Systems and methods for weaving rigid and semi-rigid tape-like materials

Abstract

A composite forming machine and method for forming composites that can start with thermoplastic prepreg weft tape and warp tapes, weave and consolidate the tapes into a lattice structure, where the machine / process is automated and continuous, while reducing waste, cycle time and material handling costs compared to conventional composite reinforcement methods.

Description

SYSTEMS AND METHODS FOR WEAVING RIGID AND SEMI-RIGID TAPE-LIKE MATERIALSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] Not Applicable.STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] This invention was made with government support under grant number 2036336 awarded by the awarded by the National Science Foundation. The government has certain rights in the invention.SEQUENCE LISTING

[0003] Not Applicable.STATEMENT REGARDING PRIOR DISCLOSURES BY THE INVENTOR OR A JOINT INVENTOR

[0004] Not Applicable.BACKGROUND OF THE DISCLOSURE1. Field of the Disclosure

[0005] The present disclosure relates generally to the field of composite lattice materials and machines and methods for making same. More specifically, the present disclosure relates to systems and methods for weaving of rigid and semi-rigid tape-like materials.2. Background

[0006] Conventional forming machines that produce woven structures from tapes are disadvantageous. Various sub-processes and sub-systems of the overall production process and system each need improvement to meet demands of a reliably safe, speedy, energy efficient, and error-free production of custom lattice structures from unidirectional, fiber-reinforced composite tapes.

[0007] One might look to conventional yam weaving loom technologies for sub-processes and sub-systems that might be transferable in a beneficial tape weaving loom. For example, In aneffort to speed weft tape insertion, yam weaving can use air jet weft tape insertion, whereby a succession of air nozzles is used to create a vortex of air that accelerates (pushes) the weft tape yam across the shed. Since yam is essentially round, the air nozzles are designed to create a vortex that centers and may even slightly twist the yam during insertion.

[0008] The yam weaving loom uses a reed used to mechanically beat the yam, where the air nozzles for weft tape insertion are integrated into the reed and used for the mechanical beat of the weft tape yam via the reed.

[0009] The yam weaving loom can include a brake nozzle and stretch nozzle to hold the yam in tension during insertion and cutting.

[0010] One might look to conventional tape weaving loom technologies for sub-processes and sub-systems that might be transferable in a beneficial tape weaving loom. For example, for tape insertion, without exception conventional tape weaving systems rely on a device to physically grip and “pull” the tape across the shed - either explicitly or implicitly a rapier weft tape inserter. This approach is thought necessary for the differences in the physicality between yams and tapes.

[0011] The conventional tape weaving loom uses a traditional mechanical beater, so it is limited to creating fully dense fabrics that can be mechanical beat, and the tape fabric is rolled up without melt bonding.

[0012] It is also of interest to increase production speeds of the machine. As an example, increasing the production speed of a tape lattice is of course not simply a function of mnning each conventional tape weaving sub-process and sub-system faster. The whole of the conventional tape weaving loom is built around mnning at a conventional rate, and “pushing” each aspect simply to mn quicker would invariably lead to tape bunching, tape breaking, tape curling, stuck tape and other innumerable failure events that leads to the situation that the conventional tape weaving loom simply needs a full transformation.

[0013] Therefore, what is needed is a composite forming machine and method for forming composites that can start with thermoplastic prepreg tapes, weaves and consolidate the tapes into a lattice stmcture of interlaced tapes, where the machine / process is automated and continuous, while reducing waste, cycle time and material handling costs compared to conventional composite reinforcement methods.BRIEF SUMMARY OF THE DISCLOSURE

[0014] The present invention comprises improvements to systems and methods for weaving rigid and semi-rigid tape-like materials. Each sub-system and sub-process of the present invention is innovative unto itself, and when combined, provide a further leap forward in tape weaving technology.

[0015] The present invention comprises systems and methods that improve upon conventional weaving systems and methods of weaving rigid and semi-rigid tape-like materials. Embodiments of the present disclosure include machines and methods for forming a woven composite at speeds and qualities not achievable by conventional means.

[0016] The present invention can form a single layer woven composite and a multi-layer woven composite.

[0017] The woven composite may be created continuously and with a dynamically controllable internal fabric geometry that enables the creation of a woven composite having customized properties of strength, stiffness, and toughness.

[0018] Spools of polymer impregnated tape may be loaded on one end of a continuous composite weaving machine and a single / multilayer composite panel may be output on the other side of the machine, with no additional lamination steps required.

[0019] A continuous composite weaving machine of the present disclosure may also be configured to vary the density of the composite by change the spacing of warp tape and weft tapes relative to one another.

[0020] As used herein, the terms “tape-like material” and “tape materials” (often shorted to “tape” herein) refer to a relatively flat material, distinct from a fiber or yam geometry, having dimensions of a thickness of between 0.1 mm and 1 mm, and a width of from 5 mm to 50 mm. More preferably, the tape has a thickness of between 0.15 mm and 0.3 mm, and a width of from 15 mm to 30 mm. In an exemplary embodiment, the width is at least ten times the thickness, and more preferably, the width is 100 times the thickness. The tape has a length substantially longer than its thickness, for example, at least 100 times the thickness, and more preferably at least 1000 times the thickness.

[0021] The tape preferably comprises reinforcement to provide the tape with beneficial stiffness characteristics so it can be manipulated in the present invention without suffering from failure events discussed hereinafter. For example, in an exemplary embodiment, the tape comprises a unidirectional fiber reinforced thermoplastic composite having a tensile modulus of at least 9 GPa, and more preferably having a tensile modulus of at least 25 GPa. In such an example, the unidirectional fiber reinforced thermoplastic composite preferably comprises at least 30% fiber fraction by volume. By unidirectional, it is meant to encompass that at least 90% of the fibers are oriented in the length direction of the tape. Further, the fibers are preferably continuous.

[0022] The tape can further include transmission material. The transmission material can be made of any material capable of conducting heat or transmitting signals, data, or electric current, including conductive metallic wire and light guide material like optical fiber. The transmission material may be pre-impregnated in the tape prior to consolidation or impregnated as part of the consolidation process. An interlaced composite can include multiple transmission material types that perform different functions. An interlaced composite can also include transmission material of the same type in multiple tapes that can interact with each other.

[0023] As used herein, a “composite” refers to a combination of two or more materials differing in form or composition on a macro scale. For example, a composite can include a composite matrix binder and reinforcing elements. The composite constituents do not dissolve or merge completely into one another although they act in concert.

[0024] As used herein, a “resin” refers to an isotropic material used as a matrix binder within a composite.

[0025] As used herein, a “thermoplastic” refers to a resin / polymer which becomes pliable or moldable above a specific temperature and returns to a solid state upon cooling. A significant aspect of thermoplastics is their reversibility, the ability to undergo reheating, melt again, and change shape.

[0026] As used herein, a “thermoset” refers to a resin / polymer which solidifies from a liquid form during processing due to an irreversible chemical reaction.

[0027] The present invention processes both commodity / bulk polymers and engineering polymers. As used herein, “an engineering polymer” refers to polymers having at least onemechanical, thermal, or electrical material property which is superior to “bulk” polymers such as polyethylene (PE), polypropylene (PP), and polyethylene terephthalate (PTE). Examples of engineering polymers include, but are not limited to, polyamide (PA), polycarbonate (PC), acetal (POM), polyetheretherketone (PEEK), poly(p-phenylene sulfide)(PPS), and poly etherketoneketone (PEKK).

[0028] In an exemplary embodiment, the present invention is a weft tape inserter / a weft tape insertion step configured to insert a weft tape in a weft direction from a continuous feedstock.

[0029] A weft inserter stack can comprise two or more of the weft tape inserters, such that two more weft tapes can be inserted sequentially or simultaneously.

[0030] In any of the embodiments disclosed herein, the weft tape inserter can comprise a double belt configuration (top and bottom belt and pulley sets) that is configured to receive the weft tape between the top and bottom belts, apply pressure to grip the weft tape, and accelerate / decelerate the weft tape in order to propel the weft tape to its designated position.

[0031] In any of the embodiments disclosed herein, the weft tape inserter can further comprise a motor to drive at least one of the two belt and pulley sets.

[0032] In any of the embodiments disclosed herein, the weft tape inserter can further comprise monitoring and adjusting abilities in order to monitor one or more of torque, speed, or position based on sensor feedback, and adjust one or more of torque, speed, or position in view of the monitored information and programmable tolerance ranges of the same monitored characteristics.

[0033] In any of the embodiments disclosed herein, the weft tape inserter can further comprise a set of inserter rollers, preferably in the middle of the double belt, to apply pressure through the belts to the weft tape in order to limit / prevent slippage. Limiting / preventing slippage of the weft tape can also be aided by the belts coated with a textured rubber or elastomer.

[0034] In any of the embodiments disclosed herein, the weft tape inserter can further comprise computer control. Having a computer controller enables, for example, adjustment to an insertion distance and a motion profile based on programmatic inputs in order to facilitate variation in a target drawn lengths of weft tape in the finished consolidated woven composite, or in order to create discontinuous segments in the weft tape.

[0035] In another exemplary embodiment, the present invention is a shear cutting assembly / shearing step configured to shear cut the feed of weft tape from the weft tape inserter into the target drawn lengths of weft tape.

[0036] In any of the embodiments disclosed herein, and for convenience of terminology, the weft inserter stack can comprise the weft tape inserters and the shear cutting assembly.

[0037] In any of the embodiments disclosed herein, the shear cutting assembly can comprise one or more shear cutters, each comprises a shear blade constrained between two plates, and placed along a weft tape insertion path.

[0038] In any of the embodiments disclosed herein, shear blade guide channels can be cut into the plates (one a pre-cut plate / another the post-cut plate), where a pre-cut plate fully constrains the lateral and vertical movement of the weft tape within it, while the post-cut plate is slotted all the way to one edge to enable the cut weft tape to be beat clear.

[0039] In any of the embodiments disclosed herein, the shear blade can be formed from a thin sheet of metal, having a thickness of between 0.005” and 0.030”, more preferably having a thickness between 0.010” and 0.020”, inclusive.

[0040] In any of the embodiments disclosed herein, the shear blade comprises at least one opening that is large enough for the weft tape to feed through. The opening can possess at least one slanted and / or curved edge to promote concentration of the shear cut force.

[0041] In any of the embodiments disclosed herein, the shear blade is preferably thin enough that no sharpened edge is required to perform the necessary quality shear cut, though thicker shear plates may benefit from a sharpened edge.

[0042] In any of the embodiments disclosed herein, the shear blade can be held in tension (top and bottom) and actuated along that axis in a manner that maintains a state of tension in the blade at all time. When actuated, the opening moves up or down while the weft tape and plates remain stationary, causing the edge of the opening to induce a high shear stress on the weft tape and cutting the weft tape.

[0043] In any of the embodiments disclosed herein, the shear blade can include two or more openings in order to concurrently cut multiple weft tapes. For example, perhaps depending on requirements for production, a plurality of openings in the shear blade can be configured such thatthe openings align with different shear blade guide channels of the plates on the up and down strokes, allowing the weft tapes to be cut in both directions. In machines configured to produce two or more layers simultaneously, the “up” opening for one layer may also be the “down” opening for another, adjacent layer.

[0044] In other embodiments, a single opening in the shear blade is sized / shaped / formed to accommodate two or more weft tapes concurrently, which would dictate the definition of the opening, including the number / arrangement of slanted or curved edges to promote concentration of the shear cut force when cutting two or more tapes.

[0045] In any of the embodiments disclosed herein, the shear blade can be configured into a looped metal belt with the openings distributed along the length of the belt. The looped blade / belt is guided by a plurality of shear assembly rollers and tensioners so that tension may be maintained and the blade can be directed around machine components. The belt may be driven in a stepwise or continuous rotary motion with an actuator - such that the openings align with the weft tape channels during the insertion step. The motion of the belt may be in one direction, or in both directions depending on the requirements for blade life and production - as such the configuration of the openings may be configured for cutting in one or both directions of blade motion.

[0046] In another exemplary embodiment, the present invention is a warp head / warp tape insertion step, the warp head including a warp tape slot configured to contain a warp tape passing therethrough in a warp direction and a weft guide channel configured to assist in the travel of the feed of weft tape traveling across an operating width of the machine.

[0047] A warp rack can comprise two or more of the warp heads.

[0048] In any of the embodiments disclosed herein, the warp tape slots for the warp tapes contain the movement of the warp tapes up, down, left, and right (relative to the direction of feed, i.e., the warp direction).

[0049] In another exemplary embodiment, the present invention is two or more weft supports / weft path guiding steps, each weft support comprising a weft guide channel, and each weft support selected from a group consisting of an air-assist draw weft support, an air-assist beat weft support, and a mechanical-assist beat weft support.

[0050] In any of the embodiments disclosed herein, and for convenience of terminology, the warp rack can comprise the warp heads and the weft supports. Additionally, a combination or series of one or more warp heads and one or more weft supports can comprise a module. The operating width of the machine can include two or more modules across the width, where the modular design of a repeating series of warp heads / weft supports simplifies interchangeability in case of failure and / or retooling for a different set of heads / supports for different woven composite structures.

[0051] In another exemplary embodiment, the present invention is a media-assist system / media- assist process to provide physical-grip-free drawing of the inserted feed of weft tape through a weft guide path. In any of the embodiments disclosed herein, the physical-grip-free drawing can comprise media-assist drawing of the inserted feed of weft tape through the weft guide path by exposing the inserted feed of weft tape to the Coanda effect. A draw media system can be configured to provide draw media to the media-assist. The draw gas can be any media that enables for the provision of the physical-grip-free drawing of the inserted feed of weft tape. In exemplary embodiments, the media is such that it exposes the inserted feed of weft tape to the Coanda effect.

[0052] In any of the embodiments disclosed herein, the media-assist system / media-assist process comprises gas-assist. An exemplary gas is air.

[0053] In another exemplary embodiment, the present invention comprises the innovative combination of the warp heads, weft supports, media-assist system, and / or one or more steps to perform the processes provided by the components (sometimes collectively referred to as “the media-assist” feature according to an exemplary embodiment of the present invention), where the weft guide channels of the warp heads and the weft supports are configured for alignment across the operating width of the machine forming a weft guide path through which the feed of weft tape passes, and wherein one or more air characteristics and one or more weft guide channel characteristics cooperate to expose the feed of weft tape passing through the weft guide path to the Coanda effect.

[0054] In any of the embodiments disclosed herein, with the media-assist system / media-assist process comprising air-assist, one of the air characteristics can be selected from a group consisting of a speed of air supplied by the air-assist system to the weft guide channel, a volume of airsupplied by the air-assist system to the weft guide channel, and a direction of air supplied by the air-assist system to the weft guide channel.

[0055] As used herein, descriptions using the term “air” and / or “gas,” each equally apply to other “media” that can be used to provide a similar function as the described exemplary case. In any of the embodiments disclosed herein, the exemplary media is pneumatic, for example, a gas or a mixture of gasses. In more exemplary embodiments, the media is air.

[0056] In any of the embodiments disclosed herein, one of the weft guide channel characteristics can be selected from a group consisting of a width of the weft guide channel, a height of the weft guide channel, and a surface profile of the weft guide channel.

[0057] In any of the embodiments disclosed herein, the air-assist draw weft supports comprise one or more internal air channels, terminating in an air-assist nozzle, designed to impart one or more of the air characteristics, including directing the airflow along the top and / or bottom of the passing feed of weft tape.

[0058] In any of the embodiments disclosed herein, the air-assist nozzle can be oriented such that it both steers the feed of weft tape against the back wall of the weft guide channel, while directing some air flow along the direction of travel to “pull” the tape along the weft guide path.

[0059] In any of the embodiments disclosed herein, the air flow within the air-assist can be electronically controlled, both in terms of pressure and activation timing, and the warp heads and / or weft supports can further comprise one or more of an array of sensors that are configured to detect the position of the weft tape as it moves across the warp heads, activating and deactivating individual air-assist locations as the feed of weft tape passes to reduce the total air consumption.

[0060] In any of the embodiments disclosed herein, for machines that insert multiple layers, weft tape insertion timing for each layer may be offset slightly, to allow one sensor to detect the passage of two or more weft tapes and verify each weft tape’s position independently. This sensing may be further used to detect slippage or jamming during the tape insertion, data which can be fed back to the weft tape inserter computer controller to correct or retry the insertion.

[0061] The Coanda effect created by the air-assist “attaches” to the surface of the feed of weft tape to create a cushion of air above and / or below the weft tape (depending on the location of the air-assist nozzles) that reduces friction and “pulls” the tape along the along the weft guide path tokeep it in tension. Maintaining tension can be advantageous to prevent undulation of the tapes during insertion and drawing.

[0062] In another exemplary embodiment, the present invention is a media-assist beat feature / a process of beating shear cut feed of weft tape (a target drawn length of weft tape) in the warp direction to clear the tape from the weft guide path within the warp heads and weft support. The media-assist beat can be provided by two or more of the weft supports embodying the form of media-assist beat weft supports. In any of the embodiments disclosed herein, and for convenience of terminology, the media-assist beat feature can be inclusive in the prior described rack / module subsystems. In any of the embodiments disclosed herein, a beat media system can be configured to provide a beat media to one or more of the weft guide channels of the media-assist beat weft supports.

[0063] In any of the embodiments disclosed herein, the media-assist beat can comprise a gasassist beat, and more preferably, an air-assist beat.

[0064] In any of the embodiments disclosed herein, the draw media / gas system and the beat media / gas system are the same media / gas system. Alternatively, the draw media / gas system and the beat media / gas system are different media / gas systems.

[0065] In any of the embodiments disclosed herein, the draw media / gas and the beat media / gas are the same media / gas. Alternatively, the draw media / gas and the beat media / gas are different media / gases.

[0066] In any of the embodiments disclosed herein, the media / gas / air-assist beat can comprise an air-assist beat system configured to provide air to the weft guide channel of the air-assist beat weft supports. Alternatively, or in combination, the air-assist system can be further configured to provide air to the weft guide channel of the air-assist beat weft supports. As noted above, the provision of air to the air-assist feature and to the air-assist beat feature need not comprise separate systems, although it can.

[0067] In any of the embodiments disclosed herein, the air-assist beat can further comprise one or more internal air channels, terminating in a beat nozzle designed to direct airflow perpendicular to the direction of insertion (“edge-on”) of the weft tape. Preferably, the beat nozzle is oriented such that air is directed to lift and thrust the weft tape (after shear cutting and being fully“pulled” / drawn through the weft guide path) clear out of the warp heads and into the warp tape shed.

[0068] In any of the embodiments disclosed herein, the beat nozzle can be further configured to generate airflow above and below the shear cut weft tape in order to stabilize it during the beat process. Without airflow, if the weft tape were solely propelled by mechanical forces, the weft tape can behave as a wing and small undulations / curvatures in the weft tape can cause it to twist or flutter as it travels.

[0069] In any of the embodiments disclosed herein, the air flow within the air-assist beat can be electronically controlled, allowing for any number of air-assist beaters along the operating width of the machine to actuate, thereby reducing the air consumption if weft tapes are only inserted a partial distance across the width of the warp rack / operating width of the machine.

[0070] In any of the embodiments disclosed herein, the air pressure within the air-assist beat can be controllable separately from the air pressure of the air-assist, allowing for the optimum pressure to be used for specific weft tapes to accommodate different weft tape densities and friction coefficients.

