NONWOVEN WEB WITH PROJECTIONS

Nonwoven web and method of making including interbonded thermoplastic fibers in an array of hollow projections extending outwardly from at least one surface of said web. The projections are separated by land areas of interbonded fibers, and the fiber orientation is greater in the projections than in the land areas. Either the projections or the land areas may be perforated as desired for controlled porosity and fluid flow properties. The nonwoven webs of the invention may be made by a number of processes but, preferably, are made by forming directly on a surface with corresponding projections with or without apertures and a vacuum assist or by forming on an apertured surface with a pressure differential sufficient to draw the fibers through the apertures forming the projections. The disclosure includes such webs with added fiber layers and as components of a wide variety of products including personal care items such as liners for sanitary napkins, household products such as cleaning materials and wipers, in the service product area such as towels, washcloths and bathmats, in the marine and automotive area as scrubbing and protective applicators, and in the hospital and veterinary areas as wipes and dispensing cloths. The method and apparatus disclosed may be varied as to steps and configuration to impart desired web constructions and properties, and preferred embodiments are disclosed.