An ultrasonic material placement and compression molding device that guides material through an ultrasonic horn element.

Abstract

A continuous filament deposition model manufacturing machine (10) for fabricating a part (66) by laying down a continuous monofilament or continuous synthetic filament material layer by layer on a tool (68) or substrate. The machine includes a system, such as a robot (12), operable to move in three degrees of freedom, and a placement module (100) coupled to the system, configured to deposit the continuous filament material. The placement module (100) includes a guide (64) for guiding the material to the part, and an ultrasonic compression molding device (102) for compression molding the material as it is deposited from the placement module (100). The compression molding device includes an ultrasonic horn (104) having at least one guide hole (106) through which the material passes before being laid down and compression molded. The ultrasonic horn (104) is ultrasonically vibrated to melt or flow the material and to cause the material to be fused and compression molded to the tool or substrate.

Description

Technical Field

[0001]

[0001] This disclosure generally relates to continuous filament additive manufacturing machines, and more particularly to continuous filament additive manufacturing machines including an ultrasonic compaction device for melting a matrix material when fusing the matrix material to a previously deposition laid layer, where the compaction device includes a horn having a guide hole for guiding the matrix material. deposition

Background Art

[0002]

[0002] Fused filament fabrication (FFF) is an additive manufacturing (AM) process for 3D printing. Typically, raw materials such as continuous filaments from a spool or pellets from a hopper are provided to a heated nozzle, and the raw materials are heated and extruded from the nozzle as filaments in a molten state and deposited as adjacent rows of deposition strips to form a layer, where the filaments (fiber-reinforced or not) in the molten state start to harden as soon as they are extruded from the nozzle. In this approach, multiple layers are built up to a specific configuration, thereby creating the desired part. Alternatively, the filament can be heated outside the nozzle by a laser or the like and wrapped around the part as it is being built.

[0003] ​

[0003] Continuous filament materials that are not fiber-reinforced are usually called monofilaments and contain only polymer or matrix materials. Continuous filament materials that are fiber-reinforced are often called composite filaments and contain fiber reinforcement and polymer or matrix materials. A variety of materials such as high-performance amorphous thermoplastics or high-performance semi-crystalline thermoplastics, including polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyphenylsulfone (PPSF or PPSU), polyetherimide (PEI), and polyphenylene (PPS), can be used for FFF. Other materials that may be suitable for FFF include acrylonitrile butadiene styrene (ABS), polylactic acid (PLA), polycarbonate (PC), polyamide (PA), polystyrene (PS), lignin, and rubber. Filaments can be reinforced with discontinuous or continuous fibers. Examples of common fibers include carbon fibers, glass fibers, quartz fibers, and Kevlar® fibers. Other materials that can be used for filament formation include ultra-high molecular weight polyethylene (UHMWPE), Dyneema, high-impact polystyrene (HIPS), nylon, high-density polyethylene (HDPE) eutectic materials, plasticine, and room-temperature vulcanization (RTV) silicones. Continuous fiber filaments, such as continuous carbon fiber (CCF) filaments, tend to have high strength and are desired in certain products. These filaments may have continuous carbon or other fibers that extend from one end of the filament to the other and are encapsulated within a suitable polymer, thereby providing the desired matrix strength. In addition, the carbon fibers may be cut or separated so as not to be continuous from one end of the filament to the other, and further, they may be impregnated with a suitable matrix or retained integrally with a suitable matrix.

[0004]

[0004] Known additive manufacturing 3D printing machines often employ a gantry-type method with end effectors that lay the additive material in the xy plane. However, the gantry-type machine method has challenges in terms of scalability, affordability, and flexibility for the fabrication cell. This is because there is a positive correlation between the size of the part to be manufactured and the size of the gantry machine required, where the gantry machine can only perform one operation at a time. Very large parts require very large machines, and therefore the required footprint and machine cost increase. The robotic method offers greater flexibility and enables easier scaling. For example, multiple robots can operate in the same space. In addition, each robot can be mounted on a movable base, and the possible bases allow for repositioning to various locations within or around the space. The robotic method allows for the addition of robot postures, thereby increasing degrees of freedom, improving the ability to manufacture in 3D, and enhancing manufacturing flexibility through multiple robots performing multiple tasks. One known system of this type is the Scalable Composite Robotic Additive Manufacturing (SCRAM) system available from Electroimpact, which is a truly six-axis continuous fiber-reinforced 3D printer for industrial use that enables the rapid, toolless manufacturing of aerospace-grade integrated composite structures.

