Method and apparatus for coated fibers

Abstract

To provide methods and apparatus for minimizing or eliminating hardly or not coated regions of coated fibers or tows.SOLUTION: A frame (112) and a method are provided for coating reinforcing fiber (104, 106') of a composite component (100). The frame (112) includes a first frame end (118A) having a first cross-sectional shape. The first cross-sectional shape has one or more contact locations (124). The reinforcing fiber (104, 106') contacts the first frame end (118A) at the one or more contact locations (124). The ratio of the length of the reinforcing fiber (104, 106') within the minimum distance from the frame (112) to the minimum distance is in the range from 0.2 to 20.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates to frame contact configurations and systems for textile coverings. [Background technology]

[0002] Reinforced ceramic matrix composites ("CMCs"), which comprise fibers dispersed in a continuous ceramic matrix of the same or different composition, are well suited for structural applications due to their toughness, heat resistance, high-temperature strength, and chemical stability. Such composites typically have a high strength-to-weight ratio, making them attractive for applications where weight is a concern, such as aerospace applications. Their stability at high temperatures makes CMCs highly suitable for applications where components come into contact with hot gases, such as in gas turbine engines. Summary of the Invention [Means for solving the problem]

[0003] A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in this specification, which makes reference to the accompanying drawings. [Brief explanation of the drawings]

[0004] [Figure 1] 1 is a schematic cross-sectional view of a portion of a ceramic matrix composite (CMC) component according to an exemplary embodiment of the present disclosure. [Figure 2] 1 is a schematic diagram of various components, such as bobbins, frames, and reactors, used in a fiber coating process, according to an exemplary embodiment of the present disclosure. [Figure 3A] 1 is a schematic front view of a frame for supporting reinforcing fibers in a fiber covering process, according to an exemplary embodiment of the present disclosure; FIG. [Figure 3B] 3B is a schematic side view of the frame of FIG. 3A with the spacer bars in a raised position, according to an exemplary embodiment of the present disclosure. [Figure 3C]FIG. 3C is a schematic side view of the frame of FIG. 3B with the spacer bars in a lowered position, according to an exemplary embodiment of the present disclosure. [Figure 4A] 3B and 3C are cross-sectional views of a frame end having a duckbill shape, according to an exemplary embodiment of the present disclosure. [Figure 4B] 3B and 3C are cross-sectional views of a frame end having an open-mouth shape, according to an exemplary embodiment of the present disclosure. [Figure 4C] 3B and 3C are cross-sectional views of a frame end having a ridged shape, according to an exemplary embodiment of the present disclosure. [Figure 4D] 3B and 3C are cross-sectional views of a frame end having a toothed shape, according to an exemplary embodiment of the present disclosure. [Figure 4E] 3B and 3C are cross-sectional views of a frame end having a grooved shape, according to an exemplary embodiment of the present disclosure. [Figure 4F] 3B and 3C are cross-sectional views of a frame end having a fin-like shape, according to an exemplary embodiment of the present disclosure. [Figure 5A] 3B and 3C are schematic end views of a fin-shaped frame end having a movement mechanism, according to an exemplary embodiment of the present disclosure. [Figure 5B] 3B and 3C are schematic end views of a fin-shaped frame end having a movement mechanism, according to an exemplary embodiment of the present disclosure. [Figure 6] 1 is a schematic diagram of a system having a movement mechanism according to an exemplary aspect of the present disclosure. [Figure 7A] FIG. 1 is a schematic end view of a frame end having an oscillating spline according to an exemplary embodiment of the present disclosure. [Figure 7B]FIG. 10 is a schematic end view of a frame end having an oscillating spline according to another exemplary aspect of the present disclosure. [Figure 8] 1 is a flow diagram of a method for coating reinforcing fibers of a composite component according to an exemplary embodiment of the present disclosure. [Figure 9] 4 is a flow diagram of a method for coating reinforcing fibers of a composite component according to another exemplary aspect of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0005] Reference will now be made in detail to the present embodiments of the present disclosure, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerical and letter designations to refer to features in the drawings. Like or similar designations in the drawings and the description are used to refer to like or similar parts of the present disclosure.

[0006] The word "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 preferred or advantageous over other implementations. Moreover, unless expressly specified otherwise, all embodiments described herein should be considered exemplary.

[0007] The singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise.

[0008] For example, the term "at least one" in the context of "at least one of A, B, and C" refers to A only, B only, C only, or any combination of A, B, and C.

[0009] The term "turbomachine" or "turbomachine" refers to a machine that includes one or more compressors, a heat generation section (e.g., a combustion section), and one or more turbines that together produce a torque output.

[0010] The term "gas turbine engine" refers to an engine that has a turbomachine as all or part of its power source. Example gas turbine engines include turbofan engines, turboprop engines, turbojet engines, turboshaft engines, as well as hybrid-electric versions of one or more of these engines.

[0011] The terms "upstream" and "downstream" refer to relative directions of fluid flow in a fluid pathway. For example, "upstream" refers to the direction from which the fluid flows, and "downstream" refers to the direction to which the fluid flows.

[0012] As used herein, the terms "axial" and "axially" refer to directions and orientations that extend substantially parallel to the centerline of the gas turbine engine. Additionally, the terms "radial" and "radially" refer to directions and orientations that extend substantially perpendicular to the centerline of the gas turbine engine. Additionally, as used herein, the terms "circumferential" and "circumferentially" refer to directions and orientations that extend arcuately about the centerline of the gas turbine engine.

[0013] Terms such as "coupled," "secured," and "attached" refer to both direct coupling, securing, and attaching, and indirect coupling, securing, and attaching through one or more intermediate components or features, unless expressly stated otherwise in this specification.

[0014] As used herein, the terms "first," "second," and "third" may be used interchangeably to distinguish one component from another and are not intended to denote the location or importance of the individual components.

[0015] For purposes of the following description, the terms "upper," "lower," "right," "left," "vertical," "horizontal," "top," "bottom," "lateral," "longitudinal," and their derivatives refer to the embodiments as oriented in the drawings. However, it is understood that the embodiments may assume various alternative variations, unless expressly stated otherwise. It is also understood that the specific devices illustrated in the accompanying drawings and described in the following specification are merely exemplary embodiments of the present disclosure. Therefore, specific dimensions and other physical characteristics related to the embodiments disclosed herein are not to be considered limiting.

[0016] In this disclosure, when a layer is described as "in" or "over" another layer or substrate, it is understood that the layers may either be in direct contact with one another or have other layers or features between them, unless expressly stated otherwise. Thus, these terms only describe the relative position of layers with respect to one another, and do not necessarily mean "over," as a relative position of above or below depends on the orientation of the device to the viewer.

[0017] As used herein, ceramic matrix composites or "CMCs" refer to a class of materials that include reinforcing materials (e.g., reinforcing fibers) surrounded by a ceramic matrix phase. Generally, the reinforcing fibers provide structural integrity to the ceramic matrix. Some examples of matrix materials for CMCs can 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, aluminum oxide (Al2O3), silicon dioxide (SiO2), aluminosilicates, or mixtures thereof), or mixtures thereof. Optionally, ceramic particles (e.g., oxides of Si, Al, Zr, Y, and mixtures thereof) and inorganic fillers (e.g., pyrophyllite, wollastonite, mica, talc, kyanite, and montmorillonite) may be included within the CMC matrix.

[0018] Some examples of reinforcing fibers for CMCs can 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 oxycarbide, silicon oxynitride, aluminum oxide (Al2O3), silicon dioxide (SiO2), aluminosilicates such as mullite), or mixtures thereof.

[0019] A reinforcing fiber can be at least a portion of an individual filament or strand. As used herein, "ceramic fiber tow," "fiber tow," or simply "tow" refers to a bundle of multiple individual fibers, filaments, or loose strands. The filaments of a tow can be randomly intermixed or arranged in a pattern, and / or can be continuous or discontinuous. For example, a tow can include broken filaments or filament fragments. As another example, the filaments of a tow can be substantially parallel, twisted, or otherwise arranged. A tow can behave in substantially the same manner as a single or individual filament. It is also understood that "individual ceramic filament" or simply "individual filament," as used herein, refers to a single or unbundled elongated ceramic member.

[0020] Generally, specific CMCs can be referred to as fiber type / matrix type combinations. For example, C / SiC for carbon fiber reinforced silicon carbide, SiC / SiC for silicon carbide fiber reinforced silicon carbide, SiC / SiN for silicon carbide fiber reinforced silicon nitride, SiC / SiC-SiN for silicon carbide fiber reinforced silicon carbide / silicon nitride matrix mixture, etc. In other examples, CMCs can include a matrix and reinforcing fibers comprising oxide-based materials, such as aluminum oxide (Al2O3), silicon dioxide (SiO2), aluminosilicates, and mixtures thereof. Aluminosilicates can include glassy aluminosilicates as well as crystalline materials such as mullite (3Al2O3, 2SiO2).

[0021] In certain embodiments, the reinforcing fibers may be bundled and / or coated prior to inclusion in the matrix. For example, the fiber bundles may be formed as reinforcing tapes, such as unidirectional reinforcing tapes. Multiple tapes may be laminated together to form a preform component. The fiber bundles may be impregnated with a slurry-like composition before or after forming the preform. The preform may undergo a heat treatment, such as curing or burnout, to produce high char residue in the preform, followed by a chemical treatment, such as melt infiltration with silicon, to arrive at a component formed from a CMC material with the desired chemical composition.

