A composite material reflective plate forming method

Abstract

The present invention discloses a composite material reflector forming method, comprising the following steps: preparing a rib forming base plate and a reflector forming mold; forming the ribs; forming the reflector body; positioning embedded nuts on the reflector body using the reflector forming mold; positioning the ribs on the reflector body using the reflector forming mold; vacuum packaging the reflector forming mold in step S5; transferring the packaged reflector forming mold to an autoclave for curing; after curing is completed, the mold is demoulded after cooling to room temperature; testing; and performing machine trimming on the reflector that has passed the test according to the required design dimensions; using the present invention, embedded nuts and ribs can be integrally formed on the surface of the reflector body to produce a lightweight and high-strength carbon fiber reflector.

Description

Technical Field

[0001] The invention relates to the technical field of composite material preparation, in particular to a method for forming a composite material reflective plate. Background Art

[0002] Satellite reflectors are components of satellite antennas used for receiving and transmitting external signals. Therefore, they often have numerous embedded components on their surfaces. Traditionally, these reflectors are made of metal, and these embedded components can be machined to ensure precise positioning and structural accuracy. However, these metal reflectors are expensive to manufacture and bulky, making them difficult to transport and maintain. To address these issues, the present invention aims to create a lightweight, high-strength carbon fiber reflector with embedded components and ribs integrally molded onto the reflector's surface. This addresses the issues of traditional reflectors, including bulkiness, inaccurate positioning of embedded components, and high secondary machining costs. Summary of the Invention

[0003] The purpose of this section is to summarize some aspects of the embodiments of the present invention and briefly introduce some preferred embodiments. Some simplifications or omissions may be made in this section and the abstract and title of this application to avoid obscuring the purpose of this section, the abstract and the title of the invention, and such simplifications or omissions should not be used to limit the scope of the present invention.

[0004] In view of the above problems and / or problems existing in the preparation of existing reflective plates, the present invention is proposed.

[0005] Therefore, the purpose of the present invention is to provide a composite material reflector molding method, which can be used to integrally mold embedded parts and ribs on the surface of the reflector body to produce a lightweight and high-strength carbon fiber reflector.

[0006] To solve the above technical problems, the present invention provides the following technical solution: a method for forming a composite material reflective plate, comprising the following steps:

[0007] S1. Prepare the rib forming base plate and the reflector forming mold;

[0008] S2, rib forming;

[0009] S3, forming the reflector body;

[0010] S4. Use the reflector forming mold to position the embedded nuts on the reflector body;

[0011] S5. Using a reflector forming mold, position the ribs on the reflector body;

[0012] S6, vacuum packaging the reflector forming mold in step S5;

[0013] S7, transferring the packaged reflector forming mold to an autoclave for curing;

[0014] S8, after curing is completed, the mold is demoulded after cooling to room temperature;

[0015] S9, detection;

[0016] S10. According to the design requirements, the reflective plates that have passed the inspection are machined and trimmed.

[0017] As a further improvement of the present invention, the step S2 is specifically:

[0018] S201, laying prepreg on the rib forming base plate, laying the prepreg from one end to the other end in the length direction, laying the first to sixth layers of prepreg;

[0019] S202, laying the seventh layer of prepreg from the upper side of the sixth layer of prepreg. After laying, perform pre-extraction and tightening, maintain for 15 to 20 minutes, and then release the pressure.

[0020] S203, laying the 8th to 11th layers of prepreg on the upper side of the 7th layer of prepreg in sequence. After laying, perform pre-extraction and tightening, maintain for 15 to 20 minutes, and then release the pressure;

[0021] S204, placing the non-paving surface of the steel mold on the surface of the rib forming base plate, and laying the 12th layer of prepreg on the rib forming base plate using the steel mold. After laying, perform pre-extraction treatment and tighten it, maintain it for 15 to 20 minutes, and then release the pressure;

[0022] S205, laying the 13th to 16th layers of prepreg in sequence on the outer edge of the 12th layer of prepreg. After laying, perform pre-extraction treatment. After tightening, maintain for 15 to 20 minutes and then release the pressure.

[0023] S206, lift the steel mold from the rib forming base plate, combine it with the 7th to 11th layers of prepreg on the rib forming base plate, fill the triangular area on the right side of the 12th layer and the upper side of the 11th layer of prepreg with carbon fiber prepreg sticky yarn, and compact the twisted yarn with a sharp rolling plate head. After compaction, perform pre-extraction, tighten it, maintain it for 15 to 20 minutes, and then release the pressure;

[0024] S207: Use the right edge of the 16th layer as the paving surface and lay the 17th layer. Perform pre-pumping treatment. After tightening, maintain pressure for 15 to 20 minutes before releasing pressure.

[0025] S208, after the pre-extraction is completed, the 18th to 21st layers of prepreg are laid in sequence along the outer edge of the 17th layer of prepreg. After the laying is completed, the pre-extraction process is carried out. After tightening, the pressure is released after maintaining for 120 to 140 minutes.

[0026] S209, placing a soft rubber conformable mold and fixing the soft rubber conformable mold to the rib forming base plate with a pressure-sensitive tape, and laying a hard silicone rubber airpad at the end of the prepreg cut;

[0027] S210. Place sealing strips around the product, and place peelable cloth, two layers of porous isolation film, breathable felt, and vacuum bag film on the surface of the prepreg in sequence for packaging;

[0028] S211, the encapsulated mold is transferred to an autoclave for curing, and after curing is completed, the mold is demoulded.

[0029] As a further improvement of the present invention, in step S211, during demoulding, after the mold is cooled to room temperature, the auxiliary materials outside the ribs are removed, and the ribs are removed with a polytetrafluoroethylene plate. After demoulding is completed, the ribs are marked.

