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

1. A method for making a unitary deflection member that is utilized for making fibrous webs, the method comprising the steps of:

a. providing an additive manufacturing making apparatus;

b. providing at least one material for the unitary deflection member that is utilized for making fibrous webs, the material being compatible for use with the additive manufacturing making apparatus;

c. generating a 3-D digital image of objects in a repeat element of the unitary deflection member, the objects including at least a reinforcing member comprising a first plurality MD-oriented elements along an MD axis and a second plurality of CD-oriented elements along a CD axis, the MD and CD-oriented elements being unitary with each other and also being unitary with a plurality of regularly spaced protuberances of the unitary deflection member, such that, in cross-section, the MD and CD-oriented elements and the plurality of protuberances are a single unit not formed from separate parts, wherein the regularly spaced protuberances extend from the reinforcing member in a Z direction and at least two of said protuberances are similar in size and shape, each said protuberance having a transition portion having a transition portion width and a forming portion having a forming portion width, and wherein the transition portion width is less than the forming portion width;

d. assembling the objects into a digitized file including the at least one protuberance being on said reinforcing member;

e. importing the digitized file to make a numerical control file of the additive manufacturing making apparatus; and

f. depositing the material using the additive manufacturing making apparatus to make the unitary deflection member that is utilized for making fibrous webs.

2. The method for making a unitary deflection member of claim 1 , wherein the additive manufacturing making apparatus is a 3-D printer.

3. The method for making a unitary deflection member of claim 1 , wherein the digitized file describes a unitary deflection member having at least two of said protuberances are adjacent one another and separated by a void defining a deflection conduit.

4. The method for making a unitary deflection member of claim 1 , wherein the digitized file describes a reinforcing member defining an X-Y plane, and a plurality of regularly spaced protuberances, wherein each protuberance has a three-dimensional shape such that any cross-sectional area of the protuberance parallel to the X-Y plane has an equal or lesser area than any cross-sectional area of the protuberance being a greater distance from the X-Y plane in the Z-direction.

5. The method for making a unitary deflection member of claim 4 , 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.

6. The method for making a unitary deflection member of claim 4 , wherein the plurality of regularly spaced protuberances are disposed in a regular, spaced apart configuration of discrete units in the X-Y plane and distributed in both the MD and CD in a regular, spaced pattern.

7. A method for making a unitary deflection member that is utilized for making fibrous webs, the method comprising the steps of:

a. providing an additive manufacturing making apparatus;

b. providing at least one material for the unitary deflection member that is utilized for making fibrous webs, the material being compatible for use with the additive manufacturing making apparatus;

c. generating a 3-D digital image of objects in an element of the unitary deflection member, the objects including at least a reinforcing member comprising a first plurality MD-oriented elements along an MD axis and a second plurality of CD-oriented elements along a CD axis, the MD and CD-oriented elements being unitary with each other and also being unitary with a plurality of regularly spaced protuberances of the unitary deflection member, such that, in cross-section, the MD and CD-oriented elements and the plurality of protuberances are a single unit not formed from separate parts, wherein the regularly spaced tuberances extend from the reinforcing member in a Z-direction and at least two of said protuberances are similar in size and shape, each said protuberance having a transition portion having a transition portion width and a forming portion having a forming portion width, and wherein the transition portion width is less than the forming portion width;

d. assembling the objects into a digitized file including the at least one protuberance being on said reinforcing member;

e. importing the digitized file to make a numerical control file of the additive manufacturing making apparatus; and

f. depositing the material using the additive manufacturing making apparatus to make the unitary deflection member that is utilized for making fibrous webs.

8. The method for making a unitary deflection member of claim 7 , wherein the additive manufacturing making apparatus is a 3-D printer.

9. The method for making a unitary deflection member of claim 7 , wherein the digitized file describes a unitary deflection member having at least two of said protuberances are adjacent one another and separated by a void defining a deflection conduit.

10. The method for making a unitary deflection member of claim 7 , wherein the digitized file describes a reinforcing member defining an X-Y plane, and a plurality of regularly spaced protuberances, wherein each protuberance has a three-dimensional shape such that any cross-sectional area of the protuberance parallel to the X-Y plane has an equal or lesser area than any cross-sectional area of the protuberance being a greater distance from the X-Y plane in the Z-direction.

11. The method for making a unitary deflection member of claim 10 , 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.

12. The method for making a unitary deflection member of claim 10 , wherein the plurality of regularly spaced protuberances are disposed in a regular, spaced apart configuration of discrete units in the X-Y plane and distributed in both the MD and CD in a regular, spaced pattern.

13. A method for making a unitary deflection member that is utilized for making fibrous webs, the method comprising the steps of:

a. providing 3-D printer apparatus;

b. providing at least one material for the unitary deflection member that is utilized for making fibrous webs, the material being compatible for use with the additive manufacturing making apparatus;

c. generating a 3-D digital image of objects in an element of the unitary deflection member, the objects including at least a reinforcing member comprising a first plurality MD-oriented elements along an MD axis and a second plurality of CD-oriented elements along a CD axis, the MD and CD-oriented elements being unitary with each other and also being unitary with a plurality of regularly spaced protuberances, such that, in cross-section, the MD and CD-oriented elements and the plurality of protuberances are a single unit not formed from separate parts, wherein the regularly spaced tuberances extend from the reinforcing member in a Z direction and at least two of said protuberances are similar in size and shape;

d. assembling the objects into a digitized file including the at least one protuberance being on said reinforcing member;

e. importing the digitized file to make a numerical control file of the additive manufacturing making apparatus; and

f. depositing the material using the additive manufacturing making apparatus to make the unitary deflection member that is utilized for making fibrous webs.

14. The method for making a unitary deflection member of claim 13 , wherein the digitized file describes a unitary deflection member having at least two of said protuberances are adjacent one another and separated by a void defining a deflection conduit.

15. The method for making a unitary deflection member of claim 13 , wherein the digitized file describes a reinforcing member defining an X-Y plane, and a plurality of regularly spaced protuberances, wherein each protuberance has a three-dimensional shape such that any cross-sectional area of the protuberance parallel to the X-Y plane has an equal or lesser area than any cross-sectional area of the protuberance being a greater distance from the X-Y plane in the Z-direction.

16. The method for making a 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.

17. The method for making a 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 the X-Y plane and distributed in both the MD and CD in a regular, spaced pattern.