Kevlar skin and nomex honeycomb core solid surface reflector and method of forming

Abstract

The application provides a Kevlar skin and Nomex honeycomb core solid surface reflector and a forming method, which comprises the following steps: performing Kevlar prepreg layering on an inner skin negative die forming tool surface to obtain an inner skin after curing; sequentially laying Tedlar film and Kevlar prepreg layering on an outer skin negative die forming tool surface to obtain an outer skin with Tedlar film after curing; performing overall machining on a Nomex honeycomb core and arranging multiple embedded parts in the flange area of the Nomex honeycomb core; assembling the inner skin and the Nomex honeycomb core, and completing the axial alignment of the honeycomb core and the inner skin by using positioning pins-embedded parts; aligning and assembling the assembly and the outer skin with Tedlar film, and curing to obtain a solid surface reflector. Through the optimization measures of double negative die forming tool, overall machining of the honeycomb core, and single-sided positioning of the embedded parts, the curing stress of the product forming process is reduced to the greatest extent, the precision loss after product demolding is reduced, and strong support is provided for the high-precision forming of the solid surface reflector of the star-borne special-shaped surface.

Description

Technical Field

[0001] This invention belongs to the field of spaceborne high-precision, special material solid surface reflective molding technology, and specifically relates to a Kevlar skin and Nomex honeycomb core solid surface reflector and a high-precision molding method. Background Technology

[0002] For the special requirements of frequency selection in large deployable antennas such as large foldable umbrella antennas, solid-surface reflectors composed of Kevlar skin and Nomex honeycomb cores have a broader application prospect. These antennas use a non-conductive Kevlar fiber composite material + Nomex aramid honeycomb core sandwich structure as the reflector body, with different patterned metal layers electroplated on the surface to achieve the antenna's specific requirements such as frequency selection. Due to the frequency band reflection requirements and the loss of surface accuracy caused by subsequent processing characteristics, higher requirements are placed on the molding precision of these antennas.

[0003] To ensure the molding accuracy of solid surface reflectors made of such special materials, it is necessary to provide a high-precision molding method for solid surface reflectors with Kevlar skin and Nomex honeycomb core. Summary of the Invention

[0004] In order to overcome the shortcomings of the existing technology, the inventors have conducted intensive research and provided a high-precision molding method for Kevlar skin and Nomex honeycomb core solid surface reflector, which effectively solves at least one problem, such as the difficulty in controlling the gap value of complex curved honeycomb sandwich structure, large molding stress, and inability to stably guarantee the surface accuracy.

[0005] The technical solution provided by this invention is as follows:

[0006] In a first aspect, a method for forming a Kevlar skin and Nomex honeycomb core solid surface reflector includes:

[0007] Kevlar prepreg is laid on the surface of the inner skin female mold forming tooling and cured to obtain the inner skin;

[0008] A Tedlar film is laid on the surface of the outer skin female mold forming tooling, and a Kevlar prepreg is laid on the Tedlar film and cured to obtain an outer skin with a Tedlar film.

[0009] The Nomex honeycomb core is integrally machined to obtain a Nomex honeycomb core that meets the dimensional requirements, and multiple embedded parts are arranged in the flanged area of ​​the Nomex honeycomb core;

[0010] The inner skin is glued and assembled with the Nomex honeycomb core. Multiple positioning pins are passed through the pre-set process holes on the Kevlar inner skin and inserted into the embedded parts of the Nomex honeycomb core to complete the axial alignment between the honeycomb core and the inner skin. Then, this assembly is glued, aligned and assembled with the outer skin with the Tedlar film, and cured to obtain the solid surface reflector.

[0011] In conjunction with the first aspect, the step of laying Kevlar prepreg on the surface of the inner skin mold forming fixture and curing it to obtain the inner skin includes: laying Kevlar prepreg on the surface of the inner skin mold forming fixture, using roller fixtures for auxiliary bonding, curing and molding after the laying is completed, and demolding.

