Method and apparatus for coating fibers

Abstract

Frameworks for use in coating reinforcing fibers are provided. The frameworks include a first framework end having a first cross-sectional shape. The first cross-sectional shape has one or more contact locations spaced apart from one another. The reinforcing fibers contact the first framework end at the one or more contact locations. Methods of coating such fibers are also provided.

Description

Technical Field

[0001] This disclosure relates to frame contact geometries and systems for fiber coating. Background Technology

[0002] Ceramic matrix reinforced composites (“CMCs”) containing fibers dispersed in a continuous ceramic matrix of the same or different compositions are well-suited for structural applications due to their toughness, heat resistance, high-temperature strength, and chemical stability. These composites typically exhibit a high strength-to-weight ratio, making them attractive for weight-sensitive applications, such as those in aerospace. Their high-temperature stability makes CMCs ideal for applications where components come into contact with high-temperature gases, such as those suitable for gas turbine engines. Attached Figure Description

[0003] The present disclosure is set forth in the specification with reference to the accompanying drawings, providing a complete and practical disclosure for those skilled in the art, including its best mode, wherein:

[0004] Figure 1 This is a schematic cross-sectional view of a ceramic matrix composite (CMC) component according to an exemplary aspect of this disclosure.

[0005] Figure 2 This is a schematic diagram of various components (such as spools, frames, and reactors) used in the fiber coating process according to exemplary aspects of this disclosure;

[0006] Figure 3A This is a schematic front view of a frame for supporting reinforcing fibers during the fiber coating process, according to an exemplary aspect of this disclosure.

[0007] Figure 3B It is an exemplary aspect of this disclosure that has a spacer bar in the raised position. Figure 3A A schematic side view of the frame.

[0008] Figure 3C It is an exemplary aspect of this disclosure that has a spacer strip at the lower position. Figure 3B A schematic side view of the frame.

[0009] Figure 4A It is a duckbill-shaped (e.g., according to an exemplary aspect of this disclosure) Figure 3B and 3C Cross-sectional view of the frame end shown in the diagram;

[0010] Figure 4B It is an example of an open-mouth shape according to an exemplary aspect of this disclosure (e.g., Figure 3B and 3C Cross-sectional view of the frame end shown in the diagram;

[0011] Figure 4C It is a ribbed shape according to an exemplary aspect of this disclosure (e.g., Figure 3B and 3C Cross-sectional view of the frame end shown in the diagram;

[0012] Figure 4D It is a toothed shape according to an exemplary aspect of this disclosure (e.g., Figure 3B and 3C Cross-sectional view of the frame end shown in the diagram;

[0013] Figure 4E It is an exemplary aspect of this disclosure having a groove shape (e.g., Figure 3B and 3C Cross-sectional view of the frame end shown in the diagram;

[0014] Figure 4F It is a fin-shaped device according to an exemplary aspect of this disclosure (e.g., Figure 3B and 3C Cross-sectional view of the frame end shown in the diagram;

[0015] Figure 5A It is an example of a mobile mechanism according to an exemplary aspect of this disclosure (e.g., Figure 3B and 3C A schematic end view of the fin-shaped frame end shown in the diagram;

[0016] Figure 5B It is an example of a mobile mechanism according to an exemplary aspect of this disclosure (e.g., Figure 3B and 3C A schematic end view of the fin-shaped frame end of the frame shown in the diagram;

[0017] Figure 6 This is a schematic diagram of a system having a moving mechanism according to an exemplary aspect of this disclosure;

[0018] Figure 7A This is a schematic end view of a frame end having a vibrating spline according to an exemplary aspect of this disclosure;

[0019] Figure 7B This is a schematic end view of a frame end with a vibrating spline according to another exemplary aspect of this disclosure;

[0020] Figure 8 This is a flowchart of a method for coating reinforcing fibers of a composite component according to an exemplary aspect of this disclosure; and

[0021] Figure 9This is a flowchart of a method for coating reinforcing fibers of a composite component according to another exemplary aspect of this disclosure. Detailed Implementation

[0022] Reference will now be made in detail to the present embodiments of this disclosure, one or more examples of which are illustrated in the accompanying drawings. Detailed descriptions use numerals and letter reference numerals to denote features in the drawings. Similar or analogous reference numerals in the drawings and description have been used to denote similar or analogous portions of this disclosure.

[0023] The term "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any implementation described herein as "exemplary" is not necessarily to be construed as superior or better than other implementations. Additionally, unless explicitly stated otherwise, all embodiments described herein should be considered exemplary.

[0024] Unless the context clearly indicates otherwise, the singular forms “a,” “a,” and “the” include plural references.

[0025] In a context such as “at least one of A, B and C”, the term “at least one” means only A, only B, only C, or any combination of A, B and C.

[0026] The term “turbine” or “turbomachinery” refers to a machine that includes one or more compressors, a heating section (e.g., a combustion section), and one or more turbines that together generate torque output.

[0027] The term "gas turbine engine" refers to an engine that has a turbine as its power source, in whole or in part. Examples of gas turbine engines include turbofan engines, turboprop engines, turbojet engines, turboshaft engines, and hybrid electric versions of one or more of these engines.

[0028] The terms "upstream" and "downstream" refer to the relative directions of fluid flow within a fluid path. For example, "upstream" refers to the direction from which the fluid flows, while "downstream" refers to the direction from which the fluid flows.

[0029] As used herein, the terms "axial" and "axially" refer to a direction and orientation that extends substantially parallel to the centerline of the gas turbine engine. Furthermore, the terms "radial" and "radially" refer to a direction and orientation that extends substantially perpendicular to the centerline of the gas turbine engine. Additionally, as used herein, the terms "circumferential" and "circumferentially" refer to a direction and orientation that extends in an arc around the centerline of the gas turbine engine.

[0030] Unless otherwise specified herein, the terms “connection,” “fixed,” “attached to,” etc., refer to both direct connection, fixation, or attachment, and indirect connection, fixation, or attachment via one or more intermediate components or features.

[0031] As used herein, the terms “first,” “second,” and “third” are used interchangeably to distinguish one component from another and are not intended to indicate the location or importance of the individual components.

[0032] For the purposes described below, the terms “upper,” “lower,” “right,” “left,” “vertical,” “horizontal,” “top,” “bottom,” “lateral,” “longitudinal,” and their derivatives should be associated with the embodiments in which they are oriented in the accompanying drawings. However, it should be understood that various alternative variations may be assumed in the embodiments unless explicitly stated otherwise. It should also be understood that the specific devices shown in the drawings and described in the following description are merely exemplary embodiments of this disclosure. Therefore, the specific dimensions and other physical characteristics associated with the embodiments disclosed herein should not be considered limiting.

[0033] In this disclosure, when a layer is described as being “on” or “above” another layer or substrate, it should be understood that, unless explicitly stated otherwise, these layers may be in direct contact with each other or have another layer or feature between them. Therefore, these terms simply describe the relative position of the layers relative to each other and do not necessarily mean “on top of”, as the relative position of above or below depends on the orientation of the apparatus to the observer.

[0034] As used herein, ceramic matrix composites or “CMC” refers to a class of materials comprising a reinforcing material (e.g., reinforcing fibers) surrounded by a ceramic matrix phase. Typically, the reinforcing fibers provide structural integrity to the ceramic matrix. Some examples of matrix materials for CMCs may include, but are not limited to, non-oxide silicon-based materials (e.g., silicon carbide, silicon nitride, or mixtures thereof), oxide ceramics (e.g., silicon oxycarbide, silicon oxynitride, alumina (Al₂O₃), silicon dioxide (SiO₂), aluminosilicates, or mixtures thereof), or mixtures thereof. Optionally, ceramic particles (e.g., oxides of Si, Al, Zr, Y, and combinations thereof) and inorganic fillers (e.g., pyrophyllite, wollastonite, mica, talc, kyanite, and montmorillonite) may also be included within the CMC matrix.

[0035] Some examples of reinforcing fibers for CMC may include, but are not limited to, non-oxide silicon-based materials (e.g., silicon carbide, silicon nitride, or mixtures thereof), non-oxide carbon-based materials (e.g., carbon), oxide ceramics (e.g., silicon oxycarbonate, silicon oxynitride, alumina (Al2O3), silicon dioxide (SiO2), aluminosilicates (such as mullite), or mixtures thereof), or mixtures thereof.

[0036] The reinforcing fibers can be at least a portion of individual filaments or strands. As used herein, “ceramic fiber bundle,” “fiber bundle,” or simply “bundle” refers to a bundle of multiple individual fibers, filaments, or loose strands. The filaments of a bundle can be randomly mixed or arranged in a pattern, and / or can be continuous or discontinuous. For example, a bundle can include broken filaments or filament segments. As another example, the filaments of a bundle can be substantially parallel, twisted, or otherwise arranged. A bundle can function in substantially the same way as a single or individual filament. It will also be understood that, as used herein, “individual ceramic filament” or simply “individual filament” refers to a single or non-bundled elongated ceramic component.

