Abstract: A reflective panel and method of construction thereof from post consumer mixed Asian cardboard for forming structural and/or acoustic and/or thermal panels is provided. The method includes providing post consumer mixed Asian cardboard and comminuting the cardboard into predetermined reduced sized pieces. Then, combining the reduced sized pieces with a heat bondable textile material to form a substantially homogenous mixture. Further, forming a web of the mixture of a predetermined thickness in a dry nonwoven webbing process. Then, heating the web to bond the heat bondable material with the reduced sized pieces to form a nonwoven sheet having opposite sides. Further, bonding at least one reflective layer to at least one of the opposite sides of the nonwoven sheet.

Abstract: A chemical sorbent article comprising a nonwoven containing a plurality of thermoplastic nanofibers and a textile, where the textile at least partially surrounds the non-woven. Also an oil boom fence containing a nonwoven comprising a plurality of thermoplastic nanofibers, a weight, a buoyancy article, and a fabric. The fabric at least partially surrounds the nonwoven, the weight, and the buoyancy article and the weight and buoyancy article are separated by the nonwoven.

Abstract: Methods of treating laminates, treated laminates, and articles with treated laminates.

Abstract: A waterproof, insulated multi-layer fabric structure is described, including a first and second layer to bound an interior volume. A baffle layer is located in the bounded volume and undulates between the first layer and second layer. The baffle layer is directly attached to the first layer. Adhesive tape portions are attached to the second layer to eliminate the need of stitching through the second layer, improving the structure's waterproof qualities. The baffle layer is attached to the adhesive tape portions which extend from the second layer. A method for manufacturing the multi-layer structure is also described.

Abstract: A floral sleeve is made from two layers of non-woven thermoplastic fabric such as polypropylene. The layers are joined at the side seams of the sleeve by first pre-sealing the edges and thereafter trimming them. Pre-sealing compresses the fabric to make it denser along a band and applying heat causes the band to retain the compressed and at least partially fused set. Trimming may be done using a hot knife that completes the fusing process of the layers to each other. Alternately, the pre-sealing step may form a satisfactory fusion between the layers and the trimming step need not effect further fusion.

Abstract: The present invention relates to an arc flash protection, multiple-use nonwoven fabric structure comprising one or more layers having fire resistant properties. The fabric structure has an arc flash facing nonwoven surface, and a nonwoven part of the fabric structure comprises non-inherent, and/or inherently fire resistant fibers, said fibers being mechanically, chemically, or thermally bonded, whereby the fabric structure has a minimum Arc Thermal Protection Value (ATPV) to fabric basis weight ratio of 250 cal/g, preferably greater than 350 cal/g, more preferably greater than 500 cal/g when measured in accordance with ASTM F1959—Standard Test Method for Determining the Arc Rating of Materials for Clothing, and the fabric structure maintains said ATPV to fabric basis weight ratio through at least 25 washing cycles when washed according to AATCC Method 135 (3, 1V, A iii).

Abstract: A stretch nonwoven fabric 10 contains inelastic fibers having a varied thickness along the length and elastic fibers. The nonwoven fabric 10 preferably includes an elastic fiber layer 1 and a substantially inelastic, inelastic fiber layer 2 on at least one side of the elastic fiber layer 1. The fibers with a varied thickness along the length are contained in the inelastic fiber layer 2. The nonwoven fabric 10 is conveniently produced by (a) superposing a web containing low-drawn, inelastic fibers having an elongation of 80% to 800% on at least one side of a web containing elastic fibers, (b) subjecting the webs, while in a non-united state, to through-air technique to obtain a fibrous sheet having the webs united together by thermal bonding the fibers at their intersections, and (c) stretching the fibrous sheet in at least one direction to draw the low-drawn inelastic fibers, followed by releasing the sheet from the stretch.

Abstract: In some embodiments, a nonwoven fabric includes a first web that is at least partially formed of extruded strands which include an auto-adhesive material. The nonwoven fabric is adapted to be bonded to another item that includes a similar auto-adhesive material. In other embodiments, a method of forming a nonwoven fabric includes extruding a plurality of strands that are formed of an auto-adhesive material. The method further includes routing the plurality of strands toward a moving support, depositing the plurality of strands onto the moving support, and then stabilizing the plurality of strands to form a web. In other embodiments, a fastening system includes a nonwoven fabric that has a web which is formed of a plurality of extruded strands that include an auto-adhesive material. The fastening system further includes a foam layer that has a surface with a plurality of free-standing struts that include a similar auto-adhesive material.

