JPH06152228A - Manufacture of reflector - Google Patents

Abstract

PURPOSE:To obtain the manufacturing method of the reflector whose manufacture process is omitted of a process forming a surface protection layer. CONSTITUTION:A metallic net 14 is arranged in a core mold 18 forming a reflecting face of a reflector 10. A protection film of the same color as that oaf a backup member 12 is formed on the metallic net 14. A backup member 12 is put on the metallic net 14 and they are put in a die and pressed and heated in a cavity mold 19 to form integrally the metallic net 14 and the backup member 12. Since the protection film is formed on the metallic net 14, it is not required to form a protection layer on a reflection face of the reflector 10 by post-paint and the color of the protection film is made the same as that of the backup member 12, the metallic net 14 does not appear on the external appearance.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a reflector for microwaves, which can be used for satellite broadcasting reception, communication satellite transmission / reception, and relay station radio transmission.

[0002]

2. Description of the Related Art Currently, a reflector for a parabolic antenna is manufactured by the following method. That is, to the core mold that forms the reflective surface of the reflector,
Set a metal mesh as a reflective material, and put SMC (Sheet Molding Compound) as a backup material on the metal mesh. Next, the mold is clamped with a cavity mold that forms the backup surface of the reflector, and heated and pressed to integrally mold the metal net and SMC. After that, the core mold and the cavity mold are opened, the molded product is taken out, and post-painted by spraying or the like to form a surface protective layer on the reflecting surface, and the metal net is subjected to rust prevention and weather resistance treatment.

However, this method requires equipment for a coating line and requires primer treatment in order to secure the adhesion of the topcoat. Further, since the number of steps for taking out the molded product and holding it laterally increases, the cost as a whole increases.

[0004]

SUMMARY OF THE INVENTION In consideration of the above facts, an object of the present invention is to provide a reflector manufacturing method capable of omitting the step of forming a surface protective layer in the reflector manufacturing step.

[0005]

According to the method of manufacturing a reflector of the present invention, a reflecting material is arranged in a core mold for molding the reflecting surface of the reflector, and a backup material for the reflector is put on the upper surface of the core mold to form the core. In a method of manufacturing a reflector in which a mold and a cavity mold for molding the backup surface of the reflector are clamped, and the reflector and the backup material are integrally molded by heating and pressing, a protective film having the same color as the backup material is used in advance. It is characterized by using a coated reflective material.

[0006]

In the present invention having the above structure, the reflecting material is arranged on the core mold for molding the reflecting surface of the reflector. The reflective material is coated with a protective film having the same color as the backup material.

Next, a backup material is put on the reflecting material, and the cavity mold is clamped and heated and pressed.
The reflector and backup material are integrally molded.

Since the protective film is formed on this reflective material, it is not necessary to form a protective layer on the reflective surface of the reflector by post-coating, and the color of the protective film is the same as that of the backup material. , The reflective material does not appear in the appearance.

[0009]

【Example】

(Structure of Reflector) FIG. 1 shows a sectional view of a reflector 10 manufactured by the reflector manufacturing method according to this embodiment. On the surface of the backup material 12 formed of SMC which is the base material of the reflector 10, a metal net 14 is provided as a reflective material. This metal net 1
The outer periphery of 4 is coated with a protective film 15. As the material of the protective film 15, a two-component reaction type resin such as urethane type, polyester type, vinyl ester type, epoxy type, acrylic type, or a resin obtained by modifying or mixing these is used.

Further, the back-up member 12 and the metal net 1
4 is continuous from the flat portion F through the flat portion F to a flange portion 16 bent at an acute angle. As described above, by providing the flat portion F, the flange portion 16 of the reflector 10 is not bent at an acute angle, so that the reflective layer can be formed smoothly. The flange portion 16 has a shape that opens outward at an inclination angle θ with respect to a perpendicular line at the outer end of the flat portion F.

(Metal Net Manufacturing Method) The manufacturing process of the metal net used for manufacturing the reflector 10 will be described. The metal net 14 is manufactured by a painting process and a punching process.

As shown in FIG. 2, in the coating process, the long metal net 14 wound in a roll shape is wound by the winding roller 30.
It is unwound by the pulling force of. This metal net 14
It is guided by the guide roller 32 and wound around the coating roller 34. The coating roller 34 is immersed in a coating tank 38 containing a two-liquid reaction type resin 36, and conveys the metal net 14 into the coating tank 38. As a result, the outer peripheral surface of the metal wire forming the metal net 14 is uniformly coated with the two-liquid reaction type resin 36, and the protective film 15 (see FIG. 1) having a predetermined thickness is formed. The metal net 14 on which the protective film 15 is formed is
It is transported to the drying chamber 40. The drying chamber 40 is provided with a plurality of transport rollers 42. While being conveyed to the plurality of conveying rollers 42, the metal net 14 is dried by a drying fan and a heater (not shown), and is taken up by a take-up roller 30 rotated by a driving device.