[0030] As a further improvement of the present invention, the reflective plate forming mold includes a fixed base, the upper side of the fixed base is fixedly connected to a paving base plate, the upper side of the paving base plate is fixedly connected to a front flange plate, the upper side of the paving base plate at the rear left end and the rear right end of the front flange plate are respectively fixedly connected to a left flange plate and a right flange plate, the upper side of the paving base plate between the rear ends of the left flange plate and the right flange plate is fixedly connected to a rear flange plate, and the upper side of the paving base plate, the front flange plate, the left flange plate, the right flange plate and the rear flange plate form a paving area.

[0031] As a further improvement of the present invention, an embedded part positioning assembly is detachably connected to the fixed base, and the embedded part positioning assembly includes a first embedded fixing seat that is detachably connected to the front of the front flange plate and a second embedded fixing seat behind the rear flange plate, respectively, the first embedded fixing seat and the second embedded fixing seat are fixedly connected to the first embedded positioning plate on the left side, and the first embedded fixing seat and the second embedded fixing seat are fixedly connected to the second embedded positioning plate on the right side, and the first embedded positioning plate is arranged with a plurality of positioning parts on one side of the first embedded positioning plate relative to the second embedded positioning plate and the second embedded positioning plate is fixedly arranged with a plurality of positioning parts, and a positioning sleeve is fixedly connected in the positioning part, and a plug-in groove is provided on the downward side of the positioning sleeve, and the upper part of the embedded part can be inserted into the plug-in groove, and a connecting hole is provided on the positioning sleeve on the upper side of the plug-in groove, and a through hole is provided on the positioning sleeve on the upper side of the connecting hole, and the outer diameter of the through hole is larger than the outer diameter of the connecting hole.

[0032] As a further improvement of the present invention, the paving base plate can be detachably connected to a rib positioning assembly, and the rib positioning assembly includes a first positioning connecting seat and a second positioning connecting seat which are respectively detachably connected to the front of the front flange plate and the rear of the rear flange plate, and the first positioning connecting seat and the second positioning connecting seat are fixedly connected to the rib positioning plate on one side in the left and right directions.

[0033] As a further improvement of the present invention, in step S3, the specific steps of forming are:

[0034] S301, laying the first layer of prepreg on the upper side of the laying bottom plate in the laying area. After the laying is completed, a layer of non-porous isolation film and vacuum bag film are laid on the surface of the prepreg, and the bags are put into the autoclave for cold pressing treatment at 60-80°C for 1-3 hours at room temperature and 0.5-0.8 MPa vacuum pressure;

[0035] S302. Fill the prepreg with 3-5 mm wide carbon fiber prepreg at the edges and corners around the prepreg. After filling, perform pre-evacuation. Each pre-evacuation time is not less than 10 minutes. The pre-evacuation time is calculated starting when the vacuum degree in the vacuum bag is ≤-0.095 MPa.

[0036] S302, laying the second to fifth layers of prepreg on the upper side of the first layer of prepreg. When laying the second to fourth layers of prepreg, each time a layer of prepreg is laid, fill the flanges and corners around the reflector with 3-5 mm wide carbon fiber prepreg. After filling, use the sharp end of a rolling board to roll it firmly. Use a blanking machine to cut out the holes for the embedded nuts in the fourth and fifth layers, with a size that is 2-3 mm larger than the diameter of the embedded nuts.

[0037] S303. Lay a layer of non-porous isolation film, breathable felt, and vacuum bag film on the surface of the prepreg, make the bag and perform pre-evacuation. The pre-evacuation time is not less than 120 minutes. The pre-evacuation time starts when the vacuum degree in the vacuum bag is ≤-0.095MPa. When the pre-evacuation is completed, the processing of the reflective body is completed.

[0038] As a further improvement of the present invention, in step S4, the specific steps of positioning the embedded nuts on the reflector body are as follows:

[0039] S401. Install several embedded nuts on the lower part of the positioning sleeve respectively. Insert the embedded nuts into the positioning sleeve through the insertion groove. Insert the positioning bolts into the through holes and the connecting holes and screw them into the embedded nuts to fix the embedded nuts relative to the embedded positioning plate.

[0040] S402, laying 1 to 2 layers of adhesive film on the bottom of the embedded nut, and laying 1 layer of glass fiber prepreg on the bottom of the adhesive film;

[0041] S403. Install the embedded positioning assembly to the designated position on the paving base plate. Press the embedded nut down to the surface of the reflector body. Protect the portion of the embedded nut protruding from the prepreg with a release cloth or pressure-sensitive tape.

[0042] S404. Perform pre-evacuation on the entire product in S403. The pre-evacuation time shall not be less than 15 minutes. The pre-evacuation time shall be calculated starting from when the vacuum degree in the vacuum bag is ≤-0.095 MPa.

[0043] As a further improvement of the present invention, the step S5 is specifically as follows:

[0044] S501. Use 40-120 grit sandpaper to roughen the joints between the ribs and the reflector body. After polishing, clean the joints with anhydrous ethanol 2-3 times. After the alcohol on the ribs evaporates, apply a layer of adhesive film to the joints.

[0045] S502, laying the processed ribs along the rib positioning plate in sequence. After laying, check the fit between the ribs and the rib positioning plate and fix them with pressure-sensitive tape;

[0046] S503. Perform pre-evacuation on the entire product in step S502. The pre-evacuation time is ≥15 min, and the pre-evacuation time starts when the vacuum degree in the vacuum bag is ≤-0.095 MPa.

[0047] As a further improvement of the present invention, in step S7, the curing step is specifically as follows:

[0048] S701. Place the thermocouple according to the thermocouple placement position marked on the mold, and seal the thermocouple along the edge of the sealing strip of the packaging bag with a sealing tape.

