Methods for foam-forming a multi-layer absorbent substrate and such absorbent substrates

A method for foam forming a multi-layer substrate, the method comprising:

• providing a first foam supply, the first foam supply comprising a first supply of fibers;
• providing a second foam supply;
• providing a supply of particulates;
• providing a headbox, the headbox including a first z-directional layer and a second z-directional layer;
• providing a forming surface;
• providing a dewatering system;
• transferring the first foam supply including the first supply of fibers to the first z-directional layer of the headbox;
• transferring the second foam supply and the supply of particulates to the second z-directional layer of the headbox;
• transferring the first supply of fibers from the first foam supply, the second foam supply, and the supply of particulates through an outlet of the headbox to the forming surface to form a resultant slurry, the resultant slurry being configured such that the first supply of fibers are directly against the forming surface;
• and
• dewatering the resultant slurry such that the first supply of fibers forms a containment layer directly against the forming surface, the containment layer comprising at least one of a thickness from about 0.10 mm to about 1.00 mm and a basis weight of between about 5 gsm to about 50 gsm.

A substrate comprising:

• a containment layer comprising a first plurality of fibers, the containment layer comprising at least one of a thickness of between about 0.10 mm to about 1.00 mm and a basis weight of between about 5 gsm to about 50 gsm;
• and
• an absorbent layer comprising a second plurality of fibers and a plurality of particulates, the second plurality of fibers comprising absorbent fibers;
• wherein the containment layer and the absorbent layer provide an integrated material including an interface between the containment layer and the absorbent layer, the interface including at least some of the first plurality of fibers of the containment layer being mixed with at least some of the second plurality of fibers of the absorbent layer.