JPS60206205A - Reflector for circular polarized wave antenna - Google Patents

Abstract

PURPOSE:To improve the durability and radio wave reflection characteristics of the reflector by laminating a metallic layer which has a coating layer with superior weather resistance and a shock-resisting resin layer containing an inorganic filler, specifying thicknesses of the coating layer, metallic layer, and shock-resisting resin layer containing the inorganic filler respectively, and specifying the content of the inorganic filler of the resin layer. CONSTITUTION:The metallic layer which has the coating layer 3 with excellent weather resistance and the shock-resisting resin layer containing the inorganic filler are laminated. The coating layer 3 is 5mum-1mm., the metallic layer 2 is 5mum-1mm., and the resin layer 1 is 500mum-15mm.. The content of the inorganic filler of this layer 1 is 10-80wt% and the shock-resisting resin contains at least one kind among polyethylene chlorate, a graft copolymer obtained by graft- copolymerizing styrene and at least one kind of other vinyl compound with polyethylene chlorate, and a copolymer of styrene and at least one kind of other vinyl compound.

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 weather resistance and (B) an impact-resistant resin layer containing an inorganic filler are laminated, and the thickness of the coating layer is 5 microns or more. 1+n
m, the thickness of the metal layer is 5 microns to 1 mm, and the Jl thickness of the inorganic filler-containing impact-resistant resin layer is 50
The object of the present invention is to provide a reflector for a circularly polarized antenna, characterized in that the thickness of the layer is 0 micron to 15 mm, and the content of the inorganic filler in this layer is 10 to 80% by weight.

[11] Background of the Invention Satellite broadcasting using geostationary satellites is planned to be put to practical use in the near future in countries around the world such as Europe, the United States, and Japan. 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 cross-polarization identification of satellite broadcast receiving antennas. 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. However, when receiving radio waves from a broadcasting satellite, the polarization plane shifts 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, so the above-mentioned method is not possible. It is difficult to match such planes of polarization.

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 magnitude of interference between broadcast channels, it is not possible to expect to obtain a high degree of cross-polarization discrimination when broadcast satellite radio waves are linearly polarized. 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 conical horn, those that combine two Goupoles at right angles, and parabolic antennas that use these antennas as the primary radiator. The structure is complex and large, and manufacturing costs are high, so it is not suitable for general audience receiving antennas for receiving 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 Hehat-type parabolic ann in which the focal point is opposed to a parabolic reflector and this is used 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 reflectors in which glass fibers with metallized surfaces are laminated to thermosetting resins such as unsaturated polyester resins as a radio wave reflective layer, but the manufacturing method is complicated and □ , It was extremely difficult to maintain the radio wave reflective layer at a constant thickness and without unevenness.

[III] Structure of the Invention From 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, we found that it is a laminate consisting of at least (A) a metal layer having a coating layer with good weather resistance and (B) an inorganic filler base/impact-resistant resin layer; The thickness of the membrane layer is 5 microns to 1 m
m, the thickness of the metal layer is 5 microns to 1 mm, and the thickness of the inorganic filling and cutting impact resistant resin layer is 500 mm.
micron to 15 mm, the content of inorganic filler in this layer is 10 to 80% by weight, and the impact-resistant resin is chlorinated polyethylene, chlorinated polyethylene grafted with styrene and at least one other vinyl compound. An impact-resistant resin containing at least one of a graph I copolymer obtained by copolymerization and a copolymer of styrene and another vinyl compound of at least one year old (however, the impact-resistant resin For a circularly polarized antenna, characterized in that the total amount of chlorinated polyethylene and chlorinated polyethylene graft copolymerized with styrene and at least one other vinyl compound is 5 to 40% by weight. The inventors have discovered that a reflector plate not only has good durability but also has excellent radio wave repulsion 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) 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 hyperemic agent-containing J impact resistant resin 11M 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,
There is no uneven reflection of radio waves.

(5) Impact-resistant resins 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 paints are classified into solvent type, which uses solvents such as toluene and xylene, water-based emulsion type, and solvent-free type. 1. Any type of paint can be selected depending on the mounting method. Typical examples of these paints include uncelled or saturated polyester resin paints, polyurethane resin paints obtained by reacting polyester polyols, polyether polyols, or polyurethane polyols with diisocyanates, and aminoalkyd 4All resin paints. Paints, acrylic resin paints, melamine resin paints, cyanoacrylate resin paints, epoxy resin paints, silicone resin paints, organic titanate paints, vinyl chloride resin paints, acrylic urethane resin paints, amide resin paints, and Examples include fluorine-containing resin paints such as vinylidene fluoride 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-mentioned paints, polyurethane resin paints, acrylic resin paints, epoxy resin paints, aminoalkyl resin paints, and fluorinated vinyl 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, those that have been painted or printed can also be preferably used.