[0049] S702, lay two layers of breathable felt on the vacuum bag film above the thermocouple and secure them with a release strip;

[0050] S703. Connect to the vacuum system, apply a vacuum pressure below -0.092 MPa and an air pressure of 0.2 MPa, close the vacuum valve of the autoclave and the valve of the pipeline, and keep it leak-free for at least 15 minutes.

[0051] Compared with the prior art, the present invention has the following technical effects: the present invention ensures the molding accuracy of the surface embedded parts and ribs of the composite material reflector by designing the layup of the composite material, controlling the placement method of the embedded nuts and the positioning and gluing method of the ribs, and finally sending the entire mold into an autoclave for curing to achieve the integrated molding of the reflector body, the embedded nuts and the ribs; and can be applied to the preparation of composite material reflectors. BRIEF DESCRIPTION OF THE DRAWINGS

[0052] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for describing the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. Those skilled in the art can also derive other drawings based on these drawings without inventive effort. Among them:

[0053] Figure 1 It is the front view of the reflector forming mold in the present invention.

[0054] Figure 2It is a three-dimensional structural diagram of the reflector forming mold in the present invention.

[0055] Figure 3 for Figure 2 A partial enlarged view of point A in the middle.

[0056] Figure 4 for Figure 2 A partial enlarged view of point B in the middle.

[0057] Figure 5 This is a three-dimensional structural diagram of the embedded positioning components in the reflector forming mold.

[0058] Figure 6 for Figure 5 A partial enlarged view of point C in the middle.

[0059] Figure 7 The figure is a three-dimensional structural diagram of the launch plate prepared using the present invention.

[0060] Figure 8 This is a schematic diagram of the explosion during the preparation of reinforcement bars in the present invention.

[0061] Figure 9 This is a schematic diagram of laying out the reinforcement bars in the present invention.

[0062] Figure 10 This is a schematic diagram of the structure before the ribs are encapsulated in the present invention.

[0063] In the figure: 100 fixed base, 200 embedded positioning assembly, 201 first embedded fixing seat, 2011 first connecting plate, 2012 embedded fixing plate, 2012-1 first upper positioning hole, 2012-2 first lower positioning hole, 2013 first reinforcing plate, 202 second embedded positioning plate, 203 embedded reinforcing plate, 204 first embedded fixing plate, 205 second embedded fixing seat, 206 first bolt, 207 positioning sleeve, 2071 through hole, 2072 plug-in sink, 2073 connecting hole, 208 positioning part, 209 positioning bolt, 210 first positioning pin 210, 300 rib positioning assembly, 301 second positioning pin, 302 first positioning connecting seat, 3021 rib fixing plate, 3021-1 second upper positioning hole, 3022 second reinforcing plate, 3023 second connecting plate , 303 second fixing bolt, 304 rib positioning plate, 305 second positioning connecting seat, 400 paving base plate, 500 front flange plate, 600 left flange plate, 700 rear flange plate, 800 right flange plate, 900 reflector, 901 embedded nut, 902 rib, 903 reflector body, 1000 carbon fiber prepreg sticking wire, 2000 steel mold, 3000 hard silicone rubber, 4000 soft rubber mold, 5000 rib forming base plate, a 1st to 6th layer of prepreg, b 7th to 11th layer of prepreg, c 12th to 16th layer of prepreg, d 17th to 21st layer of prepreg, e triangle area. DETAILED DESCRIPTION

[0064] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the specific embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0065] In the following description, many specific details are set forth to facilitate a full understanding of the present invention. However, the present invention may also be implemented in other ways different from those described herein. Those skilled in the art may make similar generalizations without violating the connotation of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0066] Secondly, the term "one embodiment" or "embodiment" herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The phrase "in one embodiment" appearing in various places throughout this specification does not necessarily refer to the same embodiment, nor does it refer to a separate or selective embodiment that is mutually exclusive of other embodiments.

[0067] Example 1: Reference Figures 7 to 10 , which is the first embodiment of the present invention, provides a composite material reflective plate forming method. The present invention can reliably prepare a reflective plate 900 with a composite material reflective plate 900 body and a metal embedded nut 901 integrally formed.

[0068] A method for forming a composite material reflective plate 900 includes the following steps:

[0069] S1. Prepare the rib forming base plate 5000 and the reflector plate 900 forming molds: After the new molds have passed the inspection, they should be cleaned repeatedly with acetone 2-4 times, then placed in an oven for degreasing at a temperature of 180°C-200°C for 2-5 hours. After degreasing, use 40-120 grit sandpaper to roughen the area where the sealing tape will be bonded to a surface greater than 10 μm, and then clean with acetone. Apply release agent to the paving area. Apply 8-10 coats of release agent to new molds, with an interval of 15-30 minutes between each coat. For molds that are used twice, only 3-5 coats are required.

[0070] S2, rib 902 is formed, specifically:

[0071] S200: Based on the 3D digital model of the product, draw the paving sheets at a specific angle. Import the designed blanking diagram into the blanking machine's supporting software. Use the blanking machine to cut the required prepreg sheets. The width edge of the prepreg must be placed on the reference line on the CNC blanking machine.

[0072] S201, laying prepreg on the rib forming base plate 5000, laying prepreg from one end to the other end in the length direction (referring to the length direction of the rib 902), laying the 1st to 6th layers of prepreg a, specifically, after laying the 1st layer of rib 902 prepreg, perform pre-extraction treatment, after tightening, keep it for 15 to 20 minutes and then release the pressure, remove the auxiliary materials; after the pre-extraction is completed, lay the 2nd to 5th layers of prepreg, and use a rolling board after each layer is laid Compact the prepreg and remove air bubbles between them. Stagger the joints of the 2nd to 5th layers of prepreg by 150-200mm. After the 5th layer of prepreg is laid, perform pre-extraction. After tightening, hold for 15-20 minutes, then release the pressure and remove the auxiliary materials. After the pre-extraction is completed, lay the 6th layer of prepreg. After the laying is completed, perform pre-extraction. After tightening, hold for 120-130 minutes, then release the pressure and remove the auxiliary materials for later use.