[0022] Such materials, along with certain monolithic ceramics (i.e., ceramic materials without reinforcing materials), are particularly suited to higher temperature applications. These ceramic materials are also lightweight compared to superalloys, yet can still provide strength and durability to components made therefrom. As such, such materials are currently being considered for many gas turbine components used in the higher temperature sections of gas turbine engines, such as airfoils (e.g., turbines and vanes), combustors, shrouds, and other similar components that can benefit from the lighter weight, higher temperature capabilities that these materials can offer.

[0023] During the manufacture of CMCs, fibers are typically coated to help ensure they survive the manufacturing process as well as to improve the mechanical properties of the CMC during maintenance. Often, the fibers are gathered into fiber bundles called tows, which undergo a tow coating process. For example, the tows may be wound around a rigid frame and suspended in a reactor for coating, such as under high temperature and vacuum conditions. Therefore, improved methods and apparatus that address one or more of these challenges are desirable.

[0024] The present disclosure generally relates to methods and apparatus for minimizing or eliminating undercoated or uncoated areas of coated fibers or tows. For example, the present disclosure is directed to a frame around which individual fibers and / or one or more tows can be wound to support the fibers or tows while a coating is applied, the frame having a shape to reduce contact between the fibers or tows and the frame. For example, the frame ends of a frame for tow coating can have a shape or configuration that minimizes contact between the tows and the frame ends. Minimizing contact between the tows and the frame ends allows for tow coating while minimizing undercoated or uncoated areas on the tows. As another example, a semi-static coating process in which the tows are moved relative to the frame can help minimize or eliminate undercoated or uncoated areas on coated tows. Furthermore, utilizing a frame design and / or coating method as described herein can help ensure that a composite part meets material specifications by minimizing or eliminating defects introduced during coating of the fibers or tows used to form the composite part.

[0025] Referring now to the drawings, wherein like numerals refer to like elements throughout the views, FIG. 1 is a schematic cross-sectional view of a composite part 100, such as a CMC part. As previously described, one process for manufacturing CMC parts involves the use of slurry-impregnated reinforcing tapes, which may be referred to as prepregs. Prepregs are typically in the form of plies or sheets, with unidirectional prepregs often comprising a two-dimensional fiber arrangement comprising a single layer of aligned tows that are impregnated with a matrix precursor to create a generally two-dimensional sheet. Multiple plies of the resulting prepregs can be overlapped and debulked to form a laminate preform, a process referred to as "stacking." Prepregs are typically, although not necessarily, arranged so that the tows of adjacent prepregs are oriented transversely (e.g., perpendicularly) relative to one another, providing greater strength in the sheet plane of the preform (corresponding to the primary (load-bearing) direction of the final CMC part). However, the prepregs may be arranged in other ways, for example, the tows of one or more adjacent prepregs may not be oriented transverse or perpendicular to one another, but may in various embodiments be parallel to one another, offset from one another by less than 90 degrees, etc. A prepreg stack may include adjacent prepregs having various tow orientations relative to one another.

[0026] FIG. 1 depicts a cross-sectional view of a portion of a composite part 100 including laminae 102. Each laminae 102 is formed from individual prepreg tapes or sheets. As shown in FIG. 1, each laminae 102 includes a ceramic reinforcement made from unidirectionally aligned fibers 104 formed into tows 106 and encased in a ceramic matrix 108. The ceramic matrix 108 is formed by conversion (e.g., after firing) of a ceramic matrix precursor in a slurry used to impregnate the reinforcing tape.

[0027] Referring to FIG. 2 , prior to or as part of forming a reinforcement tape, an uncoated tow 106′ is wound onto a bobbin 110, i.e., a fiber supply. The uncoated tow 106′ can be unwound from the bobbin 110 for coating. Fibers, such as those bundled together in the form of an uncoated tow 106′, are coated for several purposes, such as to protect the fibers during composite processing, to alter the reinforcement of the fiber-matrix interface, and / or to promote or prevent mechanical and / or chemical bonding between the fiber and the matrix. Several different techniques have been developed for applying fiber coatings, including slurry dipping, sol-gel, sputtering, and chemical vapor deposition (CVD). Of these, CVD has been the most successful in producing impervious coatings of uniform thickness and controlled composition.

[0028] In a typical CVD process, the fiber and reactants are heated to an elevated temperature at which the coating precursor decomposes and deposits as a coating. CVD coatings can be applied in either a continuous or batch process. In a continuous process, the fiber and coating precursor are continuously passed through a reactor.

[0029] 2, in a batch process, a length of fiber (e.g., a length of uncoated tow 106′) is unwound from a bobbin 110 onto a frame 112. The fiber may be under tension as it is wound onto the frame 112. For example, a winding tension may be maintained as the fiber is unwound from the bobbin 110 onto the frame 112. In some embodiments, the winding tension may be in a range from about 0.01% of the breaking strength of the uncoated tow 106′ to about 90% of the breaking strength of the uncoated tow 106′. By way of example, the winding tension may be in a range from about 20 grams to about 100 grams.

[0030] Once placed on the frame 112 and unwinding from the bobbin 110 has stopped, the tension in the fiber can be relaxed to a steady-state tension. For example, the frame 112 or a component thereof (such as a spacer bar as described below in connection with FIGS. 3B and 3C) can be relaxed, such as retracted, to change the circumference of the frame 112, which relaxes the tension in the fiber. The steady-state tension in the fiber can be less than the winding tension and can be very small, such as substantially zero.

[0031] After the fibers are transferred to the frame 112, the frame 112 is introduced into the reactor 114 and remains therein while the reactants 115 are passed through the reactor 114. As previously described, as the reactants 115 are passed through the reactor 114, the temperature within the reactor 114 may be elevated so that the coating precursor decomposes and deposits as a coating 116 on the uncoated tow 106′ to form the tow 106. The tow 106, now coated with the coating 116, may then be formed into a reinforcing tape, which may be impregnated with a slurry to form a prepreg tape, sheet, or ply used to form a CMC part, such as the composite part 100, as described herein.

[0032] 2 provides only a general, schematic depiction of an apparatus for transferring uncoated fiber from a fiber source to a frame for depositing a coating on the fiber in the reactor. Other components, such as a drive mechanism, one or more pulleys, one or more sensors, and a controller, may be used with the bobbin 110, frame 112, and reactor 114 to coat the uncoated tow 106′ using a batch process as described herein.

[0033] 3A, 3B, and 3C, the frame 112 will be described in more detail. FIG. 3A provides a schematic diagram of the frame 112 according to various embodiments of the present subject matter. FIGS. 3B and 3C, respectively, provide schematic side views of the frame 112 shown in FIG. 3A. FIGS. 3A, 3B, and 3C each show reinforcing fibers extending around the frame end 118, with it being understood that the reinforcing fibers wrapped around the frame 112 can be fibers 104 or uncoated tows 106′, and that hereafter, references to “reinforcing fibers” can refer to either the fibers 104, the uncoated tows 106′, or both. Additionally, although the following description uses the singular term "tow," it is understood that the following description applies to a single tow (e.g., a single uncoated tow 106' wound onto the frame 112 to be coated and unwound from the frame 112 as a single coated tow 106), or to multiple tows (e.g., multiple lengths of uncoated tow 106' wound onto the frame 112, coated, and unwound from the frame 112 as multiple lengths of coated tow 106).

[0034] 3A, the frame 112 includes a first frame end 118A and a second frame end 118B opposite the first frame end 118A. The first frame end 118A and the second frame end 118B may be configured similarly, 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 configured differently from the second frame end 118B. Unless otherwise stated, a description herein directed to a "frame end 118" may apply to the first frame end 118A, the second frame end 118B, or both.

[0035] The first frame end 118A is spaced apart from the second frame end 118B 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. A rectangular frame 112 is shown in the embodiment of FIG. 3A , with a first frame side 122A and a second frame side 122B opposite the first frame side 122A extending between the first frame end 118A and the second frame end 118B, respectively. The first frame side 122A and the second frame side 122B are spaced apart from each other along the transverse direction T by a frame end length 121. It is understood that the frame 112 may have other shapes with different numbers of frame ends 118 and frame sides 122.

[0036] 3A , the reinforcing fibers 104, which may be in the form of uncoated tows 106′ as previously described, are wrapped around the frame 112 such that the reinforcing fibers 104 contact each frame end 118 at one or more contact locations 124 ( FIGS. 3B and 3C ). However, it is understood that in other embodiments, the reinforcing fibers 104 may be wrapped around the frame 112 in contact with the frame sides 122 in addition to, or as an alternative to, the frame ends 118. Accordingly, any descriptions provided herein of the shape and / or configuration of the frame ends 118 and / or the movement of the reinforcing fibers 104 relative to the frame ends 118 may also apply to the frame sides 122.

[0037] As previously described, the frame 112 can be configured to help maintain tension in the fiber as it is wound onto the frame 112, and can be configured to help relax or remove tension in the fiber as it is wound onto the frame 112, which can help ensure proper coverage of the fiber. For example, as shown in Figures 3B and 3C, the frame 112 can include components such as spacer bars 119 that can transition from a raised position (Figure 3B) to a lowered position (Figure 3C) to relax tension in the uncoated tow 106' wound onto the frame 112.

