A forming method of a large high-precision carbon fiber composite material reflector

Abstract

The application discloses a forming method of a large high-precision carbon fiber composite reflector in the technical field of composite material products, and comprises the following steps: 1) reflector manufacturing, first curing and forming an inner skin, and then co-curing and forming the formed inner skin, a honeycomb and an outer skin; copper mesh is added in the process of laying the inner skin, and after the inner skin is cured and formed, adhesive film, the honeycomb, adhesive film and the outer skin are laid in sequence, and then co-cured to obtain the reflector; 2) back rib manufacturing, laying adhesive film on the back of the reflector, fixing foam at the position of the back rib, placing a pre-embedded part in the corresponding position in the foam, laying adhesive film on the surface of the foam after the pre-embedded part is placed, pre-extracting, laying carbon fiber prepreg on the surface of the adhesive film after the pre-extraction is completed, the width of the turned edge is less than or equal to the width of the adhesive film on the back of the reflector, and the laying is completed to be cured in a tank; and 3) demolding to obtain the product. The application solves the problems of difficult forming of a large reflector, large weight, high installation and maintenance cost and short service life.

Description

Technical Field

[0001] This invention relates to the field of composite material manufacturing technology, and in particular to a method for forming a reflector. Background Technology

[0002] Large, high-precision reflectors are key components in constructing large compact fields and developing millimeter-wave antennas. The reflector panels are characterized by their large area, extremely high surface precision requirements, and high structural stiffness-to-strength ratio requirements. Therefore, manufacturing high-precision reflector panels is extremely difficult, and conventional metal forming methods cannot meet these requirements. Large reflectors, due to their large mass, are also difficult to install and disassemble, hindering later maintenance and replacement, and resulting in a short service life. To address these problems, this invention aims to develop a high-strength, lightweight carbon fiber honeycomb sandwich reflector, solving the problems of difficult molding, heavy weight, high installation and maintenance costs, and short service life of large reflectors. Summary of the Invention

[0003] To address the shortcomings of existing technologies, this invention provides a method for molding large, high-precision carbon fiber composite material reflectors, solving the problems of difficult molding, heavy weight, high installation and maintenance costs, and short service life of large reflectors.

[0004] The objective of this invention is achieved as follows: a method for molding a large, high-precision carbon fiber composite reflector, comprising the following steps: Step 1) Reflector fabrication: First, solidify the inner skin, then solidify the inner skin together with the honeycomb and outer skin; add copper mesh during the inner skin laying process; after the inner skin is solidified, lay the adhesive film, honeycomb, adhesive film, and outer skin in sequence, and then solidify them together to obtain the reflector. Step 2) Backing Rib Fabrication: Lay an adhesive film on the back of the reflector, fix the foam at the location of the backing rib, and place the embedded part into the corresponding position inside the foam. After the embedded part is placed, lay an adhesive film on the foam surface and perform pre-extraction. After pre-extraction, lay carbon fiber prepreg on the adhesive film surface. The flange width is less than or equal to the width of the adhesive film on the back of the reflector. After laying, put it into the can for curing. Step 3) Demolding to obtain the product.

[0005] As a further limitation of the present invention, step 1) specifically includes: first, the inner skin of the reflector is laid on the surface of the mold. During the laying process of the inner skin, a copper mesh is added. The thickness and number of layers of the copper mesh can be designed according to the frequency requirements of the reflector. After curing, the surface of the inner skin is cleaned and an adhesive film is laid. After the adhesive film is laid, a honeycomb is placed on the upper surface of the adhesive film. The honeycomb splices are bonded with expanding foam. An adhesive film is laid on the honeycomb and pre-extraction is performed. Finally, the outer skin is laid and the bag is made and cured.

[0006] As a further limitation of the present invention, the copper mesh also includes multiple layers, and an adhesive film is provided between the copper mesh and the prepreg, and between the copper meshes.

[0007] As a further limitation of the present invention, the inner skin and outer skin need to be vacuum sealed before curing: a peelable cloth, a non-porous isolation film, a breathable felt, and a vacuum bag film are placed sequentially on the upper surface of the blank. A vacuum nozzle is placed at the position marked on the mold. The sealing strip area is first roughened by grinding, then cleaned, then the sealing strip is applied, the vacuum bag film is sealed, and finally a vacuum leak test is performed.