[0037] Generally, a particular CMC can be referred to as a combination of its fiber type / matrix type. For example, C / SiC is carbon fiber reinforced silicon carbide, SiC / SiC is silicon carbide fiber reinforced silicon carbide, SiC / SiN is silicon carbide fiber reinforced silicon nitride, SiC / SiC-SiN is silicon carbide fiber reinforced silicon carbide / silicon nitride matrix mixture, and so on. In other examples, a CMC may include a matrix and reinforcing fibers comprising oxide-based materials such as alumina (Al₂O₃), silicon dioxide (SiO₂), aluminosilicates, and mixtures thereof. Aluminosilicates may include crystalline materials (such as mullite (3Al₂O₃ / 2SiO₂)) and glassy aluminosilicates.

[0038] In some embodiments, the reinforcing fibers may be bundled and / or coated before being incorporated into the matrix. For example, the fiber bundles may be formed as reinforcing tapes, such as unidirectional reinforcing tapes. Multiple tapes may be stacked together to form a preform component. The fiber bundles may be impregnated with a slurry composition before or after the preform is formed. The preform may then be heat-treated (such as cured or burned off) to produce a high coke residue in the preform, and subsequently chemically treated (such as with silicon melt infiltration) to obtain a component formed from a CMC material having the desired chemical composition.

[0039] This material, along with certain monolithic ceramics (i.e., ceramic materials without reinforcement), is particularly well-suited for higher-temperature applications. Furthermore, these ceramic materials are lighter than superalloys, yet still provide strength and durability for components made from them. Therefore, the use of this material in many gas turbine components used in the higher-temperature range of gas turbine engines, such as airfoils (e.g., turbine and blades), combustors, and shrouds, is currently under consideration. These gas turbine components would benefit from the lighter weight and higher-temperature capabilities offered by these materials.

[0040] During the manufacturing of CMCs, the fibers are typically coated to help ensure their survival during the manufacturing process and to improve the mechanical properties of the CMCs in use. Typically, the fibers are bundled into fiber bundles, called filament bundles, and these bundles undergo a filament bundle coating process. For example, the filament bundles may be wrapped around a rigid frame and suspended in a reactor for coating, for example, under high temperature and vacuum conditions. Therefore, improved methods and apparatus to address one or more of these challenges would be necessary.

[0041] This invention generally relates to methods and apparatus for minimizing or eliminating under- or uncoated areas of coated fibers or filaments. For example, this disclosure relates to frames on which individual fibers and / or one or more filaments can be wrapped to support the fibers or filaments while a coating is applied, wherein the frame has a geometry to reduce contact between the fibers or filaments and the frame. For example, the frame ends of a frame for filament coating may have shapes or geometries that minimize contact between the filaments and the frame ends. Minimizing contact between the filaments and the frame ends allows for coating of the filaments while minimizing under- or uncoated areas within the filaments. As another example, a semi-static coating process in which the filaments move relative to the frame can help minimize or eliminate under- or uncoated areas of the coated filaments. Furthermore, utilizing the frame design and / or coating methods described herein can help ensure that composite components meet material specifications by minimizing or eliminating defects introduced during the coating of fibers or filaments used to form composite components.

[0042] Referring now to the accompanying drawings, where the same numerals indicate the same elements throughout the drawings, Figure 1 This is a schematic cross-sectional view of a composite component 100 (such as a CMC component). As previously mentioned, one process for manufacturing a CMC component requires the use of reinforcing tape impregnated with a slurry, which may be referred to as a prepreg. Prepregs are typically in the form of sheets or laminates, and unidirectional prepregs often comprise a two-dimensional fiber array comprising single-layer aligned filament bundles impregnated with a matrix precursor to produce a generally two-dimensional laminate. Multiple layers of the resulting prepreg can be stacked and debulked to form a laminated preform, a process known as “lay-up.” Prepregs are typically, but not necessarily, arranged such that the filament bundles of adjacent prepregs are oriented laterally (e.g., perpendicularly) to each other, thereby providing greater strength in the layering plane of the preform (corresponding to the primary (load-bearing) direction of the final CMC component). However, prepregs can also be arranged in other ways; for example, one or more adjacent prepreg bundles may not be oriented laterally or perpendicularly to each other, but in various embodiments, they may be parallel to each other, offset from each other by less than 90 degrees, etc. A stack of prepregs may include adjacent prepregs having multiple filament orientations relative to each other.

[0043] Figure 1This is a cross-sectional view showing a portion of a composite component 100 comprising multiple layers 102. Each layer 102 is formed from a separate prepreg strip or sheet. Figure 1 As shown, each layer 102 comprises a ceramic reinforcement made of unidirectionally aligned fibers 104, which are formed as bundles 106 and encased in a ceramic matrix 108. The ceramic matrix 108 is formed by the conversion (e.g., after firing) of the ceramic matrix precursor in a slurry used to impregnate the reinforcing strip.

[0044] refer to Figure 2 Before or as part of forming the reinforcing band, uncoated filament bundles 106' are wound onto a bobbin 110 (i.e., the fiber source). The uncoated filament bundles 106' can be unwound from the bobbin 110 for coating. For example, fibers bundled together in the form of uncoated filament bundles 106' are coated for various purposes, such as protecting them during composite processing, altering fiber-matrix interfacial strength, and / or promoting or preventing mechanical and / or chemical bonding between the fibers and the matrix. Many different techniques have been developed for applying fiber coatings, such as slurry impregnation, sol-gel, sputtering, and chemical vapor deposition (CVD). Of these, CVD has been most successful in producing impermeable coatings with uniform thickness and controlled composition.

[0045] In a typical CVD process, fibers and reactants are heated to a specific high temperature, at which the coating precursor decomposes and deposits as a coating. CVD coatings can be applied in a continuous or batch process. In a continuous process, fibers and coating precursors continuously pass through the reactor.

[0046] like Figure 2 As shown, during the batching process, a certain length of fiber (e.g., a certain length of uncoated filament bundle 106') is unwound from spool 110 onto frame 112. The fiber can be under tension as it is wound onto frame 112. For example, winding tension can be maintained on the fiber as it is unwound from spool 110 onto frame 112. In some embodiments, the winding tension can range from about 0.01% to about 90% of the breaking strength of the uncoated filament bundle 106'. As an example, the winding tension can range from about 20 grams to about 100 grams.

[0047] Once set on frame 112 and unwinding from spool 110 has stopped, the tension on the fibers can be relaxed to a steady-state tension. For example, frame 112 or its components (such as those referenced below) Figure 3B and 3CThe spacers described can be relaxed, withdrawn, etc., to change the perimeter of the frame 112, which relaxes the tension on the fibers. The steady-state tension on the fibers is lower than the winding tension and can be very low, for example, essentially zero.

[0048] After the fibers are conveyed to frame 112, frame 112 is then introduced into and held within reactor 114 while reactant 115 passes through reactor 114. As previously described, the temperature within reactor 114 can be raised such that as reactant 115 passes through reactor 114, the coating precursor decomposes and is deposited as coating 116 onto the uncoated filament bundle 106' to form filament bundle 106. The filament bundle 106 now coated with coating 116 can then be formed into a reinforcing tape, which can be impregnated with slurry to form a prepreg tape, sheet, or laminate for forming CMC components (such as composite component 100 described herein).

[0049] Will understand, Figure 2 Only a general schematic depiction of the apparatus for transferring uncoated fibers from a fiber source to a frame for depositing a coating onto the fibers in a reactor is provided. Other components, such as a drive mechanism, one or more pulleys, one or more sensors, a controller, etc., may be used with the spool 110, the frame 112, and the reactor 114 to coat the uncoated tow 106' using a batching process as described herein.

[0050] Turning Figure 3A , 3B And 3C, will describe framework 112 in more detail. Figure 3A A schematic diagram of a framework 112 according to various embodiments of this subject is provided. Figure 3B and 3C Each provided Figure 3A A schematic side view of the frame 112 shown. Figure 3A , 3B Each of Figures 112 and 3C shows reinforcing fibers extending around frame end 118; it will be understood that the reinforcing fibers wrapped around frame 112 may be fiber 104 or uncoated filament bundle 106', and the term "reinforcing fiber" as used below applies to fiber 104, uncoated filament bundle 106', or both. Further, the following description uses the singular term "filament bundle," but it will be understood that the following description may apply to a single filament bundle (e.g., a single uncoated filament bundle 106' wound around frame 112 is coated and unwound from frame 112 as a single coated filament bundle 106), or multiple filament bundles (e.g., multiple lengths of uncoated filament bundles 106' are wound around frame 112, coated, and unwound from frame 112 as multiple lengths of coated filament bundles 106).