[0071] In another exemplary embodiment, the present invention is an innovative two-component process / system of beating the shear cut weft tape clear of the weft guide path in the warp direction. A first component can be a mechanical-assist beating by mechanical means, and a second component can be the media-assist beating with media.

[0072] In any of the embodiments disclosed herein, the beating can comprise the mechanicalassist beat (an initial mechanical beat pulse) followed by air-assist beating. In this more preferred embodiment of beating, the weft supports include one or more gas-assist beat weft supports and one or more mechanical-assist beat weft supports.

[0073] In any of the embodiments disclosed herein, the mechanical-assist beat weft support includes a rod, plunger, or similar actuatable shape, configured to push the weft tape perpendicular to the direction of tape insertion (“edge-on”).

[0074] In any of the embodiments disclosed herein, the mechanical-assist beat weft support can be actuated by solenoid, air cylinder, or similar high-speed mechanism.

[0075] In any of the embodiments disclosed herein, the mechanical-assist beat weft support is designed to provide an initial impulse to overcome friction and resting inertia of the shear cut weft tape, while the air-assist beat stabilizes the shear cut weft tape and propels it forward (in the warp direction). Due to this division of effort between the two beat sub-systems, the mechanical-assist beat can be shorter than the width of the weft guide channel and is able to extend and retract in the same amount of time as it takes the air-assist beat to push the shear cut weft tape all the way to a desired location. In exemplary embodiments, the mechanical-assist beat is able to extend and retract in a shorter amount of time than the air-assist beat takes, as it just needs sufficient time to clear the back edge of the shear cut weft tape from the front of the weft guide channel.

[0076] In any of the embodiments disclosed herein, the warp heads and weft supports alternate across the operating width of the machine, being designed such that a warp head interlocks with vertical channels or ribs along the sides of an adjacent weft support in order to guide and stabilize the warp heads when they are actuated up and down.

[0077] In any of the embodiments disclosed herein, at least a portion of the warp heads and weft supports further comprise one or more vents along a back wall of the respective weft guide channels to reduce pressure build up in the respective channels caused by the air-assist - thus limiting if not preventing the weft tape from being pushed out of the respective channels prematurely due to a buildup of air pressure.

[0078] In another exemplary embodiment, the present invention is a positioner. Manipulating the orientation / spacing of weft tapes (and warp tapes), while available at different locations in the process, and with different capabilities at each location, can be consider under a broadly encompassing “ability to position / re-position,” or can include discrete steps / locations, for example, catching / a catch device in proximity to the recently-beat weft tape, pre-positioning / a prepositioner, and post-positioning / a post- positioner.

[0079] Not unlike other components of the present invention, labels are assigned to different positioning locations / capabilities for ease of description. Indeed, in certain instances, this aspect is described as a step of transforming an initial orientation of interlaced warp and weft tapes into a pre-consolidation orientation of the interlaced warp and weft tapes.

[0080] In any of the embodiments disclosed herein, a catch device can be configured to provide a repeatable reference stop location as the weft tapes are beat out of the weft guide paths. Afterarresting the weft tape, the catch device can be actuated to drop or lift out of the way of the weft tape. By synchronizing the timing of this actuation, it is possible to control the gap between the “held” weft tape and a previous weft tape. One of ordinary skill in the art will appreciate that beat weft tapes need not be caught by a discrete catch device, if, for example, operating conditions present a friction profile that arrests the weft tapes without a catch device.

[0081] In any of the embodiments disclosed herein, a second form of positioner can comprise a pre-positioner, although the actions of the catch device and pre-positioning can be handled by a single mechanism. Alternatively, the catch device can be considered to comprise this second form of positioner, such that the catch device includes pre-positioning.

[0082] In any of the embodiments disclosed herein, the catch device can further comprise a prepositioner, which is able to move forward and backward in the warp direction. This enables the pre-positioner, either by using the catch device itself or through the use of a secondary set of actuatable pushing / gripping elements, to change the angular alignment and relative spacing of the weft tape relative to the previous weft tape.

[0083] In any of the embodiments disclosed herein, where the catch device is limited by only being able to increase the spacing between these two weft tapes, the pre-positioner can also push the weft tape closer to the previous weft tape to make up for a delayed, or short, beat (under the assumption that the line speed (output of material from the machine) is constant or the rate of interlacing is constant).

[0084] In any of the embodiments disclosed herein, an array of more than one catch device and / or pre-positioner may be used to hold, reposition, and release multiple weft tapes in order to create a buffer stock for situations where a number of weft tapes must be placed in close proximity to one another.

[0085] In any of the embodiments disclosed herein, the catch device or pre-positioner may comprise a set of sensors that detect the location of the weft tape, which a controller can use to determine how far to move the weft tape (pre-positioning) and when to release the weft tape to achieve the desired spacing between the current and previous weft tapes.

[0086] In any of the embodiments disclosed herein, a third form of positioner can comprise a post-positioner station and / or the steps thereof. Following a first nip roll station, but before aconsolidation zone, a post-positioner station comprising a post-positioner can be located and configured to correct small angle and position deviations in the interlaced tapes. The catch device and / or pre-positioner are upstream the first nip roll station, while the post-positioner is downstream the first nip roll station.

[0087] In any of the embodiments disclosed herein, the post-positioner can comprise multiple actuatable rods that can extend up (or down) into the plane of the interlaced tapes, with the rods mounted on a moveable platform or similar mechanism allowing them to be moved forward and backward along the warp direction.

[0088] In any of the embodiments disclosed herein, the post-positioner station can further comprise one or more sensors or an array of sensors, for example, position sensors, lidar, and / or computer vision), wherein utilizing sensor input to measure the actual spacing between adjacent weft tapes and the actual relative angle of the weft tapes, relative to a desired spacing and / or desired angle, the post-positioner can reposition the tape to the desired spacing and / or desired angle.

[0089] In any of the embodiments disclosed herein, the post-positioner station can further comprise a tacking device that applies heat and pressure to one or more locations of interlacing (of a warp and weft tape) in order to fix their position prior to full consolidation. In exemplary embodiments, multiple locations of tacking / welding / melt-bonding is utilized, for example, at least one weft tape is tacked to two or more warp tapes. In order to function effectively and avoid loss of positioning, the post-positioner is preferably configured to maintain direct contact with the weft tape until it is fully gripped or otherwise secured by the tacking device.

[0090] In any of the embodiments disclosed herein, the tacking device may use one or more heated wheels, belts, or a clamping device configured to consolidate one or more pairs of warp tape and weft tapes at the location(s) of interlace (where the consolidation area may be substantially smaller than the size of the interlace area)

[0091] In any of the embodiments disclosed herein, the tacking device may comprise an ultrasonic sealer (rotary heat sealer).

[0092] These steps of post-positioning and tacking are particularly valuable when continuous ultrasonic welding is used in a downstream ultrasonic consolidation zone where the woven composite is consolidated. In this case, a vibration isolation roller configuration can be placedbetween the tack welder and the ultrasonic consolidation zone, which is configured to dampen vibrations propagating upstream from the ultrasonic consolidation, and thus permits the tack welder to secure the position and alignment of the weft tapes such that they are not vibrated out of position or misaligned as they enter the ultrasonic welding zone.

[0093] In another exemplary embodiment, the present invention is a method comprising forming a woven composite of one or more warp tapes and one or more weft tapes comprising inserting a feed of weft tape in a weft direction, gas-assist drawing of the inserted feed of weft tape through a weft guide path by exposing the inserted feed of weft tape to the Coanda effect, shear cutting the drawn feed of weft tape top form a target drawn length of weft tape, beating the target drawn length of weft tape clear of the weft guide path in the warp direction, and interlacing a feed of warp tapes and the beat target drawn length of weft tape, and consolidating the interlaced warp and weft tapes to form a consolidated woven composite

[0094] In any of the embodiments disclosed herein, the feed of weft tape is media-assisted,” as the weft tape is “pushed” by the inserting step, and “pulled” by the media-assist. In any of the embodiments disclosed herein, the present invention “pushes” the feed of weft tape across the shed leveraging the weft tape’s own rigidity, using weft guide channels in the warp heads and in static weft supports to provide support with media-assist to enhance acceleration and “pull” the weft tape across the shed.

[0095] In any of the embodiments disclosed herein, the inserting can comprises continuously inserting over repeated weft tape insertion cycle times. A weft tape insertion cycle includes the steps of inserting, drawing, shear cutting, beating, and repositioning (the warp heads, enabling a subsequent weft insertion cycle to begin after a preceding weft insertion cycle has ended. In any of the embodiments disclosed herein, each weft tape insertion cycle time can be 1 second or less.

[0096] The time duration of each weft insertion cycle more preferably is 800 ms or less. The time duration of each weft insertion cycle can be 500 ms or less.

[0097] In any of the embodiments disclosed herein, the feed of weft tape traverses the weft guide path in a physical-grip-free traversal. The feed of weft tape is not “gripped” by a mechanical mechanism to be dragged across the weft guide path. The feed of weft tape is pushed by the inserting step, and pulled by the media-assist, where in exemplary embodiments, the media-assist is tuned so as to expose the feed of weft tape to the Coanda effect.

[0098] In any of the embodiments disclosed herein, one or more pneumatic sources is used both to deliver the media-assist and to form at least a portion of the beating step. For example, air is used along specific locations of the weft guide path to expose the feed of weft tape to the Coanda effect, and air is used to provide an air-assist beating step.

[0099] In any of the embodiments disclosed herein, an air-assist system can independently provide air to different locations of the weft guide path. The provision of air at different locations can be at different times one from one another, at different speeds one from one another, and combinations of the same and different such characteristics to optimally subject the inserted feed of weft tape to the Coanda effect.

[0100] In any of the embodiments disclosed herein, the shear cutting can comprise exposing the feed of weft tape to a concentrated region of high shear stress using a shearing blade as part of a single shear cutting cycle.

[0101] In any of the embodiments disclosed herein, the shear cutting can comprise shear cutting over repeated shear cutting cycle times. In any of the embodiments disclosed herein, each shear cutting cycle time can be less than 100 ms.

[0102] In any of the embodiments disclosed herein, the beating step is wholly an air-assisted beat, or is a combination of mechanical-assist beating via one or more of the mechanical-assist beat weft supports and air-assist beating by an air gas system configured to provide air to one or more of the weft guide channels of the air-assist beat weft supports.

[0103] In another exemplary embodiment, the present invention is a method comprising forming a woven composite of one or more warp tapes and one or more weft tapes comprising a continuous series of weft insertion cycles and interlacing a feed of warp tapes and the beat target drawn length of weft tape.

[0104] Each of the weft insertion cycles can comprise inserting a feed of weft tape in a weft direction, physical-grip-free drawing of the inserted feed of weft tape through a weft guide path to a target drawn location, shear cutting the drawn feed of weft tape to form a target drawn length of weft tape, beating the target drawn length of weft tape clear of the weft guide path in the warp direction, and repositioning, which enables a subsequent weft insertion cycle to begin after apreceding weft insertion cycle has ended. A time duration of each weft insertion cycle is preferably 1 second or less

[0105] In any of the embodiments disclosed herein, the method can further comprise consolidating the interlaced warp and weft tapes to form a consolidated woven composite.

[0106] In any of the embodiments disclosed herein, the consolidating comprises applying heat and pressure to the woven composite of warp tapes and weft tapes. Consolidating the woven composite can comprise heating the composite weave in a heated zone configured to meld together one or more warp tapes and one or more weft tapes of the woven composite and compressing the woven composite.

[0107] In any of the embodiments disclosed herein, the heating and the compressing can comprise an ultrasonic welding bar that, for heating, vibrates the woven composite to generate heat by elastic losses and, for compressing, compresses the woven composite against an anvil. In an exemplary embodiment, the heating and the compressing comprises a continuous ultrasonic welding with an anvil roller.

[0108] In any of the embodiments disclosed herein, the heating zone can comprise a heating device selected from the group consisting of an inductive heater, a convection device, and a microwave heating device, wherein the inductive heater can induce current in the woven composite by generating an alternative or rotating magnetic field to generate heat through resistive losses, and wherein the convection device can circulate hot air around the woven composite.

[0109] In any of the embodiments disclosed herein, compressing the woven composite can comprise compressing the woven composite by drawing the woven composite through a first pair of opposing rollers of a consolidating roller assembly.

[0110] In any of the embodiments disclosed herein, the method can further comprise tensioning the consolidated woven composite as it cools by drawing the consolidated woven composite through a second pair of opposing rollers of the consolidating roller assembly after compressing the woven composite through the first pair of opposing rollers of the consolidating roller assembly.[OHl] In any of the embodiments disclosed herein, sensing / monitoring steps and / or sensors can be integrated into the methods and systems to, for example, detect where the weft tape is locatedduring insertion (to time the air-assist), and when the weft tapes have been beat clear of the channels (to permit the warp heads to move to their next position).

[0112] In another exemplary embodiment, the present invention is a machine comprising a weft tape inserter configured to insert a feed of weft tape in a weft direction, a weft guide path defined at least in part by weft guide channels in the warp heads and the weft supports, a physical-grip- free system configured to draw the inserted feed of weft tape through the weft guide path to a target drawn location, and a shear cutting assembly configured to shear cut the drawn feed of weft tape, forming a target drawn length of weft tape.

[0113] In any of the embodiments disclosed herein, the components of the machine can be modular, and scaled to a wide variety of dimensions.

[0114] In any of the embodiments disclosed herein, the machine can further comprise a beat system configured to beat the target drawn length of weft tape clear of the weft guide path in the warp direction.

[0115] In any of the embodiments disclosed herein, the machine can further comprise a draw gas system configured to provide a draw gas to the weft guide path, and a beat gas system configured to provide a beat gas to the beat system.

[0116] In any of the embodiments disclosed herein, the physical-grip-free system can comprise a gas-assist drawing system configured to draw the inserted feed of weft tape through the weft guide path by exposing the inserted feed of weft tape to the Coanda effect.

[0117] In any of the embodiments disclosed herein, each weft support can be selected from a group consisting of a gas-assist draw weft support, a gas-assist beat weft support, and a mechanical-assist beat weft support.

[0118] In any of the embodiments disclosed herein, the draw gas system can be configured to provide the draw gas to the weft guide channel of one or more of the warp heads and the weft guide channel of one or more of the gas-assist draw weft supports.

[0119] In any of the embodiments disclosed herein, the beat gas system can be configured to provide the beat gas to the weft guide channel of one or more of the gas-assist beat weft supports.

[0120] In any of the embodiments disclosed herein, the weft guide path can comprise an alignment of the weft guide channels across an operating width of the machine through which the feed of weft tape is inserted and drawn.

[0121] In any of the embodiments disclosed herein, the weft tape inserter can be further configured to insert the feed of weft tape in the weft direction from a continuous feedstock.

[0122] In any of the embodiments disclosed herein, each warp head can have a warp tape slot configured to contain a warp tape passing therethrough in a warp direction.

[0123] In any of the embodiments disclosed herein, the beat system can further comprise the mechanical-assist beat weft supports that provide a mechanical beat means to the target drawn length of weft tape.

[0124] In another exemplary embodiment, the present invention is a machine comprising one or more weft tape inserters, each weft tape inserter configured to insert a feed of weft tape in a weft direction from a continuous feedstock, warp heads, each comprising a warp tape slot configured to contain a warp tape passing therethrough in a warp direction, and a weft guide channel, weft supports, each comprising a weft guide channel, and each selected from a group consisting of a gas-assist draw weft support, a gas-assist beat weft support, and a mechanical-assist beat weft support, a gas-assist drawing system configured to draw the inserted feed of weft tape through a weft guide path by exposing the inserted feed of weft tape to the Coanda effect, a shear cutting assembly configured to shear cut the drawn feed of weft tape, forming a target drawn length of weft tape, and a beat system configured to beat the target drawn length of weft tape clear of the weft guide path in the warp direction, wherein the weft guide channels of the warp heads and the weft supports are configured for alignment across an operating width of the machine forming the weft guide path through which the feed of the weft tape pass, and wherein the gas-assist drawing system is configured for physical-grip-free passing of the feed of the weft tape through the weft guide path.

[0125] In any of the embodiments disclosed herein, the machine can be configured to run a continuously repeating series of weft insertion cycles.

[0126] In any of the embodiments disclosed herein, each weft insertion cycle can comprise the steps of inserting the feed of weft tape, drawing the feed of weft tape through the weft guide path,shear cutting the drawn feed of weft tape, beating the target drawn length of weft tape, and repositioning the warp heads, wherein the repositioning enables a subsequent weft insertion cycle to begin after a preceding weft insertion cycle has ended.

[0127] In any of the embodiments disclosed herein, a time duration of each weft insertion cycle can be 1 second or less.

[0128] In any of the embodiments disclosed herein, the weft guide path can have a height of from 1-5 mm and a width between a width of the weft tape and 150% of the weft tape width.

[0129] In any of the embodiments disclosed herein, the weft guide channel of one or more of the warp heads and the gas-assist draw weft supports can incorporate an array of surface features on a top surface and / or a bottom surface.

[0130] In any of the embodiments disclosed herein, the array of surface features can run along the weft direction in order to reduce contact area and direct gas flow along the weft direction.

[0131] In any of the embodiments disclosed herein, one or more characteristics of the gas from the gas-assist drawing system and one or more characteristics of the weft guide channel of one or more of the gas-assist draw weft supports can cooperate to maintain the feed of the weft tape passing through the weft guide path in an insertion orientation.

[0132] In any of the embodiments disclosed herein, each weft tape inserter can comprise a weft tape insertion control mechanism configured to apply a grip pressure to grip the feed of weft tape, and accelerate / decelerate the feed of weft tape in order to propel the feed of weft tape in the weft direction.

[0133] In any of the embodiments disclosed herein, the machine can further comprise a catch device configured to provide a repeatable reference stop location as the target drawn lengths of weft tape are beat out of the weft guide path.

[0134] In any of the embodiments disclosed herein, the catch device can be further configured to increase spacing between consecutively beat target drawn lengths of weft tape.

[0135] In any of the embodiments disclosed herein, the machine can further comprise a positioner.

[0136] In any of the embodiments disclosed herein, when the beat target drawn lengths of weft tape are clear of the weft guide path, an initial orientation of a woven composite can be formed from an interlacing of the warp tapes and the target drawn lengths of weft tape.

[0137] In any of the embodiments disclosed herein, the positioner can be configured to position one or more of the tapes of the initial orientation of the woven composite to form a preconsolidation orientation of the woven composite.

[0138] In any of the embodiments disclosed herein, the time duration of each weft insertion cycle can be 800 ms or less. In any of the embodiments disclosed herein, the time duration of each weft insertion cycle can be 500 ms or less.

[0139] In any of the embodiments disclosed herein, the weft tape insertion control mechanism can comprise a double belt set comprising a top belt / pulley assembly and a bottom belt / pulley assembly.

[0140] In any of the embodiments disclosed herein, a portion of each of the belts can be proximate one another in a tape inserter zone.

[0141] In any of the embodiments disclosed herein, the double belt set can be configured to apply the grip pressure to grip the feed of weft tape and accelerate / decelerate the feed of weft tape in the tape inserter zone.

[0142] In any of the embodiments disclosed herein, the positioner can comprise a pre-positioner. In any of the embodiments disclosed herein, the pre-positioner can comprise a catch for catching the beat target drawn lengths of weft tape. In any of the embodiments disclosed herein, the pre- positioner can further comprise a pre-positioner monitoring system configured to monitor one or more pre -positioning characteristics of the caught target drawn lengths of weft tape. In any of the embodiments disclosed herein, the catch can be configured to increase a relative spacing between consecutively beat target drawn lengths of weft tape when one or more of the pre-positioning characteristics warrants the increase.