[0008] As a further limitation of the present invention, the edges of the honeycomb attached to the inner skin surface need to be chamfered. After chamfering, impurities in the honeycomb are removed, and the honeycomb is cleaned with alcohol and then placed in an oven to dry. The honeycomb is laid out in a splicing manner. The honeycomb is cut according to the size of the honeycomb and the reflective surface. When laying it out, the honeycomb is laid out sequentially along the width direction of the reflective surface. The honeycomb splicing seams are staggered, and the splicing area is filled with expanding foam, pre-pressed, and the honeycomb is completely attached to the inner skin.

[0009] As a further limitation of the present invention, when the embedded part is placed in the corresponding position inside the foam, the embedded part is wrapped with adhesive film around its perimeter and then placed into the pre-drilled embedded hole on the foam.

[0010] As a further limitation of the present invention, when fixing the foam in step 2), a back rib positioning fixture is used. The back rib positioning fixture includes a baffle fixed on the base. The end face of the baffle near the reflector is conformal to the back face of the reflector. The baffle is provided with a plurality of slots for positioning the back rib.

[0011] Compared with the prior art, the beneficial effects of the present invention are as follows: (1) The reflector made of high-strength lightweight carbon fiber has high strength, good fatigue resistance, low technical risk and high molding efficiency; (2) Carbon fiber material is lightweight and easy to install, disassemble and maintain; (3) Carbon fiber material has strong corrosion resistance and works stably in high-salt and high-humidity environments; (4) It is easy to form using molds and has low manufacturing costs. Attached Figure Description

[0012] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0013] Figure 1 This is a schematic diagram of the reflector structure obtained by the present invention. Figure 1 .

[0014] Figure 2 This is a schematic diagram of the reflector structure obtained by the present invention. Figure 2 .

[0015] Figure 3 This is a schematic diagram of the reflector layup obtained by the present invention.

[0016] Figure 4 This is a schematic diagram of the cellular docking in this invention.

[0017] Figure 5 This is a schematic diagram of the back rib forming process in this invention.

[0018] Figure 6 This is a schematic diagram of the back rib positioning fixture structure in this invention.

[0019] Among them, 100 is the reflector; 101 is the inner skin; 102 is the upper adhesive film; 103 is the honeycomb; 104 is the lower adhesive film; 105 is the outer skin; 106 is the copper mesh; 107 is the expanding foam; 111 is the back rib skin; 112 is the adhesive film; 113 is the foam; 114 is the embedded part; 201 is the baffle; 202 is the screw; 203 is the connecting plate; 204 is the positioning pin; 205 is the positioning plate; 206 is the base; and 207 is the bayonet. Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] The figure shows a molding method for a large, high-precision carbon fiber composite reflector. Step 1) Material Preparation Carbon fiber prepreg stored in a -18℃ cold storage should be taken out in advance and left outside for at least 6 hours. It can only be used after the surface of the sealed bag is free of moisture. The operator should record the information and the quality inspector should check it.

[0022] Step 2) Mold preparation After the new mold passes inspection, clean it repeatedly with acetone 2-4 times, then put it in an oven to remove oil. The degreasing temperature should not be lower than 180°C and the degreasing time should be at least 5 hours. After degreasing, roughen the area where the sealing tape runs through the mold with sandpaper and clean it with acetone. Apply release agent to the laying part. Apply release agent 8-10 times to the new mold, with an interval of at least 30 minutes between each application. For molds that have been used, only 3-5 applications are needed.

[0023] Step 3) Cutting the inner skin 101 The inner skin 101 is designed using professional software, and the carbon fiber prepreg required for the inner skin 101 is cut using an automatic cutting machine. The prepreg needs to be placed on the baseline of the CNC cutting machine. Before cutting, it is necessary to check that there are no impurities on the cutting machine.

