Fiber-bound engineered materials formed utilizing carrier screens

A method of forming a plurality of fiber-bound engineered components that can be incorporated into articles, the method comprising:

• providing a carrier screen having a plurality of apertures through which fluid can pass, the carrier screen being configured as a continuous elongated screen;
• placing a plurality of discrete fiber elements on a surface of the carrier screen at discrete spaced locations along a length of the carrier screen;
• sequentially delivering each discrete fiber element to a first station with the carrier screen;
• sequentially placing a discrete scrim on top of and in registration with each discrete fiber element at the first station to form a plurality of composite elements on the carrier screen;
• sequentially delivering each composite element to a second station with the carrier screen;
• and
• sequentially entangling the discrete fiber element and the discrete scrim of each composite element together at the second station by passing a fluid stream through the apertures of the carrier screen to form the plurality of fiber-bound engineered components.

A method of forming a plurality of fiber-bound engineered components that can be incorporated into articles, the method comprising:

• providing a carrier screen having a plurality of apertures through which fluid can pass, the carrier screen being configured as a continuous elongated screen;
• placing a plurality of first discrete fiber elements on a surface of the carrier screen at discrete spaced locations along a length of the carrier screen;
• sequentially delivering each first discrete fiber element to a first station with the carrier screen;
• sequentially placing a discrete fluid-impervious scrim on top of and in registration with each first discrete fiber element at the first station to form a plurality of first composite elements on the carrier screen;
• sequentially delivering each first composite element to a second station with the carrier screen;
• sequentially placing a second discrete fiber element on top of and in registration with each first discrete fiber element to form a plurality of second composite elements on the carrier screen at the second station, each second composite element including a discrete fluid-impervious scrim positioned between the two discrete fiber elements;
• sequentially delivering each second composite element to a third station with the carrier screen;
• and
• sequentially entangling the first and second discrete fiber elements of each second composite element together at the third station by passing a fluid stream through the apertures of the carrier screen to form the plurality of fiber-bound engineered components, each fiber-bound engineered component having a discrete fluid-impervious scrim encased between two discrete fiber elements.