[0051] like Figure 3AAs shown, frame 112 includes a first frame end 118A and a second frame end 118B opposite to the first frame end 118A. The first frame end 118A and the second frame end 118B may be constructed in the same manner, such that the first frame end 118A and the second frame end 118B are identical to each other, or the first frame end 118A may be constructed differently from the second frame end 118B. Unless otherwise stated, the description herein referring to "frame end 118" applies to the first frame end 118A, the second frame end 118B, or both.

[0052] The first frame end 118A and the second frame end 118B are spaced apart along the longitudinal direction L by a frame side length 120. The frame 112 also includes two or more frame sides 122 extending between the first frame end 118A and the second frame end 118B. Figure 3A The embodiment shows a rectangular frame 112, wherein a first frame side 122A and a second frame side 122B opposite to the first frame side 122A each extend between a first frame end 118A and a second frame end 118B. The first frame side 122A and the second frame side 122B are spaced apart from each other along a lateral direction T by a frame end length 121. It will be understood that the frame 112 may also have other shapes and different numbers of frame ends 118 and frame sides 122.

[0053] Furthermore, in Figure 3A In embodiments, reinforcing fibers 104, in the form of uncoated tow 106' as described above, may be wrapped around the frame 112 such that the reinforcing fibers 104 contact each frame end 118 at one or more contact locations 124. Figure 3B and 3C However, it will be understood that in other embodiments, in addition to or as an alternative to frame end 118, reinforcing fiber 104 may wrap around frame 112 and contact frame side 122. Therefore, the description provided herein regarding the shape and / or geometry of frame end 118 and / or the movement of reinforcing fiber 104 relative to frame end 118 can be applied to frame side 122.

[0054] As previously described, the frame 112 can be configured to help maintain tension on the fibers when they are wound around the frame 112, and to help relax or remove tension on the fibers once they are wound around the frame 112, which can help ensure proper coating of the fibers. For example, as Figure 3B and 3C As shown, frame 112 may include components such as spacer bars 119, which can be positioned from a raised position ( Figure 3B ) shift to a lower position ( Figure 3C ), to relax the tension on the uncoated filament bundle 106' wound on the frame 112.

[0055] More specifically, Figure 3B The spacer bar 119 is shown in its raised position, and Figure 3C The spacer 119 is shown in its lowered position. In the raised position, the spacer 119 increases the perimeter of the frame 112; the uncoated filament bundle 106' can be wound around the frame 112 while the spacer 119 is in the raised position. In the lowered position, the spacer 119 retracts into the frame 112, thereby reducing the perimeter of the frame 112. After the uncoated filament bundle 106' is wound around the frame 112, the spacer 119 can be moved to its lowered position, which reduces the perimeter of the frame 112 supporting the uncoated filament bundle 106', thereby relaxing or reducing the tension on the uncoated filament bundle 106'. Relaxing the tension on the uncoated filament bundle 106' allows the uncoated filament bundle 106' to separate from each other and / or from the frame 112, providing increased space or leeway for the reactants to surround the uncoated filament bundle 106', thereby coating the uncoated filament bundle 106' to form the coated filament bundle 106.

[0056] Will understand, Figure 3B The spacer bar 119 shown is merely an example. The spacer bar 119 can have any suitable shape and size and can be positioned along the frame 112 at any suitable location to support the fibers on the frame 112 as described herein. Furthermore, in some embodiments, more than one spacer bar 119 may be used, and in other embodiments, features or components other than one or more spacer bars 119 may be used to maintain and relax tension on the fibers as described herein. Additionally, the use of foldable frames to vary the distance between the frames 112 (e.g., the distance between the respective ends of adjacent frames 112) may also be considered.

[0057] Additionally or alternatively, the shape of the frame end 118 can facilitate thorough coating of the fibers. In a particular embodiment, the frame end 118 may be static relative to the frame 112. Alternatively, the frame end 118 may be movable relative to the frame 112.

[0058] Now for reference Figures 4A to 4F Each frame end 118 has one or more contact positions 124 (in Figures 4A-4F The cross-sectional shapes are shown as 124A and 124B, where adjacent contact positions 124A and 124B are spaced apart by a separation length of 126. Figures 4A to 4F Cross-sectional views of frame ends 118 of different shapes (represented as frame ends 118, 118', 118”, 118”’, 118”” and 118””’, respectively) are provided for each frame 112. For example, in Figure 4AIn one embodiment, the cross-sectional shape of the frame end 118 is a duckbill shape, including a first contact position 124A spaced apart from the second contact position 124B by a separation length of 126.

[0059] To facilitate adequate coating, the minimum length of uncoated filament bundle 106' should be in contact with or relatively close to the frame 112. For example, the number of contact points 124 within a minimum distance 130 from the frame end 118 and / or the length of the uncoated filament bundle 106' can be minimized to promote coating of as many filament bundles as possible. (Reference) Figure 4A The frame end 118 is inclined inward toward the centerline 132 from each of the first contact positions 124A and 124B to define a generally V-groove 125 between the first contact positions 124A and 124B. Therefore, the distance between the uncoated filament bundle 106' and the frame end 118 varies along the separation length 126. More specifically, the distance between the uncoated filament bundle 106' and the frame end 118 varies from zero at contact positions 124A, 124B (i.e., the uncoated filament bundle 106' contacts the frame end 118 at contact positions 124A, 124B) to a maximum distance 134 at the deepest point of the V-groove 125 (i.e., at the centerline 132). For example, in Figure 4A As the distance moves from left to right from the first contact position 124A to the second contact position 124B, the distance between the uncoated filament bundle 106' and the frame end 118 increases from the first contact position 124A to the center line 132 and decreases from the center line 132 to the second contact position 124B.

[0060] Furthermore, as the frame side length 120 is moved from each contact position 124A, 124B, the distance between the uncoated filament bundle 106' and the frame end 118 increases. Additionally, Figure 4A The duckbill-shaped frame end 118 shown is undercut, which shortens the length of the uncoated filament bundle 106' spaced apart from the frame 112 by a minimum distance 130 or less. The minimum distance 130 can be the minimum spacing between the uncoated filament bundle 106' and the frame 112, at which point, during the coating process, reactant 115 ( Figure 2 The material does not interact with the material forming the frame 112 to suppress the formation of the coating 116 on the uncoated filament bundle 106'. In some embodiments, the minimum distance 130 may be at least twice the diameter of the uncoated filament bundle 106'; in other embodiments, the minimum distance 130 may be at least three times, at least four times, at least five times, at least six times, or at least seven times the diameter of the uncoated filament bundle 106'.

[0061] Therefore, for Figure 4A In the illustrated embodiment, the frame end 118 is inclined towards the centerline 132 along the width W of the frame end 118 and is undercut along the frame side length 120 away from the contact positions 124A, 124B. The first length 128A of the uncoated filament bundle 106' is defined by the sum of the first contact position 124A and the adjacent minimum distances 130 on both sides from the frame end 118. The second length 128B of the uncoated filament bundle 106' is defined by the sum of the first contact position 124A and the adjacent minimum distances 130 on both sides from the frame end 118. In this embodiment, the first length 128A is less than the separation length 126 adjacent to the first length 128A. Figure 4A The duckbill-shaped frame end 118 shown helps minimize the total length of the uncoated filament bundles 106' within a minimum distance 130 from the frame end 118, for example, by having only two contact positions 124, an undercut frame end 118, and an inclination away from the contact positions 124, as described herein. It will be understood that the total length of the uncoated filament bundles 106' within a minimum distance 130 from the frame end 118 is the sum of the lengths of each uncoated filament bundle 106' within a minimum distance 130 from the frame end 118. For example, for Figure 4A In one embodiment, the total length of the uncoated filament bundle 106' within a minimum distance 130 from the frame end 118 is the sum of the first length 128A and the second length 128B.

[0062] It will be understood that the centerline 132 is defined as passing through the center of the width direction of the cross-sectional shape of the frame end 118, wherein the width W of the frame end 118 is perpendicular or orthogonal to the longitudinal direction L and the lateral direction T defined by the frame 112. Figure 3A Each of the following. Further, it will be understood that in at least some embodiments, the generally V-groove 125 extends along the lateral direction T over the frame end length 121. For example, the generally V-groove 125 may be defined along the frame end 118 such that the generally V-groove 125 extends from the first frame side 122A ( Figure 3A ) extends to the second frame side 122B ( Figure 3A ).

[0063] Therefore, as Figure 4AAs shown, fibers 104 or uncoated filament bundles 106' are wrapped around the frame 112 such that the fibers 104 or uncoated filament bundles 106' contact the first contact position 124A and the second contact position 124B of the frame end 118, and are spaced from the frame 112 by a minimum distance 130 or less in a first length 128A and a second length 128B, the first length 128A including the portion of the fibers 104 or uncoated filament bundles 106' contacting the first contact position 124A, and the second length 128B including the portion of the fibers 104 or uncoated filament bundles 106' contacting the second contact position 124B. However, the remaining portion of the fibers 104 or uncoated filament bundles 106' is spaced from the frame 112 by a distance greater than the minimum distance 130 to allow a coating to be deposited on the reinforcing fibers, for example by a chemical vapor deposition (CVD) process as described herein or other suitable coating processes. It will be understood that for a frame 112 having two frame ends 118 constructed in a substantially similar manner (e.g., having the same cross-sectional shape), Figure 3B The frame end 118 shown may be a first frame end 118A, and the reinforcing fiber (i.e., fiber 104 or uncoated tow 106') may be in contact with the reinforcing fiber. Figure 4A The first and second contact positions 124A and 124B shown contact the third and fourth contact positions of the second frame end 118B in a substantially similar manner.