[0143] In any of the embodiments disclosed herein, the positioner can comprise a postpositioner. In any of the embodiments disclosed herein, the post-positioner can comprise a postpositioner monitoring system configured to monitor one or more post-positioning characteristics of the target drawn lengths of weft tape after the pre-positioner. In any of the embodimentsdisclosed herein, the post-positioner can further comprise a changing device configured to change the relative spacing and / or the relative angular alignment between warp tape and weft tapes when one or more of the post-positioning characteristics warrants the change.

[0144] In any of the embodiments disclosed herein, the machine can further comprise a tacking device. In any of the embodiments disclosed herein, the positioner can further comprise an active system configured to change a relative angular alignment of warp tape and weft tapes to perpendicular if one or more of the pre -positioning characteristics warrants the change. In any of the embodiments disclosed herein, the tacking device can be configured to apply heat and pressure to two or more locations of warp tape and weft tape interlace in order to fix the woven composite in the pre-consolidation orientation.

[0145] In any of the embodiments disclosed herein, the weft tape insertion control mechanism can further comprise a paired tape inserter roller set comprising a top roller and a bottom roller. In any of the embodiments disclosed herein, the paired tape inserter roller set can be positioned in the tape inserter zone to apply a non-slip pressure through the proximate belt portions and to the feed of weft tape in order to limit slippage.

[0146] In any of the embodiments disclosed herein, at least a portion of one or more of the belts can be coated with a textured rubber or elastomer.

[0147] In any of the embodiments disclosed herein, the weft tape insertion control mechanism can further comprise a belt / pulley assembly actuator. In any of the embodiments disclosed herein, the weft tape insertion control mechanism can further comprise a weft tape insertion control sensor. In any of the embodiments disclosed herein, at least one of the belt / pulley assemblies can be driven by the belt / pulley assembly actuator. In any of the embodiments disclosed herein, the weft tape insertion control sensor can be configured to monitor one or more belt / pulley assembly characteristics. In any of the embodiments disclosed herein, the belt / pulley assembly actuator can be adjustable in response to one or more of the monitored belt / pulley assembly characteristics.

[0148] In any of the embodiments disclosed herein, the weft tape insertion control mechanism can further comprise a weft tape insertion controller. In any of the embodiments disclosed herein, the weft tape insertion controller can be configured to adjust an insertion distance of the weft tape. In any of the embodiments disclosed herein, the weft tape insertion controller can be configured to adjust a motion profile of the weft tape. In any of the embodiments disclosed herein, the wefttape insertion controller can be configured to perform the one or more adjustments based on programmatic inputs in order to facilitate weft tape handling downstream of the one or more weft tape inserters.

[0149] In any of the embodiments disclosed herein, the machine can further comprise a consolidation zone. In any of the embodiments disclosed herein, the consolidation zone can be configured to form a consolidated woven composite from the woven composite.

[0150] In any of the embodiments disclosed herein, the double tape inserter roller can be positioned in the middle of the tape inserter zone.

[0151] In any of the embodiments disclosed herein, the belt / pulley assembly actuator can be adjustable in response to one or more of the monitored belt / pulley assembly characteristics in relation to programmable tolerance ranges for the one or more belt / pulley assembly characteristics.

[0152] In any of the embodiments disclosed herein, the machine can further comprise a vibration isolation assembly. In any of the embodiments disclosed herein, the consolidation zone can comprise an ultrasonic welder. In any of the embodiments disclosed herein, the vibration isolation assembly can be configured to dampen vibrations propagating upstream from the ultrasonic welder.

[0153] In any of the embodiments disclosed herein, at least one of the belt / pulley assembly characteristics can be selected from a group consisting of torque, speed, and position.

[0154] In another exemplary embodiment, the present invention is a machine for continuously forming a consolidated woven composite from tape material comprising a weft inserter stack comprising two or more weft tape inserters, each weft tape inserter configured to insert a feed of weft tape in a weft direction from a continuous feedstock, and a shear cutting assembly configured to shear cut a drawn feed of weft tape, forming a target drawn length of weft tape, a warp rack comprising warp heads for receiving warp tapes, each warp head comprising a warp tape slot configured to contain the warp tape passing therethrough in a warp direction, and a weft guide channel, and weft supports, each weft support comprising a weft guide channel, and selected from a group consisting of an air-assist draw weft support, an air-assist beat weft support, and a mechanical-assist beat weft support, an air system configured to provide air to the weft guide channel of one or more of the air-assist draw weft supports, and one or more of the air-assist beatweft supports, and a beat system configured to beat the target drawn length of weft tape clear of a weft guide path in the warp direction, wherein the weft guide channels of the warp heads and the weft supports are configured for alignment across an operating width of the machine forming the weft guide path through which the feed of weft tape pass, wherein one or more characteristics of the air from the air system and one or more characteristics of the weft guide channel of one or more of the air-assist draw weft supports cooperate to maintain the feed of weft tape passing through the weft guide path in an insertion orientation and to expose the feed of weft tape through the weft guide path to the Coanda effect, and wherein once the feed of weft tape has passed through the weft guide path and come to a stop in the weft direction, and before a subsequent feed of weft tape is permitted to traverse the same weft guide path, a current shear cut of the target drawn length of weft tape encounters the beat system, including a mechanical beat by mechanical means from one or more of the mechanical-assist beat weft supports, and during and / or after the mechanical beat, an air-assist beat by air from one or more of the air-assist beat weft supports.

[0155] In any of the embodiments disclosed herein, one of the air characteristics can be selected from a group consisting of a speed of air supplied by the air system to the weft guide channel of the air-assist draw weft supports, a volume of air supplied by the air system to the weft guide channel of the air-assist draw weft supports, and a direction of air supplied by the air system to the weft guide channel of the air-assist draw weft supports.

[0156] In any of the embodiments disclosed herein, one of the weft guide channel characteristics can be selected from a group consisting of a width of the weft guide channel of the air-assist draw weft supports, a height of the weft guide channel of the air-assist draw weft supports, and a surface profile of the weft guide channel of the air-assist draw weft supports.

[0157] In any of the embodiments disclosed herein, each weft tape inserter can comprise a weft tape insertion control mechanism configured to apply a grip pressure to grip the feed of weft tape and accelerate / decelerate the feed of weft tape in order to propel the feed of weft tape in the weft direction.

[0158] In any of the embodiments disclosed herein, the machine can further comprise a catch device configured to provide a repeatable reference stop location as the target drawn lengths of weft tape are beat out of the weft guide path. In any of the embodiments disclosed herein, thecatch device can be further configured to increase spacing between consecutively beat target drawn lengths of weft tape.

[0159] In any of the embodiments disclosed herein, the machine can further comprise a positioner. In any of the embodiments disclosed herein, when the beat target drawn lengths of weft tape are clear of the weft guide path, an initial orientation of a woven composite can be formed from an interlacing of the warp tapes and the target drawn lengths of weft tape. In any of the embodiments disclosed herein, the positioner can be configured to position one or more of the tapes of the initial orientation of the woven composite to form a pre-consolidation orientation of the woven composite.

[0160] In any of the embodiments disclosed herein, the weft tape insertion control mechanism can comprise a double belt set comprising a top belt / pulley assembly and a bottom belt / pulley assembly. In any of the embodiments disclosed herein, a portion of each of the belts can be proximate one another in a tape inserter zone. In any of the embodiments disclosed herein, the double belt set can be configured to apply the grip pressure to grip the feed of weft tape and accelerate / decelerate the feed of weft tape in the tape inserter zone.

[0161] In any of the embodiments disclosed herein, the positioner can comprise a pre-positioner comprising a catch for catching the beat target drawn lengths of weft tape, an active system, and a pre-positioner monitoring system configured to monitor one or more pre -positioning characteristics of the caught target drawn lengths of weft tape, wherein the catch is configured to increase a relative spacing between consecutively beat target drawn lengths of weft tape when one or more of the pre-positioning characteristics warrants the increase, and wherein the active system is configured to change a relative angular alignment of warp tapes and weft tapes to perpendicular if one or more of the pre -positioning characteristics warrants the change, and a post-positioner comprising a post-positioner monitoring system configured to monitor one or more postpositioning characteristics of the target drawn lengths of weft tape after the pre-positioner, and a changing device configured to change the relative spacing and / or the relative angular alignment between warp tapes and weft tapes when one or more of the post-positioning characteristics warrants the change.

[0162] In any of the embodiments disclosed herein, the machine can further comprise a tacking device configured to apply heat and pressure to two or more locations of warp tape and weft tape interlace in order to fix the woven composite in the pre-consolidation orientation.

[0163] In another exemplary embodiment, the present invention is a machine for forming a woven composite of one or more warp tapes and one or more weft tapes by a method comprising inserting feeds of the weft tapes in a weft direction from continuous feedstocks, aligning a set of weft guide channels to form a weft guide path through which the feeds of weft tape are to pass, wherein each weft guide channel is selected from a group consisting of a weft guide channel of a warp head and a weft support, and wherein each weft support is selected from a group consisting of an air-assist draw weft support, an air-assist beat weft support, and a mechanical-assist beat weft support, air-assisting the feeds of weft tapes through the weft guide path defined by the aligned set of weft guide channels by exposing the feeds of weft tapes passing through the weft guide path to the Coanda effect, shear cutting the feeds of weft tapes into target drawn lengths of weft tape, and beating the target drawn lengths of weft tape clear of the weft guide path.

[0164] In any of the embodiments disclosed herein, the beating can comprise imparting a mechanical beat in a warp direction by one or more of the mechanical-assist beat weft supports. In any of the embodiments disclosed herein, the beating can comprise imparting during and / or after the mechanical beat an air-assist beat in the warp direction by air from one or more of the airassist beat weft supports.

[0165] In any of the embodiments disclosed herein, the method practiced by the machine can further comprise monitoring one or more inserting characteristics of the inserting. In any of the embodiments disclosed herein, the method practiced by the machine can further comprise adjusting the inserting in response to one or more of the monitored inserting characteristics.

[0166] In any of the embodiments disclosed herein, the method practiced by the machine can further comprise catching the beat target drawn lengths of weft tape to provide a repeatable reference stop location for the caught beat target drawn lengths of weft tape. In any of the embodiments disclosed herein, the method practiced by the machine can further comprise increasing spacing between consecutively beat target drawn lengths of weft tape.

[0167] In any of the embodiments disclosed herein, the method practiced by the machine can further comprise changing an angular alignment and / or a relative spacing of the consecutively beat target drawn lengths of weft tape.

[0168] In any of the embodiments disclosed herein, the method practiced by the machine can further comprise applying heat and pressure to two or more locations of warp tape and weft tape interlace in order to fix the position of the interlace.

[0169] In any of the embodiments disclosed herein, the method practiced by the machine can further comprise consolidating the fixed position of the interlace to form a consolidated woven composite.

[0170] In any of the embodiments disclosed herein, the air-assisting practiced by the machine can electronically controlling air flow within two or more weft guide channels of air-assist draw weft supports, both in terms of pressure and activation timing.

[0171] In any of the embodiments disclosed herein, one or more of the weft supports and / or the warp heads can further comprise an array of sensors that detect the position of the feed of weft tape as it moves through the weft guide path, activating and deactivating individual air-assist units as the feed of weft tape passes to reduce a total air consumption.

[0172] In any of the embodiments disclosed herein, the method practiced by the machine can be configured to insert multiple layers of weft tapes.

[0173] In any of the embodiments disclosed herein, the method practiced by the machine can further comprise offsetting a weft tape insertion timing for each layer to allow at least one sensor of the array of sensors to detect the passage of two or more weft tapes and verify the position of each weft tape independently.

[0174] In any of the embodiments disclosed herein, the method practiced by the machine can further comprise sensing to detect slippage or jamming during the weft tape insertion. In any of the embodiments disclosed herein, the sensing data from the sensing can be fed back to a weft tape inserter controller to correct or retry the weft tape insertion.

[0175] In any of the embodiments disclosed herein, the roles of pre- and post-positioning need not be so delineated, as any of the “positioning” features mainly depend on an extent of - how much - shifting (if any) occurs as tapes pass through the nip rollers. As such, with thisnomenclature, exemplary embodiments may include only the “post-positioner,” and it is capable of large angle and position corrections.

[0176] In any of the embodiments disclosed herein, the method can further comprise automated control of one or more of the steps.

[0177] In any of the embodiments disclosed herein, the automated control can comprise adjusting one or more steps depending on at least one characteristic of the weft tape. In any of the embodiments disclosed herein, the automated control can comprise adjusting one or more steps depending on at least one characteristic of the warp tape. In any of the embodiments disclosed herein, the automated control can comprise adjusting one or more steps depending on at least one characteristic of the consolidating of the woven composite to form the consolidated woven composite.

[0178] In any of the embodiments disclosed herein, media-assisting can comprise physical-grip- free drawing of the feed of weft tape across the operating width. Media-assisting can comprise exposing the feed of weft tape to the Coanda effect throughout the operating width in order to maintain a media-assisted orientation of the feed of weft tape through the media-assisting process. The feed of weft tape can be subject to the media at a speed, volume, direction, density and other media operating conditions at preferably multiple different locations along the operating width, with the time / speed / volume / etc. of each media-assist location being optimized for a smooth and quick media-assist of the feed of weft tape across the operating width, all the while maintaining a consistent media-assisted orientation of the weft tape to avoid breaks, bunching and other disadvantageous events occurring with the feed of weft tape through the media-assist process.

[0179] In any of the embodiments disclosed herein, the media-assist can comprise gas, and more preferably, air.

[0180] In any of the embodiments disclosed herein, the drawing of the feed of weft tape comprises a “push” from the inserting step and a “pull” from the media (“media-assist”) to bring the feed of weft tape through the weft guide path formed of a series of aligned weft guide channels present in warp heads and in weft supports. Each weft support can be selected from a group consisting of a media-assist weft support, a media-assist beat weft support, and a mechanical-assist beat weft support. In some uses, a weft support is termed a static weft support.

[0181] In any of the embodiments disclosed herein, the media-assist comprises a physical-grip- free media-assist for the feed of weft tape across the operating width - being a draw across the operating width that is free of physically gripping the weft tape.

[0182] While any one or more of the weft guide channels can be configured to provide the media-assist (any warp head and / or any type of the weft support), in exemplary embodiments, the media-assist is located in at least the media-assist weft supports.

[0183] In any of the embodiments disclosed herein, the warp heads and the one or more static weft supports can be aligned in an alternating arrangement across the operating width of the machine, and / or partial sets of an arrangement of one or more warp heads and one or more of the static weft supports can form discrete modules, and the discrete modules arranged across the operating width of the machine, still providing for the alternating arrangement of head(s) / support(s).

[0184] In another exemplary embodiment, the present invention combines the media-assist feature (push / inserting and pull / media-assist) with the media-assist beating (preferably the mediaassist beating combined with a mechanical beat component).

[0185] In any of the embodiments disclosed herein, the present invention may only use media / air during an acceleration phase to assist the belt drive of the weft tape inserter, which also brakes (decelerates) and holds the feed of weft tape until it is shear cut.

[0186] In any of the embodiments disclosed herein, the weft guide channel has an open side to facilitate extraction of the shear cut weft tape during the beat step. In any of the embodiments disclosed herein, the weft guide channel has a height of from 1-5 mm. In any of the embodiments disclosed herein, the weft guide channel has a height of from 2-3 mm.

[0187] In any of the embodiments disclosed herein, the weft guide channel has a width of not less than the weft tape width, and not more than 150% of the weft tape width.

[0188] In any of the embodiments disclosed herein, the weft guide channel has at least portions that incorporate an array of surface features, for example, small ribs or troughs, on the top and / or bottom surface of the weft guide channel, running along the direction of weft tape insertion in order to reduce contact area and direct air flow along the insertion direction.

[0189] In any of the embodiments disclosed herein, at least one of the two belt and pulley sets is driven by a motor and is capable of monitoring and adjusting one or more of torque, speed, or position based on sensor feedback and programmable tolerance ranges.

[0190] In any of the embodiments disclosed herein, a set of rollers in the middle of the double belt is used to apply pressure through the belts to the weft tape in order to prevent slippage.

[0191] In any of the embodiments disclosed herein, the belts are coated with a textured rubber or elastomer.

[0192] In any of the embodiments disclosed herein, a computer controller can adjust the insertion distance and motion profile based on programmatic inputs in order to facilitate variation in the weft tape length in the finished composite lattice.

[0193] In any of the embodiments disclosed herein, a computer controller can adjust the insertion distance and motion profile based on programmatic inputs in order to create discontinuous segments in the weft tape.

[0194] In any of the embodiments disclosed herein, the shear blade can be actuated along the tension axis in a manner that maintains a state of tension in the blade at all times.

[0195] In any of the embodiments disclosed herein, air-assist can further comprise one or more internal air channels, terminating in a nozzle designed to direct the airflow along the top and / or bottom of the weft tape.

[0196] In any of the embodiments disclosed herein, the air flow within the air-assist can be electronically controlled, both in terms of pressure and activation timing, and the static weft supports and / or the warp heads can further comprise an array of sensors that detect the position of the weft tape as it moves across the warp heads, activating and deactivating individual air-assist units as the weft tapes passes to reduce the total air consumption.

[0197] In any of the embodiments disclosed herein, for machines that insert multiple layers, the weft tape insertion timing for each layer may be offset slightly, to allow one sensor to detect the passage of two or more weft tapes and verify each weft tape’s position independently.

[0198] In any of the embodiments disclosed herein, sensing may be further used to detect slippage or jamming during the weft tape insertion, data which can be fed back to a weft tape inserter controller to correct or retry the insertion.

[0199] In any of the embodiments disclosed herein, the warp heads can further comprise slots for the warp tapes that contain the movement of the warp tapes up, down, left, and right (relative to the direction of feed, i.e., the warp direction).

[0200] In another exemplary embodiment of the present invention, a method of using the innovative machine disclosed herein is used to produce an inventive woven composite, and / or an inventive consolidated woven composite.

[0201] These and other aspects of the present disclosure are described in the Detailed Description below and the accompanying drawings. Other aspects and features of embodiments will become apparent to those of ordinary skill in the art upon reviewing the following description of specific, exemplary embodiments in concert with the drawings. While features of the present disclosure may be discussed relative to certain embodiments and figures, all embodiments of the present disclosure can include one or more of the features discussed herein. Further, while one or more embodiments may be discussed as having certain advantageous features, one or more of such features can also be used with the various embodiments discussed herein. In similar fashion, while exemplary embodiments may be discussed below as device, system, or method embodiments, it is to be understood that such exemplary embodiments can be implemented in various devices, systems, and methods of the present disclosure.BRIEF DESCRIPTION OF THE DRAWINGS

[0202] The following detailed description of specific embodiments of the disclosure will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the disclosure, specific embodiments are shown in the drawings. It should be understood, however, that the disclosure is not limited to the precise arrangements and instrumentalities of the embodiments shown in the drawings.

[0203] FIG. 1 is a schematic of the present invention according to an exemplary embodiment.

[0204] FIG. 2 is a schematic of the present invention according to another exemplary embodiment.

[0205] FIG. 3 is a schematic of the present invention according to another exemplary embodiment.

[0206] FIG. 4 illustrates the inserting of the present invention according to an exemplary embodiment.

[0207] FIG. 5 illustrates the inserting of the present invention according to another exemplary embodiment.

