CN1188931C - 透镜天线 - Google Patents
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Abstract
本发明提供了一种复合介电模塑制品,它在用于透镜天线时表现出诸如天线增益和旁瓣等优良特性,还在个体及个体之间表现出较少的特性变化。通过对包含介电无机填料和和有机聚合物材料的复合介电材料进行模塑,从而使介电常数各向异性在1.00到1.05的范围内,这样来形成复合介电模塑制品。
Description
技术领域
本发明涉及复合介电模塑制品,尤其涉及复合介电模塑制品和使用它的透镜天线。
背景技术
近几年,已积极地开发了新一代的智能交通(transport)***(ITS),而且支持巡航中的安全驾驶的功能已日益得到开发。尤其是,在ITS中,认为起到汽车的眼睛作用的外部环境检测***是最重要的,已开发了使用红外线、CCD等的检测***。然而,这些检测***所存在的问题是不能在雨中使用,而且增加了成本。
因此,考虑把利用毫米波(76GHz)的雷达用作外部环境检测装置。这样的毫米波天线的例子包括具有平的出射面的平面天线、具有凸起的出射面的透镜天线等。然而,透镜天线在天线效率和检测角方面特别优秀。
这样的透镜天线***一般包括具有凸起的出射面的透镜主体以及设置在透镜主体后面的主发射器(transmitter)。尤其是,对于透镜主体的厚度必须减小的车载透镜天线而言,把包括树脂和介电无机填料的复合介电材料用作透镜主体的材料,该复合介电材料表现出高的介电常数,甚至具有小的厚度及优良的生产率。从模塑成本和模塑精度的观点来看,一般通过注射模塑法(injection molding)来模塑形成透镜主体。
然而,在通过对常规的复合介电材料进行模塑而获得的透镜主体(复合介电模塑制品)中,不可能根据设计来实现天线增益值以及透镜天线的旁瓣,而且其特性发生变化而降低成品率。
发明内容
相应地,本发明的一个目的是提供一种复合介电模塑制品,它在用于透镜天线时表现出诸如天线增益、旁瓣等优良特性,而且在个体中和个体之间表现出较少的特性变化。
为了实现本发明的这一目的,依据第一方面,一种复合介电模塑制品包括包含介电无机填料和有机聚合物材料的复合介电材料,其中介电常数的各向异性在1.00到1.05的范围内。介电常数各向异性代表沿介电常数为最大的方向的介电常数A与介电常数为最小的方向的介电常数B之比(A/B)。
通过使用此复合介电材料并控制所获得的模塑制品的介电常数各向异性,可获得具有优良电学特性且特性变化较少的复合介电模塑制品。即,由于注意到复合介电模塑制品的介电常数随有关所使用的复合介电材料和模塑条件的电场方向而变化这一事实,发明人发现,表现出介电常数变化大的复合介电模塑制品产生了不可能获得所需介电常数特性的电场方向以及复合介电模塑制品的特性变化。因此,继而又发现,通过减少介电常数相对于电场方向的变化,即通过把介电常数各向异性控制在1.00到1.05,可解决上述问题,从而实现本发明。
在依据本发明第二方面的复合介电模塑制品中,复合介电材料最好在模塑期间在1000s-1的剪切速率下具有170Pa·s或更大的熔融粘度。
在此熔融粘度下,即使在复合介电模塑制品的介电常数各向异性可能增加的注射模塑方法中,也可把介电常数各向异性控制在1.00到1.05的范围内。
在依据本发明第三方面的复合介电模塑制品中,有机聚合物材料最好包括热塑性树脂。
通过使用此有机聚合物材料,可通过注射模塑法来模塑形成复合介电材料,从而减少生产成本并允许形状精度高的简单模塑。
在依据本发明第四方面的复合介电模塑制品中,有机聚合物材料最好包括包含树脂填料的热塑性树脂。
通过使用这种有机聚合物材料,介电常数各向异性可减小,这是因为树脂填料抑制了介电无机填料的取向。
在依据本发明第五方面的复合介电模塑制品中,介电无机填料最好包括从IIa、IVa、IIIb或IVb族元素的氧化物、碳酸盐、磷酸盐、硅酸盐以及包含IIa、IVa、IIIb或IVb族元素的化合氧化物中选出的至少一种。
