Molded product, clothing, production process for laminate, and production process for molded product

Patent metadata

Field	Value
Publication number	US-9238345-B2
Application number	US-201013508942-A
Country	US
Kind code	B2
Filing date	Nov 5, 2010
Priority date	Nov 11, 2009
Publication date	Jan 19, 2016
Grant date	Jan 19, 2016

Abstract

A molded product obtained by molding a laminate which comprises a stretchable substrate made of a sheet-shaped synthetic resin foam and including multiple slits, and a stretchable surfacing material affixed to at least one surface of the substrate, wherein the substrate is bonded to the surfacing material in a state that at least some of the slits are kept opened.

First claim

The invention claimed is:

1. An article of clothing including a molded product obtained by hot press molding a laminate which comprises a stretchable substrate made of a sheet-shaped synthetic resin foam and including multiple slits, and a stretchable surfacing material affixed to at least one surface of the substrate,
wherein the substrate is bonded to the surfacing material in a state that at least some of the slits are kept opened, the slits extend in a first direction, and the surfacing material has a greater elongation rate in a second direction perpendicular to the first direction than in the first direction, the molded product is molded in a cup-like shape, a compression rate in a central region of the laminate in a thickness direction is 40-50%, and a compression rate in a peripheral region of the laminate in a thickness direction is 85-96%, such that the slits are opened to larger extents at positions in the central region than at positions in the peripheral region of the molded product.

2. The article of clothing according to claim 1 , wherein the stretchable surfacing material is affixed to the substrate with an emulsion adhesive or a hot-melt adhesive.

3. The article of clothing according to claim 1 , wherein the elongation rate of the surfacing material in the second direction is 1.5-4 times the elongation rate thereof in the first direction.

4. The article of clothing according to claim 1 , wherein the synthetic resin foam is a soft polyurethane foam.

5. The article of clothing according to claim 1 , wherein the surfacing material is a cloth.

6. The article of clothing according to claim 1 , wherein a thickness of the substrate is 7-25 mm, a slit length is 3-15 mm, and the slits are formed in number of 3000-21000 per 1 m 2 .

7. The article of clothing according to claim 1 , wherein the central region corresponds to a region having a length of 10-30 mm from a center of the molded product toward the peripheral region, and
wherein the peripheral region corresponds to a region outside the central region.

8. A production process for an article of clothing comprising a molded product obtained by hot press molding a laminate comprising a stretchable substrate made of a sheet-shaped synthetic resin foam and including multiple slits, and a stretchable surfacing material affixed to at least one surface of the substrate, the method comprising:
overlaying and affixing the surfacing material is overlaid and affixed to the substrate while the substrate is continuously fed in a first direction;
bonding the substrate to the surfacing material in a state that at least some of the slits are kept opened, the slits extend in the first direction, and the surfacing material has a greater elongation rate in a second direction perpendicular to the first direction than in the first direction;
molding the laminate in a cup-like shape forming the molded product,
wherein a compression rate in a central region of the laminate in a thickness direction is 40-50%, and a compression rate in a peripheral region of the laminate in a thickness direction is 85-96%, such that the slits are opened to larger extents at positions in the central region than at positions in the peripheral region of the molded product.

9. The production process for the article of clothing according to claim 8 , wherein the surfacing material is affixed to a surface of the substrate by using a hot-melt adhesive.

10. The production process for the article of clothing according to claim 8 , wherein the laminate is cut into a predetermined size and the cut laminate is subjected to the hot press molding under pulling in a second direction perpendicular to the first direction.

11. The production process for the article of clothing according to claim 8 , wherein an elongation rate of the laminate in the second direction is 1.2-3 times an elongation rate thereof in the first direction when a same load is applied to the laminate in the first direction and in the second direction.

Assignees

• Noda Yosuke
• Tsuchiya Kazuhiro
• Kabeya Yasuyuki
• Bridgestone Corp

Inventors

• Noda Yosuke
• Tsuchiya Kazuhiro
• Kabeya Yasuyuki

Classifications

• A41D2400/20

  Human Necessities · mapped topic

• B32B5/04

  characterised by a layer being specifically extensible by reason of its structure or arrangement {, e.g. by reason of the chemical nature of the fibres or filaments} · CPC title

• B32B2266/0278

  Polyurethane · CPC title

• B32B38/0004

  Cutting, tearing or severing, e.g. bursting; Cutter details (cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence) · CPC title

• A41C3/144

  Pads · CPC title