[0073] S202, laying the seventh layer of prepreg on the upper side of the sixth layer of prepreg. After laying, perform a pre-extraction process (the pre-extraction process is a conventional technology, not the invention of this application, and will not be described in detail in this application). After tightening, maintain the pressure for 15 to 20 minutes and then release the pressure;

[0074] S203, laying the 8th to 11th layers of prepreg on the upper side of the 7th layer of prepreg in sequence. After laying, perform pre-extraction treatment, tighten, maintain for 15 to 20 minutes, and then release the pressure;

[0075] S204, placing the non-paving surface of the steel mold 2000 on the surface of the rib forming base plate 5000, and laying the 12th layer of prepreg on the rib forming base plate 5000 using the steel mold 2000 (from bottom to top along the left bottom of the steel mold 2000, then from left to right along the upper side of the steel mold 2000, and finally from top to bottom along the right side of the steel mold 2000). After laying, perform pre-extraction treatment, tighten, maintain for 15-20 minutes, and then release the pressure;

[0076] S205, laying the 13th to 16th layers of prepreg in sequence on the outer edge of the 12th layer of prepreg. After laying, perform pre-extraction treatment. After tightening, maintain for 15 to 20 minutes and then release the pressure.

[0077] S206, lift the steel mold 2000 from the rib forming base plate 5000, and combine it with the 7th to 11th layers of prepreg b on the rib forming base plate 5000. After the combination is completed, perform pre-extraction. After tightening, keep it for 15 to 20 minutes and then release the pressure to ensure that the 12th to 16th layers of prepreg c laid on the steel mold 2000 and the 7th to 11th layers of prepreg laid on the flat plate are tightly fitted. Fill the triangular area e on the right side of the 12th layer and the upper side of the 11th layer of prepreg with carbon fiber prepreg sticky yarn 1000, and compact the twisted yarn with a sharp rolling board head. After the compaction is completed, perform pre-extraction. After tightening, keep it for 15 to 20 minutes and then release the pressure. After the pre-extraction is completed, check whether the twisted yarn in the triangular area e is missing. According to the filling situation, perform local additional filling. After the additional filling is completed, perform pre-extraction. After tightening, keep it for 15 to 20 minutes and then release the pressure.

[0078] S207. Using the outer edge of the 16th prepreg layer as the paving surface, lay the 17th layer (from left to right along the upper side of the 16th prepreg layer, then from top to bottom along the right surface of the 16th prepreg layer, and finally from left to right along the upper side of the 11th prepreg layer). The right side of the 16th prepreg layer is flush with the right side of the 11th prepreg layer. After paving is completed, perform pre-extraction. After tightening, maintain pressure for 15 to 20 minutes and then release pressure.

[0079] S208, after the pre-extraction is completed, the 18th to 21st layers of prepreg are laid in sequence along the outer edge of the 17th layer of prepreg. After the 17th to 21st layers of prepreg are laid, the pre-extraction process is performed. After tightening, the pressure is released after maintaining for 120 to 140 minutes.

[0080] S209, place the soft rubber follow-up mold 4000 and fix it to the rib forming base plate 5000 with pressure-sensitive tape. Place a hard silicone rubber 3000 airpad at the end of the prepreg cut to prevent the vacuum bag film from sinking into the gap between the forming mold and the prepreg during the curing process, causing the bag to burst.

[0081] S210. Place sealing strips around the product, and place peelable cloth, two layers of porous isolation film on the surface of the prepreg in sequence (the vacuum air conduction effect of the porous isolation film is better, but it is easy to absorb the resin in the prepreg into the breathable felt, affecting the glue content of the final product, so the porous isolation film is laid twice), breathable felt and vacuum bag film. The edges of the peelable cloth should be larger than the edge of the prepreg, and the edges of the isolation film should be 50mm larger than the edge of the peeling cloth. A layer of breathable felt is laid outside the isolation film, and the edges of the breathable felt should be 50mm larger than the isolation film. The edges of the auxiliary materials can be fixed to the mold surface with pressure-sensitive tape, and 40~120 mesh coarse sandpaper is used for polishing. The position where the sealing strip is required on the mold is polished, and then wiped clean with acetone solution using wiping paper. The standard for cleaning is that there is no stain on the wiping paper after wiping the mold surface; run a circle of sealing strips on the position wiped with acetone, and the surface protective white film is not removed. Use a rolling board to roll the sealing strip to fit the surface of the mold, check the matching of the vacuum nozzle base and the upper part and whether the vacuum nozzle head is leaking. It is strictly forbidden to use if it does not match or leaks. Place the vacuum nozzle base on the mold; then use the sealing strip to seal the vacuum bag film, and use a rolling board to roll the place where the sealing strip and the vacuum bag film are bonded. Check whether the root and tip of the pleats are completely in fit with the vacuum bag film and have a sealing effect. Install the upper part of the vacuum nozzle, vacuumize, and check whether there are any bridges in the bag. If there are, they need to be leveled; then perform vacuum leak detection. When the vacuum in the bag reaches -0.095~-0.085MPa, turn off the vacuum source for 10~15 minutes. Manually detect that the vacuum degree does not drop by more than 0.02MPa, and the vacuum bag is sealed. If the vacuum pressure drop exceeds 0.02MPa, check the vacuum bag for air leaks until the pressure drop meets the requirements. Package the furnace parts, and place the auxiliary materials in the furnace parts in accordance with the parts.

