JPS60167503A - Production of reflecting plate for circular polarized antenna - Google Patents

Abstract

PURPOSE:To obtain the titled reflecting plate having the reflecting performance of radio waves for a long period of time by using a lamination structure of a thermoplastic resin layer excelling in weather resistance, a metallic foil which reflects radio waves and an olefin polymer layer containing an inorganic filler which functions as a structure matter. CONSTITUTION:A dry lamination process is applied to laminate a thermoplastic resin layer A and an olefin polymer layer C to a metallic foil B. Then the layer B of the laminated foil B is attached to the mobile side of a metallic mode of an injection molding machine with the layer C set to the metallic mold side of the fixed side. Then the metallic mold is closed. An olefin polymer D containing an inorganic filler is injection-molded to obtain a reflecting plate. In this case, the injection molding temperature is set higher than the melting point of the olefin polymer containing the inorganic filler and also lower than the thermal decomposition temperature of said olefin polymer. Furthermore either one or both of two primer layers (a) and (b) are not added.

Description

[Detailed Description of the Invention] [I] Purpose of the Invention The present invention provides a thermoplastic resin layer with excellent weather resistance, a metal foil that reflects radio waves, and an olefinic polymer layer containing an inorganic filler that functions as a structure. The present invention relates to a method of manufacturing a reflector for a circularly polarized antenna made of a laminate comprising: More specifically, a metal foil is laminated with a thermoplastic resin layer with excellent weather resistance on one side and an olefin polymer layer on the other side, and the thermoplastic resin layer of the laminated metal foil is injected. The olefin polymer layer is attached to the movable mold surface of the molding mold so that it is on the stationary mold side, and after the mold is closed, the inorganic filler-containing olefin polymer is injection molded. This relates to a method for manufacturing a reflector for a circularly polarized antenna, which is characterized by a circularly polarized antenna that has significantly improved adhesion between the metal foil and the inorganic filler-containing olefin polymer layer that functions as a structure. The purpose of this invention is to provide a reflector for

[II] Background of the Invention Satellite broadcasting using geostationary satellites is planned to be put into practical use in Europe, America, Japan, and other countries around the world in the near future. However, since a geostationary satellite has only one orbit, there is a risk of interference between multiple broadcast radio waves. In order to avoid such mutual interference of broadcast waves,
It is necessary to utilize the cross-polarization identification of the satellite broadcasting antenna. In this way, when receiving terrestrial broadcast waves, the radio waves are linearly polarized horizontally or vertically, and the polarization plane of the receiving antenna is matched to the polarization plane of the broadcast waves, using cross-polarization discrimination. It's not that difficult to do, but
When receiving radio waves from a broadcasting satellite, there is a shift in the plane of polarization due to interference caused by the ionosphere in the radio wave propagation path and the angle of incidence of the radio wave at the reception point, so it is necessary to align the planes of polarization as described above. It is difficult.

Frequency allocation to multiple broadcasting satellites is considered to be done taking into consideration polarization plane discrimination from the point of view of effective use of satellite broadcasting frequency bands, but for satellite broadcasting radio waves with such frequency allocation, Since the quality of the polarization plane adjustment of the receiving antenna directly determines the level of interference between broadcast channels, it cannot be expected to obtain a high degree of cross-polarization discrimination when broadcast satellite radio waves are linearly polarized waves. However, when broadcasting satellite radio waves are circularly polarized waves, it is easy for ordinary listeners to identify them by the direction of the circularly polarized wave, regardless of the deviation of the polarization plane as described above. The receiving antenna not only adjusts its pointing direction to point to the desired broadcasting satellite, but also does not require adjustment of the plane of polarization, making it much easier to adjust the receiving antenna than when linearly polarized waves are used. Therefore, it is possible to obtain the degree of polarization discrimination as designed for the receiving antenna.

For these reasons, plans are being made to use circularly polarized waves for broadcast satellite radio waves in future satellite broadcasting systems. In contrast, conventional circularly polarized antennas include those that use a conical horn, those that combine two Gui balls at right angles, and parabolic antennas that use these antennas as the primary radiator. However, since the structure is complex and large, and manufacturing costs are high, it is not suitable as a receiving antenna for general viewers to receive satellite broadcast radio waves using microwaves in the 12 gigahertz (GH2) band. Not yet.