(C) Impact Resistant Resin The 1TIJ impact resin used to produce the inorganic filler-containing impact resin layer in the present invention is also grafted with chlorinated polyethylene and styrene and at least one other vinyl compound. The total amount of copolymerized chlorinated polyethylene is 5 to 40% by weight.
(preferably 10 to 40% by weight, suitably 15 to 35% by weight). The impact resistant resin contains chlorinated polyethylene, a copolymer of styrene and at least one other vinyl compound (for example, acrylonitrile methyl methacrylate), and/or a copolymer of styrene and at least one other vinyl compound. It is made of chlorinated polyethylene.

The impact-resistant resin of the present invention is a composition obtained by mixing chlorinated polyethylene and the above copolymer, and a composition obtained by graft copolymerizing styrene and at least one other vinyl compound to chlorinated polyethylene. Graft copolymer and a graft copolymer obtained by graft copolymerizing a small amount of styrene and at least one other vinyl compound to previously chlorinated polyethylene, which is obtained by further mixing the above-mentioned copolymer. It is a composition. When using a composition among the impact-resistant resins of the present invention, a composition obtained by mixing the constituent components in advance may be used, and when producing the composition that is the final product of the present invention. These may be mixed. Among the above compositions or graft copolymers as impact resistant resins in the present invention,
Regardless of which method is used, it is necessary to blend the graft copolymerized and graft copolymerized 111-polyethylene in the impact-resistant resin of the final product composition so that the ratio is as described above. is important.

The chlorinated polyethylene used in the production of impact-resistant resins is obtained by chlorinating polyethylene powder or particles in an aqueous suspension or by chlorinating polyethylene dissolved in an organic solvent ( (preferably those obtained by chlorination in aqueous suspension)
. In general, it is amorphous or crystalline chlorinated polyethylene with a chlorine content of 20 to 50% by weight, and particularly preferably amorphous chlorinated polyethylene with a chlorine content of 25 to 45% by weight.

Said polyethylene is obtained by homopolymerizing ethylene or copolymerizing ethylene with at most 10% by weight of α-olefin (generally having at most 6 carbon atoms). Its density is generally between 0.910 and 0.910.
It is 970g/cc. In addition, its molecular weight is 50,000 to 70
Ten thousand.

Specific examples of the impact-resistant resin used in the present invention include 11! Graft products obtained by graft copolymerization of styrene and acrylonitrile to chlorinated polyethylene, graft products obtained by graft copolymerization of styrene and methyl methacrylate to chlorinated polyethylene, chlorinated polyethylene, and combinations of styrene and acrylonitrile. Blends with copolymer resins, chlorinated polyethylene and acrylic resins, etc. can be mentioned. The acrylic resin is a polymer containing methacrylic ester or acrylic ester as a main component. Typical examples include polymers based on butyl acrylate, butyl acrylate and/or methyl methacrylate.