[0038] More specifically, Figure 3B shows the spacer bar 119 in its raised position, and Figure 3C shows the spacer bar 119 in its lowered position. In the raised position, the spacer bar 119 increases the circumference of the frame 112, and the uncoated tow 106' can be wound onto the frame 112 with the spacer bar 119 in the raised position. In the lowered position, the spacer bar 119 is retracted within the frame 112 such that the circumference of the frame 112 is shortened. The spacer bar 119 can be moved to its lowered position after winding of the uncoated tow 106' onto the frame 112 is completed, which shortens the circumference of the frame 112 supporting the uncoated tow 106', thereby relaxing or reducing tension in the uncoated tow 106'. Releasing the tension in the uncoated tows 106' moves the uncoated tows 106' away from each other and / or from the frame 112, providing increased space or room for the reactants to surround and thereby coat the uncoated tows 106' to form coated tows 106.

[0039] It is understood that the spacer bars 119 shown in FIG. 3B are by way of example only. The spacer bars 119 can have any suitable shape and size and can be positioned at any suitable location along the frame 112 to support the fiber in the frame 112 as described herein. Additionally, in some embodiments, two or more spacer bars 119 can be used, and in still other embodiments, features or components other than one or more spacer bars 119 can be used to maintain and release tension in the fiber as described herein. The use of a foldable frame to vary the distance between the frames 112 (e.g., the distance between the respective ends of adjacent frames 112) can also be contemplated.

[0040] Additionally or alternatively, the shape of the frame end 118 may be developed through a fabric coating. In a specific 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.

[0041] 4A-4F, each frame end 118 has a cross-sectional shape that includes one or more contact locations 124 (shown as 124A and 124B in FIGS. 4A-4F), with adjacent contact locations 124A, 124B spaced apart from one another by a separation length 126. Each of FIGS. 4A-4F provides a cross-sectional view of a differently shaped frame end 118 of frame 112 (represented as frame ends 118, 118', 118", 118'", 118"", and 118"", respectively). For example, in the embodiment of FIG. 4A, the cross-sectional shape of frame end 118 is duckbill-shaped, including a first contact location 124A spaced apart from a second contact location 124B by a separation length 126.

[0042] To promote adequate coverage, a minimum length of the uncoated tow 106' should contact or be relatively close to the frame 112. For example, the number of contact locations 124 and / or the length of the uncoated tow 106' within a minimum distance 130 from the frame end 118 may be minimized to promote maximum tow coverage. Referring to FIG. 4A , the frame end 118 slopes inwardly from each of the first and second contact locations 124A, 124B toward a midline 132 to define a generally V-shaped slot 125 between the first and second contact locations 124A, 124B. The distance between the uncoated tow 106' and the frame end 118 thereby varies along the separation length 126. More specifically, the distance between the uncoated tow 106' and the frame end 118 varies from zero at the contact locations 124A, 124B (i.e., the uncoated tow 106' contacts the frame end 118 at the contact locations 124A, 124B) to a maximum distance 134 at the deepest point of the V-shaped slot 125 (i.e., at the midline 132). For example, when moving from the first contact location 124A to the second contact location 124B, from left to right in FIG. 4, the distance between the uncoated tow 106' and the frame end 118 increases from the first contact location 124A to the midline 132 and decreases from the midline 132 to the second contact location 124B.

[0043] Additionally, as one moves along the frame side length 120 from each contact location 124A, 124B, the distance between the uncoated tow 106' and the frame end 118 increases. Additionally, the duckbill-shaped frame end 118 shown in FIG. 4A is an undercut that reduces the length of the uncoated tow 106' spaced from the frame 112 by a minimum distance 130 or less. The minimum distance 130 may be the smallest spacing between the uncoated tow 106' and the frame 112 where reactants 115 (FIG. 2) do not interact with the material from which the frame 112 is formed during the coating process to inhibit the formation of a coating 116 on the uncoated tow 106'. In some embodiments, the minimum distance 130 may be at least two times the diameter of the uncoated tow 106', and in other embodiments, the minimum distance 130 may be at least three times the diameter of the uncoated tow 106', at least four times the diameter of the uncoated tow 106', at least five times the diameter of the uncoated tow 106', at least six times the diameter of the uncoated tow 106', or at least seven times the diameter of the uncoated tow 106'.

[0044] 4A , the frame end 118 is undercut, sloping toward the midline 132 along the width W of the frame end 118 and moving away from the contact locations 124A, 124B along the frame side length 120. A first length 128A of the uncoated tow 106′ is defined by the sum of the first contact location 124A and the adjacent minimum distance 130 from the frame end 118 on either side. A second length 128B of the uncoated tow 106′ is defined by the sum of the first contact location 124A and the adjacent minimum distance 130 from the frame end 118 on either side. In such an embodiment, the first length 128A is less than the separation length 126 adjacent to the first length 128A. The duckbill-shaped frame end 118 shown in FIG. 4A , for example, as provided herein, helps minimize the overall length of the uncoated tow 106′ within the minimum distance 130 from the frame end 118 by undercutting the frame end 118 and having only two contact locations 124 that slope away from the contact locations 124. It is understood that the overall length of the uncoated tow 106′ within the minimum distance 130 from the frame end 118 is the sum of the lengths of each of the uncoated tows 106′ within the minimum distance 130 from the frame end 118. For example, for the embodiment of FIG. 4A , the overall length of the uncoated tow 106′ within the minimum distance 130 from the frame end 118 is the sum of the first length 128A and the second length 128B.

[0045] It is understood that a midline 132 is defined through the widthwise center of the cross-sectional shape of the frame end 118, and that the width W of the frame end 118 is perpendicular or orthogonal to each of the longitudinal direction L and lateral direction T (FIG. 3A) defined by the frame 112. It is further understood that, in at least some embodiments, a generally V-shaped slot 125 extends along the lateral direction T through the frame end length 121. For example, the generally V-shaped slot 125 can be defined along the frame end 118 such that the generally V-shaped slot 125 extends from the first frame side 122A (FIG. 3A) to the second frame side 122B (FIG. 3A).

[0046] 4A , the fiber 104 or uncoated tow 106′ is wound around the frame 112 so that the fiber 104 or uncoated tow 106′ contacts the first and second contact locations 124A, 124B at the frame end 118 and is spaced from the frame 112 by no more than a minimum distance 130 along a first length 128A that includes the portion of the fiber 104 or uncoated tow 106′ that contacts the first contact location 124A and a second length 128B that includes the portion of the fiber 104 or uncoated tow 106′ that contacts the second contact location 124B. However, the remaining portion of the fiber 104 or uncoated tow 106′ is spaced from the frame 112 by more than the minimum distance 130 to allow for the deposition of a coating on the reinforcing fiber, for example, by a chemical vapor deposition (CVD) process or other suitable coating process as described herein. It is understood that for a frame 112 having two frame ends 118 configured in a substantially similar manner (e.g., having the same cross-sectional shape), the frame end 118 shown in FIG. 3B can be a first frame end 118A, and the reinforcing fibers (i.e., fibers 104 or uncoated tows 106′) can contact the third and fourth contact locations of the second frame end 118B in a substantially similar manner to how the reinforcing fibers contact the first and second contact locations 124A and 124B shown in FIG. 4A.

[0047] As shown in FIG. 4A , the cross-sectional shape of the frame end 118 defines two contact locations 124 configured to contact the reinforcing fibers. FIGS. 4B-4F depict additional or alternative embodiments of the frame end 118, each of which depicts the cross-sectional shape of the frame end 118 having multiple contact locations 124. It is understood that the additional or alternative frame end embodiments are not mutually exclusive and can be utilized in combination on the same frame and / or in the same system having multiple frames. As shown in FIGS. 4A-4F , in various embodiments of the frame end 118, the multiple contact locations 124 can have a periodicity factor of at least two. That is, the contact locations 124 can have a pattern that appears at least twice.

[0048] 4B, the cross-sectional shape of the frame end 118' can be an open-mouth shape that is a large sector of a circle with or without rounded edges, or can also be referred to as a Pac-Man shape. Like the duckbill shape shown in FIG. 4A, the open-mouth shape of the frame end 118' shown in FIG. 4B includes a generally V-shaped slot 125 between the first contact location 124A and the second contact location 124B. The generally V-shaped slot 125 can extend along the frame end length 121 along the lateral direction T. For example, in at least some embodiments, the generally V-shaped slot 125 is defined along the frame end 118 such that the generally V-shaped slot 125 extends from the first frame side 122A (FIG. 3A) to the second frame side 122B (FIG. 3A).

[0049] The open-mouth shape shown in FIG. 4B differs from the duckbill shape shown in FIG. 4A along the widthwise edge of each frame end 118, 118′. For example, the duckbill shape of FIG. 4A is undercut as previously described, with the widest portion or greatest width W of the duckbill-shaped frame end 118 including the first contact location 124A and the second contact location 124B. In contrast, the open-mouth shape of FIG. 4B includes rounded edges 138, with the first rounded edge 138A arcing outward in the widthwise direction from the first contact location 124A to the frame end 118′ and the second rounded edge 138B arcing outward in the widthwise direction from the second contact location 124B to the frame end 118′. The widest portion or greatest width W of the open-mouthed shape of the frame end 118' shown in Figure 4B is spaced from each of the contact locations 124 between a line extending tangent to the rounded edge 138 and a line extending parallel to the longitudinal direction L. Thus, the length 128 of the uncoated tow 106' is within the minimum distance 130 of the frame end 118' adjacent each rounded edge 138 at the greatest width W of the open-mouthed shape of the frame end 118' in Figure 4B. More specifically, the first length 128A of the uncoated tow 106' is within the minimum distance 130 from the first rounded edge 138A to a first location 136A beyond the first contact location 124A along the width direction toward the second contact location 124B, and the second length 128B of the uncoated tow 106' is within the minimum distance 130 from the second rounded edge 138B to a second location 136B beyond the second contact location 124B along the width direction toward the first contact location 124A.

