Tape laying head

Abstract

A shear mechanism (5) for use in a tape laying head (1) configured to lay tow material (22) onto a form (3) in constructing a composite structure, the shear mechanism (5) configured to receive the tow material (22) from a tow supply (4) and steer the tow material (22) by applying a shear deformation to the tow material (22) between a pair of shear boundaries defined by the shear mechanism (5), the shear mechanism including a compression shoe (14) configured to press the tow material (22) onto the form (3). (51), wherein the compression shoe includes a compression member (552, 553) defining at least one of a pair of shear boundaries, an attachment member (511, 551) configured to couple the compression member to a shear mechanism or another portion of the tape laying head, and a compressible member (552, 553) disposed between the compression member and the attachment member, wherein compression and elongation of the compressible member permits movement of at least a portion of the compression member toward or away from the attachment member (511, 551).

Description

[Technical Field]

[0001] Embodiments of the present invention relate to a tape laying head configured to lay tow material onto a form in the construction of a composite structure, a controller used to control the tape laying head, related control methods, and related computer readable media. [Background technology]

[0002] background Composite materials have a matrix material (e.g., a thermosetting resin) that forms a matrix that holds elongated reinforcing elements (e.g., carbon fibers) and are generally used to provide strong, lightweight structures. Such materials are currently used in a variety of applications, ranging from sporting goods to aerospace.

[0003] Composite structures can be formed using tapes or tows of substantially parallel carbon fibers (the terms "tape" and "tow" are used synonymously herein, although a tape can include multiple tows). The tows can be pre-impregnated with a matrix material, or the matrix material can be added later in the manufacturing process. The tows are laid down in layers on a mold structure. The laid down mold structure is then heated under pressure, for example in an autoclave, to polymerize the matrix material and form the composite structure (which is later removed from the mold).

[0004] Laying a tow on a mold structure may require the tow to traverse one or more bends or curves. This can affect the parallel alignment of the carbon fibers within the tow because the fiber path lengths vary depending on their location relative to the width of the tow (e.g., inside or outside the bend or curve). Effects can include, for example, structural defects such as carbon fibers buckling or moving into a non-parallel alignment, or deviations from the intended tow lay path. These problems can adversely affect the properties of the resulting composite structure.

[0005] Patent Document 1 discloses a tow placement head member for laying a tow tape containing reinforcing fibers and a matrix or binder material, the tow placement head member being used to form a variable angle tow composite structure, and including a pinch device configured to receive the tow tape and allow the tow tape to pass therethrough, the pinch device including a tow supply roller and a tow supply shoe configured to guide the tow tape toward a compression shoe, and a compression shoe configured to receive the tow tape from the pinch device and press the tow tape against a surface on which the tow tape is to be laid, the pinch device being configured to apply shear deformation to a portion of the tow tape between the compression shoe and the pinch device.

[0006] However, the mold structure may not have an ideal, flat or uniform surface. In practice, this can lead to separation between the compression shoe or portions of the compression shoe and the mold structure. This can also result in defects, including buckling or movement of the carbon fibers into a non-parallel arrangement, deviation from the intended tow laying path, or improper adhesion of layers of tow material (which can result in air bubbles within the composite structure).

[0007] Therefore, there is a need to provide a tow placement head member that can reduce the risk of these problems.

[0008] The '611 patent discloses the use of a flexible or soft compression shoe to allow some conformance to the surface of the mold structure. However, there is a need to improve the conformance and provide more consistent and / or more accurate contact between the compression roller and the surface of the mold structure.

[0009] Furthermore, conventional automated fiber placement equipment (which does not include a pinch device, such as in U.S. Patent No. 5,929,399) will generally struggle to lay tow tape in molds with significant curvatures. Typically, the compression shoe or roller of such equipment must remain perpendicular to the direction of movement of the tow placement head member relative to the mold, requiring the compression shoe or roller to lift at least partially off the mold surface when traversing large curvatures in the mold. This lack of compression creates defects in the laid tow tape.

[0010] For example, Patent Document 3 discloses a tape laminating machine having a compression roller that laminates a composite tape onto a substrate having a convex radius of curvature, but the compression roller bends the tape as it moves over the convex radius of curvature and at the same time pivots around the trailing end of the tape to prevent the compression roller from lifting off the tape laid just before the convex radius of curvature. This machine therefore presents considerable drawbacks. [Prior art documents] [Patent documents]

[0011] [Patent Document 1] British Patent No. 2492594 [Patent Document 2] International Publication No. 2022 / 058703 [Patent Document 3] U.S. Patent No. 9,522,506 Summary of the Invention [Problem to be solved by the invention]

[0012] Therefore, a need exists to provide a tow placement head member that can maintain compression of the tow tape against the mold even when there is significant curvature in the mold (i.e., one or more high angle transition zones). [Means for solving the problem]

[0013] BRIEF DESCRIPTION OF THE INVENTION One aspect provides a shear mechanism for use in a tape laying head configured to lay tow material onto a form in the construction of a composite structure, the shear mechanism configured to receive tow material from a tow supply and steer the tow material by applying a shear deformation to the tow material between a pair of shear boundaries defined by the shear mechanism, the shear mechanism including a compression shoe configured to force the tow material onto the form, the compression shoe including a compression member defining at least one of the pair of shear boundaries and an attachment member configured to connect the compression member to the shear mechanism or another portion of the tape laying head, the compression shoe further including a compressible member disposed between the compression member and the attachment member, wherein compression and expansion of the compressible member allows movement of at least a portion of the compression member toward or away from the attachment member, and / or an actuator configured to connect the attachment member to the shear mechanism or another portion of the tape laying head, wherein actuation of the actuator allows movement of at least a portion of the compression member toward or away from the attachment member.

[0014] Both the compressible member and the actuator may be provided as part of a compression shoe.

[0015] The compression member may be a flexible elongate member.

[0016] The compression member may include a plate configured to contact the mold.

[0017] The compression member may include one or more protrusions configured to inhibit movement of the compressible member across the surface of the compression member.

[0018] The compressible member may include multiple compressible segments or portions.

[0019] The compressible member may be formed from one or more of a foamed polymer and a gas or liquid filled bladder.

[0020] The attachment member may be a flexible member.

[0021] The attachment member may be an elongate member.

[0022] The shearing mechanism may further include a plurality of actuators configured to couple the attachment member to other portions of the tape laying head, and the actuators may be distributed along the length of the elongate attachment member.

[0023] Each actuator may be coupled to the mounting member by a knuckle joint. The attachment member may be a rigid member.

[0024] The attachment member may include a hollow body configured to at least partially receive the compressible member.

[0025] The compressible member may include multiple compressible portions or segments, and each portion or segment may be coupled to a block to secure the compressible portion or segment to the mounting member.

[0026] The compression member may be in the form of a compression roller configured to rotate relative to the mounting member.

[0027] The compressible member may be provided as a layer on a compression roller.

[0028] The shear mechanism may further include a gripping member in the form of a roller configured to define, together with the compression member, one of the pair of shear boundaries.

[0029] The gripping member may be mounted towards one end of the L-shaped gripping member arm and the actuator may be mounted towards the other end of the L-shaped gripping member arm, the actuator being configured to drive pivotal movement of the L-shaped gripping member arm about a corner of the L-shaped gripping member arm to control the force applied by the gripping member to the compression member.

[0030] Another aspect provides a compression shoe or roller that includes a compression member that at least partially defines a shear boundary of the tow material, a mounting member configured to couple the compression member to a portion of the shear mechanism or tape laying head, and a compressible member disposed between the compression member and the mounting member, wherein compression and elongation of the compressible member permits movement of the compression member toward or away from the mounting member.

[0031] Another aspect provides a tape laying head configured to lay tow material onto a form in the construction of a composite structure, the tape laying head including a shearing mechanism as described above.

[0032] Another aspect provides a system including a plurality of tape laying heads configured to lay tow material onto a form in building a composite structure, each tape laying head including a shear mechanism configured to receive tow material from a tow supply and steer the tow material by applying shear deformation to the tow material between a pair of shear boundaries defined by the shear mechanism, the tape laying heads being arranged in a front row and a rear row, the tape laying head or heads in the front row being arranged alternately with the tape laying head or heads in the rear row, and the front and rear rows being movable relative to each other to change the alternating arrangement of the tape laying heads in the rows.

[0033] There may be multiple tape laying heads in the front row.

[0034] The tape laying heads in the front row may be parallel to one another and may be aligned to form the front row.

[0035] There may be multiple tape laying heads in the back row.

[0036] The tape laying heads in the trailing row are parallel to one another and may be aligned to form a trailing row.

[0037] The shear mechanism can be a shear mechanism as described above.

[0038] Another aspect provides a method of operating a tape laying head having a shear mechanism, the tape laying head configured to lay tow material onto a form in building a composite structure, the shear mechanism configured to receive the tow material from a tow supply and steer the tow material by applying a shear deformation to the tow material between a pair of shear boundaries defined by the shear mechanism, the shear mechanism including a compression shoe configured to press the tow material onto the form, the method including providing the tow material from the tow supply such that a width of the tow material extends across a length of the compression shoe; pressing the tow material onto the form using the compression shoe; and moving the tape laying head relative to the form such that the length of the compression shoe remains substantially parallel to a line defined by the center of curvature of the radius of curvature of the curved portion of the form as the tape laying head traverses the curved portion of the form.

[0039] The compression shoe may include a compressible member disposed between the compression member and the attachment member of the compression shoe, where compression and expansion of the compressible member allows movement of at least a portion of the compression member toward or away from the attachment member, and / or the compression shoe may include an actuator configured to couple the attachment member of the compression shoe to a shearing mechanism or other portion of the tape laying head, where actuation of the actuator allows movement of at least a portion of the compression member toward or away from the attachment member, and the method may further include allowing the compression member to move relative to the attachment member as the tape laying head traverses the curved portion of the mold.

[0040] Another aspect provides a system, the system including a tape laying head having a shear mechanism, the tape laying head configured to lay a tow material onto a form in building a composite structure, the shear mechanism configured to receive the tow material from a tow supply and steer the tow material by applying a shear deformation to the tow material between a pair of shear boundaries defined by the shear mechanism, the shear mechanism including a compression shoe configured to press the tow material onto the form, the system configured to provide the tow material from the tow supply such that a width of the tow material extends across a length of the compression shoe, press the tow material onto the form using the compression shoe, and move the tape laying head relative to the form such that as the tape laying head traverses the curvature of the form, the length of the compression shoe remains substantially parallel to a line defined by the center of curvature of the curvature of the form.