[0005]

[0005] Due to the properties of laminated thermoplastic materials, it is possible to produce fully compacted materials without post-processing such as using an oven, an autoclave, or other energy-adding techniques to completely polymerize the composite matrix for strength and rigidity. However, laminated continuous filament composite structures made using a placement head and with monofilaments or synthetic filaments (fiber-reinforced), or other reinforcing materials such as woven strips or mesh tubes, will not have sufficient interlaminar strength if the interfaces between adjacent layers are not densely fused together to eliminate voids or cold bonds. [Overview of the Initiative] [Means for solving the problem]

[0006]

[0006] The following discussion discloses and describes a continuous filament lamination machine for manufacturing parts by laying down continuous monofilament material or continuous synthetic filament material layer by layer on a tool or substrate. The machine comprises a system, such as a robot, which is capable of moving with at least three degrees of freedom, and the continuous filament material. deposition It includes a placement module connected to the system, configured to allow the material to be placed to the part, and from the placement module deposition The device includes an ultrasonic compression molding device for compression molding a material when it is being compressed. The compression molding device includes an ultrasonic horn having at least one guide hole through which the material passes before being laid and compression molded. The ultrasonic horn is vibrated ultrasonically to melt or flow the material and to cause the material to fuse with a tool or substrate and be compression molded.

[0007]

[0007] Additional features of this disclosure will become apparent from the following description and the attached claims in conjunction with the attached drawings. [Brief explanation of the drawing]

[0008] [Figure 1]

[0008] This is an isometric view showing a 3D printing machine including a robot and an end effector. [Figure 2]

[0009] Figure 1 is a cutaway side view showing a continuous filament placement module including an ultrasonic compression molding device and a laser, which may be used in an end effector for the machine shown. [Figure 3]

[0010] Figure 1 is a cutaway side view showing a continuous filament placement module, including an ultrasonic preheating source and ultrasonic compression molding device used in combination with an active cooling / consolidation element that may be used in the end effector for the machine shown. [Figure 4]

[0011] This is a cutaway side view showing a continuous filament placement module including an ultrasonic compression molding device having a horn with through holes, which may be used in an end effector for the machine shown in Figure 1. [Figure 5]

[0012] Figure 4 is a cutaway side view showing the horn. [Figure 6]

[0013] Figure 4 is a cutaway top view showing the horn. [Figure 7]

[0014] This is a cutaway side view showing a horn for an ultrasonic compression molding device, including two through holes oriented 180° to each other. [Figure 8]

[0015] This is a side view showing an ultrasonic compression molded assembly comprising two staggered rows, each having two ultrasonic compression molding devices, each containing a horn, each having a through-hole. [Figure 9]

[0016] Figure 8 is a top view showing an ultrasonically compressed assembly. [Figure 10]

[0017] This is an isometric view showing an ultrasonic compression molding device containing a pair of spaced-apart flat horns. [Figure 11]

[0018] It is a top view showing an ultrasonic compression molding assembly including two staggered rows each having two ultrasonic compression molding devices with flat horns. [Figure 12]

[0019] It is a side view showing an ultrasonic compression molding device including a single converter, a single booster, and a plurality of horns having independent motions following the surface contour. [Figure 13]

[0020] It is a top view showing the ultrasonic compression molding device shown in FIG. 12. [Figure 14]

[0021] It is a top view showing an ultrasonic compression molding device including two synchronized converters, two boosters, and a plurality of horns. [Figure 15]

[0022] It is a cutaway side view showing a continuous filament placement module including an ultrasonic compression molding device having a plurality of roller horns and a lateral operating mode that can be used for an end effector for the machine shown in FIG. 1 [Figure 16]

[0023] It is a top view showing an ultrasonic compression molding device separated from the module shown in FIG. 15. [Figure 17]

