Ultrasonic compaction of continuous filament materials for laminated fabrication

Abstract

A continuous filament deposition model manufacturing machine (10) for fabricating a part by laying down a continuous monofilament or continuous synthetic filament material layer by layer on a tool or substrate. The machine includes a system, such as a robot (12), operable to move in at least three degrees of freedom, and a placement module (60) coupled to the system configured to deposit the continuous filament material. The placement module includes a guide (64) for guiding the material to the part, a heat source (72) for preheating the material as it is deposited from the placement module, and an ultrasonic compression molding device (76) for compression molding the material as it is deposited from the placement module. The compression molding device includes an ultrasonic horn (84) that is ultrasonically vibrated to melt or flow the material and to cause it 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 a continuous filament additive manufacturing machine including a heat source with an ultrasonic compaction device that aids in melting and consolidating a continuous filament material when deposited and in controlling the height of the deposited layer, for the purpose of assisting in fusing the continuous filament material to a previously deposited layer and controlling the height of the deposited layer.

Background Art

[0002]

[0002] Fused filament fabrication (FFF) is an additive manufacturing (AM) process for 3D printing. Typically, a raw material such as a continuous filament from a spool or pellets from a hopper is provided to a heated nozzle, the raw material is heated and extruded from the nozzle as a filament in a molten state, and deposited as adjacent rows of strips to form a layer, where the molten filament (either fiber-reinforced or non-fiber-reinforced) begins to harden immediately upon extrusion from the nozzle. In this approach, multiple layers are constructed to a particular configuration, thereby creating a desired part. Alternatively, the filament can be heated outside the nozzle by a laser or the like and wrapped onto 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 down the additive material in the xy plane. However, the gantry-type machine method presents 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 continuous material layers layer by layer on a tool or substrate. The machine includes a system, such as a robot, which is operable to move in six degrees of freedom, and a placement module connected to the system, configured to deposit continuous filament material. The placement module includes a guide for guiding the material to the part, an optional heat source for preheating the material as it is deposited from the placement module, and an ultrasonic compression molding device for compression molding the material as it is deposited from the placement module. The compression molding device includes an ultrasonic horn that is vibrated ultrasonically to melt and flow the material and to cause the material to fuse and compression mold to the part while maintaining a pre-programmed position of the upper surface of the deposited material.

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

[0019] 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] A top view showing the ultrasonic compression molding device shown in FIG. 12. [Figure 14]

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

[0022] 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 actuation mode that can be used in an end effector for the machine shown in FIG. 1. [Figure 16]

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

[0024] 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, each having a plurality of roller horns and a lateral actuation mode that can be used in an end effector for the machine shown in FIG. 1. [Figure 18]

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

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

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

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

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

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

[0031] It is a top view showing the device shown in FIG. 23. [Figure 25]

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

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

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

Embodiments for Carrying Out the Invention

[0009]

[0035] The following discussion of embodiments of the present disclosure directed to a continuous filament deposition manufacturing machine including a heat source for melting a matrix material when deposited and an ultrasonic compression molding device for fusing the matrix material to a previously deposited layer is illustrative in nature and is not intended to limit the present disclosure or its use or application.

