# US 11,027,500 B1 · Construction of structures by joining of pre-formed tape > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,027,500 B1 - Document ID: US11027500B1 - Status: Granted - Kind: B1 - Application number: 16/012,228 - Filed: 2018-06-19 - Granted: 2021-06-08 - Earliest claimed: 2017-06-19 - Assignees: Triad National Security, LLC - Applicants: Triad National Security, LLC - Inventors: Lawrence Eugene Bronisz; Laura Catherine Stonehill; Dominic S. Peterson - Web page: https://patentgrep.com/patent/US11027500B1 ## CPC - B29C 66/435: {Making large sheets by joining smaller ones or strips together} - H01Q 15/141: {Apparatus or processes specially adapted for manufacturing reflecting surfaces} - B29C 65/20: with direct contact, e.g. using "mirror" - B29C 65/48: using adhesives {, i.e. using supplementary joining material; solvent bonding} - B29C 65/58: Snap connection - B29C 66/1222: {comprising at least a lapped joint-segment} - B29C 66/12421: {Teardrop-like, waterdrop-like or mushroom-like interlocking undercuts} - B29C 66/21: {said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding} - B29C 66/71: {characterised by the composition of the plastics material of the parts to be joined (welding bar compositions B29C65/125)} - B29C 65/08: using ultrasonic vibrations {(non-plastics element to plastics elements B29C65/645)} - B29C 65/18: using heated tools - B29C 66/1122: {Single lap to lap joints, i.e. overlap joints (B29C66/45, B29C66/472, B29C66/52272 take precedence)} - B29C 66/4326: {for making hollow articles or hollow-preforms, e.g. half-shells} - B29C 66/7212: {characterised by the composition of the fibres} - B29C 66/73921: {characterised by the materials of both parts being thermoplastics} - B29C 66/81427: {comprising a single ridge, e.g. for making a weakening line; comprising a single tooth} - B29C 66/8362: {Rollers, cylinders or drums moving relative to and tangentially to the parts to be joined} - B29C 66/845: {C-clamp type or sewing machine type} - B29L 2031/3456: {Antennas, e.g. radomes} - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - H01Q: ANTENNAS, i.e. RADIO AERIALS (radiators or antennas for microwave heating H05B6/72) - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES ## Abstract Various components, such as radio frequency (RF) or thermal reflectors, may be constructed from joining of pre-formed tape. For reflectors, this process may reduce the number of ribs, only require partial ribs, or eliminate the use of ribs altogether. To build such a reflector, a spool of tape, a joining tractor, and a foundation ring may be employed. ## Claims ### Claim 1 An apparatus, comprising: a spool comprising tape, the spool configured to dispense the tape; a joining tractor configured to receive the tape from the spool and join a newly dispensed section tape to an adjacent inner section of the tape or to a foundation ring; and juxtaposed rollers on opposite sides of the tape that are configured to guide the tape as the tape is joined, at least one of the juxtaposed rollers configured to provide propulsion for the joining tractor, wherein the joining tractor is configured to move along the foundation ring, and subsequently, the adjacent inner section of tape, to attach a next section of the tape outside of the foundation ring or the adjacent inner section of the tape. ### Claim 2 (depends on 1) The apparatus of claim 1, wherein the foundation ring is circular, elliptical, another two-dimensional geometric shape, non-planar, irregular, an open-ended geometric shape, or any combination thereof. ### Claim 3 (depends on 1) The apparatus of claim 1, wherein the tape is pre-formed along some or all of its length to have a desired yaw radius or camber based on a position of a respective section of the tape. ### Claim 4 (depends on 1) The apparatus of claim 1, wherein the tape is formed upon being dispensed. ### Claim 5 (depends on 1) The apparatus of claim 1, wherein the tape is joined by the joining tractor using pre-applied adhesives, spot or continuous hot-melt joining, Tongue-in-Groove (TiG) snap joints, a zipper, tabbed interlocks, hook-and-loop fasteners, or any combination thereof. ### Claim 6 (depends on 1) The apparatus of claim 1, further comprising: a foot on an opposite side of the tape from a roller of the juxtaposed rollers, the foot configured to