[0024] Step 4) Inner skin 101 layup The carbon fiber prepreg is laid, with the inner skin 101 laid according to the designed layup angle. When laying the inner skin 101, the cut prepreg is laid on the mold, with the edge of the prepreg 20mm outside the product line of the mold. The first layer of prepreg is connected by an overlap of 5-10mm, and subsequent layers are butt-jointed, with each butt joint staggered by at least 100mm. After laying 4-6 layers, 2-4 layers of copper mesh 106 are laid, connected with adhesive film 112 (to avoid delamination). Vacuuming and compaction are performed every 4-6 layers, with each pre-vacuuming time being 15-25 minutes. After the last layer of inner skin 101 is laid, vacuuming is performed for 1-2 hours for thorough compaction.

[0025] It should be noted that traditionally, surface metallization is used to achieve shielding and reflection. However, direct surface metallization makes it difficult to control the surface accuracy and roughness of the reflective surface. Furthermore, the metal powder directly sprayed onto the composite material surface is prone to detachment in outdoor working environments, affecting the working accuracy of the reflective surface. The technical solution of this invention solves the problems of high spray roughness, uneven spraying affecting surface accuracy, and metallization layer detachment in composite material reflectors 100 by adding a metal mesh to the inner skin 101 layer. The copper mesh 106 is integrally cured and molded with the inner skin 101, resulting in a stable structure, simple molding method, strong operability, and low cost. Moreover, the distribution of the copper mesh 106 can be adjusted according to actual parameter requirements. For example, multiple layers of copper mesh 106 can be used to form the entire copper mesh 106 layer, or the copper mesh 106 can be spaced apart from the prepreg to achieve the multi-band reflection requirements of the reflector 100.

[0026] Step 5) Vacuum sealing Place a peelable cloth, a non-porous isolation membrane, a breathable felt, and a vacuum bag film on the upper surface of the part blank in sequence. Place the vacuum nozzle at the marked position on the mold. First, roughen the sealing strip area with sandpaper, then clean it with acetone, then apply the sealing strip, seal the vacuum bag film, and finally perform a vacuum leak test. Turn off the vacuum source for more than 10 minutes and manually check that the vacuum level decreases by no more than 0.02 MPa.

[0027] Step 6) Curing Hoist the reflector 100 to the autoclave platform and move the mold into the autoclave. Place the thermocouples according to the positions marked on the mold, and seal them with sealing strips along the edges of the sealing strips on the sealing bag. Cover with excess vacuum bag film to secure the sealing strips and prevent them from shifting due to heat. Then, place two layers of breathable felt on the vacuum bag film above the thermocouples and secure them with release cloth strips. Prevent the sealing strips covering the thermocouples from coming into contact with air after reaching medium temperatures, as air temperature can interfere with thermocouple detection. Connect to the vacuum system and apply a vacuum pressure below -0.085 MPa, followed by an air pressure of 0.3~0.6 MPa, maintaining this pressure for at least 15 minutes without leakage. Turn off the vacuum system. If the vacuum gauge reading drops by no more than 0.03 MPa within 15 minutes, the bag must be inspected and repaired. If repair is not possible, the parts must be resealed in the vacuum bag. Increment the temperature at a rate of 0.5~2℃ / min. When the temperature reaches 50~80℃, hold for 1~3 hours, then pressurize to 0.3~0.6 MPa and continue heating to 90~130℃, holding for 0.5~2 hours. Then, increase the temperature to 160~190℃ and hold for 3~6 hours. Refer to the air temperature readings for accurate temperature readings. Decrease the temperature at a rate not exceeding 2℃ / min. When the temperature reaches room temperature, open the can and release the pressure. Refer to the temperature readings on the thermocouple. After curing, carefully remove the thermocouples and obtain the temperature-pressure curve.

[0028] It should be noted that the composite material reflector 100 manufactured by the autoclave molding process has good quality consistency and dimensional stability, low porosity, and high strength. The autoclave molding process used in this invention can ensure the overall quality stability and structural strength of the reflector 100.

[0029] Step 7) Chamfering of honeycomb 103 After receiving the honeycomb 103, bevel it according to the template, then use a vacuum cleaner to remove impurities from the honeycomb 103, clean it with alcohol, and put it in an oven at 70~100℃ for 2~3 hours to ensure that the moisture inside the honeycomb 103 is removed.