[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 (in this case, three) spools 40 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, through 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 may be wider than the ribbon deposited by that horn. This results in spaces or gaps between adjacent rows of ribbons 62, which may be undesirable for part integrity or otherwise. Such gaps can be eliminated by offsetting multiple horns in an alternating manner, such that one horn is positioned in front of or behind another. 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 relative to each other such that ribbon 96 is deposited by the subsequent horn filling the gap between ribbons 62 deposited by the preceding horn. The multiple horns and associated material supply paths allow for independent motion of the thin ribbons of material to avoid buckling or distortion when 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 pivotably mounted on a mounting rod 168 connected to the booster 164. An arm 170 is further connected to the booster 164 at its fixed point, and a separate pneumatic actuation device 174 is mounted on the arm 170 and each of the horns 166. When the arm 170 and the pneumatic device 174 simultaneously compress the deposited ribbon, the arm 170 does not vibrate, and the pneumatic device 174 applies pressure to the horns 166. Therefore, as the device 160 moves with the module during the fabrication of the part, the horn 166 will move independently up and down along the contour of the part 66 against the biasing force of the pneumatically actuated device 174. Note that in some cases, it may be desirable to fix the position of the individual horns, for the purpose of eliminating the pneumatically actuated device 174 and to allow 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. The various forms of this disclosure are as follows: (Form 1) A continuous filament lamination manufacturing machine for producing parts by laying continuous filament material, which is a continuous monofilament material or a continuous synthetic filament material, layer by layer on a tool or substrate, wherein the continuous filament lamination manufacturing machine is A system capable of operating with at least 3 degrees of freedom, A placement module connected to the system, configured to deposit the continuous filament material, wherein the placement module includes a guide for guiding the continuous filament material to the component, a heat source for preheating the continuous filament material as it is deposited from the placement module, and at least one compression molding device for compression molding the continuous filament material as it is deposited from the placement module, wherein the at least one compression molding device includes at least one ultrasonic horn that is vibrated ultrasonically to melt or flow the continuous filament material and to cause the continuous filament material to fuse with the tool or the substrate and be compression molded, A continuous filament lamination manufacturing machine equipped with the following features. (Form 2) The continuous filament lamination manufacturing machine according to Embodiment 1, wherein the heat source for preheating is a laser. (Form 3) The continuous filament lamination machine according to Embodiment 1, wherein the heat source for preheating is an ultrasonic device. (Form 4) The continuous filament lamination machine according to Embodiment 1, wherein the heat source for preheating is an induction heater. (Form 5) The continuous filament lamination manufacturing machine according to Embodiment 1, wherein the heat source for preheating is an infrared heater. (Form 6) The continuous filament lamination manufacturing machine according to Embodiment 1, wherein the continuous filament material is a continuous ribbon made of a plurality of continuous filaments that have been fused together in advance. (Form 7) The continuous filament lamination machine according to Embodiment 1, wherein the arrangement module further includes cooling rollers that assist in compression molding and cooling the continuous filament material as it is being deposited. (Form 8) The continuous filament lamination machine according to Embodiment 1, wherein the arrangement module further includes a cooling skid that assists in compression molding and cooling the continuous filament material as it is being deposited. (Form 9) The continuous filament lamination machine according to Embodiment 1, wherein the arrangement module further includes a pressure device for pressing the at least one compression molding device against the continuous filament material as it is being deposited. (Form 10) The continuous filament lamination manufacturing machine according to Embodiment 9, wherein the pressure device is a pneumatic pressure device. (Form 11) A continuous filament lamination machine according to Embodiment 1, wherein the arrangement module is positioned in space according to a program by the system to achieve compression molding. (Form 12) The continuous filament lamination machine according to Embodiment 1, wherein the continuous synthetic filament material is a short fiber reinforced filament, a particle-filled filament, a blended monomer filament, a continuous fiber filament, or a long discontinuous reinforced filament. (Form 13) The continuous filament lamination manufacturing machine according to Embodiment 1, wherein the continuous synthetic filament material is made from only one material. (Form 14) A continuous filament lamination machine according to Embodiment 1, wherein at least one ultrasonic horn is initially a cylindrical horn, and its tip or end is shaped for a particular application. (Form 15) A continuous filament lamination machine according to Embodiment 1, wherein at least one ultrasonic horn is initially a flat horn and its tip or end is shaped for a particular application. (Form 16) The continuous filament lamination machine according to Embodiment 1, wherein the at least one ultrasonic horn is a plurality of spaced-apart ultrasonic horns. (Form 17) A continuous filament lamination machine according to Embodiment 16, wherein the plurality of ultrasonic horns are configured to form two separate rows of horns, the two rows of horns being offset from each other, so that the horns in one row compress every other filament or ribbon of filament, and the horns in the other row compress the remaining filament or ribbon of filament. (Form 18) A continuous filament lamination machine according to Embodiment 17, wherein the two horns are spaced apart from each other and sized to create an overlapping portion of the compression-molded footprint of the continuous filament material when deposited by the arrangement module. (Form 19) The continuous filament lamination machine according to Embodiment 1, wherein the at least one compression molding device is a plurality of compression molding devices each comprising a plurality of ultrasonic horns, and the plurality of ultrasonic horns in one compression molding device are staggered with the plurality of ultrasonic horns in another compression molding device. (Form 20) A continuous filament lamination machine according to Embodiment 19, wherein two of the ultrasonic horns are spaced apart from each other and sized to create an overlapping portion of the compression-molded footprint of the continuous filament material when deposited by the arrangement module. (Form 21) The continuous filament lamination manufacturing machine according to Embodiment 1, wherein the system is a robot. (Form 22) The continuous filament lamination machine according to Embodiment 1, wherein the heat source for preheating is installed on the leading end side of the arrangement module, and the compression molding device is installed on the rear end side of the arrangement module. (Form 23) A continuous filament lamination manufacturing machine for producing parts by laying continuous filament material, which is a continuous monofilament material or a continuous synthetic filament material, layer by layer on a tool or substrate, wherein the continuous filament lamination manufacturing machine is A robot capable of moving with at least 3 degrees of freedom, A placement module connected to the robot, configured to deposit the continuous filament material, wherein the placement module includes a guide for guiding the continuous filament material to the component, a laser connected to the front end of the module for preheating the next continuous filament material to be deposited from the substrate and the placement module, a compression molding device connected to the rear end of the module for compression molding the continuous filament material as it is deposited from the placement module, and a subsequent device for maintaining the compaction of the continuous filament material as it solidifies, wherein the compression molding device includes an ultrasonic horn that is vibrated ultrasonically to melt or flow the continuous filament material and to cause the continuous filament material to fuse with the tool or the substrate and be compression molded, A continuous filament lamination manufacturing machine equipped with the following features.