[0041] The compression shoe may include a compressible member disposed between the compression member and the attachment member of the compression shoe, where compression and expansion of the compressible member allows movement of at least a portion of the compression member toward or away from the attachment member, and / or the compression shoe may include an actuator configured to couple the attachment member of the compression shoe to the shearing mechanism or other portion of the tape laying head, where actuation of the actuator allows movement of at least a portion of the compression member toward and away from the attachment member.

[0042] Another aspect provides a method of operating a tape laying head having a shear mechanism, the tape laying head configured to lay tow material onto a form in building a composite structure, the shear mechanism configured to receive the tow material from a tow supply and steer the tow material by applying shear deformation to the tow material between a pair of shear boundaries defined by the shear mechanism, the shear mechanism including a compression shoe configured to press the tow material onto the form, the method including providing the tow material from the tow supply such that a width of the tow material extends across a length of the compression shoe; pressing the tow material onto the form using the compression shoe; and rotating the compression shoe in a pivotal motion relative to the tow material as the tow material is pressed onto the form, the compression shoe rotating and sliding over the laid tow material, the tape laying width decreasing with the pivotal motion.

[0043] Another aspect provides a system, the system including a tape laying head having a shear mechanism configured to lay tow material onto a form in building a composite structure, the shear mechanism configured to receive the tow material from a tow supply and steer the tow material by applying shear deformation to the tow material between a pair of shear boundaries defined by the shear mechanism, the shear mechanism including a compression shoe configured to press the tow material onto the form, the system configured to provide the tow material from the tow supply such that a width of the tow material extends across a length of the compression shoe, press the tow material onto the form using the compression shoe, rotate the compression shoe in a pivotal motion relative to the tow material as the tow material is pressed onto the form, the compression shoe rotates and slides over the laid tow material, and a tape laying width decreases with the pivotal motion. Brief description of the diagram In order that the present disclosure may be more readily understood, preferred embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0044] [Figure 1]FIG. 1 is a diagram of a tape laying head that can be used in several versions. [Figure 2] 1 is a schematic diagram of a system that can be used in several versions. [Figure 3] FIG. 1 is a schematic diagram of the tow material and shear boundary as implemented in some versions. [Figure 4] FIG. 10 is an exploded view of the compression shoe arrangement and actuator according to some versions. [Figure 5] 1A-1C are schematic diagrams of the compression shoe configuration and actuator in use according to some versions. [Figure 6] FIG. 10 is an exploded view of some versions of the compression shoe configuration. [Figure 7] 10A-10C are cross-sectional views of several versions of a compression shoe configuration in use with the compressible member fully compressed. [Figure 8] 10A-10C are cross-sectional views of several versions of a compression shoe configuration in use, where the compressible member is not fully compressed. [Figure 9] 1 is a schematic diagram of several versions of the system. [Figure 10] FIG. 1 is another schematic diagram of some versions of the system. [Figure 11] 1A-1C show portions of several versions of a tape laying head. [Figure 12] FIG. 10 is an exploded view of some versions of the compression shoe configuration. [Figure 13a] FIG. 1 shows a schematic example of tow material laid on a form traversing a high angle transition zone. [Figure 13b] FIG. 1 shows a schematic example of tow material laid on a form traversing a high angle transition zone. [Figure 14a] 1 is a diagram of a beam that can be formed according to some versions. [Figure 14b] 10A-10C are diagrams of different beams that can be formed according to some versions. [Figure 15a] FIG. 15c is a top-down view of the mold shown in FIG. [Figure 15b] FIG. 15c is a front view of the mold shown in FIG. [Figure 15c] FIG. 1 is a diagram of a mold with two rows of tow material laid down. [Figure 16] 10A-10C show diagrammatically the movement of the compression shoe along the mold and the execution of the pivoting movement. DETAILED DESCRIPTION OF THE INVENTION

[0045] Detailed Description of the Disclosure Versions of the present technology are based on the disclosure of U.S. Patent No. 6,277,999. Accordingly, to aid in understanding versions of the present technology, components of the tape laying head 1 and system 100 described herein are shown with reference to Figures 2 and 3 of U.S. Patent No. 6,277,999 (which form the basis of Figures 1 and 2 herein).

[0046] FIG. 3 illustrates the desired result of using this technology: intra-tow shear with minimal inter-tow shear using two shear boundaries defined by shear mechanism 5. General System Overview Versions of the present technology may include a tape laying head 1 (see, e.g., FIGS. 1 and 2). The tape laying head 1 is configured to lay a tape 2 onto a form 3. The tape laying head 1 may be part of a tape laying system 100, and some versions of the present technology may include a tape laying system 100, which may include, for example, multiple tape laying heads 1 as described herein.

[0047] The tape laying head 1 may be configured to lay a tape 2 onto a form 3, for example as part of building a composite structure.

[0048] The tape laying system 100 is configured to move the or each tape laying head 1 across the mold 3, for example, using a robotic arm or gantry. The or each tape laying head 1 is configured to lay tape 2 onto the mold 3 as the mold 3 is traversed by the or each tape laying head 1. In some versions, the tape laying system 100 is configured to move the or each tape laying head 1 across a substantially stationary mold 3, but the tape laying system 100 can likewise be configured to move the mold 3 (or to move both the mold 3 and the or each tape laying head 1) relative to one or more tape laying heads 1 that are substantially stationary. In any event, the tape laying system 100 may be configured to move the, or each, tape laying head 1 relative to the mold 3, however this is achieved.

[0049] The tape laying head 1 is configured to receive tape 2 from a tape supply 4 for laying on a form 3. The tape supply 4 may, for example, form part of the tape laying head 1 or may be part of a wider tape laying system 100.

[0050] The tape 2 from the tape supply 4 is configured to be fed by the tape laying head 1 to the shearing mechanism 5. The shearing mechanism 5 is configured to receive the tape 2 from the tape supply 4 and lay the tape 2 onto the form 3.

[0051] In some embodiments, the tape 2 provided by the tape supply 4 may have a backing material 21 and a tow material 22, with the backing material 21 supporting the tow material 22 (e.g., as the tape 2 is fed from the tape supply 4 to or toward the shearing mechanism 5). For example, the tow material 22 may be laid down on the mold 3, and the backing material 21 discarded. The tow material 22 may include one or more reinforcing fibers, as described in more detail herein. In some embodiments, the backing material 21 provides a binder or resin material that may be combined with the one or more reinforcing fibers to form the tow material 22. For example, the binder or resin material may be provided as a layer on the backing material 21.

[0052] At or in the region of the shearing mechanism 5, the backing material 21 may be removed from the tow material 22. This may occur before or as the tow material is laid down on the mold 3. A heater (not shown) may be provided to heat the tow material 22, particularly the binder or resin material. The heater may be provided, for example, in the path of the tow material 22 upstream of the shearing mechanism.

[0053] The tow laying head 1 may be configured to deliver the backing material 21 to a backing material collector 6 once it has been separated from the tow material 22. The backing material collector 6 may be configured to collect the backing material 21 for later disposal, which may include, for example, recycling. For example, the backing material collector 6 may form part of the tape laying head 1 or may be part of a wider tape laying system 100.

[0054] Thus, during operation, the tape 2 may advance from the tape supply 4 to the shearing mechanism 5 (see the solid arrows in FIG. 1 for the direction of movement of the tape 2 and / or backing material 21). At or within the shearing mechanism 5, the backing material 21 of the tape 2 may be separated from the tow material 22. The shearing mechanism 5 may apply the tow material 22 to the former 3 (the dashed arrows in FIG. 1 indicate the direction of movement of the shearing mechanism 5 relative to the former 3), and the backing material 21 may be fed to a backing material collector for collection. All or some of these operations may be performed as part of the operation of the tape laying head 1, although, as will be explained, some parts (such as the tape supply 4 and / or the backing material collector 6) may be part of a wider tape laying system 100, and thus the feeding and / or collecting operations may, in some cases, be operations performed by the wider tape laying system 100.

[0055] The version may include a tension control system, such as that described in U.S. Patent Application Publication No. 2007 / 0129990. The version may include, for example, one or more additional rollers 71 a, 71 b, 72 a, 72 b, which may form part of the tension control system. The tension control system may be configured to control the tension of the tow material 22 at a stage just prior to the laying of the tow material 22 onto the mold 3. In other words, the tension control system may be configured to control the tension of the tow material 22 in the shear mechanism 5. tape The illustrated tape 2 includes a backing material 21 and a tow material 22. The backing material 21 can be, for example, a paper-based backing material 21. The backing material 21 can be configured to support the tow material 22, for example, prior to laying the tow material 22 onto the former 3. The backing material 21 can also be configured to aid in storage of the tape 2, such as when the tape 2 is wound onto a bobbin 41 (e.g., a bobbin of the tape supply 4).

[0056] The tow material 22 may take a variety of forms, including one or more reinforcing fibers 22a (see, e.g., FIG. 3), which may be carbon fiber, glass fiber, hemp fiber, or flax fiber, and may be fibers formed from recycled materials (such as glass or carbon fiber). The reinforcing fibers 22a may be elongated fibers and may be in a woven or non-woven configuration within the tow material 22. When multiple reinforcing fibers 22a are provided, the reinforcing fibers 22a may be provided in the form of one or more bundles known as tows 22b.

[0057] The tow material 22 may include a binder material. The binder material may be configured, for example, to help maintain the relative orientation of the reinforcing fibers 22 a relative to one another and / or to help adhere the tow material 22 to the mold 3 (or other layers of tow material 22 already laid on the mold 3). The binder material may be insufficient as a resin material for use in forming a composite structure from the tow material 22. Thus, the tow material 22 may be configured and / or intended to be impregnated with a thermosetting or thermoplastic resin material, for example, after laying the tow material 22 on the mold 3. Such tow material 22, in its supplied form, may be described as dry tow material 22 due to the absence of a suitable resin material.