[0050] Referring now to FIG. 4C, in some embodiments, the cross-sectional shape of the frame end 118" is ribbed. As shown in FIG. 4C, the ribbed shape can include a plurality of ridges 140, each ridge 140 spaced apart from an adjacent ridge 140 by a separation length 126, with either similar or different spacing between adjacent ridges 140. That is, each ridge 140 defines a contact location 124, and may be spaced apart from an adjacent ridge 140 by a separation length 126, with either similar or different spacing between adjacent ridges 140. As such, adjacent contact locations may be spaced apart by a separation length 126. It is noted that each ridge 140 may be the same size and shape, or each ridge may vary in size and shape. Additionally, as described with respect to FIGS. 4A and 4B , the length 128 of the uncoated tow 106′ may be within a minimum distance 130 that is adjacent not only each ridge 140 but also adjacent the rounded edge 138 of the ridge-shaped frame end 118″. The total length of the uncoated tow 106′ within the minimum distance 130 may be minimized as described herein to minimize undercoated and uncoated areas of the tow upon completion of the coating process.

[0051] As shown in FIG. 4D , in another embodiment, the cross-sectional shape of the frame end 118′″ is tooth-like. Similar to the embodiment of FIGS. 4A and 4B , the tooth-like shape of the frame end 118′″ of FIG. 4D includes two contact locations 124: a first contact location 124A and a second contact location 124B. The tooth-like shape may include a first straight edge 142A extending inward from the first contact location 124A toward the midline 132 and a second straight edge 142B extending inward from the second contact location 124B toward the midline 132. An angle α may be defined between each of the first and second straight edges 142A and 142B and the midline 132. Angle α can be a non-zero angle less than 90°, such as in some embodiments within the range of about 5° to about 80°, in some embodiments within the range of about 15° to about 60°, and in some embodiments within the range of about 20° to about 45°. Additionally, such as in the embodiment shown in FIGS. 4A-4C , a length 128 of uncoated tow 106′ can be within a minimum distance 130 adjacent each contact location 124A, 124B of tooth-shaped frame ends 118′″, and the overall length of uncoated tow 106′ within minimum distance 130 can be minimized as described herein to minimize undercoated and uncoated areas of the tow upon completion of the coating process.

[0052] 4E, in yet another embodiment of the frame end 118'''', the cross-sectional shape is grooved. The grooved shape may include a plurality of semicircular protrusions 144. As shown in FIG. 4E, each semicircular protrusion 144 may be spaced apart from an adjacent semicircular protrusion 144 by a separation length 126. It is noted that any number of protrusions may be utilized, with even or uneven spacing. Furthermore, each semicircular protrusion 144 may define a contact location 124 where the reinforcing fiber contacts the grooved frame end 118'''' as the reinforcing fiber is wrapped around the frame 112. Similar to the embodiment of Figures 4A-4D, the length 128 of the uncoated tow 106' can be within a minimum distance 130 adjacent to each contact location 124 of the grooved frame end 118'''', and the overall length of the uncoated tow 106' within the minimum distance 130 can be minimized as described herein to minimize undercoated and uncoated areas of the tow upon completion of the coating process.

[0053] Referring to FIG. 4F, in yet another embodiment of the frame end 118''''', the cross-sectional shape is fin-shaped. The fin-shaped shape may include a plurality of fins 146. Each fin 146 of the plurality of fins 146 may be spaced apart from an adjacent fin 146 by a separation length 126. It is noted that any number of protrusions may be utilized, along with equal or unequal spacing. Furthermore, each fin 146 may define a contact location 124 where the reinforcing fiber contacts the fin-shaped frame end 118''''' when the reinforcing fiber is wrapped around the frame 112. As in the embodiment shown in FIGS. 4A-4E, the length 128 of the uncoated tow 106' may be within a minimum distance 130 adjacent to each contact location 124 of the fin-shaped frame end 118'''''. The total length of uncoated tow 106' within minimum distance 130 may be minimized as described herein to minimize undercoated and uncoated areas of the tow upon completion of the coating process.

[0054] In each embodiment described herein, the frame 112 and frame end 118 can be configured to minimize the overall length 128 of the uncoated tows 106′ to the frame 112 (e.g., the sum of the length of the tows 106′ within the minimum distance 130 on either side of the contact area 124A and the length of the tows 106′ within the contact area 124A). In that way, reactants interact with the reinforcing fibers (rather than the frame 112) to coat the reinforcing fibers in the minimum area of ​​uncoated or undercoated fiber locations. For example, the ratio of the overall length of the uncoated tows 106′ (i.e., the sum of the respective lengths 128 for a given frame end 118) to the separation length 126 for a given frame end 118 can be within a range of about 2 to 10,000, such as about 5 to 1,000. Additionally, as described herein, the minimum distance 130 can be at least two times the diameter of the uncoated tow 106′, such as two, three, four, five, six, seven, or a greater multiple of the diameter of the uncoated tow 106′. In some embodiments, the minimum distance 130 can depend on the material from which the frame 112 is formed, the reactants 115 ( FIG. 2 ) used to deposit the coating 116 ( FIG. 2 ) on the uncoated tow 106′, a combination of these elements, or other factors.

[0055] Additionally, each contact location 124 can form a point contact between the frame end 118 and the reinforcing fibers. In some embodiments, the contact between the frame end 118 and the reinforcing fibers can be a line contact (i.e., having multiple adjacent points of contact) or a combination of point and line contact. For example, for a given configuration of the frame ends 118, some contact locations 124 can form a point contact between the frame end 118 and the reinforcing fibers, while other contact locations 124 can form a line contact between the frame end and the reinforcing fibers.

[0056] As previously described, coated reinforcing fibers (e.g., coated fibers or coated tows 106) may be formed into composite parts or articles, such as the composite part 100 shown in FIG. 1 , which may be a ceramic matrix composite (CMC) component. In at least some embodiments, the composite part 100 is a CMC part comprising silicon carbide (SiC) reinforcing fibers in a silicon carbide (SiC) matrix material, such that the CMC part is a SiC / SiC part. However, CMC parts may be formed from other ceramic materials as described herein, and in suitable embodiments, the composite part 100 may be formed from a non-ceramic material or a mixture of ceramic and non-ceramic materials.

[0057] Here, additional or alternative frame ends 118 X , 118 Y 5A and 5B, which illustrate a frame 112 (e.g., of FIG. 3B and FIG. 3C ) of a reinforcement fiber (e.g., an uncoated tow 106′ as shown in FIG. 5A and FIG. 5B ) is moved relative to a midline 132 (of the frame 112 in FIG. 3B and FIG. 3C ) to reduce or eliminate areas of light coverage or uncoated coverage on the reinforcement fiber upon completion of the coating process. For example, as shown in FIG. 5A and FIG. 5B , at least one frame end 118 can be rotated, e.g., clockwise or counterclockwise relative to a transverse direction T ( FIG. 2 ) extending into and out of the page, to advance or move the reinforcement fiber during the coating process. One or more areas of the reinforcement fiber, where the formation of a coating 116 ( FIG. 2 ) on the fiber may be prevented by the frame 112 prior to advancement or movement, can be exposed to a reactant 115 ( FIG. 2 ) after advancing or moving the reinforcement fiber relative to the frame 112. For example, the regions 152A, 152B of the reinforcing fibers that were in contact with the contact locations 124 of the frame end 118 at the first position P1 may be advanced or moved to a second position P2 that is spaced apart from the respective contact locations 124 to provide sufficient space for the reactants to interact with the reinforcing fibers to form the coating 116 (FIG. 2) on the reinforcing fibers.

[0058] For illustrative purposes only, two such regions 152 are shown in Figures 5A and 5B and are indicated by enlarged circles outlined with dashed lines for illustrative purposes only, it being understood that the enlarged circles indicating regions 152 are not intended to convey the size, extent, etc., of any such region 152.

[0059] As shown in Figures 5A and 5B, the frame end 118 can have a cross-sectional shape that is the same as or substantially similar to one of the cross-sectional shapes described with respect to Figures 4A-4F. For example, the frame end 118 shown in Figures 5A and 5B has a cross-sectional shape that is fin-shaped, such as that described with respect to Figure 4F, including a plurality of fins 150 spaced apart from one another. With reference to Figures 5A and 5B, the reinforcing fibers can contact the frame end 118 at a plurality of contact locations 124, each defined by a respective fin 150. By moving the frame end 118, such as by rotating the frame end 118 clockwise or counterclockwise as indicated by the arrows in Figure 5A, the reinforcing fibers (in the form of uncoated tows 106' in the depicted embodiment) initially contacting the contact locations 124 can be advanced or moved away from the contact locations 124. For example, as shown in FIG. 5B, by rotating the frame end 118 clockwise 180 degrees, the uncoated tow 106′ can be advanced so that the regions 152A, 152B that respectively define the contact locations 124 are no longer in contact with the fins 150A, 150B, respectively.

