System and process for producing a composite article

Abstract

According to one or more embodiments, a system includes a cutter for cutting a composite material to form composite pieces, an ultrasonic welding device for connecting two or more of the composite pieces to form a composite stack, and a compression molding device for forming a composite article from the composite stack. The system may further include a transfer arm for delivering the composite pieces to the ultrasonic welding device. The system may further include a forming device to generate a composite preform which is then delivered to the compression molding device. Excess material may be trimmed off before, during or after the forming step to deliver a net-shape for the subsequent molding step.

What is claimed is: 
     
         1 . A system comprising:
 a cutter for cutting a composite material to form composite pieces;   an ultrasonic welding device for connecting two or more of the composite pieces to form a composite stack; and   a compression molding device for forming a composite article from the composite stack.   
     
     
         2 . The system of  claim 1 , further comprising a transfer arm for delivering the composite pieces to the ultrasonic welding device. 
     
     
         3 . The system of  claim 2 , wherein the transfer arm has a receiving end with a number of vacuum cups. 
     
     
         4 . The system of  claim 1 , wherein the ultrasonic welding device includes a platform to receive the two or more of the composite pieces. 
     
     
         5 . The system of  claim 4 , wherein the platform includes a receiving surface with a number of vacuum cups. 
     
     
         6 . The system of  claim 4 , wherein the platform includes one or more stabilizing arms to stabilize one or more the composite pieces as present on the platform. 
     
     
         7 . The system of  claim 1 , further includes one or more stops to separate the composite material from a carrier film prior to entry of composite material to the cutter. 
     
     
         8 . The system of  claim 1 , further comprising a forming device to generate a composite preform which is then delivered to the compression molding device. 
     
     
         9 . The system of  claim 8 , further comprising a trimmer to trim excess materials from the composite preform to generate a trimmed composite preform which is then delivered to the compression molding device. 
     
     
         10 . A system comprising:
 a cutter for cutting a composite material to form composite pieces;   a transfer arm for delivering the composite pieces to the ultrasonic welding device   an ultrasonic welding device for connecting two or more of the composite pieces to form a composite stack, the ultrasonic welding device including a platform to receive the two or more of the composite pieces; and   a compression molding device for forming a composite article from the composite stack.   
     
     
         11 . The system of  claim 10 , wherein the detachable platform includes one or more stabilizing arms to stabilize one or more the composite pieces as present on the platform. 
     
     
         12 . The system of  claim 10 , further includes one or more stops to separate the composite material from a carrier film prior to entry of composite material to the cutter. 
     
     
         13 . The system of  claim 10 , further comprising a forming device to generate a composite preform which is then delivered to the compression molding device. 
     
     
         14 . The system of  claim 10 , further comprising a trimmer to trim excess materials from the composite preform to generate a trimmed composite preform which is then delivered to the compression molding device. 
     
     
         15 . A method of producing a composite article, comprising:
 subjecting a composite material to a cutter to form composite pieces;   subjecting two or more the composite pieces to an ultrasonic welding device for connecting two or more of the composite pieces to form a composite stack; and   subjecting the composite stack to a compression molding device to form a composite article from the composite stack.   
     
     
         16 . The method of  claim 15 , further comprising delivering the composite pieces to the ultrasonic welding device via a transfer arm. 
     
     
         17 . The method of  claim 15 , further comprising stabilizing one or more of the composite pieces prior to activating welding operation by the ultrasonic welding device. 
     
     
         18 . The method of  claim 15 , further comprising separating the composite material from a carrier film prior to entry of composite material to the cutter. 
     
     
         19 . The method of  claim 15 , further comprising generating a composite preform from the composite stack via a forming device. 
     
     
         20 . The method of  claim 19 , further comprising trimming excess materials from the composite preform via a trimmer to generate a trimmed composite preform which is then delivered to the compression molding device.