JPH0341328B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a method for manufacturing a highly accurate fiber-reinforced plastic reflecting mirror that reflects light in the infrared to visible light range.

[Conventional technology]

Conventional reflecting mirrors of this type have been manufactured by the manufacturing method shown in FIGS. 3 and 4. FIG. 3 is a sectional view showing the state of manufacturing by the conventional manufacturing method, and FIG.
FIG. 3 is a cross-sectional view showing a reflecting mirror manufactured by a conventional manufacturing method. In the figure, 1 is a sanderch structure which is the core material of the reflecting mirror, and 2 is the central member of this sanderch structure 1, which uses a lightweight honeycomb core made of metal or polymer thin plate or polymer foam. . Reference numeral 3 denotes a fiber-reinforced plastic board (hereinafter referred to as an FRP board) bonded to both sides of the central member 2 via a semi-cured resin-impregnated sheet 4 as an adhesive, such as a carbon fiber-reinforced plastic board (hereinafter referred to as a CFRP board). ). Further, 5 is a metal having a high reflectance, for example, an aluminum layer, which is vapor-deposited on the surface that will become the reflective surface after the sanderch structure 1 is formed. Reference numeral 6 denotes a mold for forming a reflecting mirror, and the upper surface on which the reflecting mirror is placed is processed to have a shape and size that match the mirror surface of the reflecting surface, and a mold release agent 7 is applied thereto.

A conventional reflecting mirror is constructed as described above and manufactured as follows. First, a mold release agent 7 is applied to the mirror-finished surface of the mold 6. Next, the FRP board 3, the center member 2, and the FRP board 3 are laminated in this order via an adhesive 4, and heated and pressed to form a sandwich structure 1 that will become a reflecting mirror base material. Next, after demolding, the mold release agent 7 is removed, and the surface of the sandwich structure 1 that will become the reflective surface is polished to a mirror finish, and then aluminum is vapor-deposited on that surface to serve as the reflective surface of the reflective mirror. The sanderch structure 1 with the reflective surface formed is attached to a mounting frame (not shown) to complete the reflective mirror.

[Problem that the invention seeks to solve]

In the conventional manufacturing method of a reflecting mirror as described above, a mold release agent is applied to the top surface of a mold, and an FRP board and a center member are laminated on top of this using an adhesive to form a sandwich structure. Therefore, after molding and demolding, the release agent adhering to the surface that will become the reflective surface must be removed, otherwise the adhesion of the vapor-deposited aluminum film to the reflective surface will not be good.

This invention was made in order to solve these problems, and it is possible to easily release the sandwich structure without using a mold release agent, and after the mold release, aluminum vapor deposition is applied to the surface that will become the reflective surface. The purpose of this study is to obtain a method for manufacturing a reflecting mirror that improves the adhesion of aluminum during processing.

[Means for solving problems]

The method for manufacturing a reflecting mirror according to the present invention is to attach a mold with good adhesion to the upper surface of a mold made of a material with a low coefficient of linear expansion and having a mirror-finished molding surface with the shape and dimensional accuracy required for the reflecting mirror. The first step is plating non-ferrous metal, the second step is placing a semi-hardened FRP plate on the plated surface, heating and pressurizing it to form a reflective mirror base material, and forming a mold. The mold was removed and non-ferrous metal from the mold was attached.
This is a method for manufacturing a reflecting mirror, which includes a third step of vapor depositing a metal with high reflectance, such as aluminum, on the non-ferrous metal surface of an FRP plate.

[Effect]

In this invention, a non-ferrous metal that does not have good adhesion to the mold is plated onto the mirror-finished surface of the mold, an FRP board, etc. is placed on top of it, and the reflective mirror base material is formed by heating and pressurizing it. Then, by transferring the mirror surface of the mold onto the FRP board and attaching non-ferrous metals to create a mirror surface base, immediately deposit a highly reflective metal on top of it to create a mirror surface.
It eliminates the need for removal of mold release agents, etc. that adhere to the board, and for groundwork such as polishing of the FRP board, reducing processing time.

〔Example〕

FIG. 1 shows a partial sectional view of a reflecting mirror manufactured by a manufacturing method according to an embodiment of the present invention. FIG. 2 is a sectional view showing a state in which a reflecting mirror is manufactured according to an embodiment of the present invention. In the figure, numerals 1 to 4 are the same as or equivalent to the conventional example, so a description thereof will be omitted.
Reference numeral 10 is a mold made of a material with a low coefficient of expansion such as glass, and the upper surface serving as the molding surface is mirror-finished to a dimensional accuracy of a reflecting mirror, for example, a surface roughness of 0.05S or less. Reference numeral 11 denotes a hard non-ferrous metal layer, such as copper, which is plated on the mirror-finished surface of the mold 10 and has poor adhesion to the mold. 12 constitutes Sanderutsch structure 1
After the FRP board 3 is formed, the non-ferrous metal layer 11 applied to the top surface of the mirror-finished mold is transferred and a mirror-like base is created. Aluminum is deposited.