[0012] In conjunction with the first aspect, the step of laying Kevlar prepreg on the surface of the inner skin mold forming tool and curing it to obtain the inner skin includes: marking the XY axis on the process area of ​​the inner skin mold forming tool to plan the quadrants and assist in positioning the prepreg layup angle; when demolding the inner skin, extending the quadrant markings of the process area on the tooling facade to the inner skin.

[0013] In conjunction with the first aspect, the steps of laying a Tedlar film on the surface of the outer skin mold forming tooling, laying a Kevlar prepreg on the Tedlar film, and curing to obtain an outer skin with a Tedlar film include:

[0014] Tedlar film is tensioned on the outer skin female mold forming fixture, and auxiliary fixation is achieved in the vertical process area of ​​the outer skin female mold forming fixture using sealing strips. Negative pressure is formed on the inner surface through the air extraction holes on the outer skin female mold forming fixture and the external vacuum system, so that the Tedlar film adheres to the surface of the female mold forming fixture. Then, Kevlar prepreg is laid on the film surface, and roller fixtures are used for auxiliary bonding to ensure that there are no air bubbles between the Kevlar prepreg and the Tedlar film. After the laying is completed, it is cured and formed without demolding.

[0015] In conjunction with the first aspect, the steps of laying a Tedlar film on the surface of the outer skin female mold forming fixture, laying a Kevlar prepreg on the Tedlar film, and curing to obtain an outer skin with a Tedlar film include: marking the XY axis by marking the process area of ​​the outer skin female mold forming fixture to plan the quadrants and assist in positioning the prepreg layup angle; the outer skin is not demolded after curing, and the quadrant markings of the process area on the fixture facade are extended to the outer skin.

[0016] In conjunction with the first aspect, the step of machining the Nomex honeycomb core as a whole also includes: verifying the surface accuracy of the Nomex honeycomb core by photogrammetry, requiring the surface accuracy RMS≤0.1mm; during photogrammetry, single-point contact target points are used to assist in measurement on the irregular curved surfaces on both sides of the honeycomb core.

[0017] In conjunction with the first aspect, the step of integrally machining the Nomex honeycomb core further includes: drilling holes in the sidewalls of the Nomex honeycomb core.

[0018] In conjunction with the first aspect, the Kevlar outer skin, Nomex honeycomb core, and Kevlar inner skin are composite-cured in an autoclave, with the heating and cooling rate controlled to be no greater than 1.5℃ / min.

[0019] In conjunction with the first aspect, when assembling the Kevlar outer skin, Nomex honeycomb core, and Kevlar inner skin, the inner skin and outer skin are aligned using quadrant markings.

[0020] In a second aspect, a Kevlar skin and Nomex honeycomb core solid surface reflector is manufactured by the molding method of the Kevlar skin and Nomex honeycomb core solid surface reflector described in the first aspect.

[0021] The Kevlar skin and Nomex honeycomb core solid surface reflector and molding method provided by the present invention have the following beneficial effects:

[0022] (1) The present invention provides a Kevlar skin and Nomex honeycomb core solid surface reflector and molding method. Through optimization measures such as double negative mold molding tooling, overall machining of honeycomb core, and single-sided positioning of embedded parts, the curing stress during the product molding process is reduced to the greatest extent, and the precision loss after product demolding is reduced. This provides strong support for high-precision molding of solid surface reflectors with irregular curved surfaces on space.

[0023] (2) The present invention provides a Kevlar skin and Nomex honeycomb core solid surface reflector and molding method. In order to ensure that there are no air bubbles between the Kevlar plain weave prepreg and the Tedlar film during the molding of the outer skin and that the co-curing quality meets the index requirements, roller tooling is used for auxiliary bonding to ensure that there are no air bubbles in the curved surface. At the same time, a dual vacuum air path of air extraction hole and vacuum bag air path is used during the curing process to ensure that the Tedlar film layer is taut and to avoid the film layer deformation and wrinkles affecting the appearance quality.