[0030] It should be noted that the reflector 100 needs to be sealed on both sides by the inner skin 101. When the inner skin 101 is flanged, an R-angle will be formed. Therefore, the corners where the honeycomb 103 contacts the flanged edge need to be chamfered.

[0031] Step 8) Surface treatment of inner skin 101 and application of adhesive film 112 After the inner skin 101 is formed, the tooling is cleaned, the surface peelable fabric is removed, and the surface is cleaned with anhydrous ethanol. The surface of the inner skin 101 is checked to ensure there are no impurities. Then, a layer of lower adhesive film 104 is laid on the surface of the inner skin 101, and a layer of expanding foam 107 is laid in the honeycomb 103 area at the R-corner, and then vacuum-pressed.

[0032] It should be noted that the inner skin 101 has been cured. To ensure adhesion between the honeycomb 103 and the inner skin 101, a layer of adhesive film 104 is applied to the surface of the inner skin 101. Since the inner skin 101 has a flanged structure on all four sides, the rounded corners are prone to appearing during the curing process. The honeycomb 103, however, has a right-angled structure. To ensure a tight fit between the honeycomb 103 and the inner skin 101, the right-angled areas of the honeycomb 103 are chamfered. To ensure a tight fit between the chamfered areas, expanding foam 107 is filled into the chamfered areas. During the curing process, under certain pressure and temperature, the expanding foam 107 fills the gaps between the honeycomb 103 and the chamfered areas of the inner skin 101.

[0033] Step 9) Honeycomb 103 laying Due to the large size of the reflective surface, multiple honeycomb 103 sheets need to be spliced ​​and laid out. The honeycomb 103 sheets are cut according to the size of the honeycomb 103 and the reflective surface. Marks are made on the corresponding honeycomb 103 sheets with masking tape. When laying the honeycomb 103 sheets, they are laid sequentially along the width of the reflective surface, following the markings on the honeycomb 103 sheets. The seams of the honeycomb 103 sheets are staggered, and the joints between honeycomb 103 sheets are filled with expanding foam 107. Pre-pressing and compacting are performed; the pre-pressing time can be extended to 30-60 minutes. The honeycomb 103 sheets are then completely adhered to the inner skin 101 of the reflective surface, ensuring there are no gaps.

[0034] It should be noted that the reflector 100 is relatively large and has an irregular curved structure. Therefore, the honeycomb 103 is laid out in a splicing manner. In order to ensure the strength of the reflector 100 structure, the splicing seams of the honeycomb 103 are staggered to avoid the splicing seams being in a straight line. The internal honeycomb 103 is preferably laid out as a whole honeycomb 103, while the perimeter is spliced ​​honeycomb 103 to reduce the splicing of honeycomb 103 in the middle working area and affect the structural strength of the reflector 100.

[0035] Step 10) Applying adhesive film 112 A layer of adhesive film 102 is laid on the surface of the honeycomb 103. The adhesive film 102 is overlapped and laid. The bag is pre-extracted and compacted. The pre-extraction time is less than 5 minutes to prevent the adhesive film 102 from collapsing and falling into the honeycomb 103 grid. After the pre-extraction is completed, it is necessary to check whether there are any uncovered areas of the adhesive film 102. If so, the adhesive film 102 should be filled.

[0036] It should be noted that the adhesion between the surface of the honeycomb 103 and the outer skin 105 is poor. Therefore, an adhesive film 102 is applied between the surface of the honeycomb 103 and the upper skin to improve the adhesion between the honeycomb 103 and the upper skin and ensure the final molding quality of the reflector 100.

[0037] Step 11) Laying the outer skin 105 Carbon fiber prepreg stored in a -18℃ cold storage should be taken out in advance and left outside for at least 6 hours. It can only be used after the surface of the sealed bag is free of moisture. The operator should record the information and the quality inspector should check it. The blanking diagram of the inner skin 101 is designed using professional software. At the same time, the carbon fiber prepreg required for the inner skin 101 is cut using an automatic blanking machine. The prepreg needs to be placed on the baseline of the CNC blanking machine. Before blanking, it is necessary to check that there are no impurities on the blanking machine.

