Method for stabilizing non-woven fibers and reusable moisture-absorbing article

Abstract

A method of stabilizing nonwoven fibers is disclosed. A stabilizing material 120 is applied to at least a portion or all of a non-woven material 110, the non-woven material comprising or in the form of a plurality of non-woven fibers, such that the stabilizing material 120 is applied to at least some or all of the non-woven fibers. The non-woven fibers to which the stabilizing material 120 is applied are bonded to the stabilizing material 120 by adhesive and / or thermal bonding, thereby stabilizing at least a portion or all of the non-woven material 110.

Description

TECHNICAL FIELD

[0001] The present invention relates to a method of stabilizing nonwoven fibers and a reusable absorbent article. BACKGROUND

[0002] Disposable absorbent articles, such as those designed for the absorption of urine or menstrual fluid, are widely used, but due to their disposable nature, present an environmental challenge. On the other hand, reusable absorbent products, while more environmentally friendly, are more complex to manufacture and more expensive to the consumer than their disposable counterparts, particularly in the early stages of production.

[0003] The absorbent hygiene industry is facing a major challenge globally due to upcoming regulatory bans on disposable products containing plastic polymers. Current disposable adult hygiene products contain plastic polymers.

[0004] Disposable product manufacturers are investigating the use of natural fibers in their products. However, natural fibers provide much less surface space for moisture to attach to, and therefore they do not absorb light as well as synthetic fibers. One solution could be to recycle synthetic fibers, which would require the collection of used hygiene products from the market, which would be extremely difficult, if not impossible.

[0005] Another possible method to comply with upcoming regulations is to manufacture nonwoven products that can be washed and reused. However, so far, disposable product manufacturers have not been successful in manufacturing a viable reusable alternative, because nonwoven fibers are so unstable that they easily fall apart when washed or laundered.

[0006] Although there do exist reusable hygiene products, their current mass production is not economically viable. They are simply too expensive, due to the large amount of manual labor required to make them and the high cost of raw materials (knitted and woven textiles are substantially more expensive than nonwoven materials). Sacrificing product performance in order to reduce manufacturing costs is not desirable, because a product that does not perform well creates more waste and is more expensive to the end user in the long term.

[0007] OBJECT OF THE INVENTION

[0008] It is therefore an object of the present invention to provide a method of stabilizing nonwoven fibers that overcomes or at least ameliorates some of the above-mentioned disadvantages, or that at least provides the public with a useful choice.

[0009] Additionally, or alternatively, it is an object of the present invention to provide a reusable absorbent article manufactured by stabilizing nonwoven fibers that overcomes or at least ameliorates some of the above-mentioned disadvantages, or that at least provides the public with a useful choice. SUMMARY

[0010] In a first aspect, the present invention relates to a method of stabilizing nonwoven fibers, the method comprising the steps of: providing a nonwoven material comprising or in the form of a plurality of nonwoven fibers; providing a stabilizing material; applying the stabilizing material to at least a portion or all of the nonwoven material such that the stabilizing material is applied to at least some or all of the plurality of nonwoven fibers, the stabilizing material being a material configured to bond the nonwoven fibers by adhesive and / or thermal bonding; and bonding the plurality of nonwoven fibers to which the stabilizing material is applied and the stabilizing material by adhesive and / or thermal bonding.

[0011] Preferably, the nonwoven fibers are bonded to form a bonded nonwoven fiber layer comprising at least a portion of the nonwoven fibers, the degree of bonding of the nonwoven fibers being such that the bonded nonwoven fibers do not disintegrate or do not substantially disintegrate when the layer is washed or laundered at least once or more.

[0012] Preferably, the nonwoven material is a layer of nonwoven material.

[0013] Preferably, the nonwoven material is a nonwoven article, a nonwoven fabric, or a nonwoven textile.

[0014] Preferably, the thermal bonding comprises fusing at least some or all of the nonwoven fibers at a temperature related to the melting point of the fibers to be fused and / or the melting point of the stabilizing material.

[0015] Preferably, the thermal bonding is performed at a temperature between 70 degrees Celsius and 240 degrees Celsius.

[0016] Preferably, the thermal bonding is performed at a temperature between 100 degrees Celsius and 240 degrees Celsius.

[0017] Preferably, the stabilizing material is formed as a stabilizing layer.

[0018] Preferably, the stabilizing layer is a film or a membrane.

[0019] Preferably, the stabilizing layer has a thickness based on the type of nonwoven material and the melting point of the nonwoven material.

[0020] Preferably, the thickness of the stabilizing layer is between 0.005 mm and 0.5 mm.

[0021] Preferably, the stabilizing layer is a breathable layer.

[0022] Preferably, the stabilizing layer is an integral layer.

[0023] Preferably, the stabilizing layer is a partial layer.

[0024] Preferably, the stabilizing layer is a frame layer.

[0025] Preferably, the stabilizing layer is a polyurethane (PU) material layer.

[0026] Preferably, the stabilizing layer is a polyethylene (PE) material layer.

[0027] Preferably, the stabilizing layer is a textile adhesive layer.

[0028] Preferably, the non-woven fibers are synthetic polymers, bi-component fibers, natural fibers, man-made fibers, or combinations thereof.

[0029] Preferably, the synthetic polymers are selected from polyethylene (PE), polypropylene (PP), or polyethylene terephthalate (PET).

[0030] Preferably, the natural fibers are selected from wood, pulp, cotton, or bamboo.

[0031] Preferably, the man-made fibers are selected from viscose, lyocell, polylactic acid (PLA), or cellulose acetate.

[0032] Preferably, the bonding is performed in a patterned manner.

[0033] Preferably, the stabilizing material is an adhesive material.

[0034] Preferably, the adhesive material is a glue.

[0035] Preferably, the adhesive material is a spray-on glue or a roll-on glue.

[0036] Preferably, the adhesive material is a polyurethane (PU) adhesive.

[0037] Preferably, the adhesive material is a polyethylene (PE) adhesive.

[0038] Preferably, the adhesive material is a polylactic acid (PLA) adhesive.

[0039] Preferably, the adhesive material is a textile adhesive.

[0040] Preferably, an adhesive substance is applied to the stabilizing material for bonding.

[0041] Preferably, the adhesive substance is a glue.

[0042] Preferably, the glue is a spray-on glue or a roll-on glue.

[0043] Preferably, the adhesive substance is a polyurethane (PU) adhesive.

[0044] Preferably, the adhesive substance is a polyethylene (PE) adhesive.

[0045] Preferably, the adhesive substance is a polylactic acid (PLA) adhesive.

[0046] Preferably, the adhesive substance is a textile adhesive.

[0047] In a second aspect, the present invention relates to a reusable absorbent article comprising a plurality of nonwoven fibres stabilised using a method defined by any one or more of the above or below statements.

[0048] Preferably, the reusable absorbent article is a garment or is for use with a garment to be positioned adjacent to a user's body and to absorb (preferably, absorb and retain) moisture from the user's body.

[0049] Preferably, the reusable absorbent article is one of: a nappy, a sanitary napkin, an incontinence pad, an incontinence bag, a female incontinence brief, a male incontinence brief, a care pad, a protection pad (preferably a bed protection pad, a seat protection pad), a baby nappy pad, or a cot protection pad.

[0050] In a third aspect, the present invention relates to a method of constructing a reusable absorbent article that is a garment or is for use with a garment to be positioned adjacent to a user's body and to absorb (preferably, absorb and retain) moisture from the user's body, the method comprising: providing at least one layer of nonwoven material comprising or being in the form of a plurality of nonwoven fibres; applying at least one stabilising material to at least a portion of the at least one layer of nonwoven material such that the stabilising material is applied to at least some or all of the plurality of nonwoven fibres, the stabilising material being a material configured to bond the nonwoven fibres by adhesive and / or thermal bonding, and the stabilising material forming a stabilising layer; and bonding the plurality of nonwoven fibres to which the stabilising material is applied and the stabilising material by adhesive and / or thermal bonding to form the reusable absorbent article.

[0051] Preferably, the degree of bonding of the nonwoven fibres is such that the bonded nonwoven fibres do not disintegrate or do not substantially disintegrate upon exposure to at least one or more washes or launderings.

[0052] Preferably, the thermal bonding comprises or involves fusing at least some or all of the non-woven fibres at a temperature related to the melting point of the fibres to be fused and / or the melting point of the stabilising material.

[0053] Preferably, the thermal bonding comprises or involves fusing at least some or all of the non-woven fibres at a temperature related to the melting point of the fibres to be fused and / or the melting point of the stabilising material.

[0054] Preferably, the thermal bonding is performed at a temperature between 70 degrees Celsius and 240 degrees Celsius.

[0055] Preferably, the thermal bonding is performed at a temperature between 100 degrees Celsius and 240 degrees Celsius.

[0056] Preferably, the stabilising layer is a film or membrane.

[0057] Preferably, the stabilising layer has a thickness based on the type of non-woven material layer and the melting point of the non-woven material layer.

[0058] Preferably, the thickness of the stabilising layer is between 0.005 mm and 0.5 mm.

[0059] Preferably, the stabilising layer is a breathable layer.

[0060] Preferably, the stabilising layer is a full layer.

[0061] Preferably, the stabilising layer is a partial layer.

[0062] Preferably, the stabilising layer is a frame layer.

[0063] Preferably, the stabilising layer is a polyurethane (PU) material layer.

[0064] Preferably, the stabilising layer is a polyethylene (PE) material layer.

[0065] Preferably, the stabilising layer is a polylactic acid (PLA) material layer.

[0066] Preferably, the stabilising layer is a textile adhesive layer.

[0067] Preferably, the bonding is performed in a patterned manner.

[0068] Preferably, the stabilising material is an adhesive material.

[0069] Preferably, the adhesive material is a glue.

[0070] Preferably, the adhesive material is a spray-on glue or a roll-on glue.

[0071] Preferably, the adhesive material is a polyurethane (PU) adhesive.

[0072] Preferably, the adhesive material is a polyethylene (PE) adhesive.

[0073] Preferably, the adhesive material is a polylactic acid (PLA) adhesive.

[0074] Preferably, the adhesive material is a textile adhesive.

[0075] Preferably, the adhesive substance is applied to the stabilizing material for bonding.

[0076] Preferably, the adhesive substance is a glue.

[0077] Preferably, the glue is a spray glue or a roll glue.

[0078] Preferably, the adhesive substance is a polyurethane (PU) adhesive.

[0079] Preferably, the adhesive substance is a polyethylene (PE) adhesive.

[0080] Preferably, the adhesive substance is a polylactic acid (PLA) adhesive.

[0081] Preferably, the adhesive substance is a textile adhesive.