[0024] During the inner skin molding process, in order to ensure that there are no air bubbles between the Kevlar plain weave prepreg and the mold surface and that the curing quality meets the requirements, roller tooling is used for auxiliary bonding. Attached Figure Description

[0025] Figure 1 A schematic diagram showing the external dimensions of the Kevlar skin and Nomex honeycomb core solid surface reflector;

[0026] Figure 2 A schematic diagram showing the cross-sectional composition of the Kevlar skin and the Nomex honeycomb core solid surface reflector;

[0027] Figure 3 This diagram illustrates the use of roller fixtures to assist in the bonding process of the outer skin.

[0028] Figure 4 This diagram illustrates the positioning process of the Kevlar skin and Nomex honeycomb core solid surface reflector during the curing process. Detailed Implementation

[0029] The features and advantages of the present invention will become clearer and more apparent from the following detailed description.

[0030] The term “exemplary” as used herein means “serving as an example, embodiment, or illustration.” Any embodiment illustrated herein as “exemplary” is not necessarily to be construed as superior to or better than other embodiments.

[0031] like Figure 1 and Figure 2 As shown, this invention provides a high-precision molding method for a Kevlar skin and Nomex honeycomb core solid surface reflector. The solid surface reflector is Ω-shaped and includes a Tedlar film, a Kevlar outer skin, a Nomex honeycomb core, and a Kevlar inner skin. The Kevlar outer skin and the Kevlar inner skin are Kevlar fiber / epoxy resin skins. The Kevlar outer skin and the Nomex honeycomb core are bonded together with a curing adhesive, and the Kevlar inner skin and the Nomex honeycomb core are bonded together with a curing adhesive. The Tedlar film is attached to the outer working surface of the Kevlar outer skin. PI material embedded parts are arranged at equal intervals inside the flange of the Nomex honeycomb core, and process holes for corresponding embedded parts are provided at the flanges of the Nomex honeycomb core and the Kevlar inner skin.

[0032] The working surface of the Kevlar outer skin is formed using a negative mold to ensure the overall external precision of the product. To ensure that the fit gap between the irregular curved surfaces of the Kevlar inner and outer skins and the honeycomb core is less than the thickness of the adhesive film, the honeycomb core is machined as a whole. Photogrammetry is used to measure the contour accuracy of the irregular curved surfaces on both sides. The Kevlar inner skin also uses a negative mold forming fixture, thereby ensuring effective fit between the non-working curved surfaces and the machined surfaces of the honeycomb core, effectively avoiding the loss of surface precision caused by the accumulation of gap errors.

[0033] The high-precision forming method for this reflector specifically includes the following steps:

[0034] (1) The inner and outer skins are formed separately using inner and outer skin forming fixtures.

[0035] The convex surface of the Kevlar outer skin is a curved working surface, which requires high external precision. The convex surface of the Kevlar inner skin needs to ensure effective fit with the machined surface of the honeycomb core. Therefore, an outer skin female mold forming fixture + an inner skin female mold forming fixture are used to replace the conventional male mold forming fixture, forming the outer skin and inner skin respectively to obtain a high-precision target surface.

[0036] The inner and outer skin female mold forming fixtures have surfaces that match the outer surface of the inner skin (the bonding surface with the honeycomb core) and the working surface of the outer skin. The bottom of the outer skin female mold forming fixture has an air extraction hole, which connects to an external vacuum system during the outer skin forming process. Before the inner and outer skins are laid up, the surface accuracy of the two female mold forming fixtures is precisely measured using a coordinate measuring machine (CMM). The accuracy of the two female mold forming fixtures is required to be better than 1 / 5 of the required skin accuracy.

