A method for making a high topography nonwoven substrate includes generating a foam including water and synthetic binder fibers; depositing the foam on a planar surface; disposing a template form on the foam opposite the planar surface to create a foam/form assembly; heating the foam/form assembly to dry the foam and bind the synthetic binder fibers; and removing the template from the substrate after heating the foam/form assembly, wherein the substrate includes a planar base layer having an X-Y surface and a backside surface opposite the X-Y surface; and a plurality of projection elements integral with and protruding in a Z-direction from the X-Y surface, wherein the projection elements are distributed in both the X- and Y-directions, and wherein the density of a projection element is the same as the density of the base layer.

A method for making a high topography nonwoven substrate includes generating a foam including water and synthetic binder fibers; depositing the foam on a planar surface; disposing a template form on the foam opposite the planar surface to create a foam/form assembly; heating the foam/form assembly to dry the foam and bind the synthetic binder fibers; and removing the template from the substrate after heating the foam/form assembly, wherein the substrate includes a planar base layer having an X-Y surface and a backside surface opposite the X-Y surface; and a plurality of projection elements integral with and protruding in a Z-direction from the X-Y surface, wherein the projection elements are distributed in both the X- and Y-directions, and wherein the density of a projection element is the same as the density of the base layer.

A coated nonwoven product used to make engine hood insulation material is produced by a method which involves needle punching a carded, cross-lapped web, then calendering the resulting web and then applying a foam coating. Rotary screen printing is used to apply a dot pattern of an acrylic emulsion to the dried, foam-coated web. Thermoplastic and/or thermoset material is deposited onto the acrylic coating and excess material is removed by vacuum, leaving a corresponding dot coating pattern of said material. The coated web is heated using infrared energy before cooling, cold calendering and winding-up.

A coated nonwoven product used to make engine hood insulation material is produced by a method which involves needle punching a carded, cross-lapped web, then calendering the resulting web and then applying a foam coating. Rotary screen printing is used to apply a dot pattern of an acrylic emulsion to the dried, foam-coated web. Thermoplastic and/or thermoset material is deposited onto the acrylic coating and excess material is removed by vacuum, leaving a corresponding dot coating pattern of said material. The coated web is heated using infrared energy before cooling, cold calendering and winding-up.

A method for making a high topography nonwoven substrate includes generating a foam including water and synthetic binder fibers; depositing the foam on a planar surface; disposing a template form on the foam opposite the planar surface to create a foam/form assembly; heating the foam/form assembly to dry the foam and bind the synthetic binder fibers; and removing the template from the substrate after heating the foam/form assembly, wherein the substrate includes a planar base layer having an X-Y surface and a backside surface opposite the X-Y surface; and a plurality of projection elements integral with and protruding in a Z-direction from the X-Y surface, wherein the projection elements are distributed in both the X- and Y-directions, and wherein the density of a projection element is the same as the density of the base layer.

A method for making a high topography nonwoven substrate includes generating a foam including water and synthetic binder fibers; depositing the foam on a planar surface; disposing a template form on the foam opposite the planar surface to create a foam/form assembly; heating the foam/form assembly to dry the foam and bind the synthetic binder fibers; and removing the template from the substrate after heating the foam/form assembly, wherein the substrate includes a planar base layer having an X-Y surface and a backside surface opposite the X-Y surface; and a plurality of projection elements integral with and protruding in a Z-direction from the X-Y surface, wherein the projection elements are distributed in both the X- and Y-directions, and wherein the density of a projection element is the same as the density of the base layer.

A porous body including an inorganic fiber and an organic binder, wherein the average fiber diameter of the inorganic fiber is 2.0 μm or less, the amount of the inorganic fiber is 90% by mass or more, the amount of the organic binder is 0.5% by mass or more and 10% by mass or less, the organic binder contains an elastomer, and the bulk density of the porous body is 30 kg/m.sup.3 or less.

A method for making a high topography nonwoven substrate includes generating a foam including water and synthetic binder fibers; depositing the foam on a planar surface; disposing a template form on the foam opposite the planar surface to create a foam/form assembly; heating the foam/form assembly to dry the foam and bind the synthetic binder fibers; and removing the template from the substrate after heating the foam/form assembly, wherein the substrate includes a planar base layer having an X-Y surface and a backside surface opposite the X-Y surface; and a plurality of projection elements integral with and protruding in a Z-direction from the X-Y surface, wherein the projection elements are distributed in both the X- and Y-directions, and wherein the density of a projection element is the same as the density of the base layer.

A method for making a high topography nonwoven substrate includes generating a foam including water and synthetic binder fibers; depositing the foam on a planar surface; disposing a template form on the foam opposite the planar surface to create a foam/form assembly; heating the foam/form assembly to dry the foam and bind the synthetic binder fibers; and removing the template from the substrate after heating the foam/form assembly, wherein the substrate includes a planar base layer having an X-Y surface and a backside surface opposite the X-Y surface; and a plurality of projection elements integral with and protruding in a Z-direction from the X-Y surface, wherein the projection elements are distributed in both the X- and Y-directions, and wherein the density of a projection element is the same as the density of the base layer.

A multi-layered web is disclosed that is resilient and/or elastic in the Z-direction. Thus, when the web is compressed, the web assumes a compacted state and then expands to an expanded state when the compressive forces are removed. In one embodiment, the multi-layered web includes a middle layer made from a resilient blend of fibers positioned inbetween two outer layers. The middle layer, for instance, can contain elastomeric fibers, three-dimensional fibers, and/or debonded fibers.