Abstract: The present invention is directed to a pneumatically actuated redirection surface guide tool for use in tape laying systems. In the laying of unidirectional, pre-impregnated carbon fiber tapes, for instance, a tape can be directed between a tape supply reel and a tape laying head through use of one or more of the disclosed guide tools. The surface of the guide tool includes small holes that allow for positive and negative air pressure to be applied to the surface to increase or decrease the friction between the tape that is passing over and being redirected by the surface.

Abstract: An automated tape head assembly for a multiple axis tape laying machine includes a tape supply reel and a tape compaction roller, and a chute. Tape passes from the supply reel, through the chute, to the tape compaction roller. The tape path and at least a portion of the chute are maintained substantially at a zero Gaussian curvature. The tape path and chute are curved to define a compliance loop that results from a substantially or partially unrestrained curved path between the supply reel and the compaction roller. This structure allows the compaction roller to shift laterally and vertically with respect to the supply reel while the supply reel is in a fixed position with respect to the tape head assembly generally. This structure also allows the compaction roller to roll, steer, and follow the fiber tape's natural path, all with significant independence from the supply reel.

Abstract: An automated tape head assembly for a multiple axis tape laying machine includes a tape supply reel and a tape compaction roller, and a chute. Tape passes from the supply reel, through the chute, to the tape compaction roller. The tape path and at least a portion of the chute are maintained substantially at a zero Gaussian curvature. The tape path and chute are curved to define a compliance loop that results from a substantially or partially unrestrained curved path between the supply reel and the compaction roller. This structure allows the compaction roller to shift laterally and vertically with respect to the supply reel while the supply reel is in a fixed position with respect to the tape head assembly generally. This structure also allows the compaction roller to roll, steer, and follow the fiber tape's natural path, all with significant independence from the supply reel.

Abstract: A rotating roller imparts complex curvature onto a web of material. The roller includes a flexible outer surface and a plurality of control rings inside the rotating roller. The control rings are mounted coaxial to a central shaft and are disposed side by side along an axial length of the shaft. The outside of each ring supports a substantially circular slice of the flexible outer surface of the rotating roller. Each control ring defines a diameter that may be changed independent from the diameter of the other control rings.

Abstract: An automated tape head assembly for a multiple axis tape laying machine includes a tape supply reel and a tape compaction roller. Tape from the supply reel passes through the space between the two independent structures of the supply reel and compaction roller defining a tape path that substantially maintains a zero Gaussian curvature of the tape. The tape path is a curved path referred to as a compliance loop that results from a substantially or partially unrestrained curved path between the supply reel and the compaction roller. This structure allows the compaction roller to shift laterally and vertically with respect to the supply reel while the supply reel is in a fixed position with respect to the tape head assembly generally. This structure also allows the compaction roller to roll, steer, and follow the fiber tape's natural path, all with significant independence from the supply reel.

Abstract: A method and apparatus provide for continuous automatic cutting of a web of material wherein the web has a web anomaly that prevents the web from lying flat and straight. The web anomalies include when a web has a non-zero Gaussian curvature and/or when the web or roll of material follows an arc when the roll is unrolled onto a flat surface. These web anomalies may be justified through use of computer controlled cutters that correct the motion trajectory of the cutter relative to the web and also by means of distortions to the support surface upon which the cutting of the web is to occur.

Abstract: An automated tape head assembly for a multiple axis tape laying machine includes a tape supply reel and a tape compaction roller. Tape from the supply reel passes through the space between the two independent structures of the supply reel and compaction roller defining a tape path that substantially maintains a zero Gaussian curvature of the tape. The tape path is a curved path referred to as a compliance loop that results from a substantially or partially unrestrained curved path between the supply reel and the compaction roller. This structure allows the compaction roller to shift laterally and vertically with respect to the supply reel while the supply reel is in a fixed position with respect to the tape head assembly generally. This structure also allows the compaction roller to roll, steer, and follow the fiber tape's natural path, all with significant independence from the supply reel.

Abstract: A method of cutting pattern pieces from a continuous roll of material comprising the steps of unrolling said material unto a rotating cylindrical cutting surface, and then cutting said material while said material is in rolling contact on said cylindrical surface during rotation of said cylindrical surface. Furthermore this invention describes a method and apparatus for producing vinyl pool covers.

Abstract: A method of forming an extruded membrane of solidified flowable material having a desired curvature comprising extruding flowable material through a die in a curved section; measuring a characteristic of said extruded material at a plurality of positions along said die slot; comparing said plurality of measurements against a desired plurality of measurements respectively at each said position along said die slot and generating a plurality of signals respectively in response thereto; effecting a change in said measured characteristics of said extruded material at said positions along said die slot in response to said signals so as to produce said extruded material having a desired curvature.

Abstract: A method of an extruded membrane of solidified flowable material having a desired curvature comprising extruding flowable material through a die in a curved section; measuring a characteristic of said extruded material at a plurality of positions along said die slot; comparing said plurality of measurements against a desired plurality of measurements respectively at each said position along said die slot and generating a plurality of signals respectively in response thereto; effecting a change in said measured characteristics of said extruded material at said positions along said die slot in response to said signals so as to produce said extruded material having a desired curvature.

Abstract: A method of cutting pattern pieces from a continuous roll of material comprising steps of unrolling said material unto a rotating cylindrical cutting surface, and then cutting said material during rotation of said cylindrical surface.

Abstract: A three dimensional sail of one piece construction is made on a rotating roll having a deformable outer surface. The roll is divided into a large number of segments, extending across the width of the roll, with the convex profile of each segment being adjustable. A sail is made on the roll on a continuous basis by applying a first layer of film, deforming the film on the roll, applying adhesive and reinforcing the yarns, and applying a second layer of film to form a 3-D laminate.