JPS614304A - Production of electromagnetic wave reflector - Google Patents

Abstract

PURPOSE:To reduce the deformation of electromagnetic wave reflecting materials and to confirm forming conditions of a reflector at the forming time by forming a surface protective layer after forming fiber reinforced resin materials and electromagnetic wave reflecting materials. CONSTITUTION:After electromagnetic wave reflecting materials 10 are placed on a fiber reinforced resin materials 12, a top force 22 is brought closely into contact with a bottom force 14, and 50kg/cm<2> molding pressure is applied for 2min to mold them. The top force 22 is raised to open the mold, and molding conditions of electromagnetic wave reflecting materials 10 are confirmed. A glass surface mat 25 (about 30g/m<2>) is placed as a protective layer 24 on electromagnetic wave reflecting materials 10, and an unsaturated vinylester resin compound is mixed with a hardener and is supplied from a resin supply device 26, an the top force 22 is brought closely into contact with the bottom force 14 again to form them by pressurizing and heating. Thus, the electromagnetic wave reflector where electromagnetic wave reflectin materials 10, fiber reinforced resin materials 12, an the protective layer 24 are laminated into one body is obtained.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Application of the Invention] The present invention relates to a method of manufacturing an electromagnetic wave reflector used for an electromagnetic wave reflecting plate, an electromagnetic shielding plate, etc.

[Background technology] Electromagnetic wave reflector used in parabolic antenna for radio communication,
Used in office automation equipment such as personal computers, facsimile machines, and copiers - E-magnetic
ctro magnetic interference
e) The shield plate requires an electromagnetic wave reflector.

If you need a radio wave reflector with a wall thickness of 0°3mm or more,
A metal plate such as aluminum, metal foil, etc. may be used, but
These are easily deformed and have no restorability. Furthermore, when a fiber-reinforced resin is used for reinforcement on the back surface of these reflectors, it is difficult to integrally mold the reflector with the fiber-reinforced resin.

Therefore, if a flexible wire mesh, woven fabric, non-woven fabric, etc. is used as the conductive reflective material and these are integrally molded together with a reinforcing material, it becomes optimal when a curved surface is required as the reflective surface.

The methods for forming this protective layer include: first, spraying Gelco I on the mold on the parabolic mirror side, and then layering reflective material, glass mat, etc. by hand lay-up or resin injection; Compression molding is performed by sandwiching the material between sheet-like resin materials such as SMC (sheet molding compound) and glass cloth prepreg.
Typical methods include integral molding by vacuum molding, and methods in which the reflective material is molded with a resin material along the parabolic mirror surface at t53, and then a coating film is formed on the mirror surface by spray painting, electrostatic painting, etc. It is.

However, the first method described above requires many man-hours to spray the gel coat, resulting in low productivity. Although the second method improves productivity, it tends to cause reflections to wave, break, or get into the ribs, and it is impossible to check them. Furthermore, the third method requires specialized equipment, increases the number of layers, and is susceptible to surface defects such as orange skin, pinholes, and dripping.

[Object of the Invention] Taking the above facts into consideration, the present invention is a manufacturing method for obtaining an electromagnetic wave reflector with a laminated structure by sandwiching an electromagnetic wave reflective material between resin materials, and in which deformation of the electromagnetic wave reflective material occurs during molding. The purpose is to obtain a manufacturing method 1 for an electromagnetic wave reflector that is difficult to manufacture and that also allows the molding status of the reflective material to be checked during molding 1 and 5.

[Summary of the Invention] In the method for manufacturing an electromagnetic wave reflector according to the present invention, a fiber-reinforced resin material and an electromagnetic wave reflective material placed thereon are heated under pressure in a mold to be in a semi-cured state. Thereafter, the mold is opened, and the fluid resin to be the protective layer is placed on the ``-'U magnetic wave reflective material'' and heated under pressure to obtain an integral laminated structure.

