JPS60173902A - Reflecting plate for circularly polarized wave antenna - Google Patents

Abstract

PURPOSE:To form a reflecting plate for circularly polarized wave antenna with excellent durability and radio reflecting characteristic by laminating a film coating layer excellent in the weather-proof characteristic and a polycarbonate resin layer including inorganic filler. CONSTITUTION:A metallic layer 2 having the coating film layer 3 excellent in the weather-proof performance and the polycarbonate resin layer 1 including an inorganic filler are laminated so as to form the reflecting plate for circularly polarized antenna. Then the thickness of the coating film layer 3 and the metallic layer 2 is set respectively to 5mu-1mm.. Moreover, the thickness of the resin layer 1 set to 500mu-15mm. and the content of the inorganic filler is selected to 10-80wt%. The reflecting plate for circularly polarized wave antenna with excellent durability and radio reflecting characteristic is formed.

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 a coating layer with excellent illllt weatherability and (B) a polycarbonate resin layer containing an inorganic filler are laminated, and the thickness of the coating layer is 5 μm to 5 μm. 1 mm, the thickness of the metal layer is 5 microns to 1 mm, and the thickness of the inorganic filler-containing polycarbonate resin layer is 500 microns to 15 mm, and the content of the inorganic filler in this layer is 10 to 80 wt. %.An object of the present invention is to provide a reflector for a circularly polarized antenna, which is characterized in that:

[11] 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 broadcast radio waves from the ground, the radio waves are made horizontally or vertically linearly polarized, and the polarization plane of the receiving antenna is adjusted to match the polarization plane of the broadcast radio waves to achieve cross-polarization discrimination. However, when receiving radio waves from broadcasting satellites, deviations in the plane of polarization occur due to disturbances caused by the ionosphere in the radio wave propagation path and the angle of incidence of the radio waves at the receiving point. It is difficult to match the planes of polarization as described above.

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, regardless of the shift in the plane of polarization as described above, it is easy for ordinary listeners to distinguish by the direction of the circularly polarized wave. The receiving antenna not only adjusts its pointing direction to point to the desired broadcasting satellite, but also does not require ym adjustment of the polarization plane, so the receiving antenna Due to the extremely simple adjustment and design of receiving antennas, plans are being made to use circularly polarized waves for broadcasting satellite radio waves in future satellite broadcasting systems. In contrast, as a conventional circularly polarized antenna:
There are antennas that use a conical horn, antennas that combine two Goupoles at right angles, and parabolic antennas that use these antennas as the primary radiator, but all of them have complex structures, are large, and Because of the high manufacturing costs, it is not suitable as a receiving antenna for general viewers to receive satellite broadcast radio waves using microwaves in the 12 gigahertz (GH7,) band.

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. It faces a parabolic reflector at the focus position, and is widely used in microwave antennas, etc., but all conventional Hehat-type parabolic antennas use linearly polarized waveguides as described above. It is designed to transmit and receive 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 reflectors in which glass fibers with metallized surfaces are laminated to thermosetting resins such as unsaturated polyester resins, but the manufacturing method is complicated. In addition, it is extremely difficult to maintain the radio wave reflecting layer at a constant thickness and without unevenness.

[■] Structure of the Invention Based on the following two points, the inventors have developed a repellent plate for circularly polarized antennas 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 coating film, it was found that at least (A) a metal layer having a coating layer with good IFI weatherability and (B) a polycarbonate resin layer containing an inorganic filler are laminated, and the coating film The thickness of the layer is 5 microns to in++n, the thickness of the metal layer is 5 microns to 1 mm, and the thickness of the unfilled polycarbonate resin layer is 50 microns to 15 m.
, m, and the content of inorganic filler in the layer τ is approximately 10 to 80
The inventors have discovered that a reflector for a circularly polarized antenna, which is characterized by a % by weight, not only has good durability but also has excellent radio wave reflection characteristics, and has thus arrived at the present invention.

