an effect that it is possible to provide the manufacturing method of the antenna reflector 10 and the antenna reflector 10 with few manufacturing processes.

  The antenna reflector 10 according to the first embodiment includes at least two metal vapor-deposited cloths 1 on which a metal film is formed and a glass cloth 2 on which no metal film is formed, and at least two metal vapor-deposited sheets. The cloths 1 may be characterized by different fiber directions. For this reason, there exists an effect that reflection efficiency can be raised, without increasing a manufacturing process.

Moreover, the antenna reflector manufacturing method according to Embodiment 1 can use a mold 8 that is less expensive than a mold in the case of using a prepreg that requires pressure heating. Furthermore, an autoclave required when using a prepreg is unnecessary. Therefore, there is an effect that the cost for manufacturing can be reduced.
Furthermore, the environment resistance such as weather resistance is expected to be improved as compared with a metal antenna reflector that is conventionally used.

  In addition, when forming FRP using a prepreg as described in Patent Document 1, it is necessary to form a conductive layer on the surface in order to give radio wave reflectivity. In the case of application, a certain technique is required for uniform application. Furthermore, the electromagnetic wave absorber is difficult to process and requires high accuracy.

  If molding is performed by using a molding method such as the VaRTM method without using a prepreg, a molding die can be a resin die instead of a so-called mold. Moreover, if VaRTM method is used, it can shape | mold without using the autoclave currently used by FRP shaping | molding. In addition, if an exothermic curable resin is used in terms of equipment, a large-scale drying and curing furnace is not necessary, and it can be manufactured at low cost. When using a prepreg, the life of the prepreg is short, so the burden of life management is large.On the other hand, when using the manufacturing method according to this embodiment, the cloth and the resin can be stored separately, so the burden of life management is reduced. There is an effect that it can be reduced.

Embodiment 2. FIG.
FIG. 3 is a diagram showing a layer configuration of the antenna reflector 10 according to the second embodiment of the present invention. In the figure, the same reference numerals as those in FIG.
In the antenna reflector 10 according to the second embodiment, all the layers are configured by the metal vapor deposition cloth 1 (first fiber, second fiber) shown in the first embodiment.
Thereby, the reflection characteristic of the antenna reflector 10 can be improved.

  The metal vapor-deposited cloth 1 may be laminated with an angle shifted from each other. That is, you may laminate | stack in the state which does not depend on the direction of a fiber. With such a configuration, there is an effect that the reflection characteristics can be further improved without increasing the number of manufacturing steps.

Embodiment 3 FIG.
FIG. 4 is a diagram showing a layer configuration of the antenna reflector 10 according to the third embodiment of the present invention. In the figure, the same reference numerals as those in FIG.
The antenna reflector 10 according to the third embodiment has a metal-deposited cloth 1 (first fiber, third fiber) whose front surface (reflection surface side) and back surface (opposite side of the reflection surface) are shown in the first embodiment. ). A glass cloth 2 (second fiber) having a thickness that appropriately maintains the distance between the metal vapor deposition cloths 1 on the front surface and the back surface is laminated so as to be sandwiched between the metal vapor deposition cloths 1 on the front surface and the back surface.
Thereby, the leak from an antenna reflector reflective surface can be suppressed. In addition, there is an effect that reflection of radio waves on the back surface can be suppressed.

  The number of metal vapor deposition cloths 1 on the surface may be set to an electrically optimal number, and may be laminated with the angles shifted from each other. That is, you may laminate | stack in the state which does not depend on the direction of a fiber. With such a configuration, there is an effect that the reflection characteristics can be improved without increasing the number of manufacturing steps.

  In the present invention, within the scope of the invention, any combination of the embodiments, or any modification of any component in each embodiment, or omission of any component in each embodiment is possible. .

  1 metal vapor deposition cloth, 2 glass cloth, 3 peel ply (peeling sheet), 4 resin diffusion net (diffusion net), 5 bagging film (film), 6 tube, 7 seal tape, 8 mold, 10 antenna reflector.

Claims (5)

A metal film forming step of forming a metal film on the yarn or cloth fiber;
The first fiber on which the metal film is formed in the metal film forming step, the second fiber on which the metal film is not formed, and a release sheet that is permeable to the resin and has a release property to the cured resin An installation step of sequentially installing a diffusion net having a gap for promoting the flow of the resin and a non-breathable film on a mold;
Adhesion step of sealing the mold and the film, sandwiching the tube between them and sealing other than the through-hole of the tube by adhering without gaps;
An exhaust step for discharging the air in the space surrounded by the film and the mold through the through hole to the outside;
An injection step of injecting the resin through the through hole into the space where air is discharged in the exhaust step;
After the resin injected in the injection step is cured, the film, the diffusion net, the release sheet, and the tube are removed, and the first fiber and the second fiber after being cured are removed from the mold. Steps,
A method for manufacturing an antenna reflector, comprising: A metal film forming step of forming a metal film on the yarn or cloth fiber;
The first fiber on which the metal film is formed in the metal film formation step, the second fiber on which the metal film is formed in the metal film formation step, and the resin is permeable and is peeled from the cured resin An installation step of sequentially installing a release sheet having properties, a diffusion net having a gap for promoting the flow of the resin, and a non-breathable film on a mold;
Adhesion step of sealing the mold and the film, sandwiching the tube between them and sealing other than the through-hole of the tube by adhering without gaps;
An exhaust step for discharging the air in the space surrounded by the film and the mold through the through hole to the outside;
An injection step of injecting the resin through the through hole into the space where air is discharged in the exhaust step;
After the resin injected in the injection step is cured, the film, the diffusion net, the release sheet, and the tube are removed, and the first fiber and the second fiber after being cured are removed from the mold. Steps,
A method for manufacturing an antenna reflector, comprising: In the installation step, the first fiber in which the metal film is formed in the metal film formation step, the second fiber in which the metal film is not formed, and the first fiber in which the metal film is formed in the metal film formation step 3, a release sheet that is permeable to the resin and has a releasability to the cured resin, a diffusion net having voids for promoting the flow of the resin, and a non-breathable film on the mold In order,
In the removal step, after the resin injected in the injection step is cured, the film, the diffusion net, the release sheet, and the tube are removed, and the cured first fiber, second fiber, and Removing the third fiber from the mold;
The method of manufacturing an antenna reflector according to claim 1.   4. The apparatus according to claim 1, wherein in the installation step, at least two first fibers on which the metal film is formed are installed so that the directions of the fibers are different from each other. 5. A method for manufacturing the antenna reflector according to claim 1.   The method for manufacturing an antenna reflector according to any one of claims 1 to 4, wherein the mold is made of a resin material.

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