[0037] The outer skin and Tedlar film are co-cured and molded. The molding process is as follows: the Tedlar film is tensioned on the outer skin female mold forming fixture, and auxiliary fixation is achieved in the vertical process area of ​​the outer skin female mold forming fixture using sealing strips. Negative pressure is created on the inner surface through air extraction holes and an external vacuum system, causing the Tedlar film to adhere to the surface of the female mold forming fixture. Then, Kevlar prepreg, such as plain weave prepreg, is laid on the film surface. After laying, curing is performed. To ensure no air bubbles between the Kevlar plain weave prepreg and the Tedlar film, and to meet the co-curing quality requirements, roller fixtures are used for auxiliary bonding to ensure no air bubbles are trapped on the curved surface. Simultaneously, a dual vacuum air path, consisting of air extraction holes and a vacuum bag air path, is used during curing to ensure the Tedlar film layer is taut, preventing film deformation and wrinkles that would affect the appearance quality.

[0038] The inner skin forming process is as follows: Kevlar prepreg, such as plain weave prepreg, is laid on the surface of the inner skin female mold forming fixture, and then cured after laying. To ensure that there are no air bubbles between the Kevlar plain weave prepreg and the mold surface, and that the curing quality meets the requirements, roller fixtures are used for auxiliary bonding.

[0039] The surface characteristics of the inner and outer skin prepreg forming fixtures make it easy for gaps to appear between the prepreg and the mold surface during Kevlar inner and outer skin prepreg layup, preventing strict adherence to the mold surface and affecting the forming accuracy. Therefore, during the Kevlar inner and outer skin prepreg layup process, rollers are used to roll the surface of the laid-up prepreg. Figure 3 This process ensures that the prepreg adheres tightly to the surface of the female mold forming tooling. Simultaneously, after the layup is complete, the female mold forming tooling containing the prepreg is placed in a vacuum bag for vacuum pre-compaction, further ensuring a tight fit between the prepreg and the mold surface.

[0040] During the layup process, the XY axes are marked with lines in the process areas of the inner and outer skin female mold forming fixtures to plan the quadrants. The XY axes are used to assist in positioning and ensure the layup angle of the prepreg. Layup is performed according to the layup angles shown in the drawings. After the product cures, the outer skin is not demolded, and the quadrant markings of the process area on the fixture facade are extended to the outer skin. When demolding the inner skin, the quadrant markings of the process area on the fixture facade are extended to the inner skin.

[0041] (2) Nomex honeycomb core integral machining

[0042] To ensure the stability of the Nomex aramid paper honeycomb core's surface accuracy, a non-porous Nomex aramid paper honeycomb core is used for integral machining, avoiding splicing methods that would compromise the product's integrity. Both sides of the Nomex honeycomb core are milled. After the overall machining is completed, the surface accuracy of the Nomex honeycomb core is verified by photogrammetry, requiring a surface accuracy RMS ≤ 0.1mm. Simultaneously, to ensure the Nomex honeycomb core's air permeability, manual perforation or laser drilling is used to achieve air permeability in the Nomex honeycomb core's sidewalls.

[0043] When photogrammetrically measuring the profile accuracy of the irregular curved surfaces on both sides of the Nomex honeycomb core, a single-point bonding method of the target points is used on the irregular curved surfaces on both sides of the honeycomb core to avoid the incomplete bonding of the entire strip or sheet of target points with the curved surface, which would affect the accuracy of product re-inspection.

[0044] (3) Pre-curing of Nomex honeycomb core and embedded parts

[0045] The Nomex honeycomb core has the same shape as the inner and outer skins, and since the Nomex honeycomb core lacks positioning features, multiple pre-embedded parts are pre-placed within the flanged area of ​​the Nomex honeycomb core and then bonded and cured. These pre-embedded parts serve as positioning features for the Nomex honeycomb core, aiding in axis alignment during the assembly of the Kevlar outer skin, Nomex honeycomb core, and Kevlar inner skin. After the solid-surface reflector is formed and installed, these pre-embedded parts act as adapters connecting to other external mechanisms.

[0046] The curing adhesive used for bonding and curing the embedded parts is the same as the curing adhesive used between the Kevlar outer skin and the Kevlar inner skin and the Nomex honeycomb core.