[0208] FIG. 6 illustrates components of the air-assisting and the beating of the present invention according to an exemplary embodiment.

[0209] FIGS. 7A, 7B illustrate warp heads and weft supports, including components of the air assisting and beating of the present invention according to an exemplary embodiment.

[0210] FIGS. 8A-8C illustrate weft guide channel design and beating (by an air beat and a mechanical beat) of the present invention according to an exemplary embodiment.

[0211] FIG. 9A, 9B illustrates the shear cutting of the present invention according to an exemplary embodiment.

[0212] FIG. 10 illustrates the positioner of the present invention according to an exemplary embodiment.

[0213] FIG. 11 illustrates a pre-positioner of the present invention according to an exemplary embodiment.

[0214] FIG. 12 illustrates a post-positioner of the present invention according to an exemplary embodiment.DETAILED DESCRIPTION

[0215] Some implementations of the disclosed technology will be described more fully with reference to the accompanying drawings. This disclosed technology may, however, be embodied in many different forms and should not be construed as limited to the implementations set forth herein. The components described hereinafter as making up various elements of the disclosed technology are intended to be illustrative and not restrictive. Indeed, it is to be understood that other examples are contemplated. Many suitable components that would perform the same or similar functions as components described herein are intended to be embraced within the scope of the disclosed electronic devices and methods. Such other components not described herein mayinclude, but are not limited to, for example, components developed after development of the disclosed technology.

[0216] Herein, the use of terms such as “having,” “has,” “including,” or “includes” are open- ended and are intended to have the same meaning as terms such as “comprising” or “comprises” and not preclude the presence of other structure, material, or acts. Similarly, though the use of terms such as “can” or “may” are intended to be open-ended and to reflect that structure, material, or acts are not necessary, the failure to use such terms is not intended to reflect that structure, material, or acts are essential. To the extent that structure, material, or acts are presently considered to be essential, they are identified as such.

[0217] It is to be understood that the mention of one or more method steps does not preclude the presence of additional method steps or intervening method steps between those steps expressly identified. Similarly, it is also to be understood that the mention of one or more components in a device or system does not preclude the presence of additional components or intervening components between those components expressly identified. Further, it is contemplated that the disclosed methods and processes can include, but do not necessarily include, all steps discussed herein. That is, methods and processes in accordance with the disclosed technology can include some of the disclosed while omitting others.

[0218] Throughout the specification and the claims, the following terms take at least the meanings explicitly associated herein, unless otherwise indicated. The term “or” is intended to mean an inclusive “or. “ Further, the terms “a,” “an,” and “the” are intended to mean one or more unless specified otherwise or clear from the context to be directed to a singular form. By “comprising,” “containing,” or “including” it is meant that at least the named element, or method step is present in article or method, but does not exclude the presence of other elements or method steps, even if the other such elements or method steps have the same function as what is named.

[0219] As used herein, unless otherwise specified, the use of the ordinal adjectives “first,” “second,” “third,” etc. , to describe a common object, merely indicate that different instances of like objects are being referred to, and are not intended to imply that the objects so described must be in a given sequence, either temporally, spatially, in ranking, or in any other manner.

[0220] Although the disclosed technology may be described herein with respect to various systems and methods, it is contemplated that embodiments or implementations of the disclosedtechnology with identical or substantially similar features may alternatively be implemented as methods or systems. For example, any aspects, elements, features, or the like described herein with respect to a method can be equally attributable to a system. As another example, any aspects, elements, features, or the like described herein with respect to a system can be equally attributable to a method.

[0221] The characteristics described as defining the various elements of the invention are intended to be illustrative and not restrictive. For example, if the characteristic is a material, the material includes many suitable materials that would perform the same or a similar function as the material(s) described herein are intended to be embraced within the scope of the invention. Such other materials not described herein can include, but are not limited to, for example, materials that are developed after the time of the development of the invention.

[0222] Reference will now be made in detail to examples of the disclosed technology, examples of which are illustrated in the accompanying drawings and disclosed herein. Wherever convenient, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

[0223] As noted previously, conventional yam weaving technologies typically use air jet weft tape insertion. Since yam is essentially round, the air nozzles are designed to create a vortex that centers and may even slightly twist the yam during insertion. These assemblies include a reed used to mechanically beat the yam and the air nozzles are integrated into the reed. Additionally, a brake nozzle and stretch nozzle are used to hold the yam in tension during insertion and cutting.

[0224] As one of skill in the art appreciates, these aspects of conventional yam weaving cannot be successfully used in a composite forming machine and method for forming composites that use thermoplastic prepreg tapes, that weaves and consolidates the tapes into a lattice structure of a single layer or of multiple layers, where the tape machine / process is automated and continuous, reduces waste, reduces cycle times and reduces material handling costs.

[0225] To the extent the present invention in some instances can be described as embodying “improvements” over these limitations in conventional yam weaving, in exemplary embodiments, the present invention necessary deviates from known prior wearing technologies by integrating air-assist for the feed of weft tape through the weft guide path defined by an aligned set of weft guide channels by exposing the feed of weft tape passing through the weft guide path to the Coanda effect, and a beating system including both a mechanical beat component and an air-assist beatcomponent. Mechanically beating the weft tape can be an initial step prior to or concurrently with an air-assist beat. Mechanically beating can include a process to push the weft tape perpendicular to the direction of tape insertion (“edge-on”). Mechanically beating is designed to provide initial impulse to overcome friction and resting inertia of the weft tape, while the air-assist beat stabilizes the weft tape and propels it forward to the target location in the shed.

[0226] In any of the embodiments disclosed herein, the present invention utilizes the Coanda effect to create a laminar cushion of air and / or suction across the flat surface(s) of the tape to (pull) the weft tape. Additionally, in an exemplary embodiment, the present invention only uses air during an acceleration phase to assist a belt driven insertion of the weft tape, which also brakes (decelerates) and holds the tape until cut by a weft tape shear cutter.

[0227] As noted previously, conventional tape weaving loom technologies are capable of weaving partially or fully impregnated thermoplastic tapes, but use a device (such as a rapier) to physically grip and “pull” the tape across the shed. Examples include the manufacture of TeXtreme® Spread Tow fabrics and the DORNIER Composite Systems® machines.

[0228] The conventional tape weaving looms are also limited to creating fully dense fabrics (unless a leno weave or binder yam is used) as a traditional beater is used and the tape fabric is rolled up without melt bonding. Of course, tapes cannot be used in leno weaves as they will become damaged if twisted.

[0229] As one of skill in the art appreciates, in most real respects none of these aspects of conventional tape weaving loom technologies can be successfully used in a beneficial composite forming machine and method for forming composites that can start with thermoplastic prepreg tapes, weaves and consolidate the tapes into a lattice structure, where the machine / process is automated and continuous, while reducing waste, cycle time and material handling costs compared to conventional composite reinforcement methods.

[0230] To the extent the present invention in some instances can be described as embodying “improvements” over these limitations in conventional tape weaving looming, in exemplary embodiments, the present invention “pushes” the tape across the shed, leveraging the tape’s own properties including rigidity, using the static weft guide channels to provide support in its travel, and air-assist to enhance acceleration.

[0231] In a more general sense, without regard to order of importance to the present invention, and not including an exhaustive list of the many innovations of the present invention, the following areas for improvement over convention systems were investigated, and the present invention embodies components, elements, stations, mechanisms, assemblies, and / or steps to address each one:

[0232] increasing weft tape insertion speed as much as technically feasible to minimize what conventionally is the longest single process step;

[0233] reducing the amount of time spent cutting the weft tape and beating it clear of the warp heads as the warp heads are unable to reposition until these actions are complete;

[0234] implementing a realignment / repositioning system to correct for errors or “catch up” missed insertions;

[0235] isolating vibration upstream if an ultrasonic welding process is used in order to preserve tape alignment and spacing; and

[0236] maintaining controllable tension throughout the machine, from the infeed rolls until after the lattice is fully bonded.

[0237] As disclosed herein, and shown in the figure, while discrete actions / sy stems are assigned reference numbers, and arrows are used to show representative directions / timings, those of skill in the art will appreciate that the various reference numbers and arrows and descriptions of components of the inventive methods and machines are not specific as to either spatial or temporal aspects to other components. Indeed, in many exemplary embodiments of the present invention, two or more steps may be nearly, if not completely, simultaneous (although one step is shown “before” or “after” another step). Similarly, two or more physical components may be in all real respect combined into a single or unitary sub-system (although one mechanism is shown separate from another).

[0238] The present invention as shown in FIG. 1 is a method 10 comprising inserting a feed of weft tape in a weft direction, physical-grip-free drawing 200 of the inserted feed of weft tape through a weft guide path to a target drawn location, shear cutting 300 the drawn feed of weft tape, forming a target drawn length of weft tape, and beating 400 the target drawn length of weft tape clear of the weft guide path in the warp direction. The method 10 further comprises interlacing500 a feed of warp tapes and the beat target drawn length of weft tape into an initial orientation of interlaced warp and weft tapes.

[0239] The method 10 can further comprise consolidating 900 the woven composite to form a consolidated woven composite.

[0240] The method 10 can further comprising transforming 600 the initial orientation of the interlaced warp and weft tapes into a pre-consolidation orientation of the interlaced warp and weft tapes. The transforming 600 can comprise positioning one or more of the tapes of the initial orientation of the woven composite to form a pre-consolidation orientation of the woven composite. With transforming / positioning 600, consolidating 900 comprises consolidating the pre-consolidation orientation of the woven composite to form the consolidated woven composite.

[0241] The method 10 can further comprise tacking 700 two or more locations of warp tape and weft tape interlace in order to fix the position of the woven composite prior to consolidating 900. Tacking 700 occurs between beating 400 and consolidating 900, and if the method includes the transforming / positioning 600, tacking 700 occurs between positioning 600 and consolidating 900.

[0242] The consolidating 900 can include heating and clamping configured to consolidate one or more pairs of warp tape and weft tapes at the location of interlace (where the consolidation area may be substantially smaller than the size of the interlace area). The consolidating process can include ultrasonic welding.

[0243] If the consolidating 900 creates vibratory issues during operation, for example, when using an ultrasonic welder, the method 10 can further dampening 800 located between the tacking 700 and the ultrasonic welder, to dampen vibrations propagating upstream from the ultrasonic welder and enable the tacking 700 to secure the position and alignment of the pre-consolidation orientation of the woven composite such that one or more of the tapes are not vibrated out of position or misaligned prior to tacking 700.

[0244] The method 10 can further comprises controlling / control processes 1000 to effectively control the various aspects of the present invention. Those of ordinary skill in the art will appreciate that controlling can include a number of different types of sensing, monitoring, computing, processing, evaluating, comparing, communicating and other features that provide for control, autonomous or otherwise, to operate the method or a machine for performing the method.

[0245] Any one or more of the process 100-900, in whole or in part, can be controlled by control processes 1000. In most embodiments, each process 100-900 embodies automation, control, computer-assistance, etc. that is addressed by control processes 1000, and in many instances, simultaneously controlled as one process may depend on the successful control of another process, so the various processes can be synchronized by the control processes 1000.

[0246] For example, as the present invention might work with tapes with various different physical attributes at different times, and run at various different production speeds, in exemplary embodiments the components of the present invention are designed to run efficiently with a variety of different types of tapes, and at varying production speeds, and the smooth operation of the whole process is handled by changes implemented by the control processes 1000, and not necessarily by changing out components.

[0247] Various computing elements of control processes 1000 comprise a microcontroller (MC, UC, or pC) or microcontroller unit (MCU), typically having one or more CPUs (processor cores) along with memory and programmable input / output peripherals. The use of microcontrollers provides autonomous control over various components of the present invention.

[0248] As used herein, microcontrollers can include, but are not limited to, 8-bit microcontrollers, 16-bit microcontrollers, 32-bit microcontrollers, 8051 microcontrollers, Peripheral Interface Controllers (PICs), Atmel AVR microcontrollers, Advanced Rise Machine (ARM) processors, Reduced Instruction Set Computing (RISC) processors, Complex Instruction Set Computing (CISC) processors, and the like.

[0249] Other microcontrollers and microprocessors of similar computational capacity, or custom logic circuitry, may alternatively be used for the control activities of the present invention, so long as adequate computational capacity is provided. Those of skill in the art will be readily able to select and implement the appropriate device or circuitry compatible with a variety of operating systems for use with control system(s) of the present invention.

[0250] The present invention is described in terms of process improvements. The tapes are at various times handled, manipulated, tacked, consolidated, etc. via innovative processes. Conventional disadvantages of weaving and consolidating tapes are overcome with the disclosed process technologies, where in essence, a tape is processed from a first state (before the disclosed process) to a second state (after the disclosed process), or via interim states, but the inventionresides in providing a methodology of processing the tape through states, which the convention machines simply cannot perform.

[0251] These various process steps are actions, but there are physical and electrical and computing components that “perform” various aspects of the actions. A main concept here is that the processes themselves are innovative, while there are myriad ways of using different physical and / or different electrical and / or different computing components to carry out the various aspects of the actions.

[0252] As just one example, a goal of the innovative inserting 100 is to insert the weft tape safely and reliably to a downstream process. Another goal is to insert / accelerate / decelerate the weft tape without, for example, exceeding the buckling strength of the tape (break the tape). Yet another goal is to insert / accelerate / decelerate the weft tape in such a way that the feed of tape is presented to the shear cutting 300 in the media-assisted orientation and tension / compression to be safely and reliably shear cut. The conventional weft tape insertion process cannot achieve these “actions” of the innovative inserting 100, and the present weft tape insertion process is innovative without specific regard to the physical and electrical and computing components that can achieve the weft tape insertion process.

[0253] The media-assisted orientation of the feed of weft tape is the orientation of the drawn weft tape traveling along the weft guide path and prior to being shear cut and beat. More broadly, a “configuration” of tape includes features / properties of the tape, for example, whether it is under tension, its spatial features (is fully flat, or curled in areas, or has other geometries), its temperature, its material properties (which may change upon heating, stress / strain, being welded, have material(s) inserted in a particular area / step), etc.

[0254] Each tape configuration can be different one from another (generally, like warp from weft; or specifically, like the warp tape at feeding vs. the warp at interlacing vs. the warp tape in the pre-consolidation orientation of the woven composite), the same, or a combination of different and similar. For example, the weft tape at various stages can embody an insertion orientation, a shear cutting orientation, the media-assisted orientation, a beat orientation, etc. Thus, properties of the weft tape and warp tapes can be modified at various stages to improve the specific tape’s performance in a particular station.

[0255] Conventional disadvantages are overcome with the disclosed technologies, including improvements in the ways to present the weft tape in optimal configurations throughout the process, which configuration(s) improve tape handling at such time / place.

[0256] The steps 200-800 can be substeps in a larger forming process that forms the woven composite of one or more warp tapes and one or more weft tape, and thereafter consolidating 900 the woven composite to form a consolidated woven composite.

[0257] For example, the method 10 can comprise forming the woven composite of one or more warp tapes and one or more weft tapes comprising inserting 100 a weft tape in a weft direction. The inserting 100 can comprises inserting, by a weft tape inserter, weft tape in a weft direction from a continuous feedstock. The inserting 100 can comprises applying a grip pressure to grip the weft tape, accelerating / decelerating the weft tape in order to propel the weft tape in the weft direction to a weft tape designated position, monitoring one or more inserting characteristics of the inserting, and adjusting the inserting in response to one or more of the monitored inserting characteristics. Control processes 1000 can monitor and adjust one or more of torque, speed, or position based on sensor feedback and programmable tolerance ranges. Control processes 1000 can adjust the insertion distance and motion profile of the feed of weft tape based on programmatic inputs in order to facilitate variation in the weft tape length in the finished composite lattice.

[0258] Forming the woven composite of one or more warp tapes and one or more weft tapes can further comprise gas-assisting 200 the feed of weft tape through a weft guide path by exposing the feed of weft tape passing through the weft guide path to the Coanda effect. Gas-assisting 200 can comprise gas-assisting by a gas system configured to provide gas to one or more weft guide channels, wherein the weft guide path comprises an aligned set of weft guide channels, wherein each of the weft guide channels is selected from a group consisting of a weft guide channel of a warp head and a weft support, wherein each of the weft supports is selected from a group consisting of a gas-assist draw weft support, a gas-assist beat weft support, and a mechanical-assist beat weft support, and wherein the gas-assisting comprises gas from the gas system to the weft guide channel of one or more of the gas-assist draw weft supports. Each of the weft guide channels can have a height of from 1-5 mm and a width between a width of the weft tape and 150% of the weft tape width.

[0259] Gas-assisting 200 the feed of weft tape across the shed along the weft guide path preferably utilizes air-assist to direct airflow along the top and / or bottom of the weft tape as it is pushed (by the insertion 100) / pulled (by the gas-assist 200) along the weft guide path. Conventional disadvantages are overcome with the disclosed technologies, including using air in an innovative way.

[0260] As important, gas-assisting 200 is patentably distinct over conventional tape weaving systems that rely on a device to physically grip and “pull” the feed of warp tape across the shed. The present gas-assisting is a “physical-grip-free” method of pulling the feed of weft tape across the shed. The present invention uses media (in an exemplary embodiment, compressed air) to draw or “pull” the weft tape, which assists the “push” on the feed of weft tape from the inserting 100. While the general operating environment of the machine is at standard pressure and temperature, the pressure inside the nozzle and weft guide channels is elevated, and in some embodiments, vents are placed to alleviate same.

[0261] Goals of the present invention include how best to move tape(s) (rather than yam(s)) and how to maintain a continuous process of woven composite forming without unnecessary delay. One solution is based on having the weft tape, by an advantageous means, pushed by the weft inserter, and pulled by the media-assist, where the media-assist is tuned only to provide enough force to keep the tape tensioned to avoid buckling.

[0262] In an exemplary embodiment, the design / geometry of the weft guide path is cooperatively tied to the air-assist, so it pulls the feed of weft tape smoothly across the shed.

[0263] It can be appreciated that the present invention comprises gas-assisting that meets / exceeds draw cycle time demands, can handle various types of tapes, is energy efficient, and minimized production disruptions with imperfect drawing.

[0264] For example, the weft guide path can be a path of a continuous channel formed through one or more physical components, like one or warp heads and weft supports laid out across the shed, so weft guide channels in each of the warp heads and weft supports align to form the path.

[0265] Alternatively, the weft guide path can include a physical channel portion defined by a channel formed through one or more physical components, and a free portion defined by the absence of a physical channel. In this example, spaced-apart warp heads and / or weft supports canextend a width of the machine, and the weft guide path is defined as a path moving in and out of aligned physical channels, but nonetheless defines a continues path along the shed.

[0266] In each embodiment, for the portion(s) of the weft guide path that includes a channel formed through a physical component, the design / geometry of each channel can be uniform along the length of the channel. The design / geometry of the each channel can be non-uniform along the length of the channel. Different channels can embodiment different designs / geometries.

[0267] These variances can be found in the provision of the gas in the gas-assisting. The weft guide path design and the use of gas cooperate to provide the gas-assisting. For example, a particular location of provided air can include numerous characteristics, like the direction of air and the volume of air. Each characteristic at each location can remain the same during a cycle of air-assist, or can be non-uniform during a cycle of air-assist. For example, the direction of the air can change over time or remain the same over the cycle. The volume of air supplied at a location can change over time or remain the same over the cycle. If including more than one location of air-assist, each location can embody these variations. For example, at a first location of provided air, the direction of air and the volume of air can be the same through the cycle, can change during the cycle, or one remain the same and one different. At a second location of provided air, the direction of air and the volume of air can be a mirror of the same / different characteristics of the first location, or can be different, although likely the timing of the provision of air will be offset so the air-assist profile is optimal across the shed.