Therefore, before forming the protective layer, the electromagnetic wave reflecting material '1
After molding with fiber reinforced resin material, with the mold open,
The molded state of the electromagnetic wave reflective material exposed on the surface can be checked, and in some cases, the electromagnetic wave reflective material can be shaped. Therefore, the mirror precision of the electromagnetic wave reflector can be ensured, the resin material can be prevented from entering into the ribs and bosses of the two reflectors, and the pressure of the surface protective layer can also be made 0.7 mm or less. This thickness can be freely changed by adjusting the viscosity of the glass fibers and coating resin.

However, before molding the protective layer, it is necessary that the fiber-reinforced resin material is in an uncured state, and when molding the surface protective layer after complete curing, the fiber-reinforced resin material, electromagnetic wave reflecting material, and protective layer must be in an uncured state. adhesion is reduced.

As the electromagnetic wave reflecting material used in the present invention, conductive materials such as porous materials can be used, including carbon fibers, metal-plated organic fibers, aluminum-coated glass i-fibers, metal edge 1F, woven fabrics, nets, braids, articles made of these, etc. Non-woven paper and lumps thereof, metal plated forms, compressed bodies thereof, metal foils such as aluminum foil, and punched products of these can be used.

The fiber reinforced resin material (FRP) preferably has weather resistance, snow accretion resistance, and heat resistance, and resin materials containing short glass fibers are preferred. -Sheet materials commonly referred to as sheet molding compounds (SMC) are applicable. In addition, sheet molding compound (TMC), which is a thicker version of this sheet molding compound, / Herc molding compound (
BMC), fiber reinforced polypropylene (product name: AZ
DEL) can also be applied.

If necessary, an intermediate layer such as a glass fiber surface mat, cloth, or continuous mat can be interposed between the fiber-reinforced resin material and the electromagnetic wave reflector, and this intermediate layer is made of a carbon edge M[ It may be omitted if the material has excellent tensile strength, such as cloth or aluminum-coated glass cloth.

The protective layer may be made of a mixture of thermosetting resin such as urethane, vinyl ester, epoxy, furan, etc. with a curing agent. This protective layer increases the strength of the coating film by using glass fiber surface mat glue and loss, and the coating thickness can be adjusted from 0.1 to 0.7 mm, and the weather resistance is improved to the next level. do. Further, resin-impregnated sheets of woven and non-woven glass fibers can also be used as the protective layer.

A surface coating agent can also be applied to the surface of the protective layer. After molding the protective layer, the mold is opened, the coating agent is applied, and the surface is heated and pressurized again to improve the surface gloss. , and the toners that are mixed can be varied to obtain the desired tonal appearance.

In this way, the glass content is 30% by weight or less and the thickness is 0.7%.
It is possible to form a strong surface protective layer with a diameter of 1 mm or less and an excellent surface appearance on the mirror surface of the antenna.

Note that the electromagnetic wave reflecting material #l, the reinforcing material, and the intermediate layer used in the present invention may have a multilayer structure by stacking a plurality of them.

[Embodiments of the Invention] (Example 1) The present invention was applied to manufacturing an FRP parabolic antenna. As the electromagnetic wave reflecting material 1O shown in FIG.
A short glass fiber reinforced unsaturated polyester resin sheet (SMC) is used as the Li fiber reinforced resin material 12, and the electromagnetic wave reflecting material II 10 and the fiber reinforced resin material 12 sandwich the intermediate layer 13 and are arranged along the reflective surface. Lower mold 141
．． are laminated to. The lower mold 14 is provided with a recess for forming reinforcing ribs 18 on the back surface of the molded product.

In this FIG. 1, electric current is applied onto the fiber reinforced resin material 12.
tsu□wa1o, 1□[11”22tTya14: Arrive,
Molding temperature 140℃, molding pressure 50K g/cm
2 for 2 minutes to form a shape.