[0024] It is a cutaway side view showing a continuous filament placement module including an ultrasonic compression molding assembly having two staggered rows of ultrasonic compression molding devices having a plurality of roller horns and a lateral operating mode that can be used for an end effector for the machine shown in FIG. 1 [Figure 18]

[0025] It is a top view showing an ultrasonic compression molding device assembly separated from the module shown in FIG. 17. [Figure 19]

[0026] It is a top view showing a ribbon arrangement and an overlapping compression molding footprint of a second set of rollers, of an ultrasonic compression molding device assembly separated from the module shown in FIG. 17. [Figure 20]

[0027] A cut-away side view showing a continuous filament placement module including an ultrasonic compression molding device having a reciprocating disk horn that can be used for an end effector for the machine shown in FIG. 1. [Figure 21]

[0028] A top view showing an ultrasonic compression molding device separated from the module shown in FIG. 20. [Figure 22]

[0029] A front view showing an ultrasonic compression molding device separated from the module shown in FIG. 20. [Figure 23]

[0030] A front view showing an ultrasonic compression molding device including a plurality of reciprocating disk horns. [Figure 24]

[0031] A top view showing the device shown in FIG. 23. [Figure 25]

[0032] A cut-away side view showing a continuous filament placement module including an ultrasonic compression molding device assembly having two staggered rows of ultrasonic compression molding devices with a plurality of circular reciprocating disk horns, having an independent compression molding motion for following a contoured surface, and being usable for an end effector for the machine shown in FIG. 1. [Figure 26]

[0033] A front view showing the ultrasonic compression molding device assembly shown in FIG. 25. [Figure 27]

[0034] A side view showing an ultrasonic compression molding device including a circular reciprocating disk horn having a notch portion that provides space for a subsequent compression molding / cooling roller nearby.

Best Mode for Carrying Out the Invention

[0009]

[0035] Previously deposition To fuse the matrix material to the previously made layer depositionThe following considerations of embodiments of the present disclosure relating to a continuous filament lamination machine including an ultrasonic compression molding device for melting a matrix material when it is being manufactured are essentially illustrative and are not intended to limit the present disclosure or its applications or uses, wherein the compression molding device includes a horn having guide holes for guiding the matrix material.

[0010]

[0036] Figure 1 is an isometric view of a 3D printing machine 10 including a robot 12 having a base portion 14, an extension arm 16 connected to the base portion 14 by a rotary-pivot joint 18, and a working arm 20 connected to the extension arm 16 on the opposite side of the base portion 14 by an elbow pivot joint 22. An end effector 26 is connected at an angle to the working arm 20 on the opposite side of the joint 22 by a pivot joint 28 having a coupling mechanism 30. The robot 12 is intended to represent any appropriate positioning device for the end effector 26. The end effector 26 acts as a print head assembly for laying molten synthetic filaments, monofilaments, etc., for fabricating complex structures as described herein. A variety of end effectors for various applications can be mounted on the robot 12. Note that during operation, the machine 10 may or may not be placed inside an oven (not shown) to control the temperature of the printing process and the ambient temperature around the parts.

[0011]

[0037] The end effector 26 includes an outer housing 34 and a rotatable connector 36 releasably and rotatably connected to a coupling mechanism 30, where the housing 34 is shown transparently to show the various components inside. These components include a plurality of spools 40, here three, on which a plurality of filaments 42 of various materials are wound; a motor 44 for selectively and independently drawing the filaments 42 away from the spools 40; a right-angle gearbox 32 connected to a filament supply assembly 48 by a shaft 56; a rotary assembly 38 having a barrel 46 rotated by an index motor 58, on which the filaments 42 are drawn or melted; an end plate 54 mounted at the end of the barrel 46; and a nozzle assembly 50 extending through the plate 54 and being part of the extruder module. The spool 40 may be mounted on the end effector 26 as shown, or it may be mounted separately, in which case the material is supplied to the end effector 26 through a tube (not shown).