[0047] (4) Solid surface reflector composite curing

[0048] During the composite process, the inner skin of the solid-surface reflector is first assembled with the honeycomb core. Multiple locating pins, such as eight Φ2mm locating pins, are inserted through the Kevlar inner skin and into the pre-embedded parts of the Nomex honeycomb core to achieve axial alignment between the honeycomb core and the inner skin. Figure 4As shown; then assemble this assembly with the Kevlar outer skin, using quadrant markings to align the inner and outer skins.

[0049] The honeycomb sandwich structure of the solid-surface reflector is formed using an autoclave heating and pressurization method. The uniform temperature field and spatial pressure inside the autoclave apply temperature and pressure to the composite material to achieve curing, with the heating and cooling rate strictly controlled to not exceed 1.5℃ / min. After curing, the product is demolded and allowed to stand for at least 24 hours. A coordinate measuring machine (CMM) is then used to precisely measure and fit the forming accuracy of the bare surface of the solid-surface reflector. The Nomex honeycomb core is positioned only with the inner skin, and the inner and outer skins are aligned using quadrant markers, ensuring proper alignment. Furthermore, during the curing and pressurization process, there are no strong constraints, allowing for free alignment and preventing product interference that could cause internal stress deformation.

[0050] To address the challenge of ensuring precise molding accuracy for solid-surface reflectors made of "Ω" special materials, this invention provides an effective and convenient method for controlling molding accuracy. This method effectively solves problems such as difficulty in controlling the gap value of complex curved honeycomb sandwich structures, high molding stress, and unstable surface accuracy. Through optimized measures such as dual-mold molding fixtures, integral machining of the honeycomb core, and single-sided positioning of embedded parts, this invention minimizes curing stress during the molding process and reduces accuracy loss after demolding, providing strong support for high-precision molding of irregularly shaped solid-surface reflectors for spaceborne applications.

[0051] Example

[0052] solid surface reflectors such as Figure 1 As shown, the product has an "Ω" shape, a product size outline of Φ442mm, an effective diameter of Φ400mm, a surface accuracy requirement of better than 0.1mmRMS, a flange flatness requirement of better than 0.1mm, and a hole spacing requirement of better than ±0.05mm.

[0053] A cross-sectional view of an "Ω"-shaped solid surface reflector is shown below. Figure 2 As shown, the structure includes a Tedlar membrane, a Kevlar outer skin, a Nomex honeycomb core, and a Kevlar inner skin. The Kevlar outer and inner skins are made of Kevlar fiber / epoxy resin. The Kevlar outer skin and the Nomex honeycomb core, as well as the Kevlar inner skin and the Nomex honeycomb core, are bonded using J-47B primer and J-47C film medium-temperature curing adhesive. The Tedlar membrane is attached to the outer working surface of the Kevlar outer skin. PI material embedded parts are evenly spaced within the flanges of the Nomex honeycomb core, also bonded using J-47B primer and J-47C film medium-temperature curing adhesive. Eight process holes corresponding to the embedded parts are provided at the flanges of the Nomex honeycomb core and the Kevlar inner skin.

[0054] The molding method of this solid surface reflector includes:

[0055] (1) The inner and outer skins are formed separately using inner and outer skin forming fixtures.

[0056] The outer skin and Tedlar film are co-cured and pre-formed. The forming process is as follows: the Tedlar film is tensioned on the outer skin female mold forming fixture, and auxiliary fixation is achieved in the vertical process area of ​​the outer skin female mold forming fixture using sealing strips. Negative pressure is created on the inner surface through air extraction holes and an external vacuum system, causing the Tedlar film to adhere to the surface of the female mold forming fixture. Then, a Kevlar plain weave prepreg is laid on the film surface. After laying, a roller fixture is used for auxiliary bonding to ensure no air bubbles between the Kevlar plain weave prepreg and the film. During the curing process, a dual vacuum air path is used, consisting of air extraction holes and a vacuum bag, to ensure the Tedlar film layer is taut and to prevent film deformation and wrinkles that would affect the appearance quality.