[0064] like Figure 4A As shown, the cross-sectional shape of the frame end 118 defines two contact positions 124, which are configured to contact reinforcing fibers. Figures 4B to 4F Additional or alternative embodiments of the frame end 118 are depicted, and in each embodiment, the cross-sectional shape of the frame end 118 depicted has multiple contact locations 124. It will be understood that the additional or alternative embodiments of the frame end are not mutually exclusive and can be combined in the same frame and / or in the same system having multiple frames. Figures 4A to 4F As shown, in various embodiments of the frame end 118, the plurality of contact positions 124 may have a periodicity factor of at least 2. That is, the contact positions 124 may have a pattern that appears at least twice.

[0065] Turning Figure 4B The cross-sectional shape of the frame end 118' can be an open shape, which is the main sector of a circle, with or without rounded edges, or it can also be called a Pac-Man shape. Figure 4A The shape of the duckbill shown is the same. Figure 4BThe open shape of the frame end 118' shown includes a generally V-shaped groove 125 between the first contact position 124A and the second contact position 124B. The generally V-shaped groove 125 may extend along the lateral direction T over the frame end length 121. For example, in at least some embodiments, the generally V-shaped groove 125 is defined along the frame end 118 such that the generally V-shaped groove 125 extends from the first frame side 122A (… Figure 3A ) Extends to the second frame side 122B ( Figure 3A ).

[0066] Figure 4B The shape of the open mouth shown is similar to Figure 4A The shapes of the duckbill shown differ along the width direction of the corresponding frame ends 118, 118'. For example, Figure 4A The duckbill shape is undercut as described above, wherein the widest portion or maximum width W of the frame end 118 of the duckbill shape includes a first contact position 124A and a second contact position 124B. Conversely, Figure 4B The opening shape includes a circular edge 138, wherein the first circular edge 138A is arc-shaped outward in the width direction from the first contact position 124A relative to the frame end 118', and the second circular edge 138B is arc-shaped outward in the width direction from the second contact position 124B relative to the frame end 118'. Figure 4B The widest portion, or maximum width W, of the open shape of the frame end 118' shown is spaced apart from each contact position 124 between lines extending tangent to the rounded edge 138 and parallel to the longitudinal direction L. Therefore, the length 128 of the uncoated filament bundle 106' is adjacent to... Figure 4B Within the minimum distance 130 of the frame end 118' of the frame end 118' at the maximum width W of the open-mouth shaped frame end 118'. More specifically, the first length 128A of the uncoated filament 106' extends from the first circular edge 138A along the width direction toward the second contact position 124B, passing through the first contact position 124A to the first position 136A within the minimum distance 130, and the second length 128B of the uncoated filament 106' extends from the second circular edge 138B along the width direction toward the first contact position 124A, passing through the second contact position 124B to the second position 136B within the minimum distance 130.

[0067] Now for reference Figure 4C In some embodiments, the cross-sectional shape of the frame end 118” is rib-shaped. For example... Figure 4C As shown, the rib shape may include a plurality of ribs 140, wherein each rib 140 is spaced apart from adjacent ribs 140 by a separation length 126, and adjacent ribs 140 have similar or different spacing. That is, each rib 140 defines a contact position 124, and as per [the relevant information]... Figure 4AAs described, adjacent contact positions can be spaced apart by a separation length of 126. It should be noted that each rib 140 can be identical in size and shape, or each rib can be different in size and shape. Further, as per [the relevant information]... Figure 4A and 4B The length 128 of the uncoated filament bundle 106' is within a minimum distance 130 of the circular edge 138 adjacent to each rib 140 and the frame end 118" of the adjacent rib shape. As described herein, the total length of the uncoated filament bundle 106' within the minimum distance 130 can be minimized to minimize the low and uncoated areas of the filament bundle when the coating process is completed.

[0068] like Figure 4D As shown, in other embodiments, the cross-sectional shape of the frame end 118”’ is toothed. Similar to Figure 4A and 4B Implementation examples, Figure 4D The tooth shape of the frame end 118”' includes two contact positions 124, a first contact position 124A and a second contact position 124B. The tooth shape may also include a first linear edge 142A and a second linear edge 142B, the first linear edge 142A extending inward from the first contact position 124A toward the centerline 132, and the second linear edge 142B extending inward from the second contact position 124B toward the centerline 132. An angle α may be defined between each of the first linear edge 142A and the second linear edge 142B and the centerline 132. Angle α may be a non-zero angle less than 90°, such as, in some embodiments, in the range of about 5° to about 80°; in some embodiments, in the range of about 15° to about 60°; and in some embodiments, in the range of about 20° to about 45°. Further, with Figures 4A-4C As in the illustrated embodiment, the length 128 of the uncoated filament bundle 106' can be within a minimum distance 130 at each contact position 124A, 124B adjacent to the tooth-shaped frame end 118"', and as described herein, the total length of the uncoated filament bundle 106' within the minimum distance 130 can be minimized to minimize the low and uncoated areas of the filament bundle when the coating process is completed.

[0069] Now for reference Figure 4E In other embodiments of the frame end 118", the cross-sectional shape is a groove shape. The groove shape may include a plurality of semi-circular protrusions 144. For example... Figure 4EAs shown, each semicircular protrusion 144 can be spaced apart from adjacent semicircular protrusions 112 by a separation length 126. It should be noted that any number of protrusions and uniform or non-uniform spacing can be used. Further, each semicircular protrusion 144 can define a contact position 124 at which the reinforcing fibers contact the groove-shaped frame end 118” when the reinforcing fibers are wrapped around the frame 112. Figures 4A-4D Similar to the embodiments, the length 128 of the uncoated filament bundle 106' can be within a minimum distance 130 of each contact position 124 of the adjacent groove-shaped frame end 118, and as described herein, the total length of the uncoated filament bundle 106' within the minimum distance 130 can be minimized to minimize the low and uncoated areas of the filament bundle when the coating process is completed.

[0070] Turning Figure 4F In further embodiments of the frame end 118””’, the cross-sectional shape is a fin shape. The fin shape may include a plurality of fins 146. Each of the plurality of fins 146 may be spaced apart from adjacent fins by a separation length 126. It should be noted that any number of protrusions and uniform or non-uniform spacing can be used. Furthermore, each fin 146 may define a contact position 124 at which the reinforcing fibers contact the frame end 118””’ of the fin shape when the reinforcing fibers are wrapped around the frame 112. Figures 4A-4E As in the illustrated embodiment, the length 128 of the uncoated filament bundle 106' can be within a minimum distance 130 of each contact position 124 of the adjacent fin-shaped frame end 118””’. As described herein, the total length of the uncoated filament bundle 106' within the minimum distance 130 can be minimized to minimize the low and uncoated areas of the filament bundle when the coating process is completed.

[0071] In each embodiment described herein, the frame 112 and frame ends 118 may be configured such that the total length 128 of the uncoated filament bundles 106' to the frame 112 (e.g., the sum of the lengths of the filament bundles 106' within a minimum distance 130 on either side of the contact region 124A and the lengths of the filament bundles 106' within the contact region 124A) is minimized. Thus, the reactant can interact with the reinforcing fibers (rather than the frame 112) to coat the reinforcing fibers in a minimal area with no or low coated fiber area. For example, the ratio of the total length of the uncoated filament bundles 106' (i.e., the sum of each length 128 of a given frame end 118) to the separation length 126 of a given frame end 118 may range from about 2 to about 10,000 (e.g., from about 5 to about 1,000). Further, as described herein, the minimum distance 130 may be at least twice the diameter of the uncoated filament bundle 106', such as two, three, four, five, six, or seven or more times the diameter of the uncoated filament bundle 106'. In some embodiments, the minimum distance 130 may depend on the material forming the frame 112 for depositing the coating 116 on the uncoated filament bundle 106'. Figure 2 ) reactant 115 ( Figure 2 ), or a combination of these or other factors.

[0072] Furthermore, each contact location 124 may be defined as a point contact between the frame end 118 and the reinforcing fiber. In some embodiments, the contact between the frame end 118 and the reinforcing fiber may be a line contact (i.e., having multiple adjacent contact points), or a combination of point and line contacts. For example, for a given configuration of the frame end 118, one contact location 124 may be defined as a point contact between the frame end 118 and the reinforcing fiber, while another contact location 124 may be defined as a line contact between the frame end and the reinforcing fiber.