Abstract: A press fabric for a machine for the production of web material, especially paper or cardboard, including a carrying structure and a plurality of layers on one web material contact side of the carrying structure, whereby polymeric material is contained in at least one of the layers of fibrous material.

Abstract: A separation membrane support substrate characterized by being composed of a laminated nonwoven fabric comprising a front layer as the resin coating layer, a middle layer and a back layer which are integrally formed by heat bonding, and by satisfying the following conditions (1) to (5): (1) The front layer has at least one layer comprising thermoplastic resin filaments with a single filament diameter of 7-30 ?m; (2) the middle layer has at least one layer comprising melt blown fibers with a single fiber diameter of no greater than 5 ?m, and a fiber basis weight of at least 1 g/m2 and comprising no more than 30 wt % of the total fiber basis weight; (3) the back layer has at least one layer comprising thermoplastic resin filaments with a single filament diameter of 7-20 ?m, and has a fiber basis weight of 3-40 g/m2; (4) the laminated nonwoven fabric has an apparent density of 0.67-0.91 g/cm3; and (5) the laminated nonwoven fabric has a thickness of 45-110 ?m.

Abstract: The present invention concerns a textile support for bituminous membranes, particularly for waterproofing roof surfaces of buildings, characterised by a high dimensional stability. The support comprises at least two layers (1, 2) of non-woven polyester or polymeric material in general and a plurality of longitudinal reinforcing filaments (3). The reinforcing filaments (3), preferably of glass, have been treated in advance with a size which allows the formation of stable chemical bonds, not strongly influenced by temperature.

Abstract: The present invention provides a nonwoven web prepared from multicomponent fibers which are partially split. The partially split multicomponent fibers have at least one component of the multicomponent fiber separated from the remaining components of the multicomponent fiber along a first section of the longitudinal length of the multicomponent fibers. Along a second section of the longitudinal length of the multicomponent fibers the components of the multicomponent fibers remain together as a unitary fiber structure. In addition, part of the second section of the multicomponent fibers is bonded to part of a second section of an adjacent multicomponent fiber.

Abstract: Disclosed is a fibrous nonwoven structure comprising meltblown fibrous materials and at least one secondary fibrous material and method of preparing. In one aspect, the fibrous nonwoven structure has a formation index of between 70 and 135. In another aspect, the fibrous nonwoven structure has an opacity that is greater than 72 percent at a basis weight of between about 35 and 55 grams per square meter. The fibrous nonwoven substrate may be utilized as a moist wipe.

Abstract: Absorbent structures with nonwoven meltblown lyocell fiber webs are described which have excellent liquid distribution properties. The absorbent structures comprise at least two nonwoven meltblown lyocell fiber webs with superabsorbent polymer intermediate the two webs. Methods for making the structures are also described. The structures are particularly useful for use in disposable hygienic products.

Abstract: Mattress panels and mattresses (including mattress foundations) that satisfy the rigorous requirements of new and promulgated state and federal regulations regarding flammability of mattresses, such as Technical Bulletin 603 of the State of California department of Consumer Affairs (TB-603) and U.S. Consumer Product Safety Commission Standard for Flammability of Mattresses and Mattress/Foundation Sets (16 CFR 1633), are provided. A mattress includes one or more panels of material assembled as a non-quilted, non-perforated, multi-layered structure, wherein the mattress maintains flame and heat resistant integrity when impinged with a gas flame in accordance with the testing protocol set forth in Technical Bulletin 603 of the State of California department of Consumer Affairs (TB-603) and/or in accordance with the testing protocol set forth in U.S. Consumer Product Safety Commission Standard for Flammability of Mattresses and Mattress/Foundation Sets (16 CFR 1633).

Abstract: Provided is a three-ply insulating material which has combined properties to selected gases and vapors, thermal insulation, and humidity control. The device is built as a composite of three layers. The outer layer is made from breathable non woven composite. This layer is adjacent to and bonded to the middle layer, composed of high loft fibrous material with substantial weight to volume ratio, between about 2 to about 20 kg/m3. This middle layer is adjacent to a third layer of breathable non woven composite. The composite layered structure so designed forms an insulation blanket with thermal resistance of about 0.8 m2 ° K/W and moisture vapor transmission rate (MVTR) between 50 and 10000 l/m2/hr.

