Decorative sheet and method for manufacturing same

Patent metadata

Field	Value
Publication number	US-11035061-B2
Application number	US-201816486251-A
Country	US
Kind code	B2
Filing date	Feb 26, 2018
Priority date	Mar 7, 2017
Publication date	Jun 15, 2021
Grant date	Jun 15, 2021

Abstract

A shaped sheet including a plurality of rows of protruding portions formed on a non-woven fabric sheet and extending in a first direction and a plurality of rows of protruding portions formed on the non-woven fabric sheet and extending in a second direction that crosses the first direction, wherein: the shaped sheet is more stretchable in the first direction than in the second direction; the shaped sheet is formed from a single layer of the non-woven fabric sheet; and a fusion-bonded portion that extends discontinuously or continuously in the first direction and that has a smaller thickness than the protruding portions due to its fusion-bonded structure is provided along a part or whole of a periphery of the protruding portions on the shaped sheet.

First claim

The invention claimed is:

1. A shaped sheet including: a plurality of rows of protruding portions formed on a non-woven fabric sheet and extending in a first direction; and a plurality of rows of protruding portions formed on the non-woven fabric sheet and extending in a second direction that crosses the first direction, wherein:
the shaped sheet is more stretchable in the first direction than in the second direction;
the shaped sheet is formed from a single layer of the non-woven fabric sheet; and
a fusion-bonded portion that extends discontinuously or continuously in the first direction and that has a smaller thickness than the protruding portions due to its fusion-bonded structure is provided along a part or whole of a periphery of the protruding portions on the shaped sheet.

2. The shaped sheet according to claim 1 , wherein the fusion-bonded portion is formed by the fusion-bonded structure where constituent fibers of the single-layer non-woven fabric sheet are fusion-bonded together.

3. The shaped sheet according to claim 2 , wherein the fusion-bonded portion is formed by the fusion-bonded structure that inhibits a stretch of the shaped sheet in the first direction.

4. The shaped sheet according to claim 1 , wherein the fusion-bonded portion includes a central portion that is between two of the protruding portions that are adjacent to each other in the first direction, and the fusion-bonded portion extends at least in one direction along the first direction from the central portion.

5. The shaped sheet according to claim 1 , a fiber density of constituent fibers is higher in the fusion-bonded portions than in the protruding portions.

6. The shaped sheet according to claim 1 , a rate of elongation of the shaped sheet when pulled in the first direction is smaller in the fusion-bonded portions than in the protruding portions.

7. A method for manufacturing a shaped sheet including:
a plurality of rows of protruding portions formed on a non-woven fabric sheet and extending in a first direction; and a plurality of rows of protruding portions formed on the non-woven fabric sheet and extending in a second direction that crosses the first direction, the method comprising:
a step of conveying a single layer of the non-woven fabric sheet in a longitudinal direction, the non-woven fabric sheet being more stretchable in a width direction than in the longitudinal direction;
a shape-giving step of shaping the plurality of rows of protruding portions on the non-woven fabric sheet being conveyed; and
a fusion-bonding step of forming a fusion-bonded portion, where constituent fibers of the single-layer non-woven fabric sheet are fusion-bonded together, along a part or whole of a periphery of the protruding portions on the single-layer non-woven fabric sheet or the shaped sheet.

8. The manufacturing method according to claim 7 , wherein:
in the shape-giving step, a first roll and a second roll mesh with each other, thereby shaping the non-woven fabric sheet;
in the shape-giving step, the first roll and/or the second roll are heated to a temperature range that is lower than a melting point of the constituent fibers of the non-woven fabric sheet; and
the fusion-bonding step is performed as a heating device comes into contact with the second roll with the fusion-bonded portion of the non-woven fabric sheet interposed between the second roll and the heating device.

Assignees

• Zuiko Corp

Inventors

• Furukawa Daisuke

Classifications

• D04H3/14

  with bonds between thermoplastic yarns or filaments produced by welding · CPC title

• D04H1/54 Primary

  by welding together the fibres, e.g. by partially melting or dissolving (in combination with needling D04H1/485) · CPC title

• B32B5/26

  another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)} · CPC title

• D04H1/558

  in combination with mechanical or physical treatments other than embossing · CPC title

• D10B2401/061

  elastic · CPC title