guide the tape as the tape is joined. ### Claim 7 (depends on 1) The apparatus of claim 1, wherein the tape is stored in the spool in a conical or otherwise tapered shape. ### Claim 8 (depends on 1) The apparatus of claim 1, further comprising: a housing comprising an upper portion, an upper roller of the juxtaposed rollers, a lower portion, and a lower roller of the juxtaposed rollers, the upper portion housing the upper roller and the lower portion housing the lower roller; a motor roller; and a belt operably connected to the motor roller and the upper roller such that the motor roller drives the belt, and thus rotates the upper roller such that the joining tractor moves along the tape, wherein the tape passes between the upper roller and the lower roller. ### Claim 9 (depends on 1) The apparatus of claim 1, wherein the tape has a mesh design that comprises a monolithic inner edge, radial elements extending from the monolithic inner edge that provide structural support, and curved flexures that allow the tape to exhibit yaw compliance. ### Claim 10 (depends on 1) The apparatus of claim 1, wherein the tape is reflective, and a size of the flexures is sufficiently small to provide a continuous electromagnetic reflector for a desired radio frequency wavelength. ### Claim 11 (depends on 1) The apparatus of claim 1, further comprising: a cutting mechanism configured to cut the tape. ### Claim 12 (depends on 1) The apparatus of claim 1, further comprising: a computing system configured to control operation of the apparatus. ### Claim 13 (depends on 1) The apparatus of claim 1, wherein the apparatus further comprises at least one die, at least one of the juxtaposed rollers is a contoured roller, or both, and the tape is pushed, pulled, or both, across the at least one die, the at least one contoured roller, or both, such that the tape is formed into a desired shape. ### Claim 14 A system for creating a structure with tape, comprising: a foundation ring that provides a foundation for the structure; a spool containing tape, the spool configured to dispense the tape; a joining tractor configured to receive the tape and join newly dispensed tape from the spool to an adjacent inner section of the tape or to the foundation ring, the joining tractor configured to move along the foundation ring, and subsequently, the adjacent inner section of the tape to attach the newly dispensed tape outside of the foundation ring or the adjacent inner section of the tape; and juxtaposed rollers on opposite sides of the tape that are configured to guide the tape as the tape is joined, at least one of the juxtaposed rollers configured to provide propulsion for the joining tractor. ### Claim 15 (depends on 14) The system of claim 14, further comprising: one or more additional joining tractors that are initially spaced apart from one another on the foundation ring, the joining tractors configured to form the structure using multiple spirals of tape. ### Claim 16 An apparatus, comprising: a spool comprising tape, the spool configured to dispense the tape; a joining tractor configured to receive the tape from the spool and join a newly dispensed section tape to an adjacent inner section of the tape or to a foundation ring; juxtaposed rollers on opposite sides of the tape that are configured to guide the tape as the tape is joined, at least one of the juxtaposed rollers configured to provide propulsion for the joining tractor; and a computing system configured to control operation of the apparatus, wherein the joining tractor is configured to move along the foundation ring, and subsequently, the adjacent inner section of tape, to attach a next section of the tape outside of the foundation ring or the adjacent inner section of the tape. ### Claim 17 (depends on 16) The apparatus of claim 16, further comprising: a housing comprising an upper portion, an upper roller of the juxtaposed rollers, a lower portion, and a lower roller of the juxtaposed rollers, the upper portion housing the upper roller and the lower portion housing the lower roller; a motor roller; and a belt operably connected to the motor roller and the upper roller such that the motor roller drives the belt, and thus rotates the upper roller such that the joining tractor moves along the tape, wherein the tape passes between the upper roller and the lower roller.