A method for manufacturing a reflector surface and a reflector

Abstract

The present application provides a method for processing a reflector surface and a reflector. The method can cut multiple layers of prepreg according to a preset size, and lay the prepreg on a forming mandrel layer by layer. After each layer is laid, vacuum pre-pressing treatment is performed on the prepreg to obtain a prepreg sheet. A carbon fiber skin is laid on the prepreg sheet, and internal inserts are placed at preset positions between the forming mandrel and the carbon fiber skin. The carbon fiber skin far from the internal inserts is turned outwards from the edge at a preset angle, and the turned-out carbon fiber skin is hardened to form a groove part between the carbon fiber skin and the prepreg sheet. Finally, a honeycomb core structure is installed in the groove part to form a reflector surface. The present application obtains a model of the reflector surface by laying prepreg and carbon fiber skin on the forming mandrel, and then increases the reflection area of the reflector surface by turning out the carbon fiber skin, improving the utilization rate of the reflector surface, thereby improving the signal reception efficiency of the receiving system.

Description

Technical Field

[0001] This application relates to the technical field of aviation equipment, and particularly to a method for machining a reflector surface and a reflector. Background Art

[0002] A satellite refers to a natural celestial body that orbits a planet and moves in a closed orbit periodically. An artificial satellite can generally also be called a satellite. An artificial satellite is built by humans and launched into space by a space vehicle such as a rocket or a space shuttle. Artificial satellites can be divided into meteorological satellites, earth observation satellites, astronomical satellites, application satellites, broadcast satellites, etc. according to their different functions. Artificial satellites can send specified signals to the ground (the earth) according to their respective functions.

[0003] When an artificial satellite is working, for example, when a broadcast satellite wants to send a broadcast signal to the ground, the broadcast satellite will convert the collected broadcast data into electromagnetic waves suitable for propagation in free space and send out the electromagnetic waves. At this time, the receiving system on the ground will align the signal reflector with the direction where the satellite will appear. When the broadcast satellite sends out electromagnetic waves, the receiving system will lock and track the electromagnetic waves. When the signal reflector receives the electromagnetic waves, it will reflect the electromagnetic waves to the specified signal receiver, so that the signal receiver can perform processes such as amplification, frequency conversion, and demodulation on the electromagnetic waves, and finally play the broadcast data in the broadcast equipment.

[0004] The above-mentioned signal reflector is manufactured by integrally processing the front skin and turning it over backward. Neither the inner skin nor the outer skin of the reflector surface of the signal reflector extends. However, the butt joint gap generated during the processing of the reflector will have a negative impact on the electromagnetic waves. Workers will wrap a protective material around the end surface of the reflector surface during the manufacture of the reflector to cover the butt joint gap, such as an aluminum base tape, a glass cloth, or a carbon cloth. However, after wrapping the protective material, an obvious interface will be generated on the reflector surface, resulting in a significant reduction in the performance of the reflector surface in reflecting electromagnetic waves and affecting the receiving efficiency of the signal by the receiving system. Summary of the Invention

[0005] To solve the problem that the interface causes a significant reduction in the performance of the reflector surface in reflecting electromagnetic waves and affects the receiving efficiency of the signal by the receiving system.

[0006] In a first aspect, some embodiments of the present application provide a method for machining a reflector surface, the method comprising: cutting a plurality of layers of prepreg;

[0007] Laying the prepreg layer by layer on a forming mandrel, and performing a vacuum pre-pressing treatment on the prepreg after each layer is laid to obtain a prepreg sheet;

[0008] Laying a carbon fiber skin on the prepreg sheet;

[0009] Place an internal insert between the forming die blank and the carbon fiber skin, and turn the carbon fiber skin away from the internal insert outwards from the edge;

[0010] After the hardened treatment of the turned-out carbon fiber skin, take out the internal insert to form a groove between the carbon fiber skin and the prepreg sheet;

[0011] Install a honeycomb core structure in the groove so that the honeycomb core structure fits with the carbon fiber skin to form a reflecting surface.