[0082] Preferably, the non-woven fibers are synthetic polymers, bi-component fibers, natural fibers, man-made fibers, or combinations thereof.

[0083] Preferably, the synthetic polymers are selected from polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET).

[0084] Preferably, the natural fibers are selected from wood, pulp, cotton, or bamboo.

[0085] Preferably, the man-made fibers are selected from viscose, lyocell, polylactic acid (PLA), or cellulose acetate.

[0086] Preferably, the article is an incontinence absorbent article (incontinence bag).

[0087] Preferably, the article is a menstrual fluid article (feminine hygiene article or catamenial hygiene article).

[0088] Preferably, the article is a menstrual fluid article (feminine hygiene article or catamenial hygiene article) configured to be positioned adjacent to a person's genitalia for receiving menstrual fluid from the person's genital area.

[0089] Preferably, the article is one of: a diaper, a sanitary napkin, an incontinence pad, an incontinence bag, a female incontinence brief, a male incontinence brief, or nursing pad, protective pad (preferably a bed protective pad, a seat protective pad), a baby diaper changing pad, or a crib protective pad.

[0090] In a fourth aspect, the present invention relates to a method of constructing a reusable moisture management article, the reusable moisture management article being a garment or for use with a garment to be positioned adjacent to a body of a user and to absorb and retain moisture from the body of the user, the method comprising: providing a reusable absorbent and moisture management insert having at least a portion thereof exposed or configured to be exposed to define an inner layer of the article, the inner layer being configured to be positioned adjacent to and facing the body of the user for contact with the body of the user to directly absorb and retain moisture from the body of the user, the insert comprising at least an inner layer of nonwoven material, the nonwoven material comprising or being in the form of a plurality of nonwoven fibers; providing an inner layer of nonwoven material, the nonwoven material comprising or being in the form of a plurality of nonwoven fibers, and being located on an outer side of the insert; providing a stabilizing layer formed of a stabilizing material, the stabilizing material being a material configured to bond the nonwoven fibers by adhesive and / or thermal bonding; providing an outer cover layer configured to define an outer layer of the article; and assembling the insert, the inner layer, the stabilizing layer, and the outer cover layer by: positioning the inner layer, the insert, the stabilizing layer, and the outer cover layer such that the insert is located between the outer cover layer and the stabilizing layer, at least a first portion of the stabilizing layer is located between the inner layer and the insert, and wherein at least a second portion of the stabilizing layer is also configured to be bonded with the outer cover layer, bonding at least a portion of the inner layer with the stabilizing layer by applying heat and / or adhesive bonding, bonding at least a portion of the insert with the stabilizing layer by applying heat and / or adhesive bonding, and bonding at least a portion of the outer cover layer with the second portion of the stabilizing layer by applying heat and / or adhesive bonding, the insert being located between the outer cover layer and the stabilizing layer.

[0091] Preferably, the degree of bonding of the nonwoven fibers is such that the bonded nonwoven fibers do not disintegrate or do not substantially disintegrate upon exposure to at least one or more water washes or launderings.

[0092] Preferably, the insert comprises at least a first inner layer and a second inner layer, the first inner layer being closer to the outer cover layer than the second inner layer, and the second inner layer being closer to the inner layer than the second inner layer, at least the first inner layer comprising or being in the form of a plurality of nonwoven fibers.

[0093] Preferably, the second inner layer is a fast-drying knitted textile layer.

[0094] Preferably, the second inner layer is a quilted stitch structure to reduce friction.

[0095] Preferably, the method comprises bonding at least a portion of the second inner layer to the stabilizing layer by applying heat and / or adhesive bonding.

[0096] Preferably, the inner layer is located outside of the second inner layer.

[0097] Preferably, the thermal bonding comprises or involves fusing at least some or all of the non-woven fibers at a temperature related to the melting point of the fibers to be fused and / or the melting point of the stabilizing material.

[0098] Preferably, the thermal bonding is performed at a temperature between 70 degrees Celsius and 240 degrees Celsius.

[0099] Preferably, the thermal bonding is performed at a temperature between 100 degrees Celsius and 240 degrees Celsius.

[0100] Preferably, the stabilizing layer is a film or membrane.

[0101] Preferably, the stabilizing layer has a thickness based on the type of non-woven material layer and the melting point of the non-woven material layer.

[0102] Preferably, the stabilizing layer has a thickness between 0.005 mm and 0.5 mm.

[0103] Preferably, the stabilizing layer is a breathable layer.

[0104] Preferably, the stabilizing layer is a full layer.

[0105] Preferably, the stabilizing layer is a partial layer.

[0106] Preferably, the stabilizing layer is a frame layer.

[0107] Preferably, the stabilizing layer is a polyurethane (PU) material layer.

[0108] Preferably, the stabilizing layer is a polyethylene (PE) material layer.

[0109] Preferably, the stabilizing layer is a polylactic acid (PLA) material layer.

[0110] Preferably, the stabilizing layer is a textile adhesive layer.

[0111] Preferably, the bonding is performed in a patterned manner.

[0112] Preferably, the stabilizing material is an adhesive material.

[0113] Preferably, the adhesive material is a glue.

[0114] Preferably, the adhesive material is a spray glue or a roll glue.

[0115] Preferably, the adhesive material is a polyurethane (PU) adhesive.

[0116] Preferably, the adhesive material is a polyethylene (PE) adhesive.

[0117] Preferably, the adhesive material is a polylactic acid (PLA) adhesive.

[0118] Preferably, the adhesive material is a textile adhesive.

[0119] Preferably, the adhesive substance is applied to the stabilizing material for bonding.

[0120] Preferably, the adhesive substance is a glue.

[0121] Preferably, the glue is a spray glue or a roll glue.

[0122] Preferably, the adhesive substance is a polyurethane (PU) adhesive.

[0123] Preferably, the adhesive substance is a polyethylene (PE) adhesive.

[0124] Preferably, the adhesive substance is a polylactic acid (PLA) adhesive.

[0125] Preferably, the adhesive substance is a textile adhesive.

[0126] Preferably, the nonwoven fibers are synthetic polymers, bi-component fibers, natural fibers, man-made fibers, or combinations thereof.

[0127] Preferably, the synthetic polymers are selected from polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET).

[0128] Preferably, the natural fibers are selected from wood, pulp, cotton, or bamboo.

[0129] Preferably, the man-made fibers are selected from viscose, lyocell, PLA, or cellulose acetate.

[0130] Preferably, the inner layer defines a window through which a portion of the second inner layer is exposed or configured to be exposed.

[0131] Preferably, the inner layer and the stabilizing layer 240 only cover the periphery of the second inner layer at the surface of the article that is configured to face the user's body.

[0132] Preferably, the inner layer includes a central portion that extends longitudinally from a top end of the article to a bottom end of the article.

[0133] Preferably, the inner layer comprises a first side flap and a second side flap located between the top end of the article and the bottom end of the article, respectively.

[0134] Preferably, the first side flap extends away from the central portion of the inner layer in a first direction, and the second side flap extends from the central portion of the inner layer in a second direction opposite the first direction.

[0135] Preferably, the window is located in the central portion.

[0136] Preferably, the first and second side flaps of the inner layer each comprise a fastening member for releasable connection with an undergarment.

[0137] Preferably, the article comprises at least one fastener for releasable connection with an undergarment.

[0138] Preferably, the at least one fastener is a hook and loop fastener.

[0139] Preferably, the article is an incontinence absorbent article (an incontinence bag).

[0140] Preferably, the article is a menstrual fluid article (a feminine hygiene article or a catamenial hygiene article).

[0141] Preferably, the article is a menstrual fluid article (a feminine hygiene article or a catamenial hygiene article) configured to be positioned adjacent to a person's genitalia for receiving menstrual fluid from a person's genital area.

[0142] Preferably, the article is one of: a diaper, a sanitary napkin, an incontinence pad, an incontinence bag, a feminine incontinence panty, a male incontinence panty, a nursing pad, a shield (preferably a bed shield, a seat shield), a baby changing pad, or a crib protector pad.

[0143] Preferably, the outer cover layer is formed or assembled to define an outermost layer of the article.

[0144] Preferably, the outer cover layer 250 is a nonwoven layer.

[0145] Preferably, the method further comprises: providing an outer layer configured to be located between the outer cover layer and the insert; and assembling the outer layer by positioning the outer layer between the outer cover layer and the insert or the first inner layer of the insert to form a portion of the article.

[0146] Preferably, the outer layer is an adhesive layer, such that the insert (or first inner layer) and the outer cover are adhered together using the outer layer.

[0147] Preferably, the outer layer is coextensive with the first inner layer and / or the outer cover.

[0148] Preferably, the outer layer is an adhesive glue or comprises an adhesive glue.

[0149] Preferably, the outer layer is fused with the waterproof textile.

[0150] Preferably, the outer layer is moisture resistant or leak resistant, thereby serving as a leak barrier.

[0151] Preferably, the method comprises applying a moisture resistant solution to the outer layer.

[0152] Preferably, the outer layer is coated with a moisture resistant solution.

[0153] Preferably, the outer layer is made of the same material as the stabilizing layer 220.

[0154] Preferably, the stabilizing layer is a primary stabilizing layer and the outer layer is a secondary stabilizing layer.

[0155] Preferably, the article is configured to be positioned adjacent to a user's vulva region to receive and absorb moisture from the user's vulva region.

[0156] One or more statements relating to any of the aspects described above can equally apply to this aspect.

[0157] In a fifth aspect, the present invention relates to a reusable moisture absorbing article manufactured using the method defined in any one or more statements of the first, third or fourth aspects.

[0158] One or more statements relating to any of the aspects described above can equally apply to this aspect.

[0159] In a sixth aspect, the present invention relates to a reusable moisture absorbing article, the article comprising: at least one nonwoven material comprising or being in the form of a plurality of nonwoven fibers; at least one stabilizing material; wherein the at least one nonwoven layer and the at least one stabilizing layer are adhered together by applying the stabilizing material to at least a portion or all of the nonwoven material, such that the stabilizing material is applied to at least some or all of the plurality of nonwoven fibers; and the plurality of nonwoven fibers with the stabilizing material applied thereto are adhered with the stabilizing material by an adhesive and / or thermal bonding.

[0160] One or more statements related to any of the above aspects can equally apply to this aspect.

[0161] In a seventh aspect, the present application relates to an undergarment comprising or incorporating an article constructed using any of the defined methods described above.

[0162] Preferably, the undergarment is a brief.

[0163] Preferably, the undergarment is a men's brief.

[0164] Preferably, the undergarment is a women's brief.

[0165] One or more statements related to any of the above aspects can equally apply to this aspect.

[0166] In the foregoing, unless otherwise stated, one or more statements related to one aspect can equally apply to another aspect.