On the other hand, the structure is extremely simple, and as a small and lightweight microwave antenna, a rectangular waveguide is extended in the axial direction from the center of a parabolic reflector, and its tip is curved so that the open end surface becomes parabolic. There is a so-called Hiha I-type parabolic ann which faces a parabolic reflector at its focal point and uses this as a -order radiator. This antenna is widely used in microwave antennas for mobile relays, etc., but all conventional Heehat-type parabolic antennas use the aforementioned rectangular waveguide to transmit and receive linearly polarized waves. Therefore, it cannot be used for circularly polarized waves.

Generally, metal plates or metal nets have been used as parabolic antennas. However, since metals corrode, it is necessary to use anti-corrosion alloys or apply anti-corrosion coatings. If anti-corrosion alloys are used, they are expensive. On the other hand, with anti-corrosion coatings, it is necessary to repeat the coating several times to achieve complete corrosion protection, which is not only expensive but also
There is a problem in that the painted material deteriorates after being used for many years. Furthermore, attempts have been made to manufacture radio wave reflecting plates in which glass fibers with metallized surfaces are laminated to thermosetting resins such as unsaturated polyester resins as radio wave reflecting layers, but the manufacturing method is complicated and It has been extremely difficult to maintain the radio wave reflective layer at a constant thickness and without unevenness.

[■] Structure of the invention Based on the above, the present inventors have obtained a reflector for a circularly polarized antenna that has a simple manufacturing process, has radio wave reflecting ability, and can maintain its performance for a long period of time. As a result of various searches for this, we found that we used a metal foil laminated with a thermoplastic resin layer with excellent weather resistance on one side and an olefin polymer layer on the other side, and developed a thermoplastic resin layer for the laminated metal foil. The olefin polymer layer is attached to the movable mold surface of the injection mold so that the olefin polymer layer is on the fixed mold side, and after the mold is closed, the inorganic filler-containing olefin polymer is injection molded. We have discovered that a method for manufacturing a reflector for circularly polarized antennas, which is characterized by , arrived at the present invention.

[IV] Effects of the Invention The circularly polarized antenna reflector manufactured by the present invention exhibits the following effects (features) including its manufacturing process.

(1) Since it has excellent corrosion resistance, there is no change in radio wave reflection characteristics over a long period of time.

(2) Since the coefficient of linear expansion of the metal layer and the inorganic filler-containing olefin polymer layer is extremely small, peeling between the layers will not occur even if subjected to heat cycles (repetition of cold and heat) for a long period of time.

(3) The reflector for a circularly polarized antenna is lightweight and the manufacturing process is simple.

(4) The metal layer can be formed uniformly,
There is no uneven reflection of radio waves.

(5) Olefinic polymers containing inorganic fillers can be easily formed into various complex shapes, and therefore have good appearance and functionality.

(6) Since the olefin polymer layer is interposed between the inorganic filler-containing olefin polymer layer and the metal foil, which functions as a structure, the inorganic filler-containing olefin polymer layer and the metal foil The adhesion of the olefin polymer layer containing an inorganic filler is greatly improved, and even if an attempt is made to separate the olefin polymer layer containing an inorganic filler from the metal foil, by selecting a primer between the metal foil and the olefin polymer layer, the metal foil can be easily removed. It can exhibit adhesive strength to the extent that it can be cut.

(7) Contains an inorganic filler that functions as a structure because the olefin polymer layer on which the metal foil is laminated and the olefin polymer layer containing an inorganic filler are partially mixed during injection molding. It does not adversely affect the mechanical strength such as rigidity of the olefin polymer layer.

(8) The laminated metal foil is easy to handle;
For example, it is possible to store it in a roll.

(9) When setting the laminated metal foil in the mold during injection molding, the laminated metal foil can be used in a roll, so it can be continuously supplied, increasing productivity. is significantly improved.