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

(1) # Excellent corrosion resistance, so 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 polycarbonate resin layer is extremely small, no peeling occurs between the layers 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, so there is no uneven reflection of radio waves.

(5) Inorganic filler-containing polycarbonate resins can be easily shaped 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 manufacture 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 ways. The manufacturing method and various physical properties of these paints are well known. These paints are classified into solvent type using organic solvents such as toluene and xylene, aqueous emulsion type, and solvent-free type, but 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, Fluorine-containing paints such as acrylic resin paints, melamine resin paints, silicone resin paints, organic titanate paints, vinyl chloride resin paints, acrylic titanium resin paints, amide resin paints, and vinylidene fluoride resins. Examples include resin-based paints. Furthermore, additives such as matting agents such as silicic acid, coloring agents such as pigments and dyes, antioxidant IF agents, 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. Particularly, by incorporating an antioxidant and an ultraviolet absorber into the paint of the present invention, a paint with good weather resistance can be obtained, which is suitable.

(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, painted or printed items are also good.
It can be used with

(G) Polycarbonate resin Furthermore, the polycarbonate resin used to produce the inorganic filler-containing polycarbonate resin layer in the present invention can generally be produced by the following four methods.

(1) Transesterification reaction of a diester of carbonic acid obtained from a monofunctional aromatic or aliphatic hydroxy compound with a hydroxy compound [hereinafter referred to as "Method (1)"] (2) Transesterification of a dihydroxy compound itself or other Transesterification reaction of dihydroxy compound with bisalkyl or bisaryl carbonate, hereinafter referred to as "Method (2)"
(3) Reaction of a dihydroxy compound with phosgene in the presence of an acid binder (hereinafter referred to as "method (3)") (4) Reaction of a dihydroxy compound with a bischlorocarbonate of the dihydroxy compound in the presence of an acid binder (hereinafter referred to as "Method (4)")] Among these production methods, the methods that are generally industrially produced are the above-mentioned Method (1) and Method (3).

Method (1) is called the melt method, and is a method in which bisphenol A and diphenyl carbonate are reacted at temperature and pressure of M in an inert gas atmosphere in the absence or presence of a transesterification catalyst. Various metals, metal alcoholades, oxides, carbonates, acetates, hydrides, alkali salts of organic acids, alkaline earth amides, and the like are used as Qp transesterification catalysts.

Further, method (3) is called a solvent method, and is a method in which bisphenol A and phosgene are reacted in the presence of a solvent at around room temperature in the presence of an acid binder (eg, caustic alkali, pyridine).

The molecular weight of the polycarbonate resin produced by method (1) is usually 0.5 to 50,000, particularly 10,000 to 50,000.
30,000 is common. On the other hand, the molecular weight of the polycarbonate resin obtained by method (3) is usually 10,000 to 20
10,000, and 20,000 to 150,000 is particularly common.

These polycarbonate resins are industrially produced and used in a wide range of fields, such as:
Edited by Tachikawa and Sakajiri "Plastic Materials Course [17] φ Polycarbonate" (Nikkan Kogyo Shimbun, published in 1972)
Their manufacturing methods, properties, etc. are known in detail.

