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US 4,171,563 AGranted
Method of manufacturing an antenna reflector
AssigneeU.S. Philips Corporation
InventorWilhelmus H. C. Withoos
Life of this patent
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AssigneeU.S. Philips Corporation
InventorWilhelmus H. C. Withoos
Estimating the term…
The invention relates to the maufacture of reflectors of electromagnetic radiation, in which a flat and thin metal foil, for example an annealed copper foil which is clamped along its circumference is deformed plastically by means of a mould which has a convex surface. In the final position the mould with the deformed foil is at some distance from the surface of the matrix. The space between deformed foil and matrix is filled with a liquid synthetic resin, for example a foam-forming polyurethane resin. After complete or partial curing of the synthetic resin the mould is removed and the resulting assembly of deformed foil and synthetic resin layer connected thereto is removed from the matrix. In an interesting embodiment a matrix is used the concave surface of which has recesses so that in the finished reflector the supporting layer is provided with corresponding bosses, such as reinforcement ribs. In a further interesting embodiment a mould is used which has a central annular recess so that in the finished reflector in the optical center thereof a perforated hub is obtained which is of importance for aligning the reflector.
A method of making an antenna reflector comprising the steps of positioning a metal sheet between a die having a convex surface and a mould spaced from said die and having a cavity adapted to receive said convex surface with a gap therebetween, clamping said sheet at the periphery thereof, moving said die towards said mould and into engagement with said sheet to plastically deform and impart to said sheet a shape corresponding to the shape of said convex surface, said deformation of said sheet being effected solely by said convex surface of said die, arresting the movement of said die at a position such that said convex surface and the deformed sheet are spaced from the wall of said cavity, injecting a liquid synthetic resin into the space defined by said deformed sheet and said wall of said cavity, curing said resin to form a support member for said deformed sheet, withdrawing said die and removing said sheet and said support member attached thereto from said mould.
A method of making the antenna reflector comprising the steps of positioning a metal sheet having a thickness of 10 to 100.mu. and an aperture formed in the center thereof between a die having a convex surface and a mould spaced from said die and having a first cavity adapted to receive said convex surface with a gap therebetween, said die further having a central cavity of generally circular cross-section opening at said convex surface and a pin of a cross-section smaller than the cross-section of said central cavity affixed to said die and extending along said central cavity to define with the wall of said central cavity a first space therebetween, said sheet being positioned so that said aperture is aligned with said opening of said central cavity, clamping said sheet at the periphery thereof, moving said die towards said mould and into engagement with said sheet to plastically deform and impart to said sheet a shape corresponding to the shape of said convex surface, said deformation of said sheet being effected solely by said convex surface, arresting the movement of said die at a position such that said convex surface and the deformed sheet are spaced from the wall of said first cavity, filling the space defined by said deformed sheet and said wall of said first cavity and said first space with a liquid sythetic resin, curing said resin to form a support member for said deformed sheet, said support member having a central hub formed by the cured resin in said first space which extends from the side of said support member adjacent said sheet, withdrawing said die and removing said sheet and support member attached thereto from said mould.
Dependencies are inferred from the claim text.