[0268] The innovation lies in the way that media / gas / air is provided and weft guide path formation are cooperative such that along the length of the weft guide path, downstream process(es) and upstream process(es) can operate under optimal conditions to meet the cycle times / production times, production quality, etc. of the demands of the present invention.

[0269] Although described as air-assist technology, one of skill in the art will appreciate that it is the result that matters, and achieving results can be had in different ways. As such, the present invention can utilize other types of media to pull the feed of weft tape in order to meet the needs of increased speed, error reduction, and other goals. Other gas(es) or even liquid(s) at various temperatures and pressures can be used, which may or may not utilize the Coanda effect, but nonetheless enable the tape properties to provide the “push” (insertion) and the media properties to provide the “pull” (media-assist) for the feed of weft tape across the weft guide path withoutresort to using a gripper system, such as a rapier, to handle the weft tape. The choices of weft guide channel characteristics coupled with the way media is delivered, can provide the same or similar improvements sought (media-assist of the weft tape), but using different media than air means. Those of skill in the art appreciate how to make such changes.

[0270] Control processes 1000 can monitor, adjust, and / or control one or more the aspects of the gas-assisting, including air flow, air direction, changing weft guide path profiles / geometries, etc.

[0271] Forming the woven composite of one or more warp tapes and one or more weft tapes can further comprise shear cutting 300 the inserted feed of weft tape, forming target drawn lengths of weft tape - discrete lengths of weft tape. Shear cutting 300 can comprise shear cutting, by a shear cutting assembly, the inserted feed of weft tape from the weft tape inserter into target drawn lengths of weft tape. Shear cutting 300 can comprise using a single shear blade with openings, at least one respective opening for a respective inserted weft tape, wherein each opening possesses at least one slanted or curved edge to promote concentration of the shear cut force. In other embodiments, the openings in the shear blade can be designed to accommodate two (or more) inserted weft tapes, wherein each opening possesses at least one slanted or curved edge to promote concentration of the shear cut force.

[0272] Shear cutting 300 shear cuts the inserted feed of weft tape so as to not interrupt upstream and downstream processes. In an exemplary embodiment, the shear cutting has a cycle time of less than 100 ms. Shear cutting 300 induces a high shear stress on the weft tape in order to cut the tape. Depending on the requirements for production, shear cutting can shear cut more than one weft tape. In an exemplary embodiment, two different weft tapes can be shear cut on different strokes of the shear cutting. For example, if the shear cutting utilizes a shear blade moving up and down, one weft tape is cut as the shear blade moves up while another weft tape is shear cut as the shear blade moves down.

[0273] Control processes 1000 can monitor, adjust, and / or control one or more the aspects of the of the shear cutting process, including shear cutting time, speed, synchronization, etc.

[0274] Forming the woven composite of one or more warp tapes and one or more weft tapes can further comprise beating 400 the target drawn lengths of weft tape clear of the weft guide path in the warp direction, forming an initial orientation of the woven composite from an interlacing of the warp tapes and the target drawn lengths of weft tape. The beating 400 can comprise gas beatingby a gas system configured to provide gas to one or more of the gas-assist beat weft supports. The beating 400 can comprise mechanically beating a mechanical impulse from of one or more of the mechanical-assist beat weft supports. Beating 400 can comprise both a mechanical beat component and a media-assist beat component. For example, the mechanical beat component can comprise beating by mechanical means. For example, the media-assist beat component can comprise beating by media.

[0275] Like each process, the beating is designed to enable the continuous production of the lattice. The beating utilize aspect(s) of the warp heads, weft supports and the air system used in the air-assist (or a separate air system) to perform the beating. One or more internal air channels can be formed in the warp heads and / or air-assist beat weft supports, terminating in an air delivery system designed to direct airflow perpendicular to the direction of insertion (“edge-on”) of the weft tape. Preferably, the direction of the delivered air is oriented such that air is directed to lift and thrust the weft tape (after shear cutting) clear out of the warp heads and into the warp tape shed.

[0276] The beating process preferably generates airflow above and below the weft tape in order to stabilize it during the beat process. For example, without airflow, if the weft tape were solely propelled by mechanical forces (via only a mechanical beat), the weft tape would behave as a wing and small undulations / curvatures in the weft tape can cause it to twist or flutter as it travels.

[0277] Air flow within the air-assist beat is electronically controlled, allowing for any number of air-assist beat weft supports along the width of the warp rack to fire, thereby reducing the air consumption if weft tapes are only inserted a partial distance

[0278] Air pressure within the air-assist beat is controllable separately from the air pressure of the air-assist, allowing for the optimum pressure to be used for specific weft tapes to accommodate different tape densities and friction coefficients.

[0279] The beating can further comprise mechanically beating the weft tape as an initial step prior to or concurrently with an air-assist beat. Mechanically beating can include a process to push the weft tape perpendicular to the direction of tape insertion (“edge-on”). Mechanically beating is designed to provide an initial impulse to overcome friction and resting inertia of the weft tape, while the air-assist beat stabilizes the weft tape and propels it forward to the target location in the shed.

[0280] Control processes 1000 can monitor, adjust, and / or control one or more the aspects of the of beating.

[0281] Forming the woven composite of one or more warp tapes and one or more weft tapes can further comprise interlacing 500 a feed of warp tapes and the beat target drawn length of weft tape into an initial orientation of interlaced warp and weft tapes. Warp heads can each comprise a warp tape slot configured to contain a warp tape passing therethrough in the warp direction, and the weft guide channel being used in the gas-assisting 200.

[0282] Forming the woven composite of one or more warp tapes and one or more weft tapes can further comprise transforming / positioning 600 one or more of the tapes of the initial orientation of the woven composite to form a pre-consolidation orientation of the woven composite.

[0283] The positioning 600 can comprise at least one of changing a relative spacing between consecutively beat target drawn lengths of weft tape, or changing a relative angular alignment of the consecutively beat target drawn lengths of weft tape.

[0284] The positioning 600 can comprise catching the beat target drawn lengths of weft tape to provide a repeatable reference stop location for the caught target drawn lengths of weft tape. The method 10 can further comprise monitoring one or more characteristics of the caught target drawn lengths of weft tape, and adjusting the catching in response to one or more of the monitored caught target drawn lengths of weft tape characteristics.

[0285] The positioning 600 can further comprise pre-positioning and post-positioning, or comprise the performance step(s) of just one of the pre-positioning or post-positioning. The beat weft tape can skip the catching and go straight into pre -positioning, where for example the weft tape momentum from the beating is arrested by friction rather than by catching.

[0286] The catching process is configured to provide a repeatable reference stop as the weft tapes are beat out of the warp heads and weft supports. After arresting the weft tape (unless as described above, arrested via friction), the weft tape catching process clears out of the way of the weft tape. Weft tape catching increases the spacing between a held weft tape and a previous weft tape. By synchronizing the timing of weft tape catching actuation, it is possible to control the gap between the held weft tape and the previous weft tape. Utilizing the weft tape catching process to control this gap at this stage of the process removes a need to control the gap in other ways, likechanging the frequency of insertions (allowing the inserter to buffer tapes that need to be tightly spaced). For example, the frequency of insertions and managing the gap characteristics between the consecutively beat weft tapes are decoupled from one another.

[0287] The positioning 600 can further comprises pre-positioning process, which moves forward and backward in the warp direction. Pre-positioning can change the angular alignment and relative spacing of the weft tape relative to the previous tape. Pre-positioning can move the weft tape closer to the previous tape to make up for a delayed, or short, beat process (under the assumption that the lattice forming line is moving at a constant or near constant speed).

[0288] Weft tape catching and pre-positioning occur prior to entering the nip roller. Following the nip roller, the positioning 600 can further comprise the post-positioning configured to correct small angle and position deviations.

[0289] The post-positioning extends up (or down) into the plane of the lattice, and using the positioning process control 1000, for example, utilizing sensor input, such as an array of position sensors, lidar, or computer vision, measures the spacing between adjacent weft tapes and the relative angle of the weft tapes, relative to a desired spacing and angle, when the post-positioning process repositions the tape to the desired spacing and angle.

[0290] The positioning 600 can comprise the pre-positioning and the post-positioning, or comprise the performance step(s) of just one of the pre -positioning or post-positioning.

[0291] Forming the woven composite of one or more warp tapes and one or more weft tapes can further comprise tacking 700 two or more locations of warp tape and weft tape interlace in order to fix the position of the woven composite. Tacking 700 can comprise tacking with a tacking device configured to apply heat and pressure to two or more locations of warp tape and weft tape interlace in order to fix the woven composite in the pre-consolidation orientation.

[0292] Forming the woven composite of one or more warp tapes and one or more weft tapes can further comprise dampening 800 to dampen vibrations propagating upstream from, for example, ultrasonic welder of the consolidating 900, and enable the tacking 700 to secure the position and alignment of the pre-consolidation orientation of the woven composite such that one or more of the tapes are not vibrated out of position or misaligned prior to tacking 700.

[0293] Referring to FIG. 2, the present invention also will be described in terms of system improvements. The tapes are at various times handled, manipulated, tacked, consolidated, etc. via specific physical and electrical and computing components. Conventional disadvantages of weaving and consolidating tapes are overcome with the disclosed mechanical, electrical and computing / control technologies, where in essence, a tape is processed from a first state (before the disclosed process) to a second state (after the disclosed process), or via interim states, but the invention resides in providing systems to take the tape through states, which the conventional machines simply do not incorporate. The main concept here is, again, that the arrangement of components themselves are innovative, while there are myriad “processes” that can be carried out by the systems.

[0294] The present invention as shown in FIG. 2 is a machine 20 comprising one or more weft tape inserters 1000 each weft tape inserter configured to insert a feed of weft tape in a weft direction from a continuous feedstock, a media-assist system 2000 that “pulls” the feed of weft tape across the shed, leveraging the weft tape’s own properties including rigidity (that provides a “push”), using the aligned weft guide channels to provide support in its travel, and media-assist to “pull” the feed of weft tape across the shed by exposing the weft tape passing through the weft guide path to the Coanda effect, a shear cutting assembly 3000 configured to shear cut the inserted feed of weft tapes from the weft tape inserters into target drawn lengths of weft tape, a beat system 4000 configured to beat the target drawn lengths of weft tape from the weft guide path in the warp direction, and which results in the formation of a woven composite from an interlacing of the warp tapes and the target drawn lengths of weft tape, and a interlacing zone 5000 where a feed of warp tapes and the beat target drawn length of weft tapes form an initial orientation of interlaced warp and weft tapes. Warp heads can each comprise a warp tape slot configured to contain a warp tape passing therethrough in the warp direction, and the weft guide channel being used in the mediaassist system 2000.

[0295] The machine 20 can further comprise a consolidation zone 9000 for consolidating the woven composite to form the consolidated woven composite.

[0296] The machine 20 can further comprise a positioner 6000 wherein, when the beat target drawn lengths of weft tape are clear of the weft guide path, an initial orientation of a woven composite is formed from an interlacing of the warp tapes and the target drawn lengths of wefttape, and wherein the positioner 6000 is configured to position one or more of the tapes of the initial orientation of the woven composite to form a pre-consolidation orientation of the woven composite.

[0297] The machine 20 can further comprise a tacking device 7000 for tacking two or more locations of warp tape and weft tape interlace in order to fix the position of the woven composite prior to the consolidation zone 9000. The tacking device 7000 is located between beat system 4000 and the consolidation zone 9000, and if the machine includes the positioner 6000, the tacking device 7000 is located between positioner 6000 and the consolidation zone 9000.

[0298] If the consolidation zone 9000 creates vibratory issues during operation, for example, when using an ultrasonic welder, the machine 20 can further comprise a vibration isolation assembly 8000 located between the tacking device 7000 and the ultrasonic welder, to isolate vibrations propagating upstream from the ultrasonic welder and enable the tacking device 7000 to secure the position and alignment of the pre-consolidation orientation of the woven composite such that one or more of the tapes are not vibrated out of position or misaligned before they enter the tacking device 7000.

[0299] The machine 20 can further comprises controllers 10000 to effectively control the various aspects of the present invention, which controllers are the same described in reference to the controlling / control processes 1000.

[0300] As noted above, the present invention comprises innovation in processing steps of the tape weaving / consolidation process, and innovation in components of the tape weaving / consolidation equipment.

[0301] As just one example, the weft tape inserters cam comprise an innovative coupling of belts, pulleys, and controls that reach / exceed the goal of safely and reliably inserting the weft tape to a downstream station / component. The innovative weft tape inserter reaches / exceeds the goals of inserting / accelerating / decelerating the weft tape without exceeding the buckling strength of the tape (break the tape), and inserting / accelerating / decelerating the weft tape so it is presented to a shear cutter with an orientation and tension / compression profile to be safely and reliably shear cut.

[0302] As those of skill in the art appreciate, there is a range of overlap between process steps and components of the present invention. For example only, the invention comprises a weft taperack / stack with various components and a warp rack with various components. Discussion of “components” of the weft tape rack / stack and the warp rack will include reference numbers that associate the various components with, for ease of convention, what will be assigned to one of the racks.

[0303] Y et components from different “systems” will at times be described as working together to perform what is described under a single process step. For example, while the weft tape inserter might be described as residing in the weft tape rack, the process of weft tape insertion might involve components outside the description of the weft tape rack. And vice versa. Descriptions of the present invention as incorporating discrete inventive steps, need not be tied to components making up a single system, and very likely is not so tied. The present invention marries elements and components from different / discretely described systems, to perform an inventive processes. Singularly described innovative process steps may involve multiple components from multiple systems, and singularly described innovative systems may involve multiple (sub-)processes from multiple different processes.

[0304] FIG. 3 is a top view of several of the stations of the present invention, where the warp direction is from left to right. A weft inserter stack of weft tape inserters 1000 provides a feed of weft tapes in the weft direction. The weft tape is controllingly inserted, drawn across the weft guide path via the media-assist system 2000, which includes the weft guide channels in the warp heads and the weft supports. Once the drawn feed of weft tape has reached an assigned / target location (which need not be the full width of the machine), the feed of weft tape is then cut via shear cutting assembly 3000. The beat system 4000 beats the target drawn lengths of weft tape from the weft guide path in the warp direction. The warp tapes are fed in the warp direction in the proximity of the target drawn lengths of weft tape, and in the interlacing zone 5000 the feed of warp tapes and the beat target drawn length of weft tapes form an initial orientation of interlaced warp and weft tapes.

[0305] The interlaced warp and weft tapes travel in the warp direction to the pre-positioner 6100 of the positioner 6000, upstream the first nip roll station NP1. Downstream the first nip roll station NP1, the post-positioner 6200 of the positioner 6000 is configured to make set of changes. After the post-positioner 6200, the tacking device 7000 followed by the consolidation zone 9000 and the second nip roll station NP2.

[0306] FIGS. 1 -3 illustrate that one or more areas of improvement addressed by the present invention can be handled in different ways to achieve the same / similar improvements. Thus, while exemplary embodiments of particular components and method steps are disclosed, it will be understood that the manifestations of each are designed to improve function(s), and that to accomplish each function, various other designs of particular components might change to meet the same or similar benefits as those delivered by the exemplary embodiments.

[0307] For example, in exemplary embodiments, as discussed the present invention utilizes airassist to pull the feed of weft tape in a consistent media-assisted orientation across the weft guide path in order to meet / exceed the needs of the “improved” speed / error reduction / tape configuration. Various components of the machine and operating characteristics of the method are based upon the use of air (for example, in the air-assist and the air-assist beat). While air, and attendant designs in the components of the present invention use air as a medium, other gases, with various densities, water content, etc. can be used with appropriate design changes to the components. Indeed, suitable liquids can be used to drive the weft tape in a clean draw across the machine and in proper alignment for optimal cutting / shearing, optimal beating and optimal lattice forming, without departing from the inventive concepts of the present invention. Those of skill in the art appreciate how to implement media-assist and media-assist beat with different media.

[0308] As previously discussed, a main issue with drawing a feed of weft tape across the shed is how it deforms along its width and / or length, and that the only known commercially viable methods include mechanical-assist. Such deformations can make a clean-cut step (shear cutting) imperfect. Or with such deforming / curling, the feed of weft tape will not easily (if at all) be drawn across the machine for subsequent cutting and weaving with the warp tape(s), and / or be reliably beat into an orientation that is advantageous for the interlacing and / or weaving processes.

[0309] While an element’s design / function may be described using a particular media, like air at standard room temperature and pressure, the element can operate in different media, like air at different temperatures / pressures, or at high / low relative humidity, or with other gases altogether, or in a liquid environment or using a liquid to complete a particular function. Indeed, that may be the norm rather than the exception. The various design aspects of the present invention led to improvements in speed, error reduction, tape handling, etc., and as the conventional problems wereaddressed with specific embodiments of “solutions,” other solutions exist that with design change, can provide the same or better improvements.

[0310] Additionally, an element’s design / function, while housed in one subsystem of the present invention, can have an affect over another subsystem. Again, that may be the norm rather than the exception. Those of skill in the art appreciate that while the present invention is described as, for example, having stations, mechanisms, assemblies, and steps, many innovative advancements of the present invention lie in design of particular components in locations of the system and / or times in the process that might play a part in more than one location / time. For example, a component that is described (using vernacular) as being a part of the media-assisting 200 of the present invention, and therefore having a component in the media-assist system 2000 (a number in the 2000s), may be a passive or active component in other components, elements, stations, mechanisms, assemblies, steps of the present invention.

[0311] For example only, the present invention presents an innovative weft guide path. The weft guide path is formed from an aligned set of weft guide channels. The warp heads have weft guide channels. The weft supports have weft guide channels. The weft guide channels play important roles in both the media-assisting / media-assist system and the beating / beating system. Here, a single component / step is beneficial to the other subsystems, and to the overall systems and methods beyond just that one location / time where that component / step is described.

[0312] Further, the media used across the methods / systems is air. Thus, to provide the functions with air-assist, the gas-assist draw weft support and the gas-assist beat weft support each have a design / tolerances / material make-up that provide the functions with air. Those of skill in the art appreciate that using different media could / would alter the design / tolerances / material make-up of the particular support, and more specifically, the design(s) of the weft guide channels. But the goals of the media-assist remain the same, and to reach those goals the present invention includes alternative paths to get there.

[0313] The amount of time it takes for each weft tape insertion is the largest single rate limiting step for the present invention, and it cannot be solved by simply increasing the speed of insertion. Upstream components of the invention can present issues with sinusoidal waves and buckling stress once the tape has moved some distance into weft guide channels of static weft supports, there are still acceleration limits in bringing the tape up to speed from a standing start.

[0314] Previous weft tape inserter versions use a nip roller drive, whereby the weft tape is pinched between two rubberized rollers - one driven and one idle. Springs connected to the idle roller were used to set the pressure on the tape. While this was a straightforward approach, the nip only achieves a narrow rectangular patch contact on the tape, so its ability to stabilize the tape once a sinusoid wave develops was minimal and the combination of a small contact patch and limited spring force meant that grip force was inconsistent.

[0315] For fast insertions, this translates to slipping during acceleration, causing the tape travel distance to be shorter than programed and creating some circumstances where very fast acceleration would cause the tape to buckle adjacent to the nip, which had the further detrimental side effect of causing the now broken tape to wrap itself around the drive roller and lock the inserter - a critical failure that immediately shut down the machine.

