The present invention discloses the fabrication of polymer-coated, coated
fiber composites, hybrid composites and a method and apparatus for
fabricating the same. The invention provides for the maximum spraying and
coating of a roving of coated fibers with molten polymer streams without
making physical contact with a solid media, thus simultaneously
preventing the fiber surface from getting damaged and stripping off the
coating. When metal-coated fiber is used the invention improves the
electromagnetic shielding properties of any subsequent product made from
the inventive composite. The method and apparatus of the present
invention uses sets of nozzle-type sprayers having multiple orifices to
enable the thermoplastic or thermoset polymer to penetrate more
efficiently into the fiber bundle, thereby providing a more uniform
coverage of all fibers. The hybrid composites can consist of two or more
types of reinforcements and one or more type of matrix polymer.