[0073] As previously described, the coated reinforcing fibers (e.g., coated fibers or coated tow 106) can be formed into composite components or articles, such as... Figure 1 The composite component 100 shown may be a ceramic matrix composite (CMC) component. In at least some embodiments, the composite component 100 is a CMC component comprising silicon carbide (SiC) reinforcing fibers in a silicon carbide (SiC) matrix material, such that the CMC component is a SiC / SiC component. However, the CMC component may be formed from other ceramic materials as described herein, and in suitable embodiments, the composite component 100 may be formed from a non-ceramic material or a mixture of ceramic and non-ceramic materials.

[0074] Now for reference Figure 5A and 5B , Figure 5A and 5B It was shown (for example, Figure 3B and 3C (Frame 112) Additional or alternative frame end 118 X 118 Y Reinforcing fibers (e.g., such as) Figure 5A and 5B The uncoated filament bundle 106' shown can be relative to ( Figure 3B and 3C The centerline 132 of the frame 112 is moved to reduce or eliminate low- or uncoated areas in the reinforcing fibers when the coating process is complete. For example, as Figure 5A and 5B As shown, at least one frame end 118 can extend, for example, in a lateral direction T relative to the page entry / exit direction. Figure 2 Rotate clockwise or counterclockwise to push or move the reinforcing fibers during the coating process. After pushing or moving the reinforcing fibers relative to the frame 112, the formation of coating 116 on the fibers, which may have been hindered by the frame 112 before pushing or moving, is completed. Figure 2 One or more regions of the reinforcing fiber can be exposed to reactant 115 ( Figure 2 For example, regions 152A and 152B of the reinforcing fibers that are in contact with the contact position 124 of the frame end 118 at the first position P1 can be pushed or moved to a second position P2 spaced apart from the corresponding contact position 124, thereby providing sufficient space for the reactant to interact with the reinforcing fibers for the formation of the coating 116 thereon. Figure 2 ).

[0075] For illustrative purposes only, the two such regions 152 are... Figure 5A and 5B The area 152 is indicated by an enlarged circle outlined with a dashed line, solely for illustrative purposes. It will be understood that the enlarged circle indicating area 152 is not intended to convey any size, extent, etc., of such area 152.

[0076] like Figure 5A and 5B As shown, frame end 118 can have the same characteristics as... Figures 4A to 4F The described cross-sectional shapes are the same as or substantially similar to one of the cross-sectional shapes. For example, Figure 5A and 5B The frame end 118 shown has a cross-sectional shape such as the fin shape described with respect to FIG. 4, comprising a plurality of fins 150 spaced apart from each other. Reference Figure 5A and 5B The reinforcing fibers can contact the frame end 118 at multiple contact locations 124, each contact location 124 being defined by a corresponding fin 150. This is achieved by moving the frame end 118, for example, by... Figure 5ARotating the frame end 118 clockwise or counterclockwise as indicated by the arrows in the diagram can push or move the reinforcing fibers (in the form of uncoated filament bundles 106' in the depicted embodiment) initially in contact with contact position 124 away from contact position 124. For example, as... Figure 5B As shown, by rotating the frame end 118 clockwise by 180°, the uncoated filament bundle 106' can be pushed so that regions 152A and 152B no longer contact the fins 150A and 150B at their respective defined contact positions 124.

[0077] refer to Figure 5A and Figure 5B It will be understood that, in at least some embodiments, movement of the frame end 118 prevents the fibers (e.g., uncoated filament bundle 106') from slipping relative to the frame end 118, which helps to minimize fuzzing and broken filament ends. When the uncoated filament bundle 106' is not slipping relative to the frame end 118, the region 152 of the uncoated filament bundle 106' will remain in contact with the fin 150 until the rotation of the frame end 118 reaches its right or left limit position (in... Figure 5A and 5B In the end view), at the right or left extreme position, region 152 will travel downwards along the side of the "curtain" formed by the uncoated filament bundle 106' for coating in a free state. Figure 5A and 5B In the depicted embodiment, the amount of rotation required for region 152 to be "free" from contact at contact position 124 is 180°, but the linear distance that the uncoated filament bundle 106' must move to avoid contact with fin 150 can be reduced by decreasing the circumference of frame end 118. In some embodiments, using with Figure 5A and 5B The construction is similar to that of two or more support frame ends 118 in the form of rollers (e.g., generally cylindrical in shape, wherein the length of the roller is along such a direction as...). Figure 3A The lateral extension shown allows for a further reduction in the circumference of the frame end 118, and the smaller diameter end rollers, due to their smaller diameter, do not need to rotate a full 180° to release the uncoated filament bundle 106', which minimizes the length of the linear filament bundle that momentarily contacts the fin 150. In some embodiments, multiple (e.g., two or more) small end rollers can be correlated by synchronously moving the central gear of all end rollers, which helps prevent slip contact with the filament bundle.

[0078] like Figure 6 As shown, frame 112 can be used for coating composite components (such as...) Figure 1The composite component 100 is part of the reinforcing fiber system 10. In addition to the frame 112, the system 10 may also include a movement mechanism 154, which includes an actuator 156, for example, the actuator 156 actuates movement of one or more components of the movement mechanism 154. The movement mechanism 154 may be operatively coupled to the frame 112 to cause movement of the reinforcing fiber relative to the frame 112.

[0079] In some embodiments (such as) Figure 6 In the illustrated embodiment, the moving mechanism 154 includes a rack 158 and at least one gear 160, the at least one gear 160 being operatively connected to the rack 158, for example, in a rack and pinion configuration. Figure 6 As shown, in some embodiments, at least one gear 160 may be a first gear 160A and a second gear 160B disposed at opposite ends of the rack 158.

[0080] and Figure 6 Consistent with the embodiments described, the actuator 156 includes a rotating vacuum feeder 162 operably coupled to a drive motor 164. A screw drive member 166 is operably coupled to the rotating vacuum feeder 162, and a slider 168 defining a cam 170 is disposed on the screw drive member 166. The cam 170 is configured to contact the rack 158, thereby causing linear movement of the rack 158, for example, when the slider 168 translates along the screw drive member 166. For example, the drive motor 164 drives the rotating vacuum feeder 162 to rotate the screw drive member 166, which causes the slider 168 to translate along the screw drive member 166. When the cam 170, for example, is in such a position as Figure 6 When the rack end 172 of the rack 158 is in contact with the rack 158, the cam 170 moves along the end surface 173 of the rack end 172 and supports the rack 158 to initiate linear motion of the rack 158. For example, the end surface 173 may define a driven surface with a shape complementary to that of the cam 170.

[0081] It will be understood that, although not depicted in the figures, each of the rack 158 and at least one gear 160 defines a plurality of gear teeth that mesh with each other, such that linear movement of the rack 158 causes rotational movement of one or more gears 160. In some embodiments, the rotational movement of one or more gears 160 can be used, for example, to rotate the frame end 118 of the frame 112, as per [reference to...]. Figure 5A and 5BAs described. In other embodiments, the reinforcing fibers may contact the rack 158 and / or gear 160 such that linear movement of the rack 158 and / or rotational movement of the gear 160 causes the reinforcing fibers to move relative to the frame 112. This can promote adequate coating of the reinforcing fibers by exposing poorly or insufficiently coated or uncoated areas of the reinforcing fibers while the coating process is underway. Furthermore, it will be understood that instead of translating the rack 158 with actuator 156, in other embodiments, with... Figure 6 The actuator 156 shown is constructed differently so that it can rotate one or more gears 160 instead of causing linear motion of the rack 158.

[0082] like Figure 6 As further shown, in at least some embodiments, system 10 may include a plurality of rack and gear assemblies 174. Each rack and gear assembly 174 may include a rack 158 constructed as described above and at least one gear 160. The rack and gear assemblies 174 may be equidistant from each other within or adjacent to frame 112, or in other embodiments, at least one spacing distance between adjacent rack and gear assemblies 174 may differ from at least one other spacing distance between other adjacent rack and gear assemblies 174. Additionally, a plurality of cams may be included to similarly or by means of other motion mechanisms move the plurality of frame ends.

[0083] In addition, system 10 may include controller 176, which is operatively connected to actuator 156, such as to... Figure 6 The actuator 156 shown drives the motor 164. Specifically, the controller 176 generally includes a network interface 178. The network interface 178 can operate with any suitable wired or wireless communication network for data communication with, for example, other components of system 10 and / or other components or systems not depicted. As shown using dashed lines, for Figure 6 In one embodiment, network interface 178 uses wireless communication network 180 to communicate data with other components. For example, controller 176 is operatively coupled to actuator 156 via network interface 178 and wireless communication network 180. It will be understood, of course, that although for Figure 6 In one embodiment, network interface 178 uses wireless communication network 180, but in other embodiments, network interface 178 may alternatively use wired communication network or a combination of wired and wireless communication networks.