(D) Inorganic filler The inorganic filler used to produce the inorganic filler-containing polycarbonate resin 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 that do not decompose during kneading and molding. The inorganic fillers include metals such as aluminum, copper, iron, lead and nickel, oxides of these metals and metals such as magnesium, coccium, barium, zinc, zirconium, molybdenum, silicon, antimony and titanium; It is broadly classified into compounds such as its hydrate (hydroxide), sulfate, carbonate, and silicate, their double salts, and mixtures thereof. Typical examples of the inorganic fillers include the metals mentioned above, aluminum oxide (alumina), its hydrates, calcium hydroxide, magnesium oxide (magnesia), magnesium hydroxide, zinc oxide (zinc white), red lead, and lead. Lead oxide such as mortar, magnesium carbonate, calcium carbonate 7, basic magnesium carbonate, white carbon, asbestos,
Squid, talc, glass fiber, glass powder, glass beads, clay, diatom ±, silica, wollastonite, iron butyride, antimony oxide, titanium oxide (titania), lithopone, pumice grains, aluminum sulfate (gypsum, etc.), Examples include zirconium silicate, zirconium diluted, barium carbonate, dolomite, molybdenum disulfide, and iron sand. Among these inorganic fillers, those in powder form preferably have a diameter of 1++un or less (preferably 0.5 mm or less). In addition, 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+
n+n (preferably O, 1 to 5 mm) is desirable. Further, the diameter of the flat plate-shaped one is 2) or less (preferably 1).
Preferably, the diameter is less than mm. ) (E) Structure of each layer (1) Coating layer The coating layer of the present invention serves to prevent corrosion of the metal layer. From this, the thickness is preferably 5 microns to 0.5 mm, preferably 10 microns to 0.3 nm, and particularly preferably 10 microns to 0.3 nm. If the thickness of this coating layer is less than 5 microns, not only will the metal layer corrode, but it will also wear out and be exposed due to contact and friction with other items during use. I have a problem. On the other hand, if it exceeds 5m++n, not only will the reflectance of radio waves decrease,
This is not preferable because it increases the cost and the 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 5 microns and 1 mm;
5-500 microns is preferred, especially 10-50 microns.
0 micron 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 mm, not only will the weight increase, but also the cost will increase, and furthermore, it will cause problems when bending or bending the laminate.

(3) Inorganic filler-containing polycarbonate resin layer The composition ratio of the inorganic filler in the inorganic filler-containing polycarbonate resin layer of the present invention is 10 to 80% by weight (that is, the composition ratio of the polycarbonate resin is 90 to 20% by weight). %
), preferably 10 to 70% by weight, particularly preferably 10 to 60% by weight. If the composition ratio of the inorganic filler in the inorganic filler-containing polycarbonate resin layer is less than 10% by weight, the linear expansion coefficient of the inorganic filler-containing polycarbonate resin layer will be too different from that of the metal layer, and the heat cycle will cause the metal layer to There is a problem that not only is there a possibility of peeling between the layer and the inorganic filler-containing polycarbonate resin layer, but also that the resulting laminate lacks rigidity. on the other hand,
If it exceeds 80% by weight, it will be difficult to produce a uniform composition, and even if a uniform composition is obtained, it will be difficult to produce a laminate by sheet production or injection molding as described below. However, it is not possible to obtain a good product (laminate).

The thickness of this inorganic filler-containing polycarbonate resin layer is 5
00 microns to 15 mm, preferably 1 to 10 mm, especially 1 to 10 mm. mm is preferred. If the thickness of the inorganic filler-containing polycarbonate resin layer is less than 500 microns, it is undesirable because it lacks rigidity and may be deformed or 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 inorganic filler-containing polycarbonate resin layer, ingredients commonly used in the field of polycarbonate resins such as fluorine, heat and UV stabilizers, metal deterioration inhibitors, flame retardants, colorants, and electrical properties are used. improver,
Additives such as antistatic agents, lubricants, processability improvers, and tackiness improvers may be added to the extent that they do not impair the properties of the inorganic filler-containing polycarbonate resin layer composition of the present invention.

When producing the inorganic filler-containing polycarbonate resin of the present invention (including cases in which the above additives are blended), triblending may be performed using a mixer such as a Henschel mixer that is commonly used in the polycarbonate resin industry. It can often be obtained by melt-kneading using a mixer such as a Banbury mixer, a kneader, a roll mill, and a souffle 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 polycarbonate resin in the form of powder because it can be mixed more uniformly.

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

In producing the inorganic filler-containing polycarbonate resin of the present invention, all the ingredients may be mixed at the same time, or some of the ingredients may be mixed in advance to produce a so-called masterbatch, and the resulting masterbatch and the remaining may be mixed with other ingredients.