Claims

1. A continuous filament lamination manufacturing machine for producing parts by laying continuous filament material, which is a continuous monofilament material or a continuous synthetic filament material, layer by layer on a tool or substrate, wherein the continuous filament lamination manufacturing machine is 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, wherein the placement module includes a guide for guiding the continuous filament material to the component, a heat source for preheating the continuous filament material when deposited from the placement module, and at least one compression molding device for compression molding the continuous filament material when deposited from the placement module, wherein the at least one compression molding device includes at least one ultrasonic horn that is vibrated ultrasonically to melt or flow the continuous filament material and to cause the continuous filament material to fuse with the tool or the substrate and be compression molded, Equipped with, The arrangement module further includes cooling rollers or cooling skids to assist in compressing and cooling the continuous filament material as it is being deposited. Continuous filament lamination manufacturing machine.

2. The continuous filament lamination machine according to claim 1, wherein the heat source for preheating is a laser.

3. The continuous filament lamination machine according to claim 1, wherein the heat source for preheating is an ultrasonic device.

4. The continuous filament lamination machine according to claim 1, wherein the heat source for preheating is an induction heater.

5. The continuous filament lamination manufacturing machine according to claim 1, wherein the heat source for preheating is an infrared heater.

6. The continuous filament lamination manufacturing machine according to claim 1, wherein the continuous filament material is a continuous ribbon made of a plurality of continuous filaments that have been fused together in advance.

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

8. The continuous filament lamination machine according to claim 7, wherein the pressure device is a pneumatic pressure device.

9. The continuous filament lamination machine according to claim 1, wherein the arrangement module is positioned in space according to a program by the system to achieve compression molding.

10. The continuous filament lamination machine according to claim 1, wherein the continuous synthetic filament material is a short fiber reinforced filament, a particle-filled filament, a blended monomer filament, a continuous fiber filament, or a long discontinuous reinforced filament.

11. The continuous filament lamination manufacturing machine according to claim 1, wherein the continuous synthetic filament material is made from only one material.

12. A continuous filament lamination machine for manufacturing a component by laying a continuous filament material, which is a continuous monofilament material or a continuous synthetic filament material, layer by layer on a tool or substrate, wherein the continuous filament lamination machine is 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, wherein the placement module includes a guide for guiding the continuous filament material to the component, a heat source for preheating the continuous filament material when deposited from the placement module, and at least one compression molding device for compression molding the continuous filament material when deposited from the placement module, wherein the at least one compression molding device includes at least one ultrasonic horn that is vibrated ultrasonically to melt or flow the continuous filament material and to cause the continuous filament material to fuse with the tool or the substrate and be compression molded, Equipped with, The at least one ultrasonic horn is a cylindrical horn, and the tip or end of the cylindrical horn is formed into a shape suitable for compression molding. Continuous filament lamination manufacturing machine.