[0167] It is to be understood that the term "comprise" can be used in different jurisdictions with different connotations. For the purpose of the present specification, unless otherwise stated, the term "comprise" shall have a inclusive meaning, i.e. it shall be taken to mean that it includes not only something directly mentioned but also something indirectly mentioned or even something which is not mentioned at all. This principle shall also apply when the terms "comprises", "comprised" or "comprising" are used in the context of a device or method or process comprising one or more steps.

[0168] As used hereinabove and hereinbelow, the term "and / or" means "and" or "or", or both.

[0169] As used hereinabove and hereinbelow, the term "(s)" following a noun means the plural and / or singular form of the noun.

[0170] As used hereinabove and hereinbelow, unless otherwise stated, the term "liquid" in the context of the present specification can include "liquid", but can also include "moisture".

[0171] As used hereinabove and hereinbelow, unless otherwise stated, the term "moisture resistant" in the context of the present specification can include "water resistant", "waterproof" and "leakproof".

[0172] As used hereinabove and hereinbelow, unless otherwise stated, the term "waterproof" in the context of the present specification can include "waterproof", but can also include a substance that is not permeable to body moisture.

[0173] As used hereinabove and hereinbelow, unless otherwise indicated, the word "stabilise" in the context of the present specification means to prevent at least some of the nonwoven fibres from disintegrating or readily disintegrating on washing and / or laundering, such that the nonwoven fibres and / or articles comprising such nonwoven fibres can be reused even after washing and / or laundering. This principle also applies when the term "stabilising" or "stabilises" is used in relation to a layer, a fibre, a product or one or more steps in a method or process.

[0174] As used hereinabove and hereinbelow, unless otherwise indicated, the word "wetness" in the context of the present specification can include any fluid, liquid and / or wetness discharged from the human body and can also include menstrual fluid / discharge and / or urine.

[0175] As used hereinabove and hereinbelow, unless otherwise indicated, the word "compression force" in the context of the present specification can include compression force but can also include compression force applied with heat at a suitable temperature for bonding purposes. The same principle applies to "compression forces".

[0176] As used hereinabove and hereinbelow, unless otherwise indicated, the word "retain" in the context of the present specification can mean "to continue to hold or contain something" but can also be released, such as by evaporation, squeezing and wringing. The word "retain" is different from "absorb" which in the context of the specification can mean "to take in and / or suck up" liquid from a surrounding surface or space. This principle also applies to the words "retaining" and / or "retention" as used hereinabove and hereinbelow, unless otherwise indicated.

[0177] The word "for" when used in the claims, unless otherwise indicated, should be construed that it means only "adapted for" and not for example "especially adapted for" or "configured to" for the stated purpose.

[0178] It will be known to the person skilled in the art of patents that the word "substantially" can in some instances be used to enlarge the scope of a term. It should be noted that in the present application the word "substantially" is used with a term to qualify (characterise) the feature to obtain all the benefits provided by the use of the word "substantially" (i.e. any enlargement of scope benefits) and within its scope also includes the feature that the term precisely corresponds to (no enlargement of scope). For example, if a feature is described / defined as "substantially vertical" in the present application, this includes within its scope a feature that is "close to" vertical (the word "substantially" being seen to enlarge the scope of the term "vertical") and also includes within its scope a feature that is "exactly" vertical. BRIEF DESCRIPTION OF DRAWINGS

[0179] The application will now be described, by way of example only, and with reference to the accompanying drawings in which:

[0180] Figures 1A-1D is a breakdown view showing stabilization of nonwoven fibers according to the method of the present application.

[0181] Figure 2A is an outside view of the article according to the first example of the present application in assembled form.

[0182] Figure 2B is an inside view of the article of Figure 2A in assembled form.

[0183] Figure 2C is a breakdown view of the article of Figure 2A .

[0184] Figure 3A is an outside view of the article according to the second example of the present application in assembled form.

[0185] Figure 3B is an inside view of the article of Figure 3A in assembled form.

[0186] Figure 3C is a breakdown view of the article of Figure 3A .

[0187] Figure 4A is an outside view of the article according to the third example of the present application in assembled form.

[0188] Figure 4B is an inside view of the article of Figure 4A in assembled form.

[0189] Figure 4C is a breakdown view of the article of Figure 4A .

[0190] Figure 5A is an outside view of the article according to the fourth example of the present application in assembled form.

[0191] Figure 5B is an inside view of the article of Figure 5A in assembled form.

[0192] Figure 5C is a breakdown view of the article of Figure 5A .

[0193] Figure 6A is an inside view of the article according to the fifth example of the present application in assembled form.

[0194] Figure 6B is an outside view of the article of Figure 6A in assembled form.

[0195] Figure 6C is a breakdown view of the article of Figure 6AAn exploded view of the product.

[0196] Figure 7A This is an internal view of the article of the sixth example according to the present invention in an assembled form.

[0197] Figure 7B yes Figure 7A An external view of the product in its assembled form.

[0198] Figure 7C yes Figure 7A An exploded view of the product.

[0199] Figure 8A A front view of women's underwear, including an article according to the seventh example of the present invention, is shown.

[0200] Figure 8B It shows Figure 8A A rear view of women's underwear.

[0201] Figure 8C This is an internal view of the article of the seventh example according to the present invention in an assembled form.

[0202] Figure 8D yes Figure 8A An exploded view of the product.

[0203] Figure 9A A front view of men's underwear including the article according to the eighth example of the present invention is shown.

[0204] Figure 9B It shows Figure 9A Rear view of men's underwear.

[0205] Figure 9C It shows Figure 9A A flattened internal view of men's underwear.

[0206] Figure 9D It is a product of men's underwear and Figure 9A An exploded view of the product.

[0207] Figure 10A An exploded view of an article of manufacture according to the ninth example of the present invention is shown.

[0208] Figure 11A An exploded view of an article of manufacture according to a tenth example of the present invention is shown.

[0209] Figure 11B It shows Figure 11A An assembled view of the product. Detailed Implementation

[0210] The present invention provides a reusable absorbent article that is designed to be washable, and preferably printable, non-abrasive, and dimensionally stable. The article is made by stabilizing a nonwoven fabric material using a stabilizing material that also has high absorbency, as well as rapid wicking and moisture retention capabilities. This makes it well suited for absorbing exudates from the human body, such as menstrual fluid and urinary incontinence.

[0211] Reference will now be made to the drawings wherein Figures 1A-1D A nonwoven material 110 is shown that will be stabilized according to the claimed invention using a stabilizing material 120. The nonwoven material 110 comprises or is in the form of a plurality of nonwoven fibers. The stabilizing material 120 is applied to at least a portion or all of the nonwoven material 110. The nonwoven fibers 110 with the stabilizing material 120 applied are then bonded with the stabilizing material 120 through an adhesive and / or thermal bonding. This bonding stabilizes at least a portion or all of the nonwoven material 110. Possible nonwoven fibers are non-limiting examples of synthetic polymers such as, but not limited to, polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), etc., bicomponent fibers, natural fibers (e.g., wood pulp, cotton, bamboo, etc.), man-made fibers (e.g., viscose, lyocell, PLA, cellulose acetate), or combinations thereof.

[0212] As shown, the nonwoven material 110 can be a layer of nonwoven material. Thus, the same reference number 110 has been used to refer to the nonwoven material and the nonwoven layer. The nonwoven material 110 can be a nonwoven, a nonwoven fabric, or a nonwoven textile.

[0213] The thermal bonding process can include fusing at least some or all of the nonwoven fibers at a temperature related to the melting point of the fibers to be fused / bonded and / or the melting point of the stabilizing material. In this way, the fibers and / or the stabilizing material can melt, and this melting can cause the fibers to bond together / fuse to form a stabilized configuration of the nonwoven material. As a result of the melting of the fibers and the fusing of the fibers during thermal bonding, even those portions of the nonwoven fibers that are not covered by the stabilizing layer are converted to the stabilized configuration. By stabilized configuration, it is meant that the bonded nonwoven fibers will be fused or bonded so as not to disintegrate or easily disintegrate upon washing or laundering, such that the nonwoven fibers can be reused even after washing or laundering. Most preferably, the thermal bonding is performed at a temperature between 70 degrees Celsius and 240 degrees Celsius. This temperature range corresponds to the melting points of most, if not all, possible types of fibers of the nonwoven material 110. In some embodiments, the thermal bonding can be performed at a temperature range between 100 degrees Celsius and 240 degrees Celsius.

[0214] As shown, the stabilizing material 120 can be formed as a stabilizing layer. Thus, the same reference numeral 120 has been used to refer to the stabilizing material and the stabilizing layer. The stabilizing layer 120 can be a film or a membrane. The stabilizing layer 120 can have a thickness based on the type of nonwoven material and the melting point of the nonwoven material. The thickness of the stabilizing layer 120 can be between 0.005 mm to 0.5 mm. The stabilizing layer 120 can be a breathable layer. The stabilizing layer 120 can be a full layer (i.e. completely covers the nonwoven layer) or a partial layer (i.e. completely covers the nonwoven layer) or a frame layer (i.e. has a window portion 121 that does not cover the nonwoven layer). Figure 1A An example is shown where the stabilizing layer 120 is a full layer configured to completely cover the nonwoven layer 110. Figure 1B An example is shown where the stabilizing layer 110 is a frame layer configured to cover the nonwoven layer except at the window portion 121. In this example, the stabilizing layer 120 is a partial layer. Figure 1B In this example, the stabilizing layer 121 covers the nonwoven layer 110 at or near the periphery of the nonwoven layer. The stabilizing layer 120 can be a polyurethane (PU) material layer. However, it is possible that the stabilizing layer 120 can be a polyethylene (PE) material layer, a polylactic acid (PLA) material layer or many other suitable textile adhesive material layers.

[0215] The bonding can be done in a patterned manner.

[0216] The nonwoven layer 110 and / or the stabilizing layer 120 can have any suitable shape or size.

[0217] The stabilizing material can be an adhesive material, preferably a glue (e.g. a spray glue or a roll glue) or a polyurethane (PU) adhesive. However, it is possible that the stabilizing material can be a polyethylene (PE) adhesive, a polylactic acid (PLA) adhesive or many other suitable textile adhesives.

[0218] In one example, where the bonding is done only by adhesive bonding, the nonwoven fibrous material 110 can be stabilized by bonding to the stabilizing material using a spray or roll adhesive glue.

