Process of manufacturing metalized plastic microwave lens

Claim 1

THE PROCESS OF MANUFACTURING AT LEAST A SECTOR OF A METALIZED PLASTIC MULTICELLULAR MICROWAVE LENS COMPRISING THE STEPS OF COATING THE SMOOTH SURFACES OF A PLURALITY OF MANDRELS WITH A SUSPENSION OF THIN MATALLIC FLAKES IN A BINDING VEHICLE, WHEREIN THE FLAT SURFACES OF THE FLAKES BECOME ALIGNATED SUBSTANTIALLY PARALLEL WITH THE ADJACENT SMOOTH SURFACES OF THE MANDRELS, EACH MANDREL CONFORMING IN CROSS SECTION TO THE INTERIOR SHAPE OF A PARTICULAR LENS CELL, THE LENGTHS OF SAID SMOOTH MANDREL SURFACES BEING EQUAL TO THE LENGTHS OF THE CORRESPONDING LENS CELLS, SAID BINDING VEHICLE CONTAINING A BINDING MATERIAL AND A SOLVENT ADAPTED TO EVAPORATE WHEREBY AFTER EVAPORATION OF SAID SOLVENT SAID FLAKES AND BINDING MATERIAL FROM CONTINUOUS METALLIC FILMS CONFORMAL WITH THE SMOOTH SURFACES OF EACH MANDREL, COVERING THE COATED SURFACES OF EACH MANDREL WITH A THIN LAYER OF FLUID PLASTIC MOLDING MATERIAL AFTER EVAPORATION OF SAID SOLVENT, SAID FLUID MOLDING MATERIAL BEING ADAPTED TO HARDEN SUBSTANTIALLY VOID FREE BY POLYMERIZATION AND TO ADHERE TO THE OUTSIDE OF SAID METALLIC FILMS, PLACING FABRIC ADJACENT SAID THIN LAYER ON EACH MANDREL AFTER THE THIN LAYERS HAVE HARDENED, ASSEMBLING THE MANDRELS IN A MOLDING BOX IN ACCORDANCE WITH THE DESRIRED DESIGN OF THE LENS, FILLING THE INTERIOR OF SAID MOLDING BOX TO A PREDETERMINED LEVEL AT LEAST ABOVE THE TOP OF THE HIGHEST SMOOTH MANDREL SURFACE WITH ADDITIONAL FLUID PLASTIC MOLDING MATERIAL, DISASSEMBLING SAID MOLDING BOX AFTER SAID ADDITIONAL MOLDING MATERIAL HAS HARDENED, AND WITHDRAWING THE MANDREL FROM THE INTERIOR OF EACH LENS CELL.