[0012] In some embodiments, in the step of laying the prepreg on the forming die blank layer by layer, the method further includes:

[0013] Obtain a preset coordinate system and angular scale lines;

[0014] Lay the prepreg according to the coordinate system and the angular scale lines to obtain the laying angle of the prepreg;

[0015] Calculate the angular error of the laying angle;

[0016] If the laying error is less than or equal to the error threshold, perform the step of laying the carbon fiber skin on the prepreg sheet;

[0017] If the laying error is greater than the error threshold, re-lay the prepreg.

[0018] In some embodiments, after performing vacuum pre-pressing treatment on the prepreg after each layer is laid, the method further includes:

[0019] Perform quality inspection on the prepreg sheet to detect the lack of material layer inside the prepreg sheet;

[0020] Use a unidirectional prepreg tape to fill the lack of material layer;

[0021] Perform vacuum pre-pressing treatment on the prepreg sheet after filling.

[0022] In some embodiments, in the step of laying the carbon fiber skin on the prepreg sheet, the method further includes:

[0023] Set the laying angle between the carbon fiber skins;

[0024] Lay the carbon fiber skins in sequence according to the laying angle.

[0025] In some embodiments, there are positioning grooves provided on the forming die blank; in the step of placing an internal insert between the forming die blank and the carbon fiber skin, the method further includes:

[0026] Select the first reference plane of the forming die blank;

[0027] Coincide the top surface of the inner insert block with the first reference plane, and move the inner insert block in a direction parallel to the first reference plane so as to insert the vertex angle of the inner insert block into the positioning groove.

[0028] In some embodiments, before the step of installing the honeycomb core structure in the groove portion, the method further includes:

[0029] Fill a preset number of layers of the first foam adhesive layer at both ends of the honeycomb core structure at a first interval distance;

[0030] Fill a second foam adhesive layer between the first foam adhesive layers at a second interval distance, and the thickness of the second foam adhesive layer is twice that of the first foam adhesive layer.

[0031] In some embodiments, the method further includes:

[0032] Select the second reference plane of the forming die blank;

[0033] Position the honeycomb core structure according to the second reference plane;

[0034] Bond the outer skin to the bottom of the positioned honeycomb core structure.

[0035] In some embodiments, after the step of installing the honeycomb core structure in the groove portion, the method further includes:

[0036] Use light irradiation to detect the light-transmitting area between the honeycomb core structure and the carbon fiber skin;

[0037] If there is such a light-transmitting area, reinstall the honeycomb core structure.

[0038] In some embodiments, the step of laying the carbon fiber skin on the prepreg sheet includes:

[0039] Lay a separator film between the carbon fiber skins, and the area of the separator film is larger than that of the carbon fiber skins.

[0040] In a second aspect, some embodiments of the present application further provide a reflector, and the reflector includes a reflecting surface prepared by the method according to any one of the first aspect.

[0041] As can be seen from the above solution, the present application provides a method for processing a reflector surface and a reflector. The method can cut multiple layers of prepreg according to preset dimensions, lay the prepreg layer by layer on a forming mandrel, and perform vacuum pre-pressing treatment on the prepreg after each layer is laid to obtain a prepreg sheet. Then, a carbon fiber skin is pasted on the prepreg sheet, internal inserts are placed at preset positions between the forming mandrel and the carbon fiber skin, the carbon fiber skin far from the internal inserts is turned outwards from the edge at a preset angle, and after the turned-out carbon fiber skin is hardened, the internal inserts are taken out to form a groove portion between the carbon fiber skin and the prepreg sheet. Finally, a honeycomb core structure is installed in the groove portion to make the honeycomb core structure fit with the carbon fiber skin to form a reflector surface. By laying prepreg and carbon fiber skin on a forming mandrel to obtain a model of the reflector surface, and then turning out the carbon fiber skin, the present application increases the reflection area of the reflector surface and improves the utilization rate of the reflector surface, thereby improving the signal reception efficiency of the receiving system. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] To more clearly illustrate the technical solutions of the present application, the drawings required for use in the embodiments will be briefly introduced below. Obviously, for those of ordinary skill in the art, other drawings can also be obtained based on these drawings without creative efforts.