[0219] Similarly, in one example, where bonding is performed only through thermal bonding, a polyurethane (PU) adhesive 123 or similar (e.g., a polyethylene (PE) adhesive, a polylactic acid (PLA) adhesive, or other suitable textile adhesive material layer) can be applied to the stabilizing layer 120 to fuse to the nonwoven layer 110, thereby being thermally fused to the nonwoven layer 110. More specifically, the nonwoven fibers of the nonwoven layer 120 can be stabilized by fusing the nonwoven fibers to the intact, partial, or frame breathable stabilizing material 120 using heat bonding (thermo bonding) at high temperatures of 70 degrees Celsius to 240 degrees Celsius. The polyurethane (PU) film can have various thicknesses, preferably ranging from 0.005 mm to 0.5 mm, depending on the type of nonwoven and the melting point of the fibers of the nonwoven material 110. Instead of a polyurethane film, a polyethylene (PE) film, a polylactic acid (PLA) film, or other suitable textile adhesive material film can be used.

[0220] The use of polyurethane (PU), polyethylene (PE), or polylactic acid (PLA) in the stabilizing layer 120 and / or using it as an adhesive is advantageous because it allows for the manufacture of sanitary (hygiene) products that include nonwoven materials that are washable and reusable. Similarly, it allows for the manufacture of sanitary (hygiene) products that include any number or combination of nonwoven materials as well as knitted or woven materials that are washable and reusable. Many other suitable textile adhesives or materials that provide the same or similar functionality as polyurethane (PU), polyethylene (PE), or polylactic acid (PLA) can be used in the stabilizing layer 120, providing the same or similar advantages.

[0221] The addition of a knitted or woven layer is optional, but can be advantageous to further improve and control the stabilization of the nonwoven fibers, thereby allowing for enhanced reusability or washing or laundering before the nonwoven fibers disintegrate.

[0222] The above-described methods of the present invention can be used to construct / manufacture reusable absorbent articles that are undergarments or used with undergarments to be positioned adjacent to a user’s body and to absorb (and preferably also retain) moisture from the user’s body. Some non-limiting examples of such articles include diapers, sanitary napkins, incontinence pads, incontinence bags, female incontinence briefs, male incontinence briefs, care pads, and the like. Thus, the reusable moisture retaining articles can be reusable sanitary articles.

[0223] Such an article can include an inner layer, which can be the same as the nonwoven material 110 described above, and a stabilizing material 120 forming a stabilizing layer as described above. The stabilizing material 120 can be applied to at least a portion or all of the inner layer, such that the stabilizing material is applied to at least some or all of the nonwoven fibers.

[0224] The nonwoven fibers 110 to which the stabilizing material 120 is applied are then bonded with the stabilizing material 120 by adhesive and / or thermal bonding, thereby stabilizing at least a portion or all of the nonwoven material and forming the reusable absorbent article 100.

[0225] In some embodiments, the stabilizing material / layer 120 is moisture resistant or leak resistant.

[0226] Example 1

[0227] Figures 2A-2C An example of a reusable article is shown. Figure 2A An outer view of a reusable absorbent article 200 according to the present application is shown. Figure 2B An inner view of the article of Figure 2A is shown. Figure 2C An inner view of the article of Figure 2A and Figure 2B is shown.

[0228] The article 200 is a panty or is used with a panty to be positioned adjacent to and receive moisture from a user’s body. The user can be a person wearing the article. The article 200 can be used as a menstrual fluid absorbent article (also referred to as a “feminine hygiene article” or “menstrual hygiene article,” “sanitary napkin,” “feminine pad,” or “menstrual pad”). The article 200 can also be suitable for absorbing any other moisture from a user’s body. The article 200 can also be suitable for absorbing moisture during light to moderate incontinence, and thus can be used as an incontinence pad.

[0229] The article 200 includes a nonwoven layer in the form of an inner layer 210 (a first inner layer 210) for absorbing moisture. The nonwoven layer can be the same as the nonwoven layer 110 described above, and thus need not be described in further detail.

[0230] The article 200 includes a second inner layer 230 and a stabilizing layer 240. The stabilizing layer 240 can be the same as or similar to the stabilizing layer 120 or stabilizing material 120 described above, and thus need not be explained in further detail. As shown, at least a portion 232 of the second inner layer 230 is exposed to define an interior region of the article 200. The interior region of the article is configured to be adjacent to and face a user’s body for contact with the user’s body to directly receive moisture from the user’s body. Figure 2B

[0231] ​Part 232 may optionally be covered by a removable material (such as a removable film or the like), which exposes part 232 when such removable material is removed. This helps prevent contamination of part 232, which is an inner layer of the article configured to come into contact with the user's body.

[0232] like Figure 2C As shown, article 200 comprises multiple layers. These multiple layers are at least an outermost layer 250 (also referred to as an outer cover layer 250), an outer more layer 220 (also referred to as an outer more layer 220), an insert including a first inner layer 210 and a second inner layer 230, and a stabilizing layer 240. An inner more layer 260 (also referred to as an inner more layer 260) is also present. These layers are assembled together to form article 200. As described above, the first inner layer 210 is a nonwoven layer (preferably the same as the nonwoven layer 110 described above). It serves as the internal nonwoven core of article 200. The thickness (gsm) of this first inner layer 210 may depend on the desired absorption level.

[0233] When the layers are assembled, at least a portion 232 of the second inner layer is exposed or configured to be exposed to define the inner layer of the article. The inner layer (i.e., the exposed or configured portion) is configured to be adjacent to and in contact with the user's body to directly absorb moisture from the user's body. If the article 200 is used as a menstrual fluid and / or urine-absorbing article, the moisture from the user's body absorbed through the exposed portion 232 of the insert 232 will be menstrual fluid / menstrual discharge and / or urine.

[0234] At least some of the absorbed moisture from the second inner layer 230 can be transferred to the first inner layer 210. By having at least two inner layers 210 and 230, the service life of the article 200 is improved. More specifically, having a second inner layer 230 can improve and control the stability of the nonwoven fibers in the first inner layer 210, thereby allowing for more reuses or washes before the nonwoven fibers gradually disintegrate. Having two inner layers thus contributes to improving the service life of the article 200. Optionally, more than two inner layers may be present.

[0235] like Figure 2C As shown, the innermost layer 260 may be located outside the second inner layer 230. At least a portion of the stabilizing layer 240 may be positioned or sandwiched between the second inner layer 230 and the innermost layer 260. More specifically, at least a portion of the stabilizing layer 240 may be positioned or sandwiched between the surface of the second inner layer 230 configured to face the innermost layer 260 and the surface of the innermost layer 260 configured to face the second inner layer 230, thereby interconnecting the second inner layer 230 and the innermost layer 260.

[0236] The stabilizing layer 240 can be the same as or similar in construction and function to the stabilizing layer 120 described above.

[0237] The inner layer 260 can be the innermost layer of the article 200. The inner layer 260 can be a nonwoven layer or a nonwoven textile. Thus, the inner layer 260 can be similar in construction to the nonwoven layer 110 described above. The nonwoven fibers of the inner layer 260 can be stabilized using the stabilizing layer 240 in the same or similar manner as described above with reference to the nonwoven layer 110. Figures 1A-1D The inner layer 260 can have the same shape and size as the stabilizing layer 240.

[0238] The second inner layer 230 and the inner layer 260 can be bonded together (e.g., by adhesive and / or thermal bonding). A compressive force (i.e., a compression force) can be applied to the article 200 to facilitate such bonding. This eliminates or at least reduces the need for stitching and / or other complex processes for bonding the layers together, thereby significantly reducing manufacturing processes and costs. Moreover, with such bonding techniques, complex machinery is not needed to manufacture the article 200.

[0239] Returning to the embodiment of Figure 2C , the inner layer 260 can define a window 265 through which a portion 232 of the second inner layer 230 is exposed or configured to be exposed. As shown, a majority of the second inner layer is exposed or configured to be exposed to form the inner layer of the article 200. In this example shown, the entirety of the second inner layer 230 is exposed or configured to be exposed to form the inner layer of the article 200 except for the edges. Thus, only the edges or perimeter of the second inner layer 230 can be unexposed or configured to be unexposed on the surface configured to face the body of the user. The inner layer 260 and the stabilizing layer 240 can only cover the perimeter of the second inner layer 230 on the surface configured to face the body of the user. If the second inner layer 230 is nonwoven, the nonwoven fibers of the second inner layer 230 can still be stabilized using the stabilizing layer 240, by adhesive, and / or thermal bonding in the manner described above with reference to the nonwoven layer 110. Figures 1A-1D

[0240] The inner layer 260 can include a central portion 261 extending longitudinally from the top end 204 to the bottom end 206 of the article 200. The inner layer 260 can include a first side wing 262 and a second side wing 263 located between the top end 204 and the bottom end 206 of the article 200, respectively. The first side wing 262 can extend away from the central portion 261 of the inner layer 260 in a first direction, and the second side wing 263 can extend from the central portion 261 of the inner layer 260 in a second direction opposite the first direction. The window 265 can be located in the central portion.

[0241] ​In the possible embodiment where the second inner layer 230 is not present, the stabilizing layer 240 can be directly sandwiched between the first inner layer 210 and the inner layer 260 in the same or similar manner as the stabilizing layer would be sandwiched between the second inner layer 230 and the inner layer 260. In this case, a portion of the first inner layer 210 will be exposed in a similar manner to the exposed portion 232 of the second inner layer, such that the exposed portion of the first inner layer becomes the innermost layer of the article 200. In this case, the nonwoven fibers of the first inner layer 210 can still be stabilized using the stabilizing layer 240, by adhesive and / or thermal bonding in the same or similar manner as described above with reference to the second inner layer 230. Figures 1A-1D The stabilizing layer 240 can be bonded with at least the second inner layer 240, the inner layer 260, and the outer cover layer 250.

[0242] The outer cover layer 250 is formed or assembled to define the outermost layer of the article.

[0243] The outer layer 220 is positioned or sandwiched between the first inner layer 210 and the outer cover layer 250, thereby interconnecting the first inner layer 210 and the outer cover layer 250. More specifically, the outer layer 220 is positioned or sandwiched between the surface of the first inner layer 210 configured to face the outer cover layer 250 and the surface of the outer cover layer 250 configured to face the first inner layer, thereby interconnecting the first inner layer 210 and the outer cover layer 250.

[0244] The stabilizing layer 240 can be bonded with at least the second inner layer 240, the inner layer 260, and the outer cover layer 250.

[0245] In this example, as shown in FIG. 2, the fibers of the nonwoven layer are not prone to disintegration during water washing and / or laundering since the first inner layer 210 is sandwiched between the other layers. It is possible that the stabilizing layer 240 is also bonded with all the layers. For example, the outer layer 220, the first inner layer 210, and the second inner layer 230 can have different suitable sizes or shapes to ensure that the stabilizing layer 240 is bonded with one or more or all of these layers. Figure 2C

[0246] In some embodiments, the outer layer 220 can be an adhesive layer, such that the first inner layer 210 and the outer cover layer 250 are bonded together using the outer layer 220. The first inner layer 210 and the outer cover layer 250 can be bonded together by adhesive and / or thermal bonding. A compressive force (i.e., a compression force) can be applied to facilitate such bonding. This eliminates or at least reduces the need for stitching and / or other complex processes for bonding the layers together, thereby significantly reducing the manufacturing process and cost. Furthermore, with such bonding techniques, complex machinery is not required to manufacture the article 200.