[0012]

[0038] This disclosure proposes various devices and assemblies for ultrasonic compression molding and compaction of laminated monomer parts and fiber-reinforced composite parts, thereby improving filament adhesion, interlayer properties, part tolerances, surface smoothness, and reducing part porosity. By applying ultrasonic compression molding during the layering process in the laminate manufacturing process, interlayer strength and product consistency / quality can be improved, and it can be applied to increased composite materials. More specifically, this disclosure describes a continuous filament laminate manufacturing machine that includes an ultrasonic compression molding and compaction device for melting / flowing filament matrix material and fusing the filament matrix material to a preceding layer or to a tool surface. The ultrasonic compression molding and compaction device may be combined with mechanical energy, laser energy, and / or thermal energy. Ultrasonic compaction may be performed when a part is in the middle of part manufacturing or at the end of part manufacturing. Ultrasonic compaction may be used to preheat a tool for better bonding with new material to be applied, or even new material to be added to the tool. Ultrasonic compaction may be performed on each layer or on a specified number of layers. Ultrasonic consolidation may be limited to specific locations or structural parts. This process can be carried out manually or through an automated and / or robotic integrated manufacturing system.

[0013]

[0039] Figure 2 is a cutaway side view of a continuous filament arrangement module 60, which is an indefinite embodiment of the types of modules that may be provided in relation to the end effector 26, wherein the module 60 includes the necessary components and elements for performing the operations considered herein. The module 60 includes a robot head interface 74 for connecting the module to the robot 12, and a body portion 86. A suitable filament or ribbon 62 (multiple filaments joined together to form a flat rectangular shape), which is a monofilament or synthetic filament composed of a thermoplastic matrix encapsulating fibers, such as a continuous fiber filament, short fiber-filled filament, particle-filled filament, blended monomer filament, or long discontinuous reinforced filament extruded material, is drawn from the spool 88 through the ribbon guide 64 and laid on the part 66 when constructed on the tool 68 in the manner described above, wherein the module 60 is moved from left to right. The ribbon 62 is referred to herein as a ribbon due to its flat cross-sectional shape. However, composite materials of other shapes, such as circular filaments, may also be employed. A diffuse laser 72 positioned at the tip of module 60 directs the laser beam to the back of the ribbon 62 as it exits module 60 and to the underlying layer or tool 68, thereby melting or fluidizing the ribbon 62 and fusing it to form part 66. Cooling rollers 70 assist in maintaining the compression molding and further assist in absorbing heat to solidify the ribbon 62 against part 66.

[0014]

[0040] The ultrasonic compression molding device 76 is positioned on the rear end side of the module 60 in an appropriate manner so as to have a desired small angle with respect to the tool 68. The device 76 includes a converter 78 housing the device electronics and a multiplier or booster 80 that amplifies the ultrasonic signal through a stationary connection point to the ultrasonic horn 84. The horn 84 is ultrasonically vibrated to achieve additional heating, with the aim of contacting the leading side of the ribbon 62 as it exits the module 60 and melting or flowing the ribbon 62, and, optionally referred to as ultrasonic tape lamination (UTL), to further fuse and compression mold the ribbon 62 to the part 66 in order to reduce voids, inclusions, bubbles, etc. Module 60 includes the necessary components for providing the desired pressure of the horn 84 and roller 70 to the ribbon 62, where pneumatic pressure may be employed, or their positions may be controlled by the robot 12 so that they are held in a fixed position in space, relative to the tool surface / part surface and to the material to be melted and compressed to a fixed height.

[0015]

[0041] Module 60 employs a laser to melt or fluidize the ribbon 62 and component 66. However, other modules may employ other heat sources for the same purpose. Figure 3 is a cutaway side view of a continuous filament placement module 90, which is similar to placement module 60, where similar elements are indicated by the same reference numerals. In this embodiment, the laser 72 is replaced by a heat source 92, which is similarly installed on the leading end side of module 90 and preheats component 66 before the fusion of the ribbon 62 and component 66 using an ultrasonic horn 84 to form component 66. The heat source 92 can be any heat source suitable for the purposes described herein, such as an ultrasonic device similar to device 76, an induction heater, or an infrared heater. In addition to this embodiment, the roller 70 is replaced by a skid 94 installed on the rear end side of module 90 so as to contact the ribbon 62 when it is laid. Pressure is applied to the skid 94 to further compress the ribbon 62 against component 66, where the skid 94 is cooled to solidify the ribbon 62 in a compacted state.