[0084] Still referencing Figure 6The controller 176 further includes one or more processors 182 and a memory device 184. The memory device 184 stores data 186 and instructions 188 accessible by the one or more processors 182. The one or more processors 182 may include any suitable processing means, such as a microprocessor, microcontroller, integrated circuit, logic device, and / or other suitable processing means. The one or more memory devices 184 may include one or more computer-readable media, including but not limited to non-transitory computer-readable media, RAM, ROM, hard disk drives, flash drives, and / or other memory devices. Instructions 188, when executed by the one or more processors 182, cause the controller 176 to perform a function. The instructions 188 within the memory device 184 may be any set of instructions that, when executed by the one or more processors 182, cause the one or more processors 182 to perform operations such as one or more operations described herein. In some exemplary embodiments, the instructions 188 within the memory device 184 may be software written in any suitable programming language or may be implemented in hardware. Additionally and / or alternatively, the instructions may be executed in logically and / or virtually decoupled threads on the processor 182. The memory device 184 may further store other data 188 that can be accessed by the processor 182.

[0085] In this way, it will be understood that, in at least some embodiments, controller 176 may be configured to, for example, initiate movement of moving mechanism 154 via actuator 156 to cause movement of reinforcing fibers relative to frame 112. For example, controller 176 may be configured to operate actuator 156 in response to, for example, actions disposed on frame 112 and / or reactor 114 (…). Figure 2 Data received by one or more sensors within the reaction stream 115 triggers movement of the moving mechanism 154. As an example, the controller 176 can be configured to move within the reaction stream 115. Figure 2 The actuator 156 is operated after a given amount of time has passed since the flow began in reactor 114, or when the temperature and / or pressure in reactor 114 has reached a threshold.

[0086] As described herein, in at least some embodiments, frame 112 includes frame end 118, frame end 118 including at least one contact location 124 (e.g., 124A, 124B), at at least one contact location 124, reinforcing fibers (e.g., fiber 104) are present. Figure 1 ) and / or uncoated filament bundle 106' ( Figure 2)) Contact frame 112. For example, frame end 118 may have a cross-sectional shape defining one or more contact locations 124 (e.g., 124A, 124B, etc.). As previously discussed, the cross-sectional shape may be a duckbill shape, an open mouth shape, a rib shape, a tooth shape, a groove shape, or a fin shape, for example, as per the discussion of Figures 3B to 4E As described. The moving mechanism 154 can be configured to rotate the frame end 118 to change the position of the reinforcing fiber relative to at least one contact position 124. For example, the actuator 156 of the moving mechanism 154 (e.g., as...) Figure 6 (As shown) can be operated to rotate the frame end 118, thereby pushing the reinforcing fiber from the first position P1 to the second position P2, as... Figure 5A and 5B As shown.

[0087] Now for reference Figure 7A and Figure 7B In some embodiments, (e.g., Figure 3B and 3C (Frame 112) Frame end 118 Z Vibration is possible, which causes the reinforcing fibers to move relative to contact positions 124A, 124B. For example, frame end 118 of frame 112 may define one or more openings 190, each of which is provided with a spline 192. Each spline 192 may define at least one contact position 124 (e.g., 124A, 124B respectively).

[0088] The frame 112 may include a retaining cap 194 that holds one or more splines 192 within a corresponding opening 190. For example, as Figure 7A As shown, the retaining cap 194 may have a cross-sectional shape complementary to the cross-sectional shape of each opening 190 to ensure that one or more splines 192 do not separate from the frame 112, while allowing movement of each spline 192. That is, one or more splines 192 may move relative to the frame end 118 and the retaining cap 194; for example, one or more splines 192 may vibrate, but the frame end 118 and the retaining cap 194 may be shaped such that one or more splines 192 do not separate from the frame 112.

[0089] In at least some embodiments, one or more splines 192 are connected to a moving mechanism 154 (such as regarding...). Figure 6 The described mobile mechanism 154 (or different mobile mechanisms 154) is operatively connected. (See reference...) Figure 7A One or more splines 192 of frame 112 may have a generally T-shaped cross-sectional shape. (See reference) Figure 7B One or more splines 192' of frame 112 may have a generally teardrop-shaped cross-sectional shape.

[0090] Each spline 192, 192' may include a rocker end 196 and a contact end 198 opposite to the rocker end 196. For Figure 7A The generally T-shaped spline 192 shown has a crossbar that defines the rocker end 196. For Figure 7B The generally teardrop-shaped spline 192' shown has a spherical end that defines a rocker end 196'. For any cross-sectional shape of splines 192, 192', the contact ends 198 of splines 192, 192' can define contact positions 124A, 124B for reinforcing the contact between the fiber and the frame 112.

[0091] It will be understood that the rocker end 196 can be operatively connected to the moving mechanism 154 to initiate movement of the spline 192. For example, the actuator 156 of the moving mechanism 154 can be operated to drive one or more splines 192 in vibration or other types of motion. One or more splines 192 can move along the longitudinal direction L, the lateral direction T, or... Figure 3A The splines 192 can be driven along the width direction W or in any other suitable direction or motion by a track. In other embodiments, one or more splines 192 can be driven by a support rod (not shown) below the spline 192, by a gas jet (not shown) below the spline 192, or by any other suitable actuator 156 and / or moving mechanism 154.

[0092] Various mechanical mechanisms for initiating vibrations of the reinforcing fibers and / or frame 112. Figure 7A and 7B As described. Alternatively or additionally, non-mechanical actuation can be used to initiate vibration of the reinforcing fibers and / or frame 112. For example, if reactor 114 ( Figure 2 If the rate of the reactant stream 115 (i.e., gas flow rate) within reactor 114 is higher than a threshold gas flow rate, the reinforcing fibers can vibrate naturally. Similarly, when reactor 114 ( Figure 2 When the gas pressure inside the reactor is at or above the threshold pressure, the reinforcing fibers can vibrate naturally. As another example, in the permeation reactor 114... Figure 2 The acoustic waveguide can be used to drive the vibration of the reinforcing fibers and / or frame 112 within reactor 114. The vibration of the reinforcing fibers and / or frame 112 can be achieved using any individual or combination of the mechanical or non-mechanical actuation mechanisms described herein.

[0093] Furthermore, it will be understood that regardless of whether the vibration is mechanically or non-mechanically actuated, a vibration mode can be established for the reinforcing fiber and / or frame 112. The vibration mode can be fixed, swept, sudden, or random in frequency or amplitude.

[0094] Now for reference Figure 8A flowchart of a method 800 for coating reinforcing fibers of a composite component according to an exemplary aspect of this disclosure is provided. Figure 8 Method 800 uses the above reference Figures 2 to 7B One or more exemplary systems 10 and / or frames 112 are described to coat composite components (such as those related to...). Figure 1 The composite component 100 described has reinforcing fibers. Therefore, it will be understood that method 800 can generally be used with a frame having a cross-sectional shape and / or a movement mechanism to minimize or eliminate low- or uncoated areas of the reinforcing fibers upon completion of the coating process. However, in other exemplary aspects, method 800 can additionally or alternatively be used with any other suitable support frame and / or mechanism to facilitate movement of the fibers relative to the support frame during the coating process.

[0095] As depicted, method 800 includes, at (802), wrapping reinforcing fibers around frame 112, which is shown as an optional step for preparing fibers for coating thereon. As described herein, the frame includes at least one frame end 118 having a cross-sectional shape including a first contact position 124A spaced apart by a separation length 126 from a second contact position 124B. In at least some embodiments, wrapping the reinforcing fibers around frame 112 includes from bobbin 110 (… Figure 2 The fibers are unwound, for example, wherein, as described herein, the fibers are under winding tension, and the reinforcing fibers are positioned or placed to contact the first contact position 124A and the second contact position 124B. When wrapped around the frame 112, the reinforcing fibers extend from the first contact position 124A to the second contact position 124B such that the minimum length of the uncoated filament bundle 106' is within the minimum distance 130 of the frame 112, for example, wherein, as described herein, once the fibers are unwound from the spool 110 ( Figure 2 When unwound, it is under steady-state tension. This article, for example, discusses… Figures 4A to 4F Various cross-sectional shapes of frame end 118 are described.

[0096] As described herein, chemical vapor deposition (CVD) processes can be used to deposit coatings 116 ( ) on reinforcing fibers. Figure 2 ). refer to Figure 8 Method 800 includes inserting a frame into reactor 114 at (804). Figure 2 In ), and at (806), the reaction stream 115 ( Figure 2 The reactant 115 enters reactor 114. For example, the temperature and pressure inside reactor 114 may be increased compared to ambient temperature and pressure to facilitate the formation of coating 116 on the reinforcing fibers by reactant 115. Upon completion of the deposition process, as shown at (808), method 800 includes removing frame 112 from reactor 114.