通过使用这种介电无机填料,即使在复合介电模塑制品的厚度小时,也可获得高的介电常数。
依据本发明第六方面的透镜天线包括具有凸起出射面的至少一个透镜单元以及设在透镜单元后面的主发射器,其中透镜单元包括依据本发明第一到第四方面中任一个的复合介电模塑制品。
在具有此结构的透镜天线中,可增加天线增益,并可减少旁瓣和特性变化。
在依据本发明第七方面的透镜天线中,透镜单元最好包括透镜主体以及在透镜主体的表面上形成的用以使透镜主体与大气匹配的匹配层。
通过在透镜主体上设置匹配层,可进一步抑制电磁波发射和接收期间的电磁波反射。
附图说明
图1是示出本发明的透镜天线示意平面图;
图2是示出本发明的复合介电模塑制品的示意透视图;以及
图3是本发明的复合介电材料的水平剖面图。
具体实施方式
通过对包括介电无机填料和有机聚合物树脂的复合介电材料进行模塑,从而使模塑制品的所需结构部分的介电常数各向异性在1.00到1.05的范围内,这样来形成本发明的复合介电模塑制品。
介电常数各向异性代表沿介电常数最大的方向的介电常数A与沿介电常数最小的方向的介电常数B之比(A/B)。作为测量方法,使用测量由复合介电模塑制品的所需部分获得的十个测试件的介电常数同时旋转测试件的方法。
复合介电模塑制品的介电常数基本上由介电无机填料来确定,并可通过控制所添加的介电无机填料的类型和数量来控制。介电无机填料最好包括从从IIa、IVa、IIIb或IVb族元素的氧化物、碳酸盐、磷酸盐和硅酸盐以及包含IIa、IVa、IIIb或IVb族元素的化合氧化物中选出的至少一种。这些填料的例子包括TiO2、CaTiO3、MgTiO3、Al2O3、BaTiO3、SrTiO3、CaCO3、Ca2P2O7、SiO2、Mg2SiO4、Ca2MgSi2O7、Ba(Mg1/3Ta2/3)O3等。
添加到复合介电材料的介电无机填料的比例较佳为1.0到55.0体积百分比,更好为10.0到55.0体积百分比。这是由于以55.0体积百分比或更小的比例添加的介电无机填料,可容易地对复合介电材料进行注射模塑,而以1.0体积百分比或更大的比例,可保证实用的介电常数。
作为有机聚合物材料,最好使用热塑性树脂,这是因为可对它进行注射模塑。有机聚合物材料的例子包括聚乙烯、聚丙烯、聚苯乙烯、间同立构聚苯乙烯、液晶聚合物、聚苯硫、ABS树脂、聚酯树脂、聚缩醛、聚酰胺、甲基戊烯聚合物、降冰片烯树脂、聚碳酸酯、聚苯醚、聚砜、聚酰亚胺、聚醚酰亚胺、聚酰胺酰亚胺、聚醚酮等。尤其是,聚乙烯、聚丙烯、聚苯乙烯、间同立构聚苯乙烯、液晶聚合物和聚苯硫是较佳的,因为其在射频下的Q值高。
当有机聚合物材料包括包含树脂填料的热塑性树脂时,可把所述热塑性树脂中的任一种用作作为基质的热塑性树脂。作为树脂填料,除了所述热塑性树脂以外,还可使用诸如环氧树脂、三聚氰胺树脂、聚氨酯树脂、硅酮树脂等热固性树脂。然而,在把热塑性树脂用作树脂填料时,选择在被选为热塑性基质的热塑性树脂的熔化温度下不熔化的热塑性树脂。
添加到复合介电材料的树脂填料的比例较佳为1.0到45.0体积百分比,更好为10.0到45.0体积百分比。这是由于添加过多量的树脂填料,难于对复合介电材料进行注射模塑,同时量过少,不能容易地抑制介电无机填料的取向。
由于即使在进行注射模塑时也可减小复合介电材料的介电常数各向异性,所以在1000s-1的剪切速率下,熔融粘度较佳为170Pa·s或更大,更好为200Pa·s或更大。虽然粘度的上限与制模机的性能有关,因而不受限制,但从目前制模机的功能的观点来看,粘度最好为8000Pa·s或更小。
以下将描述本发明的透镜天线。图1是示出本发明的透镜天线的示意图。
本发明的透镜天线1包括透镜单元2、波导(主发射器)3和与透镜单元2及主发射器3啮合的支承板4。