Abstract: Disclosed is an airfoil comprising a plurality of ceramic matrix composite (CMC) fabric sheets which are layered to form a single, layered fabric sheet. The layered fabric sheet is formed so as to define a pressure and suction side of the airfoil. The airfoil includes primary fibers which extend radially outwardly from a rotor disk, for example. In this way, the airfoil is suitable for use in a gas turbine engine due to the temperature resistance of CMC and the strength provided by the primary fibers.

Abstract: In a clothing support for a card flat covering, the belt-shaped support is made of plastics material, and there is embedded in a base body at least one reinforcing insert which is also belt-shaped and which is arranged in the vicinity of the back of the support. In order to make possible stronger anchoring by simple means and to allow undisrupted oscillation of clothing wires, the base body has at least two layers (bottom layer and top layer) of different plastics materials connected to one another, and the bottom layer incorporates a fabric.

Abstract: An elastic-powered shrink laminate includes a shrinkable layer and an elastic layer bonded together while the elastic layer is in a dimensionally unstable, stretched state. The elastic layer remains substantially in the stretched state prior to shrinkage of the shrinkable layer. When the shrinkable layer is activated, the laminate retracts, and the retraction is aided (i.e. powered) by the elastic layer. The elastic-powered shrink laminate is useful in personal care absorbent articles where latent, post-assembly retraction of a waistband region is desired.

Abstract: Provided herein is a non-stratified, or homogeneous, non-woven composite having (a) strength-imparting fibers of a relatively high denier and (b) binder fibers of a lower denier that adhere the composite together and that form a smooth, stiff skin on the outer surfaces of the composite. In one instance, the strength-imparting fibers are staple fibers and the binder fibers are bicomponent fibers having a low melt component. In a variation, the composite also contains a small percentage by weight (that is, less than 20%) of flame retardant fibers that impart flame resistant properties to the composite. Preferably, all of the fibers are comprised of the same polymeric material (e.g., polyester), so that the composite is recyclable. The resulting composite exhibits excellent flame retardance, strength, and stiffness, as well as having a smooth surface for attachment of a decorative fabric or other material. A process for manufacturing such composites is also provided.

Abstract: A melt-extruded substrate (e.g., film, nonwoven web, etc.) that contains a thermoplastic starch formed from a starch and plasticizer is provided. The starch and plasticizer are melt blended together in the presence of a weak organic acid (e.g., lactic acid, formic acid, acetic acid, etc.). By selectively controlling certain parameters of the melt blending process (e.g., extrusion temperature, content of the components, etc.), the present inventors have discovered that the starch may be hydrolyzed in a highly efficient manner to form compositions having a comparably lower weight average molecular weight, polydispersity index, and viscosity, which are particularly suitable for use in the formation of melt-extruded substrates.

Abstract: The present invention discloses a disposable meltblown scrubbing product for use in household cleaning or personal care applications and an abrasive aggregate fiber which may be utilized in the scrubbing product. The meltblown web is formed primarily of polymeric fibers in a disordered or random distribution as is typical of fibers deposited in meltblown processes so as to form an open, porous structure. The aggregate fibers of the present invention generally are formed of two or more separate abrasive polymer fibers or strands which are adhered together along at least about 5 mm of the fiber length. The abrasive fibers of the meltblown web are generally greater than about 15 microns in diameter.

Abstract: A cushion element for a vehicle seat or headrest comprises a non-woven layer and a fiber composite material. An insert material is arranged between the non-woven layer and the fiber composite material, and has different compression properties than the fiber composite material. The fiber composite material forms together with the insert material and the non-woven layer a one-piece material composite.

Abstract: The web of the invention can comprise a super absorbent layer that can act as an moisture sensitive fuel shut-off valve, absorbent, adsorbent or reactant. The web of the invention can comprise a super absorbent fabric or layer made of a superabsorbent particle or fiber. The web can comprise a nanofiber layer having dispersed within the nanofiber layer a super absorbent particulate and optionally a second particulate material that can act as an absorbent, adsorbent or reactant. Fluid, gas or liquid, that flows through or by the assemblies of the invention can have any gas, liquid or solid material dispersed or dissolved in the fluid interact with the super absorbent particulate. If needed these materials can also react with, be absorbed by, or adsorbed onto, the active particulate within the nanofiber layer.

