Prepreg Tape Assembly With Metered Slurry Impregnation

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Solution Overview

Problem

Traditional methods for impregnating dry fiber tows in prepreg tape assemblies suffer from slurry drift towards the front wall of the slurry bath, leading to inconsistent slurry absorption and thickness variability, which results in gaps and inconsistencies in the prepreg tape.

Innovation Solution

A prepreg tape assembly with a slurry bath and series of rollers, featuring a first metering device that overlays the slurry reservoir and a second metering device to regulate slurry thickness, minimizing slurry drift and ensuring consistent impregnation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional prepreg tape assembly methods are used with slurry bath, then impregnation of fiber tow can be achieved, but slurry drift occurs leading to inconsistent thickness and variability in prepreg tape

Engineering Contradiction:

Improveprepreg tape thickness consistencyVSAvoidslurry distribution uniformity

Core Design Contradiction:

Manufacturing precisionVSStability of the object's composition

Solution Approach 1:

A metering device is introduced as an intermediary component between the slurry bath and the fiber tow. This device includes a metering surface that contacts the slurry and a metered opening that controls slurry flow, acting as a mediator to regulate and stabilize slurry distribution onto the tow, thereby eliminating slurry drift and ensuring consistent thickness

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention changes the parameters of slurry delivery by controlling the metered opening dimensions and the metering surface geometry. By adjusting these parameters, the slurry flow rate, pressure, and distribution pattern are optimized to prevent drift while maintaining uniform impregnation, directly improving thickness consistency

Inventive Principle:

Principle #35Parameter changes

2Reliability

If slurry is applied generously to ensure complete impregnation, then fiber tow can be fully coated, but thickness variability increases and gaps may still form

Engineering Contradiction:

Improveimpregnation completenessVSAvoidprepreg tape thickness control

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The metering device serves as a controlled intermediary that regulates slurry flow precisely. It ensures complete impregnation by maintaining adequate slurry supply while preventing over-application that causes thickness variability, thus achieving both reliability and precision simultaneously

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The metering device creates a controlled flow path where slurry is delivered at a regulated rate based on the metered opening geometry. This inherent feedback mechanism ensures that slurry application matches the requirements for complete impregnation without excess, preventing both gaps and thickness variations

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS12629867B2Prepreg tape assembly

Publication Date: 2026.05.19 GENERAL ELECTRIC CO

AI summary

A prepreg tape assembly for impregnating a dry fiber tow to make composite components. The prepreg tape assembly can include a bath defining a slurry reservoir, a series of rollers located in the bath, and a take-up drum located outside of the slurry reservoir. The prepreg tape assembly also includes a first metering device capable of metering slurry, where the first metering device has a tow passage. The tow passage includes an inlet and an outlet, where the inlet of the tow passage overlies or is located in the slurry reservoir.