Patent ID: 8871123

Claim:
A method of making an absorbent core structure for a sanitary article comprising the steps of: providing fibrous pulp; maintaining the fibrous pulp in a chamber; mounting a mold to a rotating forming drum, the mold having: i) a first porous portion; ii) a nonporous mounting plate portion surrounding the first porous portion, the nonporous mounting plate having a height; and iii) a plurality of nonporous projections, the plurality of nonporous projections having a height that is less than the height of the mounting plate portion for receiving less fibrous pulp than the first porous portion; rotating the mold on the rotating forming drum until the mold is arranged in communication with the chamber; drawing the fibrous pulp into the mold to thereby form a core having a plurality of first regions and a second region, each one of said first regions being arranged in spaced relationship from each of the other first regions and each of the first regions being entirely surrounded by the second region, the mold being adapted so that each of the plurality of first regions has a basis weight and the second region has a basis weight that is different than the basis weight of each of the first regions; and each of the plurality of nonporous projections being in the shape of one of the plurality of first regions; expelling the core structure from the mold; and conveying the core structure through a calendar roll to compress the core structure until the plurality of first regions and second region have a uniform thickness to thereby provide a core structure wherein the plurality of first regions and second region have different basis weights but a uniform thickness.