(D) Inorganic filler The inorganic filler used to produce the inorganic filler-containing impact-resistant 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 do not decompose during kneading and molding. The inorganic fillers include metals such as aluminum, copper, iron, lead and nickel, and these metals as well as magnesium, calcium, barium, zinc, zirconium, molybdenum, silicon, antimony,
Butyride of metals such as titanium, their hydrates (hydroxides),
It is broadly classified into compounds such as sulfates, carbonates, and silicates, their double salts, and mixtures thereof. Typical examples of the inorganic fillers include the above-mentioned metals, aluminum oxide (alumina), its hydrates, calcium hydroxide, magnesium oxide (magnesia), magnesium hydroxide, zinc oxide (zinc white), red lead, and lead. Lead liquefaction such as H, 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 powder, aluminum sulfate (gypsum, etc.), zirconium silicate, oxide Examples include zirconium, +
．． 5 mm or less) is preferable. In the case of a fibrous material, it is desirable that the diameter is 1 to 500 microns (preferably 1 to 300 microns) and the length is 0.1 to 6IIIn (preferably 0.1 to 5 mm). Furthermore, the diameter of the flat plate is 2 mm or less (preferably 1 mm or less) (E) Structure of each layer (1) Coating layer The coating layer of the present invention prevents corrosion of the metal layer. It is something that does the work of From this, the thickness is 5 microns to Inon, preferably 10 microns to 0.5 mm, particularly preferably 10 microns to 0.3 mm. If the thickness of this coating 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. occurs and there is a problem. On the other hand, if it exceeds 5+nm, 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 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 microns is preferred. If the thickness of the metal layer is less than 5 microns, the metal layer is likely to wrinkle or fold when laminated or manufactured, 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 impact-resistant resin layer The composition ratio of the inorganic filler in the inorganic filler-containing impact-resistant resin layer of the present invention is 10 to 80% by weight (i.e., the composition of the impact-resistant resin The ratio is 80 to 20 weight L1%), 1
It is preferably 0 to 70% by weight, particularly preferably 10 to 60% by weight. If the composition ratio of the inorganic filler in the inorganic filler-containing impact-resistant resin layer is less than 10%, the tensile modulus of the inorganic filler-containing impact-resistant resin layer will be different from that of the metal layer. If the heat cycle is too high, not only may peeling occur between the metal layer and the impact-resistant resin layer containing the filler, but also the resulting laminate may lack rigidity. be. 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 impact-resistant resin layer is 500 microns to 15 mm, preferably 1 to 10 mm,
In particular, 1 to 7I[1m is preferred. If the thickness of the inorganic filler-containing impact-resistant 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+nm, it will take time to cool down during molding, and not only will sink marks be more likely to occur on the surface, but also the weight j1 will increase, causing problems in use.

In producing the inorganic filler-containing impact-resistant resin layer, stabilizers against oxygen, heat and ultraviolet rays, metal deterioration inhibitors, flame retardants, colorants, and electricity commonly used in the field of impact-resistant resins are used. Additives such as physical property improvers, antistatic agents, lubricants, processability improvers, and tackiness improvers are added to the extent that they do not impair the properties of the composition of the inorganic filler-containing impact-resistant resin layer of the present invention. You may.

When producing the inorganic filler-containing impact resistant resin of the present invention (including cases in which the above additives are blended), trials were conducted using a mixer such as a Henschel mixer commonly used in the impact resistant resin industry. They may be blended and can be obtained by melt-kneading using a mixer such as a Banbury mixer, Nigu, roll mill, or single screw extrusion type. 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 impact-resistant resin 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 impact-resistant resin of the present invention, all of 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 remaining ingredients may be mixed.

When melt-kneading is carried out in the production of the above-mentioned blends, it must be carried out at a temperature higher than the melting point or softening point of the impact-resistant resin used; however, if carried out at high temperatures, the impact-resistant resin deteriorates. For these reasons, the temperature is generally 20°C higher than the melting point or softening point of the impact-resistant resin (preferably higher than 50°C), but 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. Also, 882
In the figures and FIG. 3, 1 is an impact-resistant resin layer containing an inorganic filler, and 2 is a metal layer (metal foil). Also,
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 reflection plate for a circularly polarized antenna of the present invention contains an I agent in a metal layer having a coating layer and an inorganic light layer.
IIIJ impact resin layer, but as long as the metal layer and the coating layer and the metal layer and the inorganic filler-containing impact resin layer have good adhesion, it can be used as is. However, if the adhesion is poor, an adhesion imparting agent such as a primer may be interposed to maintain sufficient adhesion (adhesion) between them.

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. Furthermore, after laminating the metal layer and the impact-resistant resin layer containing an inorganic filler, a paint may be applied to the upper surface of the metal layer. In order to attach the antenna reflector to the support, ribs may be attached to the impact-resistant resin layer containing an inorganic filler to allow for attachment, and reinforcing ribs may be attached to the reflector to reinforce the reflector. You can also add . 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 cm to 120 cm+a.