透镜单元2包括透镜主体2a和匹配层2b,透镜主体2包括本发明的复合介电模塑制品,它是通过注射模塑法形成的,从而出射面2a1具有凸起形状和圆弧状纵截面,入射面2a2具有板状。设置匹配层2b是为了使透镜主体2a与大气匹配,与透镜主体2a相同,匹配层2b包括本发明的复合介电模塑制品。把匹配层2b模塑成如此形状,从而覆盖透镜主体2a的***并接合到透镜主体2a。匹配层2b的相对介电常数最好与透镜主体2a的相对介电常数的平方根相同或接近。此外,匹配层2b的厚度最好约为所需微波波长的1/4。
在本实施例中,主发射器包括由铝制成且具有直角棱镜形状的波导3。波导3的上表面中形成有发射孔3a,其侧面形成有***孔3b,孔3a和3b在波导3中相通。
支承板4具有向透镜单元2的边缘四周展宽的圆锥形状,且用于固定波导3与透镜单元2之间的位置关系。此外,支承板4的内表面镀有金属,从而反射电磁波。
介质线5从***孔3b***,从而其末端到达发射孔3a的位置。虽然在图中未示出,但在介质线5上形成一电极。
以下将参考例子更详细地描述本发明的复合介电模塑制品。
例子
例1
以下将描述本发明的复合介电模塑制品。图2是示出本发明的复合介电模塑制品的透视图,图3是本发明的复合介电材料的水平剖面图。图3A是沿图2的线A-A’所取的剖面图;图3B是沿图2的线B-B’所取的剖面图;图3C是沿图2的线C-C’所取的剖面图。
首先,制备CaTiO3粉末和聚丙烯粉末分别作为介电无机填料和有机聚合物材料,并以表1所示的混合比称量。用Henschel混合机预先混合这些材料,以形成混合粉末。接着,在200℃的气缸温度下,用双轴挤压机在熔融状态下搅和如此获得的粉末,以制备复合介电材料,然后通过头孔(head orifice)模塑成线。把获得的模塑制品在水中冷却,然后切割成约φ2×5mm而获得片。把如此获得的片置于注射模塑机中,熔化并注射模塑成直径为73.2mm且最大厚度为20mm的类凸透镜形状,以获得复合介电模塑制品。在注射模塑时,在1000s-1的剪切速率下测量每个样品的熔融粘度。
接着,测量获得的复合介电模塑制品的介电常数各向异性和介电常数。通过使用TEO1δ模式下为12GHz的电场的摄动法来测量介电常数。如下测量介电常数各向异性。首先,如图2所示,通过沿厚度方向的A-A’面、B-B’面和C-C’面把复合介电模塑制品10分成四个相等的部分,如图3所示,从断片10a、10b和10c切割出总共15个样品11。接着,通过使用TEO1δ模式下的电场的摄动法同时电场的方向每次旋转30°来测量每个样品11的介电常数。然后,计算每个样品最大介电常数与最小介电常数之比作为介电常数各向异性,对片的介电常数各向异性值求平均,以确定复合介电模塑制品的介电常数各向异性。
表1中示出结果。在表1中,符号*指本发明范围之外的样品。
样品号 | CaTiO3的量(vol%) | 聚丙烯的量(vol%) | 注射模塑的熔融粘度(Pa·s) | 介电常数各向异性 | 介电常数εr | 介电常数的变化3σ |
*1 | 11.2 | 88.8 | 122 | 1.07 | 3.9 | 0.38 |
*2 | 19.5 | 80.5 | 160 | 1.06 | 5.8 | 0.33 |
3 | 26.6 | 73.4 | 180 | 1.05 | 7.8 | 0.3 |
4 | 29.1 | 70.9 | 200 | 1.02 | 8.8 | 0.1 |
5 | 35.6 | 64.4 | 260 | 1.01 | 12.5 | 0.07 |
6 | 40 | 60 | 285 | 1.006 | 14.9 | 0.05 |
*:本发明范围之外的样品
表1示出介电常数各向异性在1.00到1.05范围内,即使介电常数改变,介电常数的变化也较少。
把复合介电模塑制品的介电常数各向异性限制在1.00到1.05的原因在于,象在介电常数各向异性在1.05或更大的样品1和2中,介电常数不想要地变化大。
此外,把注射模塑期间1000s-1的剪切速率下复合介电材料的熔融粘度限制在170Pa·s或更大的原因在于,象熔融粘度为170Pa·s或更小的样品1和2中,包含在复合介电材料中的介电无机填料容易沿某一方向取向,从而不想要地把介电常数各向异性增加到超过1.05。