Abstract: A process for making a fibrous product using a binder based on a formaldehyde-containing resin and especially for making fiberglass insulation products, and to the fibrous products themselves, wherein the fibrous product has a backing sheet affixed thereto and the backing sheet is coated or impregnated with a formaldehyde scavenger composition, with the result that the fibrous products exhibit a reduced level of formaldehyde emission.

Abstract: A composite membrane comprises: a first layer of high-density polyethylene (HDPE) and a layer of asphalt applied over the first layer of HDPE. A second layer of HDPE sheeting is applied over the layer of asphalt. A method of creating a composite barrier to chemical vapors is also disclosed which comprises applying a base layer comprising high density polyethylene (HDPE); applying an asphalt layer over the base layer; and applying a top layer comprising HDPE over the asphalt layer.

Abstract: A thermal barrier fabric includes an inner impermeable material layer, an outer impermeable material layer, a spacer material disposed between the inner and outer impermeable material layers, and a reflective layer of material disposed between the spacer and a selected one of the inner impermeable material layer and the outer impermeable material layer. The inner and outer impermeable material layers are bound to each other along portions thereof outboard of the spacer material and the reflective layer of material to define a closed compartment. The compartment is under a vacuum, such that the reflective layer of the fabric reflects thermal energy back toward the source thereof and the vacuum substantially prevents thermal energy transfer through the compartment.

Abstract: Nonwoven polymer materials and articles made therefrom. Materials of the invention include at least one nonwoven polymer web with at least one layer of at least about 50% by weight of a multi-lobal fiber. Materials and articles of the invention have improved properties, such as particle retention capacity, acoustic absorption, stiffness, crop color uniformity, and crop yield, when compared with nonwoven polymer materials and articles made with round fiber in place of all of the multi-lobal fiber.

Abstract: A water-absorbent sheet composition comprising a structure in which a water-absorbent resin and a hot melt adhesive are sandwiched with two or more sheets of hydrophilic nonwoven fabrics, wherein the hydrophilic nonwoven fabrics have a basis weight of 25 g/m2 or more, and wherein the water-absorbent resin is contained in an amount of from 200 to 400 g/m2, and wherein the hot melt adhesive is contained in an amount of from 0.10 to 0.50 times that of the amount of the water-absorbent resin contained (based on weight). According to the present invention, a water-absorbent sheet composition which has sufficient absorbency without undergoing deformation of shape after liquid absorption, while being thin in style can be provided.

Abstract: An apparatus for manufacturing a multi-layered preform molding material includes a reinforcement material and a resin material. The apparatus includes a mechanism for joining the reinforcement layers together by impregnation of the resin material into the reinforcement material to form the molding material, thereby obviating the need for any additional bonding to join the individual reinforcement layers before impregnation.

Abstract: A method of placing a logo on an article or substrate by placing a contrast sheet behind the logo and a blocking sheet therebetween to prevent a shadow effect. The contrast sheet and blocking sheet may be hidden within the hem of an article.

Abstract: An interior building system which includes a curved, acoustical, self-supporting composite panel which differentiates and accents the interior building space, and, at the same time, provides substantial sound absorbing capabilities. The composite panel is composed of two or more layers of non self-supporting soft fiber material and a discontinuous layer of adhesive interposed between each of the soft fiber layers. The system further includes mounting hardware for attaching the panel to the building structure. The mounting hardware has a perforated plate which is embedded in the panel which minimizes the visibility of the hardware, and, at the same time, provides enhanced load bearing capabilities.

Abstract: The present invention provides a laminated nonwoven fabric wherein the nonwoven fabric is a laminated one formed by integrating, through compressive bonding, a stacked nonwoven fabric structure comprising an upper and a lower thermoplastic synthetic filamentary fiber layer that have a fiber diameter from 7 ?m or more to 20 ?m, and an intermediate layer composed of thermoplastic synthetic fine fibers that have a fiber diameter of 5 ?m or less, the laminated nonwoven fabric having an intimately mixed structure in which a portion of the fine fibers is intruded into at least one face side of the filamentary fiber layers with an intrusion index of 0.36 or more to bond, surround or interlace the filamentary fibers, a basis of weight of from 10 g or more to 250 g/m2, and a bulk density of 0.20 g/cm3 or more.