[0247] ​The outer layer 220 can be coextensive with the first inner layer 210 and / or the outer cover layer 250. The outer layer 220 can be or can include adhesive glue. In some embodiments, the outer layer 220 can be fused with the waterproof textile. The outer layer 220 can be moisture resistant or leak resistant, thereby serving as a leak barrier. In some embodiments, a moisture resistant solution is applied to the outer layer 220. The outer layer 220 can be coated with a moisture resistant solution. By serving as a leak or moisture resistant barrier, the outer layer provides leak resistant properties to the article 200, thereby providing ultimate protection to the user. More specifically, this helps to prevent any moisture absorbed in the first inner layer 210 from leaking to the outer cover layer 250.

[0248] In some embodiments, the outer layer 220 can also be made of the same material as the stabilization layer 240, in which case the stabilization layer 240 is the primary stabilization layer and the outer layer 220 is the secondary stabilization layer. As the first inner layer 210 is a nonwoven layer, such a secondary stabilization layer can further stabilize the nonwoven fibers of the first inner layer 210. Such further stabilization can be performed in the same or similar manner as described above with reference to the stabilization layer 240. Figures 1A-1D

[0249] The article 200 can be configured to be positioned adjacent to a user’s crotch region to receive and absorb moisture from the user’s crotch region. The article 200 can or can not also be used to receive or absorb urinary incontinence. The received, absorbed moisture can optionally be retained by the article 200.

[0250] The outer cover layer 250 is most preferably a nonwoven layer. In such a case, the nonwoven fibers of the outer cover layer 250 can still be stabilized by adhesive and / or thermal bonding in the manner described above with reference to the stabilization layer 240. Figures 1A-1D The portion of the stabilization layer 240 that is configured to be bonded with the outermost layer can be used to stabilize at least that portion of the outer cover layer in the same or similar manner as described above with reference to the stabilization layer 240. Figures 1A-1D Similarly, if the outer layer 220 is a secondary / second stabilization layer (as described above), in such a case, the nonwoven fibers of the first inner layer 210 and the outer layer 250 will be further stabilized by the outer layer 220 in the same or similar manner as described above with reference to the stabilization layer 240. Figures 1A-1D The melting of the nonwoven fibers of the outer cover layer 250 during thermal bonding can also result in stabilization of the outer cover layer fibers in the same or similar manner as described above with reference to the stabilization layer 240. Figures 1A-1D

[0251] As explained, the first inner layer 210 is a layer of nonwoven. However, the second inner layer 230 can be a nonwoven, woven, or knitted moisture absorbing layer. In some embodiments, the second inner layer 230 can be a moisture retaining textile assembly as described in PCT Publication No. WO2020121176A1, which is incorporated by reference herein in its entirety. ​​

[0252] The first and second side flaps 262, 263 of the inner layer 260 can each include fasteners 267 (e.g., snap / press / pull hook and loop fasteners or Velcro® fasteners) for releasable connection with an undergarment, such as briefs. For example, the fasteners in the first and second side flaps can be connected by forming a loop around a crotch region of the briefs and releasably connecting with the briefs. Alternatively, the undergarment can have fasteners adapted to connect with the fasteners 267.

[0253] The outer cover layer 250 and the inner layer 260 can be identical in shape and / or size, except that the central portion of the inner layer 260 includes the window 265, while the outer cover layer 250 does not have such a window. Thus, the outer cover layer 250 can include a central portion 251 that extends longitudinally from the top end 204 of the article to the bottom end 206 of the article 200. The outer cover layer 250 can include first and second side flaps 252, 253 located between the top end 204 and the bottom end 206 of the article 200, respectively. The first side flap 252 can extend away from the central portion 251 of the outer cover layer 250 in a first direction, and the second side flap 253 can extend from the central portion 251 of the outer cover layer 250 in a second direction opposite the first direction.

[0254] Additionally, or alternatively, the outer cover layer 250 can include similar fastening members 268 (e.g., snap / press / pull hook and loop fasteners or Velcro® fasteners) for releasable connection with an undergarment, such as briefs. In the case where both the outer cover layer and the inner layer include fasteners, the fasteners 267 and 268 can be adapted to connect together. Alternatively, the undergarment can have fasteners adapted to connect with the fasteners 268.

[0255] The outer cover layer 250 and the inner layer 260 can extend longitudinally from the top end 204 of the article 200 to the bottom end 206 of the article 200. The first and second inner layers 210, 230 and the outer layer 220 can each be smaller than the central portion 251 of the outer cover layer 250 and / or the central portion 261 of the inner layer 260. In some embodiments, the first and second inner layers 210, 230 and the outer layer 220 can each have the same size as the central portion 251 of the outer cover layer 250 and / or the central portion 261 of the inner layer 260. In some embodiments, the outer layer 220 is larger (preferably slightly larger) than the first and second inner layers 210, 230. Such a configuration can allow the stabilization layer 240 to seal and / or adhere to the outer layer or at least be in direct contact with the outer layer. Different sizes / sizes and / or shapes of the layers are possible to allow the stabilization layer to be in direct contact and / or to seal and / or adhere to the respective layer. In some embodiments, all of the layers 250, 220, 210, 230, 240, and 260 can extend longitudinally from the top end 204 of the article 200 to the bottom end 206 of the article 200.

[0256] In one embodiment, the article 200 can have an elongated shape, with the layers extending longitudinally at the top end 204 and the bottom end 206, and without any side flaps. Such an article can optionally include a tape or similar fastening means for releasable connection with an undergarment.

[0257] In one embodiment, the outer cover 250 can be or also be optional. However, it is most preferred to have an outer cover due to the advantageous features of the outer cover 250 as explained above.

[0258] The adhesive and / or thermal bonding of the layers of the article 200 can use the same methods as described above with reference to Figures 1A-1D Similarly, the fibers of the nonwoven layers of the article 200 are stabilized by the stabilization layer in the same way as described above and with reference to Example 2 , so that no further description is required.

[0259] Figures 3A-3C

[0260] Figure 2A An article 300 according to another preferred embodiment of the present application is shown.

[0261] The article 300 is a panty or is used with a panty to be positioned adjacent to the body of a user and to receive moisture from the body of the user. The user can be a person wearing the article. The article 300 can be used as an incontinence absorbent insert article (also known as a "male guard" or "male panty shield", or "male pouch" or incontinence pouch). The article 300 can also be suitable for absorbing any other moisture from the body of a user. In some embodiments, the article is a female incontinence article configured to be positioned adjacent to the genitals of a person for receiving menses or other fluids, including urine, from the genital area of the person.

[0262] The article 300 of this example is similar in most respects to the article 200 described above, the differences can be identified by comparing Figure 3A with Figure 2B , Figure 3B with Figure 2C and Figure 3C with Example 3 In the figures relating to the article 300, features similar to those shown in the figures relating to the article 200 are identified with the same reference numerals plus 100. Most of the description of the preferred embodiment of the article 200 described above applies equally to the article 300, so that no further detailed description is required. In most cases, only the main differences will be discussed.

[0263] One main difference is the shape of the layers, all of which are suitably shaped for use as an incontinence absorbent insert article.

[0264] The inner layer 360 is in the form of a strip. The stabilizing layer 340 is also in the form of a strip. The stabilizing layer 340 can be an adhesive frame or a stabilized adhesive frame. The stabilizing layer 340 can be positioned or sandwiched between the second inner layer 330 and the inner layer 360. Similarly, the outer layer 320 can be positioned or sandwiched between the first inner layer 310 and the outer cover 350.

[0265] The inner layer 360 can be made of the same textile as the outer cover 350. The inner layer and / or the outer cover 350 can be made of a nonwoven textile or nonwoven material having a plurality of nonwoven fibers. Such nonwoven fibers are stabilized using adhesive and / or thermal bonding in the same or similar manner as described above.

[0266] The first inner layer 310 and the second inner layer 330 can be the same or similar type as described above for the article 200. Similarly, the outer layer 320 can also be a stabilizing layer (secondary stabilizing layer) similar to example 1. Any of the layers described above in the article 200 as optional can also be optional in the article 300.

[0267] In some embodiments, the outer cover 350 can optionally have been provided with sutures provided to allow the outer cover 350 to have a specific shape. In such a case, a suture-adhering adhesive layer 354 can optionally be provided to extend along and hide such sutures for additional protection. The suture-adhering adhesive layer 354 can be a suture-adhering glue seal or strip and can be or can function as a hot melt adhesive strip. The suture-adhering adhesive layer 354 can be made of the same material as the first stabilizing layer 320. It should be noted that there can be no sutures in the outer cover 350 and that alternative methods to sutures (e.g., folds) can be used to create the shape of the article 300. But even if present, they are pre-shaped sutures and are sutures configured to adhere the multiple layers together. The multiple layers can be adhered by applying adhesive and / or thermal bonding, preferably with the application of a compressive force as described above. Hot melt or ultrasonic melt seams are more preferred than sutures.

[0268] Except for the above differences and differences apparent from the drawings, all other features of the article 300, including the properties of its layers, can be the same as described above with reference to the article 200.

[0269] Figures 4A-4C

[0270] Figure 2A An article 400 according to another preferred embodiment of the present application is shown. The article 400 in this example is a baby diaper or training pant.

[0271] The article 400 is a pant or is used with a pant to be positioned adjacent to and to receive moisture from a user's body. The user can be the person wearing the article.

[0272] The article 400 of this example is similar in most respects to the article 200 described above, with differences that can be identified by comparing Figure 4A with Figure 2B , Figure 4B with Figure 2C and Figure 4C with Figures 1A-1D In the drawings involving the article 400, features similar to those shown in the drawings involving the article 200 are identified with the same reference numeral plus 200. Much of the description of the preferred embodiment of the article 200 described above applies equally to the article 400, so no further detailed description is needed. In most cases, only the major differences will be discussed.

[0273] One major difference is the shape of the various layers, all of which are suitably shaped to allow the article 400 to be used as a diaper.