[0058] The tow material 22 may include one or more layers of other material, which may include, for example, one or more layers of polymeric material, and these one or more layers of other material may include one or more layers disposed on either side of the one or more reinforcing fibers 22 a (i.e., below or above the or each reinforcing fiber 22 a relative to the mold 3 when the tow material 22 is laid on the mold 3).

[0059] The tow material 22 may be a pre-impregnated tow material 22. The pre-impregnated tow material 22, in its supplied form, includes sufficient resin material (i.e., a thermosetting resin material) to form a composite structure from the tow material 22. Thus, there is no need to apply, for example, additional thermosetting or thermoplastic resin material. Thus, the pre-impregnated tow material 22 includes one or more reinforcing fibers 22a and a resin material. The resin material may also be referred to as a matrix material and could take other forms.

[0060] Pre-impregnated tow material 22 tends to have a higher shear stiffness than dry tow material 22 .

[0061] In some versions, the tow material 22 is provided in two parts: one or more reinforcing fibers and a binder or resin material. The two parts may be combined, for example, with the tape laying head 1 or with a wider tape laying system 100. The binder or resin material may be provided on a backing material 21, for example.

[0062] In some versions, an endless backing material 21 may be provided (as part of the tape laying head 1), which serves the same purpose as the backing material 21 described herein with respect to supporting the tow material 22 (but not related to storing the tow material 22 or providing a binder or resin material). Thus, in such versions, the tow material 22 may be provided to the endless backing material 21 in the tape laying head 1 from a tape supply 4. In these versions, references to tape 2 in relation to the tape supply 4 are references to the tow material 22 (e.g., the tow material 22 may be provided on a bobbin 41).

[0063] Although versions of the technology are described in relation to a tape 2 that includes a backing material 21 in its supplied form, it should be understood that the same applies to versions in which the backing material 21 is in the form of an endless backing material 21 provided in the tape laying head 1, or to embodiments in which the tow material 22 is added to the resin material in the tape laying head 1 or in a wider tape laying system 100.

[0064] Generally, as used herein, a reference to tape 2 may be interpreted as a reference to one or more tows (each of which may include one or more reinforcing fibers 22a). Accordingly, a reference to tape 2 may be a reference to a tow, and unless otherwise specified, these terms are not used to any special effect herein. Tape Supply The tape supply 4 may include a bobbin 41 around which the tape 2 may be wound. The tape supply 4 may include a creel that may be configured to receive and support the bobbin 41. In some versions, there are multiple bobbins 41, each of which is received and supported by a creel.

[0065] As will be explained, the tape supply 4 may form part of the tape laying head 1 or part of a wider tape laying system 100 .

[0066] The tape supply 4 may be configured to supply the tape 2 to the shearing mechanism 5, and as such, a tape path may be defined between the tape supply and the shearing mechanism 5. This tape path may be formed, at least in part, by the tape laying head 1. One or more portions of this tape path may be defined, for example, by a tube through which the tape 2 may travel.

[0067] In some versions, the tape supply 4 is configured to supply tape 2 to multiple tape laying heads 1 of the tape laying system 100 (e.g., in versions where multiple tape laying heads 1 are present as part of the tape laying system 100). Thus, the tape supply 4 may include at least one bobbin 41 for each tape laying head 1, and a separate tape (or tow) 2 may be supplied to each tape laying head 1. In some versions, multiple tapes (or tows) 2 are supplied in parallel or generally simultaneously to a single (i.e., only one) tape laying head 1 (and there may be multiple such tape laying heads 1 that each receive multiple tapes 2 in parallel or generally simultaneously from the tape supply 4).

[0068] The or each bobbin 41 may be removable, and the tape supply 4 may include a creel configured to receive one or more bobbins 41. The tape supply 4 may at least partially define one or more tape paths through which the tape 2 is configured to advance toward the shearing mechanism 5 (or possibly multiple mechanisms 5).

[0069] The tape 2 supplied by the tape supply 4 can be any tape 2 described herein. Thus, in some versions, the tape 2 can include a tow material 22 and a backing material 21. In some versions, the tape 2 supplied by the tape supply 4 includes the tow material 22, but the backing material 21 is provided separately, for example, as an endless loop. The tow supply 4 can, in some such embodiments, be configured to pass the tow material 22 to the backing material 21, for example, as an endless loop. In some versions, the endless loop may be considered to be part of the tape supply 4. In some versions, the endless loop may be part of the tape laying head 1, for example. Shear Mechanism The shearing mechanism 5 may be, at least in terms of its operating principle and / or in terms of some of its components, generally a mechanism as described in US Pat. No. 5,629,999 and / or US Pat. No. 5,629,999.

[0070] The shearing mechanism 5 may include a compression shoe 51 configured to press the tow material 22 onto the mold 3 (it will be understood that in this specification, references to laying material such as the tow material 22 onto the mold 3 include indirectly laying the material onto the mold 3 (e.g., laying the material on top of a layer of material already laid on the mold 3)).

[0071] The compression shoe 51 may have a first side 51a opposite a second side 51b across the width of the compression shoe 51. The first side 51a may have a generally flat or planar surface, as shown, or may have a surface of a different shape. At the base of the first side 51a (which may also be the base of the compression shoe 51) may be a trailing edge of the compression shoe 51. The trailing edge defines the first side 51a of the compression shoe 51 and a compression side 51c of the compression shoe 51. The compression side 51c includes a compression surface 51c, and these terms are used synonymously herein.

[0072] The compression surface 51c is configured to press the tow material 22 against the mold 3. The compression surface 51c may be configured to allow the tow material 22 to pass between the compression shoe 51 and the mold 3 as the compression shoe 51 (and, for example, the tape laying head 1) moves across the mold 3 to lay the tow material 22. The compression surface 51c may be a substantially smooth surface and may have a relatively low coefficient of friction to allow the compression shoe 51 to slide over the laid tow material 22.

[0073] The trailing edge of the compression shoe 51 represents the last portion of the compression shoe 51 that presses the tow material 22 against the mold 3 as the compression shoe 51 moves relative to the mold 3 during normal laying operations. Accordingly, it may also be referred to as the trailing edge of the compression shoe 51, or more specifically, the trailing edge of the compression surface 51c (rear (and front) being defined by the direction of movement of the compression shoe 51 relative to the mold 3).

[0074] The compression shoe 51 may also include a leading edge that may be opposite the trailing edge across the width of the compression shoe 51 (which may be at the base of the compression shoe 51). The leading edge may define a space between the second side 51b of the compression shoe 51 and the compression side 51c of the compression shoe 51.

[0075] The leading edge of the compression shoe 51 represents the initial portion of the compression shoe 51 that presses the tow material 22 against the mold 3 as the compression shoe 51 moves relative to the mold 3 during normal laying operations (this may be the shear boundary as described herein). Accordingly, this will also be referred to as the leading edge of the compression shoe 51, or more specifically, the leading edge of the compression surface 51c (again, leading (and trailing) is defined by the direction of movement of the compression shoe 51 relative to the mold 3).

[0076] In some versions, the trailing edge is a relatively sharp edge, and first side 51 a may meet compression side 51 c along a thin edge (i.e., an edge with a relatively small radius of curvature). In some versions, the leading edge is a relatively rounded edge, and second side 51 b may meet compression side 51 c along a curved edge (in cross section) having a relatively large radius of curvature (compared to said thin edge).

[0077] The trailing edge and the leading edge may both be substantially straight edges. In other words, the two edges may each extend along a substantially straight axis. The leading edge and the trailing edge may be substantially parallel to each other (e.g., the substantially straight axes may be substantially parallel to each other).

[0078] Second side 51b could have a curved surface, for example, as shown in Figure 1, or could have a differently shaped surface. In some versions, for example, as shown, second side 51b can have both a generally flat portion and a generally curved portion.

[0079] The second side 51b may be configured (e.g., shaped and sized) to at least partially receive the tow guide roller 52. Thus, the tow guide roller 52 may be part of the shearing mechanism 51 and may be disposed adjacent to the compression shoe 51. In particular, the tow guide roller 52 may be disposed adjacent to the second side 51b of the compression shoe 51.

[0080] The tow guide rollers 52 may be positioned such that the tow material 22 may pass through a portion of the tow guide rollers 52 adjacent to the compression shoe 51 before the tow material 22 reaches the compression shoe 51. In other words, the tow guide rollers 52 may be positioned upstream of the compression shoe 51 with respect to the path of the tow material 22 passing through the shearing mechanism 5.

[0081] It should be understood that the tow material 22 has a path that it travels from the tape supply 4 to the shearing mechanism 5, and that this path is formed from various portions through the tape laying head 1. The tow material path may, in some cases, be the same as the tape path, and these terms may be synonymous. However, in general, the tape path typically refers to the path of the tape 2 (i.e., the path of the tow material 22 and, if present, the backing material 21), while the tow material path may or may not be the path of the backing material. The path (tow material or tape) has an upstream direction and a downstream direction, which are defined by the normal direction of movement of the tow material 22 or tape 2, as the case may be, during the laying operation, i.e., typically from the tape supply 4 toward the shearing mechanism 5 (particularly toward the compression shoe 51).

[0082] The tow guide roller 52 may be configured to rotate about an axis that is generally parallel to the leading edge of the compression shoe 51. In some embodiments, the tow guide roller 52 may have an outer surface made of silicone.

[0083] The shearing mechanism 5 may include a gripping shoe 53 (which may also be referred to as a tow feed shoe, for example). The gripping shoe 53 may be positioned adjacent to the tow guide roller 52 such that the tow material may pass between the gripping shoe 53 and the tow guide roller 52. In other words, at least a portion of the tow material path (and, in some cases, the tape path) may be defined between the tow guide roller 52 and the gripping shoe 53.

[0084] The gripping shoe 53 may be formed from a generally elongated member pivotally mounted relative to the tow-guide roller 52 such that the distance between at least a portion of the gripping shoe 53 and at least a portion of the tow-guide roller 52 may be varied by rotation of the gripping shoe 53 about its pivot mount 53a (which may form part of the shear mechanism 5). For example, as shown, the gripping shoe 53 may have a distal end adjacent the tow-guide roller 52 and a proximal end opposite the distal end. The pivotable mount 53a may be disposed between the proximal and distal ends of the gripping shoe 53.