[0082] S211. Transfer the encapsulated mold to the effective temperature range of the autoclave for curing, place the thermocouple according to the thermocouple placement position marked on the mold, seal the thermocouple along the edge of the sealing strip of the packaging bag with sealing tape, cover it with excess packaging vacuum bag film to fix the position of the sealing strip to prevent the sealing strip from being heated and the thermocouple from shifting, then lay two layers of breathable felt on the vacuum bag film above the thermocouple and fix it with demoulding cloth to prevent the sealing strip covering the thermocouple from contacting the air after high temperature, and the air temperature from interfering with the thermocouple detection; record the vacuum pressure drop, connect to the vacuum system, apply a vacuum pressure below -0.092MPa, and apply an air pressure of 0.3~0.8MPa, close the vacuum valve of the autoclave and the valve of the pipeline, and keep it leak-free for at least 15 minutes. After the leak test is qualified, set the autoclave operation parameters. The operation process must be strictly carried out according to the heating and cooling rate of 0.5~2℃ / min, and the operation end temperature must reach 40~60℃ The can can be opened to prevent the temperature difference between the inside and outside of the can from being too large, which will lead to insufficient release of the thermal stress of the parts and the end of deformation and solidification. After the mold is cooled to room temperature, carefully remove the auxiliary materials outside the rib 902 to avoid tearing of the surface fibers of the rib 902 and excessively high temperature when removing the auxiliary materials, which will cause deformation of the rib 902 surface and affect the final bonding quality. Then use a polytetrafluoroethylene plate to remove the rib 902, and mark the rib 902 after demoulding; test the surface quality of the rib 902, and after demoulding, remove the rib The strip 902 is placed on the mold of the reflector 900, and the gap between the parts and the mold is measured with a feeler gauge. The maximum gap between the rib 902 and the mold is allowed to be no more than 0.5mm in the free state. If the gap is greater than 0.5mm, a force of 50N can be applied at a distance of 250mm. The gap after the force is applied should be no more than 0.3mm. After the film adhesion test is completed, the cured rib 902 is subjected to non-destructive testing using an ultrasonic A-scan detector. If the test meets the requirements, the rib 902 is qualified.

[0083] Among them, the 1st to 6th layer prepregs and the 7th to 21st layer prepregs are two different fibers and the same resin system prepregs. The 1st to 6th layer prepregs are woven carbon fiber prepregs, and the 7th to 21st layer prepregs are unidirectional fiber prepregs.

[0084] S3, the reflector 900 body is formed;

[0085] S4. Use the reflector 900 forming mold to position the embedded nut 901 on the reflector 900 body;

[0086] S5. Use the reflector 900 forming mold to position the ribs 902 on the reflector 900 body;

[0087] S6. Vacuum-encapsulate the mold for forming the reflector 900 in step S5 (the encapsulation step is similar to the encapsulation step in the process of forming the ribs 902 and will not be described in detail here);

[0088] S7, the packaged reflector 900 forming mold is transferred to the effective temperature range of the autoclave for curing. The curing steps are as follows:

[0089] S701. Place the thermocouple according to the thermocouple placement position marked on the mold, and seal the thermocouple along the edge of the sealing strip of the packaging bag with a sealing tape.

[0090] S702, lay two layers of breathable felt on the vacuum bag film above the thermocouple and secure them with a release strip;

[0091] S703. Connect to the vacuum system, apply a vacuum pressure of less than -0.092 MPa and an air pressure of 0.2 MPa, close the vacuum valve of the autoclave and the valve of the pipeline, and maintain no leakage for at least 15 minutes;

[0092] S704, operate at a heating and cooling rate of 0.5~2℃ / min. After the operation, the tank temperature drops to below 40~60℃ before opening the tank to prevent the temperature difference between the inside and outside of the tank from being too large, which may cause deformation of the reflector 900 surface;

[0093] S8, after curing is completed, the mold is demoulded after cooling to room temperature;

[0094] S9. Inspection: Place the processed reflective plate 900 back into the mold of the reflective plate 900 and use a feeler gauge to measure the gap between the reflective plate 900 and the mold. The maximum gap between the reflective plate 900 and the mold is allowed to be no more than 0.1mm in the free state. If the gap is greater than 0.1mm, apply a force of 50N at a distance of 250mm. The gap after the force is applied should be no more than 0.05mm. Perform non-destructive inspection with an ultrasonic A-scan detector. If there is no problem, the reflective plate 900 is qualified.

[0095] S10 . According to the outer dimensions required by the design, the reflecting plate 900 that has passed the inspection is machined and trimmed to form the final reflecting plate 900 .

[0096] Example 2: Reference Figures 1 to 7 , which is different from Example 1 in that it can further realize the shaping of the reflective plate 900.