[0043] Figure 1 Schematic diagram of the reflector reflecting satellite signals;

[0044] Figure 2 Flow chart of a method for processing a reflector surface provided by the present application;

[0045] Figure 3 Schematic diagram of placing internal inserts between the carbon fiber skin and the forming mandrel in an embodiment of the present application;

[0046] Figure 4 Schematic diagram of installing a honeycomb core structure in an embodiment of the present application;

[0047] Figure 5 Front isometric view of the reflector with the carbon fiber skin turned outwards in an embodiment of the present application. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0048] To make the objectives and implementation manners of the present application clearer, the exemplary embodiments of the present application will be clearly and completely described below with reference to the drawings in the exemplary embodiments of the present application. Obviously, the described exemplary embodiments are only a part of the embodiments of the present application, rather than all of the embodiments.

[0049] It should be noted that the brief description of terms in this application is only for facilitating the understanding of the following described embodiments, rather than intending to limit the embodiments of this application. Unless otherwise specified, these terms should be understood in their ordinary and common meanings.

[0050] In this application, the terms "first", "second", "third", etc. in the description, claims and the above-mentioned drawings are used to distinguish similar or like objects or entities, and do not necessarily mean to limit a specific order or sequence, unless otherwise noted. It should be understood that such terms can be interchanged under appropriate circumstances.

[0051] The terms "comprising" and "having" and any variations thereof are intended to cover but not exclude inclusion. For example, a product or device comprising a series of components does not necessarily have to be limited to all the components clearly listed, but may include other components not clearly listed or inherent to these products or devices.

[0052] A satellite refers to a natural celestial body that orbits around a planet and moves in a closed orbit periodically. An artificial satellite can generally also be called a satellite. An artificial satellite is built by humans and launched into space by a space vehicle such as a rocket or a space shuttle. Artificial satellites can be divided into meteorological satellites, earth observation satellites, astronomical satellites, application satellites, broadcast satellites, etc. according to their different functions. Artificial satellites can send specified signals to the ground (the Earth) according to their respective functions.

[0053] In order to receive the signals sent by satellites, a receiving system can be set up on the ground to receive the signals and send them to a specific base station. However, in order to improve the propagation speed of the signals, satellites can convert the signals into electromagnetic wave form and send them. For example, as Figure 1 shown, a broadcast satellite will convert the collected broadcast data into electromagnetic waves suitable for propagation in free space and send out the electromagnetic waves when it is working. At this time, the receiving system on the ground will align the signal reflector with the azimuth where the broadcast satellite will appear. When the broadcast satellite sends out electromagnetic waves, the receiving system will lock and track the electromagnetic waves throughout the city. When the signal reflector receives the electromagnetic waves, it will reflect the electromagnetic waves to the designated signal receiver, so that the signal receiver can perform processing such as amplification, frequency conversion, and demodulation on the electromagnetic waves, and finally play the broadcast data in the broadcast device.

[0054] To facilitate the collection of electromagnetic waves, the shape of the signal reflector can be set as a hollow hemispherical or spherical arc shape. After the broadcast satellite transmits electromagnetic waves, the receiving system can rotate the direction of the signal reflector to align it with the broadcast satellite for locking and tracking of the electromagnetic waves. When the signal reflector receives the electromagnetic waves, it will reflect the electromagnetic waves to a designated signal receiver. The signal receiver can be set in the base station. After the signal receiver receives the electromagnetic waves, it performs processing such as amplification, frequency conversion, and demodulation on the electromagnetic waves, and then sends them to the broadcast device through the base station so that the broadcast device plays the broadcast data.

[0055] To facilitate the reception of electromagnetic waves, the surface of the signal reflector is covered with inner and outer skins made of carbon fiber composite materials. The carbon fiber composite material can be made by multi-directional weaving and carbonization of carbon fibers. The carbon fiber composite material has characteristics such as good material thermal conductivity, small expansion coefficient, large specific heat capacity, large radiation coefficient, and good thermal shock resistance and ablation resistance.

[0056] Since the carbon fiber composite material has a small density and light weight, it can be used on equipment with a large self-weight to reduce the weight and save a large amount of energy loss. Also, because the strength of the carbon fiber plate is very high, the skin made of the carbon fiber composite material can bear greater pressure and can enhance the strength of the reflecting surface in the reflector.

[0057] The carbon fiber composite material not only has a high specific strength but also has a high specific modulus, with unique advantages that cannot be compared with metals. The specific strength of the carbon fiber composite material modified with epoxy resin can be 10 times higher than that of aluminum alloy, and the specific stiffness is 4 times higher than that of aluminum alloy. Applying the skin made of the carbon fiber composite material to the signal reflector to replace other composite materials can significantly reduce the weight of the signal reflector.