Abstract: A method of producing basic starting material for the manufacture of fastener tabs intended for joining the side portions of the front and rear parts of an absorbent article. The method includes stretching a first sheet of elastic material in a first direction; applying a second and third sheet of material onto respective opposite sides of the first sheet; fastening the three material sheets together in at least two mutually separated zones that extend parallel with each other in one direction perpendicular to the first direction; dividing the first sheet in each region between two zones along a line lying therebetween, whereby the first sheet contracts to a non-stretched state, and thereafter fastening the sheets together in each region between two zones. The invention also relates to an arrangement for carrying out the method, to starting material for producing fastener tabs, and to such a tab.

Abstract: A stretch laminate comprises a carrier web extending lengthwise in a machine direction and widthwise in a cross direction between opposed side edges, the carrier web including an extensible zone and an inextensible zone disposed side-by-side across the width of the carrier web; and an elastomeric element laminated to the nonwoven layer over at least a portion of the extensible zone.

Abstract: A water-absorbent sheet composition comprising a structure in which a water-absorbent resin and a hot melt adhesive are sandwiched with two or more sheets of hydrophilic nonwoven fabrics, wherein the hydrophilic nonwoven fabrics have a basis weight of 30 g/m2 or more, and wherein the water-absorbent resin is contained in an amount of from 10 to 150 g/m2, and wherein the hot melt adhesive is contained in an amount of from 0.10 to 1.0 time that of the amount of the water-absorbent resin contained (based on weight). The water-absorbent sheet composition of the present invention exhibits some excellent effects that the sheet composition has sufficient absorbency not only for a liquid having a low viscosity but also a liquid having a high viscosity, without undergoing deformation of shape before or after liquid absorption, while being thin in style.

Abstract: Disclosed is a nonwoven web material (10) comprising thermoplastic fibers or filaments and a method of manufacture thereof. The web material has properties desirable for use on machinery having conventional heat sealing stations (26). Also, disclosed is a nonwoven infusion web material comprising thermoplastic fibers or filaments and a method of manufacture thereof. The infusion web material has properties desirable for use in making infusion packages.

Abstract: A machine for producing a nonwoven feeds continuous filaments onto two surfaces that form a convergent passage. At least one of the surfaces is moving to drive the continuous filaments through the passage to form the nonwoven web. The continuous filaments have filament portions that are respectively received on the two surfaces to form spaced lateral web parts joined by a central web part formed by the continuous filament portions bridging the convergent passage. A vacuum is applied through the surfaces to assist placement of the filament portions and to direct the web as it emerges from the passage onto a horizontal take-up conveyor.

Abstract: Coated fibrous mats having properties particularly suited for a facer on gypsum wallboard, foam and other substrates and in laminates of various types, and the method of making the coated mat is disclosed. The mat contains a major portion of non-cellulosic fibers and a minor portion of cured resinous binder. The exposed surface coating has a smoothness of no more than about 15 microns and is comprised of one or more of a clay, a filler and a polymeric binder. The method comprises at least partially drying the coated mat while the exposed surface of the coating is in contact with a smooth surface.

Abstract: A separator is provided, such as for dividing an outer wet area from an inner dry area between sheet metal of a vehicle door and the door lining. The separator includes a composite of a separating film and an absorbent nonwoven material. The latter material comprises a base web of plastic fibers.

Abstract: A composite pad is made of two layers joined together at their interface. The top layer of the composite pad, which has a smooth surface has a dense and firm fine denier fibrous structure. The bottom layer of the composite pad has a lighter and softer coarser denier fibrous structure in order to be able to have a large fluid holding capacity. A method of manufacturing the composite stamp pad is described.

Abstract: A nonwoven web material that includes an elastic component or material (e.g., nonwoven web, nonwoven web laminated to an elastic material, etc.) is provided. The elastic component contains a crosslinked network formed from a pentablock copolymer containing at least two monoalkenyl aromatic midblocks positioned between conjugated diene endblocks, such as butadiene-styrene-butadiene-styrene-butadiene (“BSBSB”) or isoprene-styrene-isoprene-styrene-isoprene (“ISISI”). Prior to crosslinking, the pentablock copolymers have a relatively low viscosity and thus may be readily formed into a precursor elastic material (e.g., film, strands, web, etc.) that is subsequently crosslinked to achieve the desired elastic and mechanical properties.

