Method of forming a preform by precoating glass fibers prior to chopping and preforming

A process of manufacturing a preform comprising the steps of:

• providing an unchopped glass fiber roving from a supply source, into a tank, through cooling air from a cooling source and to a chopper, said unchopped glass fiber roving is continuously and axially moved along its length;
• coating the unchopped glass fiber roving with a curable liquid binder material along its length as it axially moves into a tank of liquified thermoplastic binder and submerging the roving in the binder and subsequently withdrawing said roving from said tank;
• solidifying the curable liquid binder material coating on said unchopped glass fiber roving as it axially moves through said cooling air;
• thereafter chopping the binder coated glass fiber roving into binder coated chopped fibers as it axially moves through said chopper;
• providing a gaseous flow and a preform screen;
• combining said binder coated chopped fibers with said gaseous flow and directing said chopper fibers from said chopper and said gaseous flow against the preform screen for depositing the binder coated chopped fibers onto the preform screen;
• retaining said binder coated chopped fibers on said preform screen to form a preform shaped to the form of said preform screen;
• and
• curing said preform by applying heat to said binder coated chopped fibers to tackify said binder material on said binder coated chopped fibers after deposition of said binder coated chopped fibers onto said preform screen, thereafter cooling said binder coated chopped fibers to solidify said binder material to bind the binder coated chopped fibers together to form a cured preform on said preform screen.