[0058] The signal reflector can be made by integrally processing the front skin and turning it over. The inner and outer skins of the reflecting surface of the signal reflector do not extend. However, the butt joints generated during the processing of the reflector will have a negative impact on the electromagnetic waves. Workers will wrap protective materials such as aluminum base tape, glass cloth, or carbon cloth around the ends of the reflecting surface when manufacturing the reflector to cover the butt joints. However, after wrapping the protective materials, obvious interfaces will be generated on the reflecting surface, resulting in a significant reduction in the performance of the reflecting surface to reflect electromagnetic waves and affecting the reception efficiency of the receiving system for signals.

[0059] To solve the problem that the interface causes a significant reduction in the performance of the reflecting surface to reflect electromagnetic waves and affects the reception efficiency of the receiving system for signals, this application provides a method for processing the reflecting surface, such as Figure 2 shown, the method includes:

[0060] S100: Cut multiple layers of prepreg.

[0061] In this embodiment, the prepreg is a composition of a resin matrix and a reinforcement made by impregnating continuous fibers or fabrics with a resin matrix under specific conditions. There are various types of prepregs. Classified by physical state, prepregs are divided into unidirectional prepregs, unidirectional fabric prepregs, and fabric prepregs; classified by different resin matrices, prepregs are divided into thermosetting resin prepregs and thermoplastic resin prepregs; classified by different reinforcing materials, they are divided into carbon fiber prepregs, glass fiber prepregs, and aramid prepregs; classified by different fiber lengths, they are divided into short fiber prepregs, long fiber prepregs, and continuous fiber prepregs; classified by different curing temperatures, they are divided into medium-temperature curing prepregs, high-temperature curing prepregs, and prepregs with a curing temperature exceeding 200 °C, etc.

[0062] The prepreg is a cloth-like material that can meet the forming requirements of products with complex shapes. In some embodiments, the size of the prepreg can also be determined according to the size of the reflector. For example, the prepreg can be cut according to a width of 30 mm and the maximum size of the reflector as the length.

[0063] S200: Lay the prepreg layer by layer on the forming mold, and, after laying each layer, perform vacuum pre-pressing treatment on the prepreg to obtain a prepreg sheet.

[0064] In this embodiment, as Figure 3 shown, after cutting the prepreg according to a predetermined size, lay the prepreg on the forming mold to shape the prepreg according to the forming mold. Among them, in order to strengthen the strength and hardness of the reflecting surface, multiple layers of prepregs can be laid on the forming mold. After laying each layer of prepreg, it is also necessary to perform vacuum pre-pressing treatment on the prepreg to obtain a prepreg sheet, where the vacuum pre-pressing time can be 15 - 20 min.

[0065] In some embodiments, in order to accurately lay the prepreg, a preset coordinate system and angle scale can also be obtained, and then the prepreg is laid according to the specified position coordinates and preset angle. Among them, the center point or corner point of the prepreg can be used as the positioning point, and the prepreg is laid at the specified position according to the predetermined coordinates. And, the accuracy of the angle of the prepreg can also be detected according to the angle scale, so as to adjust the prepreg and improve the laying accuracy.

[0066] In the above embodiment, when laying the prepreg, the laying angle of the prepreg can also be obtained. At this time, the angle error of the laying angle can be calculated according to the preset angle. If the laying error is less than or equal to the error threshold, it means that the laying angle of the prepreg can perform the step of laying the carbon fiber skin on the prepreg sheet. If the laying error is greater than the error threshold, it means that the current laying angle cannot reach the laying accuracy and the prepreg needs to be laid again.

[0067] In some embodiments, after the vacuum pre-pressing treatment of the prepreg, it is also necessary to perform quality inspection on the prepreg sheet to detect whether there is a material-deficient layer inside the prepreg sheet. If there is a material-deficient layer in the prepreg sheet, when laying the carbon fiber skin subsequently, some of the carbon fiber skin will fill into the material-deficient layer during the curing process, resulting in a depression on the plane of the carbon fiber skin, which affects the electrical performance of the reflector for electromagnetic waves. Therefore, when a material-deficient layer appears in the prepreg sheet, it is necessary to use a unidirectional prepreg tape to fill the material-deficient layer and perform vacuum pre-pressing treatment on the prepreg sheet after filling.

