# US 2019/0169724 A1 · Systems and methods for manufacturing prepreg tapes > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2019/0169724 A1 - Document ID: US20190169724A1 - Status: Published application - Kind: A1 - Application number: 15/829,484 - Filed: 2017-12-01 - Published: 2019-06-06 - Earliest claimed: 2017-12-01 - Assignees: General Electric Company - Applicants: General Electric Company - Inventors: Dennis Joseph Coyle; Henry Charles McGuigan; Krishnan Balaji Thattai Parthasarathy; Matthew Hockemeyer; Daniel Gene Dunn - Web page: https://patentgrep.com/patent/US20190169724A1 ## CPC - C22C 47/064: {Winding wires} - B28B 1/42: using mixtures containing fibres, e.g. for making sheets by slitting the wound layer - B29B 15/12: of reinforcements of indefinite length - B29C 70/443: {and impregnating by vacuum or injection} - B29C 70/543: {Fixing the position or configuration of fibrous reinforcements before or during moulding (for non-woven fabrics D04H3/08)} - B32B 18/00: Layered products essentially comprising ceramics, e.g. refractory products - C08J 5/10: characterised by the additives used in the polymer mixture - C08J 5/248: {using pre-treated fibres} - C22C 47/14: by powder metallurgy, i.e. by processing mixtures of metal powder and fibres or filaments - B28B 1/40: by wrapping, e.g. winding - B28B 23/0006: {the reinforcement consisting of aligned, non-metal reinforcing elements} - B29C 37/0075: {using release sheets} - C04B 35/62868: {Boron nitride} - C04B 35/62871: {Silicon nitride} - C04B 35/62894: {with more than one coating layer} - C04B 2235/5268: Orientation of the fibers - C04B 2235/6025: Tape casting, e.g. with a doctor blade - C04B 2235/6028: Shaping around a core which is removed later - C04B 2235/616: Liquid infiltration of green bodies or pre-forms - C04B 2237/38: Fiber or whisker reinforced - C22C: ALLOYS (treatment of alloys C21D, C22F) - B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B) - B29B: PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29) - 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 ## Abstract Systems and methods for manufacturing unidirectional fiber prepreg tapes for CMC articles are provided. In one exemplary aspect, the method includes casting a matrix material on a carrier film to form a matrix film. The matrix material of the matrix film is then allowed to dry for a predetermined time. The matrix film is then wrapped on a drum and the matrix material is wet to a predetermined viscosity with a solvent. Thereafter, a fiber tow that includes of a plurality of fibers is wound about the drum so that the fiber tow penetrates into the matrix material and the matrix material impregnates the fiber tow to form the prepreg tape. ## Claims ### Claim 1 A method for manufacturing a prepreg tape, the method comprising: winding a fiber tow comprised of a plurality of fibers about a drum so that the fiber tow penetrates into a matrix material of a matrix film disposed on the drum and so that the matrix material impregnates the fiber tow to form the prepreg tape, wherein during winding, the matrix material has a predetermined viscosity. ### Claim 2 (depends on 1) The method of claim 1, further comprising: casting a matrix material on a carrier film to form the matrix film; and drying the matrix material of the matrix film for a predetermined time. ### Claim 3 (depends on 2) The method of claim 2, wherein during casting, the matrix material is cast on the carrier film while on the drum. ### Claim 4 (depends on 2) The method of claim 2, wherein during drying, the matrix material is dried to the predetermined viscosity. ### Claim 5 (depends on 1) The method of claim 1, wherein the method further comprises: wetting the matrix material of the matrix film to the predetermined viscosity with a solvent. ### Claim 6 (depends on 1) The method of claim 1, further comprising: drying the prepreg tape for a predetermined time. ### Claim 7 (depends on 6) The method of claim 6, further comprising: compacting the prepreg tape. ### Claim 8 (depends on 6) The method of claim 6, further comprising: casting a second matrix material on a cover film to form a cover film laminate; covering the prepreg tape with the cover film laminate to form a prepreg laminate; and compacting the prepreg laminate. ### Claim 9 (depends on 8) The method of claim 8, wherein prior to covering, the method further comprises: drying the second matrix material of the cover film laminate for a predetermined time; and wetting the second matrix material of the cover film laminate. ### Claim 10 (depends on 1) The method of claim 1, further comprises: covering the prepreg tape with a cover film to form a prepreg laminate; and compacting the prepreg laminate. ### Claim 11 (depends on 1) The method of claim 1, further comprising: casting a second matrix material on the matrix material of the prepreg tape; drying the second matrix material for a predetermined time; covering the prepreg tape with a cover film to form a prepreg laminate; and compacting the prepreg laminate. ### Claim 12 (depends on 1) The method of claim 1, wherein prior to winding the fiber tow on the drum, the method further comprises: wetting the fiber tow. ### Claim 13 (depends on 12) The method of claim 12, wherein the fiber tow is wet with a solvent. ### Claim 14 (depends on 12) The method of claim 12, wherein wetting the fiber tow comprises impregnating the fiber tow with a slurry comprised of one or more solvents and an organic binder and at least one of a ceramic precursor and a ceramic powder. ### Claim 15 (depends on 1) The method of claim 1, wherein during winding, the method further comprises: compacting the fiber tow into the matrix material of the matrix film. ### Claim 16 (depends on 1) The method of claim 1, wherein the predetermined viscosity of the matrix material of the matrix film is high enough to prevent the plurality of fibers from bunching on the drum during winding and low enough to allow the matrix material to penetrate about each of the plurality of fibers of the fiber tow. ### Claim 17 A system for manufacturing a prepreg tape, the system comprising: a casting system for casting a matrix material on a carrier film to form a matrix film; and a winding system, comprising: a drum rotatable about an axis and operatively configured to be wrapped with the matrix film; a wetting apparatus for wetting the matrix material of the matrix film such that the material has a predetermined viscosity; a reinforcement drum for supplying a fiber tow comprised of a plurality of fibers to the drum, and wherein, when the fiber tow is supplied to the drum, the fiber tow is wound about the drum so that the fiber tow penetrates into the matrix material of the matrix film wrapped on the drum and the matrix material impregnates the fiber tow to form the prepreg tape. ### Claim 18 (depends on 17) The system of claim 17, further comprising: a roller positioned proximate the drum for compacting the fiber tow into the matrix material during winding of the fiber tow about the drum. ### Claim 19 A method for manufacturing a prepreg tape, the method comprising: casting a matrix material on a carrier film to form a matrix film; drying the matrix material of the matrix film for a predetermined time; wetting the matrix material of the matrix film to a predetermined viscosity with a solvent; winding a fiber tow comprised of a plurality of fibers about the drum so that the fiber tow penetrates into the matrix material and the matrix material impregnates the fiber tow to form the prepreg tape; drying the prepreg tape for a predetermined time; covering the prepreg tape with a cover film to form a prepreg laminate; and compacting the prepreg laminate. ### Claim 20 (depends on 19) The method of claim 19, wherein prior to or during winding, the method further comprises: applying heat to the matrix film to soften the matrix material of the matrix film.