[0085] The distal end of the gripping shoe 53 may be shaped to increase the surface area through which the tow material 22 (or tape 2) may pass and be clamped between the tow guide roller 52 and the gripping shoe 53. Thus, the distal end of the gripping shoe 53 may be curved, and the degree of curvature may generally correspond to the circumferential shape of at least a portion of the tow guide roller 52.

[0086] Rotation of the gripping shoe 53 about the pivot mount 53a can change the distance between at least a portion of the gripping shoe 53 (e.g., a portion of its distal end) and the tow guide roller 52. Rotation of the gripping shoe 53 about the pivot mount 53a can change the force applied to the tow material 22 or tape 2 between at least a portion of the gripping shoe 53 (e.g., a portion of its distal end) and the tow guide roller 52 (this force can be a compressive force, in other words, a gripping or clamping force).

[0087] Gripping shoe 53 includes a resilient biasing mechanism 54, such as a spring, which may be a spirally wound spring, configured to bias a distal end of gripping shoe 53 toward guide roller 52. In some versions, resilient biasing mechanism 54 includes a pneumatic or hydraulic ram.

[0088] Therefore, the tow material 22 may follow a tow material path between the tow guide roller 52 and the gripping shoe 53 (gripping zone) before proceeding to the compression shoe 51, which may press the tow material 22 against the mold 3 in the compression zone (i.e., lay the tow material 22 on the mold 3).

[0089] In some versions, the tow material 22 may be accompanied by the backing material 21 through a path between the tow guide roller 52 and the gripping shoe 53 (i.e., the gripping zone). As such, this portion of the path may similarly be described as a tape path. As the tape 2 leaves the path defined between the tow guide roller 52 and the gripping shoe 53, the backing material 21 may be removed from the tow material 22. In other words, as the tape 2 leaves the gripping zone, the backing material 21 may be separated from the tow material 22. In some versions (such as FIG. 1 ), the backing material 21 may pass around the distal-most end of the gripping shoe 53.

[0090] The distal-most end of the gripping shoe 53 may be the tip of its distal end. The distal-most end of the gripping shoe 53 may be sized and / or shaped (e.g., may have an appropriate radius of curvature) to aid in separating the backing material 21 from the tow material 22.

[0091] Thus, from the gripping shoe 53, the backing material 21 may follow a backing material path that may extend downstream of the shearing mechanism 5 (with respect to the path and normal direction of travel of the backing material 21) up to or towards the backing material collection section 6.

[0092] The final portion of the gripping shoe 53 that the tow material 22 contacts (on its way to the compression shoe 51) is referred to in some embodiments as the gripping edge, which may be a straight portion of the gripping shoe 53 that extends parallel to the leading edge of the compression shoe 51, and this edge may be a shear boundary as described herein.

[0093] As can be appreciated, the shearing mechanism 5 can be configured to move in a first direction relative to the mold 3. The first direction can be, for example, a laying direction, which in the illustrative example of FIG.

[0094] The shearing mechanism 5 is further configured to move in a second direction relative to the mold 3, the second direction being generally perpendicular to the first direction (e.g., into and out of the paper in the example depiction of FIG. 1 ). This second direction is a shear direction and is intended to subject the tow material 22 to shear deformation. As will be appreciated, this second direction can be a direction parallel to the trailing edge, leading edge, and / or the axis of rotation of the tow guide roller 52.

[0095] The movement of the shearing mechanism 5 in the first direction may be driven by the tape laying head 1 moving in the first direction relative to the mold 3. The movement of the tape laying head 1 in the first direction relative to the mold 3 may be driven by movement (relative to the mold 3) of a part of the tape laying system 100 relative to which the tape laying head 1 is mounted. To this end, the tape laying system 100 may include a gantry to which the tape laying head 1 is mounted (the same gantry may have multiple tape laying heads 1 mounted to it).

[0096] The movement of the shearing mechanism 5 in the second direction may be driven by the tape laying head 1 moving in the second direction relative to the mold 3. The movement of the tape laying head 1 in the second direction relative to the mold 3 may be driven by the movement (relative to the mold 3) of a part of the tape laying system 100 (such as a gantry) to which the tape laying head 1 is attached. In some embodiments, the movement of the shearing mechanism 5 in the second direction may be driven by the movement of the shearing mechanism 5 in the second direction relative to the tape laying head 1.

[0097] Thus, the shear mechanism 5 may be configured to provide shear deformation of the tow material 22, referred to as, for example, tow steering or shear tow steering. In some embodiments, the shear mechanism 5 may take different forms. For example, the compression shoe 51 may be in the form of a roller. Similarly, the gripper shoe 53 may also be in the form of a roller, for example. In either case, the shear mechanism 5 may provide a pair of shear boundaries. Lining material collection section 1 , the backing material collection station 6 may include a bobbin 61 (e.g., the bobbin 61 may be referred to as a collection bobbin 61 to distinguish it from the bobbin 41, and the other bobbin 41 may be referred to as a supply bobbin 41). The collection bobbin 61 may be configured to receive and collect the backing material 21 following separation from the tow material 22. In other words, used backing material 21 may be wound onto the collection bobbin 61 during operation of the tape laying head 1 and / or system 100.

[0098] The backing material collection station may include a creel that may be configured to receive and support a collection bobbin 61. In some versions, there are multiple collection bobbins 61, with each collection bobbin 61 being received and supported by a creel. The creel may be a separate creel from the creel of the tape supply station 4 and thus may be referred to as a collection creel (the other creel is referred to as a supply creel). However, in some versions, a creel is shared, such that the supply creel and collection creel are the same creel (i.e., the same creel structure).

[0099] As will be explained, the backing material collection portion 6 may form part of the tape laying head 1 or part of a wider tape laying system 100 .

[0100] The backing material collection section 6 is configured to receive the backing material 21 from the shearing mechanism 5, and as such, a backing material path may be defined between the shearing mechanism 5 and the backing material collection section 6. This backing material path may be formed, at least in part, by the tape laying head 1. One or more portions of this backing material path may be defined, for example, by a tube through which the backing material 21 may pass.

[0101] In some versions, the backing material collector 6 is configured to receive backing material 21 from multiple tape laying heads 1 of the tape laying system 100 (e.g., in versions in which multiple tape laying heads 1 are present as part of the tape laying system 100). Thus, the backing material collector 6 may include at least one bobbin 61 for each tape laying head 1, and a separate backing material 21 may be received from each tape laying head 1. In some versions, multiple strips of backing material 2 are received in parallel from a single (i.e., only one) tape laying head 1 (and there may be multiple such tape laying heads 1, each providing multiple strips of backing material 21 in parallel to the backing material collector 6).

[0102] The or each bobbin 61 may be removable, and the backing material collector 6 may include a creel 62 configured to receive one or more bobbins 61. The backing material collector 6 may at least partially define one or more backing material paths through which the backing material 21 is configured to advance towards the backing material collector 6 (or possibly multiple collectors 6).

[0103] In versions where the backing material 21 is an endless loop, the backing material path may proceed from the shearing mechanism 5 to the backing material collection section 6 and then return to the shearing mechanism 5 (in the shearing mechanism 5, the path may pass between the tow guide roller 52 and the gripping shoe 53, as described for the version where the backing material 21 is part of the tape 2 and is not an endless loop). Operating principle Accordingly, versions in which shearing of the tow material 22 is used to steer the laid tow material 22, as described in Patent Document 1 and / or Patent Document 2, may be used to lay the tow material 22 onto the mold 3. Compression shoe Versions of the present technology may relate, for example, to developments relating to compression shoes 51.

[0104] Thus, referring to FIG. 4, a version of the compression shoe 51 may be an elongated compression shoe 51 that may be configured for use in connection with one or more tapes 2 (e.g., multiple tapes 2 are distributed so as to be compressed by different portions of the length of the compression shoe 51).

[0105] The compression shoe 51 may include or be attached to multiple actuators 8 (providing a linear joint). The actuators 8 are distributed along the length of the compression shoe 51 and / or the length of the compression surface 51c. Thus, each actuator 8 may be located adjacent a different portion of the compression shoe 51 and / or compression surface 51c. Each actuator 8 is pneumatically, hydraulically, or electrically actuated, and the piston of the actuator 8 is axially movable relative to its cylinder. Each piston may be pneumatically, hydraulically, or electrically biased relative to its cylinder into an extended or partially extended configuration.

[0106] Each actuator 8 may include, for example, a piston and cylinder. Each actuator 8 may include a solenoid with a piston or plunger. Each actuator 8 may include, for example, a motor, such as a stepper motor, that may drive one or more gears (e.g., in a rack and pinion arrangement). In some versions, there is more than one actuator 8. When there are multiple actuators 8, not all of the actuators 8 need to be the same type of actuator 8. Furthermore, the biasing force generated by each actuator 8 need not be the same force, and the selection of the biasing force may be based, at least in part, on the shape of the mold 3.

[0107] The actuator 8 (eg, its cylinder) may be attached to a mounting block or frame 81 that may be moved with a gantry or robotic arm and may form part of the shear mechanism 5 as described herein.

[0108] The actuator 8 (e.g., its piston) may extend toward the compression shoe 51 or the compression shoe configuration 55 of the compression shoe 51, in a direction generally perpendicular to the direction of movement of the tape 2 past the compression shoe 51. The actuator 8 (e.g., its piston) may include a respective mounting tab 82. Each mounting tab 82 may be a flat member having an opening defined therethrough, the opening defined through the mounting tab 82 perpendicular to the surface of the mounting tab 82, the opening being generally parallel to the direction of movement of the tape 2 past the compression shoe 51 and / or the direction of movement of the shearing mechanism 5 relative to the mold 3.

[0109] In some versions, the actuator 8 may include one or more actuators 8 that may be configured to extend at least partially in a direction parallel to the direction of movement of the tape 2 through the compression shoe 51 or compression shoe configuration 55. These one or more actuators 8 may thus be used to move at least a portion of the compression shoe 51 or compression shoe configuration 55 relative to another portion of the compression shoe 51 or compression shoe configuration 55 in a direction parallel to the direction of movement of the tape 2. This may be referred to as advancing or retracting the compression shoe 51 or portion of the compression shoe configuration 55 (i.e., advancing or retracting the portion relative to the other portion in the direction of movement of the tape 2). In some versions, one or more additional actuators oriented orthogonal to the one or more actuators 8 and configured to move the or each actuator 8 may be configured to perform the advance or retract movement independently of the operation of the or each actuator 8, for example.

