Apparatus and Method for Making Preforms in Mold

Abstract

Apparatus and a method of preparing fiber preforms disperses fibers and binder on a forming support surface such that the materials are conditioned and then applied to the surface where the composite material solidifies. Reinforcing material, such as fiber, is mixed with binder, such as thermoplastic or thermoset materials, so that the materials adhere. Then, the adhesive mixture is dispersed in a controlled predetermined weight ratio on the support surface where the mixture sticks to the support surface, cools and solidifies. The deposited mixture can be an open mat having interstices between fibers. The deposited mixture can also be shaped further into a final desired shape before complete solidification. This method eliminates the need for solvents and their associated problems. The process does not require a vacuum or plenum system to hold the reinforcing material in place. The preform can be made in any shape, including sections or asymmetric configurations and remain in mold while being processed to a composite molded article.

1 - 24 . (canceled) 
   
   
       25 . A method of making a preform for use in forming a structural part, comprising:
 providing a stream of fibrous reinforcing material;   adhering particulate binder material to the reinforcing material by combining a stream of binder material to the stream of fibrous reinforcing material in a venturi device to form an adhesive mixture; and   applying the adhesive mixture of the reinforcing material and the binder material from said venturi through a heating zone and against a support surface, optionally applying a stream of gaseous cooling media to the material sprayed on said surface, such that the mixture adheres to the support surface, and solidifies into the preform.   
   
   
       26 . The method of  claim 25 , wherein said applying said adhesive mixture comprises spraying and said method includes applying said stream of gaseous cooling media by passing a cooling air curtain over the adhesive mixture sprayed on the support surface. 
   
   
       27 . The method of  claim 26 , wherein said spraying and said cooling occur in the absence of a plenum system applied about or to the support surface. 
   
   
       28 . The method of  claim 25 , wherein adhering binder material to the reinforcing material includes conditioning the binder material with heat and forcing the conditioned binder material into the stream of reinforcing material. 
   
   
       29 . The method of  claim 26 , wherein said spraying includes creating a heating zone and feeding the adhesive mixture through the heat zone. 
   
   
       30 . The method of  claim 28 , wherein providing a stream of fibrous material includes blowing chopped fiberglass. 
   
   
       31 . The method of  claim 26 , wherein spraying the adhesive mixture includes spraying the mixture onto a vertical support surface. 
   
   
       32 . The method of  claim 26 , wherein spraying the adhesive mixture includes spraying the mixture onto a solid surface. 
   
   
       33 . The method of  claim 26 , wherein spraying the adhesive mixture includes spraying the mixture onto a perforated surface. 
   
   
       34 . The method of  claim 26 , wherein spraying the adhesive mixture includes spraying the mixture onto the support surface under ambient air conditions. 
   
   
       35 - 47 . (canceled)