Method of making nonwoven material having discrete three-dimensional deformations with wide base openings

A method of forming deformations in a nonwoven web, the method comprising the steps of:

• a) providing a precursor nonwoven web, the precursor web comprising a nonwoven material comprising fibers, the precursor web having a first surface, a second surface, thermal point bonds, and a thickness;
• b) providing a pair of forming members having a machine direction orientation and a cross-machine direction orientation, the forming members comprising:
• a first forming member having a surface comprising a plurality of discrete, spaced apart male forming elements having a base that is joined to the surface of the first forming member, a top that is spaced away from the base, and sides that extend between the base and the top of the male forming elements, wherein the male elements have a plan view periphery, and a height;
• and
• a second forming member having a surface comprising a plurality of recesses in the second forming member, wherein the recesses are aligned and configured to receive the male forming elements therein, wherein the recesses have a plan view periphery that is larger than, and completely surrounds, the plan view periphery of the male elements, and the recesses have a depth;
• c) placing the precursor nonwoven web between the forming members, wherein the second surface of the precursor nonwoven web is placed in contact with the first forming member, and mechanically deforming the precursor nonwoven web with the forming members, wherein the precursor nonwoven web is formed into a nonwoven web comprising a generally planar first region and a plurality of discrete integral second regions that comprise deformations, the deformations forming protrusions extending outward from the first surface of the nonwoven web, and openings formed in the second surface of the nonwoven web, the protrusions being comprised of the fibers, wherein the protrusions comprise a base proximate the first surface of the nonwoven web, an opposed distal end extending outward in the Z-direction from the base, side walls between the base and the distal end of the protrusion, and a cap comprising at least a portion of the side walls and the distal end of the protrusions, wherein the side walls have interior surfaces, wherein the interior surfaces of the side walls define a base opening at the base of the protrusion, wherein the side walls fully surround the base opening, wherein the cap has a portion with a maximum interior width, and the base opening has a width, wherein the maximum interior width of the cap of the protrusions is greater than the width of the base opening;
• and
• d) pressure bonding at least a portion of the fibers together in the first region of the nonwoven web outside the base of at least some of the protrusions.

A method of forming deformations in a nonwoven web, the method comprising the steps of:

• a) providing a precursor nonwoven web, the precursor web comprising a nonwoven material comprising fibers, the precursor web having a first surface, a second surface, thermal point bonds, and a thickness;
• b) providing a pair of forming members having a machine direction orientation and a cross-machine direction orientation, the forming members comprising:
• a first forming member having a surface comprising a plurality of discrete, spaced apart male forming elements having a base that is joined to the surface of the first forming member, a top that is spaced away from the base, and sides that extend between the base and the top of the male forming elements, wherein the male elements have a plan view periphery, and a height;
• and
• a second forming member having a surface comprising a plurality of recesses in the second forming member, wherein the recesses are aligned and configured to receive the male forming elements therein, wherein the recesses have a plan view periphery that is larger than, and completely surrounds, the plan view periphery of the male elements, and the recesses have a depth;
• c) placing the precursor nonwoven web between the forming members, wherein the second surface of the precursor nonwoven web is placed in contact with the first forming member, and mechanically deforming the precursor nonwoven web with the forming members, wherein the precursor nonwoven web is formed into a nonwoven web comprising a generally planar first region and a plurality of discrete integral second regions that comprise deformations, the deformations forming protrusions extending outward from the first surface of the nonwoven web, and openings formed in the second surface of the nonwoven web, the protrusions being comprised of the fibers, wherein the protrusions comprise a base proximate the first surface of the nonwoven web, an opposed distal end extending outward in the Z-direction from the base, side walls between the base and the distal end of the protrusion, and a cap comprising at least a portion of the side walls and the distal end of the protrusions, wherein the side walls have interior surfaces, wherein the interior surfaces of the side walls define a base opening at the base of the protrusion, wherein the interior surfaces of the side walls surround the base opening and form an enclosed shape, wherein the cap has a portion with a maximum interior width, and the base opening has a width, wherein the maximum interior width of the cap of the protrusions is greater than the width of the base opening;
• and
• d) pressure bonding at least a portion of the fibers together in the first region of the nonwoven web outside the base of at least some of the protrusions.