[0038] The carbon fiber prepreg is laid, with the outer skin 105 laid according to the designed layup angle. When laying the outer skin 105, the cut prepreg is laid on the honeycomb 103. The first layer of prepreg is connected by an overlap of 5-10mm, and subsequent layers are butt-jointed, with each butt joint staggered by at least 100mm. Vacuuming and compaction are performed every 4-6 layers, with each pre-vacuuming lasting 15-25 minutes. After the final inner skin 101 is laid, vacuuming is performed for 1-2 hours to ensure thorough compaction.

[0039] Step 12) Vacuum sealing Place a peelable cloth, a medium-temperature non-porous isolation membrane, a medium-temperature breathable felt, and a medium-temperature vacuum bag film sequentially on the surface of the part blank. Place the vacuum nozzle at the marked position on the mold. First, roughen the sealing strip area with sandpaper, then clean it with acetone, then apply the sealing strip, seal the vacuum bag film, and finally perform a vacuum leak test. Turn off the vacuum source for more than 10 minutes and manually check that the vacuum level decreases by no more than 0.02 MPa.

[0040] Step 13) Curing Hoist the reflector 100 to the autoclave platform and move the mold into the autoclave. Place the thermocouples according to the positions marked on the mold, and seal the thermocouples along the edge of the sealing strip in the sealing bag with sealing tape. Cover the thermocouples with excess vacuum bag film to secure the sealing strip and prevent the thermocouples from shifting due to heat. Then, place two layers of breathable felt on the vacuum bag film above the thermocouples and secure them with release cloth strips. Prevent the sealing strip covering the thermocouples from coming into contact with air after reaching medium temperatures, as air temperature can interfere with thermocouple detection.

[0041] Connect to a vacuum system, apply a vacuum pressure below -0.085 MPa, and apply an air pressure of 0.1~0.3 MPa, maintaining this pressure for at least 15 minutes without leakage. Turn off the vacuum system; the vacuum gauge reading should not drop by more than 0.01 MPa within 15 minutes. Otherwise, the bag must be inspected and repaired. If repair is not possible, the part must be resealed in the vacuum bag. Increase the temperature at a rate of 0.5~2℃ / min. When the temperature reaches 50~80℃, hold for 1~3 hours, then pressurize to 0.1~0.3 MPa and continue heating to 90~130℃, holding for 0.5~2 hours. Then increase the temperature to 160~190℃ and hold for 3~6 hours, using the air temperature as a reference. Decrease the temperature at a rate not exceeding 2℃ / min. When the temperature reaches room temperature, open the can and release the pressure. Use the temperature indicated by the thermocouple as a reference. After curing, carefully remove the thermocouple and export the temperature-pressure curve.

[0042] Step 14) Positioning of foam 113 and placement of embedded part 114 Positioning fixtures are used to assist in positioning the foam 113 to ensure the accuracy of the backing foam 113 position. After positioning, the embedded part 114 is placed into the pre-drilled embedded hole on the foam 113. The embedded part 114 is wrapped with adhesive film 112. After positioning, a coordinate measuring machine is used to re-measure the position of the foam 113. Only after the re-measurement is correct can the foam 113 be fixed with adhesive film 112 and then vacuumed and compacted.

[0043] Specifically, the positioning work includes a positioning baffle 201. The middle part of the positioning baffle 201 is machined with an arc-shaped surface that conforms to the back of the reflector 100. The two ends of the positioning baffle 201 are installed on the connecting plate 203 by positioning pins 204 and screws 202. The positioning baffle 201 and the connecting plate 203 are initially connected by positioning pins 204 and then fixed by bolts. The connecting plate 203 is installed on the positioning plate 205 and the positioning plate 205 is fixed on the base 206. The arc-shaped surface of the positioning baffle 201 is provided with multiple slots 207 for cooperating with the foam 113.