[0016]

[0042] A variety of ultrasonic compression molding device designs can be employed to improve packaging with other components of the laminated manufacturing head, as well as to increase the heating efficiency of the ribbon 62 and enhance the compression molding of the ribbon 62. Figure 4 is a cutaway side view of a continuous filament placement module 100, which is similar to placement module 60, where similar elements are indicated by the same reference numerals. In this embodiment, the laser 72 is replaced by an ultrasonic compression molding device 102 which includes a horn 104 installed on the leading end side of module 100, so that the ribbon 62 passes through an opening in the horn 104 and then under the tip of the horn, where the tip of the horn melts or flows the ribbon 62, thereby fusing the ribbon 62 to form part 66. The horn 104 includes a curved guide hole 106 through which the ribbon 62 passes, which serves as a guide for the ribbon 62 to improve packaging of the compression molding source with the laminated manufacturing head. Cooling rollers 108 assist in forming the ribbon 62 against part 66 by maintaining compaction while cooling the ribbon 62 to its solidification temperature. Figure 5 is a cutaway side view of the horn tip spaced apart from the device 102 to better show the curved hole 106, and Figure 6 is a cutaway top view of the horn tip spaced apart from the device 102 to better show the curved hole 106.

[0017]

[0043] This type of horn undergoes wear as the material passes across the surface (where the material is rubbed or compression molded). In another embodiment shown in Figure 7, the horn 104 includes another curved guide hole 98 oriented 180° relative to the hole 106, so that the horn 104 can be rotated or indexed at 180°, where the hole 98 is positioned in the same location where the hole 106 was previously positioned when receiving the ribbon 62. Thus, if the performance of the horn 104 deteriorates due to wear, the horn 104 can be rotated without interrupting the lamination process. Note that for the rotation of the horn 104 to be effective as described, it is necessary for the horn 104 to have symmetry. However, other shapes may be applicable for other applications where rotation of the horn is not required.

[0018]

[0044] Some arrangement module designs allow for the simultaneous laying of multiple ribbons 62. However, in other such embodiments, a particular horn is used by that horn. deposition The ribbon may be wider than the ribbon being molded. Therefore, spaces or gaps may occur between adjacent rows of ribbon 62, which may be undesirable for the integrity of the part or in other respects. Such gaps can be eliminated by offsetting multiple horns in an alternating manner so that one horn is positioned in front of or behind another horn. Figure 8 is a side view of an ultrasonic compression molded assembly 110 including two alternating rows 112 and 114, each having two compression molding devices, each including horns 116 and 118, each having guide holes and offset relative to each other. Figure 9 is a top view of an ultrasonic compression molded assembly 110 including two alternating rows 112 and 114, each having two compression molding devices, each including horns 116 and 118, each having guide holes and offset relative to each other. In particular, horns 116 and 118 are positioned by the preceding horn deposition The gap between the ribbons 62 is filled by the subsequent horn, which then fills the gap between them, and the ribbon 96 depositionThey are positioned relative to each other so that they will be positioned accordingly. Multiple horns and associated material supply paths allow for the independent motion of thin ribbons of material to avoid buckling or distortion as the contour of the formation changes.

[0019]

[0045] The ultrasonic converter / booster / horn assemblies discussed above have a generally circular configuration. The ultrasonic assemblies can also be reconfigured to be flat, which allows them to be densely packed together and to conform more closely to the contour of part 66, where multiple ribbons can be laid simultaneously and where there are no significant gaps between the horns. This embodiment is shown in Figure 10, which shows an ultrasonic compression molding device 120 including a pair of spaced-apart flat horns 122 and 124 connected to the respective boosters 130 and 126 and converters 132 and 128. A second compression molding device with multiple horns may be further installed in the same module as the compression molding device 120 in an alternating configuration similar to that of the compression molding assembly 110 to achieve overlapping ribbons.

[0020]

[0046] Figure 11 shows an ultrasonic compression molding assembly 140 including four ultrasonic compression molding devices 142, 144, 146, and 148, each containing a converter 150, a booster 152, and a horn 156, where the horn 156 is wider than the space between adjacent devices. Devices 142 and 146 are on one compression molding surface, and devices 144 and 148 are on another compression molding surface, resulting in the horns 156 not interfering with each other.