In the coating process, the two-component urethane paint may be sprayed on both sides of the metal net 14 with a spray gun and dried (as an example, a drying temperature of 80 ° C. and a drying time of 60 minutes). This eliminates the need to provide the coating tank 38 and simplifies the coating equipment. In any of the examples, the color of the paint coating the metal net 14 is the same as that of the backup material 12.

Next, as shown in FIG. 3, the protective film 15 is formed and the metal net 14 wound into a roll is cut into a circular shape by a punching device 44, and the reflector 1 is then cut.
The metal net 14 for 0 is formed. In addition, this metal net 14
Are once packed and transported to the manufacturing plant of the reflector 10.

(Reflector Manufacturing Apparatus) FIG. 4 shows a manufacturing apparatus M used in the reflector manufacturing method of the first embodiment. The manufacturing apparatus M of the reflector 10 includes a core mold 18 and a cavity mold 19
Is equipped with. The core mold 18 is engraved with the shape of the reflector surface R of the reflector, while the cavity mold 19 is engraved with the shape of the backup surface B of the reflector 10. In addition, a boss portion 23 for mounting the reflector 10 is formed in the cavity mold 19, and a nut (not shown) is inserted therein.

The hydraulic cylinders 50 and 52 for clamping the core mold 18 and the cavity mold 19 are
The mold clamping pressure is controlled by the controller 54.

(Manufacturing Method of Reflector) Here, a manufacturing method of the reflector using the above-described metal net will be described with reference to FIG.

First, the core mold 18 forming the reflecting surface R of the reflector 10 is heated to 145 ° C.
Next, the metal net 14 is set on the core mold 18, and SMC is mounted thereon as the backup material 12. Next, the cavity mold 19 is attached to the hydraulic cylinder 5.
It is lowered by 0, 52 and the mold is clamped. The mold clamping pressure by the hydraulic cylinders 50 and 52 is 200 tons, the mold temperature is 145 ° C., and the mold is heated and pressed for about 180 seconds. As a result, the metal net 14 and the backup material 12 are integrally molded.

Next, after the mold is opened, the reflector 10 is removed from the inside of the cavity with an ejector pin (not shown), and the manufacturing process is completed.

As described above, in this embodiment, as shown in FIG. 1, the metal net 14 having the protective film 15 formed in advance on the outer peripheral surface thereof is used.
Therefore, it is not necessary to form a protective layer on the reflecting surface R of the reflector 10 by post-coating, the post-coating step is omitted, and the manufacturing cost is reduced. Further, since the color of the protective film 15 is the same as that of the backup material 12, the metal net 14 does not appear in the appearance.

In this embodiment, the metal net 14 is described as the reflecting material, but brass wire, galvanized iron wire, stainless steel wire, and aluminum wire can be used as the material of the metal net. As the conductive mesh, a woven or non-woven fabric of conductive fibers such as aluminum-coated glass, carbon fiber, nickel-plated polyester, and nickel-plated glass, or a metal wire-glass mixed woven fabric can be applied.

Further, SMC is used as the backup material 12.
(Sheet molding compound) was adopted,
In addition, BMC (bulk molding compound), TMC (sick molding compound), glass cloth prepreg, etc. can be applied.

If desired, a woven or non-woven fabric made of glass fiber, polyester fiber, vinylon fiber or the like may be interposed between the metal net 14 and the backup material 12.
It is effective in preventing the disturbance and breakage of the reflective material.

[0024]

EFFECTS OF THE INVENTION Since the present invention employs the above manufacturing method, the step of forming the surface protective layer can be omitted, and the manufacturing cost can be reduced.

[Brief description of drawings]

FIG. 1 is a cross-sectional view of a reflector manufactured by a reflector manufacturing method according to the present invention.

FIG. 2 is a conceptual diagram showing steps of a reflector manufacturing method according to the present invention.

FIG. 3 is a conceptual diagram showing steps of a reflector manufacturing method according to the present invention.

FIG. 4 is a conceptual diagram showing steps of a reflector manufacturing method according to the present invention.

[Explanation of symbols]

 12 Backup Material 14 Metal Mesh (Reflective Material) 15 Protective Film 18 Core Mold 19 Cavity Mold

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Claims (1)

[Claims] 1. A core mold for molding a reflecting surface of a reflector, a reflecting material is disposed on the core mold, and a backup material for the reflector is put on the upper surface of the core mold and a cavity mold for molding a backup surface of the reflector. In a method of manufacturing a reflector in which a mold is clamped and heated and pressed to integrally mold the reflection material and the backup material, a reflector characterized in that a reflection material coated in advance with a protective film of the same color as the backup material is used. Production method.