[0060] 5A and 5B, it will be appreciated that, in at least some embodiments, the movement of the frame end 118 prevents fibers such as the uncoated tow 106' from slipping relative to the frame end 118, which can help minimize fuzzing and broken filament ends. When the uncoated tow 106' does not slip relative to the frame end 118, a region 152 of the uncoated tow 106' remains in contact with the fin 150 until the rotation of the frame end 118 reaches a right or left extreme position (in the end view of FIGS. 5A and 5B ), at which point the region 152 will advance down the side of the "curtain" formed by the uncoated tow 106' in its free state toward the coating. 5A and 5B, the amount of rotation required to "free" region 152 from contact at contact location 124 is 180°, but the linear distance that uncoated tow 106' must travel to free itself from contact with fin 150 can be reduced by reducing the circumference of frame end 118. In some embodiments, using two or more support frame ends 118 in the form of rollers similar to the configuration of FIGS. 5A and 5B (e.g., generally cylindrical, with the length of the rollers extending along the transverse direction as shown in FIG. 3A) can allow for further reduction in the circumference of frame end 118; smaller diameter end rollers, by virtue of their smaller diameter, do not need to rotate a full 180° to free uncoated tow 106', which minimizes the linear tow length in momentary contact with fin 150. In some embodiments, multiple (e.g., two or more) small end rollers may be linked in their rotation by a central gear that moves all of the end rollers in synchronization, which can help prevent sliding contact with the tow.

[0061] As shown in Figure 6, a frame 112 may be part of a system 10 for coating reinforcing fibers of a composite part, such as the composite part 100 of Figure 1. In addition to the frame 112, the system 10 may include a movement mechanism 154 including an actuator 156, e.g., the actuator 156 initiates movement of one or more components of the movement mechanism 154. The movement mechanism 154 is operably coupled to the frame 112 to guide movement of the reinforcing fibers relative to the frame 112.

[0062] 6, the movement mechanism 154 includes a rack 158 and at least one gear 160 in operative communication with the rack 158, such as in a rack-and-pinion configuration. As shown in FIG. 6, in some embodiments, the at least one gear 160 can be a first gear 160A and a second gear 160B disposed on opposite ends of the rack 158.

[0063] Continuing with the embodiment of FIG. 6 , the depicted actuator 156 includes a rotary vacuum feedthrough 162 operably coupled to a drive motor 164. A screw drive member 166 is operably coupled to the rotary vacuum feedthrough 162, and a slider 168 forming a cam 170 is disposed on the screw drive member 166. The cam 170 is configured to contact the rack 158, e.g., to guide linear motion of the rack 158 as the slider 168 translates along the screw drive member 166. For example, the drive motor 164 drives the rotary vacuum feedthrough 162 to rotate the screw drive member 166, which in turn translates the slider 168 along the screw drive member 166. When cam 170 contacts rack 158, such as at rack end 172 of rack 158 as shown in FIG. 6 , cam 170 moves along end face 173 of rack end 172 and applies a load to rack 158 to initiate linear movement of rack 158. For example, end face 173 may define a follower surface shaped complementary to cam 170.

[0064] Although not depicted in the figures, it is understood that rack 158 and at least one gear 160 can each define a plurality of gear teeth that mesh with one another such that linear movement of rack 158 induces rotational movement of one or more gears 160. In some embodiments, the rotational movement of one or more gears 160 may be used, for example, to rotate frame end 118 of frame 112 as described with respect to FIGS. 5A and 5B . In other embodiments, the reinforcing fibers can be in contact with rack 158 and / or gears 160 such that linear movement of rack 158 and / or rotational movement of gears 160 moves the reinforcing fibers relative to frame 112, which can promote adequate coverage of the reinforcing fibers by exposing areas of low or poor coverage or uncoated areas of the reinforcing fibers while the coverage process is ongoing. It will also be appreciated that instead of translating rack 158 with actuator 156, in other embodiments, an actuator 156 configured differently from the actuator 156 shown in FIG. 6 can rotate one or more gears 160 instead of inducing linear movement of rack 158.

[0065] 6 , in at least some embodiments, multiple rack and gear assemblies 174 may be included in system 10. Each rack and gear assembly 174 may include a rack 158 and at least one gear 160 configured as previously described. The rack and gear assemblies 174 may be equidistantly spaced from one another within or adjacent to frame 112, or in other embodiments, at least one spacing distance between adjacent rack and gear assemblies 174 may be different from at least one other spacing distance between other adjacent rack and gear assemblies 174. Multiple cams may also be included to move multiple frame ends in the same manner or via other motion devices.

[0066] Additionally, system 10 may also include a controller 176 operably coupled to actuator 156, such as to drive motor 164 of actuator 156 shown in FIG. 6 . Specifically, controller 176 generally includes a network interface 178. Network interface 178 may be operable over any suitable wired or wireless communication network for communicating data with other components, such as system 10, and / or other components or systems not depicted. As shown using phantom lines for the embodiment of FIG. 6 , network interface 178 utilizes wireless communication network 180 to communicate data with other components. For example, controller 176 is operably coupled to actuator 156 through network interface 178 of controller 176 and wireless communication network 180. While network interface 178 utilizes wireless communication network 180 for the embodiment of FIG. 6 , it should be understood that in other embodiments, network interface 178 may instead utilize a wired communication network or a combination of a wired communication network and a wireless communication network.

[0067] 6 , the controller 176 further comprises one or more processing units 182 and one or more memory devices 184. The memory devices 184 store data 186 and instructions 188 accessible by the one or more processing units 182. The one or more processing units 182 may comprise any suitable processing device, such as a microprocessor, a microcontroller, an integrated circuit, a logic device, and / or other suitable processing device. The one or more memory devices 184 may comprise one or more computer-readable media, including but not limited to non-transitory computer-readable media, RAM, ROM, hard drives, flash drives, and / or other memory devices. The instructions 188, when executed by the one or more processing units 182, cause the controller 176 to perform functions. The instructions 188 in the memory devices 184 may be any set of instructions that, when executed by the one or more processing units 182, cause the one or more processing units 182 to perform operations, such as one or more of the operations described herein. In certain illustrative embodiments, the instructions 188 in 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 separate threads in processing unit 182. Memory device 184 may further store other data 188 that may be accessed by processing unit 182.

[0068] In this manner, it will be appreciated that, at least in certain embodiments, controller 176 may be configured to initiate movement of movement mechanism 154, such as via actuator 156, to induce movement of the reinforcing fibers relative to frame 112. For example, controller 176 may be configured to operate actuator 156, thereby initiating movement of movement mechanism 154, in response to data received from one or more sensors, such as those disposed on frame 112 and / or within reactor 114 (FIG. 2). By way of example, controller 176 may be configured to operate actuator 156 after a flow of reactants 115 (FIG. 2) has flowed within reactor 114 for a given length of time, or when a temperature and / or pressure within reactor 114 reaches a threshold value.

[0069] As described herein, in at least some embodiments, the frame 112 comprises a frame end 118 including at least one contact location 124 (e.g., 124A, 124B) where the reinforcing fibers (e.g., fibers 104 (FIG. 1) and / or uncoated tows 106′ (FIG. 2)) contact the frame 112. For example, the frame end 118 may have a cross-sectional shape that defines the one or more contact locations 124 (e.g., 124A, 124B, etc.). As previously discussed, the cross-sectional shape may be duckbill-shaped, open-mouth-shaped, ridged, toothed, grooved, or fin-shaped, for example, as described with respect to FIGS. 3B-4E . The movement mechanism 154 may be configured to rotate the frame end 118 to reposition the reinforcing fibers relative to the at least one contact location 124. For example, the actuator 156 of the moving mechanism 154, such as that shown in FIG. 6, may be operated to rotate the frame end 118 and advance the reinforcing fibers from a first position P1 to a second position P2, as shown in FIGS. 5A and 5B.

[0070] 7A and 7B, in some embodiments, the frame end 118 (e.g., of the frame 112 of FIGS. 3B and 3C) Zvibrates, thereby moving the reinforcing fibers relative to the contact locations 124A, 124B. For example, the frame end 118 of the frame 112 can define one or more openings 190, with a spline 192 disposed in each respective opening 190. Each spline 192 can define at least one contact location 124 (e.g., 124A, 124B, respectively).

[0071] The frame 112 may include a retaining cap 194 that retains one or more splines 192 within each opening 190. For example, as shown in FIG. 7A , the retaining cap 194 may have a cross-sectional shape that is complementary to the cross-sectional shape of the opening 190 to ensure that the one or more splines 192 do not separate from the frame 112 while allowing movement of each spline 192. That is, the one or more splines 192 may move relative to the frame end 118 and the retaining cap 194, e.g., the one or more splines 192 may vibrate, but the frame end 118 and the retaining cap 194 may be shaped to prevent the one or more splines 192 from separating from the frame 112.

[0072] In at least some embodiments, the one or more splines 192 are in operative communication with a movement mechanism 154, such as the movement mechanism 154 described with respect to Figure 6 or a different movement mechanism 154. With reference to Figure 7A, the one or more splines 192 of the frame 112 can have a cross-sectional shape that is generally T-shaped. With reference to Figure 7B, the one or more splines 192' of the frame 112 can have a cross-sectional shape that is generally teardrop-shaped.

[0073] Each spline 192, 192' may include a rocker end 196 and a contact end 198 opposite the rocker end 196. For the generally T-shaped spline 192 shown in FIG. 7A, the cross bar of the T-shape defines the rocker end 196. For the generally tear-drop-shaped spline 192' shown in FIG. 7B, the bulbous end of the tear-drop shape defines the rocker end 196'. For any cross-sectional shape of the spline 192, 192', the contact end 198 of the spline 192, 192' may define contact locations 124A, 124B for contact between the reinforcing fibers and the frame 112.

