Method of molding foam/aluminum flake microwave lenses

摘要

A microwave lens is constructed of a homogeneous body of closed cell rigid polyurethane foam with aluminum flakes dispursed throughout and having a configuration defining an axis and opposed lens surfaces. The method of the invention includes selecting a mold having a cavity of the appropriate configuration, preheating the mold, and filling the mold with a mixture of low density polyurethane foam components and fine aluminum flakes evenly dispersed throughout the foam structure allowing the mixture to cool and form a body of the appropriate configuration.