When melt-kneading is performed to produce the above-mentioned compound, it must be carried out at a temperature higher than the melting point or softening point of the polycarbonate resin used, but if carried out at a high temperature, the polycarbonate resin will deteriorate. For these reasons, the temperature is generally 20°C higher than the melting point or softening point of the polycarbonate resin (preferably, a temperature higher than 50°C).
However, it is carried out within a temperature range that does not cause deterioration.

(F) Reflector for Circularly Polarized Antenna The reflector for circularly polarized antenna of the present invention will be explained below 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. Moreover, in FIGS. 2 and 3, 1 is an inorganic filler-containing polycarbonate resin layer, and 2 is a metal layer (metal foil). Moreover, 3 is a coating layer with good weather resistance. Further, 2a and 2b are single layers of primer. 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 an inorganic filler-containing polycarbonate resin layer. If they have good adhesion, they can be used as is, but if they have poor adhesion, use a primer or other adhesive agent to maintain sufficient adhesion (adhesion) between them. An agent may also be present.

There are various methods for manufacturing the circularly polarized antenna reflector of the present invention. A typical example of this method is to coat one piece im of the metal layer with a rough adhesion promoter or undercoat and dry it, then apply a paint, and then coat the metal layer with the resulting coating layer containing an inorganic filler as shown below. It may be laminated with a polycarbonate resin layer. Moreover, after laminating the metal layer and the inorganic filler-containing polycarbonate resin layer, a paint may be applied to the upper surface of the metal layer. Further, in order to allow the reflector for a circularly polarized antenna of the present invention to be attached to the support, the mounting may be done with a ribbed 4D cut so that it can be attached to the polycarbonate resin layer containing a pyrotechnic filler. You can also add reinforcing ribs to strengthen the board. moreover,
It is also possible to drill holes in the support for a circularly polarized antenna obtained by the present invention and attach various support attachment parts using bolts, nuts, etc. In addition, the diameter of the reflector for the circularly polarized antenna is usually BOcm to 12cm.
It is 0 cm.

(G) 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 coating layer with an inorganic filler-containing polycarbonate resin layer. In this method, it can also be produced by inserting in advance into a mold of an injection molding machine one side of the metal layer or the other side not having a coating layer, and then injection molding the inorganic filler-containing polycarbonate resin. In any of these methods, if the adhesion between the metal layer and the inorganic filler-containing polycarbonate resin layer is excellent, the laminate can be formed by these methods without applying an adhesion promoter to the metal layer. may be manufactured. Alternatively, a reflector for a circularly polarized antenna may be manufactured by extrusion lamination, press molding, or insert injection molding, with or without intervening an adhesion agent between the metal layer and the inorganic filler-containing polycarbonate resin layer. good. moreover,
Manufactured by laminating a metal layer with or without a coating layer and an inorganic filler-containing polycarbonate resin layer in this order with or without intervening an adhesion agent between each layer, and bonding them under heat. You may.

In manufacturing the circularly polarized antenna reflector of the present invention,
Manufacture of a molded product for manufacturing a reflector for a circularly polarized antenna made of a metal foil and an inorganic filler-containing polycarbonate resin that do not have a coating layer and are not coated with a primer. It is also possible to paint with or without a primer as shown below. None of the above extrusion lamination method, press molding method, insert injection molding method, and heat compression bonding method is unique to the present invention.
All you have to do is use a commonly used method. The manufacturing method using these molding methods will be explained in more detail.

(1) Manufacture by vacuum forming method To manufacture by this method, a primer is applied to one side of the metal layer, which has been previously laminated with a coating layer with excellent weather resistance, and then a polycarbonate resin 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 polycarbonate resin layer with excellent weather resistance are successively laminated can be obtained. The laminate (sheet) obtained in this way is fixed with iron workpieces or claw-like objects, placed in a jig that is easy to handle, and heated with ceramic heaters or sheathed wire heaters arranged vertically. Pull it into a device that can heat it. 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 desired molded product is obtained by pulling out the sheet work, placing it on the upper part of the mold, and performing vacuum forming from the mold side under a reduced pressure of one atmosphere. 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 placed on the mold side under a pressure of 3 to 5 atm. A molded article can be obtained by pressing and lifting the mold.

