# US 10,370,292 B2 · Apparatus and methods for processing ceramic fiber

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- Number: US 10,370,292 B2
- Document ID: US10370292B2
- Status: Granted
- Kind: B2
- Application number: 15/725,889
- Filed: 2017-10-05
- Published: 2018-02-01
- Granted: 2019-08-06
- Earliest claimed: 2015-11-25
- Assignees: General Electric Company
- Applicants: General Electric Company
- Inventors: Daniel Gene Dunn; James Anthony Ruud; Pierre-Andre Bui; Gregory Scot Corman; James Scott Vartuli
- Web page: https://patentgrep.com/patent/US10370292B2

## CPC

- C04B 35/62884: {by gas phase techniques}
- C03C 17/001: {General methods for coating; Devices therefor}
- C04B 35/565: based on silicon carbide
- C04B 35/62863: {Silicon carbide}
- C04B 35/62868: {Boron nitride}
- C04B 35/62871: {Silicon nitride}
- C04B 35/62873: {Carbon}
- C04B 35/80: Fibres, filaments, whiskers, platelets, or the like
- C04B 2235/3826: Silicon carbides
- C04B 2235/5224: Alumina or aluminates
- C04B 2235/5228: Silica and alumina, including aluminosilicates, e.g. mullite
- C04B 2235/5244: Silicon carbide
- C04B 2235/5248: Carbon, e.g. graphite
- C04B 2235/5264: characterised by the diameter of the fibers
- C04B 2235/5268: Orientation of the fibers
- C04B 2235/6028: Shaping around a core which is removed later
- C04B 2235/614: Gas infiltration of green bodies or pre-forms
- C04B 2235/616: Liquid infiltration of green bodies or pre-forms
- C04B 2235/95: Products characterised by their size, e.g. microceramics
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- C03C: CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS

## Abstract

The present application provides methods and apparatus for processing ceramic fibers for the manufacture of ceramic matrix composites (CMCs). One method may include providing at least one frame including a planar array of unidirectional ceramic fibers extending across a void thereof. The method may further include depositing a coating on the ceramic fibers of the at least one frame via a chemical vapor deposition (CVD) process. The method may also include impregnating the coated ceramic fibers with a slurry including a ceramic matrix precursor composition to form at least one CMC prepreg, such as a prepreg tape. The ceramic fibers may be substantially SiC fibers, for example.

## Claims

### Claim 1

A method of processing ceramic fiber for the manufacture of a ceramic matrix composite (CMC) article, comprising:
providing at least one frame including at least one planar array of unidirectional coated ceramic fibers extending across a void thereof, wherein providing the at least one frame comprises:
winding one or more ceramic fibers a plurality of times over first and second fiber support members of a pair of overlapping or stacked frame portions to form two planar arrays of unidirectional ceramic fibers;
coupling the one or more ceramic fibers to at least one of the frame portions of the pair of overlapping or stacked frame portions, thereby forming a pair of overlapping or stacked frames; and
separating the pair of overlapping or stacked frames to form the at least one frame; and
impregnating the at least one planar array of unidirectional coated ceramic fibers with a slurry including a ceramic matrix precursor composition to form at least one CMC prepreg.

### Claim 2 (depends on 1)

The method of claim 1, wherein at least one of the coated ceramic fibers comprises a coated ceramic fiber tow.

### Claim 3 (depends on 1)

The method of claim 1, wherein at least one of the coated ceramic fibers comprises a non-bundled coated ceramic filament.

### Claim 4 (depends on 1)

The method of claim 1, wherein the coated ceramic fibers include at least one continuous coated ceramic fiber that extends across the void a plurality of times.

### Claim 5 (depends on 1)

The method of claim 1, wherein the coated ceramic fibers include at least one discrete coated ceramic fiber that extends once across the void.

### Claim 6 (depends on 1)

The method of claim 1, wherein the coated ceramic fibers comprise ceramic fibers and a coating disposed on the ceramic fibers, and wherein the ceramic fibers comprise SiC.

### Claim 7 (depends on 6)

The method of claim 6, wherein the coating comprises at least one layer including boron nitride, silicon-doped boron nitride, carbon, silicon carbide or silicon nitride.

### Claim 8 (depends on 1)

The method of claim 1, wherein providing the at least one frame further comprises coating the one or more ceramic fibers to form the coated ceramic fibers before the winding step.

### Claim 9 (depends on 1)

The method of claim 1, wherein impregnating the planar array comprises removing the planar array from at least a portion of the at least one frame and impregnating the removed planar array with the slurry.

### Claim 10 (depends on 1)

The method of claim 1, wherein impregnating the planar array comprises impregnating at least a portion of the planar array coupled to the frame, with the slurry.

### Claim 11

A method of processing ceramic fiber for the manufacture of a ceramic matrix composite (CMC) article, comprising:
providing at least one frame including at least one planar array of unidirectional coated ceramic fibers extending across a void thereof, wherein providing the at least one frame comprises:
winding one or more ceramic fibers a plurality of times over first and second fiber support members of a pair of overlapping or stacked lower frame portions to form two planar arrays of unidirectional fibers;
coupling a corresponding upper frame portion to each of the overlapping or stacked lower frame portions such that the one or more ceramic fibers are coupled between the upper frame portions and the lower frame portions, thereby forming a pair of overlapping or stacked frames; and
separating the pair of overlapping or stacked frames to form the at least one frame; and
impregnating the at least one planar array of unidirectional coated ceramic fibers with a slurry including a ceramic matrix precursor composition to form at least one CMC prepreg.