[0021]

[0047] Providing multiple ultrasonic horns arranged side-by-side to simultaneously compress multiple filaments or ribbons presents a challenge: ribbons may be fabricated on uneven surfaces because the horns do not move independently of each other. Figure 12 is a side view of an ultrasonic compression molding device 160 including a single converter 162 and a single booster 164, and Figure 13 is a top view of the ultrasonic compression molding device 160 including a single converter 162 and a single booster 164. Here, three spaced-apart horns 166 are independently pivotable on a mounting rod 168 connected to the booster 164. Furthermore, an arm 170 is connected to the booster 164 at its fixed point, and a separate pneumatic actuation device 174 is mounted on the arm 170 and each horn 166. The arm 170 and the pneumatic actuation device 174 simultaneously deposition When the ribbon is compression molded, the arm 170 does not vibrate, and the pneumatic device 174 applies pressure to the horn 166. Therefore, as the device 160 moves with the module during the fabrication of the part, the horn 166 moves independently up and down along the contour of the part 66 against the biasing force of the pneumatic actuation device 174. It should be noted that in some cases, it may be desirable to fix the position of the individual horns, with the aim of eliminating the pneumatic actuation device 174 and enabling the positioning of the horn 166 in space to be controlled by the robot 12.

[0022]

[0048] As the number of ribbons laid simultaneously increases beyond a certain limit, it may be desirable to employ multiple converters and boosters in a single compression-molded assembly of the type discussed above. This is shown in Figure 14, which shows a top view of an ultrasonic compression-molding device 180, similar to the compression-molding device 160, where similar elements are denoted by the same reference numerals. In this design, the compression-molding device 180 includes six horns 166, each independently pivotably connected to a mounting rod 182, where the mounting rod 182 is connected to two boosters from booster 164 and two converters from converter 162. The two converters 162 are synchronized, resulting in proper motion of the horns 166.

[0023]

[0049] Other configurations of the types of ultrasonic compression molding devices considered herein can offer various advantages, such as compact packaging. Figure 15 is a cutaway side view of a continuous filament arrangement module 190, similar to module 60, where similar elements are indicated by the same reference numerals. In this design, ultrasonic compression molding device 76 is replaced by ultrasonic compression molding device 192, where Figure 16 is a top view of device 192 separated from module 190. In the designs considered above, the ultrasonic horns are vibrated in a direction parallel to the direction in which the ribbon 62 is laid. In the case of module 190, the ultrasonic horns are vibrated in a direction perpendicular to the direction in which the ribbon 62 is laid. In particular, device 192 includes a plurality of spaced-apart circular roller horns 194 rotatably mounted on a common shaft 196. One end of shaft 196 is fixed to one ultrasonic drive unit made up of booster 198 and converter 200, and the other end of shaft 196 is fixed to another ultrasonic drive unit made up of booster 202 and converter 204, where the mounting arm 206 is fixed to boosters 198 and 202. Converters 200 and 204 and boosters 198 and 202 are synchronized, causing shaft 196 to vibrate axially, thereby causing horn 194 to vibrate laterally with respect to the rolling direction of horn 194. Thus, horn 194 achieves additional ribbon compression forming by the applied pressure. Note that the number of roller horns 194 is six in this design. However, this is an example, as any number of roller horns 194 can be used to lay any number of ribbons, and the number of ribbons may be less or more than the number of roller horns 194. Furthermore, note that the number of ultrasonic converter and booster combinations is two in Figure 16. However, depending on the number of ribbons and materials being compression molded, a single converter and booster combination may also be used.

[0024]