[0097] Specifically, the reflecting plate 900 forming mold includes a fixed base 100, the upper side of the fixed base 100 is fixedly connected to the paving base plate 400, the upper side of the paving base plate 400 is fixedly connected to the front flange plate 500, the upper side of the paving base plate 400 at the left rear end and the right rear end of the front flange plate 500 are respectively fixedly connected to the left flange plate 600 and the right flange plate 800, the upper side of the paving base plate 400 between the rear ends of the left flange plate 600 and the right flange plate 800 is fixedly connected to the rear flange plate 700, the upper side of the paving base plate 400, the front flange plate 500, the left flange plate 600, the right flange plate 800 and the rear flange plate 700 form a paving area; the fixed base is detachably connected to an embedded part positioning assembly, the embedded part positioning assembly includes detachably connected to The first embedded fixing seat 201 in front of the front flange plate 500 and the second embedded fixing seat 205 behind the rear flange plate 700 have the same structure. The first embedded fixing seat 201 and the second embedded fixing seat 205 are connected to the paving base plate 400 as an example for explanation. The first embedded fixing seat 201 includes an embedded fixing plate 2012, and a first reinforcing vertical plate 2013 is fixed on the upper side of the embedded fixing plate 2012. The first connecting plates 2011 are respectively fixed on the left and right sides of the first reinforcing vertical plate 2013. The centers of the embedded fixing plates 2012 on the front and rear sides of the first reinforcing vertical plate 2013 are respectively provided with first upper positioning holes 2012-1. The embedded fixing plates 2012 on the left and right sides of the first upper positioning hole 2012-1 are respectively provided with first upper positioning holes 2012-1. A first upper fixing hole 20122 is separately provided, and a plurality of first lower positioning holes 2012-2 corresponding to the first upper positioning hole 2012-1 and a plurality of first lower fixing holes corresponding to the first upper fixing hole 20122 are arranged on the paving bottom plate 400. The left side of the second embedded fixing seat 205 is fixedly connected with the first embedded positioning plate, and the right side of the first embedded fixing seat 201 and the second embedded fixing seat 205 is fixedly connected with the second embedded positioning plate 202. A plurality of embedded reinforcing plates 203 are fixed between the first embedded fixing plate and the second embedded positioning plate 202. The embedded reinforcing plates 203 can improve the structural strength of the first embedded positioning plate and the second embedded positioning plate 202, reduce the deformation of the embedded fixing plate, and improve the embedded nuts 901. Regarding the positioning accuracy on the reflector 900 body, the bottom of the first embedded positioning plate and the bottom of the second embedded positioning plate 202 are above the paving base plate 400, and a plurality of positioning parts 208 are arranged on the side of the first embedded positioning plate relative to the second embedded positioning plate 202 and the side of the second embedded positioning plate 202 relative to the first embedded positioning plate. A positioning sleeve 207 is fixedly connected in the positioning part 208, and a plug-in groove 2072 is provided on the downward side of the positioning sleeve 207. The upper part of the embedded part can be inserted into the plug-in groove 2072, and a connecting hole 2073 is provided on the positioning sleeve 207 on the upper side of the plug-in groove 2072. A through hole 2071 is provided on the positioning sleeve 207 on the upper side of the connecting hole 2073, and the outer diameter of the through hole 2071 is larger than the outer diameter of the connecting hole 2073.

[0098] In step S3, the specific steps of forming are:

[0099] S301, laying the first layer of prepreg on the upper side of the laying base plate 400 in the laying area. After the laying is completed, a layer of non-porous isolation film and vacuum bag film are laid on the surface of the prepreg, and the bags are placed in an autoclave for cold pressing at 60-80°C for 1-3 hours at room temperature and 0.5-0.8 MPa vacuum pressure;

[0100] S302. Fill the prepreg with 3-5 mm wide carbon fiber prepreg at the edges and corners around the prepreg. After filling, perform pre-evacuation. Each pre-evacuation time is not less than 10 minutes. The pre-evacuation time is calculated starting when the vacuum degree in the vacuum bag is ≤-0.095 MPa.

[0101] S302, laying the second to fifth layers of prepreg on the upper side of the first layer of prepreg. When laying the second to fourth layers of prepreg, each time a layer of prepreg is laid, fill the flanges around the reflector 900 and the corners of the reflector 900 with 3-5 mm wide carbon fiber prepreg. After filling, use the sharp end of a rolling board to roll it firmly. Use a blanking machine to cut out the holes for the embedded nuts 901 in the fourth and fifth layers. The size of the holes should be 2-3 mm larger than the diameter of the embedded nuts 901.

[0102] S303. Lay a layer of non-porous isolation film, breathable felt, and vacuum bag film on the surface of the prepreg, make the bag and perform pre-evacuation. The pre-evacuation time is not less than 120 minutes. The pre-evacuation time starts when the vacuum degree in the vacuum bag is ≤-0.095MPa. When the pre-evacuation is completed, the processing of the reflective body is completed.

[0103] In step S4, the specific steps of positioning the embedded nut 901 on the reflector 900 body are as follows:

[0104] S401, several embedded nuts 901 are respectively installed on the lower part of the positioning sleeve 207, the embedded nuts 901 are inserted into the positioning sleeve 207 through the plug-in groove 2072, and the positioning bolts 209 are inserted into the through holes 2071 and the connecting holes 2073 and then screwed into the embedded nuts 901, so that the embedded nuts 901 are fixed relative to the embedded positioning plate, and several embedded positioning components 200 are installed on the paving bottom plate 400. Take one embedded positioning component 200 as an example to illustrate, and insert the two first positioning pins 210 through the first upper positioning hole 2 012-1 are respectively inserted into the front and rear embedded fixing plates 2012, and the first positioning pins 210 are aligned with the corresponding first lower positioning holes 2012-2, so that the front and rear first positioning pins 210 are inserted into the first lower positioning holes 2012-2. The embedded fixing plates 2012 are attached to the upper side of the paving base plate 400, and the first fixing bolts 206 are screwed into the first upper fixing holes 20122 and the corresponding first lower fixing holes, so that the heads of the first fixing bolts 206 press the embedded fixing plates 2012 against the upper side of the paving base plate 400;

[0105] S402, laying 1-2 layers of adhesive film on the bottom of the embedded nut 901, and laying 1 layer of glass fiber prepreg on the bottom of the adhesive film;

[0106] S403: Install the embedded positioning assembly to the designated position on the paving base plate 400. Press the embedded nut 901 down to the surface of the reflector 900. Protect the portion of the embedded nut 901 protruding from the prepreg with a release cloth or pressure-sensitive tape.

[0107] S404. Perform pre-evacuation on the entire product in S403. The pre-evacuation time shall not be less than 15 minutes. The pre-evacuation time shall be calculated starting from when the vacuum degree in the vacuum bag is ≤-0.095 MPa.

[0108] Through the above steps, the multiple embedded nuts 901 can be accurately positioned and fixed, thereby improving the molding accuracy of the embedded nuts 901 and the launch plate body 903 being integrally formed.

