Method for manufacturing three-dimensional non-woven fabric, mold used for the method, and three-dimensional non-woven fabric manufactured using the method and the mold

Abstract

A method for manufacturing a three-dimensional non-woven fabric according to the invention is a method in which semi-molten fibers are spun on a forming surface of a mold to form the three-dimensional non-woven fabric. The method includes a step of preparing a plurality of mold pieces, which can be mutually overlapped and a step of forming a mold including forming surfaces in a certain size by partly mutually overlapping a plurality of the mold pieces and adjusting the area in which the mold pieces are mutually overlapped. This makes it possible to form plural types of three-dimensional non-woven fabrics whose sizes are different using only one unit of mold.

What is claimed is:  
     
         1 . A method for manufacturing a three-dimensional non-woven fabric in which semi-molten fibers are spun onto a forming surface of a mold to form the three dimensional non-woven fabric, comprising 
 preparing at least two mold pieces including a first mold piece, and a second mold piece which can be mutually overlapped with the first mold piece and whose area mutually overlapping with the first mold piece is adjustable, and    forming a mold including a forming surface in an desired size by partly mutually overlapping the first mold piece with the second mold piece and adjusting the area in which the two mold pieces are mutually overlapped.    
     
     
         2 . The method according to  claim 1 , wherein 
 the area in which the two mold pieces are mutually overlapped is adjusted by sliding the first mold piece with respect to the second mold piece.    
     
     
         3 . The method according to  claim 1 , wherein 
 the area in which the two mold pieces are mutually overlapped is adjusted by changing the number of portions where a plurality of concave portions formed on the first mold piece is fitted to a plurality of convex portions formed on the second mold piece.    
     
     
         4 . The method according to  claim 3 , wherein 
 the three-dimensional non-woven fabric includes a main portion and a peripheral portion which is provided on a periphery of the main portion, and the concave portions and the convex portions are provided on the forming surface of the mold which form the main portion.    
     
     
         5 . A mold used for a method for manufacturing a three-dimensional non-woven fabric in which semi-molten fibers are spun on a forming surface of a mold to form the three dimensional non-woven fabric, comprising at least 
 a first mold piece, and    a second mold piece which can be mutually overlapped with the first mold piece and whose area mutually overlapped with the first mold piece is adjustable.    
     
     
         6 . The mold according to  claim 5 , wherein 
 at least one of the first mold piece and the second mold piece is formed by press molding.    
     
     
         7 . The mold according to  claim 5 , wherein 
 at least one of the first mold piece and the second mold piece is formed by injection molding with resin.    
     
     
         8 . The mold according to  claim 5 , wherein 
 at least one of the first mold piece and the second mold piece is formed from a non-woven fabric.    
     
     
         9 . The three-dimensional non-woven fabric manufactured using the method according to  claim 1 .  
     
     
         10 . The three-dimensional non-woven fabric manufactured using the mold according to  claim 5.