[0097] Now for reference Figure 9 A flowchart of a method 900 for coating reinforcing fibers of a composite component according to an exemplary aspect of this disclosure is provided. Figure 9 Method 900 uses the above reference Figures 2 to 7B One or more exemplary systems 10 and / or frames 112 are described to coat composite components (such as those related to...). Figure 1 The composite component 100 described has reinforcing fibers. Therefore, it will be understood that method 900 can generally be used with a frame having a cross-sectional shape and / or a movement mechanism to minimize or eliminate low- or uncoated areas of the reinforcing fibers upon completion of the coating process. However, in other exemplary aspects, method 900 can additionally or alternatively be used with any other suitable support frame and / or mechanism to facilitate movement of the fibers relative to the support frame during the coating process.

[0098] As depicted, method 900 includes, at (902), wrapping reinforcing fibers around frame 112. As described herein, wrapping reinforcing fibers around frame 112 may include positioning the reinforcing fibers to contact frame ends 118 of frame 112. In some embodiments, the frame includes at least one frame end 118 having a cross-sectional shape including a first contact position 124A spaced apart by a separation length 126 from a second contact position 124B, and herein, for example, refers to... Figures 4A to 4F Various cross-sectional shapes for frame end 118 are described.

[0099] In at least some embodiments, a chemical vapor deposition (CVD) process can be used to deposit coating 116 on the reinforcing fibers. Figure 2 ). refer to Figure 9 Method 900 includes inserting a frame into reactor 114 at (904). Figure 2 In ), and at (906), the reaction stream 115 ( Figure 2 The reactants 115 enter reactor 114. For example, the temperature and pressure inside reactor 114 can be increased compared to ambient temperature and pressure to facilitate the formation of coating 116 on the reinforcing fibers by reactants 115.

[0100] Further, method 900 includes, at (908), initiating movement of the reinforcing fibers relative to the frame while the frame is positioned in the reaction stream. That is, while the reactant 115 flows within reactor 114, for example, after the initiation flow as shown at (906), the reinforcing fibers may move relative to the frame 112. This movement of the reinforcing fibers relative to the frame may expose one or more areas of the reinforcing fibers that, without movement, might not be coated or have a low coating thickness at the end of the coating process. Therefore, by initiating movement of the reinforcing fibers relative to the frame while the frame is positioned in the reaction stream, areas with low or no coating of reinforcing fibers can be minimized or eliminated. It will be understood that such areas may be minimized in terms of number and / or length, or such areas may be eliminated together.

[0101] As described herein, frame 112 may include a moving mechanism 154. In some embodiments, the moving mechanism 154 displaces the position of the reinforcing fiber relative to frame 112. For example, initiating movement of the reinforcing fiber relative to frame 112 as shown at (908) may include an actuator 156 operating the moving mechanism 154 to move the position of the reinforcing fiber relative to frame 112 from a first position P1 ( Figure 5A ) Shift or push to the second position P2 ( Figure 5B In some embodiments, the moving mechanism 154 rotates the frame end 118 of the frame 112 to push the reinforcing fibers from a first position P1 to a second position P2.

[0102] In other embodiments, the moving mechanism 154 is connected to at least one spline 192 ( Figure 7A , 7B Operable communication and initiating movement of the reinforcing fiber relative to the frame includes initiating vibration of at least one spline 192. At least one spline 192 may include a rocker end 196 and a contact end 198 opposite to the rocker end 196, and at least one spline 192 may have a cross-sectional shape that is generally T-shaped, teardrop-shaped, or other suitable shape defining the rocker end 196 and the contact end 198. In some embodiments, the contact end 198 defines a point contact between at least one spline 192 and the reinforcing fiber.

[0103] In some embodiments, initiating movement of the reinforcing fiber relative to the frame 112 includes initiating vibration of the reinforcing fiber or the frame 112. For example, initiating vibration of the frame 112 includes mechanically initiating vibration of the frame. As another example, initiating vibration of the frame 112 includes manipulating the reactor 114 ( Figure 2 The gas pressure inside the frame 112 is used to cause the frame 112 to vibrate.

[0104] Other methods can also be used to induce movement between the reinforcing fibers and the framework 112. Further, when reactant 115 ( Figure 2 In reactor 114 ( Figure 2 When the flow occurs within the device, this movement can happen once, twice, three times, or four or more times. For example, controller 176 ( Figure 6 The movement of the reinforcing fibers relative to the frame 112 can be initiated periodically, for example, based on the passage of time, the temperature inside the reactor 114, the pressure inside the reactor 114, etc.

[0105] refer to Figure 9 In the deposited coating 116 ( Figure 2 When the process is completed, as shown at (910), method 900 includes removing frame 112 from reactor 114.

[0106] As described herein, this subject matter provides apparatus and methods for reducing or eliminating under- or uncoated areas of coated fibers. For example, the number and / or configuration of contact points between frames on which uncoated fibers are disposed for support during the coating process minimizes under- or uncoated areas of the coated fibers. As another example, moving the fibers relative to the frames during the coating process can minimize or reduce under- or uncoated areas of the coated fibers.

[0107] Further aspects are provided by the subject matter of the following clauses:

[0108] A frame for use in coating reinforcing fibers, the frame comprising: a first frame end having a first cross-sectional shape, wherein the first cross-sectional shape includes one or more contact locations spaced apart from each other, and wherein the reinforcing fibers contact the first frame end at the one or more contact locations.

[0109] The frame according to any of the preceding claims further includes: a second frame end opposite to the first frame end, wherein the second frame end has a second cross-sectional shape, wherein the second cross-sectional shape includes one or more contact locations spaced apart from each other, and wherein the reinforcing fiber contacts the second frame end at the one or more contact locations.

[0110] According to any of the preceding claims, the second cross-sectional shape is the same as the first cross-sectional shape.

[0111] According to any of the preceding claims, the first frame end includes a first contact position, the first contact position being spaced apart from an adjacent second contact position by a separation length, wherein the first length is defined by the first contact position, and wherein the first length is less than the separation length.

[0112] The frame according to any of the preceding claims, wherein each contact location defines a point contact between the first frame end and the reinforcing fiber.

[0113] The frame according to any of the preceding claims, wherein the first frame end is static relative to the frame.

[0114] The frame according to any of the preceding claims, wherein the frame ends are movable relative to the frame.

[0115] According to the framework of any of the preceding claims, the one or more contact locations are multiple contact locations, and the multiple contact locations have a periodicity factor of at least 2.

[0116] According to any of the preceding claims, the first cross-sectional shape is a duckbill shape, wherein the duckbill shape includes a first contact position and a second contact position among the one or more contact positions, wherein the duckbill shape is undercut adjacent to each of the first contact position and the second contact position, and wherein the first contact position and the second contact position are separated by a generally V-shaped groove.

[0117] According to any of the preceding claims, the first cross-sectional shape is an open shape, wherein the open shape includes a first contact position and a second contact position among the one or more contact positions, the first contact position and the second contact position being separated by a generally V-shaped groove, and wherein the open shape includes a circular edge adjacent to each of the first contact position and the second contact position and opposite to the generally V-shaped groove.

[0118] According to the framework of any of the preceding claims, the first cross-sectional shape is a tooth shape, wherein the tooth shape includes a first contact position of the one or more contact positions, a second contact position of the one or more contact positions, and a centerline defined between the first contact position and the second contact position, and wherein the tooth shape further includes a first linear edge adjacent to the first contact position and a second linear edge adjacent to the second contact position, each of the first linear edge and the second linear edge extending inward toward the centerline at a non-zero angle of less than 90°.

[0119] According to any of the preceding claims, the first cross-sectional shape is a rib shape, and the rib shape includes a plurality of ribs, each of the plurality of ribs defining a contact position in one or more contact positions.

[0120] According to any of the preceding claims, the first cross-sectional shape is a groove shape, and the groove shape includes a plurality of semi-circular protrusions, each of the plurality of semi-circular protrusions defining a contact position in one or more contact positions.

[0121] According to any of the preceding claims, the first cross-sectional shape is a fin shape, and the fin shape includes a plurality of fins, each of the plurality of fins defining a contact position in one or more contact positions.

[0122] According to any of the foregoing clauses, the ratio of the total length of the reinforcing fibers within the minimum distance from the frame and the contact length of the reinforcing fibers with the frame to the separation length of the frame end is in the range of 2 to about 10,000.

[0123] According to any of the foregoing clauses, the ratio of the total length of the reinforcing fibers within the minimum distance from the frame and the contact length of the reinforcing fibers with the frame to the separation length of the frame end is in the range of 5 to 1,000.

[0124] A method for coating a composite component with reinforcing fibers, the method comprising: wrapping the reinforcing fibers around a first frame end of a frame according to any of the preceding claims; inserting the frame into a reactor; and initiating a reaction stream into the reactor.

[0125] The method according to any of the preceding claims, wherein the reinforcing fibers are in the form of a bundle, and wherein the minimum distance is at least twice the diameter of the bundle.

[0126] The method according to any of the preceding claims, wherein the reactive stream deposits a coating on the reinforcing fibers during a chemical vapor deposition process.