例2
如表2来设定介电无机填料与有机聚合物材料的类型和混合比,以获得用于形成介电常数εr约4.0的复合介电模塑制品的混合粉末。把样品的介电常数设定为恒定值的目的是为了简单地比较样品的增益和旁瓣。接着,通过与例1相同的方法,从所获得的混合粉末中获得复合介电模塑制品。通过与例1相同的方法来测量复合介电材料的熔融粘度、介电常数各向异性和介电常数。此外,在消回波室中使用TE10模式下为76GHz的电场来测量旁瓣。结果示于表2。
表2
样品号 | 介电天机填料 | 有机聚合物材料 | 注射模塑熔的熔融粘度(Pa.s) | 介电常数的变化3σ | 介电常数各向异性 | 增益(dbi) | 旁瓣(db) | ||
类型 | 数量(vol%) | 类型 | 数量(vol%) | ||||||
*11 | CaTiO3Al2O3 | 11.25 | PP | 83.8 | 135 | 0.34 | 1.055 | 31.0 | -11 |
*12 | SrTiO3 | 10 | PP | 90 | 119 | 0.4 | 1.07 | 30.5 | -8 |
*13 | CaTiO3 | 10 | PS | 90 | 130 | 0.38 | 1.06 | 30.0 | -9 |
14 | CaTiO3CaCO3 | 425 | PP | 71 | 200 | 0.15 | 1.03 | 31.5 | -19 |
15 | MgTiO3 | 23 | PP | 77 | 180 | 0.09 | 1.02 | 32.0 | -20 |
16 | CaTiO3Al2O3 | 425 | PP | 71 | 200 | 0.15 | 1.03 | 31.5 | -19 |
17 | CaCO3 | 36 | PP | 64 | 260 | 0.09 | 1.02 | 32.0 | -20 |
18 | Al2O3 | 34 | PP | 66 | 250 | 0.07 | 1.01 | 32.5 | -22 |
19 | Mg2SiO4 | 45 | PP | 55 | 550 | 0.05 | 1.002 | 32.5 | -22 |
20 | 玻璃珠 | 49 | PP | 51 | 500 | 0.05 | 1.002 | 31.0 | -22 |
*:本发明范围之外的样品
表2 (续)
样品号 | 介电天机填料 | 有机聚合物材料 | 注射模塑熔的熔融粘度(Pa.s) | 介电常数的变化3σ | 介电常数各向异性 | 增益(dbi) | 旁瓣(db) | ||
类型 | 数量(vol%) | 类型 | 数量(vol%) | ||||||
21 | BaTi4O9Al2O3 | 1015 | PP | 75 | 170 | 0.2 | 1.04 | 31.5 | -15 |
22 | CaCO3 | 20 | PPS | 80 | 180 | 0.07 | 1.01 | 32.0 | -22 |
23 | glassfiber | 26 | PPS | 74 | 300 | 0.15 | 1.03 | 31.2 | -19 |
24 | Al2O3 | 20 | PPS | 80 | 170 | 0.07 | 1.01 | 32.0 | -21 |
25 | ZrTiO4 | 18 | PS | 82 | 180 | 0.1 | 1.02 | 32.0 | -20 |
26 | SnTiO4 | 18 | PS | 82 | 180 | 0.09 | 1.02 | 32.0 | -20 |
27 | CaCO3 | 33 | SPS | 67 | 300 | 0.09 | 1.02 | 31.5 | -20 |
PP: 聚丙烯
PS: 聚苯乙烯
PPS: 聚苯硫
SPS: 间同立构聚苯乙烯
熔融粘度的测量温度:PP;200℃,PPS;300℃,PS;200℃,