[0050] Small gaps are required between the roller horns 194 in order to vibrate and roll the roller horns 194 independently. However, it may be desirable to achieve ultrasonic compression molding of material aligned to these gaps. Figure 17 is a cutaway side view of a continuous fiber arrangement module 210, which is similar to module 60, where similar elements are indicated by the same reference numerals. In this design, the ultrasonic compression molding device 76 is replaced by an ultrasonic compression molding device assembly 212, which includes a forward ultrasonic compression molding device 214 and a rear ultrasonic compression molding device 216, where Figure 18 is a top view of the assembly 212 separated from module 210. A second spool 218, ribbon 220, and ribbon guide 208 are provided for the compression molding device 216. The forward compression molding device 214 includes a set of three roller horns 222, where each horn 222 is rotatable on a separate extension arm 224. The rear compression-molded dabus 216 includes a set of three roller horns 226, where each horn 226 is rotatable on a separate extension arm 228, where the roller horns 226 are wider than the roller horns 222 and wider than the compression-molded ribbon 62, and are positioned to overlap the compression-molded footprint of the roller horns 222, so that there is no small gap at the ribbon interface during non-compression molding. Arms 224 and 228 extend from the roller horns 222 and 226 to function as counterweights and to provide a place where the horns 222 and 226 can be compressed against the ribbon 62 by a pneumatic device 232 connected to the extension arm 234, respectively. Each of the arms 224 is secured by a shaft 244 to a booster 236 and converter 238 at one end and to a booster 240 and converter 242 at the opposite end. Furthermore, a pair of boosters and converters are used to vibrate the roller horn 226 in a similar manner.While two sets of converters and boosters are shown for one set of rollers, it should be noted that in some cases only one set of converters and boosters may be needed for one set of rollers. Furthermore, it should be noted that in some cases it is advantageous to fix the position of the ultrasonic horns in space in order to eliminate the pneumatic device 232 and to allow the robotic control device to control the position of the horns 222 and 226 in space when moving the filament placement and consolidation module. Figure 19 shows ribbon 246 being compressed by roller horn 222 and ribbon 248 being compressed by roller horn 226, where the roller horn 226 further compresses the edges of ribbon 246.

[0025]

[0051] Figure 20 is a cutaway side view of a continuous filament arrangement module 260, similar to module 60, where similar elements are indicated by the same reference numerals. In this design, the ultrasonic compression molding device 76 is replaced by an ultrasonic compression molding device 262, where Figure 21 is a top view of the device 262 separated from module 260, and Figure 22 is a front view of the device 262 separated from module 260. The device 262 includes a circular reciprocating horn 264 that is rigidly mounted to a frame 268 in a central position and has a top tab 266. The device 262 further includes an ultrasonic driver 272 connected to a rod 274 through a booster 270, the rod 274 is further connected to the tab 266, where the driver 272 vibrates the horn surface back and forth, where it contacts the ribbon 62, in the direction in which the ribbon 62 is laid. A pair of pneumatic devices 276 and 278 are connected to the frame 268 and apply downward pressure to the horn 264. Note that in some cases, the pneumatic devices 276 and 278 may be eliminated, and the position of the roller horn in space is fixed by a robotic device operating the compression molding end effector.

[0026]

[0052] Figure 23 is a front view of an ultrasonic compression molding device 280, similar to a compression molding device 262, and Figure 24 is a top view of an ultrasonic compression molding device 280, similar to a compression molding device 262, except that a single horn 264 is replaced by multiple spaced circular reciprocating horns 282, each having a top tab 284, where similar elements are indicated by the same reference numerals. The horns 282 are rotatably fixed to a shaft 296 mounted on a frame 298. A connecting rod 286 is connected to all tabs 284 via tabs on the connecting rod 286 and pins 326 extending through the tabs on the connecting rod 286, and a pair of ultrasonic drivers 288 and 290 are connected to the connecting rod 286 via boosters 316 and 318 by rods 292 and 294, respectively. Although the device 280 is shown to have two sets of ultrasonic drivers, it should be noted that it may be driven using one or more sets of ultrasonic drivers if necessary.

[0027]

[0053] Figure 25 is a cutaway side view of a continuous filament arrangement module 300, similar to module 210, where similar elements are indicated by the same reference numerals. In this design, the ultrasonic compression molding assembly 212 is replaced by an ultrasonic compression molding device assembly 302, which includes a forward ultrasonic compression molding device 304 and a rear ultrasonic compression molding device 306. Instead of employing roller horns, devices 304 and 306 employ circular reciprocating horns 308 and 312, respectively, which are vibrated by separate ultrasonic drive units 310 and 314, thereby providing motion to the contact points with the ribbons 62 and 220 in the direction of laying the ribbons 62 and 220. Figure 26 is a front view of the assembly 302 spaced apart from module 210, similar to Figure 18, showing the staggered overlap between horns 308 and 312.

