Abstract: Disclosed herein is an apparatus of the type for forming a nonwoven web from a fiber forming thermoplastic polymer resin which includes a reservoir for supplying a quantity of melted fiber forming thermoplastic resin, a pump for pumping the molten resin to a fiber forming die, and a die for forming a discrete resin stream to flow therefrom. The die includes a first fluid passageway for forming a stream of fluid, such as air, in contact with and substantially surrounding the formed flow of resin for a predetermined distance within the die and a fluid interrupt system for selectively cycling the flow of resin on and off and clearing the resin from the fiber forming die. A receiving belt collects the fibers formed from the resin flow beyond the first fluid passageway spaced at a predetermined distance from the die.

Abstract: 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.