[0074] It is understood that the rocker end 196 can be in operative communication with the moving mechanism 154 to initiate movement of the splines 192. For example, the actuator 156 of the moving mechanism 154 can be operated to drive one or more splines 192 with vibration or other types of motion. The one or more splines 192 can be driven in an orbit along the longitudinal direction L, along the lateral direction T ( FIG. 3A ), along the width direction W, or in any other suitable direction or motion. In other embodiments, the one or more splines 192 can be driven from a support rod (not shown) below the splines 192, driven by a gas jet (not shown) below the splines 192, or driven by any other suitable actuator 156 and / or moving mechanism 154.

[0075] Various mechanical mechanisms for initiating vibration of the reinforcing fibers and / or frame 112 are described with respect to FIGS. 7A and 7B . Alternatively, or in addition, non-mechanical actuation may be utilized to initiate vibration of the reinforcing fibers and / or frame 112. For example, the reinforcing fibers may spontaneously vibrate when the flow rate (i.e., gas flow rate) of the reactants 115 in the reactor 114 ( FIG. 2 ) exceeds a threshold gas flow rate. Similarly, the reinforcing fibers may spontaneously vibrate when the gas pressure in the reactor 114 ( FIG. 2 ) is equal to or greater than a threshold pressure. As another example, an acoustic waveguide passing through the reactor 114 ( FIG. 2 ) may be used to drive vibration of the reinforcing fibers and / or frame 112 in the reactor 114. Vibration of the reinforcing fibers and / or frame 112 may be achieved using any individual or combination of the mechanical or non-mechanical actuation mechanisms described herein.

[0076] Furthermore, it is understood that whether the vibration is mechanically or non-mechanically actuated, a vibration pattern can be established for the reinforcing fibers and / or frame 112. The vibration pattern can be of fixed, sweeping, bursty, or random frequency or amplitude.

[0077] Referring now to FIG. 8 , a flow diagram of a method 800 for coating reinforcing fibers of a composite component according to an exemplary embodiment of the present disclosure is provided. One or more of the exemplary systems 10 and / or frames 112 described above with reference to FIGS. 2-7B may be utilized in the method 800 of FIG. 8 to coat reinforcing fibers of a composite component, such as the composite component 100 described with reference to FIG. 1 . Accordingly, it will be appreciated that the method 800 may generally be utilized with frames having cross-sectional shapes and / or movement mechanisms for minimizing or eliminating undercoated or uncoated areas of reinforcing fibers upon completion of the coating process. However, in other exemplary embodiments, the method 800 may additionally or alternatively be utilized with any other suitable support frame and / or mechanism for facilitating movement of fibers relative to the support frame during the coating process.

[0078] As depicted, method 800 includes, at (802), winding a reinforcing fiber around a frame 112, which is shown as an optional step for preparing the fiber for coating. As described herein, the frame includes at least one frame end 118 having a cross-sectional shape that includes a first contact location 124A spaced apart from a second contact location 124B by a separation length 126. In at least some embodiments, winding the reinforcing fiber around the frame 112 includes unwinding the fiber from a bobbin 110 ( FIG. 2 ), such as with the fiber under winding tension as described herein, and placing or positioning the reinforcing fiber in contact with the first contact location 124A and the second contact location 124B. When wound around the frame 112, the reinforcing fibers extend from the first contact location 124A to the second contact location 124B such that the minimum length of the uncoated tow 106′ is within the minimum distance 130 of the frame 112, such as when the fibers are under steady-state tension upon unwinding from a bobbin 110 (FIG. 2) as described herein. Various cross-sectional shapes for the frame end 118 are described herein, for example, in connection with FIGS. 4A-4F.

[0079] As described herein, a chemical vapor deposition (CVD) process can be used to deposit a coating 116 ( FIG. 2 ) on the reinforcing fibers. Referring to FIG. 8 , method 800 includes inserting a frame into a reactor 114 ( FIG. 2 ) at (804) and initiating a flow of reactants 115 ( FIG. 2 ) into the reactor 114 at (806). The temperature and pressure within the reactor 114 can be elevated, for example, compared to ambient temperature and pressure, to support the formation of the coating 116 from the reactants 115 on the reinforcing fibers. Upon completion of the deposition process, method 800 includes removing the frame 112 from the reactor 114, as shown at (808).

[0080] Referring now to FIG. 9 , a flow diagram of a method 900 for coating reinforcing fibers of a composite component according to an exemplary embodiment of the present disclosure is provided. One or more of the exemplary systems 10 and / or frames 112 described above with reference to FIGS. 2-7B may be utilized in the method 900 of FIG. 9 to coat reinforcing fibers of a composite component, such as the composite component 100 described with reference to FIG. 1 . Accordingly, it will be appreciated that the method 900 may generally be utilized with frames having cross-sectional shapes and / or movement mechanisms for minimizing or eliminating undercoated or uncoated areas of reinforcing fibers upon completion of the coating process. However, in other exemplary embodiments, the method 900 may additionally or alternatively be utilized with any other suitable support frame and / or mechanism for facilitating movement of fibers relative to the support frame during the coating process.

[0081] As depicted, the method 900 includes, at (902), winding reinforcing fibers around a frame 112. As described herein, winding the reinforcing fibers around the frame 112 may include placing the reinforcing fibers in contact with a frame end 118 of the frame 112. In some embodiments, the frame includes at least one frame end 118 having a cross-sectional shape that includes a first contact location 124A spaced apart from a second contact location 124B by a separation length 126, various cross-sectional shapes for the frame end 118 being described herein, for example, with reference to Figures 4A-4F.

[0082] In at least some embodiments, a chemical vapor deposition (CVD) process may be used to deposit the coating 116 (FIG. 2) on the reinforcing fibers. Referring to FIG. 9, a method 900 includes, at (904), inserting a frame into a reactor 114 (FIG. 2) and, at (906), initiating a flow of reactants 115 (FIG. 2) into the reactor 114. The temperature and pressure within the reactor 114 may be elevated, for example, as compared to ambient temperature and pressure, to assist in the formation of the coating 116 from the reactants 115 on the reinforcing fibers.

[0083] Further, method 900 includes, at (908), initiating movement of the reinforcing fiber relative to the frame while the frame is positioned in the reactant flow. That is, the reinforcing fiber may be moved relative to the frame 112 while the reactants 115 are flowing through the reactor 114, for example, following initiation of the flow as shown at (906). Such movement of the reinforcing fiber relative to the frame may expose one or more regions of the reinforcing fiber that, in the absence of movement, may be uncoated or may have a low coating thickness upon completion of the coating process. Thus, by initiating movement of the reinforcing fiber relative to the frame while the frame is positioned in the reactant flow, regions of low or uncoated reinforcing fiber may be minimized or eliminated. It is understood that such regions may be minimized, e.g., in number and / or length, or may be eliminated entirely.

[0084] As described herein, the frame 112 may include a movement mechanism 154. In some embodiments, the movement mechanism 154 shifts the position of the reinforcing fiber relative to the frame 112. For example, as shown at (908), initiating the movement of the reinforcing fiber relative to the frame 112 may include operating an actuator 156 of the movement mechanism 154 to shift or advance the position of the reinforcing fiber relative to the frame 112 from a first position P1 ( FIG. 5A ) to a second position P2 ( FIG. 5B ). In some embodiments, the movement mechanism 154 rotates the frame end 118 of the frame 112 to advance the reinforcing fiber from the first position P1 to the second position P2.

[0085] In other embodiments, the movement mechanism 154 is in operative communication with the at least one spline 192 ( FIGS. 7A , 7B ), and the step of initiating movement of the reinforcing fiber relative to the frame includes initiating vibration of the at least one spline 192. The at least one spline 192 can include a rocker end 196 and a contact end 198 opposite the rocker end 196, and the at least one spline 192 can have a cross-sectional shape that is generally T-shaped, teardrop-shaped, or other suitable shape that defines the rocker end 196 and the contact end 198. In some embodiments, the contact end 198 forms a point contact between the at least one spline 192 and the reinforcing fiber.

[0086] In some embodiments, initiating movement of the reinforcing fibers relative to the frame 112 includes initiating vibration of the reinforcing fibers 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 gas pressure within the reactor 114 (FIG. 2) to induce vibration of the frame 112.

[0087] Other methods of inducing movement between the reinforcing fibers and the frame 112 may be used. Moreover, such movement may occur one, two, three, or more times as the reactants 115 (FIG. 2) flow through the reactor 114 (FIG. 2). For example, the controller 176 (FIG. 6) may periodically initiate movement of the reinforcing fibers relative to the frame 112 based on, for example, the passage of time, the temperature within the reactor 114, the pressure within the reactor 114, etc.

[0088] Referring to FIG. 9, upon completion of the process of depositing the coating 116 (FIG. 2), the method 900 includes removing the frame 112 from the reactor 114, as shown at (910).

[0089] As described herein, the present subject matter provides devices and methods for reducing or eliminating undercoated or uncoated areas of a coated fiber. For example, the number and / or configuration of contact locations between the uncoated fiber and a frame on which the fiber is placed for support during the coating process minimizes undercoated or uncoated areas of the coated fiber. As another example, moving the coating relative to the frame during the coating process can minimize or reduce undercoated or uncoated areas of the coated fiber.

[0090] Further aspects are provided by the subject matter of the following clauses.

[0091] A frame for use in covering reinforcing fibers, the frame comprising a first frame end having a first cross-sectional shape, the first cross-sectional shape including one or more contact locations spaced apart from one another, the reinforcing fibers contacting the first frame end at the one or more contact locations.