[0057] The inner skin forming process is as follows: Kevlar plain weave prepreg is laid on the mold surface of the inner skin female mold forming fixture. To ensure that there are no air bubbles between the Kevlar plain weave prepreg and the mold surface, and that the co-curing quality meets the requirements, roller fixtures are used for auxiliary bonding. See [link to details]. Figure 3 .

[0058] During the layup process, the XY axes are marked with lines in the process areas of the inner and outer skin female mold forming fixtures to plan the quadrants. The XY axes are used to assist in positioning and ensure the layup angle of the prepreg. Layup is performed according to the layup angles shown in the drawings. After the product cures, the outer skin is not demolded, and the process area quadrant markings are extended to the outer skin. When the inner skin is demolded, the process area quadrant markings are extended to the inner skin.

[0059] (2) Nomex honeycomb core integral machining

[0060] To ensure the stability of the Nomex aramid paper honeycomb core's surface accuracy, a 100mm non-porous Nomex aramid paper honeycomb core is machined as a single unit. This avoids the need for splicing, which would compromise the product's integrity. During machining, the honeycomb core is supported by tooling, and both sides are milled. After machining, the surface accuracy of the honeycomb core is verified using photogrammetry. During precision measurement, single-point alignment with target points is used to prevent misalignment of the target points with the curved surface, which could affect the accuracy of the verification. A surface accuracy RMS ≤ 0.1mm is required for use. To ensure the honeycomb core's breathability, perforations are made manually or laser-drilled in the honeycomb sidewalls.

[0061] (3) Pre-curing of Nomex honeycomb core and embedded parts

[0062] Multiple embedded parts are arranged in the flanged area of ​​the Nomex honeycomb core and then bonded and cured. The embedded parts can serve as positioning features for the Nomex honeycomb core and assist in the alignment of the axis during the assembly of the Kevlar outer skin, Nomex honeycomb core and Kevlar inner skin.

[0063] (4) Solid surface reflector composite curing

[0064] The inner skin of the solid-surface reflector is assembled with the honeycomb core. Eight Φ2mm locating pins are inserted through the Kevlar inner skin and into the pre-embedded parts of the Nomex honeycomb core to achieve axial alignment between the honeycomb core and the inner skin. Figure 4 As shown; this assembly is then assembled with the Kevlar outer skin, using quadrant markers to align the inner and outer skins. The honeycomb sandwich structure of the solid-surface reflector is formed using an autoclave heating and pressurization method, with the heating and cooling rate strictly controlled to not exceed 1.5℃ / min. After the product has cured, it is demolded and left to stand for 24 hours before using a coordinate measuring machine to precisely measure and fit the forming accuracy of the bare surface of the solid-surface reflector. The Nomex honeycomb core is positioned only with the inner skin, and the inner and outer skins are aligned using quadrant markers, ensuring the alignment and positioning of the three components. Furthermore, during the curing and pressurization process, there are no strong constraints, allowing for free alignment and avoiding product interference that could cause internal stress deformation.

[0065] The surface accuracy of the molded product is 0.085mm, the flatness of the flange is better than 0.1mm, and there are no air bubbles or gaps between the Tedlar film and the outer skin, the outer skin and the honeycomb core, and the inner skin and the honeycomb core. All indicators meet the delivery requirements.

[0066] The present invention has been described in detail above with reference to specific embodiments and exemplary examples; however, these descriptions should not be construed as limiting the present invention. Those skilled in the art will understand that various equivalent substitutions, modifications, or improvements can be made to the technical solutions and embodiments of the present invention without departing from the spirit and scope of the invention, and all such modifications and improvements fall within the scope of the present invention. The scope of protection of the present invention is defined by the appended claims.

[0067] The contents not described in detail in this specification are common knowledge to those skilled in the art.