[0044] It should be noted that the positioning plate is made of aluminum alloy, which is lightweight and easy to disassemble. It is connected to the positioning plate 205 through positioning pin 204, screw 202 and connecting plate 203. The positioning plate 205 and the forming fixture base 206 are integrally welded together during forming. The relative position of the positioning plate 205 is ensured by machining. Therefore, the positional accuracy of the positioning fixture can be guaranteed. The positioning method of the positioning fixture for the horizontal and vertical back rib foam 113 is the same. Therefore, a positioning fixture for the back rib foam 113 is described.

[0045] Step 15) Applying adhesive film 112 A layer of adhesive film 112 is laid on the surface of foam 113, with the adhesive film 112 overlapping. The bag is pre-pressed and compacted for 5-10 minutes. After pre-pressing, check if there are any uncovered areas of adhesive film 112. If so, fill in the uncovered areas with adhesive film 112. When laying the bag, the adhesive film 112 should be folded 100-150mm to both sides.

[0046] Step 16) Prepreg Laying Prepreg of backing skin 111 is laid on the surface of reinforcing foam 113. When laying, the prepreg is turned up 50~100mm to both sides and connected to the outer skin 105 of the reflective surface.

[0047] It should be noted that the reinforcing rib is a foam 113 structure, which is bonded to the reflector 100 using an adhesive film 112. To ensure the bonding strength between the reinforcing rib and the reflector 100, the prepreg on the surface of the reinforcing rib is turned up 50-100mm to both sides to increase the contact area between the reflector 100 and the reinforcing rib, thereby improving the bonding strength between them. The design determined that an excessively long turn would increase the weight of the reflector 100, while an excessively short turn would not meet the bonding strength requirements; therefore, a 50-100mm turn design was adopted.

[0048] Step 17) Curing Hoist the reflector 100 to the autoclave platform and move the mold into the autoclave. Place the thermocouples according to the positions marked on the mold, and seal the thermocouples along the edge of the sealing strip in the sealing bag with sealing tape. Cover the thermocouples with excess vacuum bag film to secure the sealing strip and prevent the thermocouples from shifting due to heat. Then, place two layers of breathable felt on the vacuum bag film above the thermocouples and secure them with release cloth strips. Prevent the sealing strip covering the thermocouples from coming into contact with air after reaching medium temperatures, as air temperature can interfere with thermocouple detection.

[0049] Connect to a vacuum system, apply a vacuum pressure below -0.085 MPa, and apply an air pressure of 0.1~0.3 MPa, maintaining this pressure for at least 15 minutes without leakage. Turn off the vacuum system. If the vacuum gauge reading drops by no more than 0.01 MPa within 15 minutes, the bag must be inspected and repaired. If repair is not possible, the part must be resealed in the vacuum bag. Increase the temperature at a rate of 0.5~2℃ / min. When the temperature reaches 50~80℃, hold for 1~3 hours, then pressurize to 0.1~0.3 MPa and continue heating to 90~130℃, holding for 0.5~2 hours. Then increase the temperature to 160~190℃ and hold for 3~6 hours, using the air temperature as a reference. Decrease the temperature at a rate not exceeding 2℃ / min. When the temperature reaches room temperature, open the can and release the pressure. Use the temperature indicated by the thermocouple as a reference. After curing, carefully remove the thermocouple and export the temperature-pressure curve. Open the can after cooling to 50~60℃, and remove the packaging material after the temperature has cooled to 20~30℃.

[0050] It should be noted that the curing parameters are for foam 113 sandwich composite parts. The collapse of the foam 113 structure under high pressure and high temperature must be considered. Therefore, a method of reducing curing pressure while ensuring the curing temperature is adopted for curing. Reducing the curing pressure ensures that the foam 113 structure will not collapse during the curing process, while the high temperature environment ensures that the prepreg and film 112 structure can reach the curing temperature and be fully cured.

[0051] Step 18) Demolding First, remove the vacuum bag, then remove all auxiliary materials from the product surface. When cleaning the auxiliary materials, be careful not to remove the product from the mold fixture surface. Finally, you will get reflector 100.

[0052] The above description of the embodiments is only for the purpose of helping to understand the method and core ideas of the present invention. It should be noted that those skilled in the art can make several improvements and modifications to the present invention without departing from the principles of the present invention, and these improvements and modifications also fall within the protection scope of the claims of the present invention.