[0110] The compression shoe arrangement 55 may include a mounting member 551, a compressible member 552, and a compression member 553 (the compression member 553 may be referred to as a compression shoe 51 in some versions).

[0111] The mounting member 551 may be configured to couple the compression shoe arrangement 55 to the actuator 8 and, therefore, may include a plurality of coupling arrangements 551a configured to engage with the actuator 8. For example, each coupling arrangement 551a may include a pair of spaced apart protrusions having an opening defined therethrough, with one mounting tab 82 of the actuator 8 configured to be received therebetween. The openings in the protrusions align with the openings in the mounting tabs 82, allowing, for example, a bolt 551b to be passed therethrough and secured with a respective nut 551c. This may thus form a respective knuckle joint. The nut 551c may include a nylon locking ring, and the nut 551c may be only loosely tightened onto the bolt 551b to ensure free movement of the knuckle joint.

[0112] Engagement of the actuator 8 with the mounting member 551 may permit rotational movement of a portion of the mounting member 551 relative to another portion of the mounting member 551, for example, about an axis generally parallel to the direction of movement of the compression mechanism 51 relative to the mold 3 (in other words, an axis generally parallel to the direction of movement of the tape 2 relative to the compression shoe 51). In some versions, this axis may be oriented differently (e.g., to permit advancement and retraction as described herein). Accordingly, the mounting member 551 may have sufficient flexibility to permit some degree of such rotational movement. The mounting member 551 may include one or more recesses between the protrusions to help provide this flexibility (e.g., the recesses may be elongated and extend in a direction generally parallel to the direction of movement of the compression mechanism 51 relative to the mold 3 (in other words, generally parallel to the direction of movement of the tape 2 relative to the compression shoe 51)).

[0113] Attachment member 551 can be configured to engage compressible member 552. In some versions, compressible member 552 is configured to engage a side of attachment member 551 opposite the side from which coupling arrangement 551a (e.g., protrusion) extends. This opposite side can be referred to as, for example, the lower surface. Attachment member 551 can include one or more recesses or openings configured to be used to secure attachment member 551 to compression member 553.

[0114] Thus, the compression member 553 may include one or more protrusions 553a, each configured to pass through a respective opening 552a in the compressible member 552 and which may be at least partially received by one or more recesses or openings in the mounting member 551, such that the mounting member 551 may move toward and away from the compression member 553, with the compressible member 552 sandwiched therebetween.

[0115] Compressible member 552 may be formed from a compressible material, such as, for example, a foamed polymer or a gas or liquid filled bladder.

[0116] For example, in some versions, compressible member 552 may include one or more bladders filled with gas or liquid, which may be fluidly connected to a fluid delivery system (which may include one or more pumps and / or valves) that may be configured to supply gas or liquid to and / or extract gas or liquid from the or each bladders. In some versions, there are multiple such bladders, which may be fluidly connected to one another in series or in parallel. In some versions, each such bladders is independently fluidly connected to a fluid delivery system, such that gas or liquid may be supplied to or extracted from each bladders independently of the other bladders.

[0117] In some versions, the connection between the fluid supply system and the or each bag may be with one or more flexible hoses. In some versions, the connection between the bags may be with one or more flexible hoses.

[0118] The or each bag and / or flexible hose may, for example, be formed from one or more polymeric materials.

[0119] In some versions (see, e.g., FIG. 12 ), a skirt 552c may be provided. The skirt 552c may be formed from one or more polymeric materials. In some versions, the skirt 552c may include an upper seal and a lower seal. The upper seal and the lower seal may be peripheral seals and may be disposed on opposing portions of the skirt 552c. In some versions, the skirt 552c is a continuous loop, where the skirt 552c defines and substantially surrounds the passageway. The loop may be any suitable shape, including oval, circular, square, or (as shown) rectangular.

[0120] In some versions, skirt 552c includes a permitter wall, which may extend, for example, between the upper and lower seals. The permitter wall may include one or more contours, living hinges, etc. that allow the permitter wall to collapse in a generally uniform manner. Such permitter wall features may, for example, encourage skirt 552c to fold in a predetermined manner.

[0121] In some versions, the skirt 552c may be configured to be connected (e.g., sealingly connected) to a portion of the compression shoe arrangement 55 (e.g., glued or bonded to the compression shoe arrangement 55). For example, the skirt 552c may be configured to be connected between the compression member 553 (e.g., its plate 553c) and a portion (e.g., body 551f) of the mounting member 551. In some versions, an upper seal is connected to the mounting member 551 and a lower seal is connected to the compression member 553. The skirt 552c may thus form a collar between these two portions and may at least partially define a volume into which a fluid (e.g., gas or liquid) may be supplied or extracted (e.g., by a fluid delivery system) to expand or contract the skirt 552c, thereby moving or enabling movement of the compression member 553 relative to the mounting member 551. The volume may further be at least partially defined by compression member 553 (eg, plate 553c) and mounting member 551 (eg, body 551f). The volume may be fluidly connected to, for example, a fluid supply system, which may be, for example, via one or more hoses (which may be flexible or rigid). Extraction of fluid from the volume may (with a small external force) move and enable movement of the compression member 553 relative to the mounting member 551. This movement may, for example, cause the skirt 552c to fold in a predetermined manner or move and enable movement of the compression member 553 relative to the mounting member 551. The fluid supply system may be fluidly connected to the volume, for example, via an opening defined by the body 551f.

[0122] Thus, the compression member 553 may move against or with the force provided by the gas or liquid within the volume, so that the compression member 553 may more closely follow the surface of the mold 3 (see herein).

[0123] The compression member 553 may be generally elongated (similar to the compressible member 552 and / or the mounting member 551, and the compression member 553 may be provided in multiple sections along either or both of them, arranged along the length of the elongated compression member 553). The compression member 553 includes a compression surface 51 c (which may be disposed opposite a surface from which one or more protrusions 553 a project), which may be a surface of a plate 553 c forming part of the compression member 553. The compression member 553 includes distal limiting members 553 b, one of which may be disposed at either end of the elongated compression member 553. Each distal limiting member 553 b may extend in approximately the same direction as the one or more protrusions 553 a. The distal limiting member 553b and / or one or more protrusions 553a may be configured to prohibit movement of the attachment member 551 and / or compressible member 552 beyond the end of the compressible member 553 (in a direction parallel to its length).

[0124] In versions with a skirt 552c, the protrusion 553a may be at least partially surrounded by the skirt 552c.

[0125] Compressible member 552 and compression member 553 may be configured to flex with attachment member 551 .

[0126] Compressible member 552 may bias compression member 553 outward (away from mounting member 551).

[0127] Thus, the actuator 8 can be used to press the attachment member 551 toward the mold 3. When the compression member 553 contacts the mold 3 (in use, the tow material 22 is between the mold 3 and the compression member 553), the additional force applied by the actuator 8 can cause the attachment member 551 to compress the compressible member 552. The compression mechanism 51 can be moved relative to the mold 3. As the compression member 553 advances over the mold 3, the actuator 8 can be actuated to provide a predetermined compressive force. If the surface of the mold 3 is curved, the actuator 8 can be actuated to provide a correspondingly curved compression member 553. In some versions, a substantially uniform force is applied to the mold 3 by the compression member 553 along its length. If a particular portion (e.g., a local region) of the surface of the mold 3 (or a previous layer of tow material 22 laid on the mold 3) does not conform to the curvature (i.e., the overall surface curvature) (e.g., has surface imperfections or undulations), the compressible member 552 may compress or expand in that local region, and the compression member 553 may conform more closely to the surface of the mold 3. This may help, for example, to avoid voids forming in the layer of tow material 22. This is shown, for example, schematically in FIG. 5. The local region may have a dimension (e.g., a width defined in a direction perpendicular to the direction of movement of the compression member 553 across the surface of the mold 3) that is smaller than the distance between two adjacent actuators 8, for example.

[0128] The actuator 8 can be actively or passively actuated.

[0129] Variations are also shown in FIGS. 6, 7, and 8. In this version, the mounting member 551 includes a body 551f with a hollow structure (e.g., defining a hollow cavity) approximately in the shape of the upper portion of the contour of the compression shoe 51. The bottom of the body 551f may define an opening providing access to the hollow cavity. A side of the body 551f of the mounting member 551 may define a row of openings configured to receive respective bolts or screws 551d. The body 551f may be rigid and may or may not be coupled to one or more actuators 8. In some versions, the body 551f is coupled to one or more actuators 8 that form part of the shear mechanism 5. In some versions, the body 551f is coupled to one or more actuators 8, which form part of a robotic arm or gantry that supports the compression shoe arrangement 55.

[0130] The mounting member 551 may further include a plurality of blocks 551e. Each block 551e may be configured to be received in the hollow cavity of the mounting member 551 and may define one or more openings configured to align with respective openings in the row of openings, and bolts or screws 551d may pass through these openings to secure the block 551e to the body 551f. The blocks 551e may each have, for example, a triangular cross-section or may otherwise be shaped to correspond to the interior shape of the hollow cavity. The blocks 551e may all be substantially the same size and shape, or there may be one or more blocks 551e of different sizes and / or shapes. The blocks 551e may be provided, for example, along the length of the mounting member 551.

[0131] In this and some other versions, compressible member 552 is provided as multiple separate compressible segments or portions 552b. Each compressible segment or portion 552b can be secured (e.g., by bonding, such as gluing) to one or more of blocks 551e. In some versions, block 551e and its associated compressible segments or portions 552b can have approximately the same length and / or width. In some versions, separate blocks 551e may not be provided, and their function may be part of the function of main body 551f (e.g., each compressible segment or portion 552b can be secured (e.g., by bonding, such as adhesive) to main body 551f). Compressible segments or portions 552b can be foamed polymer material or bladders filled with gas or liquid. In some versions, compressible member 552 can be provided by a volume at least partially defined by skirt 552c (see herein).

[0132] Replacement of individual blocks 551e and their associated compressible segments or portions 552b may be possible by removing the associated bolts or screws 551d, and removing the block 551e (and therefore also the compressible segment or portion 552b) from the body 511f (followed by re-attachment of another block 551e and its compressible segment or portion 552b).