(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 an impact-resistant resin layer containing an inorganic filler on the metal layer. In this method, one side of the metal layer or the other side that does not have a coating layer can be inserted into a mold of an injection molding machine in advance, and the inorganic filler-containing Mochidane J impact resin can be manufactured by injection molding. can. In any of these methods, if the adhesion between the metal layer and the impact-resistant resin layer containing an inorganic filler is excellent, these methods can be applied without applying an adhesion promoter to the metal layer. The laminate may be manufactured by molding by a method. In addition, we manufacture reflectors for circularly polarized antennas by combining the metal layer and the impact-resistant resin layer containing inorganic fillers with or without the intervention of an adhesion agent using an extrusion lamination method, press molding method, or insert injection molding method. You may. Furthermore, a metal layer with or without a coating layer and an inorganic filler-containing impact-resistant resin layer are laminated in this order with or without an adhesion promoter between each layer, and heated. It may also be manufactured by crimping. In manufacturing the reflector for a circularly polarized antenna of the present invention, the circularly polarized wave is made of a metal foil that does not have a coating layer and is not coated with Bry'1-, and an impact-resistant resin containing an inorganic filler. A molded product for producing a reflector for an antenna may be manufactured, and the molded product may be coated with a primer or painted without being coated, as described later. None of the extrusion lamination method, press molding method, insert injection molding method, and thermocompression bonding method described above is 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.

(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 an impact-resistant 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 with excellent weather resistance, a metal layer, and an impact-resistant resin layer containing an inorganic filler are sequentially laminated can be obtained. Laminate (sheet) obtained in this way
are fixed with iron workpieces or claw-like objects, placed in a jig that is easy to handle, and then drawn into a device that can be heated with ceramic heaters or sheathed wire heaters arranged vertically, and heated. When the sheet is heated, it begins to melt, but once the sheet sag, as the heating continues, it becomes taut in the cotton that holds 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, placed on the upper part of the mold, and vacuum-formed from the mold side under 1 atmosphere of acupuncture pressure to obtain a 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 placed against the mold side under a pressure of 3 to 5 atmospheres. A molded article can be obtained by pressing and lifting the mold.

In addition, in any molding method, the surface temperature of the sheet is 110
A preferred temperature is ~200°C.

(2) Manufacturing by stamping molding method In order to manufacture the circularly polarized antenna reciprocal plate of the present invention by this method, the weather resistance used in the order of manufacturing the circularly polarized antenna reflector plate 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 impact-resistant resin 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 equipped with a vertical press machine to form a 5 to 50 kg/crri sheet.
The desired molded product can be obtained by heating and pressing under a pressure of 10 to 20 kg/cm. The product is then 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-stage pressure conditions. In this case, in the first stage, under a pressure of 10-20 kg/cm', 15-4
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. This two-step molding method is particularly desirable when using an impact-resistant resin layer containing an inorganic filler with poor fluidity. Note that the suitable molding temperature in the stamping molding method is a sheet surface temperature of 110 to 180°C.

(3) Manufacturing by injection molding method To manufacture the reflector plate for a circularly polarized antenna of the present invention by injection molding method, an all-over layer with excellent weather resistance is laminated on one side in advance, and a primer is placed on the other side. The metal layer coated with is subjected to insert injection molding when molding anti-copper plates for circularly polarized antennas. To carry out insert injection molding, the metal layer is inserted between the male and female molds of the injection molding machine so that the coating layer with excellent weatherability is on the male mold. insert) and close the mold. after that,
A desired reflector for a circularly polarized antenna can be obtained by filling the mold with an inorganic filler and a stone-containing impact-resistant resin through the gate of the mold, cooling it, and then opening the mold. can. For insert injection molding, the resin temperature is above the melting point of the impact resin of the inorganic filled impact resin, but below the thermal decomposition temperature of the impact resin. Therefore, insert injection molding is 160-240°
It is carried out in the temperature range of C. In addition, the injection pressure is 40 kg/c gauge pressure at the Schilling nozzle part of the injection molding machine.
If it is not less than m', it is possible not only to shape the inorganic filler-containing impact-resistant resin into a shape substantially close to the shape of the mold, but also to obtain a product with good appearance.

The injection specific pressure is generally 40 to 140 kg/c rrf
and especially between 70 and 120 kg/c rri'
is desirable.

As mentioned above, the method of applying paint to the unpainted metal foil manufactured by vacuum forming, stamping molding, or injection molding is not a special method; 41
There are methods to apply the paint without applying the paint using a spray gun, a method using a brush, a method using a roll coater, etc. However, industrially, the method using a spray gun is more efficient, especially when using a robot. The preferred method is to apply it by applying it.