Claims

1. A method for molding a Kevlar skin and Nomex honeycomb core solid surface reflector, characterized in that, include: Kevlar prepreg is laid on the surface of the inner skin female mold forming tooling and cured to obtain the inner skin; A Tedlar film is laid on the surface of the outer skin female mold forming tooling, and a Kevlar prepreg is laid on the Tedlar film and cured to obtain an outer skin with a Tedlar film. The Nomex honeycomb core is integrally machined to obtain a Nomex honeycomb core that meets the dimensional requirements, and multiple embedded parts are arranged in the flanged area of ​​the Nomex honeycomb core; The inner skin is glued and assembled with the Nomex honeycomb core. Multiple positioning pins are passed through the pre-set process holes on the Kevlar inner skin and inserted into the embedded parts of the Nomex honeycomb core to complete the axial alignment between the honeycomb core and the inner skin. Then, this assembly is glued, aligned and assembled with the outer skin with Tedlar film, and cured to obtain a solid surface reflector. The step of laying Kevlar prepreg on the surface of the inner skin mold forming tooling and curing it to obtain the inner skin includes: marking the XY axis with lines in the process area of ​​the inner skin mold forming tooling to plan the quadrants and assist in positioning the prepreg layup angle; when demolding the inner skin, extending the quadrant markings of the process area on the tooling facade to the inner skin. The steps of laying a Tedlar film on the surface of the outer skin female mold forming fixture, laying a Kevlar prepreg on the Tedlar film, and curing to obtain an outer skin with a Tedlar film include: marking the XY axis by marking the process area of ​​the outer skin female mold forming fixture to plan the quadrants and assist in positioning the prepreg layup angle; the outer skin is not demolded after curing, and the quadrant markings of the process area on the fixture facade are extended to the outer skin; When assembling the outer skin, Nomex honeycomb core, and Kevlar inner skin, the inner skin and outer skin are aligned using quadrant markings.

2. The method for forming a Kevlar skin and Nomex honeycomb core solid surface reflector according to claim 1, characterized in that, The step of laying Kevlar prepreg on the surface of the inner skin mold forming fixture and curing it to obtain the inner skin includes: laying Kevlar prepreg on the surface of the inner skin mold forming fixture, using roller fixtures for auxiliary bonding, curing and molding after laying, and demolding.

3. The method for forming a Kevlar skin and Nomex honeycomb core solid surface reflector according to claim 1, characterized in that, The steps of laying a Tedlar film on the surface of the outer skin female mold forming tooling, laying a Kevlar prepreg on the Tedlar film, and curing to obtain an outer skin with a Tedlar film include: Tedlar film is tensioned on the outer skin female mold forming fixture, and auxiliary fixation is achieved in the vertical process area of ​​the outer skin female mold forming fixture using sealing strips. Negative pressure is formed on the inner surface through the air extraction holes on the outer skin female mold forming fixture and the external vacuum system, so that the Tedlar film adheres to the surface of the female mold forming fixture. Then, Kevlar prepreg is laid on the film surface, and roller fixtures are used for auxiliary bonding to ensure that there are no air bubbles between the Kevlar prepreg and the Tedlar film. After the laying is completed, it is cured and formed without demolding.

4. The method for forming a Kevlar skin and Nomex honeycomb core solid surface reflector according to claim 1, characterized in that, The step of machining the Nomex honeycomb core as a whole also includes: verifying the surface accuracy of the Nomex honeycomb core by photogrammetry, requiring the surface accuracy RMS≤0.1mm; during photogrammetry, single-point bonding target points are used to assist in measurement on the irregular curved surfaces on both sides of the honeycomb core.

5. The method for forming a Kevlar skin and Nomex honeycomb core solid surface reflector according to claim 1, characterized in that, The step of machining the Nomex honeycomb core as a whole also includes: drilling holes in the sidewalls of the Nomex honeycomb core.

6. The method for forming a Kevlar skin and Nomex honeycomb core solid surface reflector according to claim 1, characterized in that, The outer skin, Nomex honeycomb core, and Kevlar inner skin are composite and cured in an autoclave, with the heating and cooling rate controlled to be no more than 1.5℃ / min.

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