[0028]

[0054] The various embodiments of the reciprocating ultrasonic horns discussed above are circular. However, since ultrasonic heating is induced only by the contact point between the horn and the ribbon 62, they do not necessarily have to be circular. Figure 27 is a side view of an ultrasonic compression molding device 320, which is similar to the ultrasonic compression molding device 304, where similar elements are indicated by the same reference numerals. In this design, a circular notch 322 is formed on the rear side of the horn 308, and a roller 324 is positioned in the notch 322, where the roller 324 operates in the same manner as the roller 86 discussed above.

[0029]

[0055] The above discussion is merely to disclose and illustrate exemplary embodiments of the present disclosure. Those skilled in the art will readily recognize from these discussions, the accompanying drawings, and the claims that a variety of modifications, alterations, and variations can be made in the present invention without departing from the spirit and scope of the present disclosure as defined in the following claims.

Claims

1. A continuous filament lamination machine for manufacturing parts by laying continuous monofilament material or continuous synthetic filament material layer by layer on a substrate or tool, A system capable of operating with at least three degrees of freedom, A placement module connected to the system, configured to deposit the continuous filament material, Equipped with, The aforementioned arrangement module is A guide for guiding the material to the part, At least one ultrasonic compression molding device for compression molding the material as it is deposited from the arrangement module, Includes, The at least one compression molding device includes at least one ultrasonic horn having at least one guide hole through which the material passes before being laid and compression molded, The at least one ultrasonic horn is vibrated ultrasonically to melt or fluidize the material and to cause the material to fuse and compression-molde with the tool or the substrate. The aforementioned at least one guide hole is two guide holes, The two guide holes are configured symmetrically with respect to each other so that the horn can be inverted and deposited, allowing the material to pass through either guide hole. Continuous filament lamination manufacturing machine.

2. The at least one horn has symmetry, The machine according to claim 1.

3. The at least one ultrasonic horn is a plurality of ultrasonic horns, Each of the aforementioned ultrasonic horns has a guide hole, and continuous filament material is deposited separately and compressed into it. The machine according to claim 1.

4. The plurality of ultrasonic horns are configured to form two separate rows of horns, The horns are offset from each other, and the horns in one row deposit the material between the horns in another row. The machine according to claim 3.

5. The horns are spaced apart from each other so as to create an overlapping portion of the compression molding footprint of the material filament when it is deposited by the horns. The machine according to claim 4.

6. The aforementioned material is a ribbon of continuous filaments that are pre-bonded together. The machine according to claim 1.

7. The arrangement module further includes cooling rollers that help maintain the compression molding and compaction of the material as it is being deposited. The machine according to claim 1.

8. The arrangement module further includes a cooling skid that helps maintain the compression molding and compaction of the material as it is deposited. The machine according to claim 1.

9. The arrangement module further includes a pressure device for pressing the at least one compression molding device against the material as it is being deposited. The machine according to claim 1.

10. The pressure device is a pneumatic pressure device. The machine according to claim 9.

11. The material is a monofilament, a short fiber-filled filament, a particle-filled filament, a blended monomer filament, or a long discontinuous reinforced filament. The machine according to claim 1.

12. The aforementioned system is a robot. The machine according to claim 1.

13. An ultrasonic compression molding device for heating a material as it is deposited on a tool or substrate, The compression molding device comprises at least one ultrasonic horn having at least one guide hole through which the material passes before being deposited and compression molded, The at least one ultrasonic horn is vibrated ultrasonically to melt or fluidize the material and to cause the material to fuse and compression-molde with respect to the substrate or the tool. The aforementioned at least one guide hole is two guide holes, The two guide holes are configured symmetrically with respect to each other so that the material can pass through either guide hole in order for the horn to be inverted and deposited. Ultrasonic compression molding device.

14. The at least one horn has symmetry, The device according to claim 13.

15. The at least one ultrasonic horn is a plurality of ultrasonic horns, Each of the plurality of ultrasonic horns has a guide hole, and separates continuous filament material is deposited. The device according to claim 13.

16. The plurality of ultrasonic horns are configured to form two separate rows of horns, The horns are offset from each other, and the horns in one row deposit the material between the horns in another row. The device according to claim 15.

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