Abstract: An elastic material for use in an absorbent article is provided. The elastic material contains a crosslinked network formed from a branched block copolymer having a monoalkenyl aromatic midblock positioned between conjugated diene endblocks (e.g., butadiene-styrene-butadiene (“B-S-B”) triblock copolymer). Prior to crosslinking, the branched block copolymers have a relatively low viscosity and thus may be readily formed into a precursor elastic material (e.g., film, strands, web, etc.) that is subsequently crosslinked to achieve the desired elastic and mechanical properties. Crosslinking is typically achieved through the formation of free radicals (unpaired electrons) that link together to form a plurality of carbon-carbon covalent bonds at the conjugated diene endblocks.

Abstract: Multilayer meltblown composites, articles made therefrom, and methods for making same. One method can include meltblowing a first material to form a first meltblown layer; meltblowing a second material to form a second meltblown layer; and meltblowing a third material to form a third meltblown layer, wherein each material is the same or different, each material includes at least one resin having a MFR of about 2,000 dg/min or less, as measured by ASTM D1238, 2.16 kg, 230° C., and at least one of the first, second, and third materials comprises an elastomer having a recovery of at least 70% after 100% deformation, as determined by ASTM D412.

Abstract: A composite material which has excellent ballistic performance and has improved flexibility. Surprisingly, it has been found that a combination of poly(alpha-olefin) fiber and matrix resin provides these desirable product features. The resin matrix is a block copolymer of a conjugated diene and a vinyl aromatic monomer, preferably a styrene-isoprene-styrene block copolymer, that is applied as an aqueous composition. The fiber has a tenacity of at least about 35 g/d and a tensile modulus of at least about 1200 g/d. The composite has a total density equal to or less than about 100 g/m2 and a stiffness of less than about 2.5 pounds (1.14 kg) for a two layer structure of the composite, and a total areal density equal to or less than about 190 g/m2 and a stiffness of less than about 3.0 pounds (1.36 kg) for a four layer structure of the composite. The Peel Strength for a two layer structure of less than about 1.0 pounds (0.45 kg) for a two layer structure of the composite, and less than about 0.7 pounds (0.

Abstract: The present invention provides high strength nonwoven wipe materials and the process of making the materials. The high strength nonwoven wipe materials contain cellulosic fibers, synthetic fibers, or mixtures thereof, with bicomponent fibers and optionally, a binder. The present invention provides a high strength, high elongation, reduced stiffness nonwoven wipe material with superior tensile strength.

Abstract: The invention relates to a spun-bonded nonwoven fabric made of polyolefin filaments having a titer<1.6 dtex, the spun-bonded nonwoven fabric having a basis weight?18 g/m2, a waterproofness of <15 cm measured as a water column, and an air permeability of at least 230 m3/(m2·min), wherein the product of the air permeability and the basis weight is ?5000 g/(m·min).

Abstract: Ballistic resistant articles having excellent resistance to deterioration due to liquid exposure. More particularly, a ballistic resistant structures and articles formed from a hybrid of woven and non-woven fibrous components that retain their superior ballistic resistance performance after exposure to liquids such as sea water and organic solvents, such as gasoline and other petroleum-based products. The hybrid structures are particularly useful for the formation of or for use in conjunction with soft, flexible body armor.

Abstract: A stretch laminate includes a first layer including an elastomer film, the first layer having a surface, and a second layer including a nonwoven material, the second layer having a surface that is attached to the surface of the first layer. The tensile behavior in the transverse direction of the stretch laminate is within about 2.5 N/cm of the tensile behavior in the transverse direction of the film at an engineering strain of about 1.5, and exists independent of mechanical activation. A method of making the stretch laminate and an absorbent article having at least one region defined by the stretch laminate are also provided.

Abstract: In a method for forming a thermoplastic polymer sheet, a plurality of the forming blades are configured so as to have projected cross-sectional shapes on the sheet defined by similar curved lines and/or similar flexural lines arranged around a center of similitude and extending in the thickness direction of the sheet from the stationery mold and the movable mold so as to be engaged one with another but not to come in contact one with another. The method includes a step of introducing the sheet between the stationery mold and the movable mold and a step of bring the forming blades of the stationery mold and the movable mold into engagement with one another to stretch the sheet between distal ends of each pair of the adjacent forming blades.