SPS;280℃
表2示出,在介电常数各向异性在1.00到1.05范围内的样品14到27中,即使在介电无机填料和有机聚合物材料的类型改变时,介电常数也较少变化,获得了增益和旁瓣的优良值。另一方面,在介电常数各向异性为1.05或更大的样品11到13中,介电常数的变化增加2倍或更多,不能获得增益和旁瓣的优良值。
例3
制备作为介电无机填料的CaTiO3粉末和Al2O3粉末、作为热塑性基质树脂的聚丙烯粉末以及作为树脂填料的间同立构聚苯乙烯粉末,并以表3所示的混合比称量。然后,用Henschel混合机把这些材料预先混合,以获得混合粉末。接着,以与例1相同的方法从获得的混合粉末中得到复合介电模塑制品。
以与例1相同的方法测量如此获得的复合介电模塑制品的介电常数各向异性和介电常数。结果示于表3。在表3中,符号*指本发明范围之外的样品。
在样品28到30中,添加与作为例1的比较例子的样品1(表1)相同数量的介电无机填料,把树脂填料添加到热塑性树脂中。在样品31到33中,添加与例1的样品3(表1)相同数量的介电无机填料,把树脂填料添加到热塑性树脂中。在样品34到36中,添加与作为例2的比较例子的样品11(表2)相同数量的介电无机填料,把树脂填料添加到热塑性树脂中。在样品37到39中,添加与作为例2的比较例子的样品16(表2)相同数量的介电无机填料,把树脂填料添加到热塑性树脂中。
表3
样品号 | 介电天机填料 | 热塑性基质树脂 | 树脂填料 | 介电常数各向异性 | 介电常数的变化3σ | |||
类型 | 数量(vol%) | 类型 | 数量(vol%) | 类型 | 数量(vol%) | |||
*1 | CaTiO3 | 11.2 | PP | 88.8 | - | 0 | 1.07 | 0.38 |
*11 | CaTiO3Al2O3 | 11.25 | PP | 83.8 | - | 0 | 1.055 | 0.34 |
28 | CaTiO3 | 11.2 | PP | 43.8 | SPS | 45 | 1.008 | 0.07 |
29 | CaTiO3 | 11.2 | PP | 64.8 | SPS | 24 | 1.025 | 0.1 |
30 | CaTiO3 | 11.2 | PP | 78.8 | SPS | 10 | 1.05 | 0.3 |
31 | CaTiO3 | 26.6 | PP | 43.4 | SPS | 30 | 1.04 | 0.2 |
32 | CaTiO3 | 26.6 | PP | 53.4 | SPS | 20 | 1.02 | 0.1 |
33 | CaTiO3 | 26.6 | PP | 63.4 | SPS | 10 | 1.01 | 0.07 |
34 | CaTiO3Al2O3 | 11.25 | PP | 38.8 | SPS | 45 | 1.005 | 0.06 |
35 | CaTiO3Al2O3 | 11.25 | PP | 59.8 | SPS | 24 | 1.02 | 0.09 |
36 | CaTiO3Al2O3 | 11.25 | PP | 73.8 | SPS | 10 | 1.04 | 0.2 |
37 | CaTiO3Al2O3 | 425 | PP | 41 | SPS | 30 | 1.025 | 0.13 |
38 | CaTiO3Al2O3 | 425 | PP | 51 | SPS | 20 | 1.02 | 0.1 |
39 | CaTiO3Al2O3 | 425 | PP | 61 | SPS | 10 | 1.008 | 0.06 |
*:本发明范围之外的样品
PP:聚丙烯
SPS:间同立构聚苯乙烯
表3示出,当热塑性基质树脂包含树脂填料时,介电常数各向异性在1.00到1.05的范围内,从而介电常数较少变化。
通过对包含介电无机填料和有机聚合物材料的复合介电材料进行模塑,从而使介电常数各向异性在1.00到1.05的范围内,这样来形成本发明的复合介电模塑制品。因此,可提高电学特性,并可减少特性的变化。