[V] Detailed description of the invention (A) Thermoplastic resin The thermoplastic resin used to manufacture the thermoplastic resin layer of the present invention is widely produced industrially and used in many fields, Their manufacturing methods and various physical properties are well known. Their molecular weight varies depending on the type, but generally ranges from 10,000 to 1,000,000. Typical thermoplastic resins are homopolymers of monomers having double bonds such as ethylene, propylene, vinylidene fluoride, vinyl chloride, and styrene; copolymer of styrene and acrylonitrile (AS resin), resin whose main component is methyl phthalate (H
MA resin) butadiene copolymer rubber, acrylonitrile-
Such as butadiene copolymer rubber (NBR), styrene-butadiene copolymer rubber (SBR), acrylic rubber, ethylene-propylene monomer rubber (EPR), ethylene-propylene-diene ternary copolymer rubber (EPDM), and chlorinated polyethylene. Examples include graft copolymer resins obtained by graft copolymerizing styrene alone or styrene and other vinyl compounds (e.g., acrylonitrile, methyl methacrylate) to rubber, polyamide resins, polyester resins, polyphenylene oxide resins, and polycarbonate resins. Furthermore, even if these thermoplastic resins are modified by grafting an organic compound having at least one double bond (for example, an unsaturated carboxylic acid or its anhydride), they have excellent processability. You can use it if you like. Furthermore, in addition to the graft copolymer resins described above, compositions obtained by blending the above-mentioned rubbers with these thermoplastic resins (the blending ratio of rubber is generally at most 40% by weight) can also be used. Among these thermoplastic resins, fluorine-containing resins such as polyvinylidene fluoride are preferred because of their excellent weather resistance. In addition, resin containing vinyl chloride as a main component, ethylene and/or
Alternatively, even if the resin has propylene as its main component, its silkiness can be improved by adding an ultraviolet absorber, so blends of these can also be preferably used. Furthermore, polyamide resins, polyester resins and polycarbonate resins can also be used. Among these thermoplastic resins, organic compounds ( Particularly, it is advantageous to use a modified resin obtained by graft polymerization of an unsaturated carboxylic acid and its anhydride, in part or in whole, because it has excellent adhesion to the metal layer described below.

(B) Metal layer Furthermore, representative examples of metals that are raw materials for the metal layer in the present invention include simple metals such as aluminum, iron, nickel, copper, and zinc, and alloys containing these metals as main components ( For example, stainless steel, brass). These metals do not need to be surface-treated, and may be previously subjected to surface treatment such as chemical treatment or plating treatment. Furthermore, those that have been painted or printed can also be preferably used.

(C) Olefin polymer The olefin polymer used for producing the olefin polymer layer and the inorganic filler-containing olefin polymer layer on which the metal foil is laminated in the present invention is an ethylene homopolymer. a homopolymer of propylene, a copolymer of ethylene and propylene, ethylene and/or propylene and another α having at most 12 carbon atoms;
- Copolymers with olefins (copolymerization ratio of α-olefins is at most 20% by weight). Melt index of these olefin polymers (JTSK-87
According to 80, the temperature is 180℃ and the load is 2゜18.
kg, hereinafter referred to as rM, T, J) or melt flow index (according to JIS K-6758, measured at a temperature of 230°C and a load of 2.18 kg, hereinafter referred to as rMFIJ). ) is 0.01 to 100
g/10 minutes is preferable, especially 0.02 to 80
g/10 minutes is preferred. M, I41 is MF
If an olefinic polymer having an amount of less than I Kao, o+g 7 to is used, the resulting mixture will not have good moldability. On the other hand, if an olefin polymer exceeding 100 g and 710 minutes is used, the mechanical properties of the resulting molded product will be poor.

Furthermore, low density (0,900 g/cm") to high density (0,980 g/c rn") ethylene homopolymer, copolymer of ethylene and a small amount of the above α-olefin, propylene homopolymer, or Random or block copolymers of propylene and ethylene and/or other alpha-olefins are preferred.

These olefinic polymers are obtained by using a catalyst system (so-called Ziegler catalyst) obtained from a transition metal compound and an organoaluminium compound, and by supporting a chromium-containing compound (e.g., chromium oxide) on a carrier (e.g., silica). It can also be obtained by homopolymerization or copolymerization of olefins using catalyst systems (so-called Phillips catalysts) or radical initiators (eg organic peroxides).

Furthermore, in the present invention, modified polyolefins obtained by graft polymerizing a compound having at least one double bond (for example, an unsaturated carboxylic acid, a base carboxylic acid, a vinyl silane compound) to these olefin polymers are also used. included.

The production methods for these olefin resins and modified polyolefins are well known.

These olefin polymers and modified polyolefins may be used alone or in combination of two or more. Furthermore, two or more of these olefin polymers and modified polyolefins may be used as a resin blend in any proportion.

The methods for producing these olefin polymers and modified polyolefins are well known.

(D) Inorganic filler The inorganic filler used to produce the inorganic filler-containing olefin polymer layer is generally one widely used in the fields of synthetic resins and rubber. These inorganic fillers are preferably inorganic compounds that do not react with oxygen and water and do not decompose during kneading and molding. The inorganic fillers include metals such as aluminum, copper, iron, lead and nickel;
Compounds such as oxides of these metals and metals such as magnesium, calcium, barium, zinc, zirconium, molybdenum, silicon, antimony, and titanium, as well as their hydroxides, sulfates, carbonates, and silicates. , these double salts, and mixtures thereof. Typical examples of the inorganic fillers include the metals mentioned above, aluminum oxide (alumina), water products thereof, calcium hydroxide, magnesium oxide (magnesia), magnesium hydroxide, zinc oxide (zinc white), red lead, and white lead. No. 5 Lead oxide, magnesium carbonate, calcium carbonate, basic magnesium carbonate, white carbon, asbestos, mica, talc, glass fiber, glass powder, glass peas, clay, diatomaceous earth, silica, wollastonite, iron oxide , antimony oxide, titanium oxide (titania), lithopone, pumice grains, aluminum sulfate (such as gypsum), zirconium silicate, zirconium oxide, barium carbonate, dolomite, molybdenum disulfide and iron sand. Among these inorganic fillers, those in powder form preferably have a diameter of 1 mm or less (preferably 0.5 mm or less). In the case of fibrous materials, the diameter is 1 to 500 microns (preferably 1 to 300 microns) and the length is 0.1 to 8 m.
m (preferably 0.1 to 5fflI11). Furthermore, the diameter of the flat plate is 211Iff1 or less (preferably 1FFFFL or less). It works to prevent the occurrence of 6. From this, the thickness is 5 microns to 5III11, preferably 10 microns to 5III1 m, particularly preferably 10 microns to 1 ml11. If the thickness of this thermoplastic resin layer is less than 5 microns, not only will the metal layer corrode, but also the metal layer will wear out due to contact and friction with other items during use, causing the metal layer to disintegrate. occurs and there is a problem. On the other hand, if it exceeds 5 mm, it is not preferable because it not only lowers the reflectance of radio waves but also increases the cost and weight of the laminate.

(2) Metal layer (metal foil) Furthermore, the metal layer of the present invention functions to reflect radio waves. The thickness of this metal layer is between 5 microns and 1 mm.
and preferably 5 to 500 microns, especially l
O to 500 microns is preferred. The thickness of the metal layer is 5
When the thickness is less than microns, wrinkles and folds tend to occur in the metal layer during the production of a laminate, resulting in problems in terms of appearance and performance.

On the other hand, if it exceeds 1.7 cm, not only will the weight increase, but the cost will also increase, and problems will arise when the laminate is curved or bent.

(3) Olefin polymer layer The olefin polymer layer constituting the laminated metal foil in the present invention is an adhesive between the metal foil serving as a radio wave reflecting layer and the inorganic filler-containing olefin polymer layer functioning as a structure. This function not only improves the properties of the laminated metal foil but also facilitates storage and handling of the laminated metal foil. The thickness of this olefinic polymer layer is usually 5 to 5 microns.
00 microns, preferably 5 to 300 microns, and particularly preferably 5 to 200 microns. If the thickness of the olefin polymer layer is less than 5 microns, the olefin polymer tends to wrinkle when producing laminated metal foil, which affects the surface of the metal foil, resulting in poor appearance and performance. There is a problem above. On the other hand, 50
If it exceeds 0 micron, it becomes a problem because the mechanical properties such as strength and rigidity of the inorganic filler-containing olefin polymer layer deteriorate.

8 (4) Inorganic filler-containing olefin polymer layer The composition ratio of the inorganic filler in the inorganic filler-containing olefin polymer layer of the present invention is 10 to 80% by weight (i.e., Composition ratio is 90-20% by weight), 1
0 to 70% by weight is preferred, particularly 10 to 60% by weight. If the composition ratio of the inorganic filler in the inorganic filler-containing olefin polymer layer is less than 10% by weight, the linear expansion coefficient of the inorganic filler-containing olefin polymer layer will be too different from that of the metal layer, resulting in heat cycle failure. Therefore, there is a problem that not only peeling may occur between the metal layer and the inorganic filler-containing olefin polymer layer, but also that the resulting laminate lacks rigidity. On the other hand, if it exceeds 80% by weight, it is difficult to produce a uniform composition, and even if a uniform composition is obtained, it is difficult to produce a laminate by sheet production or injection molding as described below. In this case, it is not possible to obtain a good product (laminate).

The thickness of this inorganic filler-containing olefin polymer layer is 50
0 micron to 15 mm, preferably 1 to 10 mm, especially 1 to 7 mm. If the thickness of the inorganic filler-containing olefin polymer layer is less than 500 microns, it is undesirable because it lacks rigidity and is easily deformed and damaged by external forces. On the other hand, if it exceeds +5vn, it will take time to cool down during molding, and not only will sink marks be more likely to occur on the surface, but the weight will increase, causing problems in use.

In producing the thermoplastic resin layer, olefin polymer layer, and inorganic filler-containing olefin polymer layer,
Stabilizers against oxygen, heat and UV rays, metal deterioration inhibitors, flame retardants, colorants, electrical property improvers, antistatic agents, lubricants, processability improvers and adhesives commonly used in their respective fields. Additives such as modifiers may be added to the extent that the properties of the compositions of the thermoplastic resin layer and the inorganic filler-containing olefin polymer layer of the present invention are not impaired.

When blending the above additives into the thermoplastic resin and olefin polymer of the present invention, and when producing an olefin polymer containing an inorganic filler agent (including cases where the above additives are blended), each industry Tri-blending may be performed using a commonly used mixer such as a Henschel mixer, a Banbury mixer,
It can be obtained by melt-kneading using a mixer such as a Nigu, roll mill, and single screw extruder. At this time, a homogeneous composition can be obtained by tri-blending in advance and melt-kneading the resulting composition (mixture).

In particular, it is preferable to use the olefin polymer in the form of powder because it allows for more uniform mixing.

In this case, the mixture is generally melt-kneaded, then molded into pellets, and subjected to the molding described later.

In producing the inorganic filler-containing olefin polymer of the present invention, all the ingredients may be mixed at the same time, or a part of the ingredients may be mixed in advance to produce a so-called masterbatch. It is also possible to mix 1 with the remaining ingredients.

When melt-kneading is performed to produce the above blends, it must be carried out at a temperature higher than the melting point or softening point of the thermoplastic resin or olefinic polymer used, but if carried out at a high temperature, the thermoplastic resin and olefin polymer may The system polymer deteriorates. For these reasons, the temperature is generally 20°C higher than the melting point or softening point of the respective thermoplastic resin or olefin polymer (preferably higher than 50°C), but the temperature does not cause deterioration. Implemented within a range.

(F) Manufacturing method of laminated metal foil In the present invention, the method of laminating the thermoplastic resin layer and olefin polymer layer on the metal foil is a dry lamination method (extrusion lamination method) which is generally practiced. This can be achieved by applying The method will be explained in detail below.

Method 2 of laminating (adhering) a thermoplastic resin layer with excellent weather resistance and a metal foil, which is a metal layer, can generally be carried out by a dry lamination method. It is possible to extrude. Further, in the case of an olefin polymer, the thermoplastic resin layer and the metal foil can be laminated (adhered) by an extrusion lamination method. To produce laminated metal foil using the extrusion lamination method, a T-die film forming machine is used to produce a resin temperature of 2.
The thermoplastic resin forming the thermoplastic resin layer and the olefin polymer forming the olefin polymer layer are extruded at a temperature range of 40 to 370°C to the above-mentioned thickness, and at the same time cooled and pressurized. A roll may be used to adhere the metal foil.

When using thermoplastic resins and olefin polymers that have excellent adhesion to metal foil, laminated metal foil can be produced as described above.

However, if neither the thermoplastic resin nor the olefinic polymer has sufficient adhesion to the metal foil, a primer (3) commonly used in the field of thermoplastic resins (3) may be used. Anchor coating agent) is applied to one side of the metal foil by gravure coating method or perspective coating method, and
Dry at C. Next, a thermoplastic resin film or sheet is pressed onto the surface of the metal foil primer using a pressure roll heated to 50 to 100°C. The metal foil laminated with the thermoplastic resin thus obtained is then laminated with a film or sheet of olefinic polymer on the other side thereof with a primer interposed therebetween. Alternatively, in contrast to this method, an olefin polymer film or sheet may be laminated on the metal foil with a primer interposed in advance, and a thermoplastic resin film or sheet may be laminated on the other side with a primer interposed. good.

Either of the thermoplastic resin and the olefin polymer has sufficiently satisfactory adhesion to the metal foil,
If the other conditions are not satisfactory, a laminate can be produced by extrusion laminating a film or sheet with sufficient adhesion on one side of the metal foil without intervening a primer as described above. A primer may be interposed on the other surface of the metal foil of this laminate in the same manner as described above, and a film or sheet with insufficient adhesiveness may be laminated thereon. Alternatively, a receipt without a film but with insufficient adhesion is laminated on one side of metal foil with a primer interposed in the same manner as above, and a film or sheet with sufficient adhesion is coated with a primer on the other side of the laminated metal foil. The adhesive may be bonded by the extrusion lamination method described above without intervening.

The primer differs depending on the type of thermoplastic resin in the thermoplastic resin layer and the olefin polymer in the olefin polymer layer, but it is commonly used in various fields, and there are aqueous types and solvent types. The types include vinyl, acrylic, polyamide, epoxy, rubber, urethane, and titanium.

The laminated gold foil (metal layer) produced in this way will be explained with reference to FIG. FIG. 1 is a partially enlarged sectional view of the laminated metal foil.

In this drawing, A is a thermoplastic resin layer with excellent weather resistance, and B is a metal layer (metal foil). Further, C is an olefin polymer layer. Furthermore, a and b are a single layer of primers (a and/or b do not exist if one or more of the primers is not used).

(G) Production of reflector plate for circularly polarized antenna The thermoplastic resin layer of the laminated metal foil obtained as described above is placed on the moving side mold surface of the mold of an injection molding machine.
Once the olefin polymer layer is on the fixed side of the mold, the mold is closed. Next, the reflection plate for a circularly polarized antenna of the present invention can be manufactured by injection molding the inorganic filler-containing olefin polymer. At this time, the injection molding temperature is such that the resin temperature is higher than the melting point of the inorganic filler-containing olefin polymer, but lower than the thermal decomposition temperature of the olefin polymer. When a propylene polymer is used as the olefin polymer, insert injection molding is preferably carried out at a temperature in the range of 170 to 280°C. On the other hand, when an ethylene polymer is used as the olefin polymer, insert injection molding is carried out at a temperature in the range of 120 to 250°C. Also,
If the injection pressure at the nozzle part of the cylinder of the injection molding machine is 40 kg/cm or less, the olefin polymer containing the S-filler can be shaped into a shape almost similar to that of the mold. Not only can this be done, but also a product with good appearance can be obtained. Injection lf force is generally 40~
+4 (l kg/cm', especially 70-12
0 kg/cm' is desirable.

(H) Reflection plate for circularly polarized antenna The reflection plate for circularly polarized antenna of the present invention obtained as described below will be explained with reference to FIGS. 2 and 3.

FIG. 1 is a partial perspective view of an antenna with an additional reflector for a circularly polarized antenna. FIG. 2 is a sectional view of the reflector for the circularly polarized antenna. Furthermore, FIG. 3 is a partially enlarged view of the cross-sectional view. In FIG. 1, I is a reflector for a circularly polarized antenna of the present invention, and II is a reflector for a circularly polarized antenna of the present invention.
(2) is a converter support rod, and (2) is a reflector support rod. Also, ■ is wiring.

Further, in FIGS. 3 and 4, l is a laminated metal foil.

Furthermore, A is a thermoplastic resin layer with excellent weather resistance,
B is metal foil. Furthermore, C is an olefin polymer layer, and D is an inorganic filler-containing olefin polymer layer in which an olefin polymer is mixed. Furthermore, although a and b are primer layers, one or both may be absent. Furthermore, in order to attach the circularly polarized antenna reflector obtained in this way to a support, ribs may be added to the olefin polymer layer containing an inorganic filler, and ribs may be added to the inorganic filler-containing olefin polymer layer. You can also add reinforcing ribs to strengthen the board. Furthermore, it is also possible to drill holes in the circularly polarized antenna support obtained by the present invention and attach various support attachment parts using bolts, nuts, etc. Further, the diameter of the reflector for the circularly polarized antenna is usually 60 CI11 to 120 cm.

[VI] Examples and Comparative Examples The present invention will be explained in more detail with reference to Examples below.

In the Examples and Comparative Examples, the radio wave reflectance was measured as a microwave reflection coefficient based on the voltage standing wave ratio when a rectangular waveguide was used and the tip of the waveguide was short-circuited. Weather resistance tests were conducted using a Sunshine Carbon Weather Meter under the conditions of a black panel temperature of 83°C and a due cycle of 12 minutes/(60 minutes of irradiation).
After a period of time, the external appearance of the surface (detrimental changes such as discoloration, fading, gloss change, crazing, blistering, peeling of metal foil, cracking, etc.) was evaluated. Furthermore, the heat cycle test tested the sample at 80%
°C for 2 hours, followed by gradual cooling to -45 °C over 4 hours, exposure to this temperature for 2 hours, and then gradual heating to 80 °C over 4 hours, repeating this cycle for 100
After the test was repeated, the appearance of the surface of the sample was evaluated in the same manner as in the weather resistance test. In addition, 9 peel strength was measured by cutting a test piece with a width of 15III11 from the manufactured reflector for circularly polarized antenna, and measuring the peel strength according to ASTM D-9.
The strength was evaluated based on the strength when a metal foil laminated at a peeling speed of 50 mm/min was peeled at 180 degrees in accordance with 03. In this column of Table 1, ``cohesive failure'' refers to the fact that the adhesive strength between the laminated metal foil and the inorganic filler-containing olefin polymer layer is too strong, causing the metal foil to break. Furthermore, the bending stiffness is ASTM 0-
780 and the coefficient of thermal expansion is ASTM D
-EI! Measured according to 3B.

The types and physical properties of the thermoplastic resin, olefin polymer, inorganic filler, and metal foil used in the thermoplastic resin layer in Examples and Comparative Examples are shown below.

[(A) Thermoplastic resin] As a thermoplastic resin, melt flow rate (ASTM
Polyvinylidene fluoride (hereinafter referred to as PVdFJ) with a temperature of 250 ° C and a load of 10 kg according to D-1238)
0.4% by weight of benzotriazole-based ultraviolet absorber
Propylene homopolymer containing 0 and 0.5% by weight of carbon black [melt flow index (JIS
K-6758, measured at a temperature of 230°C and a load of 2.18 kg, hereinafter referred to as rMFIJ) for 0.5g 710 minutes, hereinafter referred to as rPP(A)J], benzotriazole-based ultraviolet absorption High-density polyethylene containing 0.4 wt.% carbon black and 0.5 wt.% carbon black [density 0.958 g/cm”
, melt index (measured according to JIS K-8780 at a temperature of 190°C and a load of 2.1Bkg, hereinafter referred to as rM, 1.J) is 0-8g/10
minutes, hereinafter referred to as r HDPE(1)J] as a mixture,
20 parts by weight and 80 parts by weight of acrylonitrile-styrene copolymer resin having a Mooney viscosity (ML, +4) of 108 (chlorine content 3.15% by weight, amorphous, molecular weight of raw material polyethylene approximately 200,000) (acrylonitrile content 23% by weight) and 2 as a stabilizer.
A composition obtained by mixing parts by weight of a dibutyl tin malate stabilizer [manufactured by Sankyoki Gosei Co., Ltd., trade name: Stann BM] for 10 minutes using a roll (surface temperature: 180°C) (hereinafter referred to as r AGSJ) and 20 parts by weight of dioctyl phthalate-1- (as a plasticizer) and 5.0 parts by weight of dibutyltin malate (as a dehydrochlorination inhibitor) were added to 100 parts by weight of vinyl chloride single weight. A mixture blended with polymer (polymerization degree 1100, hereinafter referred to as rPVCJ) was used.

[(B) Olefin polymer] As an olefin polymer, a propylene homopolymer having an MFI of 2.0 g 710 minutes r or less referred to as PP(B) J] A propylene-ethylene block having an MFI of 15 g/10 minutes Copolymer [ethylene content 1
5% by weight, hereinafter rPP(fll:)J,! -say]
, M, r, is 0.8 g 710 min. High-density ethylene homopolymer r density 0.950 g/cm", hereinafter r
HDPE (2) 1 called J and M, r.

High-density ethylene homopolymer [density 0% af (Ig/cm”, hereinafter referred to as rHDP) with a density of 20 g/10 min
E(3) I used 1 called J.

[(C) Inorganic filler] As the inorganic filler, talc with an average particle size of 3 microns (aspect ratio of about 7), mica with an average particle size of 3 microns (aspect ratio of about 8), glass fiber ( Single fiber diameter 11 microns, cut length 3+nm
, hereinafter referred to as rGFJ), and calcium carbonate (hereinafter referred to as rcacO3J) having an average particle size of 0.8 microns.

[(D) Metal foil] Aluminum foil each having a thickness of about 20 microns (
Copper, brass and silver foils were used.

Examples 1 to 11, Comparative Examples 1 to 3 The thermoplastic resins, PP (B) and HDPE (2) were molded to produce films each having a thickness of 50 microns. In addition, an acrylic primer (
Apply urethane primer (manufactured by Toyo Morton Co., Ltd., trade name Adko 335) to a thickness of 20 microns on each side. It was coated to a micron thickness and dried (in Examples 6 and 7, the urethane-based primer was coated on both sides). The thermoplastic resin film produced in this way (not used in Comparative Example 1), the metal foil coated with primer on both sides, and the olefin polymer film (not used in Comparative Example 3) ) was adhered by a dry lamination method to produce a laminated metal foil.

Furthermore, an inorganic filler and an olefin polymer (the types of each inorganic filler and olefin polymer and the content of the inorganic filler in the composition are shown in Table 1. In Comparative Example 2, the inorganic filler 5 each (without any agent)
Tri-blending was performed using a Henschel mixer for a minute, and each mixture was used to produce a composition using a vented extruder at a resin temperature of 230°C.

The laminated metal foil produced in this way was applied to the moving side mold surface (
The mold was inserted so that the olefin polymer layer was the surface of the fixed mold. After closing the mold, the injection pressure is 80kg/crn'
and resin temperature of 240°C, insert injection of the composition whose types of olefin resin and inorganic filler and the content of the inorganic filler in the composition are shown in Table 1 is shown in Table 1. Molding was performed to produce a reflector for a circularly polarized antenna having the same shape as in Example 1.

The elastic modulus and linear expansion coefficient of the inorganic filler-containing olefin polymer layer of each circularly polarized antenna reflector obtained as described above and the inorganic filler-containing olefin polymer layer of the metal foil were determined. Peel strength was measured. The results are shown in Table 1.

(The following is a blank space) When the radio wave reflectance of each circularly polarized antenna reflector obtained as described above was measured, it was 98% in all cases. Furthermore, we conducted a weather resistance test and a heat cycle test, but no harmful changes such as discoloration, fading, change in gloss, crazing, blistering, peeling of metal foil, or cracks were observed on the surface of all samples except for Comparative Example 1. . However, in Comparative Example 1, the aluminum foil on the surface corroded.

[Brief explanation of the drawing]

FIG. 1 is a partially enlarged sectional view of a laminated metal foil. Furthermore, FIG. 2 is a partial perspective view of an antenna to which a typical reflector for a circularly polarized antenna manufactured according to the present invention is attached. Moreover, FIG. 3 is a sectional view of the reflector for the circularly polarized antenna. Furthermore, FIG. 4 is a partially enlarged view of the sectional view. A... Thermoplastic resin layer with excellent weather resistance, B... Metal layer (metal foil), C... Olefin polymer layer, a.
... one layer of primer, b... one layer of primer, D... olefin polymer layer containing inorganic filler mixed with olefin polymer layer, 7 1... laminated metal foil, ■...・Reflector for circularly polarized antenna, II...Converter, ■...Converter support rod, ■...Reflector support rod, ■...Wiring, Patent applicant Showa Denko Co., Ltd. Agent Patent attorney Kikuchi Spirit-8

Claims (1)

[Claims] Using a metal foil laminated with a thermoplastic resin layer with excellent weather resistance on one side and an olefin polymer layer on the other side, the thermoplastic resin layer of the laminated metal foil is placed in a mold for injection molding. A circle characterized in that the olefin polymer layer is attached to the movable side mold surface so that it is on the stationary side mold side, and after the mold is closed, the olefin polymer containing an inorganic filler is injection molded. A method for manufacturing a reflector for a polarized antenna.