[0092] The frame of any preceding claim, further comprising a second frame end opposite the first frame end, the second frame end having a second cross-sectional shape, the second cross-sectional shape including one or more contact locations spaced apart from one another, and the reinforcing fibers contact the second frame end at the one or more contact locations.

[0093] Any prior claim frame, wherein the second cross-sectional shape is the same as the first cross-sectional shape.

[0094] The frame of any preceding claim, wherein the first frame end includes a first contact location spaced apart from an adjacent second contact location by a separation length, the first length being defined by the first contact location, and the first length being less than the separation length.

[0095] A frame as claimed in any preceding claim, wherein each contact location forms a point contact between the first frame end and the reinforcing fiber.

[0096] The first frame edge is static relative to the frame, any prior claim frames.

[0097] The frame edge is movable relative to the frame, any preceding claim frame.

[0098] The frame of any preceding claim, wherein the one or more contact locations are a plurality of contact locations, and the plurality of contact locations has a periodicity factor of at least two.

[0099] The frame of any preceding claim, wherein the first cross-sectional shape is a duckbill shape, the duckbill shape comprising a first contact location of the one or more contact locations and a second contact location of the one or more contact locations, the duckbill shape being undercut adjacent each of the first contact location and the second contact location, and the first contact location and the second contact location being separated by a generally V-shaped slot.

[0100] The frame of any preceding claim, wherein the first cross-sectional shape is an open-mouth shape, the open-mouth shape comprising a first contact location of the one or more contact locations and a second contact location of the one or more contact locations, the first contact location and the second contact location being separated by a generally V-shaped slot, and the open-mouth shape comprising a rounded edge adjacent each of the first contact location and the second contact location and opposite the generally V-shaped slot.

[0101] The frame of any preceding claim, wherein the first cross-sectional shape is a tooth-like shape, the tooth-like shape comprising a first contact location of the one or more contact locations, a second contact location of the one or more contact locations, and a midline defined between the first contact location and the second contact location, the tooth-like shape further comprising a first straight edge adjacent the first contact location and a second straight edge adjacent the second contact location, each of the first straight edge and the second straight edge extending inwardly toward the midline at a non-zero angle less than 90°.

[0102] The frame of any preceding claim, wherein the first cross-sectional shape is a ridged shape, the ridged shape comprising a plurality of ridges, each ridge of the plurality of ridges defining a contact location of the one or more contact locations.

[0103] The frame of any preceding claim, wherein the first cross-sectional shape is a grooved shape, the grooved shape comprising a plurality of semicircular protrusions, each semicircular protrusion of the plurality of semicircular protrusions defining a contact location of the one or more contact locations.

[0104] The frame of any preceding claim, wherein the first cross-sectional shape is a fin-like shape, the fin-like shape comprising a plurality of fins, each fin of the plurality of fins defining a contact location of the one or more contact locations.

[0105] A frame of any preceding claim in which the ratio of the overall length of the reinforcing fibers within a minimum distance from the frame to the contact length where the reinforcing fibers contact the frame to the separation length for the frame ends is within the range of about 2 to 10,000.

[0106] A frame of any preceding claim in which the ratio of the overall length of the reinforcing fibers within the minimum distance from the frame to the contact length where the reinforcing fibers contact the frame to the separation length for the frame ends is within the range of 5 to 1,000.

[0107] A method for coating reinforcing fibers of a composite component, the method comprising the steps of winding reinforcing fibers around a first frame end of a frame of any preceding claim, inserting the frame into a reactor, and initiating the flow of reactants into the reactor.

[0108] The method of any preceding claim, wherein the reinforcing fibers are in the form of tows and the minimum distance is at least twice the diameter of the tows.

[0109] The method of any preceding claim, wherein the reactant flow deposits the coating on the reinforcing fibers in a chemical vapor deposition process.

[0110] The method of any preceding claim, wherein the reinforcing fibers comprise a non-oxide silicon-based material, a non-oxide carbon-based material, an oxide ceramic, or a mixture thereof.

[0111] The first frame edge is static relative to the frame, as in any previously claimed method.

[0112] The method of any preceding claim, further comprising the step of moving the first frame edge to vary the contact location during flow of reactants into the reactor.

[0113] A system for coating reinforcing fibers of a composite part, comprising: a frame including at least one contact location for contacting the reinforcing fibers; and a movement mechanism including an actuator, the movement mechanism operably coupled to the frame to induce movement of the reinforcing fibers relative to the frame.

[0114] The system of any preceding clause, wherein the movement mechanism comprises a rack and at least one gear in operative communication with the rack.

[0115] 10. The system of any preceding clause, wherein the actuator comprises a rotary vacuum feedthrough operably coupled to the drive motor, a screw drive member operably coupled to the rotary vacuum feedthrough, and a slider forming a cam, the slider being disposed on the screw drive member, the cam configured to contact the rack.

[0116] 10. The system of any preceding clause, wherein the frame includes a frame end with at least one contact location.

[0117] 10. The system of any preceding clause, wherein the frame end has a cross-sectional shape, the cross-sectional shape including at least one contact location, and the movement mechanism is configured to rotate the frame end to change the position of the reinforcing fiber relative to the at least one contact location.

[0118] 10. The system of any preceding clause wherein the cross-sectional shape is duckbill-shaped, open-mouthed, ridged, toothed, grooved, or fin-shaped.

[0119] 10. The system of any preceding clause, wherein the frame includes a frame end defining an opening, the spline disposed in the opening, the spline in operative communication with the moving mechanism, and the spline having at least one contact location.

[0120] 10. The system of any preceding clause, wherein the spline includes a rocker end and a contact end opposite the rocker end, the spline having a cross-sectional shape that is generally T-shaped, with a cross bar of the T defining the rocker end, and the contact end defining at least one contact location.

[0121] 10. The system of any preceding clause, wherein the spline includes a rocker end and a contact end opposite the rocker end, the spline having a generally teardrop-shaped cross-sectional shape with a bulbous end defining the rocker end, the contact end defining at least one contact location.

[0122] 10. The system of any preceding clause, further comprising a controller in operative communication with the movement mechanism, the controller configured to actuate the movement mechanism to induce movement of the reinforcing fibers relative to the frame.

[0123] The frame is positioned within the reactor system of any preceding clause.

[0124] 1. A method of coating reinforcing fibers in a composite component, the method comprising the steps of: inserting a frame wrapped with reinforcing fibers into a reactor; initiating a flow of reactants into the reactor; and initiating movement of the reinforcing fibers relative to the frame while the frame is positioned in the reactant flow.

[0125] 10. The method of any preceding clause, wherein the step of initiating movement of the reinforcing fibers relative to the frame includes the step of activating a movement mechanism provided on the frame, the movement mechanism shifting the position of the reinforcing fibers relative to the frame.

[0126] 10. The method of any preceding clause, wherein the actuating the moving mechanism advances the reinforcing fiber from a first position to a second position.

[0127] 10. The method of any preceding clause, further comprising, prior to the step of inserting the frame wrapped with the reinforcing fiber into the reactor, winding the reinforcing fiber around the frame by placing the reinforcing fiber in contact with a frame end of the frame, wherein the moving mechanism rotates the frame end to advance the reinforcing fiber from the first position to the second position.

[0128] 10. The method of any preceding clause, wherein the movement mechanism is in operative communication with at least one spline, and wherein initiating movement of the reinforcing fibers relative to the frame includes initiating vibration of the at least one spline.

[0129] The method of any preceding clause, wherein the at least one spline includes a rocker end and a contact end opposite the rocker end, the contact end forming a point contact between the at least one spline and the reinforcing fibers.

[0130] 10. The method of any preceding clause, wherein at least one spline has a generally teardrop-shaped cross-sectional shape having a bulbous end and a contact end opposite the bulbous end, the contact end forming a point contact between the at least one spline and the reinforcing fibers.

[0131] The method of any preceding clause, wherein initiating movement of the reinforcing fibers relative to the frame includes initiating vibration of the frame.

[0132] 10. The method of any preceding clause, wherein initiating vibration of the frame includes mechanically initiating vibration of the frame, manipulating gas pressure within the reactor to induce vibration of the frame, or both.

[0133] The written description uses examples to disclose the present disclosure, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using the devices or systems, and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal words of the claims, or if they include equivalent structural elements that have insubstantial differences from the literal words of the claims.

[0134] Further aspects of the invention are provided by the subject matter of the following clauses.

[0135] 1. A frame for use in covering reinforcing fibers, comprising: A frame comprising a first frame end having a first cross-sectional shape, the first cross-sectional shape including one or more contact locations spaced apart from one another, and the reinforcing fibers contact the first frame end at the one or more contact locations.

[0136] 2. The frame of claim 1, further comprising a second frame end opposite the first frame end, the second frame end having a second cross-sectional shape, the second cross-sectional shape including one or more contact locations spaced apart from one another, and the reinforcing fibers contact the second frame end at the one or more contact locations.

[0137] 3. The frame of claim 2, wherein the second cross-sectional shape is the same as the first cross-sectional shape.

[0138] 4. The frame of claim 1, wherein the first frame end includes a first contact location spaced apart from an adjacent second contact location by a separation length, the first length being defined by the first contact location, and the first length being less than the separation length.

[0139] 5. The frame of claim 1, wherein each contact location forms a point contact between the first frame end and the reinforcing fiber.

[0140] 6. The frame of claim 1, wherein the first frame end is static relative to the frame.

[0141] 7. The frame of claim 1, wherein the frame end is movable relative to the frame.

[0142] 8. The frame of claim 1, wherein the one or more contact locations are a plurality of contact locations, and the plurality of contact locations has a periodicity factor of at least two.

