Seamless unitary deflection member for making fibrous structures having increased surface area and process for making same

1. A seamless unitary deflection member, the seamless unitary deflection member being a seamless belt and having a backside defining an X-Y plane and a thickness in a Z-direction, and further comprising a reinforcing member and a plurality of protuberances extending from and having the same material as the reinforcing member, such that, in cross-section, the plurality of protuberances are a single unit with the reinforcing member not formed from separate parts, wherein each protuberance has a three-dimensional shape such that at least one cross-sectional area of the protuberance parallel to the X-Y plane has a lesser area than any cross-sectional area of the protuberance being a greater distance from the X-Y plane in the Z-direction.

2. The deflection member of claim 1 , wherein the at least two of said protuberances are adjacent one another and separated by a void defining a deflection conduit.

3. The deflection member of claim 1 , wherein said plurality of regularly spaced protuberances are linear segments spaced apart in either the MD or CD.

4. The deflection member of claim 1 , wherein said plurality of regularly spaced protuberances are generally parallel linear segments oriented predominantly in the MD or CD.

5. The deflection member of claim 1 , wherein said plurality of regularly spaced protuberances are linear segments, the linear segments having a cross-sectional shape, the cross-sectional shape being selected from smooth rounded, pointed, ridged, and stepped, multilevel.

6. The deflection member of claim 1 , wherein said plurality of regularly spaced protuberances are linear segments, the linear segments having a cross-sectional shape, the cross-sectional shape being selected from key-hole-shaped, mushroom-shaped, circular, oval, inverted triangle, T-shaped, inverted L-shaped, egg- or pebble-shaped and combinations thereof.

7. The deflection member of claim 1 , wherein the plurality of regularly spaced protuberances are disposed in a regular, spaced apart configuration of discrete units in an X-Y plane and distributed in both the MD and CD in a regular, spaced pattern.

8. The deflection member of claim 1 , wherein the plurality of regularly spaced protuberances are discrete units disposed in a regular, spaced apart configuration in both the MD and CD, each discrete unit having a cross-sectional shape, the cross-sectional shape being selected from smooth rounded, pointed, ridged, and stepped, multilevel.

9. The deflection member of claim 1 , wherein said plurality of regularly spaced protuberances are discrete units disposed in a regular, spaced apart configuration in both the MD and CD, each discrete unit having a cross-sectional shape, the cross-sectional shape being selected from key-hole-shaped, mushroom-shaped, circular, oval, inverted triangle, T-shaped, inverted L-shaped, egg- or pebble-shaped and combinations thereof.

10. The deflection member of claim 1 , wherein the framework is a semi-continuous framework.

11. The deflection member of claim 1 , wherein at least two of the plurality of regularly spaced protuberances are substantially identical in size and shape.

12. A seamless belt unitary deflection member comprising a reinforcing member and a plurality of protuberances extending from the reinforcing member and having the same material as the reinforcing member, such that, in cross-section, the plurality of protuberances are a single unit with the reinforcing member not formed from separate parts.

13. The seamless belt seamless unitary deflection member of claim 12 , the seamless unitary deflection member having a patterned framework comprising a plurality of regularly spaced protuberances extending from the reinforcing member.

14. The seamless belt seamless unitary deflection member of claim 12 , wherein the at least two of the plurality of protuberances are adjacent one another and separated by a void defining a deflection conduit.

15. The seamless belt seamless unitary deflection member of claim 13 , wherein the plurality of regularly spaced protuberances are linear segments spaced apart in either the MD or CD.

16. The seamless belt seamless unitary deflection member of claim 13 , wherein the plurality of regularly spaced protuberances are generally parallel linear segments oriented predominantly in the MD or CD.

17. The seamless belt seamless unitary deflection member of claim 13 , wherein the plurality of regularly spaced protuberances are linear segments, the linear segments having a cross-sectional shape, the cross-sectional shape being selected from key-hole-shaped, mushroom-shaped, circular, oval, inverted triangle, T-shaped, inverted L-shaped, egg- or pebble-shaped and combinations thereof.

18. The seamless belt seamless unitary deflection member of claim 13 , wherein the plurality of regularly spaced protuberances are disposed in a regular, spaced apart configuration of discrete units in an X-Y plane and distributed in both the MD and CD in a regular, spaced pattern.

19. The seamless belt seamless unitary deflection member of claim 13 , wherein the plurality of regularly spaced protuberances are discrete units disposed in a regular, spaced apart configuration in both the MD and CD, each discrete unit having a cross-sectional shape, the cross-sectional shape being selected from key-hole-shaped, mushroom-shaped, circular, oval, inverted triangle, T-shaped, inverted L-shaped, egg- or pebble-shaped, and combinations thereof.

20. The seamless belt seamless unitary deflection member of claim 13 , wherein the patterned framework is a semi-continuous framework.