[0274] Another major difference is the presence of additional layers, namely an adhesive layer 470 and an inner most layer 480 (also referred to as an innermost layer). The inner most layer can be in the form of protective strips 480A, 480B, which are spill guard strips. The strips 480A, 480B can be nonwoven, or can be knitted. The adhesive layer 470 is also in the form of strips 470A, 470B. The adhesive layer 470 can be positioned or sandwiched between the inner layer 460 and the inner most layer 480, thereby adhering the inner layer 460 and the inner most layer 480. Such adhesion can be by heat bonding and / or adhesive bonding applied in the same or similar manner as described above. In some embodiments, the outer layer 420 can also be a stabilizing layer (secondary stabilizing layer) similar to that of Example 1. In some embodiments, the adhesive layer 470 can be made of the same material as the stabilizing layer 440 and the outer layer 420, in which case each of the three layers 420, 440, and 480 can function as a stabilizing layer to stabilize any nonwoven fibers adhered to those layers in the same or similar manner as described above with reference to the stabilizing layer 440. Example 4

[0275] The inner layer 460 can be made of the same textile as the outer cover 450. The inner layer 460 and / or the outer cover 450 can be made of a nonwoven textile or nonwoven material having a plurality of nonwoven fibers. Such nonwoven fibers are stabilized by adhesive and / or heat bonding in the same or similar manner as described above.

[0276] ​Like the outer layer 220, the outer layer 420 can be moisture resistant. In some embodiments, a moisture resistant solution is applied to the outer layer 420. The outer layer 420 can be coated with a moisture resistant solution.

[0277] The first inner layer 410 and the second inner layer 430 can be the same or similar types as described above for the article 200. The outer layer 420 and the adhesive layer 470 can be made of the same or similar materials as the stabilizing layer 440. The stabilizing layer 440 can have the same materials as the stabilizing layer 240 described above for the article 200. The layers described above for the article 200 as optional can also be optional for the article 400.

[0278] The innermost layer 480 can include fasteners 467. Similarly, the outer layer 460 can also include fasteners 468. The fasteners 467, 468 can allow releasable connection with an undergarment in a similar manner as described above for the article 200. The fasteners in this embodiment are most preferably Velcro® (also known as hook and loop fasteners). However, many other alternative fasteners are possible, such as but not limited to buttons, snaps / press studs, and the like.

[0279] Except for the differences described above and apparent from the drawings, all other features of the article 400, including the properties of its layers, can be the same as described above with reference to the article 200.

[0280] Figures 5A-5C

[0281] Figure 2A An article 500 according to another preferred embodiment of the present application is shown.

[0282] The article 500 is a panty or is used with a panty to be positioned adjacent to and to receive moisture from a user’s body. The user can be a person wearing the article. The article 500 can be used as a menstrual fluid absorbing article (also known as a “feminine hygiene article” or “menstrual hygiene article”, “feminine pad” or “menstrual pad”). The article 500 can also be suitable for absorbing any other moisture from a user’s body.

[0283] The article 500 is designed for moderate to heavy incontinence.

[0284] The article 500 of this example is similar in most respects to the article 200 described above, the differences can be seen by comparing Figure 5A With Figure 2B , Figure 5B With Figure 2C And Figure 5C With Figures 1A-1Dto identify. In the drawings involving article 500, features similar to those shown in the drawings involving article 200 are identified with the same reference numeral plus 300. Much of the description of article 200 of the preferred embodiment described above applies equally to article 500, and need not be described in detail again. For the most part, only the major differences will be discussed.

[0285] One major difference is the shape of the layers, which are more suitably shaped to allow article 500 to be used in moderate to severe incontinence situations. However, outer layer 520 can have many other suitable shapes.

[0286] Another major difference is the presence of additional layers, namely adhesive layer 570 and inner most layer 580 (which can also be referred to as innermost layer). Inner most layer 580 is in the form of protective strips 580A, 580B, which are spill guard strips. Strips 580A, 580B can be nonwoven, or can be knitted. Adhesive layer 570 is also in the form of strips 570A, 570B. Adhesive layer 570 can be positioned or sandwiched between inner layer 560 and inner most layer 580, thereby adhering inner layer 560 and inner most layer 580. Such adhesion can be by heat bonding and / or adhesive bonding applied in the same or similar manner as described above. In some embodiments, outer layer 520 can also be a stabilizing layer (secondary stabilizing layer) similar to example 1. In some embodiments, adhesive layer 570 can be made of the same material as stabilizing layer 540 and outer layer 520, in which case each of the three layers 520, 540, and 570 can serve as a stabilizing layer to stabilize any nonwoven fibers bonded to these layers in the same manner as described above with reference to example 1. Example 5

[0287] Similar to outer layer 220, outer layer 520 can be moisture resistant. In some embodiments, a moisture resistant solution is applied to outer layer 520. Outer layer 520 can be coated with a moisture resistant solution.

[0288] Inner layer 560 can be made of the same textile as outer cover 550. Inner layer 560 and / or outer cover 550 can be made of a nonwoven textile or nonwoven material having a plurality of nonwoven fibers. Such nonwoven fibers are stabilized by adhesive and / or heat bonding in the same or similar manner as described above.

[0289] ​The first inner layer 510 and the second inner layer 530 can be the same or similar types as described above for the article 200. The outer layer 520 and the adhesive layer 570 can be made of the same or similar materials as the stabilizing layer 540. The stabilizing layer 540 can have the same materials as the stabilizing layer 240 described above for the article 200. The layers described above in the article 200 as optional can also be optional in the article 500.

[0290] The innermost layer 580 can include fasteners 567. Similarly, the outer layer 560 can also include fasteners 568. The fasteners 567, 568 can allow releasable connection with an undergarment in a similar manner as described above for the article 200. The fasteners in this embodiment are most preferably Velcro® (also known as hook-and-loop fasteners). However, many other alternative fasteners are possible, such as but not limited to buttons, snaps / poppers, etc.

[0291] Except for the differences described above and apparent from the figures, all other features of the article 500, including the properties of its layers, can be the same as described above with reference to the article 200.

[0292] Figures 6A-6C

[0293] Figure 2A An article 600 according to another preferred embodiment of the present application is shown.

[0294] The article 600 is a panty or is used with a panty to be positioned adjacent to a user's body and to receive moisture from the user's body. The user can be a person wearing the article. The article 600 can be used as an incontinence absorbent insert article (also known as a "male guard" or "male panty liner", or "male pouch" or incontinence pouch). Its purpose is similar to the article 300 of Example 2 described above, except that the article 600 is designed for heavy incontinence. The article 600 can also be suitable for absorbing any other moisture from the user's body. In some embodiments, the article 600 is a female incontinence article configured to be positioned adjacent to a person's genitalia for receiving menses or other fluids, including urine, from the genital area of the person.

[0295] The article 600 of this example is similar in most respects to the article 300 or the article 200 described above, with the differences being apparent by comparing Figure 6B or 3A with Figure 2B , Figure 6A or 3B with Figure 2C and Figure 6C or 3C with Figures 1A-1Dsimilar to the features shown in the figures relating to article 200 are identified with the same reference numerals plus 400. Similarly, features in article 600 similar to the features shown in the figures relating to article 300 are identified with the same reference numerals plus 300. Much of the description of articles 200 or 300 of the preferred embodiments described above applies equally to article 600, and need not be described in detail again. Only the major differences will be discussed.

[0296] One major difference is the shape of the layers, all of which are suitably shaped for use as an incontinence absorbent article in the case of heavy incontinence.

[0297] Another major difference is the presence of additional layers, namely an adhesive layer 670 and an inner most layer 680 (also referred to as an innermost layer). The inner most layer 680 is in the form of protective strips 680A, 680B, 680C, 680D, which are spill guard strips. The strips 680A, 680B, 680C, 680D can be non-woven, or can be knitted. The adhesive layer 670 is also in the form of strips 670A, 670B. The adhesive layer 670 can be positioned or sandwiched between the inner layer 660 and the inner most layer 680, thereby adhering the inner layer 660 and the inner most layer 680. Such adhesion can be by thermal adhesion and / or adhesive adhesion in the manner described above. In some embodiments, the outer layer 620 can also be a stabilizing layer (secondary stabilizing layer) similar to example 1. In some embodiments, the adhesive layer 670 can be made of the same material as the stabilizing layer 640 and the outer layer 620, in which case each of the three layers 620, 540 and 670 can act as a stabilizing layer to stabilize any non-woven fibers adhered to these layers in the same or similar manner as described above with reference to the stabilizing layer 640. Figure 6C

[0298] The inner layer 660 can be made of the same textile as the outer cover 650. The inner layer 660 and / or the outer cover 650 can be made of a non-woven textile or non-woven material having a plurality of non-woven fibers. Such non-woven fibers are stabilized by adhesive and / or thermal adhesion in the same or similar manner as described above.

[0299] Similar to the outer layer 220, the outer layer 620 can be moisture resistant. In some embodiments, a moisture resistant solution is applied to the outer layer 620. The outer layer 620 can be coated with a moisture resistant solution.

[0300] Another point of difference is that the stabilizing layer 640 is also in the form of a plurality of strips 640A, 640B, 640C and 640D to match the shape of the strips 660A, 660B, 660C and 660D of the inner layer. ​

[0301] Apart from any visual differences, the first inner layer 610 and the second inner layer 630 may be of the same or similar type as described above for article 200. Layers described above as optional in article 200 may also be optional in article 600. Figures 1A-1D As shown, an optional bottom strip 635 may be present, suitable for bottom bonding to the surface of the second inner layer 630 facing away from the first inner layer 610. This bonding can be achieved using an adhesive strip 636 configured to be sandwiched between the second inner layer 630 and the bottom strip 635. The bottom strip 635 may be a nonwoven strip, in which case bonding allows the nonwoven fibers of the bottom strip 635 to be stabilized. Alternatively, the bottom strip 635 may be a woven or knitted fabric, in which case the fourth stabilizing strip 636 can still function as an adhesive strip. This arrangement with the bottom strip 635 can help prevent accidental transfer of moisture from the bottom of the article. In some embodiments, the adhesive strip 636 may be made of the same material as the stabilizing layer 640, in accordance with the above reference. Example 6 Any nonwoven fibers that are stably bonded to the strip in the same manner.

[0302] Apart from the differences described above and those obvious from the accompanying drawings, all other features of article 500 (including the properties of its layers) are the same as those described in reference articles 200 or 300 above.

[0303] Figures 7A-7C

[0304] Figure 2A Article 700 according to another preferred embodiment of the invention is shown. In this example, article 700 is an adult diaper or pad. It may be a neutral adult diaper or pad.

[0305] Product 700 is an underwear or is used with underwear to be positioned close to the user's body and to receive moisture from the user's body. The user may be an adult wearing the product.

[0306] Article 700 in this example is similar to article 200 described above in most respects; the differences can be identified through comparison. Figure 7B and Figure 2B , Figure 7B and Figure 2C as well as Figure 7C and Figures 1A-1D To identify. In the drawings relating to article 700, features similar to those shown in the drawings relating to article 200 are identified by the same reference numerals plus 500. Much of the description of article 200 of the preferred embodiment described above also applies to article 700, and therefore need not be described in detail again. In most cases, only the main differences will be discussed.

