Compliant consolidation block for continuous welding of polymer matrix composites
A compliant consolidation block is provided. The compliant consolidation block includes a non-articulating component, a first articulating self-aligning component coupled to the non-articulating component, and two second articulating self-aligning components coupled to the first articulating self-aligning component. The first articulating self-aligning component is configured to articulate with respect to the non-articulating component. Each of the two second articulating self-aligning components are individually configured to articulate with respect to the first articulating self-aligning component.
1 . A compliant consolidation block comprising:
a non-articulating component;
a first articulating self-aligning component coupled to the non-articulating component, wherein the first articulating self-aligning component is configured to articulate with respect to the non-articulating component and wherein the first articulating self-aligning component is coupled to the non-articulating component via a pin that is configured to slide within the confines of voids in the non-articulating component; and
two second articulating self-aligning components coupled to the first articulating self-aligning component, wherein each of the two second articulating self-aligning components are individually configured to articulate with respect to the first articulating self-aligning component.
2 . The compliant consolidation block of claim 1 , wherein a first force applied by the non-articulating component is divided by the first articulating self-aligning component such that a second force is applied to each of the second articulating self-aligning components, the second force being half of the first force.
3 . The compliant consolidation block of claim 2 , wherein each of the second articulating self-aligning components apply the second force as a consolidation pressure distribution in order to consolidate a first polymer composite component and a second polymer composite component into one component.
4 . The compliant consolidation block of claim 2 , further comprising:
two third articulating self-aligning components coupled to each of the two second articulating self-aligning components, wherein each of the third articulating self-aligning components are individually configured to articulate with respect to a respective second articulating self-aligning component.
5 . The compliant consolidation block of claim 4 , wherein the second force applied by the first articulating self-aligning component is divided by each of the second articulating self-aligning components such that a third force is applied to each of the third articulating self-aligning components, the third force being half of the second force or a quarter of the first force.
6 . The compliant consolidation block of claim 1 , wherein the non-articulating component includes a recess, wherein the first articulating self-aligning component comprises a protruding portion, and wherein the protruding portion of the first articulating self-aligning component is received within the recess of the non-articulating component.
7 . The compliant consolidation block of claim 6 , wherein the pin protrudes through a first of the voids, through the protruding portion of the first articulating self-aligning component, and through a second of the voids.
8 . The compliant consolidation block of claim 1 , wherein each of the second articulating self-aligning components are individually coupled to the first articulating self-aligning component via a pin that is configured to slide within the confines of voids in the first articulating self-aligning component.
9 . The compliant consolidation block of claim 8 , wherein the first articulating self-aligning component includes a recess for each of the second articulating self-aligning components, wherein each of the second articulating self-aligning components comprise a protruding portion, wherein the protruding portion of each of the second articulating self-aligning components is received within a respective recess of the first articulating self-aligning component.
10 . An ultrasonic welder, the ultrasonic welder comprising:
a roller;
a sonotrode; and
a compliant consolidation block, the compliant consolidation block comprising:
a non-articulating component;
a first articulating self-aligning component coupled to the non-articulating component, wherein the first articulating self-aligning component is configured to articulate with respect to the non-articulating component and wherein the first articulating self-aligning component is coupled to the non-articulating component via a pin that is configured to slide within the confines of voids in the non-articulating component; and
two second articulating self-aligning components coupled to the first articulating self-aligning component, wherein each of the two second articulating self-aligning components are individually configured to articulate with respect to the first articulating self-aligning component.
11 . The ultrasonic welder of claim 10 , wherein a first force applied by the non-articulating component is divided by the first articulating self-aligning component such that a second force is applied to each of the second articulating self-aligning components, the second force being half of the first force.
12 . The ultrasonic welder of claim 11 , wherein each of the second articulating self-aligning components apply the second force as a consolidation pressure distribution in order to consolidate a first polymer composite component and a second polymer composite component into one component.
13 . The ultrasonic welder of claim 11 , wherein the compliant consolidation block further comprises:
two third articulating self-aligning components coupled to each of the two second articulating self-aligning components, wherein each of the third articulating self-aligning components are individually configured to articulate with respect to a respective second articulating self-aligning component.
14 . The ultrasonic welder of claim 13 , wherein the second first force applied by the first articulating self-aligning component is divided by each of the second articulating self-aligning components such that a third force is applied to each of the third articulating self-aligning components, the third force being half of the second force or a quarter of the first force.
15 . The ultrasonic welder of claim 10 , wherein the non-articulating component includes a recess, wherein the first articulating self-aligning component comprises a protruding portion, and wherein the protruding portion of the first articulating self-aligning component is received within the recess of the non-articulating component.
16 . The ultrasonic welder of claim 15 , wherein the pin protrudes through a first of the voids, through the protruding portion of the first articulating self-aligning component, and through a second of the voids.
17 . The ultrasonic welder of claim 10 , wherein each of the second articulating self-aligning components are individually coupled to the first articulating self-aligning component via a pin that is configured to slide within the confines of voids in the first articulating self-aligning component.
18 . The ultrasonic welder of claim 17 , wherein the first articulating self-aligning component includes a recess for each of the second articulating self-aligning components, wherein each of the second articulating self-aligning components comprise a protruding portion, wherein the protruding portion of each of the second articulating self-aligning components is received within a respective recess of the first articulating self-aligning component.