[0133] There may be a space defined between each block 551e. This space may also be defined between each compressible segment or portion 552b. Thus, block 551e and compressible segment or portion 552b, when attached to body 551f, may define at least one slot, and in some versions, multiple such slots, therebetween.

[0134] The compression member 553 may be approximately in the shape of a plate 553c which may be approximately in the shape of the lower portion of the contour of the compression shoe 51 and which may provide a compression surface 51c.

[0135] The compression member 553 may include one or more protrusions 553a, and in some versions, each of these protrusions 553a is configured (e.g., shaped and sized) to be received (at least partially) by a space or spaces (e.g., slots) defined between the block 551e and / or the compressible segment or portion 552b. Thus, the one or more protrusions 553a may be at least partially received within the hollow cavity of the body 551f. The one or more protrusions 553a may be the same size and shape as one another, or may include at least one protrusion 553a that is a different size and / or shape from another one of the one or more protrusions 553a. The one or more protrusions 553a may, for example, have a generally triangular cross-sectional shape, although other shapes (e.g., a rectangular cross-sectional shape) are also possible. The one or more protrusions 553a may be integrally formed with the plate 553c, or may be adhered or otherwise secured thereto (e.g., by welding). The or each protrusion 553a so received by the body 551f may serve to limit unwanted movement of the compression member 553 in directions parallel to and / or perpendicular to the direction of movement of the tape 2 relative to the compression member 553.

[0136] As will be explained, the compression member 553 may be flexible to allow the compression member 553 to follow the undulations of the surface of the mold 3 .

[0137] The compressible member 552 may bias the compression member 553 outward from the mounting member 551 (as described with respect to the other versions) so that the compression member 553 can conform more closely to the surface of the mold 3 .

[0138] In some versions, compression shoe arrangement 55 may be pressed against mold 3 (e.g., by a gantry or robotic arm) such that compressible member 552 is fully compressed (see, e.g., FIG. 7 ). In some versions, this fully compressed state is defined by the compressibility of compressible member 552, but in some versions, compression member 553 may include one or more abutment surfaces configured to abut corresponding surfaces of mounting member 551, the fully compressed state being when these surfaces abut upon compression of compressible member 552 (the abutment substantially inhibiting or preventing further compression of compressible member 552). In such a version, compressible member 552 (or portions thereof) is at least partially depressurized along a portion thereof (or even along its entire length (see, e.g., FIG. 8 )) as the distance between attachment member 551 and mold 3 increases, attempting to keep compression member 553 in contact with mold 3 (or other layers of tow material already laid) and / or to maintain a force on mold 3 via compression member 553 above a threshold and / or that is substantially constant.

[0139] In some versions, the abutment surfaces may be provided as edges or end surfaces 553d of the mounting member 551 and compression member 553, respectively (although other configurations are envisioned).

[0140] As will be explained, compression member 553 may be a flexible member and may be formed from a polymeric material, hi some versions, compression member 553 is formed from PTFE.

[0141] The compression member 553 may be bonded (e.g., using an adhesive) to one or more of the compressible members 552 and to the attachment member 551 to prevent the compression member 553 from releasing from the attachment member 551, for example, when the compression member 553 is lifted from the mold 3. Cellular System In some versions, the system 100 may be provided with multiple tape laying heads 1. In conventional systems 100, the tape laying heads 1 are aligned with one another, and the tape laying heads 1 are in a fixed positional relationship relative to one another.

[0142] Some versions of the present technology may be particularly useful for laying down tape material 2 onto the surface of a single or double curved mold 3. Some such versions may be particularly useful for laying down tape material 2 onto a mold 3 that includes slopes and / or valleys.

[0143] Versions of the present technology may provide for different arrangements of the tape laying head 1 in the system 100 (see Figures 9 and 10, which show one such different arrangement).

[0144] As mentioned above, the tape laying heads 1 may be provided on a gantry or robotic arm of the system 100. Each tape laying head 1 may include at least one actuator 8 (providing a prismatic joint), for example, as described herein. The or each actuator 8 is configured, in use, to urge a compression member 553 of a compression shoe arrangement 55 (of the shearing mechanism 5) of the tape laying head 1 towards the mold 3.

[0145] The tape laying heads 1 may include one head 1 that is biased by one or more actuators 8 independently of the other heads 1. In some versions, each tape laying head 1 is biased by one or more actuators 8 independently of the other tape laying heads 1. This may be considered, for example, as biasing along the z-axis. Thus, the tape laying heads 1 may generally move along the x-axis on the mold 3 (the y-axis is orthogonal to the x- and z-axes).

[0146] Each tape laying head 1 may be configured to lay a single tow 22b (which may be formed, for example, from a plurality of reinforcing fibers 22a).

[0147] Multiple tape laying heads 1 can be operated together in the system 100 to lay wider tracks of tow material 22 than would be possible with a single tape laying head 1 .

[0148] In some versions, two rows of tape laying heads 1 may be provided. The two rows may include a front row 101 and a rear row 102. When the system 100 is activated, the front row 101 may traverse the mold 3 before the rear row 102.

[0149] The tape laying heads 1 in the front row 101 and the back row 102 may be staggered (in the y-axis direction) such that the tape laying head 1 in the back row is approximately aligned with the junction between the two tape laying heads 1 in the front row. Multiple tape laying heads 1 may be configured for use in connection with the same mold 3. Thus, in some versions, the tape laying heads 1 in the front row 101 and the back row 102 may generally be disposed in a common plane, which may be perpendicular to the Z-axis (although this need not necessarily be the case).

[0150] The tension in the tow material 22 laid by a particular tape laying head 1 can be set (or controlled) independently for one head 1, independent of the other heads 1. In some versions, each tape laying head 1 is configured to set (or control) the tension in the tow material 22 laid by that head 1, independent of the other tape laying heads 1.

[0151] The tape laying heads 1 in the front row 101 may be generally aligned with one another. Similarly, the tape laying heads 1 in the back row 102 may be generally aligned with one another. The front row 101 and back row 102 may be parallel to one another.

[0152] Thus, the tow material 22 laid by the leading row 101 may be interleaved with the tow material 22 laid by the trailing row 102. There may be some overlap between the tow material 22 laid by the two rows of tape laying heads 1. There may be no overlap between the tow material 22 laid by the two rows of tape laying heads 1. The tow material 22 laid by the leading row of tape laying heads 1 may be immediately adjacent to the tow material 22 laid by the trailing row of tape laying heads 1.

[0153] In some versions, the rear row 102 of tape laying heads 1 may be configured to move linearly (e.g., in the y-axis direction) relative to the front row 101 of tape laying heads 1 to enable shearing of the tow material 22. This may be achieved by movement of the front row 101 or rear row 102 of tape laying heads 1 relative to the mold 3 and the other of the front row 101 or rear row 102 of tape laying heads 1. Thus, in some versions, the front row 101 of tape laying heads 1 is attached to a front arm or gantry, and the rear row 102 of tape laying heads 1 is attached to a rear arm or gantry, such that the front or rear arm or gantry can be moved relative to the other of the front or rear arm or gantry, moving all of the tape laying heads 1 attached thereto. An actuator 103, such as an electric motor, may be provided to move the front row 101 relative to the rear row 102.

[0154] Because each tape laying head 1 may be able to move towards and away from the mold 3 independently of the other tape laying heads 1, the tape laying heads 1 may maintain more contact and / or more contact with a more consistent force between the tape laying head 1 and the mold 3 (or, of course, the tow material 22 already laid on the mold 3).

[0155] The tape laying heads 1 thus form cells of the system 100, each cell laying tow material 2 in synchronism with the other cells, but also allowing several independent operations. Thus, actuation of the tape laying head 1 may each take advantage of the compression shoe configuration 55 described herein, for example, the actuator 8 allowing the compression member 553 to follow the overall curvature of the mold 3, and the compressible member 552 allowing the compression member 553 to follow smaller variations in the surface of the mold 3.

[0156] In some versions, only one row of tape laying heads 1 may be provided, but the spacing between each tape laying head 1 is typically the width of the tape material 2. Thus, a first pass may be performed laying tape material 2 onto the form 3, and then a second pass may be performed laying tape material 2 onto the form, but the rows of tape laying heads 1 are offset relative to their positions in the first pass, and the second pass lays tape material 2 between the tape material 2 laid from the first pass. Rollercell For example, with reference to Figure 11, some versions may include a tape laying head 1 having a compression shoe 51 or member 553 in the form of a roller. This type of tape laying head 1 may be particularly compact and therefore well suited for use in, for example, a cellular system 100 as described herein.

[0157] This version may include one or more actuators 8 (as described herein) mounted to a mounting member 551. The connection between the or each actuator 8 and the mounting member 551 may not be bonded (i.e., may be a fixed connection). The or each actuator 8 may provide a prismatic joint between the mounting member 551 and the gantry or robotic arm. The mounting member 551 may carry a compression member 553, which in this example is in the form of a roller. In some such versions, the compressible member 552 may not be provided, or the compressible member 552 may be provided as a layer of the compression member 553 or roller (e.g., an outer layer such that the compressible member 552 may also form the compression surface 51c). The compression member 553 may be configured to rotate relative to the mounting member 551 as the compression member 553 traverses the mold 3. Thus, the axis of rotation of the compression member 553 may be approximately perpendicular to the direction of movement of the tape laying head 1 relative to the mold 3. The compression member 553 may be, for example, cylindrical.

[0158] The gripping shoe 53 may also be provided as a roller in some such versions and in other versions (and thus the gripping shoe 53 described herein may also be referred to as a gripping member 53), the roller being configured to press a portion of the compression member 553 with the tow material 22 therebetween (providing one of the shear boundaries).

[0159] To control the tension in the tow material 22, the position of the gripping member 53 relative to the compression member 553 (and / or the force applied to the compression member 553 by the gripping shoe 53) may be varied. To this end, the gripping member 53 may be attached to the tape laying head 1, and in particular to a gripping member arm 53c of the shearing mechanism 5. The gripping member 53, which in this example is in the form of a roller, may be configured, for example, to rotate relative to the gripping member arm 53c. The gripping member arm 53c may be configured to rotate relative to the compression member 553, which may be achieved, for example, by a pivotable attachment to the attachment member 551. A portion of the gripping member arm 53c may be connected to an arm actuator 53d configured to drive movement of the gripping member arm 53c about the pivotable attachment. In some versions, the gripping member arm 53c is generally L-shaped with the gripping member 53 attached to one end and the arm actuator 53d attached to the other end, with pivotable mountings at the corners of the L-shaped arm 53c.