[0109] Specifically, the paving base plate 400 is further detachably connected to a rib positioning assembly 300, and the rib positioning assembly 300 includes a first positioning connection seat 302 and a second positioning connection seat 305 which are detachably connected to the front of the front flange plate 500 and the rear of the rear flange plate 700, respectively. The first positioning connection seat 302 and the second positioning connection seat 305 have the same structure. The structure of the first positioning connection seat 302 is used for explanation. The first positioning connection seat 302 includes a rib fixing plate 3021, and a second reinforcing vertical plate 3022 is fixed on the upper side of the rib fixing plate 3021. The rib fixing plate 3021 on one side of the second reinforcing vertical plate 3022 in the left and right directions is fixed to the rib fixing plate 3021. A second connecting plate 3023 is fixed on the upper side, and the two corresponding second connecting plates 3023 in the front-to-back direction are fixedly connected to the rib 902 positioning plate 304 on one side in the left-to-right direction. The rib 902 positioning plate 304 is fixedly connected to the side of the two corresponding rib 902 positioning connecting plates away from the second reinforcing vertical plate 3022. The rib fixing plates 3021 in front and behind the second reinforcing vertical plate 3022 are respectively provided with second upper fixing holes and second upper positioning holes 3021-1. The paving bottom plate 400 is provided with several second lower fixing holes corresponding one-to-one to the second upper fixing holes and several second lower positioning holes corresponding one-to-one to the second upper positioning holes 3021-1.

[0110] Step S5 specifically includes:

[0111] S501, use 40-120 grit sandpaper to roughen the bonding area between the rib 902 and the reflector 900 body, and then clean it with anhydrous ethanol 2-3 times after grinding. After the alcohol on the surface of the rib 902 evaporates, apply a layer of adhesive film to the bonding surface of the rib 902;

[0112] S502, install several rib positioning assemblies 300 on the paving base plate 400, taking the installation of one set of rib positioning assemblies 300 as an example, insert the four second positioning pins 301 into the two rib 902 positioning plates 304 through the second upper positioning holes 3021-1, align the second positioning pins 301 with the corresponding second lower positioning holes, and insert the second positioning pins 301 into the corresponding second lower positioning holes until the rib fixing plate 3021 is attached to the paving base plate 400. Until then, use the second fixing bolt 303 to screw into the second upper fixing hole and the second lower fixing hole, so that the head of the second fixing bolt 303 presses the rib fixing plate 3021 against the upper side of the paving base plate 400, thereby fixing the rib positioning assembly 300 and the paving base plate 400, and then lay the processed ribs 902 along the rib 902 positioning plate 304 in sequence. After the laying is completed, check the fit between the ribs 902 and the rib 902 positioning plate 304, and use pressure-sensitive tape to assist in fixing;

[0113] S503. Perform pre-evacuation on the entire product in step S502. The pre-evacuation time is ≥15 min, and the pre-evacuation time starts when the vacuum degree in the vacuum bag is ≤-0.095 MPa.

[0114] Through the above steps, the accurate positioning and fixation of the plurality of ribs 902 and the positioning plate 304 can be achieved, thereby improving the molding accuracy of the integral molding of the ribs 902 , the positioning plate 304 and the launch plate body 903 .

[0115] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

Claims

1. A method for forming a composite material reflective plate, characterized in that: The following steps are included: S1. Prepare a rib forming base plate and a reflector forming mold, the reflector forming mold includes a fixed base, the fixed base is detachably connected to an embedded part positioning assembly, the embedded part positioning assembly includes a first embedded fixing seat in front of the front flanging plate and a second embedded fixing seat behind the rear flanging plate, the first embedded fixing seat and the second embedded fixing seat are fixedly connected to the first embedded positioning plate on the left side, and the first embedded fixing seat and the second embedded fixing seat are fixedly connected to the second embedded positioning plate on the right side, the first embedded positioning plate is opposite to the second embedded positioning plate on one side and the second embedded positioning plate is opposite to the first embedded positioning plate. A plurality of positioning parts are arranged, the positioning part is fixedly connected to a positioning sleeve, and the downward side of the positioning sleeve has a plug-in groove, the upper part of the embedded part can be inserted into the plug-in groove, and the upper side of the fixed base is fixedly connected The left and right side panels are fixedly connected to the upper side of the paving base, and the upper side of the paving base is fixedly connected to the left and right side panels at the rear ends of the left and right side panels, and the upper side of the paving base between the rear ends of the left and right side panels is fixedly connected to the rear side panels, and the upper side of the paving base, the front and left side panels, the right and right side panels and the rear side panels form a paving area. The upper side of the paving base, the front and left side panels, the right and left side panels and the rear side panels are fixedly connected to the rear side panels; S2, rib forming; S3, forming the reflector body; S4. Use the reflector forming mold to position the embedded nuts on the reflector body. The specific steps are as follows: S401. Install several embedded nuts on the lower part of the positioning sleeve respectively. Insert the embedded nuts into the positioning sleeve through the insertion groove. Insert the positioning bolts into the through holes and the connecting holes and screw them into the embedded nuts to fix the embedded nuts relative to the embedded positioning plate. S402, laying 1 to 2 layers of adhesive film on the bottom of the embedded nut, and laying 1 layer of glass fiber prepreg on the bottom of the adhesive film; S403. Install the embedded positioning assembly to the designated position on the paving base plate. Press the embedded nut down to the surface of the reflector body. Protect the portion of the embedded nut protruding from the prepreg with a release cloth or pressure-sensitive tape. S5. Using a reflector forming mold, position the ribs on the reflector body; S6, vacuum packaging the reflector forming mold in step S5; S7, transferring the packaged reflector forming mold to an autoclave for curing; S8, after curing is completed, the mold is demoulded after cooling to room temperature; S9, detection; S10. According to the design requirements, the reflective plates that have passed the inspection are machined and trimmed.