[0307] One major difference is in the shape of the layers, all of which are suitably shaped to allow the article 700 to be used as an adult diaper or pad or an adult incontinent diaper or pad.

[0308] Another major difference is the presence of additional layers, namely an adhesive layer 770 and an inner most layer 780 (also referred to as an innermost layer). The inner most layer can be in the form of protection strips 780A, 780B, which are spill guard strips. The strips 780A, 780B can be nonwoven or can be knitted. The adhesive layer 470 is also in the form of strips 770A, 770B. The adhesive layer 770 can be positioned or sandwiched between the inner layer 760 and the inner most layer 780, thereby adhering the inner layer 760 and the inner most layer 780. Such adhesion can be by thermal adhesion and / or adhesive adhesion in the manner described above. In some embodiments, the outer layer 720 can also be a stabilizing layer (secondary stabilizing layer) similar to that of example 1. In some embodiments, the adhesive layer 770 can be made of the same material as the stabilizing layer 740 and the outer layer 720, in which case each of the three layers 720, 740 and 770 can serve as a stabilizing layer to stabilize the nonwoven fibers adhered to these layers in the same manner as described above with respect to the article 200. Figure 7C

[0309] Another difference is that the inner layer 760 is also in the form of strips 760A and 760B, each extending from the top end to the bottom end of the article 700. In addition, the outer layer 740 is also in the form of strips 740A and 740B, each extending from the top end to the bottom end of the article 700.

[0310] The inner layer 760 can be made of the same textile as the outer cover 750. The inner layer 760 and / or the outer cover 750 can be made of a nonwoven textile or nonwoven material having a plurality of nonwoven fibers. Such nonwoven fibers are stabilized by adhesive and / or thermal adhesion in the same or similar manner as described above.

[0311] Similar to the outer layer 220, the outer layer 620 can be moisture resistant. In some embodiments, a moisture resistant solution is applied to the outer layer 620. The outer layer 620 can be coated with a moisture resistant solution.

[0312] The first inner layer 710 and the second inner layer 730, as well as the stabilizing layer, can be of the same or similar type as described above with respect to the article 200. The layers described above as optional in the article 200 can also be optional in the article 700.

[0313] ​The outer cover 750 may be in the form of multiple sheets, namely a top sheet 750A near the top of the article 700, a bottom sheet 750B near the bottom of the article 700, and an intermediate sheet 750C extending from the top sheet 750A to the bottom sheet 750B or vice versa. The intermediate sheet 750C may be releasably attached to one or both of the top sheet 750A and the bottom sheet 750B using suitable fasteners 781A and 781B. The fasteners in this embodiment are most preferably Velcro® (also known as hook and loop fasteners). However, many other alternative fasteners are also possible, such as, but not limited to, buttons, snaps, etc.

[0314] The outer surface of the outer cover 750 may include fasteners 782A and 782B. Fasteners 782A and 782B allow for a releasable connection to the underwear in a manner similar to that described above for article 200. The fasteners in this embodiment are most preferably Velcro® (also known as hook and loop fasteners). However, many other alternative fasteners are possible, such as, but not limited to, buttons, snaps, etc.

[0315] like Figures 1A-1D As shown, an optional bottom strip 735 may be present, suitable for bottom bonding to the surface of the second inner layer 730 facing away from the first inner layer 710. This bonding can be achieved using a bottom bonding strip 736 configured to be sandwiched between the second inner layer 730 and the bottom strip 635. The bottom strip 635 may be a nonwoven strip, in which case bonding allows the nonwoven fibers of the bottom strip to be stabilized. Alternatively, the bottom strip 735 may be a woven or knitted fabric, in which case the bottom bonding strip 736 can still function as an bonding strip. This arrangement with the bottom strip 735 can help prevent accidental transfer of moisture from the bottom of the article 700. In some embodiments, the bottom bonding strip 736 may be made of the same material as the stabilizing layer 740, in accordance with the above reference. Figure 7C Any nonwoven fibers that are stably bonded to the strip in the same manner.

[0316] Similarly, such as Figures 1A-1DAs shown, there can be an optional top strip 737 suitable for bonding to the top of the second inner layer 730 opposite the surface of the first inner layer 710. Such bonding can be performed using a top bonding strip 738 configured to be sandwiched between the second inner layer 730 and the top strip 737. The top strip 635 can be a nonwoven strip, in which case the bonding allows the nonwoven fibers of the bottom strip to stabilize. Alternatively, the top strip 735 can be a woven or knitted fabric, in which case the top bonding strip 738 can still act as a bonding strip. Such an arrangement with a top strip 737 can help avoid unintended moisture transfer from the top of the article 700. In some embodiments, the bottom top bonding strip 738 can be made of the same material as the stabilizing layer 740 to stabilize any nonwoven fibers bonded to the strip in the same manner as described above with respect to the article 200. Example 7

[0317] Except for the above differences and differences apparent from the drawings, all other features of the article 700, including the properties of its various layers, can be the same as described above with respect to the article 200.

[0318] Figures 8A-8D

[0319] Figure 2A An article 800 according to another preferred embodiment of the present application is shown. The article 200 in this example is a female panty 5 or a portion of a female panty 5.

[0320] The article 800 of this example is similar to the article 200 described above in most respects, differences can be identified by comparing Figure 8C with Figure 2B and Figure 8D with Figures 8A-8D In Figures 1A-1D , features similar to those shown in the drawings relating to the article 200 are identified with the same reference numerals plus 600. Much of the description of the article 200 of the preferred embodiments described above applies equally to the article 800, and need not be described in further detail. In most cases, only the main differences will be discussed.

[0321] Here, the outer cover 850 is a female panty panel, and can be made of a knitted textile, preferably with high elasticity to ensure comfort.

[0322] The outer layer 820 is positioned or sandwiched between the first inner layer 810 and the outer cover 850, thereby interconnecting the first inner layer 810 and the outer cover 850.

[0323] The first inner layer 810 and the outer cover 860 are bonded together using the outer layer 820.

[0324] ​The inner layer 860 is in the form of strips 860A, 860B. The stabilizing layer 840 is also in the form of strips 840A, 840B. The strip 840A can be positioned or sandwiched between the second inner layer 830 and the inner layer strip 860A. Similarly, the strip 840B can be positioned or sandwiched between the second inner layer 830 and the inner layer strip 860B. Thus, the stabilizing strips 840A, 840B can interconnect the second inner layer 830 and the inner strips 860A, 860B.

[0325] The inner strips 860A, 860B can be made of the same textile as the outer cover 850. Alternatively, the inner strips can be made of a nonwoven textile.

[0326] The inner strips 860A, 860B and the stabilizing strips 840A, 840B can extend laterally along a first edge of the second inner layer 830 proximate the top end 804 of the article 800 and a second edge of the second inner layer 830 proximate the bottom end 806 of the article 800. More specifically, the inner strip 860A and the stabilizing strip 840A can extend laterally along the first edge of the second inner layer 830 proximate the top end 804 of the article 800. Similarly, the inner strip 860B and the stabilizing strip 840B can extend laterally along the second edge of the second inner layer 860B proximate the bottom end 806 of the article 800.

[0327] The adhesive layer 870 can be in the form of two strips 870A, 870B. The third stabilizing strips 870A, 870B can be adhesive strips. The adhesive strips 870A, 870B can be adhered (adhesive and / or heat adhered) to the two longitudinal sides of the second inner layer 830 and also to the inner strips 860A and 860B. Also shown is an additional adhesive strip 859, which can optionally be made of a similar material as the stabilizing layer 840. In some embodiments, the outer layer 820 can also be a stabilizing layer (a secondary stabilizing layer) similar to that of Example 1. In some embodiments, the adhesive layer 870 can be made of the same material as the stabilizing layer 840 and the outer layer 820, in which case each of the three layers 820, 840 and 870 can act as a stabilizing layer to stabilize any nonwoven fibers adhered to these layers in the same manner as described above with reference to the stabilizing layer 840. Example 8

[0328] Except for the above differences and any other differences that will be apparent from the drawings, all other features of the article 800, including the properties of its layers, can be the same as described above with reference to the article 200.

[0329] Figures 9A-9B

[0330] Figure 9D ​are front and back views of a men's (men / male) brief 10, including an article 900 according to yet another embodiment of the present application, which is identical or similar to the article 300 of Example 2.

[0331] The article 900 of this example is similar in most respects to the article 300 described above, the differences can be identified by comparing Figure 3C with Figure 9C In the drawings relating to the article 900, features similar to those shown in the drawings relating to the article 300 are identified with the same reference numerals plus 600. Most of the description of the article 300 of the preferred embodiment described above applies equally to the article 900, and need not be described in detail again. In most cases, only the main differences will be discussed.

[0332] Example 9 A flattened view of a brief 10 is shown, showing an article 900 forming part of a men's brief. Figure 12D shows an exploded view, showing an article 900 forming part of a men's brief. An outer cover 950 can be attached to a men's brief panel 990A, and can be made of a knitted textile, preferably with high elasticity to ensure comfort. Alternatively, the outer cover 950 can be made of a nonwoven fabric similar to the outer cover 450. Other panels 990A, 990B, 990C of the brief are also shown. These panels can also be made of a knitted textile, preferably with high elasticity. A waist elastic 995 of the brief is also shown. These parts of the brief can be pre-attached to the brief panels using adhesive strips 960 (which can be similar to the stabilizing layer 940) before or after the layers of the article 900 are bonded using compression force.

[0333] Except for the above differences and any other differences that will be apparent from the drawings, all other features of the article 900, including the properties of its layers, can be the same as described above with reference to the article 300.

[0334] Figure 10A

[0335] Figure 2C An exploded view of an article 1000 according to another preferred embodiment of the present application is shown.

[0336] The article 1000 is a bra or is used with a bra, positioned adjacent to the breasts of a user and receiving moisture from the breasts of the user. The article 1000 can be used as a nursing pad. The article 1000 can also be suitable for absorbing any other moisture from the body of a user.

[0337] The article 1000 of this example is similar in most respects to the article 200 described above, the differences can be identified by comparing Figure 10A with Example 10to be identified. In the drawings relating to article 1000, features similar to those shown in the drawings relating to article 200 are identified with the same reference numeral plus 800. Much of the description of article 200 of the preferred embodiment described above applies equally to article 1000, and need not be described in detail again. In most cases, only the main differences will be discussed.

[0338] One main difference is the shape of the layers, all of which are suitably shaped for use as a care pad.