[0160] In some versions, the tow material 22 may be supported by the backing material 21 described herein, and the backing material 21 may be separated from the tow material 22 after the tape 2 (i.e., the tow material 22 and the backing material 21) passes through the gripping member 53 (i.e., when the tape 2 exits between the gripping member 53 and the compression member 553). The backing material 21 may be collected by the backing material collector 6 (which may be a reel in this and other versions). The tension of the backing material 21 may be measured and controlled (e.g., by controlling the rate at which the tape 2 is fed and / or the rate at which the backing material collector 6 collects the backing material 21). Thus, for the avoidance of doubt, the tension control system described in U.S. Patent Application Publication No. 2009 / 0129994 may be implemented in connection with this version of the technology.

[0161] The arm actuator 53d can be, for example, a pneumatic, hydraulic or electrically operated actuator. High-Angle Transition Zone In some versions, the tape laying head 1 (which may be configured to be moved across the form 3 by a robotic arm or gantry) may be controlled so that the longitudinal axes of the tow material 22 and the compression shoe 51 are not perpendicular. In particular, the tape laying head 1 may be moved relative to the form 3, e.g., the compression shoe 51 oriented to maintain contact both between the form 3 and the tow material 22 and between the compression shoe 51 and the tow material 22. This contact may be maintained across the entire width or substantially the entire width of the tow material at the compression shoe 51. This contact may be maintained substantially throughout the traversal of the curve in the high-angle transition zone of the form 3. The high-angle transition zone of the form 3 may be a portion of the form 3 along the planned path for the tow material 22 that curves toward or away from the tape laying head 1 (e.g., upward or downward). For example, such a curve may be found in a girder, beam, or column. The curvature of the high angle transition zone may provide a portion of the mold 3 with a convex or concave shape. The curvature may provide a radius of curvature between two other surfaces of the mold 3.

[0162] Contact between the compression shoe 51 and substantially the entire width of the tow material 22 around such a curve can be achieved, for example, by controlling the movement of the tape laying head 1 relative to the mold 3 (e.g., through the use of a gantry or robotic arm) so that the longitudinal axis of the compression shoe 51 (which may extend across the width of the tow material 22) is parallel or substantially parallel to the length of the curve in the high-angle transition zone (which may be the edge of the radius of curvature of the curve). This contact can generally be maintained regardless of the angle of the tow material 22 relative to the mold and / or the angle relative to the curve. As will be appreciated, the angle of the tow material 22 relative to the compression shoe 51 will depend on the angle between the tow laying path and the curve. This may impose practical limits on the angle that can be achieved between the tow laying path and the curve; too shallow an angle will result in excessive shearing of the tow material 22, resulting in defects. In some versions, angles of more than + / - 80 degrees between the tow laying path and the compression shoe 51 (during the traversal of the curve in mold 3) can result in such defects when traversing a curve in the manner described above. Therefore, the tape laying head 1 can be controlled to avoid angles exceeding this range. In some versions, an angle of + / - 45 degrees is achieved between the tow laying path and the compression shoe 51 (during the traversal of the curve in mold 3).

[0163] As will be appreciated, in this manner, a more uniform compressive force is applied to the tow material 22 as it passes through the bend in the mold 3, generally reducing the likelihood of defects (as compared to conventional automated tow placement equipment) regardless of the angle of the tow laying path relative to the line of the bend (the line that defines the end of the bend) (see above).

[0164] Such control of the orientation of the compression shoe 51 relative to the mold 3 as the compression shoe 51 moves along the curved portion of the mold 3 may or may not use a compressible member 552 (which may or may not be present). In some versions, the compressible member 552 is present, and thus may conform to the shape of the mold 3. Thus, not only may a relatively uniform compressive force be applied across the width of the tow material 22 as the tow material 22 passes through a single curve, but the same may be true if the single curve itself is also curved. Thus, in some versions, the length of the curve may be a line (such as an axis) around which the radius of curvature of the curve will be defined, and the line itself may be curved (e.g., the edge of the radius of curvature of the curve may be a curved edge). The extent to which such a second curve may facilitate a substantially uniform compressive force applied by the compression shoe 51 to the tow material 22 across the width will depend on the characteristics of the compressible member 552.

[0165] Thus, in some such versions, the compression member 553 may contact the tow material 22 and the mold 3, pressing the tow material 22 against the mold 3. The orientation of the compression member 553 may be controlled to maintain a pressing force across the width of the tow material 22 passing through the compression member 553 as the pressing force is applied to the mold 3. This may include aligning the longitudinal axis of the compression member 553 (which may be parallel to the aforementioned width of the tow material 22) to be parallel (or substantially parallel) to a line defining the center of the radius of curvature of the curved portion. That line itself may be curved, such that the compressible member 552 may provide at least some conformance of the compression member 553 to that curved line to maintain a pressing force across the width of the tow material through this doubly curved portion of the mold 3.

[0166] Such high-angle transition zones may be found, for example, in beams, girders, and columns, with examples of a single-curved beam section shown in FIG. 14a (from three different viewing angles) and a doubly-curved beam section shown in FIG. 14b (also from three different viewing angles). Such high-angle transition regions may generally be found in association with molds or parts having at least one bend with a convex radius of curvature. These are the types of objects that may be formed using the techniques disclosed herein. Versions of the techniques may be used in association with convex bends.

[0167] 13a and 13b, there are schematic diagrams of this process, showing the position and orientation of the compression shoe 51 as the tow material 22 passes through the bend in the high-angle transition zone. Similarly, FIGS. 15a-15c show schematic diagrams of the process for two different tow lay paths, one at a 90-degree angle relative to the line of the bend and one at an angle δ relative to the line of the bend. In these figures, the position and orientation of the compression shoe 51 are shown at different times, and arrows indicate the tow lay paths and directions.

[0168] In particular, conventional methods used with automated tow placement equipment require a limited tow width to be used to traverse a curve (usually at most a single curve). However, versions of the present technology may use the full width of the tow material 22 for its tape laying head 1. Thus, in some versions, the width of the tow material 22 that may be used is decoupled from the configuration of a convex radius of curvature or a high-angle transition zone.

[0169] The tape laying head 1 can be used in such a manner because the direction of movement of the tape laying head 1 does not need to be maintained perpendicular to the longitudinal axis of the tape laying head 1 (the shearing of the tow material 22 makes this possible).

[0170] Additionally, in some versions, shear deformation can be used to steer the tow material 22 as the tape laying head traverses the high angle transition zone of the mold 3. This allows for even more freedom in how the tow material 22 is laid down on the mold 3 without introducing undue defects.

[0171] Thus, in such a version, tow material 22 can be laid with fewer defects, and the tow material 22 is not perpendicular to a line defined by the center of curvature of the curved portion of mold 3 along the length of the curved portion of mold 3.

[0172] These techniques may be used in combination with the tape laying head 1 disclosed herein and / or the systems 100 disclosed herein, including, for example, the system 100 shown in FIGS.

[0173] The high angle transition zone can be part of Mold 3, where the outer surface has a curve that requires the tow material 22 to travel 45° or more, or 65° or more, or 75° or more, or 85° or more, or 90° or more. The same technique can be used for shallower angle curves.

[0174] These techniques can be particularly useful when traversing a curve in a mold 3 with tow material 22, where the path of the tow material 22 (i.e., the tow path) is not at 90 degrees to the line (e.g., axis) about which the radius of curvature of the curve is defined (or, for example, the edge of the radius of curvature of the curve). In other words, in situations where the tow path is not perpendicular to the edge of the curve. Running Tapering When the tow material 22 is laid using a tape laying head 1 of a version of the present technology (e.g., with a shear mechanism 5), using shear to reduce the laying width of the tow material 22 necessarily results in an increase in the thickness of the laid tow material 22.

[0175] In some use cases, there may be a need to reduce the width of the tow material 22 laid along the tow path. This may be required, for example, to ensure that the part being manufactured has required structural properties and / or because the mold 3 has a tapered portion (such as a tapered girder, column, or beam section).

[0176] In some versions of the present technology, the tape laying head 1 and / or the compression shoe 51 may be pivoted along the tow path as the tow material 22 is laid down on the form 3. This may include rotating and sliding the compression shoe 51 relative to the tow material 22.

[0177] This sliding of the compression shoe 51 results in a rotational movement of the compression shoe 51 relative to the tow material 22, which risks causing defects. Therefore, in some versions, the rate of rotational movement (i.e., pivoting) is maintained below a predetermined threshold. This rate may be a maximum rotation angle (relative to the tow material 22) over a predetermined length of the tow material 22 laid on the form 3. Similarly, the rate may be a maximum rotation angle over time, and different rates may be set depending on the laying speed of the tow material 22.

[0178] An example of this is shown, for example, in Figure 16, where the width of the tow material 22 can be reduced along the tapered length of the mold 3. The straight arrows in this figure represent the vectors of the compression shoe movement, and the curved arrows indicate the rotational movement of the compression shoe 51.

[0179] During this process, there is no tow shear as described herein (although this does not necessarily have to be the case), and as a result, the tow material 22 is laid down in a straight line (see, for example, FIG. 16 ). However, as will be appreciated, the shear angle, i.e., the angle of the tow material 22 relative to the longitudinal axis of the compression shoe 51, increases as the compression shoe 51 is pivoted. This results in a decrease in the width of the laid tow material 22 as the fibers of the tow material 22 move closer together.

[0180] This can be described as a pivoting of the compression shoe 51, or indeed the tape laying head 1.

[0181] To allow the pivoting to occur without tow steering, for example, it may be necessary for the compression force (i.e., the force applied to the mold 3 by the compression shoe 51) to be reduced (i.e., lower) than the compression force imposed during tow steering.

[0182] Thus, the pivoting of the compression shoe 51 increases the shear angle of the tow material 22 imparted by the tape laying head 1 and reduces the width of the tow material 22 laid on the form 3, while the steering angle remains substantially constant or is kept smaller than the shear angle.

[0183] As will be appreciated, the operation of this technique means that the length of the compression shoe 51 does not necessarily have to be 90 degrees to the angle of the tow path, but can be oriented at a non-perpendicular angle while still performing the tow shear described herein.