[0143] 9. The frame of claim 1, wherein the first cross-sectional shape is a duckbill shape, the duckbill shape comprising a first contact location of the one or more contact locations and a second contact location of the one or more contact locations, the duckbill shape being undercut adjacent each of the first contact location and the second contact location, and the first contact location and the second contact location being separated by a generally V-shaped slot.

[0144] 10. The frame of claim 1, wherein the first cross-sectional shape is an open-mouth shape, the open-mouth shape comprising a first contact location of the one or more contact locations and a second contact location of the one or more contact locations, the first contact location and the second contact location being separated by a generally V-shaped slot, and the open-mouth shape comprising a rounded edge adjacent each of the first contact location and the second contact location and opposite the generally V-shaped slot.

[0145] 11. The frame of claim 1, wherein the first cross-sectional shape is a tooth-like shape, the tooth-like shape comprising a first contact location of the one or more contact locations, a second contact location of the one or more contact locations, and a midline defined between the first contact location and the second contact location, the tooth-like shape further comprising a first linear edge adjacent to the first contact location and a second linear edge adjacent to the second contact location, each of the first linear edge and the second linear edge extending inward toward the midline at a non-zero angle less than 90°.

[0146] 12. The frame of claim 1, wherein the first cross-sectional shape is a ridged shape, the ridged shape comprising a plurality of ridges, each ridge of the plurality of ridges defining a contact location of the one or more contact locations.

[0147] 13. The frame of claim 1, wherein the first cross-sectional shape is a grooved shape, the grooved shape comprising a plurality of semicircular protrusions, each semicircular protrusion of the plurality of semicircular protrusions defining a contact location of the one or more contact locations.

[0148] 14. The frame of claim 1, wherein the first cross-sectional shape is a fin-like shape, the fin-like shape comprising a plurality of fins, each fin of the plurality of fins defining a contact location of the one or more contact locations.

[0149] 15. A method of coating reinforcing fibers in a composite component, comprising: wrapping reinforcing fibers around a first frame end of the frame of claim 1; Inserting the frame into a reactor; and initiating the flow of reactants to the reactor.

[0150] 16. The method of claim 15, wherein the reinforcing fibers are in the form of a tow and the minimum distance is at least twice the diameter of the tow.

[0151] 17. The method of claim 15, wherein the reactant stream deposits the coating on the reinforcing fibers in a chemical vapor deposition process.

[0152] 18. The method of claim 15, wherein the reinforcing fibers comprise a non-oxide silicon-based material, a non-oxide carbon-based material, an oxide ceramic, or a mixture thereof.

[0153] 19. The method of claim 15, wherein the first frame end is static relative to the frame.

[0154] 20. The method of claim 15, further comprising the step of moving the first frame end to vary the contact location during flow of reactants into the reactor. [Explanation of symbols]

[0155] 10 Systems 100 composite parts 102 Thin plate 104 Reinforced Fiber 106 Tou 106' Uncoated Tow 108 Ceramic Matrix 110 Bobbin 112 frames 114 Reactor 115 Reactants 116 Covering 118, 118', 118", 118''', 118'''', 118'''', 118 X , 118 Y , 118 Z Frame edge 118A First Frame End 118B Second Frame End 119 Spacer bar 120 Frame side length 121 Frame end length 122 Frame side 122A First Frame Side 122B Second frame side 124 Contact points 124A First Contact Point 124B Secondary Contact Point 125 V-shaped slot 126 Separation length 128 Uncoated tow 106' length 128A First length of uncoated tow 106' 128B Second length of uncoated tow 106' 130 minimum distance 132 Midline 134 maximum distance 136A 1st Place 136B Second Place 138 Rolled Edges 138A First Rounded Edge 138B Second Rolled Edge 142A First straight edge 142B Second straight edge 144 Semicircular protrusion 146 fins 150 fins 152, 152A, 152B area 158 racks 160 Gears 160A First Gear 160B Second Gear 162 Rotary Vacuum Feedthrough 164 Drive motor 166 Screw drive member 168 Slider 170 Cam 172 End of rack 173 End face 174 Rack and gear assembly 176 Control Device 178 network interfaces 180 Wireless Communication Network 182 Processing equipment 184 Memory Devices 186 Data 188 Instructions and other data 190 Aperture 192, 192' spline 194 Retaining Cap 196, 196' Rocker end 198 Contact end L longitudinal direction of frame 112 P1 First position P2 Second position T Frame 112 horizontal W Width of frame end 118

Claims

1. A frame (112) for covering reinforcing fibers (104, 106') of a composite component (100), comprising: a first frame end (118A) having a first cross-sectional shape, said first cross-sectional shape including one or more contact locations (124), said reinforcing fibers (104, 106') contacting said first frame end (118A) at said one or more contact locations (124); A frame (112) in which at least a portion of the reinforcing fibers are spaced from the first frame end by support from the one or more contact locations where a portion of the reinforcing fibers wrap around the first frame end.

2. 10. The frame (112) of claim 1, further comprising a second frame end (118B) opposite the first frame end (118A), the second frame end (118B) having a second cross-sectional shape, the second cross-sectional shape including one or more contact locations (124).

3. 3. The frame (112) of claim 2, wherein the second cross-sectional shape is the same as the first cross-sectional shape.

4. The first frame end (118A) includes a first contact location (124) spaced apart from a second contact location (124), the second frame end (118B) includes a third contact location (124) spaced apart from a fourth contact location (124), and the first length (128A) of the reinforcing fibers (104, 106') includes a first portion adjacent to and in contact with the first contact location (124) and a second portion adjacent to and in contact with the second contact location (124).

4. The frame (112) of claim 2 or 3, wherein the second length (128B) of the reinforcing fibers (104, 106') includes a second portion adjacent to the third contact location (124) and in contact with the second contact location (124), and the second length (128B) of the reinforcing fibers (104, 106') includes a third portion adjacent to the third contact location (124) and in contact with the third contact location (124), and a fourth portion adjacent to the fourth contact location (124) and in contact with the fourth contact location (124).

5. A frame (112) according to any one of claims 1 to 3, wherein the reinforcing fibres (104, 106') are tows (106').

6. 4. A frame (112) according to any one of claims 1 to 3, wherein each contact location (124) forms a point contact between the first frame end (118A) and the reinforcing fibres (104, 106').

7. 4. A frame (112) according to any one of claims 1 to 3, wherein the one or more contact locations (124) are a plurality of contact locations (124), the plurality of contact locations (124) having a periodicity factor of at least 2.

8. 4. The frame (112) of claim 1, wherein the first cross-sectional shape is a duckbill shape, the duckbill shape comprising a first contact location (124) of the one or more contact locations (124) and a second contact location (124) of the one or more contact locations (124), the duckbill shape being undercut adjacent each of the first contact location (124) and the second contact location (124), and the first contact location (124) and the second contact location (124) being separated by a generally V-shaped slot.

9. 4. The frame (112) of claim 1, wherein the first cross-sectional shape is an open-mouth shape, the open-mouth shape comprising a first contact location (124) of the one or more contact locations (124) and a second contact location (124) of the one or more contact locations (124), the first contact location (124) and the second contact location (124) being separated by a generally V-shaped slot, and the open-mouth shape comprising rounded edges adjacent each of the first contact location (124) and the second contact location (124) and opposite the generally V-shaped slot.

10. 4. The frame (112) of claim 1, wherein the first cross-sectional shape is a tooth-like shape, the tooth-like shape comprising a first contact location (124) of the one or more contact locations (124), a second contact location (124) of the one or more contact locations (124), and a midline defined between the first contact location (124) and the second contact location (124), the tooth-like shape further comprising a first straight edge adjacent to the first contact location (124) and a second straight edge adjacent to the second contact location (124), each of the first straight edge and the second straight edge extending inward toward the midline at a non-zero angle less than 90°.

11. 4. A frame (112) according to any one of claims 1 to 3, wherein the first cross-sectional shape is a ridged shape, the ridged shape comprising a plurality of ridges, each ridge of the plurality of ridges defining a contact location (124) of the one or more contact locations (124).

12. 4. A frame (112) according to any one of claims 1 to 3, wherein the first cross-sectional shape is a grooved shape, the grooved shape comprising a plurality of semicircular protrusions (144), each semicircular protrusion (144) of the plurality of semicircular protrusions (144) defining a contact location (124) of the one or more contact locations (124).

13. 4. A frame (112) according to any one of claims 1 to 3, wherein the first cross-sectional shape is a fin (146)-like shape, the fin (146)-like shape comprising a plurality of fins (146), each fin (146) of the plurality of fins (146) defining a contact location (124) of the one or more contact locations (124).

14. 4. A frame (112) according to any one of claims 1 to 3, wherein the composite component (100) is a ceramic matrix composite component (100) comprising a silicon carbide matrix material and the reinforcing fibers (104, 106') are silicon carbide fibers.

15. A method of coating reinforcing fibers (104, 106') of a composite component (100), comprising the steps of: winding the reinforcing fibers (104, 106') around a frame (112); Inserting the frame (112) into a reactor; initiating the flow of reactants into the reactor; Including, the frame (112) comprises a first frame end (118A) having a first cross-sectional shape, the first cross-sectional shape including one or more contact locations (124), the reinforcing fibers (104, 106') contacting the first frame end (118A) at the one or more contact locations (124); The method wherein at least a portion of the reinforcing fibers are spaced from the first frame end by support from the one or more contact locations where a portion of the reinforcing fibers wrap around the first frame end.

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