[0316] In order to reach the speeds and repeatably reliable successful feed of the weft tape demanded by the present invention, the belt drive weft tape insertion mechanism was developed. In this configuration, there are a pair of belts, one above the tape and one below the tape, with one belt driven and the other idle. In the middle, at least one pair of pulleys, one of which is an idle pulley, attached to a pneumatic cylinder apply adjustable pressure to squeeze the belt together and create a very large contact area on the tape. This contact area is formed between the drive pulley and return pulley for the driven belt, so no sinusoidal wave can develop and the risk of slip is very minimal.

[0317] Combined with one or more distance sensors along the weft guide channels, the weft tape can be precisely inserted to the specified distance without concern of slip or buckling.

[0318] FIG. 4 illustrates an exemplary embodiment of the belt drive weft tape insertion mechanism, presenting a pair of weft tape inserters 1000, each comprising a weft tape insertion control mechanism 1100 configured to apply a grip pressure to grip the weft tape, and accelerate / decelerate the weft tape in order to propel the weft tape in the weft direction to the weft tape designated position. The weft tape insertion control mechanism 1100 can comprises a double belt set 1200 comprising a top belt / pulley assembly 1220 and a bottom belt / pulley assembly 1240, wherein a portion of each of the belts are proximate one another in a tape inserter zone 1260. In some exemplary embodiments, at least a portion of one or more of the belts 1222, 1224 is coated with a textured rubber or elastomer.

[0319] The weft tape insertion control mechanism 1100 can further comprises a paired tape inserter roller set 1310 comprising a top roller 1312 and a bottom roller 1314. The paired tape inserter roller set 1310 is positioned in the tape inserter zone 1260 to apply a non-slip pressure through the proximate belt portions and to the weft tape in order to limit slippage. The lateral position of the paired tape inserter roller set 1310 in relation to the tape inserter zone 1260 can be adjustable for optimization of its function. In some exemplary embodiments, the paired tape inserter roller set 1310 is positioned in the middle of the tape inserter zone 1260.

[0320] The weft tape insertion control mechanism 1100 can further comprise a belt / pulley assembly actuator 1400 and a weft tape insertion control sensor of the control 10000, wherein at least one of the belt / pulley assemblies is driven by the belt / pulley assembly actuator, wherein the weft tape insertion control sensor is configured to monitor one or more belt / pulley assembly characteristics, and wherein the belt / pulley assembly actuator is adjustable in response to one or more of the monitored belt / pulley assembly characteristics.

[0321] FIG. 5 illustrates an exemplary embodiment of the double belt set 1200, wherein the belt / pulley assembly actuator / motive mechanism 1400 drives a drive pulley PD of the set of pulleys P. At least one of the two belt and pulley sets is driven by the motive mechanism 1400, which can be a motor, and the sensor is capable of monitoring and adjusting one or more of torque, speed, or position based on sensor feedback and programmable tolerance ranges.

[0322] Computer control 10000 can, for example, adjust the insertion distance and motion profile based on programmatic inputs in order to facilitate variation in the weft tape length in the finished composite lattice, or in order to create discontinuous segments in the weft tape.

[0323] In any of the embodiments disclosed herein, each weft tape inserter 1000 presents one or more weft tapes from a continuous feed without concern of slip or buckling with an insertion time of less than 350 ms.

[0324] In another exemplary embodiment, the weft tape inserter comprises a secure guidance system and a control system. The secure guidance system comprises the belts, pulleys, motive mechanism, a sensor system, and the rollers. A double belt configuration includes a top set of a belt and pulley and a bottom set of a belt and pulley. The weft tape inserter is configured to receive the weft tape from a continuous feedstock of weft tape, for example, from wind rolls between thetop and bottom belts, apply pressure to grip the weft tape, and accelerate / decelerate the weft tape in order to propel the weft tape to its designated position.

[0325] At least one of the two belt and pulley sets is driven by the motive mechanism, which can be a motor, and the sensor system is capable of monitoring and adjusting one or more of torque, speed, or position based on sensor feedback and programmable tolerance ranges.

[0326] The set of rollers in the middle of the double belt are used to apply pressure through the belts to the weft tape in order to prevent slippage. Preferably, the belts are coated with a textured rubber or elastomer.

[0327] The control system of the weft tape inserter can be a part of an overall control system for the invention, a discrete weft tape inserter control system, and / or a combination thereof. Computer control can, for example, adjust the insertion distance and motion profile based on programmatic inputs in order to facilitate variation in the weft tape length in the finished composite lattice, or in order to create discontinuous segments in the weft tape.

[0328] Media-assisting 200 / media-assist system 2000 is configured to accept and support the inserted weft tape from the weft tape inserter across the shed for shear cutting and beating.

[0329] As shown in FIG. 6, the media-assist system 2000 comprises a design for a “physical- grip-free” method of drawing the feed of weft tape. In an exemplary embodiment, the “physical- grip-free” weft tape draw system uses air assist that cooperates with a weft guide path 2100 defined by an alignment of weft guide channels 2200 in weft supports 2300 and warp heads 2400.

[0330] The weft supports 2300 are one of an air-assist draw weft support 2310, an air-assist beat weft support 2320, and a mechanical-assist beat weft support 2330.

[0331] The media-assist system 2000 is designed to pull the feed of weft tape via the Coanda effect through channels 2200. Other designs to provide the weft tape drawing path are contemplated, with each design overcoming the shortcomings of the prior art. Some use air assist while others use different media that provide the laminar flow profile(s) needed to “pull” the tape along the weft guide path 2100.

[0332] The weft guide channel 2200 in one or more weft supports 2300 and warp heads 2400 can have different shapes / dimensions from one another. For example only, the weft guide channel 2200 of one or more of the air-assist draw weft supports 2310 can incorporate an array of surfacefeatures 2210 (FIG. 8A) for example, surface features like small ribs or troughs on the top and / or bottom surface of the weft guide channels 2200, running along the direction of weft tape insertion in order to reduce contact area and direct air flow along the weft direction.

[0333] In an exemplary embodiment, media-assist further comprises one or more internal air channels in the air-assist draw weft supports 2310 terminating in media propulsion, which can be a nozzle designed to direct the airflow along the top surface and / or bottom surface of the weft tape.

[0334] FIGS. 7A, B illustrate an exemplary an air-assist draw weft support 2310.

[0335] Compressed media from a media source is delivered to the nozzles. In exemplary embodiments, this is compressed air from a compressed air source. Each nozzle is preferably oriented such that it “steers” the weft tape against the back wall of the weft guide channels 2200 in weft supports 2300, while providing the air flow in the weft direction, providing for an optimal pull.

[0336] The Coanda effect created by the media propulsion attaches to the surface of the weft tape to create a cushion above and / or below the tape (depending on the location of the nozzles) that reduces friction and “pulls” the weft tape along the weft guide path 2100 to keep it in tension.

[0337] The present “air assist” improves the insertion speed of the feed of weft tapes traveling through the weft guide channels 2200 in weft supports 2300 and warp heads 2400. Increasing the speed of the feed of weft tape insertion is not simply a matter of running the weft tape inserter faster. As the weft tape inserter is effectively pushing (rather than pulling) the feed of weft tape through the weft guide channels 2200, the actual insertion speed is limited by the stiffness of the weft tape and the drag of the weft tape as the leading edge moves further away from the insert. As distance increases, the combination of weft tape flexibility and drag creates a sinusoidal wave to form, which further exacerbates the drag and causes stress in the weft tape. If the acceleration rate is too aggressive or if the weft tape clips an edge during insertion, the stress can exceed the buckling strength of the weft tape and break the weft tape.

[0338] By orienting an air jet to steer the weft tape against the back wall of the weft guide channels, this prevents the fed tape from “falling” out of the front of the weft guide channel due to curl of the weft tape causing it to steer out, as the airflow itself keeps the tape contained. Toconserve air during insertion, brief air pulses can be synchronized to the tape motion, with the pulses starting before the tape arrives, effectively creating a linear accelerator of air.

[0339] The control system of the media-assist system can be a part of an overall control system for the invention, a discrete media-assist control system, and / or a combination thereof. For example, a sensor system can electronically control air flow of the air assist, both in terms of pressure and activation timing along the length of the weft guide path 2100, and weft guide channels 2200. The sensor system can include an array of sensors that, among other features, detect the position of the weft tape as it moves across the warp heads 2400, activating and deactivating individual air assist units as the weft tapes passes to reduce the total air consumption.

[0340] For embodiments of machines that insert multiple layers, weft tape insertion timing for each layer may be offset slightly, to allow one sensor to detect the passage of two or more weft tapes and verify each weft tape’s position, independently.

[0341] In exemplary embodiments, the warp heads 2400 and the weft supports 2320 alternate across the width of the machine and are designed such that the warp head 2400 interlocks with vertical channels or ribs along the sides of adjacent the weft supports 2320 in order to guide and stabilize the warp heads 2400 when they are actuated up and down.

[0342] Further, at least some of the warp heads 2400 and the weft supports 2320 further comprise one or more vents along the back wall of the weft guide channels 2200 to reduce pressure build up in the channels caused by the air assist - thus preventing the weft tape from being pushed out of the channels prematurely due to a buildup of air pressure.

[0343] Beating 400 / beating system 4000 is configured is configured to beat out shear cut weft tape portions in the warp direction, and with the warp feeding (via warp tape slots in the warp heads 2400 configured to contain movement of the warp tapes up, down, left, and right (relative to the direction of feed, i.e., warp direction)), interlace the tapes.

[0344] As shown in FIGS. 6 and 8, the beating system 4000 shares components of the air-assist system, comprising the forms of air-assist beat weft supports 2320 and mechanical-assist beat weft supports 2330 of the weft supports 2300. While exemplary embodiments of the present invention include a beating system with a mechanical component and a media / air component, other embodiments may utilize only one form of beat.

[0345] An exemplary beating system 4000 includes a mechanical beat from the mechanicalassist beat weft supports 2330 via a rod, plunger, or similar actuatable shape, configured to push the weft tape perpendicular to the direction of tape insertion (“edge-on”). The mechanical beat can be actuated by a mechanical beat actuator, for example, by solenoid, air cylinder, or similar high-speed mechanism.

[0346] In the exemplary embodiment, the beating system 4000 further includes a media-assist beat (air-assist beat) from the air-assist beat weft supports 2320 beat channels for air delivery, wherein one or more of the beat channels terminate in a media-assist beat propulsion system designed to direct airflow perpendicular to the direction of insertion (“edge-on”) of the weft tape.

[0347] The mechanical beat can be designed to provide an initial impulse to overcome friction and resting inertia of the tape, while the air-assist beat stabilizes the weft tape and propels it forward to the target location in the shed. Due to this division of effort between the two systems, the mechanical-assist beat weft supports 2330 can be shorter than the width of the weft guide channels 2200 in the warp heads 2400, and is able to extend and retract in the same amount of time, or less, as it takes the air-assist beat to push the weft tape all the way to its target location.

[0348] Air flow within the air-assist beat can be electronically controlled by a control system allowing for any number of air-assist beat weft supports 2320 along the width of the warp rack to fire, thereby reducing the air consumption if weft tapes are only inserted a partial distance.

[0349] Air pressure within the air-assist beat can be controllable separately from the air pressure of the air assist, allowing for an optimum pressure to be used for specific weft tapes to accommodate different weft tape densities and friction coefficients.

[0350] The present beating system 4000 is superior to, for example, an electrically- or pneumatically-actuated metal plate used to force the weft tape clear of the warp heads to permit head repositioning, much in the same way that a textile loom uses a beater. This methodology, while simple and consistent, has a number of drawbacks. As tape width increases, the beating action with a plate is much more likely to fold, flip, or twist the tape, causing misalignment or damage. This effect is worsened as beater speed increases, so beater cycle time becomes a significant limiting factor.

[0351] Furthermore, this type of beat “blocks” weft tape insertion during its entire forwardreverse stroke length - so the weft tape inserter must wait until the beater has recovered back to its origin point before the next tape can be inserted, exacerbating the cycle time problem. The airassist beat weft supports 2320 ameliorate this barrier.

[0352] One advantage of the air-assist beat weft supports 2320 is that it requires no moving parts, ejects the weft tape without inducing damage or twist, and does not require a reset stroke before the next weft tape insertion - as soon as the weft tape clears the weft guide channels 2200, the warp heads can reposition and as soon as the reach their new position, the next weft tape can be inserted.

[0353] The control system of the beating system can be a part of an overall control system for the invention, a discrete beating control system, and / or a combination thereof.

[0354] Shear cutting 300 / shear cutting assembly 3000 is configured to convert the continuous feed of weft tape from the weft tape inserter, in a shear configuration, into discrete lengths of weft tape. The shear cutter assembly comprises a repeatably reliable process of shearing the weft tape with speed, precision, and wear characteristics that enable successful implementation of the present invention.

[0355] A shear configuration / orientation of the weft tape is the configuration / orientation of the weft tape that conforms to the ftmction(s) of the shear cutting process. Goals for a preferred cutting mechanism include safely and reliably cutting the weft tape with cut cycle times of less than 100 ms per channel.

[0356] In prior iterations, a guillotine-style cutter was developed in which a fixed blade set at an angle to the weft tape is driven down by pneumatic actuation between two steel plates to cut the tape. Y et, after the cut, the guillotine must wait for the weft tape to beat clear before it can reset to its original position, which impacts overall cycle time.

[0357] To achieve the goals set for the present invention, including improved speed and addressing a number of issues relating to blade wear, blade alignment, jammed cuts, hanging cut edges, and incomplete cuts, alternative cutting mechanisms were investigated. Some, such as laser cutting, were excluded due to cost or complexity while others, such as rotary cutting, were deemed unsafe or too difficult to synchronize.

[0358] One exemplary embodiment of the shear cutting assembly 3000 that accomplishes the lofty goals comprises two steel plates, between which is sandwiched a very thin sheet of steel. The steel sheet extends out the top and bottom of the plates, where it is connected to two double acting air cylinders, one on each end, which can move the sheet up and down when actuated. Each time the sheet is actuated, openings in the sheet slide past slots in the steel plates, shearing the weft tape cleanly. By having two sets of openings, one aligned in the up position and another aligned in the down position, the cutter does not have to reset to a starting position after each cut. Furthermore, as the thin sheet lacks a sharpened edge it should not lose cutting efficiency as it wears and the cost of replacement is much lower than that of a custom blade. Preliminary testing of the shear cutter system shows cut cycle times at approximately 60 ms per channel, and promising results for blade wear and durability.

[0359] In this example, as shown in FIGS. 9A-9B, the shear cutting assembly 3000 comprises shear blade 3100 comprising at least one opening 3110 constrained between two plates 3210, 3220 having one or more plate guide channels. The plate guide channels are machined into the plates (pre-cut plate 3210 and post-cut plate 3220), where the pre-cut plate 3210 fully constrains the lateral and vertical movement of the weft tape within it, while the post-cut plate 3220 is slotted all the way to one edge to enable the cut weft tape to be beat clear. The shear cutting assembly 3000 can further comprise an actuation mechanism, a sensor system, a clean-out system and a control system.

[0360] The shear blade 3100 can be made from thin sheet of metal, having a thickness of between 0.005 in and 0.030 in (most preferably having a thickness between 0.010 in and 0.020 in, inclusive) and comprising at least one opening 3110 that is large enough for the weft tape to feed through, possessing at least one slanted or curved edge to promote concentration of cut force. The shear blade 3100 is preferably thin enough that no sharpened edge is required, though thicker shear blades 3100 may benefit from a sharpened edge.

[0361] The shear blade 3100 is held in tension (top and bottom) and actuated with an actuation mechanism along that axis in a manner that maintains a state of tension in the shear blade 3100 at all times. When actuated by, for example, shear blade cylinders of the actuation mechanism, the opening 3110 moves up or down while the weft tape and plates 3210, 3220 remain stationary,causing the edge of the opening 3110 to induce a high shear stress on the weft tape, thus cutting the weft tape.

[0362] The sensor system comprises components configured to sense various operating characteristics of the shear cutting assembly 3000, with feedback from the sensor system enabling for more optimal operation.

[0363] A clean-out system comprises a system that can maintain, as best as possible, the shear cutting assembly 3000 free of particulates that are inevitably created during shear cutting. The clean-out system can comprise a variety of cleaning systems, for example, a blower that can blow particulates away from proximity of the cutter components to extend the life of the shear cutter system.

[0364] Depending on the requirements for production, a plurality of openings 3110 in the shear blade 3100 can be configured such that the openings align with different plate guide channels on the up and down strokes, allowing the tapes to be cut in both directions. In machines configured to produce two or more layers simultaneously, the “up” opening for one layer may also be the “down” opening for another, adjacent layer.

[0365] The shear blade 3100 may also be configured into a looped metal belt with the openings 3110 distributed along the length of the belt. The looped blade / belt is guided by a plurality of rollers and tensioners so that tension may be maintained and that the blade can be directed around machine components. The belt may be driven in a stepwise or continuous rotary motion with an actuator - such that the openings align with the weft tape channels during the insertion step. The motion of the belt may be in one direction, or in both directions depending on the requirements for blade life and production - as such the configuration of the windows may be configured for cutting in one or both directions of blade motion.

[0366] The control system of the shear cutting assembly can be a part of an overall control system for the invention, a discrete shear cutting control system, and / or a combination thereof.

[0367] As discussed, the naming / drawing conventions used herein are for ease of description, as inventive benefits of the present invention span categorization in single subsystems or method steps. For example, it is unsurprising that goals for a preferred weft tape inserter to operate optimally are tied to mechanisms and operations of the shear cutting assembly, and vice versa.That is, optimal performance of a weft tape inserter cycle of the weft tape inserter depends upon optimal performance of a weft tape shear cycle of the shear cutting assembly, as the weft tape must be cut and beat clear before the machine can reposition the warp heads for a next insertion.

[0368] The positioning 600 / positioner 6000 comprises positioning one or more of the tapes of the initial orientation the woven composite (just after beat of the weft tape) to form a preconsolidation orientation of the woven composite.

[0369] As used herein and shown in FIG. 10, the positioning 600 can occur on either or both sides of the first nip rollers NP1. It can include one or more of catching the beat target drawn lengths of weft tape to provide a repeatable reference stop location for the caught target drawn lengths of weft tape, changing a relative spacing between consecutively beat target drawn lengths of weft tape, or changing a relative angular alignment of the consecutively beat target drawn lengths of weft tape.

[0370] As used herein, the positioning 600 can comprise a pre-positioner 6100 and a postpositioner 6200. If design permits, the positioning 600 may only include the post-positioning 6200. The pre -positioning can include increasing a relative spacing between consecutively beat target drawn lengths of weft tape, and / or changing a relative angular alignment of warp tape and weft tapes to perpendicular if askew from perpendicular. The post-positioning can include changing the relative spacing between consecutively beat target drawn lengths of weft tape, and / or changing the relative angular alignment of warp tape and weft tapes.

[0371] As shown in FIGS. 10-12, the first nip rollers NP1 pairs a hard metal roller with a coated roller (coated, for example, by rubber, silicone or thermoplastic elastomer), includes an electrically actuated gap control system to ensure parallelism between the rolls, and failsafe plus lockout safety features to ensure the rollers are locked during machine setup and maintenance.

[0372] In other exemplary embodiments, the hard metal roller can be chrome plated or coated with a high-hardness ceramic, such as TiN or CrN.

[0373] A second nip roller of similar build can be located after the consolidating.

[0374] With ultrasonic consolidation, neither nip roller sets final composite thickness, as that is done by the ultrasonic welders themselves.