[0068] S300: Lay the carbon fiber skin on the prepreg sheet.

[0069] The carbon fiber skin is the main material constituting the reflector surface. Similar to the prepreg, in order to enhance the reflection intensity of the reflector surface, multiple layers of carbon fiber skin can be laid.

[0070] In some embodiments, when laying multiple layers of carbon fiber skin, the placement of the carbon fiber skin will generate certain stress on the reflector, and these stresses will affect and increase the laying difficulty of the carbon fiber skin. Therefore, in this embodiment, the laying placement angle between the carbon fiber skins can be set, and the carbon fiber skins can be laid sequentially according to the laying placement angle to cancel out the stresses generated by the carbon fiber skins. For example, when 4 layers of carbon fiber skin need to be laid, or when laying 4 layers of carbon fiber skin batch by batch, the laying placement angle between the carbon fiber skins can be set to 45°, then the placement angles of each layer of carbon fiber skin can be -45°, 0°, 45°, and 90°. In this way, the first carbon fiber skin and the third carbon fiber skin are placed perpendicular to each other, and the second carbon fiber skin and the fourth carbon fiber skin are placed perpendicular to each other, so as to cancel out the generated stresses and facilitate the laying of the carbon fiber skin.

[0071] Since the carbon fiber skins will stick to each other, resulting in a reduction in the strength of the carbon fiber skin. In some embodiments, in order to prevent the carbon fiber skins from sticking to each other, an isolation film can also be laid between the carbon fiber skins. The area of the isolation film can be larger than that of the carbon fiber skin so that the isolation film completely covers the carbon fiber skin to prevent local carbon fiber skins from sticking.

[0072] S400: Place an internal insert between the forming die and the carbon fiber skin, and turn the carbon fiber skin away from the internal insert outwards from the edge.

[0073] In this embodiment, in order to increase the reflection area of the reflector surface, it is necessary to place a honeycomb core structure between the carbon fiber skin and the forming die. However, since the carbon fiber skin is relatively soft before hardening and cannot be formed. Therefore, as Figure 3 shown, it is also necessary to place an internal insert between the forming die and the carbon fiber skin to create a space for installing the honeycomb core structure through the internal insert.

[0074] Secondly, in order to make the carbon fiber skin completely cover the prepreg sheet, the area of the carbon fiber skin should be larger than that of the prepreg sheet. Therefore, part of the carbon fiber skin will extend out of the prepreg sheet, resulting in the need to use other materials to wrap the ends, which affects the electrical performance of the reflector surface.

[0075] Therefore, after installing the internal insert block, the carbon fiber skin far from the internal insert block can be turned outwards from the edge at a preset angle to avoid the extension of the edge of the carbon fiber skin and increase the reflection area of the reflector surface. As Figure 5 shown, in some embodiments, in order to support the turned-out skin, an auxiliary mold can also be used. As Figure 3 shown, the auxiliary mold can be an edge insert block to support the turned-out skin. Among them, the size of the turned-out carbon fiber skin can be 10 mm.

[0076] In some embodiments, in order to accurately install the internal insert block, it is also necessary to position the internal insert block according to the forming die blank. A positioning groove can also be provided on the forming die blank. During the positioning process, the first reference plane of the forming die blank can be selected, and one edge of the internal insert block can be positioned according to the first reference plane. For example, the internal insert block can be placed in coincidence with the first reference plane to position the degree of freedom in the first direction, and then the internal insert block can be moved in the direction parallel to the first reference plane to insert the apex angle of the internal insert block into the positioning groove, thereby completing the positioning of the internal insert block.

[0077] S500: After the hardened treatment of the turned-out carbon fiber skin, take out the internal insert block to form a groove part between the carbon fiber skin and the prepreg sheet.

[0078] In this embodiment, after the hardened treatment of the carbon fiber skin, the internal insert block is taken out, and the carbon fiber skin remains in its original shape. A groove part with the same size as the internal insert block is formed between the carbon fiber skin and the prepreg sheet, and the groove part is used to place the honeycomb core structure.