[0127] The method according to any of the preceding claims, wherein the reinforcing fiber comprises a non-oxide silicon-based material, a non-oxide carbon-based material, an oxide ceramic, or a mixture thereof.

[0128] The method according to any of the preceding claims, wherein the first frame end is static relative to the frame.

[0129] The method according to any of the preceding claims further includes: moving the first frame end such that the contact position changes during the entry of the reaction stream into the reactor.

[0130] A system for coating reinforcing fibers of a composite component, the system comprising: a frame including at least one contact position for contacting the reinforcing fibers; and a moving mechanism including an actuator, wherein the moving mechanism is operatively coupled to the frame to cause movement of the reinforcing fibers relative to the frame.

[0131] According to any of the foregoing provisions, the moving mechanism includes a rack and at least one gear operatively connected to the rack.

[0132] According to any of the foregoing provisions, the actuator includes: a rotary vacuum feeder operably coupled to a drive motor; a screw drive member operably coupled to the rotary vacuum feeder; and a slider defining a cam disposed on the screw drive member, wherein the cam is configured to contact the rack.

[0133] According to any of the foregoing provisions, the frame includes a frame end, the frame end including the at least one contact location.

[0134] According to any of the foregoing provisions, the frame end has a cross-sectional shape, the cross-sectional shape including the at least one contact position, and the moving mechanism is configured to rotate the frame end to change the position of the reinforcing fiber relative to the at least one contact position.

[0135] According to any of the foregoing provisions, the cross-sectional shape is a duckbill shape, an open mouth shape, a rib shape, a tooth shape, a groove shape, or a fin shape.

[0136] According to any of the foregoing provisions, the frame includes a frame end defining an opening, wherein a spline is disposed in the opening, the spline being operatively connected to the moving mechanism, and wherein the spline includes the at least one contact position.

[0137] According to any of the foregoing provisions, the spline includes a rocker end and a contact end opposite the rocker end, wherein the spline has a generally T-shaped cross-sectional shape, wherein the crossbar of the T-shape defines the rocker end, and wherein the contact end defines the at least one contact position.

[0138] According to any of the foregoing provisions, the spline includes a rocker end and a contact end opposite the rocker end, wherein the spline has a generally teardrop-shaped cross-sectional shape, wherein the spherical end defines the rocker end, and wherein the contact end defines the at least one contact position.

[0139] The system according to any of the foregoing provisions further includes: a controller operatively connected to the moving mechanism, wherein the controller is configured to activate the moving mechanism to cause movement of the reinforcing fiber relative to the frame.

[0140] The system of claim 1, wherein the frame is positioned within the reactor.

[0141] A method for coating a composite component with reinforcing fibers, the method comprising: inserting a frame encapsulating the reinforcing fibers into a reactor; initiating a reaction stream into the reactor; and, while the frame is positioned in the reaction stream, initiating movement of the reinforcing fibers relative to the frame.

[0142] According to any of the foregoing provisions, wherein initiating movement of the reinforcing fiber relative to the frame while the frame is positioned in the reactive stream comprises actuating a movement mechanism disposed on the frame, wherein the movement mechanism displaces the position of the reinforcing fiber relative to the frame.

[0143] The method according to any of the foregoing provisions, wherein the actuation of the moving mechanism pushes the reinforcing fiber from a first position to a second position.

[0144] The method according to any of the foregoing provisions further includes: wrapping the reinforcing fiber around the frame by positioning the reinforcing fiber in contact with the frame end of the frame before inserting the frame containing the reinforcing fiber into the reactor, wherein the moving mechanism rotates the frame end to push the reinforcing fiber from a first position to a second position.

[0145] According to any of the foregoing provisions of the method, wherein the moving mechanism is operatively connected to at least one spline, and wherein initiating the movement of the reinforcing fiber relative to the frame comprises initiating vibration of the at least one spline.

[0146] According to any of the foregoing provisions of the method, wherein the at least one spline includes a rocker end and a contact end opposite to the rocker end, and wherein the contact end defines a point contact between the at least one spline and the reinforcing fiber.

[0147] According to any of the foregoing provisions of the method, wherein the at least one spline has a generally teardrop-shaped cross-sectional shape, the teardrop shape having a spherical end and a contact end opposite to the spherical end, and wherein the contact end defines a point contact between the at least one spline and the reinforcing fiber.

[0148] The method according to any of the foregoing provisions, wherein initiating the movement of the reinforcing fiber relative to the frame includes initiating vibration of the frame.

[0149] The method according to any of the foregoing clauses, wherein initiating vibration of the frame includes mechanically initiating vibration of the frame, manipulating gas pressure within the reactor to cause vibration of the frame, or both.

[0150] This written description uses examples to disclose this disclosure, including best practices, and also enables any person skilled in the art to practice this disclosure, including making and using any device or system and methods of making any combination. The patentable scope of this disclosure is defined by the claims, but may include other examples that would occur to a person skilled in the art. Such other examples are intended to fall within the scope of the claims if they include structural elements that are not indistinguishable from the literal language of the claims, or if they include equivalent structural elements that are not substantially different from the literal language of the claims.

Claims

1. A frame for use in coating reinforced fibers, characterized in that, The framework includes: A first frame end having a first cross-sectional shape, wherein the first cross-sectional shape includes a plurality of contact positions spaced apart from each other, and wherein the reinforcing fiber contacts the first frame end at the plurality of contact positions; and wherein at least a portion of the reinforcing fiber is spaced apart from the first frame end via supports from the plurality of contact positions.

2. The framework according to claim 1, characterized in that, Further includes: A second frame end opposite to the first frame end, wherein the second frame end has a second cross-sectional shape, wherein the second cross-sectional shape includes a plurality of contact positions spaced apart from each other, and wherein the reinforcing fiber contacts the second frame end at the plurality of contact positions.

3. The framework according to claim 2, characterized in that, The shape of the second cross section is the same as that of the first cross section.

4. The framework according to claim 1, characterized in that, Each contact location defines a point contact between the first frame end and the reinforcing fiber.

5. The framework according to claim 1, characterized in that, The first frame end is static relative to the frame.

6. The framework according to claim 1, characterized in that, The frame end is movable relative to the frame.

7. The framework according to claim 1, characterized in that, The plurality of contact locations have a pattern that appears at least twice.

8. The framework according to claim 1, characterized in that, The first cross-sectional shape is a duckbill shape, wherein the duckbill shape includes a first contact position and a second contact position among the plurality of contact positions, wherein the duckbill shape is undercut adjacent to each of the first contact position and the second contact position, and wherein the first contact position and the second contact position are separated by a generally V-shaped groove.

9. The framework according to claim 1, characterized in that, The first cross-sectional shape is an open shape, wherein the open shape includes a first contact position and a second contact position among the plurality of contact positions, the first contact position and the second contact position being separated by a generally V-shaped groove, and wherein the open shape includes a circular edge adjacent to each of the first contact position and the second contact position and opposite to the generally V-shaped groove.

10. The framework according to claim 1, characterized in that, The first cross-sectional shape is a tooth shape, wherein the tooth shape includes a first contact position among the plurality of contact positions, a second contact position among the plurality of contact positions, and a centerline defined between the first contact position and the second contact position, and wherein the tooth shape further includes a first linear edge adjacent to the first contact position and a second linear edge adjacent to the second contact position, each of the first linear edge and the second linear edge extending inward toward the centerline at a non-zero angle of less than 90°.

11. The framework according to claim 1, characterized in that, The first cross-sectional shape is a rib shape, and the rib shape includes a plurality of ribs, each of the plurality of ribs defining a contact position among the plurality of contact positions.

12. The framework according to claim 1, characterized in that, The first cross-sectional shape is a groove shape, and the groove shape includes a plurality of semi-circular protrusions, each of the plurality of semi-circular protrusions defining a contact position among the plurality of contact positions.

13. The framework according to claim 1, characterized in that, The first cross-sectional shape is a fin shape, and the fin shape includes a plurality of fins, each of the plurality of fins defining a contact position among the plurality of contact positions.

14. A method for coating reinforcing fibers of a composite component, characterized in that, The method includes: The reinforcing fibers are wrapped around the first frame end of the frame according to claim 1; Insert the frame into the reactor; and The reaction stream is initiated and enters the reactor.

15. The method according to claim 14, characterized in that, The reinforcing fiber is in the form of a bundle, and the minimum distance between the portion of the reinforcing fiber and the end of the first frame is at least twice the diameter of the bundle.

16. The method according to claim 14, characterized in that, The reactive stream is deposited on the reinforcing fibers during a chemical vapor deposition process.

17. The method according to claim 14, characterized in that, The reinforcing fibers include non-oxide silicon-based materials, non-oxide carbon-based materials, oxide ceramics, or mixtures thereof.

18. The method according to claim 14, characterized in that, The first frame end is static relative to the frame.

19. The method according to claim 14, characterized in that, Further includes: The first frame end is moved so that the contact position changes as the reaction stream enters the reactor.

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