[0375] The pre-positioner 6100 can include a catch system 6120 is configured to provide a repeatable reference stop location as the weft tapes are beat out of the weft guide path. After arresting the weft tape, the catch system 6120 can be actuated to drop or lift out of the way of the weft tape. By synchronizing the timing of this actuation, it is possible to control the gap between the held weft tape and the previous weft tape.

[0376] The pre-positioner 6100 can further include an active system 6140 which is able to move forward and backward in the warp direction. This enables the pre-positioner 6100, either by using the catch system 6120 itself or through the use of a secondary set of actuatable pushing / gripping elements 6140, to change the angular alignment and relative spacing of the weft tape relative to the previous tape. Where the catch system 6120 is limited by only being able to increase the spacing between these two tapes, the active system 6140 can also push the weft tape closer to the previous tape to make up for a delayed, or short, beat (under the assumption that the lattice forming line is moving at a constant or near constant speed).

[0377] An array of more than one systems 6120 / 6140 can be used to hold, reposition, and release multiple weft tapes in order to create a buffer stock for situations where a number of tapes must be placed in close proximity to one another.

[0378] The pre-positioner 6100 can further comprise a set of sensors that detect the location of the tape, which a controller uses to determine how far to move the tape (pre-positioning) and when to release the tape to achieve the desired spacing between the current and previous weft tapes.

[0379] The post-positioner 6200 is configured to correct small angle and position deviations. The post-positioner 6200 comprises actuatable rods 6220 that can extend up (or down) into the plane of the lattice, with the rods 6220 mounted on a moveable platform 6240 or similar mechanism allowing them to be moved forward and backward along the warp direction.

[0380] Utilizing sensor input, such as an array of position sensors, lidar, or computer vision, to measure the spacing between adjacent weft tapes and the relative angle of the weft tapes, relative to a desired spacing and angle, the post-positioner 6200 can reposition the tape to the desired spacing and angle.

[0381] The present composite forming system 100 can further comprise the tack station 7000. downstream the post-positioner 6200. The tack station 7000 can comprise a tacking device thatapplies heat and pressure to two or more tapes in order to fix their position prior to full consolidation.

[0382] In order to function effectively and avoid loss of positioning, the post-positioner 6200 is preferably configured to maintain positive contact with the weft tape until it is fully gripped or otherwise secured by the tacking device.

[0383] The control system of the positioning system can be a part of an overall control system for the invention, a discrete positioning control system, and / or a combination thereof.

[0384] Returning to FIGS. 1-3, a tacking device 7000 may use one or more heated wheels, belts, or clamping devices configured to consolidate one or more pairs of warp tape and weft tapes at the location of interlace (where the consolidation area may be substantially smaller than the size of the interlace area). Alternatively, it may use an ultrasonic sealer (rotary heat sealer).

[0385] The positioning 600 and tacking 700 are particularly valuable when continuous ultrasonic welding is used to consolidate the lattice material. The present invention can further comprise vibration isolation assembly 8000. The vibration isolation / dampening assembly 8000 can comprise a vibration isolation roller configuration placed between the tacking device 7000 and the consolidation zone 9000, which damps the vibrations propagating upstream and permits the tacking device 7000 to secure the position and alignment of the weft tapes such that they are not vibrated out of position or misaligned as they enter the consolidation zone 9000.

[0386] Vibration isolation protects the tapes from disturbance prior to tacking and then the tack welder secures the position of the tapes so they cannot be disturbed as they pass assembly 8000 and enter zone 9000.

[0387] The control systems of the taking and / or dampening and / or consolidation zone systems can be a part of an overall control system for the invention, a discrete positioning control system, and / or a combination thereof.

[0388] It is to be understood that the embodiments and claims disclosed herein are not limited in their application to the details of construction and arrangement of the components set forth in the description and illustrated in the drawings. Rather, the description and the drawings provide examples of the embodiments envisioned. The embodiments and claims disclosed herein are further capable of other embodiments and of being practiced and carried out in many ways. Also,it is to be understood that the phraseology and terminology employed herein are for the purposes of description and should not be regarded as limiting the claims.

[0389] Accordingly, those skilled in the art will appreciate that the conception upon which the application and claims are based may be readily utilized as a basis for the design of other structures, methods, and systems for carrying out the several purposes of the embodiments and claims presented in this application. It is important, therefore, that the claims be regarded as including such equivalent constructions.

[0390] Furthermore, the purpose of the Abstract is to enable the United States Patent and Trademark Office and the public, and especially including the practitioners in the art who are not familiar with patent and legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The Abstract is neither intended to define the claims of the application, nor is it intended to be limiting to the scope of the claims in any way.

Claims

CLAIMSWhat is claimed is:

1. A method comprising: inserting a feed of weft tape in a weft direction; physical-grip-free drawing of the inserted feed of weft tape through a weft guide path to a target drawn location; shear cuting the drawn feed of weft tape, forming a target drawn length of weft tape; and beating the target drawn length of weft tape clear of the weft guide path in the warp direction.

2. The method of Claim 1 , wherein the inserting comprises inserting by a weft tape inserter configured to insert the feed of weft tape in the weft direction from a continuous feedstock.

3. The method of Claim 1 , wherein the shear cuting comprises shear cuting by a shear cuting assembly configured to shear cut the inserted feed of weft tape into the target drawn length of the weft tape.

4. The method of Claim 1 , wherein the inserting comprises inserting two or more feeds of weft tape in the weft direction; wherein shear cuting comprises shear cuting using a shear blade with an opening configured such that two or more feeds of weft tape pass therethrough; and wherein the opening possesses at least one slanted or curved edge to promote concentration of the shear cut force.

5. The method of Claim 1, wherein the inserting comprises inserting two or more feeds of weft tape in the weft direction; wherein shear cuting comprises shear cuting using a shear blade with two or more openings, each opening configured such that a feed of weft tape passes therethrough; and wherein each of the openings possess at least one slanted or curved edge to promote concentration of the shear cut force.

6. The method of Claim 1, wherein the physical-grip-free drawing comprises media-assist drawing of the inserted feed of weft tape through the weft guide path by exposing the inserted feed of weft tape to the Coanda effect.

7. The method of Claim 1 , wherein the media-assist drawing comprises gas-assist drawing of the inserted feed of weft tape through the weft guide path by exposing the inserted feed of weft tape to the Coanda effect; and wherein the inserting comprises: applying a grip pressure to grip the feed of the weft tape; accelerating / decelerating the feed of the weft tape in order to, in combination with the gas-assist drawing, advance the feed of the weft tape in the weft direction to a weft tape target position, so the shear cutting forms the target drawn length of weft tape; monitoring one or more inserting characteristics of the inserting; and adjusting the inserting in response to one or more of the monitored inserting characteristics.

8. The method of Claim 1 , wherein the media-assist drawing comprises gas-assist drawing of the inserted feed of weft tape through a warp head and a weft support; wherein the warp head defines a portion of the weft guide path via a weft guide channel; wherein the weft support defines a portion of the weft guide path via a weft guide channel; and wherein the weft support is selected from a group consisting of a gas-assist draw weft support, a gas-assist beat weft support, and a mechanical-assist beat weft support.

9. The method of Claim 1, wherein the beating comprises: mechanical-assist beating by mechanical means; and media-assist beating with media.

10. The method of Claim 1 further comprising interlacing a feed of warp tapes and the beat target drawn length of weft tape.

11. The method of Claim 1 further comprising repositioning after the beating; wherein the method comprises a series of weft insertion cycles; wherein each weft insertion cycle comprises the steps of inserting, drawing, shear cutting, beating, and repositioning; wherein the repositioning enables a subsequent weft insertion cycle to begin after a preceding weft insertion cycle has ended; and wherein a time duration of each weft insertion cycle is 1 second or less.

12. The method of Claim 10, wherein the interlacing comprises interlacing the feed of warp tapes and the beat target drawn length of weft tape into an initial orientation of interlaced warp and weft tapes.

13. The method of Claim 10 further comprising transforming the initial orientation of the interlaced warp and weft tapes into a pre-consolidation orientation of the interlaced warp and weft tapes.

14. The method of Claim 11, wherein the time duration of each weft insertion cycle is 800 ms or less.

15. The method of Claim 11, wherein the time duration of each weft insertion cycle is 500 ms or less.

16. The method of Claim 13 further comprising consolidating the pre-consolidation orientation of the interlaced warp and weft tapes.

17. The method of Claim 13, wherein the transforming comprises catching the beat target drawn length of weft tape to provide a repeatable reference stop location for the caught beat target drawn length of weft tape.

18. The method of Claim 13, wherein the transforming comprises at least one of: changing a relative spacing between consecutively beat target drawn lengths of weft tape; or changing a relative angular alignment of the consecutively beat target drawn lengths of weft tape.

19. A method comprising: inserting a feed of weft tape in a weft direction; physical-grip-free drawing of the inserted feed of weft tape through a weft guide path to a target drawn location; shear cutting the drawn feed of weft tape, forming a target drawn length of weft tape; beating the target drawn length of weft tape clear of the weft guide path in the warp direction; interlacing a feed of warp tapes and the beat target drawn length of weft tape into an initial orientation of the interlaced warp and weft tapes; transforming the initial orientation of the interlaced warp and weft tapes into a preconsolidation orientation of the interlaced warp and weft tapes; and consolidating the pre-consolidation orientation of the interlaced warp and weft tapes.

20. The method of Claim 19, wherein the physical-grip-free drawing comprises gas-assist drawing of the inserted feed of weft tape through the weft guide path by exposing the inserted feed of weft tape to the Coanda effect.

21. The method of Claim 19 further comprising repositioning after the beating; wherein the method comprises a series of weft insertion cycles; wherein each weft insertion cycle comprises the steps of inserting, drawing, shear cutting, beating, and repositioning; wherein the repositioning enables a subsequent weft insertion cycle to begin after a preceding weft insertion cycle has ended; and wherein a time duration of each weft insertion cycle is 1 second or less.

22. The method of Claim 20, wherein the inserting comprises: applying a grip pressure to grip the feed of the weft tape; accelerating / decelerating the feed of the weft tape in order to, in combination with the gasassist drawing, advance the feed of the weft tape in the weft direction to a weft tape target position, so the shear cutting forms the target drawn length of weft tape; monitoring one or more inserting characteristics of the inserting; and adjusting the inserting in response to one or more of the monitored inserting characteristics.

23. The method of Claim 20, wherein the gas-assist drawing comprises gas-assist drawing the inserted feed of weft tape through warp heads and weft supports by a draw gas system; wherein each warp head defines a portion of the weft guide path via a weft guide channel; wherein each weft support defines a portion of the weft guide path via a weft guide channel; wherein each weft support is selected from a group consisting of a gas-assist draw weft support, a gas-assist beat weft support, and a mechanical-assist beat weft support; and wherein the draw gas system is configured to provide a draw gas to the weft guide channel of one or more of the warp heads and the gas-assist draw weft supports.

24. The method of Claim 21, wherein the time duration of each weft insertion cycle is 800 ms or less.

25. The method of Claim 21, wherein the time duration of each weft insertion cycle is 500 ms or less.

26. The method of Claim 23, wherein: the inserting comprises inserting by a weft tape inserter configured to insert the feed of weft tape in the weft direction from a continuous feedstock; the shear cutting comprises shear cutting by a shear cutting assembly configured to shear cut the inserted feed of weft tape into the target drawn length of the weft tape; and the beating comprises: mechanical-assist beating via one or more of the mechanical-assist beat weft supports; and gas-assist beating by a beat gas system configured to provide a beat gas to the weft guide channel of one or more of the gas-assist beat weft supports.

27. The method of Claim 26, wherein the draw gas system and the beat gas system are the same gas system.

28. The method of Claim 26, wherein the draw gas system and the beat gas system are different gas systems.

29. The method of Claim 26, wherein the draw gas and the beat gas are the same gas.

30. The method of Claim 26, wherein the draw gas and the beat gas are different gases.

31. A method of forming a consolidated woven composite from a woven composite of one or more warp tapes and one or more weft tapes comprising: a continuous series of weft insertion cycles, each weft insertion cycle comprising: inserting a feed of weft tape in a weft direction; physical-grip-free drawing of the inserted feed of weft tape through a weft guide path to a target drawn location; shear cutting the drawn feed of weft tape, forming a target drawn length of weft tape; beating the target drawn length of weft tape clear of the weft guide path in the warp direction; and repositioning, which enables a subsequent weft insertion cycle to begin after a preceding weft insertion cycle has ended; and interlacing a feed of warp tapes and the beat target drawn length of weft tape; and consolidating the interlaced warp and weft tapes to form the consolidated woven composite; wherein a time duration of each weft insertion cycle is 1 second or less.

32. The method of Claim 31, wherein the physical-grip-free drawing comprises gas-assist drawing of the inserted feed of weft tape through the weft guide path by exposing the inserted feed of weft tape to the Coanda effect.

33. The method of Claim 31 , wherein the time duration of each weft insertion cycle is 800 ms or less.

34. The method of Claim 31 , wherein the time duration of each weft insertion cycle is 500 ms or less.

35. The method of Claim 32, wherein: the interlacing comprises interlacing the feed of warp tapes and the beat target drawn length of weft tape into an initial orientation of the interlaced warp and weft tapes; each weft insertion cycle further comprises transforming the initial orientation of the interlaced warp and weft tapes into a pre-consolidation orientation of the interlaced warp and weft tapes; and the consolidating comprises consolidating the pre-consolidation orientation of the interlaced warp and weft tapes to form the consolidated woven composite.

36. The method of Claim 32, wherein the gas-assist drawing comprises gas-assist drawing of the inserted feed of weft tape through a weft guide path by exposing the inserted feed of weft tape to the Coanda effect; and wherein the inserting comprises: applying a grip pressure to grip the feed of the weft tape; accelerating / decelerating the feed of the weft tape in order to, in combination with the gas-assist drawing, advance the feed of the weft tape in the weft direction to a weft tape target position, so the shear cutting forms the target drawn length of weft tape; monitoring one or more inserting characteristics of the inserting; and adjusting the inserting in response to one or more of the monitored inserting characteristics.

37. The method of Claim 32, wherein the inserting comprises inserting two or more feeds of weft tape in the weft direction; wherein shear cutting comprises using a single shear blade with openings, at least one of openings configured for at least two feeds of the weft tape; and wherein each opening possesses at least one slanted or curved edge to promote concentration of the shear cut force.

38. The method of Claim 35, wherein the transforming comprises catching the beat target drawn length of weft tape to provide a repeatable reference stop location for the caught target drawn length of weft tape.

39. The method of Claim 35, wherein the transforming comprises at least one of: changing a relative spacing between consecutively beat target drawn lengths of weft tape; or changing a relative angular alignment of the consecutively beat target drawn lengths of weft tape.

40. The method of Claim 35, wherein the transforming comprises: pre-positioning by at least one of: increasing a relative spacing between consecutively beat target drawn lengths of weft tape; or changing a relative angular alignment of warp tape and weft tapes to perpendicular if askew from perpendicular; and post-positioning by at least one of: changing the relative spacing between consecutively beat target drawn lengths of weft tape; or changing the relative angular alignment of warp tape and weft tapes.

41. The method of Claim 36, wherein the inserting further comprises comparing one or more of the monitored inserting characteristics to programmable tolerance ranges for the monitored inserting characteristics; and wherein the adjusting is based on the comparing.

42. The method of Claim 38, wherein the transforming further comprises: monitoring one or more characteristics of the caught target drawn lengths of weft tape; and adjusting the catching in response to one or more of the monitored caught target drawn lengths of weft tape characteristics.

43. The method of Claim 40 further comprising tacking two or more locations of warp tape and weft tape interlace in order to fix the position of the pre-consolidation orientation of the woven composite.

44. A method comprising: forming a woven composite of one or more warp tapes and one or more weft tapes comprising: inserting, by a weft tape inserter, a feed of weft tape in a weft direction from a continuous feedstock; gas-assist drawing of the inserted feed of weft tape by a draw gas system through a weft guide path defined in warp heads and weft supports, wherein the inserted feed of weft tape is drawn through the weft guide path by exposing the inserted feed of weft tape to the Coanda effect, wherein each warp head defines a portion of the weft guide path via a weft guide channel, wherein each weft support defines a portion of the weft guide path via a weft guide channel, wherein each weft support is selected from a group consisting of a gas-assist draw weft support, a gas-assist beat weft support, and a mechanical-assist beat weft support, wherein the draw gas system is configured to provide a draw gas to the weft guide channel of one or more of the warp heads and the gas-assist draw weft supports, and wherein each of the weft guide channels has a height of from 1 -5 mm and has a width between a width of the weft tape and 150% of the weft tape width; shear cutting the drawn feed of weft tape, forming a target drawn length of weft tape; beating the target drawn length of weft tape clear of the weft guide path in the warp direction comprising: mechanical beating by mechanical means from one or more of the mechanical-assist beat weft supports; and gas beating with beat gas from a beat gas system to one or more of the gasassist beat weft support;venting the weft guide channel of one or more of the warp heads and the gas-assist draw weft supports to reduce pressure build up; interlacing a feed of warp tapes and the beat target drawn length of weft tape into an initial orientation of the interlaced warp and weft tapes; transforming the initial orientation of the interlaced warp and weft tapes into a preconsolidation orientation of the interlaced warp and weft tapes; tacking two or more locations of warp tape and weft tape interlace in the preconsolidation orientation; and consolidating the pre-consolidation orientation of the woven composite to form a consolidated woven composite.

45. The method of Claim 44, wherein the draw gas system and the beat gas system are the same gas system; or wherein the draw gas system and the beat gas system are different gas systems.

46. The method of Claim 44, wherein the draw gas and the beat gas are the same gas; or wherein the draw gas and the beat gas are different gases.

47. The method of Claim 44, wherein the inserting comprises: applying a grip pressure to grip the feed of the weft tape; accelerating / decelerating the feed of the weft tape in order to, in combination with the gasassist drawing, advance the feed of the weft tape in the weft direction to a weft tape target position, so the shear cutting forms the target drawn length of weft tape; monitoring one or more inserting characteristics of the inserting; and adjusting the inserting in response to the comparing.

48. The method of Claim 44, wherein shear cutting comprises using one or more shear blades, each with one or more openings, at least one of openings configured for at least two feeds of the weft tape; and wherein at least one of the openings possesses at least one slanted or curved edge to promote concentration of the shear cut force.

49. The method of Claim 44, wherein the transforming comprises: pre-positioning comprising: catching the beat target drawn length of weft tape; actively positioning; monitoring one or more pre-positioning characteristics of the caught beat target drawn length of weft tape; increasing a relative spacing between consecutively beat target drawn lengths of weft tape by the catching when one or more of the pre -positioning characteristics warrants the increasing; and changing a relative angular alignment of warp and weft tapes to perpendicular by the actively positioning when one or more of the pre-positioning characteristics warrants the changing; and post-positioning comprising: monitoring one or more post-positioning characteristics of the warp and weft tapes after pre-positioning; and changing the relative spacing and / or a relative angular alignment of the warp and weft tapes when one or more of the post-positioning characteristics warrants the changing.