此外,把热塑性树脂选为有机聚合物材料,把1000s-1下复合介电材料的熔融粘度设定为170Pa·s或更大,以允许复合介电材料的注射模塑。因此,可降低生产成本,并可容易地实现具有高精度形状的模塑。
此外,把包含树脂填料的热塑性树脂选为有机聚合物材料,因而可抑制介电无机填料的取向,从而减小介电常数各向异性。
作为介电无机填料,从IIa、IVa、IIIb或IVb族元素的氧化物、碳酸盐、磷酸盐、硅酸盐以及包含IIa、IVa、IIIb或IVb族元素的化合氧化物中选出至少一种,从而即使在复合介电模塑制品薄时,也可获得高的介电常数。
通过把本发明的复合介电模塑制品用于透镜天线,使得透镜天线具有大的天线增益,低的旁瓣和较小的特性变化。
Claims (7)
1.一种透镜天线,包括具有凸起出射面的至少一个透镜单元以及设在透镜单元后面的主发射器;
其中透镜单元包括复合介电模塑制品,所述复合介电模塑制品包括包含介电无机填料和有机聚合物材料的复合介电材料;
其中所述复合介电模塑制品的介电常数各向异性在1.00到1.05的范围内,介电常数各向异性代表沿介电常数为最大的方向的介电常数A与介电常数为最小的方向的介电常数B之比。
2.如权利要求1所述的透镜天线,其特征在于复合介电材料在模塑期间在1000s-1的剪切速率下具有170Pa·s或更大的熔融粘度。
3.如权利要求1所述的透镜天线,其特征在于有机聚合物材料包括热望性树脂。
4.如权利要求1所述的透镜天线,其特征在于有机聚合物材料包括包含树脂填料的热塑性树脂。
5.如权利要求1所述的透镜天线,其特征在于介电无机填料包括从IIa、IVa、IIIb或IVb族元素的氧化物、碳酸盐、磷酸盐、硅酸盐以及包含IIa、IVa、IIIb或IVb族元素的化合氧化物中选出的至少一种。
6.如权利要求1所述的透镜天线,其特征在于透镜单元包括透镜主体以及在透镜主体的表面上形成的用以使透镜主体与大气匹配的匹配层。
7.如权利要求6所述的透镜天线,其特征在于匹配层的相对介电常数与透镜主体的相对介电常数的平方根相同。
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- 2001-04-11 JP JP2001112816A patent/JP3664094B2/ja not_active Expired - Lifetime
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- 2001-10-17 US US09/978,745 patent/US6489928B2/en not_active Expired - Lifetime
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- 2001-10-18 DE DE10151501A patent/DE10151501B4/de not_active Expired - Lifetime
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DE10151501B4 (de) | 2011-06-09 |
FR2815459B1 (fr) | 2006-09-22 |
KR100443496B1 (ko) | 2004-08-09 |
CN1349227A (zh) | 2002-05-15 |
KR20020031300A (ko) | 2002-05-01 |
JP2002197923A (ja) | 2002-07-12 |
DE10151501A1 (de) | 2002-08-01 |
US20020067317A1 (en) | 2002-06-06 |
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