Fibrous Nonwoven Web with Uniform, Directionally-Oriented Projections and a Process and Apparatus for Making the Same

Abstract

A process and apparatus is used for making a fibrous nonwoven web with uniform, directionally-oriented projections by depositing fibrous material onto a first forming surface with holes positioned above a second forming surface with both forming surfaces traveling at different speeds to one another. As the fibers are deposited onto the first forming surface, a portion of the fibers are drawn down into the holes of the first forming surface forming the projections which contact the second forming surface. Due to the speed differential between the two forming surfaces the projections are uniformly skewed in the same direction. The resultant material is particularly suited for use as a wiping material which can be more abrasive in one direction but which is softer to the touch when wiped in the opposite direction thus making it a dual purpose material.

1 - 18 . (canceled) 
     
     
         19 . A fibrous nonwoven web having a textured surface comprising:
 a coherent web of fibers, said nonwoven web having a top surface, an opposed bottom surface, a length, a width and a thickness;   a plurality of fibrous projections emanating from said top surface of said web, said projections being integrally formed from said web and comprise said fibers;   said projections have a base portion and a head portion connected to said base portion and wherein said head portion is skewed relative to said base portion thereby forming an overhang and further wherein said projections are directionally-oriented being skewed in a uniform direction.   
     
     
         20 . The fibrous nonwoven web of  claim 19  wherein said plurality of fibrous projections form a pattern. 
     
     
         21 . The fibrous nonwoven web of  claim 19  wherein said fibers comprise thermoplastic fibers. 
     
     
         22 . The fibrous nonwoven web of  claim 19  wherein said web comprises a stabilized matrix of thermoplastic fibers and a secondary fibrous material selected from the group consisting of woody pulp, non-woody pulp, rayon, superabsorbent and treated staple fibers. 
     
     
         23 . The fibrous nonwoven web of  claim 19  wherein said web comprises a stabilized matrix of thermoplastic fibers and a secondary fibrous material selected from the group consisting of softwood pulp fibers, hardwood pulp fibers and rayon fibers. 
     
     
         24 . The fibrous nonwoven web of  claim 19  wherein said web comprises a nonwoven web selected from the group consisting of meltblown fiber webs, spunbond fiber webs, and carded staple fiber webs. 
     
     
         25 . The fibrous nonwoven web of  claim 19  wherein said web has a knap on said top surface due to said fibrous projections such that it is smoother to the touch when engaged in one direction as opposed to the opposite direction. 
     
     
         26 . The fibrous nonwoven web of  claim 19  wherein the base portion of said fibrous projections each have a vertical axis generally perpendicular to a plane formed by said top surface of said web, said vertical axis being located at a position in said base portion such that said base portion has a lateral dimension that is equally spaced on either side of said vertical axis, said head portion of said projection being asymmetrically located relative to said base portion and said vertical axis such that said head portion has a lateral dimension which is skewed with respect to said vertical axis so that more of said head portion is located on one side of said vertical axis than said base portion when viewing said head portion and said base portion from the same position. 
     
     
         27 . The fibrous nonwoven web of  claim 19  wherein the fibrous projections are resilient. 
     
     
         28 . The fibrous nonwoven web of  claim 27  wherein said fibrous projections have a height between about 0.25 mm and about 9 mm. 
     
     
         29 . The fibrous nonwoven web of  claim 27  wherein said fibrous projections have a height between about 0.5 mm and about 3 mm. 
     
     
         30 . A wipe comprising the fibrous nonwoven web of  claim 27 . 
     
     
         31 . A wet wipe comprising the fibrous nonwoven web of  claim 27  and wherein said web contains a liquid cleaning solution. 
     
     
         32 . The wet wipe of  claim 31  wherein said web contains said cleaning solution in an amount from about 150 to about 600 wt. % based on the dry weight of the nonwoven web. 
     
     
         33 . A personal care absorbent article comprising the fibrous nonwoven web of  claim 27 . 
     
     
         34 . The personal care absorbent article of  claim 33  wherein said absorbent article comprises a body side liner and a garment-facing sheet with an absorbent core disposed between said body side liner and said garment facing sheet, and further wherein said body side liner comprises said fibrous nonwoven web having said fibrous projections emanating therefrom. 
     
     
         35 . The personal care absorbent article of  claim 34  wherein the fibrous projections of said fibrous nonwoven web face outwardly so as to form a body contacting surface of said body-side liner.