50. A method comprising the steps of: inserting a feed of weft tape in a weft direction; physical-grip-free drawing of the inserted feed of weft tape through a weft guide path to a target drawn location; shear cutting the drawn feed of weft tape, forming a target drawn length of weft tape; beating with air and with mechanical means the target drawn length of weft tape clear of the weft guide path in the warp direction; interlacing a feed of warp tapes and the beat target drawn length of weft tape into an initial orientation of the interlaced warp and weft tapes; consolidating the pre-consolidation orientation of the interlaced warp and weft tapes into a consolidated woven composite at a line speed; monitoring a monitored characteristic of a monitored step selected from the group consisting of the inserting, the air-assist drawing, the shear cutting, the beating, the interlacing, the consolidating, and a combination thereof; and autonomously adjusting at least one monitored step based upon a comparing of the monitored characteristic with a programmable tolerance range of the monitored characteristic.

51. The method of Claim 50, wherein the physical-grip-free drawing comprises air-assist drawing of the inserted feed of weft tape through a weft guide path by exposing the inserted feed of weft tape to the Coanda effect.

52. The method of Claim 50, wherein the monitored characteristic is selected from the group consisting of inserting speed, air-assist drawing speed, shear cutting speed, beating speed, interlacing speed, consolidating speed, inserting weft tape shape, inserting weft tape orientation, air-assist drawing weft tape shape, air-assist drawing weft tape orientation, shear cutting weft tape shape, shear cutting weft tape orientation, beating weft tape shape, beating weft tape orientation, interlacing warp tape shape, interlacing weft tape shape, interlacing warp tape orientation, interlacing weft tape orientation, spacing of the weft tapes in the initial orientation, spacing of the warp tapes in the initial orientation, angular relationship between warp and weft tapes in the initial orientation, consolidating warp tape shape, consolidating weft tape shape, consolidating warp tape orientation, consolidating weft tape orientation, spacing of the weft tapes in the pre-consolidation orientation, spacing of the warp tapes in the pre-consolidation orientation, angular relationship between warp and weft tapes in the pre-consolidation orientation, heating of the consolidating, pressure of the consolidating, and a combination thereof.

53. A machine comprising: a weft tape inserter configured to insert a feed of weft tape in a weft direction; a weft guide path defined at least in part by weft guide channels of warp heads and weft supports; a physical-grip-free system configured to draw the inserted feed of weft tape through the weft guide path to a target drawn location; and a shear cutting assembly configured to shear cut the drawn feed of weft tape, forming a target drawn length of weft tape.

54. The machine of Claim 53 further comprising a beat system configured to beat the target drawn length of weft tape clear of the weft guide path in the warp direction.

55. The machine of Claim 54 further comprising: a draw gas system configured to provide a draw gas to the weft guide path; and a beat gas system configured to provide a beat gas to the beat system.

56. The machine of Claim 55, wherein the physical-grip-free system comprises a gas-assist drawing system configured to draw the inserted feed of weft tape through the weft guide path by exposing the inserted feed of weft tape to the Coanda effect.

57. The machine of Claim 56, wherein each weft support is selected from a group consisting of a gas-assist draw weft support, a gas-assist beat weft support, and a mechanical-assist beat weft support; and wherein draw gas system is configured to provide the draw gas to the weft guide channel of one or more of the warp heads and the gas-assist draw weft supports.

58. The machine of Claim 57, wherein the beat gas system is configured to provide the beat gas to the weft guide channel of one or more of the gas-assist beat weft supports.

59. The machine of Claim 58, wherein the weft guide path comprises an alignment of the weft guide channels of the warp heads and weft supports across an operating width of the machine through which the feed of weft tape is inserted and drawn.

60. The machine of Claim 59, wherein the weft tape inserter is further configured to insert the feed of weft tape in the weft direction from a continuous feedstock.

61. The machine of Claim 60, wherein each warp head has a warp tape slot configured to contain a warp tape passing therethrough in a warp direction.

62. The machine of Claim 61 , wherein the beat system further comprises the mechanical-assist beat weft supports that provide a mechanical beat means to the target drawn length of weft tape .

63. A machine comprising: one or more weft tape inserters, each weft tape inserter configured to insert a feed of weft tape in a weft direction from a continuous feedstock; warp heads, each comprising: a warp tape slot configured to contain a warp tape passing therethrough in a warp direction; and a weft guide channel; weft supports, each comprising a weft guide channel, and each selected from a group consisting of a gas-assist draw weft support, a gas-assist beat weft support, and a mechanical-assist beat weft support; a gas-assist drawing system configured to draw the inserted feed of weft tape through a weft guide path by exposing the inserted feed of weft tape to the Coanda effect; a shear cutting assembly configured to shear cut the drawn feed of weft tape, forming a target drawn length of weft tape; and a beat system configured to beat the target drawn length of weft tape clear of the weft guide path in the warp direction; wherein the weft guide channels of the warp heads and the weft supports are configured for alignment across an operating width of the machine forming the weft guide path through which the feed of the weft tape pass; and wherein the gas-assist drawing system is configured for physical-grip-free passing of the feed of the weft tape through the weft guide path.

64. The machine of Claim 63 configured to run a continuously series of weft insertion cycles; wherein each weft insertion cycle comprises the steps of inserting the feed of weft tape, drawing the feed of weft tape through the weft guide path, shear cutting the drawn feed of weft tape, beating the target drawn length of weft tape, and repositioning the warp heads; wherein the repositioning enables a subsequent weft insertion cycle to begin after a preceding weft insertion cycle has ended; and wherein a time duration of each weft insertion cycle is 1 second or less.

65. The machine of Claim 63, wherein the weft guide path has a height of from 1-5 mm and a width between a width of the weft tape and 150% of the weft tape width; wherein the weft guide channel of one or more of the warp heads and the weft supports incorporate an array of surface features on a top surface and / or a bottom surface; wherein the array of surface features run along the weft direction in order to reduce contact area and direct gas flow along the weft direction; and wherein one or more characteristics of the gas from the gas-assist drawing system and one or more characteristics of the weft guide channel cooperate to maintain the feed of the weft tape passing through the weft guide path in an insertion orientation.

66. The machine of Claim 63, wherein each weft tape inserter comprises a weft tape insertion control mechanism configured to apply a grip pressure to grip the feed of weft tape, and accelerate / decelerate the feed of weft tape in order to propel the feed of weft tape in the weft direction.

67. The machine of Claim 63 further comprising a catch device configured to provide a repeatable reference stop location as the target drawn lengths of weft tape are beat out of the weft guide path; wherein the catch device is further configured to increase spacing between consecutively beat target drawn lengths of weft tape.

68. The machine of Claim 63 further comprising a positioner; wherein, when the beat target drawn lengths of weft tape are clear of the weft guide path, an initial orientation of a woven composite is formed from an interlacing of the warp tapes and the target drawn lengths of weft tape; and wherein the positioner is configured to position one or more of the tapes of the initial orientation of the woven composite to form a pre-consolidation orientation of the woven composite.

69. The machine of Claim 64, wherein the time duration of each weft insertion cycle is 800 ms or less.

70. The machine of Claim 64, wherein the time duration of each weft insertion cycle is 500 ms or less.

71. The machine of Claim 66, wherein the weft tape insertion control mechanism comprises a double belt set comprising a top belt / pulley assembly and a bottom belt / pulley assembly; wherein a portion of each of the belts are proximate one another in a tape inserter zone; and wherein the double belt set is configured to apply the grip pressure to grip the feed of weft tape and accelerate / decelerate the feed of weft tape in the tape inserter zone.

72. The machine of Claim 68, wherein the positioner comprises: a pre -positioner comprising: a catch for catching the beat target drawn lengths of weft tape; and a pre-positioner monitoring system configured to monitor one or more prepositioning characteristics of the caught target drawn lengths of weft tape; wherein the catch is configured to increase a relative spacing between consecutively beat target drawn lengths of weft tape when one or more of the pre -positioning characteristics warrants the increase; and a post-positioner comprising: a post-positioner monitoring system configured to monitor one or more postpositioning characteristics of the target drawn lengths of weft tape after the prepositioner; and a changing device configured to change the relative spacing and / or the relative angular alignment between warp tape and weft tapes when one or more of the postpositioning characteristics warrants the change.

73. The machine of Claim 68 further comprising a tacking device; wherein the positioner further comprises an active system configured to change a relative angular alignment of warp tape and weft tapes to perpendicular if one or more of the prepositioning characteristics warrants the change; and wherein the tacking device is configured to apply heat and pressure to two or more locations of warp tape and weft tape interlace in order to fix the woven composite in the preconsolidation orientation.

74. The machine of Claim 71, wherein the weft tape insertion control mechanism further comprises a paired tape inserter roller set comprising a top roller and a bottom roller; and wherein the paired tape inserter roller set is positioned in the tape inserter zone to apply a non-slip pressure through the proximate belt portions and to the feed of weft tape in order to limit slippage.

75. The machine of Claim 71, wherein at least a portion of one or more of the belts is coated with a textured rubber or elastomer.

76. The machine of Claim 71, wherein the weft tape insertion control mechanism further comprises: a belt / pulley assembly actuator; and a weft tape insertion control sensor; wherein at least one of the belt / pulley assemblies is driven by the belt / pulley assembly actuator; wherein the weft tape insertion control sensor is configured to monitor one or more belt / pulley assembly characteristics; and wherein the belt / pulley assembly actuator is adjustable in response to one or more of the monitored belt / pulley assembly characteristics.

77. The machine of Claim 71, wherein the weft tape insertion control mechanism further comprises a weft tape insertion controller configured to one or more: adjust an insertion distance of the weft tape; or adjust a motion profile of the weft tape; based on programmatic inputs in order to facilitate weft tape handling downstream of the one or more weft tape inserters.

78. The machine of Claim 73 further comprising a consolidation zone; wherein the consolidation zone is configured to form a consolidated woven composite from the woven composite.

79. The machine of Claim 74, wherein the paired tape inserter roller set is positioned in the middle of the tape inserter zone.

80. The machine of Claim 76, wherein the belt / pulley assembly actuator is adjustable in response to one or more of the monitored belt / pulley assembly characteristics in relation to programmable tolerance ranges for the one or more belt / pulley assembly characteristics.

81. The machine of Claim 78 further comprising a vibration isolation assembly; wherein the consolidation zone comprises an ultrasonic welder; and wherein the vibration isolation assembly is configured to dampen vibrations propagating upstream from the ultrasonic welder.

82. The machine of Claim 80, wherein at least one of the belt / pulley assembly characteristics is selected from a group consisting of torque, speed, and position.

83. A machine for continuously forming a consolidated woven composite from tape material comprising: a weft inserter stack comprising: two or more weft tape inserters, each weft tape inserter configured to insert a feed of weft tape in a weft direction from a continuous feedstock; and a shear cutting assembly configured to shear cut a drawn feed of weft tape, forming a target drawn length of weft tape; a warp rack comprising: warp heads for receiving warp tapes, each warp head comprising: a warp tape slot configured to contain the warp tape passing therethrough in a warp direction; and a weft guide channel; and weft supports, each weft support: comprising a weft guide channel; and selected from a group consisting of an air-assist draw weft support, an airassist beat weft support, and a mechanical-assist beat weft support; an air system configured to provide air to: the weft guide channel of one or more of the air-assist draw weft supports; and one or more of the air-assist beat weft supports; anda beat system configured to beat the target drawn length of weft tape clear of a weft guide path in the warp direction; wherein the weft guide channels of the warp heads and the weft supports are configured for alignment across an operating width of the machine forming the weft guide path through which the feed of weft tape pass; wherein one or more characteristics of the air from the air system and one or more characteristics of the weft guide channel of one or more of the air-assist draw weft supports cooperate to maintain the feed of weft tape passing through the weft guide path in an insertion orientation and to expose the feed of weft tape through the weft guide path to the Coanda effect; and wherein once the feed of weft tape has passed through the weft guide path and come to a stop in the weft direction, and before a subsequent feed of weft tape is permitted to traverse the same weft guide path, a current shear cut of the target drawn length of weft tape encounters the beat system, including a mechanical beat by mechanical means from one or more of the mechanical-assist beat weft supports, and during and / or after the mechanical beat, an air-assist beat by air from one or more of the air-assist beat weft supports.

84. The machine of Claim 83, wherein one of the air characteristics is selected from a group consisting of a speed of air supplied by the air system to the weft guide channel of the air-assist draw weft supports, a volume of air supplied by the air system to the weft guide channel of the airassist draw weft supports, and a direction of air supplied by the air system to the weft guide channel of the air-assist draw weft supports.

85. The machine of Claim 83, wherein one of the weft guide channel characteristics is selected from a group consisting of a width of the weft guide channel of the air-assist draw weft supports, a height of the weft guide channel of the air-assist draw weft supports, and a surface profile of the weft guide channel of the air-assist draw weft supports.

86. The machine of Claim 83, wherein each weft tape inserter comprises a weft tape insertion control mechanism configured to apply a grip pressure to grip the feed of weft tape, and accelerate / decelerate the feed of weft tape in order to propel the feed of weft tape in the weft direction.

87. The machine of Claim 83 further comprising a catch device configured to provide a repeatable reference stop location as the target drawn lengths of weft tape are beat out of the weft guide path; wherein the catch device is further configured to increase spacing between consecutively beat target drawn lengths of weft tape.

88. The machine of Claim 83 further comprising a positioner; wherein, when the beat target drawn lengths of weft tape are clear of the weft guide path, an initial orientation of a woven composite is formed from an interlacing of the warp tapes and the target drawn lengths of weft tape; and wherein the positioner is configured to position one or more of the tapes of the initial orientation of the woven composite to form a pre-consolidation orientation of the woven composite.

89. The machine of Claim 86, wherein the weft tape insertion control mechanism comprises a double belt set comprising a top belt / pulley assembly and a bottom belt / pulley assembly; wherein a portion of each of the belts are proximate one another in a tape inserter zone; and wherein the double belt set is configured to apply the grip pressure to grip the feed of weft tape and accelerate / decelerate the feed of weft tape in the tape inserter zone.

90. The machine of Claim 88, wherein the positioner comprises: a pre -positioner comprising: a catch for catching the beat target drawn lengths of weft tape; an active system; and a pre-positioner monitoring system configured to monitor one or more prepositioning characteristics of the caught target drawn lengths of weft tape; wherein the catch is configured to increase a relative spacing between consecutively beat target drawn lengths of weft tape when one or more of the pre -positioning characteristics warrants the increase; andwherein the active system is configured to change a relative angular alignment of warp tapes and weft tapes to perpendicular if one or more of the pre -positioning characteristics warrants the change; and a post-positioner comprising: a post-positioner monitoring system configured to monitor one or more postpositioning characteristics of the target drawn lengths of weft tape after the prepositioner; and a changing device configured to change the relative spacing and / or the relative angular alignment between warp tapes and weft tapes when one or more of the postpositioning characteristics warrants the change.

91. The machine of Claim 88 further comprising a tacking device configured to apply heat and pressure to two or more locations of warp tape and weft tape interlace in order to fix the woven composite in the pre-consolidation orientation.

92. The machine of Claim 89, wherein the weft tape insertion control mechanism further comprises a paired tape inserter roller set comprising a top roller and a bottom roller; and wherein the paired tape inserter roller set is positioned in the tape inserter zone to apply a non-slip pressure through the proximate belt portions and to the feed of weft tape in order to limit slippage.

93. The machine of Claim 89, wherein at least a portion of one or more of the belts is coated with a textured rubber or elastomer.

94. The machine of Claim 89, wherein the weft tape insertion control mechanism further comprises: a belt / pulley assembly actuator; and a weft tape insertion control sensor; wherein at least one of the belt / pulley assemblies is driven by the belt / pulley assembly actuator; wherein the weft tape insertion control sensor is configured to monitor one or more belt / pulley assembly characteristics; andwherein the belt / pulley assembly actuator is adjustable in response to one or more of the monitored belt / pulley assembly characteristics.

95. The machine of Claim 89, wherein the weft tape insertion control mechanism further comprises a weft tape insertion controller configured to one or more: adjust an insertion distance of the weft tape; or adjust a motion profile of the weft tape; based on programmatic inputs in order to facilitate weft tape handling downstream of the one or more weft tape inserters.

96. The machine of Claim 91 further comprising a consolidation zone; wherein the consolidation zone is configured to form a consolidated woven composite from the woven composite.

97. The machine of Claim 92, wherein the paired tape inserter roller set is positioned in the middle of the tape inserter zone.

98. The machine of Claim 94, wherein the belt / pulley assembly actuator is adjustable in response to one or more of the monitored belt / pulley assembly characteristics in relation to programmable tolerance ranges for the one or more belt / pulley assembly characteristics.

99. The machine of Claim 96 further comprising a vibration isolation assembly; wherein the consolidation zone comprises an ultrasonic welder; and wherein the vibration isolation assembly is configured to dampen vibrations propagating upstream from the ultrasonic welder.

100. The machine of Claim 99, wherein at least one of the belt / pulley assembly characteristics is selected from a group consisting of torque, speed, and position.

101. A machine for forming a woven composite of one or more warp tapes and one or more weft tapes by a method comprising: inserting feeds of the weft tapes in a weft direction from continuous feedstocks; aligning a set of weft guide channels to form a weft guide path through which the feeds of weft tape are to pass, wherein each weft guide channel is selected from a group consisting of a weft guide channel of a warp head and a weft guide channel of a weft support, and wherein each weft support is selected from a group consisting of an air-assist draw weft support, an air-assist beat weft support, and a mechanical-assist beat weft support; air-assisting the feeds of weft tapes through the weft guide path defined by the aligned set of weft guide channels by exposing the feeds of weft tapes passing through the weft guide path to the Coanda effect; shear cutting the feeds of weft tapes into target drawn lengths of weft tape; and beating the target drawn lengths of weft tape clear of the weft guide path.

102. The machine of Claim 101 , wherein the beating comprises: imparting a mechanical beat in a warp direction by one or more of the mechanical-assist beat weft supports; and imparting during and / or after the mechanical beat an air-assist beat in the warp direction by air from one or more of the air-assist beat weft supports.

103. The machine of Claim 101, wherein the method further comprises: monitoring one or more inserting characteristics of the inserting; and adjusting the inserting in response to one or more of the monitored inserting characteristics.

104. The machine of Claim 101 , wherein the method further comprises: catching the beat target drawn lengths of weft tape to provide a repeatable reference stop location for the caught beat target drawn lengths of weft tape; and increasing spacing between consecutively beat target drawn lengths of weft tape.

105. The machine of Claim 104, wherein the method further comprises changing an angular alignment and / or a relative spacing of the consecutively beat target drawn lengths of weft tape.

106. The machine of Claim 105, wherein the method further comprises applying heat and pressure to two or more locations of warp tape and weft tape interlace in order to fix the position of the interlace.

107. The machine of Claim 106, wherein the method further comprises consolidating the fixed position of the interlace to form a consolidated woven composite.

108. The machine of Claim 101, wherein the air-assisting comprises electronically controlling air flow within two or more weft guide channels of air-assist draw weft supports, both in terms of pressure and activation timing.

109. The machine of Claim 108, wherein one or more of the weft supports and / or the warp heads further comprise an array of sensors that detect the position of the feed of weft tape as it moves through the weft guide path, activating and deactivating individual air-assist units as the feed of weft tape passes to reduce a total air consumption.

110. The machine of Claim 109, wherein the machine is configured to insert multiple layers of weft tapes; and wherein the method further comprises offsetting a weft tape insertion timing for each layer to allow at least one sensor of the array of sensors to detect the passage of two or more weft tapes and verify the position of each weft tape independently.

111. The machine of Claim 101, wherein the method further comprises sensing to detect slippage or jamming during the weft tape insertion; and wherein sensing data from the sensing is fed back to a weft tape inserter controller to correct or retry the weft tape insertion.

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