In addition, in any molding method, the surface temperature is 140 to 230.
°C is the preferred temperature.

(2) Manufacturing by stamping molding method In order to manufacture the circularly polarized antenna reflector of the present invention by this method, weather resistance is A coating layer, a metal layer, and an inorganic filler-containing polycarbonate resin layer each having excellent properties are laminated one after another: The laminate sheet is introduced into a drawing die attached to a vertical pressing machine, and the laminate sheet is drawn into a drawing die with a weight of 5 to 50 kg/cm'.
The desired molded product can be obtained by heating and pressing under a pressure of (preferably 10 to 20 kg/cm'). Then, the product is obtained by cooling with air or water spray and releasing from the mold. During molding, the pressurizing time is usually 15 seconds or more, typically 15 to 40 seconds. Further, in order to improve surface properties, it is preferable to perform molding under two-step pressure conditions. in this case,
15-40 under pressure of 10-20kg/cm'' in the first stage
After pressurizing for seconds, 40-50kg/crn 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 an inorganic filler-containing polycarbonate resin layer with poor fluidity,
This two-stage molding method is desirable. In addition, the molding temperature in the stamping molding method is such that the surface temperature of the sheet is 240 to 30
0°C is a preferred temperature.

(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 polycarbonate resin containing an inorganic filler is filled into the mold through the gate part 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 polycarbonate resin of the inorganic filled polycarbonate resin, but below the thermal decomposition temperature of the polycarbonate resin. For these reasons, insert injection molding is carried out at a temperature range of 250-300°C. In addition, if the injection pressure at the nozzle part of the cylinder of the injection molding machine is 40 kg/cm' or more, it is possible to form the polycarbonate resin containing inorganic filler into a shape almost similar to the shape of the mold. Not only that, but you can also obtain a product that is good in appearance.

can. Injection pressure is generally 40-140 kg/c
nf, especially 70-120 kg/cm
' is preferable.

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, but rather involves applying a primer in advance. Alternatively, there are methods of applying the paint without applying it using a spray gun, a method of brush application, a method of using a roll coater, etc. However, industrially, the method of using a spray gun is more efficient, and especially Application methods using robots are preferred.

[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).
The appearance of the surface after a period of time (adverse changes such as discoloration, fading, gloss, crazing, blistering, peeling of metal foil, cracking, etc.) was evaluated. Furthermore, the heat cycle test tested the sample 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 was determined by cutting a test piece with a width of 15 mm from the manufactured reflector for a circularly polarized antenna, and measuring the peel strength at a peel rate of 50 mm in accordance with ASTM D-903.
The strength was evaluated when the metal layer was peeled off at 180 degrees at a speed of mm/min. Furthermore, the bending stiffness is ASTM D-7.
90 and the coefficient of thermal expansion is ASTM D-
1398.

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

[(A) Paint] As the paint, a two-component fluororesin (manufactured by Dainippon Toyo Co., Ltd., trade name: V-fluorocarbon, hereinafter referred to as "F paint") and a two-component polyurethane resin (manufactured by Nippon Oil Co., Ltd., trade name High urethane (hereinafter referred to as "U paint") was used.

[(B) Polycarbonate resin] As a polycarbonate resin, medium density polycarbonate I resin manufactured with bisphenol A as the main raw material (
Density 1.2 g/cm', MFI 4.5 g/10 min, hereinafter referred to as r PCJ) was used.

[(C) Inorganic filler - As an 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), hereinafter referred to as rGFJ
), and calcium carbonate (hereinafter referred to as r CaC03J ) having an average particle size of 0.8 microns were used.

