Composite sheet and method for making the same

Details Composite sheet and method for making the same Composite sheet and method for making the same

2000-10-31

2003-01-14

Loney, Donald J. (Department: 1772)

Stock material or miscellaneous articles

Structurally defined web or sheet

Including grain, strips, or filamentary elements in...

C428S107000, C428S113000, C428S167000, C428S172000, C156S209000, C156S292000, C015S209100, C015S226000

Reexamination Certificate

active

06506472

ABSTRACT:

FIELD OF THE INVENTION
This invention relates to a bulky composite sheet comprised of continuous fibers or filaments and, more particularly, to such a composite sheet suitably used to wipe up dust and dirt on floors, walls, windows, and the like.
BACKGROUD ART
In the accompanying drawings,
FIGS. 8 and 9
are perspective views of composite sheets
101
comprising a base sheet, for example, made of a nonwoven fabric and continuous fibers heat-bonded with the base sheet and
FIG. 10
is a perspective view of a holder
103
by which the composite sheet is held. These composite sheets
101
and holder
103
are described in Japanese Patent Application Laid-open No. 1997-149873. Floors can be wiped by the composite sheet
101
with the holder
103
in a user's hands to collect dust and dirt by the upper surface of the composite sheet
101
. In this known composite sheet
101
, a multiplicity of continuous fibers
108
are heat-bonded integrally with the base sheet
107
along attaching lines
105
. Such a composite sheet
101
is made by placing the continuous fibers
108
upon the base sheet
107
and feeding them into a gap between a pair of heated rolls for embossing. As will be apparent from
FIG. 8
, crossings
131
of the attaching lines
105
are numerous in the composite sheet
101
, and, therefore, the continuous fibers
108
disadvantageously tend to be unevenly distributed in the vicinity of these crossings
131
during an embossing process.
In the case of the composite sheet
101
as illustrated by
FIG. 9
, the continuous fibers
108
tend to shift transversely along an arrow Q toward a side edge of the base sheet
107
as the continuous fibers
108
and the base sheet
107
are fed in the direction as indicated by an arrow P to the pair of embossing rolls. Consequently, it is difficult to evenly distribute the continuous fibers
108
transversely of the base sheet
107
.
SUMMARY OF THE INVENTION
An object of this invention is to provide a bulky composite sheet and a method for making such a composite sheet.
According to one aspect of this invention, there is provided a composite sheet having a longitudinal axis, the composite sheet comprising a base layer having upper and lower surfaces and a surface layer comprised of continuous fibers extending along the longitudinal axis and having a predetermined width defined between transversely opposite side edges of the surface layer extending along the longitudinal axis and attached to at least one of the upper and lower surfaces of the base layer by a plurality of attaching lines extending in a direction intersecting the longitudinal axis.
In such a composite sheet, the attaching lines comprise a plurality of first attaching lines extending at intervals in one half region of the surface layer defined on one side of the longitudinal axis extending so as to bisecting the width of the surface layer and a plurality of second attaching lines extending also at intervals in the other half region of the surface layer on the other side of the longitudinal axis. The first and second attaching lines extend obliquely to the longitudinal axis so as to intersect each other on extensions of the first and second attaching lines toward the longitudinal axis.
According to another aspect of this invention, there is provided a method for making a composite sheet having a longitudinal axis, the composite sheet comprising the steps of continuously feeding a base layer web having upper and lower surfaces and a surface layer web comprised of continuous fibers extending along the longitudinal axis and having a predetermined width defined between transversely opposite side edges of the surface layer extending along the longitudinal axis, placing the surface layer web upon at least one surface of the base layer web and attaching the surface layer web to the base layer web along a plurality of attaching lines extending in a direction intersecting the longitudinal axis.
In such a method, this invention further comprises the steps of deregistering and spreading a continuous fiber tow for the surface layer web to the predetermined width on the one surface of the base layer web and providing a plurality of first attaching lines extending at intervals in one half region of the surface layer web defined on one side of the longitudinal axis bisecting the width of the surface layer web and a plurality of second attaching lines extending also at intervals on the other half region of the surface layer web defined on the other side of the longitudinal axis so as to make the first and second attaching lines extend obliquely to the longitudinal axis and intersect each other on extensions of the first and second attaching lines toward the longitudinal axis, wherein the first and second attaching lines are successively formed from the longitudinal axis toward transversely opposite side edges of the surface layer web as the base layer web and the surface layer web are fed in the longitudinal axis.


REFERENCES:
patent: 4601938 (1986-07-01), Deacon et al.
patent: 9-149873 (1997-06-01), None
patent: 9-313416 (1997-12-01), None
patent: 10-155713 (1998-06-01), None
patent: 11-235301 (1999-08-01), None
patent: 2000-93373 (2000-04-01), None

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