[0184] The same technique can be used along a straight tow path or a curved tow path (when following a curved path, tow steering can be used, for example, using a tow shear as described herein.) Additionally, the width of the laid tow material 22 can be varied along its tow path to increase or decrease the tow width, which can be achieved independently of tow steering by pivoting the compression shoe 51.

[0185] As will be appreciated, pivoting of the compression shoe 51 may be achieved by pivoting of the shear mechanism 5 and references to pivoting of the compression shoe 51 should be interpreted accordingly.

[0186] The useful limits of this process, i.e., the maximum reduction in width that can be achieved, will depend on several factors, including the properties of the tow material 22. general It will be appreciated that in some instances, the term "shoe" as used herein is used to refer to both shoes and alternatives such as rollers, and the description should be interpreted accordingly.

[0187] As used in this specification and claims, the terms "comprises" and "comprising" and variations thereof mean that the specified features, steps or integers are inclusive. These terms are not to be interpreted as excluding the presence of other features, steps or components.

[0188] The present invention may also broadly consist of the parts, elements, steps, examples, and / or features individually mentioned or illustrated herein, or collectively consist of any combination of two or more parts, elements, steps, examples, and / or features. In particular, one or more features of any embodiment described herein may be combined with one or more features from any other embodiment described herein.

[0189] Protection may be sought for any feature disclosed in one or more of the published documents referenced herein in combination with the present disclosure.

[0190] Although specific exemplary embodiments of the present invention have been described, the appended claims are not intended to be limited to only these exemplary embodiments. The claims should be construed literally, objectively, and / or to encompass equivalents.

Claims

1. 1. A shear mechanism for use in a tape laying head configured to lay tow material onto a form in the construction of a composite structure, the shear mechanism configured to receive tow material from a tow supply and steer the tow material by applying a shear deformation to the tow material between a pair of shear boundaries defined by the shear mechanism, the shear mechanism including a compression shoe configured to press the tow material onto the form, the compression shoe comprising: a compression member at least partially defining one of the pair of shear boundaries; a mounting member configured to connect the compression member to the shear mechanism or another portion of the tape laying head, the compression shoe further comprising: a compressible member disposed between the compression member and the mounting member, wherein compression and expansion of the compressible member allows movement of at least a portion of the compression member toward or away from the mounting member; and / or a shear mechanism comprising: an actuator configured to couple the attachment member to the shear mechanism or other portion of the tape laying head, wherein actuation of the actuator allows movement of at least a portion of the compression member toward or away from the attachment member.

2. 2. The shear mechanism of claim 1, wherein both the compressible member and the actuator are provided as part of the compression shoe.

3. 3. A shear mechanism according to claim 1 or 2, wherein the compression member is a flexible elongated member.

4. The shear mechanism of claim 3 , wherein the compression member comprises a plate configured to contact the mold.

5. 5. The shear mechanism of claim 3 or 4, wherein the compression member includes one or more protrusions configured to inhibit movement of the compressible member across a surface of the compression member.

6. 6. A shear mechanism according to any one of claims 1 to 5, wherein the compressible member comprises a plurality of compressible segments or portions.

7. 7. A shear mechanism according to any one of claims 1 to 6, wherein the compressible member is formed from one or more of a foamed polymer and a gas- or liquid-filled bladder.

8. 8. The shear mechanism according to claim 1, wherein the attachment member is a flexible member.

9. 9. The shear mechanism of claim 8, wherein the mounting member is an elongated mounting member.

10. 10. The shearing mechanism of claim 9, further comprising a plurality of actuators configured to couple the attachment member to other portions of the tape laying head, the actuators being distributed along the length of the elongated attachment member.

11. 11. The shear mechanism of claim 10, wherein each actuator is coupled to the mounting member by a knuckle joint.

12. 8. A shear mechanism according to claim 1, wherein the mounting member is a rigid member.

13. 13. The shear mechanism of claim 12, wherein the mounting member comprises a hollow body configured to at least partially receive the compressible member.

14. 14. The shear mechanism of claim 12 or 13, wherein the compressible member includes a plurality of compressible portions or segments, each portion or segment being coupled to a block to secure the compressible portion or segment to the mounting member.

15. 2. The shear mechanism of claim 1, wherein the compression member is in the form of a compression roller configured to rotate relative to the mounting member.

16. 16. The shear mechanism of claim 15, wherein the compressible member is provided as a layer on the compression roller.

17. 17. The shear mechanism of claim 15 or 16, further comprising a gripping member in the form of a roller configured to define, together with the compression member, one of the pair of shear boundaries.

18. 18. The shear mechanism of claim 17, wherein the gripping member is mounted towards one end of an L-shaped gripping member arm and an actuator is mounted towards the other end of the L-shaped gripping member arm, the actuator being configured to drive pivotal movement of the L-shaped gripping member arm about a corner of the L-shaped gripping member arm to control the force applied by the gripping member to the compression member.

19. A compression shoe or roller, said compression shoe or roller comprising: a compression member at least partially defining a shear boundary of the tow material; a mounting member configured to couple the compression member to a shear mechanism or a portion of a tape laying head; a compressible member disposed between the compression member and the mounting member, wherein compression and expansion of the compressible member allows movement of the compression member toward or away from the mounting member.

20. 19. A tape laying head configured to lay tow material onto a form in the construction of a composite structure, the tape laying head comprising a shearing mechanism according to any one of claims 1 to 18.

21. 1. A system including a plurality of tape laying heads configured to lay tow material onto a form in the construction of a composite structure, the system comprising: each tape laying head includes a shearing mechanism configured to receive tow material from a tow supply and steer the tow material by applying a shear deformation to the tow material between a pair of shear boundaries defined by the shearing mechanism; the plurality of tape laying heads are arranged in a front row and a rear row, the front row tape laying head or heads being arranged alternately with the rear row tape laying head or heads; The system wherein the front row and the rear row can be moved relative to each other to change the staggering of the tape laying heads of the rows.

22. 22. The system of claim 21, wherein there are multiple tape laying heads in the front row, and optionally the tape laying heads in the front row are parallel to one another and aligned to form the front row.

23. 23. A system according to claim 21 or 22, wherein there are a plurality of tape laying heads in the rear row, optionally the tape laying heads in the rear row being parallel to one another and aligned to form the rear row.

24. A system according to any one of claims 21 to 23, characterized in that the shear mechanism is a shear mechanism according to any one of claims 1 to 18.

25. 1. A method of operating a tape laying head having a shear mechanism, the tape laying head configured to lay tow material onto a form in the construction of a composite structure, the shear mechanism configured to receive tow material from a tow supply and steer the tow material by applying a shear deformation to the tow material between a pair of shear boundaries defined by the shear mechanism, the shear mechanism including a compression shoe configured to press the tow material onto the form, the method comprising: providing the tow material from the tow supply such that the width of the tow material extends across the length of the compression shoe; pressing the tow material onto the mold using the compression shoe; and moving the tape-laying head relative to the mold such that, as the tape-laying head traverses the curved portion of the mold, the length of the compression shoe remains substantially parallel to a line defined by the center of the radius of curvature of the curved portion of the mold.

26. 26. The method of claim 25, wherein the compression shoe includes a compressible member disposed between a compression member and an attachment member of the compression shoe, wherein compression and expansion of the compressible member allows movement of at least a portion of the compression member toward or away from the attachment member, and / or the compression shoe includes an actuator configured to couple the attachment member of the compression shoe to the shear mechanism or other portion of the tape laying head, wherein actuation of the actuator allows movement of at least a portion of the compression member toward or away from the attachment member, the method further comprising: the step of allowing the compression member to move relative to the attachment member as the tape laying head traverses the curved portion of the mold.

27. 1. A system, the system including a tape laying head having a shear mechanism configured to lay a tow material onto a form in the construction of a composite structure, the shear mechanism configured to receive the tow material from a tow supply and steer the tow material by applying a shear deformation to the tow material between a pair of shear boundaries defined by the shear mechanism, the shear mechanism comprising a compression shoe configured to press the tow material onto the form, the system including: providing tow material from a tow supply such that the width of the tow material extends across the length of the compression shoe; using the compression shoe to press the tow material onto the mold; 1. A system configured to move the tape laying head relative to the mold such that as the tape laying head traverses the curved portion of the mold, the length of the compression shoe remains substantially parallel to a line defined by the center of the radius of curvature of the curved portion of the mold.

28. 28. The system of claim 27, wherein the compression shoe comprises a compressible member disposed between a compression member and an attachment member of the compression shoe, compression and expansion of the compressible member permitting movement of at least a portion of the compression member toward or away from the attachment member, and / or the compression shoe includes an actuator configured to couple the attachment member of the compression shoe to the shear mechanism or other portion of the tape laying head, and actuation of the actuator permits movement of at least a portion of the compression member toward or away from the attachment member.

29. 1. A method of operating a tape laying head having a shear mechanism, the tape laying head configured to lay tow material onto a form in the construction of a composite structure, the shear mechanism configured to receive the tow material from a tow supply and steer the tow material by applying a shear deformation to the tow material between a pair of shear boundaries defined by the shear mechanism, the shear mechanism including a compression shoe configured to press the tow material onto the form, the method comprising: providing the tow material from the tow supply such that the width of the tow material extends across the length of the compression shoe; pressing the tow material onto the mold using the compression shoe; The method comprises rotating the compression shoe in a pivoting motion relative to the tow material as the tow material is pressed onto the mold, the compression shoe rotating and sliding on the laid tow material, and the tape laying width decreasing with the pivoting motion.

30. 1. A system, the system including: a tape laying head having a shear mechanism configured to lay a tow material onto a form in building a composite structure; the shear mechanism configured to receive the tow material from a tow supply and steer the tow material by applying a shear deformation to the tow material between a pair of shear boundaries defined by the shear mechanism; the shear mechanism including a compression shoe configured to press the tow material onto the form; providing the tow material from the tow supply such that the width of the tow material extends across the length of the compression shoe; using the compression shoe to press the tow material onto the mold; The method is characterized in that the compression shoe is rotated in a pivoting motion relative to the tow material as the tow material is pressed onto the mold, the compression shoe is configured to rotate and slide on the laid tow material, and the laid width of the tape is configured to decrease with the pivoting motion.

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