Method and system for coating a substrate with a reinforced resin matrix

An apparatus for applying a coating of a reinforced resin matrix to a substrate, comprising:

• a. a spray nozzle for directing liquid resin toward the substrate, said nozzle having
• i. an orifice located substantially in the center of said nozzle,
• ii. a plurality of atomizing holes circumferentially disposed around said orifice for atomizing liquid resin after exiting said orifice
• iii. a plurality of shaping holes circumferentially disposed around said orifice at a greater distance from said orifice than said atomizing holes for controlling the spray pattern of said liquid resin
• wherein separate gas lines are connected to said atomizing holes and said shaping holes;
• b. a means for introducing said liquid resin to said nozzle, said means for introducing having a first end, a second end, and an axis which intersects said first end and said second end, wherein said nozzle is connected to said first end of said means for introducing;
• c. an outer housing located coaxial with and circumferentially disposed around said means for introducing said liquid so as to form a cavity between said means for introducing said liquid and said outer housing, said housing having an open end and a closed end, with said open end of said outer housing being located near said first end of said means for introducing said liquid resin, wherein said outer housing is capable of delivering reinforcing material to said liquid resin after said liquid resin exits said nozzle;
• d. a means for introducing said reinforcing material to said outer housing;
• and
• e. an air disc forming said closed end of said outer housing thereby closing said cavity at said second end of said means for introducing said liquid resin, said air disc having gas holes capable of introducing sufficient gas to said cavity to suspend reinforcing material and carry said reinforcing material toward the substrate, past said nozzle, in a flow path parallel to said axis of said means for introducing said liquid resin.