13. The continuous filament lamination machine according to claim 1, wherein at least one ultrasonic horn is a flat horn, and the tip or end of the flat horn is formed into a shape suitable for compression molding.

14. The continuous filament lamination machine according to claim 1, wherein the at least one ultrasonic horn is a plurality of spaced-apart ultrasonic horns.

15. A continuous filament lamination machine for manufacturing a component by laying a continuous filament material, which is a continuous monofilament material or a continuous synthetic filament material, layer by layer on a tool or substrate, wherein the continuous filament lamination machine is 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, wherein the placement module includes a guide for guiding the continuous filament material to the component, a heat source for preheating the continuous filament material when deposited from the placement module, and at least one compression molding device for compression molding the continuous filament material when deposited from the placement module, wherein the at least one compression molding device includes at least one ultrasonic horn that is vibrated ultrasonically to melt or flow the continuous filament material and to cause the continuous filament material to fuse with the tool or the substrate and be compression molded, Equipped with, The at least one ultrasonic horn is a plurality of spaced-apart ultrasonic horns, The plurality of ultrasonic horns are configured to form two separate rows of horns, and the horns in the two rows are offset from each other such that the horns in one row compress every other filament or ribbon of filaments, and the horns in the other row compress the remaining filaments or ribbon of filaments. Continuous filament lamination manufacturing machine.

16. The continuous filament lamination machine according to claim 15, wherein the two horns are spaced apart from each other and sized to create an overlapping portion of the compression-molded footprint of the continuous filament material when deposited by the arrangement module.

17. A continuous filament lamination machine for manufacturing a component by laying a continuous filament material, which is a continuous monofilament material or a continuous synthetic filament material, layer by layer on a tool or substrate, wherein the continuous filament lamination machine is 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, wherein the placement module includes a guide for guiding the continuous filament material to the component, a heat source for preheating the continuous filament material when deposited from the placement module, and at least one compression molding device for compression molding the continuous filament material when deposited from the placement module, wherein the at least one compression molding device includes at least one ultrasonic horn that is vibrated ultrasonically to melt or flow the continuous filament material and to cause the continuous filament material to fuse with the tool or the substrate and be compression molded, Equipped with, The at least one compression molding device is a plurality of compression molding devices, each containing a plurality of ultrasonic horns, wherein the plurality of ultrasonic horns in one compression molding device are staggered with the plurality of ultrasonic horns in another compression molding device. Continuous filament lamination manufacturing machine.

18. The continuous filament lamination machine according to claim 17, wherein the two ultrasonic horns are spaced apart from each other and sized to create an overlapping portion of the compression-molded footprint of the continuous filament material when deposited by the arrangement module.

19. The continuous filament lamination manufacturing machine according to claim 1, wherein the system is a robot.

20. The continuous filament lamination machine according to claim 1, wherein the heat source for preheating is installed on the leading end side of the arrangement module, and the compression molding device is installed on the rear end side of the arrangement module.

21. A continuous filament lamination manufacturing machine for producing parts by laying continuous filament material, which is a continuous monofilament material or a continuous synthetic filament material, layer by layer on a tool or substrate, wherein the continuous filament lamination manufacturing machine is A robot capable of moving with at least three degrees of freedom, A placement module connected to the robot, configured to deposit the continuous filament material, wherein the placement module includes a guide for guiding the continuous filament material to the component, a laser connected to the front end of the placement module for preheating the next continuous filament material to be deposited from the substrate and the placement module, a compression molding device connected to the rear end of the placement module for compression molding the continuous filament material as it is deposited from the placement module, and a subsequent device for maintaining the compaction of the continuous filament material as it solidifies, wherein the compression molding device includes an ultrasonic horn that is vibrated ultrasonically to melt or flow the continuous filament material and to cause the continuous filament material to fuse with the tool or the substrate and be compression molded, Equipped with, The arrangement module further includes cooling rollers or cooling skids to assist in compressing and cooling the continuous filament material as it is being deposited. Continuous filament lamination manufacturing machine.

Images