The reflecting mirror configured as described above is manufactured as follows. First, a nonferrous metal layer 11 that is hard and does not adhere well to the mold is plated on the mirror-finished upper surface of the mold 10. Next, FRP on this side
The plate 3, the center member 2, and the FRP plate 3 are laminated in this order with a film adhesive 4 interposed therebetween. Next, when hot and pressure molded, a mirror surface is transferred to the FRP plate 3 that is in contact with the mold 10 via the non-ferrous metal layer 11, and at the same time,
A non-ferrous metal layer 11 separates from the mold 10 and adheres to that surface. Therefore, it can be easily removed from the mold after molding, and the non-ferrous metal layer 11 is adhered thereto, thereby forming the sandwich structure 1 which has a mirror finish.
By immediately vapor-depositing a highly reflective metal 12 such as aluminum on the FRP board 3 and attaching it to a support frame (not shown), mirror finishing of the FRP board 3 after molding is no longer necessary, reducing work time. A reflector is manufactured.

In the above example, as the base material of the reflecting mirror,
We have explained an example in which an FRP plate is manufactured using a sandwich structure bonded to both sides of a lightweight core material made of a thin plate of metal or polymeric material.
Using only the plate 3, a nonferrous metal layer 11 is plated on the mirror-finished surface of the mold 10, and a semi-hardened FRP plate 3 is placed in place of the sandwich structure.
By applying heat and pressure, the mirror-like non-ferrous metal layer 11 was transferred, and the mold was easily removable, resulting in a mirror-like surface to which the non-ferrous metal layer 11 was attached.
FRP board 3 can be manufactured. By immediately vapor-depositing a metal 12 with a high reflectance such as aluminum on the base surface that forms this mirror surface and making it the reflective surface of the reflector, the time required for mirror finishing after molding the FRP plate that is the base material can also be omitted. , a reflective mirror with high mirror surface precision can be manufactured.

〔Effect of the invention〕

As explained above, the manufacturing method according to the present invention involves plating a nonferrous metal that does not have good adhesion to the mold on the top surface of a mirror-finished mold made of a material with a small coefficient of linear expansion, and plating the top surface of the mold with a non-ferrous metal that does not have good adhesion to the mold. Place a hardened fiber-reinforced plastic board, etc., heat and pressurize it to form a reflector base material.
Reflective mirrors are manufactured by transferring the mirror surface of the mold onto the FRP board and attaching non-ferrous metals to create a base for the mirror surface, and then depositing a highly reflective metal on top of it. The plating layer applied to the top surface of the mold, which does not adhere well to the mold, adheres and is easily removed from the mold.Also, since the plating layer is applied to the mirror-finished surface, the mirror surface is transferred as is. Since the base for the reflective surface is prepared, there is no need for post-processing such as polishing the reflective surface after demolding, and metal with good reflectivity can be immediately plated, the reflective surface is completed and the work time is shortened.

In addition, since FRP board is used as the base material, it has a low coefficient of linear expansion, and its shape changes little due to temperature changes, and the core material of the base material is a lightweight core material made of a thin plate of metal or polymer material. As a result, a lightweight and highly rigid reflector is manufactured.

[Brief explanation of drawings]

FIG. 1 is a partial sectional view of a reflecting mirror manufactured by a method according to an embodiment of the present invention, FIG. 2 is a sectional view showing a method of manufacturing a reflecting mirror according to an embodiment of the present invention, and FIG. A sectional view showing a method for manufacturing a reflecting mirror. FIG. 4 is a partial sectional view of a reflecting mirror manufactured by a conventional manufacturing method. In the figure, 1 is a sandwich structure, 2 is a central member, 3 is a fiber reinforced plastic board, 4 is a film adhesive, 10 is a mold, 11 is a non-ferrous metal layer,
12 is a metal vapor deposition layer with high reflectance. The same reference numerals in the figures indicate the same or corresponding parts.

Claims (1)

[Claims] 1. A non-ferrous metal that does not adhere well to the mold is placed on the upper surface of the mold made of a material with a low coefficient of linear expansion and has a mirror-finished molding surface with the shape and dimensional accuracy required for a reflecting mirror. The second step is to place a semi-hardened fiber-reinforced plastic plate on the plated non-ferrous metal surface of the mold and heat and pressurize it to form a reflector base material. and a third step of depositing a highly reflective metal on the non-ferrous metal surface of the fiber-reinforced plastic plate to which the plated non-ferrous metal is adhered to the mold after being removed from the mold. Method of manufacturing a reflector. 2. In the second step of molding the reflector base material, a semi-cured fiber-reinforced plastic board is laminated on the plated non-ferrous metal surface of the mold, and a metal or high-grade plastic plate is layered on top of the plated non-ferrous metal surface using an adhesive. A step of laminating at least one of a lightweight core material made of a thin plate of molecular material or a polymer foam, and further laminating a semi-cured fiber-reinforced plastic plate thereon via an adhesive, followed by heating and pressurizing. A method for manufacturing a fiber-reinforced plastic reflecting mirror according to claim 1, characterized in that: