JPS60171803A - Reflecting plate for circularly polarized wave antenna - Google Patents

Abstract

PURPOSE:To improve the durability of a reflecting plate for circularly polarized wave antenna by laminating a metallic layer having a coating film layer excellent in the weatherproof performance and a styrene group polymer layer including inorganic filler. CONSTITUTION:The reflecting plate for circularly polarized wave antenna has a three-layer structure using the metallic layer 2 being a radio wave reflecting layer as an intermediate layer. The thickness of the metallic layer 2 is 5mum- 1mm.. The coating film layer 3 excellent in the weatherproof performance is provided to the inside of the metallic layer 2. The thickness of the coating film layer 3 is 5mum-1mm.. The styrene group polymer layer 1 including inorganic filler is provided to the outside of the metallic layer 2. The thickness of the polymer layer 1 is 500mum-15mm. and has 10-80wt% of the inorganic filler. In order to improve the adhesion, it is also possible to provide primer layers 2a and 2b respectively between the metallic layer 2 and the coating film layer and between the layer 2 and the polymer layer 1.

Description

DETAILED DESCRIPTION OF THE INVENTION [I] Object of the Invention The present invention relates to a reflector for a circularly polarized antenna made of a laminate having a metal layer serving as a radio wave reflecting layer as an intermediate layer. More specifically, (A) a metal layer having 119 coating layers with excellent ilT1 weatherability and (B) a filler-containing styrenic polymer layer are laminated, and the thickness of the coating layer is 5 microns to 5 microns. 1III11, the thickness of the metal layer is 5 microns to 1IIlfll, and the thickness of the styrenic polymer layer containing an inorganic filler is 500 microns to 15 mm.
The object of the present invention is to provide a reflector for a circularly polarized antenna, characterized in that the content of the inorganic filler in this layer is 10 to 80% by weight.

[II] Satellite broadcasting using the invented geostationary satellite is planned to be put to 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 interference between broadcast waves, it is necessary to utilize cross-polarization identification of the satellite broadcast receiving antenna. In this way, when receiving broadcast radio waves from the ground, the radio waves are made into horizontal or ridge linearly polarized waves,
It is not very difficult to match the polarization plane of the receiving antenna to the polarization plane of this broadcast radio wave and utilize cross-polarization discrimination, but when receiving radio waves from a broadcasting satellite, it is difficult to use the ionosphere etc. in the radio wave propagation path. It is difficult to match the polarization planes of two series because deviations occur in the planes of polarization due to disturbances caused by radio waves and the angle of incidence of the radio waves at the receiving point.

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. On the other hand, conventional circularly polarized antennas include those that use a biconical horn, those that combine two Gui balls at right angles, and parabolic antennas that use these antennas as primary radiators. Because the structure is complex, large, and expensive to manufacture, it is not suitable for general audience receiving antennas that cannot receive satellite broadcast radio waves using microwaves in the 12 gigahertz (G&) band. do not have.

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 opening end surface becomes a parabolic shape. There is a so-called heat-type T1 parabolic ann which faces a parabolic reflector at the focal position and uses this as a -order radiator. This antenna is widely used as a microwave antenna for mobile relays, etc.
All conventional Hehat-type parabolic antennas use short waveguides as described above to transmit and receive linearly polarized waves, and 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.

[I [1] Structure of the invention -■- Based on the above, the present inventors have developed 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 obtaining a reflector for use in commercial use, we found that a laminate consisting of at least (A) a metal layer having a coating layer with good weatherability and (B) a styrene polymer layer containing an inorganic filler was found. Yes, the thickness of the coating layer is between 5 microns and 1 micron.
mff+, the thickness of the metal layer is 5 microns to 1 m
m, and the thickness of the inorganic filler-containing styrenic polymer layer is 500 microns to 15 m111, and the content of the inorganic filler in this layer is 10 to 80% by weight. We have discovered that antenna reflectors not only have good durability but also excellent radio wave reflection characteristics, and have arrived at the present invention.

[IV] Effects of the Invention The circularly polarized antenna reflector of 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 styrene polymer layer is extremely small, peeling will not occur in the living room 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) Styrenic polymers containing inorganic fillers can be easily formed into various complex shapes, and therefore have good appearance and functionality.

(6) The mechanical strength (especially rigidity) of the circularly polarized antenna reflector is excellent.

[V] Detailed Description of the Invention (A) Paint The paint used to produce the metal layer having a coating layer with good weather resistance of the present invention is widely produced industrially and is widely used as a paint for metals. It is used in many areas. The manufacturing method and various physical properties of these paints are well known. These ml are solvent-based, in which organic solvents such as toluene and xylene are used,
Although it is classified into water-based emulsion type and solvent-free type, any type of paint can be selected depending on the coating method. Typical examples of these paints include unsaturated or saturated polyester resin paints, polyurethane resin paints obtained by reacting polyester polyols, polyether polyols, or polyurethane polyols with diisocyanates, aminoalkyd resin paints, Acrylic resin paint, melamine resin paint, cyanoacrylate resin paint, epoxy resin paint, silicone resin paint, organic titanate paint, vinyl chloride resin paint, acrylic urethane resin paint, amide resin paint, and fluoride resin paint Examples include fluorine-containing resin paints such as vinylidene resin. Furthermore, additives such as matting agents such as silicic acid, coloring agents such as pigments and dyes, antioxidants, and ultraviolet absorbers can be added to these paints. Among the above paints, polyurethane resin paints, acrylic resin paints, epoxy resin paints, aminoalkyd resin paints, and vinylidene fluoride resin paints are preferred because of their excellent weather resistance. In particular, it is preferable to incorporate an antioxidant and an ultraviolet absorber into the paint of the present invention because a paint with good weather resistance can be obtained.

(B) Metal layer Furthermore, typical 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). 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) Styrenic polymer The styrenic polymer used to produce the inorganic filler-containing styrenic polymer layer in the present invention is a styrene homopolymer (generally, the molecular weight is 50.0
00 to aoo, ooo), styrene-based copolymers (at least 60% by weight) with other monomers (i.e., organic compounds having double bonds), and impact-resistant resins described below. Representative examples of the organic compound having double bonds include ethylene, vinyl acetate, maleic anhydride, acrylonitrile, and methyl methacrylate. Methods for producing these styrenic polymers are widely known and used in a wide variety of fields. The impact-resistant resin is obtained by graft copolymerizing styrene onto butadiene homopolymer rubber and styrene-butadiene copolymer rubber. The styrene-butadiene copolymer rubber is a copolymer rubber with styrene containing butanene as a main component (60% by weight or more), and may be a random copolymer rubber or a block copolymer rubber. The Mooney viscosity of these butadiene homopolymer rubbers and styrene-butadiene copolymer rubbers is usually 20.
-140, and particularly preferably 20-120. Graft copolymerization methods include bulk polymerization, solution polymerization,
There are emulsion polymerization methods, aqueous suspension polymerization methods, and methods that combine these graft polymerization methods (for example, a method of bulk polymerization followed by aqueous suspension polymerization). Butadiene alone used to produce 100 parts by weight of impact resistant resin.

The total amount of the synthetic rubber and styrene-butadiene copolymer rubber is 1 to 30 parts by weight, preferably 1 to 25 parts by weight, and particularly preferably 2 to 20 parts by weight. Incidentally, a graft polymer containing a large amount of rubber-like substances is produced using a relatively large amount of the above-mentioned rubber, and the above-mentioned styrene homopolymer and/or styrene and other monomers are added to the graft polymer. Although a copolymer may be mixed, the amount of rubber used in this case is calculated based on the mixture. The molecular weight of the monomer bonded to the rubber as a graft chain is usually 1.
,000 to 300,000, especially 2,000
~250.000 is desirable. In general, complete monomer bonding to the rubber is rare, and homopolymers of grafts, rubber, and monomers that do not bond to the rubber coexist. These grafts, rubbers and homopolymers are used as they are without being separated.

These styrenic polymers are industrially produced and used in a wide variety of fields, and their production methods, properties, and uses are widely known.

(D) Inorganic filler The inorganic filler used to produce the inorganic filler-containing styrenic 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. Examples of the inorganic filler include aluminum, copper, iron, lead, and 2000 ml of hard metals, oxides of these metals and metals such as magnesium, calcium, nohelium, zinc, zirconium, molybdenum, silicon, antimony, and titanium; Compounds such as its hydrates (hydroxides), sulfates, carbonates, and silicates,
It is broadly classified into these double salts and mixtures thereof. Typical examples of the inorganic filler include the metals mentioned above, aluminum oxide (alumina), its hydrate, calcium hydroxide,
Magnesium oxide (magnesia), magnesium hydroxide, zinc oxide (zinc white), red lead and white lead oxides, magnesium carbonate, calcium carbonate, basic magnesium carbonate, white carbon, asbestos, mica, talc , glass fiber, glass powder, glass peas, clay, diatom, silica, walrus/night, iron oxide, antimony oxide, titanium oxide (titania), lithopone, pumice grains, aluminum sulfate (gypsum, etc.), silicon Mention may be made of zirconium oxides, zirconium oxides, lium carbonate, dolomite, molybdenum disulfide and iron sand.

Among these inorganic fillers, those in powder form
If f-force≦1Bm or less (preferably 0.5 mm or less), force≦femininity. In addition, for fibrous materials, the diameter is 1 to 500.
microns (preferably 1 to 300 microns) and length 0.1 to 6 m+ (preferably 0.1 to 5 m).
m) c7) highly desirable. Furthermore, the diameter of the flat plate is 2 mm or less (preferably 1 mm or less for women) (E) Structure of the base layer (1) Coating layer The coating layer of the present invention has a diameter of 2 mm or less (preferably 1 mm or less for women). This functions to prevent the occurrence of 11z. In this case, the thickness l is 1+nm, and the thickness l is preferably 0.5 mm, especially the thickness l is 10 microns.
O, '3mm is suitable. If the thickness of this coating layer is less than 5 microns, not only will corrosion of the metal layer occur, but
Due to contact and friction with other items during use,
This causes problems such as the metal layer becoming exposed due to wear. On the other hand, if it exceeds 5 mm, it is not preferable because it not only reduces the reflectance of Lf and radio waves but also increases the cost and weight of the laminate.

(2) Metal layer The metal layer of the present invention serves to reflect radio waves. The thickness of this metal layer is between 6 microns and 1 m, preferably between 5 and 500 microns, especially between 10 and 1 m.
500 microns is preferred. If the thickness of the metal layer is less than 5 microns, the metal layer is likely to wrinkle or fold during the production of a laminate, resulting in problems in terms of appearance and performance. On the other hand, if it exceeds 1 mrD, not only will the weight increase, but the cost will also increase, and problems will arise when the laminate is curved or bent.

(3) Inorganic filler-containing styrenic polymer layer The composition ratio of the inorganic filler in the inorganic filler-containing styrenic polymer layer of the present invention is 10 to 80% by weight (i.e., the composition of the styrenic polymer The proportion is 80-20% by weight), 10-7
0% by weight is preferred, particularly 10-60% by weight. If the composition ratio of the inorganic filler in the inorganic filler-containing styrenic polymer layer is less than 10% by weight, the linear expansion coefficient of the inorganic filler-containing styrenic 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 styrenic 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 homogeneous composition, and even if a uniform composition is obtained, it is difficult to produce sheets and injection molding as described below. However, it is not possible to obtain a good product (laminate).

The thickness of this inorganic filler-containing styrenic polymer layer is 500 mm.
The thickness ranges from microns to 15 inches, preferably 1 to 10 mm, particularly preferably 1 to 7 mm. If the thickness of the inorganic filler-containing styrenic polymer layer is 50 microns, it is not desirable because it lacks rigidity and is deformed and damaged by external force. On the other hand, if it exceeds 15 mm, 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 and the inorganic filler-containing styrenic polymer layer, stabilizers against oxygen, heat and ultraviolet rays, 1F agents for metal deterioration, flame retardants, and colorants commonly used in the respective fields are used. Male additives such as additives, electrical property improvers, antistatic agents, lubricants, strength improvers, and tack improvers are added to the composition of the thermoplastic resin layer and the inorganic filler-containing styrenic polymer layer of the present invention. They may be added as long as they do not impair the properties of the product.

When blending the above-mentioned additives into the thermoplastic resin of the present invention and when producing an inorganic filler-containing styrenic polymer (including the case where the above-mentioned additives are blended), Henschel Tri-blending may be carried out using a mixer such as a mixer, and it can be obtained by melt-kneading using a mixer such as a Banbury mixer, kneader, roll mill, or screw extruder. At this time, a homogeneous composition can be obtained by triblending in advance and melt-kneading the resulting composition (mixture).

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

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

In producing the inorganic filler-containing styrenic 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. and the remaining ingredients may be mixed.

When melt-kneading is carried out in the production of the above blends, it must be carried out at a temperature higher than the melting point or softening point of the thermoplastic resin or styrenic polymer used. However, if carried out at high temperatures, the thermoplastic resin and styrene 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 styrenic polymer (preferably higher than 50°C), but the temperature does not cause deterioration. Implemented within a range.

(F) Reflector for Circularly Polarized Antenna The following is a description of the reflector for circularly polarized antenna according to the present invention with reference to FIGS. 1 to 3. FIG. 1 is a partial perspective view of an antenna to which a reflector for a circularly polarized antenna is attached. FIG. 2 is a sectional view of the reflector for the circularly polarized antenna. Also, the third
The figure is a partially enlarged view of the sectional view. In FIG. 1, A is a reflector for a circularly polarized antenna of the present invention, B is a converter, C is a converter support rod, and D is a reflector support rod. Further, E is a wiring. Further, in FIGS. 2 and 3, 1 is a styrene polymer layer containing an inorganic filler, and 2 is a metal layer (metal foil). Also,
3 is a coating layer with good weather resistance. Furthermore, -2a and 2b are primer layers. As is clear from these drawings, the feature of the reflector for a circularly polarized antenna of the present invention is that it has a structure consisting of at least three layers. The reflector for a circularly polarized antenna of the present invention is composed of a metal layer having a coating layer and a styrene polymer layer containing an inorganic filler. If the adhesion between the polymer layer and the polymer layer is good, it may be used as is, but if the adhesion is poor,
In order to maintain sufficient adhesion (adhesion) between them, an adhesion imparting agent such as a primer may be interposed.

There are various methods for manufacturing the circularly polarized antenna reflector of the present invention. A typical example of this method is to apply an adhesion promoter or primer to one side of the metal layer and dry it, then apply a paint. It may be laminated with a polymer layer. Alternatively, after laminating the metal layer and the inorganic filler-containing styrene polymer layer, a paint may be applied to the -1- side of the metal layer. Furthermore, in order to attach the reflector for a circularly polarized antenna of the present invention to a support, ribs may be added to the inorganic filler-containing styrene polymer layer, and the reflector may be reinforced. It is also possible to add reinforcing ribs. 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 80 cm to 120 cm.

CG) Method for manufacturing a reflector for a circularly polarized antenna The reflector for a circularly polarized antenna of the present invention is produced by laminating a metal layer having a coating layer or a styrenic polymer layer containing an inorganic filler on the metal layer. In this method, it can also be produced by inserting one side of the metal layer or the other side without a coating layer into a mold of an injection molding machine and then injection molding the inorganic filler-containing styrenic polymer. Either of these methods
If the adhesion between the metal layer and the inorganic filler-containing styrenic polymer layer is excellent, it is possible to produce a laminate by molding using these methods without applying an adhesion agent to the metal layer. good. In addition, a reflector for a circularly polarized antenna can be manufactured by extrusion lamination, press molding, or insert injection molding, in which a metal layer and an inorganic filler-containing styrene polymer layer are interposed in advance with or without an adhesion agent. It's okay. Furthermore, a metal layer with or without a coating layer and an inorganic filler-containing styrene polymer layer are laminated in this order with or without intervening an adhesive layer between each layer, and then heat-pressed. It may also be manufactured by In manufacturing the circularly polarized antenna reflector of the present invention, the circularly polarized antenna reflector is made of a metal foil that does not have a coating layer and is not coated with a primer, and a styrene polymer containing an inorganic filler. A molded article for producing a board may be manufactured, and this molded article may be coated with or without a primer as described below. None of the above extrusion/lamination methods, press molding methods, insert injection molding methods, and thermocompression bonding methods are unique to the present invention, and commonly used methods may be applied. The manufacturing method using these molding methods will be explained in more detail.

(I) Production by vacuum forming method To produce by this method, a primer is applied to one side of the metal layer, which has been preliminarily laminated with a coating layer with excellent weather resistance, and then a styrene polymer containing an inorganic filler is applied to the metal layer. When extruded into a sheet by the Gooey molding method, by laminating on one side, a laminate in which a coating layer, a metal layer, and an inorganic filler-containing styrenic polymer layer with excellent weather resistance are sequentially laminated can be obtained. The laminate obtained in this way (
The sheets are fixed with iron cotton or claw-like objects, placed in a jig that is easy to handle, and then drawn into a device that can be heated using ceramic heaters or sheathed wire heaters arranged vertically, and heated. When the sheet is heated, it begins to melt, but at that time, the sheet begins to sag, and then as the heating continues, it stretches inside the wafer that is holding it down. When this stretching phenomenon is observed, the best timing for sheet molding is when the molded product is in a good heating state without wrinkles or uneven thickness. At this time, the sheet work is pulled out and placed in the -L section of the mold, and vacuum forming is performed from the mold side under a reduced pressure of 1 atmosphere to obtain the desired molded product. Then, the product is cooled by wind or water spray and released from the mold.

On the other hand, in compressed air forming, the sheet that is easier to mold is pulled out to the top of the mold, a chamber (box) for compressed air is placed over the sheet, and the sheet is pressed against the mold side with a pressure of 3 to 5 atm. A molded product can be obtained by pushing up the mold together with the mold.

In addition, in any molding method, the surface temperature of the sheet is 110
A suitable temperature is between 180°C and 180°C.

(2) Manufacturing by stamping molding method In order to manufacture the reflector plate for a circularly polarized antenna of the present invention by this method, the weather resistance used in the order of manufacturing the reflector plate for a circularly polarized antenna by the vacuum forming method described above is required. A laminate sheet in which a superior coating layer, a metal layer, and an inorganic filler-containing styrene polymer layer are sequentially laminated is introduced into a drawing die attached to a vertical press machine, and the laminate sheet is drawn into a drawing die attached to a vertical press to produce a 5-50 kg/crn.
The desired molded product is obtained by heating and pressurizing it under a pressure of 10 to 20 kg/cm' (preferably 10 to 20 kg/cm').Then, the product is released by cooling with air or water spray and releasing it from the mold. In molding, the pressurizing time is usually 15 seconds or more, generally 15 to 40 seconds.Also, in order to improve the surface properties, it is preferable to mold under two-step pressure conditions. In case, the first stage is under pressure of 10-20 kg/cm'.
After pressurizing for 0 seconds, 40-50 kg/cm” in the second stage
A molded product with excellent surface smoothness can be obtained by applying pressure for 5 seconds or more under a pressure of . In particular, when using a styrene polymer layer containing an inorganic filler with poor fluidity, this two-step molding method is preferable. In addition, the suitable molding temperature in the stamping molding method is a surface temperature of 180 to 230°C. .

(3) Manufacturing by injection molding method To manufacture the circularly polarized antenna reflector of the present invention by injection molding method, a coating layer with excellent weather resistance is laminated on one side in advance, and a primer is applied on the other side. The coated metal layer is subjected to insert injection molding when molding a reflector for a circularly polarized antenna. To carry out insert injection molding,
The metal layer is inserted between the male and female molds of an injection molding machine (so that the coating layer with excellent weather resistance is on the male mold side), and the mold is closed. Thereafter, a styrene polymer containing an inorganic filler is filled into the mold through the gate of the mold, and after cooling, the mold is opened to obtain a desired reflector for a circularly polarized antenna. For insert injection molding, the resin temperature is above the melting point of the styrenic polymer of the inorganic filled styrenic polymer, but below the thermal decomposition temperature of the styrenic polymer.

Insert injection molding is preferably carried out at a temperature range of 160 to 230"O. Also, the injection pressure is 40 kg/c at the nozzle of the cylinder of the injection molding machine.
If it is not less than m', the inorganic filler-containing styrenic polymer can not only be shaped into a shape almost similar to the shape of the mold, but also a product with good appearance can be obtained. The injection pressure is generally 40 to 140 kg/cm', preferably 70 to 120 kg/cm'.

As mentioned above, the method of applying paint to the unpainted metal foil of molded products manufactured by vacuum forming, stamping molding, or injection molding is not a special method. There are methods of applying the coating 1 using a spray gun, a method of brush coating, a method of using a roll coater, etc., but from an industrial perspective, the method of using a spray gun is more efficient, especially when using a robot. The preferred method is to use the method of application.

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

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. In addition, weather resistance tests were conducted using a Sunshine Carbon Weather Meter, with a black panel temperature of 83°C and a due cycle of 12 minutes/60 minutes of irradiation. Gloss change, crazing,
(Detrimental changes such as blistering, peeling of metal foil, and cracks) were evaluated. In addition, heat cycle tests test samples at 80°
After 2 hours of exposure to 80°C, the samples were gradually cooled to -45°C over 4 hours, exposed to this temperature for 2 hours, and then gradually heated to 80°C over 4 hours, and this cycle was repeated 100 times. Afterwards, the appearance of the surface of the sample was evaluated in the same manner as in the weather resistance test. In addition, the peel strength is 15111111 (7) wider than the manufactured circularly polarized antenna reflector.
A test piece was cut out, and the strength was evaluated based on ASTM D-803 when the metal layer was peeled off at 180 degrees at a peeling rate of 50 mm/min. Furthermore, the bending stiffness is AS
Measured according to TM D-780, the coefficient of thermal expansion is A
Measured according to STM D-88El.

The types and physical properties of the paints, styrene polymers, inorganic fillers, and metal foils that constitute the coating layers used in Examples and Comparative Examples are shown below.

[(A) Coating Coating 1: Two-component fluororesin (manufactured by Dainippon Nuri Co., Ltd., trade name: V-Flon, hereinafter referred to as "F paint") and two-component polyurethane resin (Nippon Oil Co., Ltd.) (trade name: Hi-Urethane, hereinafter referred to as "r[J] material") was used.

[(B) Styrenic polymer] As a styrene polymer, styrene is suspended in water,
An emulsifier and a catalyst were added and polymerization was carried out at a temperature of 80°C.

As a result, the melt flow index (JIS K-8
According to 870, the temperature is 190℃ and the load is 10k.
13.0 g/10 min (measured under the conditions of
．． 3% by weight, Mooney viscosity (ML1+4) 25, hereinafter r
sBRJ] was graft-polymerized with 92 parts by weight of styrene, and the melt flow index was 13.0 g/10.
Impact resistant polystyrene (hereinafter referred to as rHIPsJ) was prepared and used.

[(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 3mm, hereinafter r
GFJ), and calcium carbonate (hereinafter referred to as reach3J) with an average grain size of 11 kaO', 8 microns.
was used.

[(D) Metal foil] Aluminum foil each having a thickness of about 20 microns (
(hereinafter referred to as "4-bun"), copper, brass, and silver foils were used.

Examples 1 to 12, Comparative Examples 1.2 An epoxy resin primer (manufactured by Inu Nippon Toyo Co., Ltd., trade name: V-Fron Primer) was applied to one side of the metal foil whose type is shown in Table 1, and the thickness when dry was determined. It was coated to a thickness of 20 microns and dried.

Paints whose types are shown in Table 1 (U paint for Example 6, F paint for the others) were applied to the primer-coated surface of the obtained metal foil so that the dry thickness was 30 microns.
-Leave it alone day and night. A urethane primer (manufactured by Toyo Morton Co., Ltd., trade name Atcoat 335) was applied to the other side of the metal foil having the coating layer thus obtained, so that the dry thickness was 15 microns. Dry.

Furthermore, an inorganic filler and a styrenic polymer (the types of each inorganic filler and styrenic polymer and the content of the inorganic filler in the composition are shown in Table 1.

In addition, in Comparative Example 2, the inorganic filler was not blended) were tri-blended for 5 minutes using a Henschel mixer,
A composition was produced from each mixture using a vented extruder under conditions where the resin temperature was 200°C.

A sheet having a thickness of 2 mm was produced from each of the obtained compositions (pellets) using a T-die molding machine.

A laminate was produced by dry laminating a metal foil having a coating layer coated with the primer thus produced on one side and a sheet of a styrenic polymer containing an inorganic filler. The obtained laminate was shaped into a bowl at 140°C (surface temperature of the laminate).
Outer diameter? A reflector for a circularly polarized antenna was manufactured by vacuum forming using a female mold having a diameter of 50 mm and a height of 80 mm (Example 1, 2).

Laminates produced in the same manner as in Examples 1 and 2 (the types of inorganic fillers and styrenic polymers, the content of the inorganic fillers in the compositions, and the types of metal foils are shown in Table 1) Under the condition that the surface temperature is 130°C, the first stage is under a pressure of 20 kg/cm' for 30 seconds and the second stage is 5 seconds.
Stamping molding was performed in two steps by holding the material under a pressure of 0 kg/cm' for 20 seconds (the shape of the mold was the same as in Example 1), and a reflector for a circularly polarized antenna was manufactured (Example 3). 4).

After applying the epoxy primer described above to one side of each metal foil whose type is shown in Table 1 to a dry thickness of 20 microns, apply the paint whose type is shown in Table 1 as described above. Coating and drying were carried out in the same manner. Further, the urethane-based primer was applied to one side to a dry thickness of 15 microns, and then dried. Each coated laminate obtained was placed in an injection molding machine (clamping force: 1500
) was inserted so that the coating film was in contact with the male mold surface of the mold.

After closing the mold, the types of styrenic resin and inorganic filler and the content of inorganic filler in the composition are shown in Table 1 under the conditions of injection pressure of 80 kg/crn' and resin temperature of 200°C. The composition shown in Table 1 was subjected to insert injection molding to produce a reflector for a circularly polarized antenna having the same shape as in Example 1 (Examples to Comparative Examples)
l, 2).

The elastic modulus and linear expansion coefficient of the inorganic filler-containing styrenic polymer layer of each circularly polarized antenna reflector obtained as described above, and the peel strength of the metal foil from the inorganic filler-containing styrenic polymer layer. Measurements were made. The results are shown in Table 1.

(Left below) The radio wave reflectance of each reflector for circularly polarized antennas obtained as described in 2 was measured and was 98%. Furthermore, a weather resistance test and a heat cycle test were conducted, but all except Comparative Example 1 showed discoloration, fading, change in gloss, and craze on the surface.

No harmful changes such as blistering, peeling of the metal foil, or cracks were observed. However, in Comparative Example 1, the aluminum foil on the surface corroded.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 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. 2 is a sectional view of the copper plate for the circularly polarized antenna. Furthermore, FIG. 3 is a partially enlarged view of the cross-sectional view. A...Reflector for circularly polarized antenna, B...Converter, C...Converter support, D...Reflector support rod, E...Wiring, 1...Styrene containing inorganic filler system polymer layer, 2...
Metal layer (metal foil), 3... coating layer with excellent weather resistance,
2a...Primer 1st layer, 2b...Primer 1st layer Patent applicant Showa Denko Co., Ltd. Representative Patent attorney Sei Kikuchi - Figure 2, Figure 3 = Go to 3-

Claims (1)

[Claims] At least (A) a metal layer having a coating layer with excellent weather resistance and (B) a styrenic polymer layer containing an inorganic filler are laminated, and the thickness of the coating layer is 5 microns to 1 micron.
mm, and the thickness of the metal layer is 5 microns to lIa
W, and the thickness of the inorganic filler-containing styrenic polymer layer is 500 microns to 15 m+, and the inorganic filler content of this layer is 10 to 80% by weight. Reflector for antenna.