[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 determined as the microwave reflection coefficient 'A11 from the voltage standing wave ratio when a rectangular waveguide was used and the tip of the waveguide was short-circuited. In addition, the weather resistance test was 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 00 hours (adverse changes such as discoloration, fading, gloss, crazing, blistering, peeling of metal foil, and cracks) was evaluated. Furthermore, in the heat cycle test, the sample was exposed to 80°C for 2 hours, then 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. , this cycle is 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, the All 1Wf1 strength is 15 mm wider than the manufactured circularly polarized antenna reflector.
A test piece was cut out according to ASTM D-903,
The strength was evaluated when the metal layer was peeled off at 180 degrees at a peeling speed of 50 mm/min. Furthermore, the bending stiffness is A
Measurements were made according to STM D-790 and coefficients of thermal expansion were measured according to ASTM D-8138.

The types and physical properties of the paints, impact-resistant resins, inorganic fillers, and metal foils constituting 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) Impact-resistant resin] As the impact-resistant resin, A1 was manufactured as follows.
1l:5 (1) and ACS (2) and mixture (1
) and mixture (2) were used.

[Manufacture of AC3 (1)] In a 20-liter autoclave, add Mukoichi viscosity (MS1+41
00) is 76 chlorinated polyethylene [I11 element content 4
0.6% by weight, molecular weight of raw material polyethylene approximately 200,000,
Hereinafter referred to as rC1-PE(a)J] 1B00g, polyvinyl alcohol (saponification degree 85%) 32.0g, and 8.0ml of water (ion exchange water) were charged. This was then vigorously stirred at room temperature (approximately 23°C). Add 4560 monomer to this dispersion while stirring at room temperature.
g of styrene and 1520 g of acrylonitrile, 320 g of liquid paraffin as a lubricant, and I as a polymerization initiator.
B, Og tertiary-natyl peracetate and 16.0 g of tertiary-dodecyl mercaptan as a chain transfer agent were added. After two parts of the suspension of this reaction system were replaced with nitrogen gas, the temperature was raised to 105°C. After polymerization was carried out at this temperature for 4 hours with stirring, the temperature was further increased to 145°C.
Polymerization was carried out at a temperature of 2 hours. After this reaction system was allowed to cool to room temperature, the resulting polymer (grafted product) was filtered and thoroughly washed with water. The resulting grafted product was dried under reduced pressure at 50°C overnight. The polymerization conversion of -4K (Φ, based on the +l used in the synthesis) was 85.4%, and it was in the form of a slightly coarse powder. The rubber-like material content of the sample (referred to as J) was 20.3% by weight.

To the obtained AGS (1), 2% by weight of a dibutyl tin malate stabilizer [X:, manufactured by Kyosei Gosei Co., Ltd., trade name: Stann BM] was added, and the surface of the roll was set at 180°C. Kneading was carried out for 10 minutes using a rolled roll. The resulting mixture was pressed for 5 minutes under a pressure of 100 kg/cm' using a press set at 200'0, and then pressed at 100 kg/cm' using a water-cooled press.
Pressing was carried out for 2 minutes under a pressure of rn'. The Izotsu impact strength of the obtained press plate (with / tsuchi) is 8.0 kg
*cm/cm, tensile strength is 325kg/cr
It was n'. Moreover, the Vicat softening point was 93.8°C.

(Manufacture of AC3 (2)) 0 sentences used in the manufacture of AC:S (+) - PE (a
) usage amount is 6.0 kg, and styrene usage amount is 1280 kg.
Polymerization was carried out under exactly the same conditions as in the case of AC5(1), except that the amount of the polymer and the amount of acrylonitrile used was changed to 320 g. After the polymerization was completed, filtration, washing with water, and drying were performed in the same manner as in the case of AC3(+) to produce a polymer (grafted product). The graft conversion rate of this graft product [hereinafter referred to as rAc:5(2)J] was 85.3%, and it was in the form of a slightly coarse powder. Note that the content of rubbery substances in this AGS (2) was 79.6%.

[Production of T compound (1)] Instead of the above AC3 (+), AC3 (2) and Acryloni!・Melt-knead the lyrus styrene copolymer resin [acrylonitrile content: 23% by weight, 17%, hereinafter referred to as rASJ] in the same row 1 as in the case of AC:5(1) so that the mixing ratio is 1=3. Ta. A press plate was produced from the mixture obtained by mixing 1'1 (hereinafter referred to as "mixture (1)") in the same manner as in the case of AC3 (1). The Izotsu impact strength of the 111 pressed plate is 7.8 kg a cm
/ am, and the tensile strength was 330 kg/cm'. Moreover, the Vicat softening point was 83.7°C.

