Method and apparatus for deforming a web

Abstract

Methods and apparatuses for deforming a web are disclosed. In one embodiment, the method involves feeding a web into a nip that is formed between at least two intermeshing rolls. The rolls are configured for deforming a web with at least two sets of deformations that are oriented in different directions relative to the surfaces of the web.

What is claimed is: 
     
         1 . A nonwoven web comprising:
 a first side and a second side;   land areas having a web density;   formed discrete first protrusions disposed in a plurality of spaced apart first locations, wherein at least a portion of the formed discrete first protrusions has a density that is permanently altered to be different than the web density in response to an applied stress or strain; and   formed discrete second protrusions disposed in a plurality of spaced apart second locations that are different locations than the first locations, such that the second protrusions are distributed between the first protrusions, with respect to an X-Y dimension in a plane of the web, wherein at least a portion of the formed discrete second protrusions has a density that is permanently altered to be different than the web density in response to an applied stress or strain;   apertures defined at distal ends of the formed discrete second protrusions; and   wherein the first protrusions extend out from a first side of the web and the second protrusions extend out from a second side of the web.   
     
     
         2 . The nonwoven web of  claim 1 , wherein the first protrusions and the second protrusions have different shapes when taken from a plan view. 
     
     
         3 . The nonwoven web of  claim 1 , wherein the first protrusions and the second protrusions have different sizes. 
     
     
         4 . The nonwoven web of  claim 1 , wherein the first protrusions and the second protrusions have different aspect ratios. 
     
     
         5 . The nonwoven web of  claim 1 , wherein the first protrusions and the second protrusions have different spacings. 
     
     
         6 . The nonwoven web of  claim 1 , wherein the first protrusions and the second protrusions have different heights. 
     
     
         7 . The nonwoven web of  claim 1 , wherein the first protrusions are dome-shaped. 
     
     
         8 . The nonwoven web of  claim 1 , wherein the second protrusions are volcano-shaped. 
     
     
         9 . The nonwoven web of  claim 1 , wherein a center-to-center spacing between the first and the second protrusions is less than or equal to 10 millimeters. 
     
     
         10 . The nonwoven web of  claim 1 , wherein a center-to-center spacing between the first and the second protrusions is less than or equal to 5 millimeters. 
     
     
         11 . The nonwoven web of  claim 1 , wherein, for at least a portion of the web, the total number of protrusions is 4-100 protrusions per square inch. 
     
     
         12 . The nonwoven web of  claim 1 , wherein, for at least a portion of the web, the total number of protrusions is 4-25 protrusions per square inch. 
     
     
         13 . A nonwoven web comprising:
 a first side and a second side;   land areas having a web density;   formed discrete first protrusions disposed in a plurality of spaced apart first locations, wherein at least a portion of the formed discrete first protrusions has a density that is permanently altered to be different than the web density in response to an applied stress or strain;   formed discrete second protrusions disposed in a plurality of spaced apart second locations that are different locations than the first locations, such that the second protrusions are distributed between the first protrusions, with respect to an X-Y dimension in a plane of the web, wherein at least a portion of the formed discrete second protrusions has a density that is permanently altered to be different than the web density in response to an applied stress or strain;   apertures defined at distal ends of the formed discrete second protrusions;   wherein the first protrusions extend out from a first side of the web and the second protrusions extend out from a second side of the web; and   wherein the first protrusions are dome-shaped.   
     
     
         14 . The nonwoven web of  claim 13 , wherein the second protrusions are volcano-shaped. 
     
     
         15 . The nonwoven web of  claim 13 , wherein the first protrusions and the second protrusions have different shapes when taken from a plan view. 
     
     
         16 . The nonwoven web of  claim 13 , wherein the first protrusions and the second protrusions have different sizes or different aspect ratios. 
     
     
         17 . The nonwoven web of  claim 13 , wherein the first protrusions and the second protrusions have different spacings or different heights. 
     
     
         18 . The nonwoven web of  claim 13 , wherein a center-to-center spacing between the first and the second protrusions is less than or equal to 10 millimeters. 
     
     
         19 . The nonwoven web of  claim 13 , wherein a center-to-center spacing between the first and the second protrusions is less than or equal to 5 millimeters. 
     
     
         20 . The nonwoven web of  claim 13 , wherein, for at least a portion of the web, the total number of protrusions is 4-100 protrusions per square inch.