Methods of making absorbent members having density profile

A method of reducing the defibrization energy of wet laid pulp, said method comprising:

• a) providing a precursor web material, said precursor web material comprising a wetlaid cellulosic fibrous structure, said precursor web material having a first surface, a second surface, and a thickness;
• b) providing a pair of forming members having a machine direction orientation and a cross-machine direction orientation, said forming members comprising:
• a first forming member having a surface comprising a plurality of first forming elements, wherein said first forming elements comprise discrete male forming elements that are spaced apart in the machine direction;
• and
• a second forming member having a surface comprising a plurality of second forming elements, wherein said second forming elements comprise male forming elements;
• c) providing a third forming member having a machine direction orientation and a cross-machine direction orientation, said third forming member having a surface comprising a plurality of third forming elements, wherein said third forming elements comprise discrete male forming elements that are spaced apart in the machine direction;
• d) mechanically impacting said precursor web material by placing said precursor web material between said first and second forming members, wherein said forming elements on said first forming member penetrate into the first surface of said precursor web material at least part of the way into the thickness of said precursor web material, and said forming elements on said second forming member penetrate into the second surface of said precursor web material at least part of the way into the thickness of said precursor web material;
• and
• e) repeating a step of mechanically impacting said precursor web by mechanically impacting said precursor web material by placing said precursor web material between said third forming member and either the first forming member, the second forming member or another forming member, wherein said forming elements on said third forming member penetrate into the first or second surface of said precursor web material at least part of the way into the thickness of said precursor web material, wherein the only material that is mechanically impacted in steps d) and e) consists of wetlaid cellulosic fibrous material,
• wherein said absorbent member is provided with a density profile through at least a portion of its thickness, and
• wherein said first and second surfaces of said precursor web material comprise first and second surfaces, respectively, of said absorbent member, and said first and second surfaces of said absorbent member are substantially planar and not substantially embossed.

A method for making an absorbent member having a thickness, said method comprising:

• a) providing a precursor web material, said precursor web material comprising a wetlaid cellulosic fibrous structure having a density of between about 0.25 g/cc and about 0.6 g/cc, said precursor web material having a first surface, a second surface, and a thickness;
• b) providing a pair of forming members comprising counter-rotating rolls defining a nip therebetween, said rolls having a machine direction orientation and a cross-machine direction orientation, said rolls comprising:
• a first roll having a first surface and a first axis about which said first roll rotates, wherein said first roll comprises a plurality of ridges and grooves, wherein said ridges comprise discrete teeth that are spaced apart in the machine direction;
• and
• a second roll having a second surface and a second axis about which said second roll rotates, wherein said second roll comprises a plurality of ridges and grooves, wherein said ridges on said second roll also comprise a discrete teeth that are spaced apart in the machine direction, wherein the teeth on said first roll are aligned in between the grooves on said second roll;
• c) providing a third forming member comprising a third roll having a machine direction orientation and a cross-machine direction orientation, said third roll having a surface comprising a plurality of third forming elements, wherein said third forming elements comprise discrete male forming elements that are spaced apart in the machine direction;
• d) mechanically impacting said precursor web material by moving said web material through the nip between said first and second counter-rotating rolls, wherein said teeth on said first roll penetrate into the first surface of said precursor web material, and said teeth on said second roll penetrate into the second surface of said precursor web material;
• and
• e) repeating a step of mechanically impacting said precursor web to form an absorbent member by mechanically impacting said precursor web material by moving said precursor web material through a nip between said third roll and either the first roll, the second roll or another roll, wherein said forming elements on said third roll penetrate into the first or second surface of said precursor web material at least part of the way into the thickness of said precursor web material, wherein said absorbent member is provided with a density profile through at least a portion of its thickness,
• wherein the only material that is mechanically impacted in steps d) and e) consists of wetlaid cellulosic fibrous material, and
• wherein said first and second surfaces of said precursor web material comprise first and second surfaces, respectively, of said absorbent member, and said first and second surfaces of said absorbent member are substantially planar and not substantially embossed.

A method for making an absorbent member having a thickness, said method comprising:

• a) providing a precursor web material, said precursor web material comprising a wetlaid cellulosic fibrous structure, said precursor web material having a first surface, a second surface, and a thickness;
• b) providing a pair of forming members having a machine direction orientation and a cross-machine direction orientation, said forming members comprising:
• a first forming member having a surface comprising a plurality of first forming elements, wherein said first forming elements comprise discrete male forming elements that are spaced apart in the machine direction;
• and
• a second forming member having a surface comprising a plurality of second forming elements, wherein said second forming elements comprise male forming elements;
• c) providing a third forming member having a machine direction orientation and a cross-machine direction orientation, said third forming member having a surface comprising a plurality of third forming elements, wherein said third forming elements comprise discrete male forming elements that are spaced apart in the machine direction;
• d) mechanically impacting said precursor web material by placing said precursor web material between said first and second forming members, wherein said forming elements on said first forming member contact the first surface of said precursor web material and portions of said precursor web material bend around the forming elements on the first forming member, and said forming elements on said second forming member contact the second surface of said precursor web material and portions of said precursor web material bend around the forming elements on the second forming member;
• and
• e) repeating a step of mechanically impacting said precursor web to form an absorbent member by mechanically impacting said precursor web material by placing said precursor web material between said third forming member and either the first forming member, the second forming member or another forming member, wherein portions of said precursor web material on the first or second surface of said precursor web material bend around said forming elements on said third forming member,
• wherein the only material that is mechanically impacted in steps d) and e) consists of wetlaid cellulosic fibrous material,
• wherein said absorbent member is provided with a density profile through at least a portion of its thickness, and
• wherein said first and second surfaces of said precursor web material comprise first and second surfaces, respectively, of said absorbent member, and said first and second surfaces of said absorbent member are substantially planar and not substantially embossed.