[11' Production of Compound (2) 1 100 chlorinated polyethylenes with a Mooney viscosity (MS1+4100) of 75 (chlorine content 36.2% by weight, non-crystalline, molecular weight of raw onil polyethylene approximately 250,000) As a stabilizer, 2 parts by weight of the dibutyltin malate stabilizer and As used in producing the mixture of Ta. The obtained mixture C (hereinafter referred to as "mixture (2)") was used to produce a press plate in the same manner as in the case of AC:S(+). The Izo impact strength (notched) of the pressed plate was 8.0 kgφCm/Cm, and the tensile strength was 340 kg/cm'. Moreover, the Vicat softening point was 94.5°C.

[(C) Inorganic filler] Fu! ! (As mechanical fillers, talc with an average particle size of 3 microns (aspect ratio approximately 7), mica with an average particle diameter of 3 microns (aspect ratio approximately 8), glass fiber (single fiber diameter 11 microns, force/nodule) Length 3+nm
, hereinafter referred to as "rGF"), and calcium carbonate (hereinafter referred to as rGaGOs J) having an average particle size of 0.8 microns.

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

Example 1-12, Comparative Example 1.2 An epoxy resin primer (manufactured by Dainippon Toyo Co., Ltd., trade name ■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.

Paints whose types are shown in Table 1 are applied to the primer-coated surface of the V'J metal foil (U paint for Example 6, F paint for others).
Paint) was applied to a dry thickness of 30 microns and left for 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. In addition, inorganic fillers and impact-resistant wood 11FI (
Table 1 shows the types of each inorganic filler and impact-resistant resin and the content of the inorganic filler in the composition. In addition, in Comparative Example 2, the inorganic filler was not added.
Tri-blending was carried out using a Henschel mixer for 1 minute, and each mixture was used to produce a composition using a vented extruder at a resin temperature of 230°C. A sheet having a thickness of 2 mm was produced from each of the obtained compositions (pellets) 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 impact-resistant resin containing an inorganic filler. The obtained laminate was vacuum-formed at 175°C (the surface temperature of the laminate) using a bowl-shaped female mold (outer diameter 750 m+a, height 80 mm) to form a circularly polarized antenna. A reflector was manufactured (Example 1.2).

Laminates produced in the same manner as in Examples 1 and 2 (the types of inorganic filler and impact-resistant resin, the content of the inorganic filler in the composition, and the type of metal foil were
shown in the table) at a surface temperature of 135°C, the first stage was subjected to a pressure of 20 kg/cm' for 30 seconds, and the second stage was 5 seconds.
Stamping molding was performed in two stages by holding it 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
The mold 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 olefin 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/cm' and resin temperature of 240 °C. The compositions shown in Table 1 were subjected to insert injection molding to produce reflectors for circularly polarized antennas having the same shape as in Example 1 (Examples 5 to 12 and Comparative Examples 1 and 2).

The elastic modulus and linear expansion coefficient of the inorganic filler-containing impact-resistant resin layer of each circularly polarized antenna reflector obtained as described above, and the peel strength of the metal foil from the inorganic filler-containing impact-resistant resin layer. Measurements were made. those results first
Shown in the table.

(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 88% 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 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, <-tar support rod, D...Reflector support rod, E...Wiring, ■...Inorganic Filler-containing impact-resistant resin layer, 2...Metal layer (metal foil), 3...Coating layer with excellent weather resistance, 2a...Primer single layer, 2b...Primer single layer Patent applicant Showa Electric Works Co., Ltd. Agent, Br. Sei Kikuchi - Figure 3

Claims (1)

[Claims] At least (A) a metal layer having a coating layer with excellent weather resistance and (B) an inorganic filler-containing m# impact resin layer 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 1 mm.
and the thickness of the impact-resistant resin layer containing inorganic filler is 5
00 microns to 15 mm, the content of inorganic filler in this layer is 10 to 80% by weight, and the impact-resistant resin is chlorinated polyethylene, chlorinated polyethylene with styrene and at least one other vinyl compound. An impact-resistant resin containing at least one of a graft copolymer obtained by graft copolymerization and a copolymer of styrene and at least one other vinyl compound (however, the impact-resistant resin A reflector plate for a circularly polarized antenna, characterized in that the total amount of chlorinated polyethylene and chlorinated polyethylene graft copolymerized with styrene and at least one other vinyl compound is 5 to 40% by weight.