Method of manufacturing a foam and fiber composite

A process for manufacturing a foam and fiber composite, the process comprising the steps of:

• a. providing a foam material comprising a first planar surface and a second planar surface;
• b. providing a fluid treatment device having a pressurized fluid jet capable of emitting a pressurized fluid stream of fluid from the pressurized fluid jet in a direction towards the foam material;
• c. directing the pressurized fluid stream of fluid in a direction from the pressured fluid jet of the fluid treatment device towards the first planar surface of the foam material;
• d. after directing the pressurized fluid stream of fluid towards the first planar surface of the foam material, providing a fibrous material comprising a plurality of individual fibers and layering the fibrous material onto the first planar surface of the foam material to form a layered composite;
• e. providing a fluid insertion device having a pressurized fluid jet capable of emitting a pressurized fluid stream of fluid from the pressurized fluid jet in a direction towards the layered composite;
• and
• f. directing the pressurized fluid stream of fluid in a direction from the pressurized fluid jet of the fluid insertion device towards the fibrous material of the layered composite to cause a portion of the plurality of individual fibers of the fibrous material to be directed into the foam material to form the foam and fiber composite;
• wherein the pressure of the fluid of the pressurized fluid streams of the fluid treatment device is from 150 psi to 1000 psi.