A unitary deflection member. The unitary deflection member can have a fluid pervious reinforcing member and a patterned framework. The patterned framework can have a plurality of regularly spaced protuberances extending from the reinforcing member. At least two of said protuberances can be similar in size and shape, and can have linear segments having different cross-sectional areas along the z-direction.

A seamless unitary deflection member. The seamless unitary deflection member can have a backside defining an X-Y plane and a thickness in a Z-direction. The seamless unitary deflection member may also have a reinforcing member and a plurality of protuberances positioned on the reinforcing member. Each protuberance may have a three-dimensional shape such that any cross-sectional area of the protuberance parallel to the X-Y plane can have 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.

A unitary deflection member. The unitary deflection member can have a fluid pervious reinforcing member and a patterned framework. The patterned framework can have a plurality of regularly spaced protuberances extending from the reinforcing member. At least two of said protuberances can be similar in size and shape, and can have linear segments having different cross-sectional areas along the z-direction.

A deflection member that includes a reinforcing member and a plurality of tiles fastened to the reinforcing member.

A seamless unitary deflection member. The seamless unitary deflection member can have a backside defining an X-Y plane and a thickness in a Z-direction. The seamless unitary deflection member may also have a reinforcing member and a plurality of protuberances positioned on the reinforcing member. Each protuberance may have a three-dimensional shape such that any cross-sectional area of the protuberance parallel to the X-Y plane can have 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.

A method for manufacturing a deflection member is disclosed. The method may include the step of incorporating a monomer, a photoinitiator system, a photoinhibitor, and/or a reinforcing member. A further step includes blending the monomer, photoinitiator, and/or photoinhibitor to form a blended photopolymer resin. Further steps may be exposing the photopolymer resin to radiation form a first radiation source and/or a second radiation source.

A process for foam forming tissue or paper webs is disclosed. A foamed suspension of fibers is deposited onto a forming fabric and contacted with a gas flow prior to drying the web. For instance, the web can contact the gas flow prior to dewatering the web. The gas flow can have a volumetric flow rate and/or a velocity sufficient to rearrange the fibers within the web. In one embodiment, for instance, the gas flow can increase the caliper of the web, the stretch properties of the web, and/or the absorbency characteristics of the web. In one embodiment, the gas flow can be pulsed for producing a web with a distinctive pattern.

A method for manufacturing a deflection member is disclosed. The method may include the steps of: providing an additive manufacturing apparatus that comprises at least one radiation source and a vat comprising a photopolymer resin, providing a reinforcing member comprising a first surface and a second surface that is opposite the first surface, contacting at least the second surface of the reinforcing member with the photopolymer resin, and directing radiation from a first radiation source and a second radiation source toward the first surface of the reinforcing member.

A unitary deflection member. The unitary deflection member can have a fluid pervious reinforcing member and a patterned framework. The patterned framework can have a plurality of regularly spaced protuberances extending from the reinforcing member. At least two of said protuberances can be similar in size and shape, and each protuberance can have a transition portion having a transition portion width and a forming portion having a forming portion width. The transition portion width can be less than the forming portion width.

A seamless unitary deflection member. The seamless unitary deflection member can have a backside defining an X-Y plane and a thickness in a Z-direction. The seamless unitary deflection member may also have a reinforcing member and a plurality of protuberances positioned on the reinforcing member. Each protuberance may have a three-dimensional shape such that any cross-sectional area of the protuberance parallel to the X-Y plane can have 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.