[0079] S600: Install a honeycomb core structure in the groove part to make the honeycomb core structure fit with the carbon fiber skin to form a reflector surface.

[0080] In this embodiment, as Figure 4 shown, the honeycomb core structure can be directly installed in the groove part formed in step S500. After installing the honeycomb core structure in the groove part, in order to fix the honeycomb core structure, an adhesive material can be used to make the honeycomb core structure fit with the carbon fiber skin to form a reflector surface. After the electromagnetic wave is emitted to the above reflector surface, according to the hexagonal structure in the honeycomb core structure, through the mutual reflection of angles, the reflection effect of the electromagnetic wave can be enhanced.

[0081] In some embodiments, before fixing the honeycomb core structure, it is also necessary to position the honeycomb core structure. In this embodiment, the second reference plane of the forming die blank can be selected. The second reference plane can be the first reference plane or other reference planes different from the first reference plane. After determining the second reference plane, the honeycomb core can be positioned by fitting one of the bottom surfaces or side surfaces of the honeycomb core structure to the second reference plane.

[0082] In some embodiments, in order to enhance the reflection effect of the honeycomb core structure, an outer skin can also be bonded between the honeycomb core structure and the carbon fiber skin, that is, at the bottom of the honeycomb core structure. In this embodiment, the carbon fiber skin and the outer skin can overlap each other, and the overlap dimension can be 10 - 15 mm. After overlapping, a vacuum pre-pressing treatment can be performed in the overlapping area to ensure that the overlapping area is firmly attached.

[0083] In some embodiments, before installing the honeycomb core structure, a first foam adhesive layer with a preset number of layers can also be filled at both ends of the honeycomb core structure at a first interval distance. For example, a first foam adhesive layer with a thickness of 10 mm is filled every 10 mm at both ends of the honeycomb core structure, and the filling length is 60 - 80 mm, that is, three layers or four layers are filled.

[0084] After filling the first foam adhesive layer, a second foam adhesive layer can be filled between the first foam adhesive layers at a second interval distance. The thickness of the second foam adhesive layer can be a preset multiple of the thickness of the first foam adhesive layer. For example, the thickness of the second foam adhesive layer can be twice that of the first foam adhesive layer, that is, the filling thickness is 20 mm. The first foam adhesive layer and the second foam adhesive layer can support the honeycomb core structure and enhance the strength of the honeycomb core structure.

[0085] In some embodiments, the bonding condition between the honeycomb core structure and the carbon fiber skin can also be detected. In this embodiment, the honeycomb core structure can be irradiated with light. The area with poor bonding between the honeycomb core structure and the carbon fiber skin can transmit light under the irradiation of light. Therefore, the light-transmitting area between the honeycomb core structure and the carbon fiber skin can be detected to detect the bonding condition of the honeycomb core structure. If there is a light-transmitting area, the honeycomb core structure is reinstalled.

[0086] In some embodiments, the hexagons in the honeycomb core structure can be divided into L-shaped and W-shaped according to their arrangement positions. Among them, the L-shaped and W-shaped are arranged alternately. For the convenience of product forming, the L-shaped honeycomb core in the honeycomb core structure can be aligned with the 0° angle of the reflector.

[0087] Some embodiments of the present application also provide a reflector, and the reflector includes a reflecting surface prepared by the reflecting surface processing method described in any one of the above.

[0088] As can be seen from the above solution, the present application provides a method for processing a reflector surface and a reflector. The method can cut multiple layers of prepreg according to a preset size, lay the prepreg layer by layer on a forming die blank, and perform vacuum pre-pressing treatment on the prepreg after each layer is laid to obtain a prepreg sheet. Then, a carbon fiber skin is pasted on the prepreg sheet, internal inserts are placed at preset positions between the forming die blank and the carbon fiber skin, the carbon fiber skin far from the internal inserts is turned outwards from the edge at a preset angle, and after the turned-out carbon fiber skin is hardened, the internal inserts are taken out to form a groove part between the carbon fiber skin and the prepreg sheet. Finally, a honeycomb core structure is installed in the groove part to make the honeycomb core structure fit with the carbon fiber skin to form a reflector surface. The present application obtains a model of the reflector surface by laying prepreg and carbon fiber skin on the forming die blank, and then increases the reflection area of the reflector surface by turning out the carbon fiber skin, improving the utilization rate of the reflector surface, thereby improving the signal reception efficiency of the receiving system.