As shown in No. 2-, the upper mold 22 is lifted up and the mold is opened to confirm the molding status of the electromagnetic wave reflecting material 10. Ho 5 ((layer 2
4 as glass safe mat 25 (approx. 30g/m2)
12 is placed on the electromagnetic wave reflecting material 10, an unsaturated vinyl ester resin compound is mixed with a curing agent and supplied from the resin supply device 26, and the mold 1-2 is brought into close contact with the lower mold 14 again and pressurized. Heat molded.

As a result, as shown in FIG. 3, the electromagnetic wave reflecting material lO
, the fiber-reinforced resin material 12, and the protective layer 24 were physically laminated to form an electromagnetic wave reflector. Since the protective layer 24 does not permeate the electromagnetic wave reflective material 10 and reach the H&fiber reinforced resin material 12, the electromagnetic wave reflective material 10 is not deformed or sagged.

Furthermore, as shown in FIG. 4, after opening the upper mold 22, a two-component urethane resin is supplied from the resin supply device 28 and the resin is pressurized, heated and compression molded, thereby forming a surface coating layer and further increasing the gloss. "Toward"; to do. By mixing various color toners into this resin supply device 28, various color tones can be obtained.

(Example 2) The electromagnetic wave reflecting material 1O and the fiber reinforced resin material 12 were molded using the same material as in Example 1, using the same material with -.

After opening the upper mold, a glass cloth (200 g/m2) was introduced, and 70 g of the same resin as in Example 1 was supplied, followed by heat compression molding again to produce an electromagnetic wave reflector.

(Example 3) The electromagnetic wave reflective material 10 and the fiber-reinforced flZ resin material $412 are the same as in Example 1, and the electromagnetic wave reflective material 10 is sandwiched between two glass surface mats and integrally molded with SMC, and the mold is opened. Then, a two-component urethane resin was supplied and heated under pressure.

(Example 4) Carbon fiber mat (Trading Card BO
-050), and use two pieces of crow cloth (approximately 20
0 g/m2) c7) It was sandwiched between sMc and body molding. After opening the mold, a l-liquid urethane resin was supplied and heat compression molding was performed.

(Example 5) The electromagnetic wave reflecting material 10 and the fiber reinforced resin material 12 were molded using the same materials as in Example 1 under the same conditions.

After the mold 4 was opened (l5), a two-component urethane resin was supplied and heated under pressure to form a protective layer.

Table 1 The film thickness of the protective layer 24 thus obtained is shown in Table 1.

(Examples 6 to 8) The electromagnetic wave reflecting material 10 and fiber reinforced resin material 12 were molded using the same materials as in the first example, only the pressurization time was changed, and other conditions were the same. After opening the upper mold, two-component urethane resin III was supplied and heated and compressed to form a protective layer.

Table 2 shows the pressurization time and the adhesion results of the obtained electromagnetic wave reflector's d1 layer. The rich η property results are JI
SK5400. Base] This shows the number of remaining peels in one test.

Table 2 [Effects of the Invention] As explained above, in the method for manufacturing an electromagnetic wave reflector according to the present invention, the surface protective layer is molded after molding the fiber reinforced resin material and the electromagnetic wave reflective material. It has the excellent effect of minimizing deformation of the reflector and making it possible to check the molding status of the reflector during molding.

[Brief explanation of the drawing]

1 to 4 are cross-sectional views showing the manufacturing procedure of the present invention. 10... Electromagnetic wave reflecting material 12... S fiber reinforced resin material 14Φ ・ ・ Do type 24... Protective layer

Claims (1)

[Claims] (1) A method for producing an electromagnetic wave reflector that obtains an electromagnetic wave reflector having a laminated structure in which an electromagnetic wave reflective material is integrally sandwiched between a fiber reinforced resin material and a protective layer, the method comprising: The electromagnetic wave reflecting material placed on the electromagnetic wave reflecting material is pressurized and heated in a mold to bring it into a semi-cured state, and then the mold is opened and a fluid resin is placed on the electromagnetic wave reflecting material and pressurized and heated to form a protective layer. A method for manufacturing an electromagnetic wave reflector.