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

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

On the primer-coated surface of the obtained metal foil, paints whose types are shown in Table 1 (U paint for examples only, F paint for others) were applied to a dry thickness of 30 microns.
-Leave it alone day and night. A urethane primer (manufactured by Toyo Morton Co., Ltd., trade name: Adko 335) was applied to the other side of the metal foil having the coating layer thus obtained, to a dry thickness of 15 microns. , dried. Furthermore, inorganic fillers and polycarbonate resins (the types of each inorganic filler and polycarbonate resin and the content of the inorganic fillers in the composition are shown in Table 1).

In addition, in the comparative example, two tri-blends were made using a Henschel mixer (without inorganic filler) for 5 minutes each, and each mixture was mixed into a composition using a vented extruder at a resin temperature of 300°C. Manufactured. Each composition obtained (
A sheet with a thickness of 2 mm was produced using a T-Guy 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 polycarbonate resin containing an inorganic filler. The obtained laminate was vacuum-formed at 180°C (surface temperature of the laminate) using a bowl-shaped female mold (outer diameter 750 mm, height 80 mm) to form a circularly polarized antenna. A reflector was manufactured (Example 1.2).

The laminates produced in the same manner as in Examples 1 and 2 (the types of inorganic fillers and polycarbonate resins, the contents of the inorganic fillers in the compositions, and the types of metal foils are shown in Table 1) were tested at surface temperatures. Stamping is carried out in two stages by holding the first stage under a pressure of 20 kg/crrf for 30 seconds and the second stage under a pressure of 50 kg/cm' for 20 seconds at a temperature of 170°C. (The shape is the same as in Example 1), and a reflector for a circularly polarized antenna was manufactured (Example 3゜The above epoxy primer was applied to one side of each metal foil whose type is shown in Table 1 to a dry thickness. After coating to a thickness of 20 microns, the coatings whose types are shown in Table 1 were coated and dried in the same manner as described above. The thermoplastic resin film was inserted into a mold of 1,500 mm) so that it was in contact with the male mold surface of the mold. After closing the mold, under the conditions of injection pressure 80 kg/cm' and resin temperature 280 °C, the types of polycarbonate resin and inorganic filler and the content of inorganic filler in the composition are listed in Table 1. The composition shown in Table 1 was subjected to insert injection molding to produce a reflector plate for a circularly polarized antenna having the same shape as in Example 1 (*Stream side 5 to 12. Comparative example 1°2 ).

The elastic modulus and linear expansion coefficient of the inorganic filler-containing polycarbonate resin layer and the peel strength of the metal foil from the inorganic-filled oil-containing polycarbonate resin layer of each circularly polarized antenna reflector obtained as above were measured. I did it.

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%. Furthermore, weather resistance tests and heat cycle tests were conducted, but with the exception of Comparative Example 1, no harmful changes such as discoloration, fading, changes in gloss, crazing, blistering, peeling of metal foil, or cracks were observed on the surface of all the samples. . However, in Comparative Example 1, the aluminum foil on the surface corroded.

[Brief explanation of the drawing]

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 reflector 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 rod, D...Reflector support rod,
E...Wiring, 1...Inorganic filler-containing polycarbonate resin layer, 2...
...metal layer (metal foil), 3...coating layer with excellent weather resistance, 2a...primer layer, 2b...primer layer Patent applicant Showa Denko K.K. Representative Patent attorney Sei Kikuchi Figure 1 Figure 2 Figure 3

Claims (1)

[Claims] At least (A) a metal layer having a coating layer with excellent ITI weather resistance and CB) an inorganic filler-containing polycarbonate resin layer are laminated, and the thickness of the coating layer is 5 microns to 1 mm, and the metal layer The thickness is 5 microns to 1
mm, and the thickness of the inorganic filler-containing polycarbonate resin layer is 500 microns to 15 mm, and the content of the inorganic filler in this layer is 10 to 80% by weight. a reflector.