2. The composite material reflector forming method according to claim 1, wherein: The step S2 is specifically as follows: S201, laying prepreg on the rib forming base plate, laying the prepreg from one end to the other end in the length direction, laying the first to sixth layers of prepreg; S202, laying the seventh layer of prepreg from the upper side of the sixth layer of prepreg. After laying, perform pre-extraction and tightening, maintain for 15 to 20 minutes, and then release the pressure. S203, laying the 8th to 11th layers of prepreg on the upper side of the 7th layer of prepreg in sequence. After laying, perform pre-extraction and tightening, maintain for 15 to 20 minutes, and then release the pressure; S204, placing the non-paving surface of the steel mold on the surface of the rib forming base plate, and laying the 12th layer of prepreg on the rib forming base plate using the steel mold. After laying, perform pre-extraction treatment and tighten it, maintain it for 15 to 20 minutes, and then release the pressure; S205, laying the 13th to 16th layers of prepreg in sequence on the outer edge of the 12th layer of prepreg. After laying, perform pre-extraction treatment. After tightening, maintain for 15 to 20 minutes and then release the pressure. S206, lift the steel mold from the rib forming base plate, combine it with the 7th to 11th layers of prepreg on the rib forming base plate, fill the triangular area on the right side of the 12th layer and the upper side of the 11th layer of prepreg with carbon fiber prepreg sticky yarn, and compact the twisted yarn with a sharp rolling plate head. After compaction, perform pre-extraction, tighten it, maintain it for 15 to 20 minutes, and then release the pressure; S207: Use the right edge of the 16th layer as the paving surface and lay the 17th layer. Perform pre-pumping treatment. After tightening, maintain pressure for 15 to 20 minutes before releasing pressure. S208, after the pre-extraction is completed, the 18th to 21st layers of prepreg are laid in sequence along the outer edge of the 17th layer of prepreg. After the laying is completed, the pre-extraction process is carried out. After tightening, the pressure is released after maintaining for 120 to 140 minutes. S209, placing a soft rubber conformable mold and fixing the soft rubber conformable mold to the rib forming base plate with a pressure-sensitive tape, and laying a hard silicone rubber airpad at the end of the prepreg cut; S210. Place sealing strips around the product, and place peelable cloth, two layers of porous isolation film, breathable felt, and vacuum bag film on the surface of the prepreg in sequence for packaging; S211, the encapsulated mold is transferred to an autoclave for curing, and after curing is completed, the mold is demoulded.

3. The composite material reflector forming method according to claim 1, wherein: In step S211, during demoulding, after the mold is cooled to room temperature, the auxiliary materials outside the ribs are removed, and the ribs are removed with a polytetrafluoroethylene plate. After demoulding is completed, the ribs are marked.

4. The method for forming a composite material reflective plate according to claim 1, wherein: In step S3, the specific steps of forming are: S301, laying the first layer of prepreg on the upper side of the laying bottom plate in the laying area. After the laying is completed, a layer of non-porous isolation film and vacuum bag film are laid on the surface of the prepreg, and the bags are put into the autoclave for cold pressing treatment at 60-80°C for 1-3 hours at room temperature and 0.5-0.8 MPa vacuum pressure; S302. Fill the prepreg with 3-5 mm wide carbon fiber prepreg at the edges and corners around the prepreg. After filling, perform pre-evacuation. Each pre-evacuation time is not less than 10 minutes. The pre-evacuation time is calculated starting when the vacuum degree in the vacuum bag is ≤-0.095 MPa. S302, laying the second to fifth layers of prepreg on the upper side of the first layer of prepreg. When laying the second to fourth layers of prepreg, each time a layer of prepreg is laid, fill the flanges and corners around the reflector with 3-5 mm wide carbon fiber prepreg. After filling, use the sharp end of a rolling board to roll it firmly. Use a blanking machine to cut out the holes for the embedded nuts in the fourth and fifth layers, with a size that is 2-3 mm larger than the diameter of the embedded nuts. S303. Lay a layer of non-porous isolation film, breathable felt, and vacuum bag film on the surface of the prepreg, make the bag and perform pre-evacuation. The pre-evacuation time is not less than 120 minutes. The pre-evacuation time starts when the vacuum degree in the vacuum bag is ≤-0.095MPa. When the pre-evacuation is completed, the processing of the reflective body is completed.

5. The method for forming a composite material reflective plate according to claim 4, wherein: After step S403, the following steps are further performed: S4 04. Perform pre-evacuation on the entire product in S403. The pre-evacuation time shall not be less than 15 minutes. The pre-evacuation time shall be calculated when the vacuum degree in the vacuum bag is ≤-0.095MPa.

6. The method for forming a composite material reflective plate according to claim 4, wherein: The step S5 is specifically as follows: S501. Use 40-120 grit sandpaper to roughen the joints between the ribs and the reflector body. After polishing, clean the joints with anhydrous ethanol 2-3 times. After the alcohol on the ribs evaporates, apply a layer of adhesive film to the joints. S502, laying the processed ribs along the rib positioning plate in sequence. After laying, check the fit between the ribs and the rib positioning plate and fix them with pressure-sensitive tape; S503. Perform pre-evacuation on the entire product in step S502. The pre-evacuation time is ≥15 min, and the pre-evacuation time starts when the vacuum degree in the vacuum bag is ≤-0.095 MPa.

7. The method for forming a composite material reflective plate according to claim 5, wherein: In step S7, the curing step is specifically as follows: S701. Place the thermocouple according to the thermocouple placement position marked on the mold, and seal the thermocouple along the edge of the sealing strip of the packaging bag with a sealing tape. S702, lay two layers of breathable felt on the vacuum bag film above the thermocouple and secure them with a release strip; S703. Connect to the vacuum system, apply a vacuum pressure below -0.092 MPa and an air pressure of 0.2 MPa, close the vacuum valve of the autoclave and the valve of the pipeline, and keep it leak-free for at least 15 minutes.

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