Claims

1. A method for molding a large, high-precision carbon fiber composite reflector, characterized in that, Includes the following steps: Step 1) Fabrication of reflector (100): First, solidify the inner skin (101), then solidify the solidified inner skin (101) together with the honeycomb (103) and outer skin (105); copper mesh (106) is added during the laying of inner skin (101). After the inner skin (101) is solidified, the adhesive film (112), honeycomb (103), adhesive film (112), and outer skin (105) are laid in sequence, and then solidified together to obtain reflector (100). Step 1) Specifically includes: First, the inner skin (101) of the reflector (100) is laid on the surface of the mold. The inner skin (101) is made of carbon fiber prepreg. During the laying process of the inner skin (101), copper mesh (106) is added. The thickness and number of layers of copper mesh (106) are designed according to the requirements of the reflection frequency. After curing, the surface of the inner skin (101) is cleaned and the adhesive film (112) is laid. After the adhesive film (112) is laid, honeycomb (103) is placed on the upper surface of the adhesive film (112). The splicing of the honeycomb (103) is bonded with foam adhesive (107). The adhesive film (112) is laid on the honeycomb (103) and pre-extracted. Finally, the outer skin (105) is laid and the bag is cured. The copper mesh (106) comprises multiple layers, and an adhesive film (112) is provided between the copper mesh (106) and the carbon fiber prepreg of the inner skin (101) and between the copper mesh (106) and the copper mesh (106). Step 2) Backing reinforcement fabrication: Apply adhesive film (112) to the back of the reflector (100), fix foam (113) at the location of the backing reinforcement, and place the embedded part (114) into the corresponding position inside the foam (113). After the embedded part (114) is placed, apply adhesive film (112) to the surface of the foam (113) for pre-extraction. After the pre-extraction is completed, apply carbon fiber prepreg to the surface of the adhesive film (112). Fold the carbon fiber prepreg to both sides. The folded width is less than or equal to the width of the adhesive film (112) on the back of the reflector (100). After the application is completed, put it into the can for curing. Step 3) Demold to obtain the product.

2. The molding method for a large, high-precision carbon fiber composite reflector according to claim 1, characterized in that, Before the inner skin (101) is cured separately, it needs to be vacuum sealed. Before the inner skin (101), honeycomb (103), and outer skin (105) are cured together, they need to be vacuum sealed. On the inner skin (101) blank and the blank before the inner skin (101), honeycomb (103), and outer skin (105) are cured together, peelable cloth, non-porous isolation film, breathable felt, and vacuum bag film are placed in sequence. Vacuum nozzles are placed at the marked positions on the mold. First, the sealing strip area is roughened, then cleaned, then the sealing strip is applied, the vacuum bag film is sealed, and finally, vacuum leak detection is performed.

3. The molding method for a large, high-precision carbon fiber composite reflector according to claim 1, characterized in that, The edges of the honeycomb (103) that are attached to the inner skin (101) need to be chamfered. After chamfering, the impurities in the honeycomb (103) are removed and cleaned with alcohol. Then, it is placed in an oven to dry. The honeycomb (103) is laid out by splicing. The honeycomb (103) is cut according to the size of the honeycomb (103) and the reflective surface. When laying, the honeycomb (103) is laid out in sequence along the width direction of the reflective surface. The splicing seams of the honeycomb (103) are staggered. The splicing area is filled with expanding foam (107), pre-pressed, and the honeycomb (103) is completely attached to the inner skin (101).

4. The molding method for a large, high-precision carbon fiber composite reflector according to claim 1, characterized in that, When the embedded part (114) is placed in the corresponding position inside the foam (113), the embedded part (114) is wrapped with adhesive film (112) and then placed into the pre-drilled hole on the foam (113).

5. The molding method for a large, high-precision carbon fiber composite reflector according to claim 1, characterized in that, Step 2) When fixing the foam (113), a back rib positioning fixture is used. The back rib positioning fixture includes a baffle (201) fixed on the base (206). The end face of the baffle (201) near the reflector (100) is shaped to the back of the reflector (100). The baffle (201) has multiple slots (207) for positioning the back rib.

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