[0089] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present application, rather than to limit them; although the present application has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that they can still modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements on some or all of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the scope of the technical solutions of the embodiments of the present application.

[0090] For the sake of convenience of explanation, the above description has been made in conjunction with specific embodiments. However, the above exemplary discussion is not intended to be exhaustive or to limit the embodiments to the specific forms disclosed above. According to the above teachings, various modifications and variations can be obtained. The selection and description of the above embodiments are for better explaining the present disclosure, so that those skilled in the art can better use the embodiments.

Claims

1. A method for machining a reflecting surface, characterized in that, The method includes: Cutting a multi-layer prepreg; Laying the prepreg layer by layer on a forming mandrel, and performing vacuum pre-pressing treatment on the prepreg after each layer is laid to obtain a prepreg sheet; Laying a carbon fiber skin on the prepreg sheet; Placing an internal insert between the forming mandrel and the carbon fiber skin, and turning the carbon fiber skin away from the internal insert outwards from the edge; After hardening the turned-out carbon fiber skin, removing the internal insert to form a groove portion between the carbon fiber skin and the prepreg sheet; Installing a honeycomb core structure in the groove portion, and fitting the honeycomb core structure with the carbon fiber skin to form a reflecting surface.

2. The method for machining a reflecting surface according to claim 1, wherein In the step of laying the prepreg layer by layer on the forming mandrel, the method further includes: Obtaining a preset coordinate system and angle scale lines; Laying the prepreg according to the coordinate system and the angle scale lines to obtain the laying angle of the prepreg; Calculating the angle error of the laying angle; If the angle error is less than or equal to an error threshold, performing the step of laying the carbon fiber skin on the prepreg sheet; If the angle error is greater than the error threshold, re-laying the prepreg.

3. The reflecting surface processing method according to claim 1, characterized in that, After performing vacuum pre-pressing treatment on the prepreg after each layer is laid, the method further includes: Performing quality inspection on the prepreg sheet to detect the lack-of-material layer inside the prepreg sheet; Using a unidirectional prepreg tape to fill the lack-of-material layer; Performing vacuum pre-pressing treatment on the prepreg sheet after filling.

4. The method for machining a reflecting surface according to claim 1, characterized in that, In the step of laying the carbon fiber skin on the prepreg sheet, the method further includes: Setting the laying and placing angle between the carbon fiber skins; Laying the carbon fiber skins in sequence according to the laying and placing angle.

5. The method for machining a reflecting surface according to claim 1, characterized in that, There is a positioning groove on the forming mandrel; in the step of placing the internal insert between the forming mandrel and the carbon fiber skin, it further includes: Selecting a first reference plane of the forming mandrel; Coinciding the top surface of the internal insert with the first reference plane, and moving the internal insert in a direction parallel to the first reference plane to insert the apex angle of the internal insert into the positioning groove.

6. The method for machining a reflecting surface according to claim 5, characterized in that, Before the step of installing the honeycomb core structure in the groove portion, the method further includes: Filling a first foam layer with a preset number of layers at both ends of the honeycomb core structure at a first interval distance; Filling a second foam layer at a second interval distance between the first foam layers, and the thickness of the second foam layer is twice that of the first foam layer.

7. The method for machining a reflecting surface according to claim 6, wherein The method further includes: Selecting a second reference plane of the forming mandrel; Positioning the honeycomb core structure according to the second reference plane; Bonding an outer skin at the bottom of the positioned honeycomb core structure.

8. The method for machining a reflecting surface according to claim 1, wherein After the step of installing the honeycomb core structure in the groove portion, the method further includes: Using light irradiation to detect the light-transmitting area between the honeycomb core structure and the carbon fiber skin; If there is the light-transmitting area, re-installing the honeycomb core structure.

9. The method for machining a reflecting surface according to claim 1, characterized in that, The step of laying the carbon fiber skin on the prepreg sheet includes: Laying a separator film between the carbon fiber skins, and the area of the separator film is larger than that of the carbon fiber skins.

10. A reflector, characterized in that, A reflecting surface manufactured by the reflecting surface processing method according to any one of claims 1-9.

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