[0339] Similar to outer layer 220, outer layer 1020 can be moisture resistant. In some embodiments, a moisture resistant solution is applied to outer layer 1020. Outer layer 1020 can be coated with a moisture resistant solution.

[0340] Inner layer 1060 can be made of the same textile as outer cover 1050. Inner layer 1060 and / or outer cover 1050 can be made of a nonwoven textile or nonwoven material having a plurality of nonwoven fibers. Such nonwoven fibers are stabilized by adhesive and / or thermal bonding in the same or similar manner as described above.

[0341] First inner layer 1010 and second inner layer 1030 can be the same or similar type as described above for article 200. Outer layer 1020 can be the same or similar material as stabilization layer 1040. Stabilization layer 1040 can have the same material as stabilization layer 240 described above for article 200. Any layer described above as optional in article 200 can also be optional in article 1000.

[0342] Except for the differences described above and any other differences apparent from the drawings, all other features of article 1000, including the properties of its layers, can be the same as described above with reference to article 200.

[0343] Figure 11A

[0344] Figure 11B An exploded view of article 1100 according to another preferred embodiment of the present application is shown. Figure 2C An assembled view of article 1100 is shown.

[0345] Article 1100 is or is used as a hygiene protection pad or shield or incontinence pad. Some non-limiting examples of article 1100 can be a bed shield, a seat shield, a car seat protection pad, a baby changing pad, a crib protection pad or for preventing bladder leakage / incontinence.

[0346] Article 1100 of this example is similar in most respects to article 200 described above, the differences can be seen by comparing Figure 11A with Figure 11Ato identify. In the drawings relating to article 1100, features similar to those shown in the drawings relating to article 200 are identified with the same reference numeral plus 900. Much of the description of article 200 of the preferred embodiment described above applies equally to article 1100, and thus need not be described in detail again. For the most part, only the major differences will be discussed.

[0347] One major difference is the shape of the layers, all of which are suitably shaped for use as a hygiene or protective or incontinence pad.

[0348] Similar to outer layer 220, outer layer 1120 can be moisture resistant. In some embodiments, a moisture resistant solution is applied to outer layer 1120. Outer layer 1120 can be coated with a moisture resistant solution. In this example, it can be seen that outer layer 1120 is the outermost layer of article 1100. In some embodiments, there can be a separate outer cover layer as the outermost layer adjacent to outer layer 1120. In such a case, the outer cover layer can be a nonwoven material similar to outer cover layer 250.

[0349] Inner layer 1160 can be made of a nonwoven textile or nonwoven material having a plurality of nonwoven fibers. Such nonwoven fibers are stabilized in the same or similar manner as described above by adhesive (e.g., adhesive glue) and / or thermal bonding. Inner layer 1060 can be in the form of a strip as shown. ​

[0350] Inner layer 1110 can be the same or similar type as described above for inner layer 210 of article 200. Although only one inner layer 1110 in the form of a nonwoven absorbent core is disclosed, there can be two or more such nonwoven layers. Outer layer 1020 can be the same or similar material as stabilization layer 1040. In addition, a second inner layer 1130 is disclosed. The second inner layer can be a fast-dry knit textile. The second inner layer can be a fast-dry knit textile having quilted stitching to reduce friction.

[0351] Except for the differences described above and any other differences that will be apparent from the drawings, all other features of article 1000, including the properties of its layers, can be the same as described above with reference to article 200.

[0352] It will of course be understood that, although the foregoing is framed in terms of illustrative examples of the application, all such modifications and variations that will be apparent to those skilled in the art are deemed to fall within the broad scope and ambit of the various aspects of the application as described above and / or as defined in the claims.

[0353] ​In summary, it can be appreciated that the present application allows for the nonwoven fibers to be bonded, thereby stabilizing the nonwoven fibers. Stabilization of the nonwoven fibers means that the fibers do not or do not easily disintegrate during washing, thereby allowing for the nonwoven fibers, which would otherwise not be reusable, to become reusable. Furthermore, with the present application, the layers of the article are bonded together simply by arranging the layers as described above and applying a compressive force to the article. This eliminates or at least reduces the need for stitching and / or other complex processes for bonding the layers together, thereby significantly reducing the manufacturing process, cost, and time. Furthermore, complex machinery is not required to manufacture the article. Furthermore, the lack of or reduced stitching means that the article is less likely to leak. In some embodiments, the article is leak-proof.

[0354] One or more non-limiting advantages of the present application can be as follows: • simpler design • cost effective • easy to assemble • assembly of the layers does not require complex machinery as the layers are bonded simply by applying a compressive force (i.e. pressing) to the article • reduced manufacturing time • less labor intensive to manufacture / assemble as there is no need for complex bonding processes • reusable article, i.e. more environmentally friendly than a disposable product • does not contain any harmful or hazardous chemicals • can be washed with water and dried • less likely to leak due to reduced or no stitching • absorption speed, level, and liquid retention capacity are not affected, while significantly reducing the number of steps, time, and complexity of layer assembly during manufacturing.

Claims

1. A method for stabilizing nonwoven fibers, the method comprising the following steps: A nonwoven material is provided, the nonwoven material comprising or in the form of a plurality of nonwoven fibers; Provide stable materials; The stabilizing material is applied to at least a portion or all of the nonwoven material, such that the stabilizing material is applied to at least some or all of the plurality of nonwoven fibers, the stabilizing material being a material configured to bond the nonwoven fibers by an adhesive and / or a thermal adhesive; as well as The plurality of nonwoven fibers to which the stabilizing material is applied are bonded to the stabilizing material using adhesives and / or thermal bonding.

2. The method of claim 1, wherein the nonwoven fibers are bonded to form a bonded nonwoven fiber layer, the bonded nonwoven fiber layer comprising at least a portion of nonwoven fibers, the degree of bonding of these nonwoven fibers being such that the bonded nonwoven fibers do not disintegrate or substantially do not disintegrate when the layer is washed or rinsed at least once or multiple times.

3. The method according to claim 1 or 2, wherein the nonwoven material is a nonwoven material layer.

4. The method according to claim 1 or 2, wherein the nonwoven material is a nonwoven product, a nonwoven fabric, or a nonwoven textile.

5. The method according to any one of claims 1 to 4, wherein the thermal bonding comprises fusing at least some or all of the nonwoven fibers at a temperature relating to the melting point of the fibers to be fused and / or the melting point of the stabilizing material.

6. The method according to any one of claims 1 to 5, wherein the thermal bonding is performed at a temperature between 70 degrees Celsius and 240 degrees Celsius.

7. The method according to any one of claims 1 to 6, wherein the stabilizing material is formed as a stabilizing layer.

8. The method of claim 7, wherein the stabilizing layer is a film or thin film.

9. The method according to claim 7 or 8, wherein the stabilizing layer has a thickness based on the type of the nonwoven material and the melting point of the nonwoven material.

10. The method according to any one of claims 7 to 9, wherein the thickness of the stabilizing layer is between 0.005 mm and 0.5 mm.

11. The method according to any one of claims 7 to 10, wherein the stabilizing layer is a breathable layer.

12. The method according to any one of claims 7 to 11, wherein the stabilizing layer is a complete layer.

13. The method according to any one of claims 7 to 11, wherein the stabilizing layer is a partial layer.

14. The method according to any one of claims 7 to 11, wherein the stabilizing layer is a frame layer.

15. The method according to any one of claims 7 to 14, wherein the stabilizing layer is a polyurethane (PU) material layer.

16. The method according to any one of claims 7 to 14, wherein the stabilizing layer is a polyethylene (PE) material layer.

17. The method according to any one of claims 7 to 14, wherein the stabilizing layer is a polylactic acid (PLA) material layer.

18. The method according to any one of claims 7 to 17, wherein the stabilizing layer is a textile adhesive layer.

19. The method according to any one of claims 1 to 18, wherein the bonding is performed in a patterned manner.

20. The method according to any one of claims 1 to 19, wherein the stabilizing material is an adhesive material.

21. The method of claim 20, wherein the adhesive material is glue.

22. The method according to claim 20 or 21, wherein the adhesive material is a spray adhesive or a roller adhesive.

23. The method of claim 20, wherein the adhesive material is a polyurethane (PU) adhesive.

24. The method of claim 20, wherein the adhesive material is a polyethylene (PE) adhesive.

25. The method of claim 20, wherein the adhesive material is a polylactic acid (PLA) adhesive.

26. The method of claim 20, wherein the adhesive material is a textile adhesive.

27. The method according to claims 1 to 26, wherein the adhesive substance is applied to the stabilizing material for the bonding.

28. The method of claim 20, wherein the adhesive substance is a glue, a spray adhesive, a roller adhesive, a polyurethane (PU) adhesive, a polyethylene (PE) adhesive, or a polylactic acid (PLA) adhesive.

29. The method of claim 20, wherein the adhesive substance is a textile adhesive.

30. The method according to any one of claims 1 to 29, wherein the nonwoven fiber is a synthetic polymer, a bicomponent fiber, a natural fiber, a man-made fiber, or a combination thereof.

31. The method according to claim 30, wherein the synthetic polymer is selected from polyethylene (PE), polypropylene (PP) or polyethylene terephthalate (PET).

32. The method of claim 30, wherein the natural fiber is selected from wood, pulp, cotton or bamboo.

33. The method of claim 30, wherein the man-made fiber is selected from viscose fiber, lyocell fiber, polylactic acid (PLA) or cellulose acetate.

34. A method of constructing a reusable moisture-wicking article, said reusable moisture-wicking article being part of or used with underwear to be positioned adjacent to a user's body and to absorb (preferably absorb and retain) moisture from said user's body, said method comprising: Provide at least one layer of nonwoven material, said nonwoven material comprising or in the form of multiple nonwoven fibers; At least one stabilizing material is applied to at least a portion of the at least one layer of nonwoven material, such that the stabilizing material is applied to at least some or all of the plurality of nonwoven fibers, the stabilizing material being a material configured to bond the nonwoven fibers by an adhesive and / or thermal adhesive, and the stabilizing material forming a stabilizing layer; as well as The plurality of nonwoven fibers to which the stabilizing material is applied are bonded to the stabilizing material by adhesive and / or thermal bonding, thereby forming the reusable moisture-absorbing article.

35. The method of claim 34, wherein the nonwoven fibers are bonded to such an extent that the bonded nonwoven fibers do not disintegrate or substantially do not disintegrate upon exposure to at least one or more washes or rinses.

36. A method of constructing a reusable moisturizing article, said reusable moisturizing article being part of or used with underwear to be positioned adjacent to a user's body and to absorb and retain moisture from said user's body, said method comprising: A reusable moisture-wicking insert is provided, at least a portion of which is exposed or configured to be exposed to define an inner layer of the article, the inner layer being configured adjacent to and facing the user's body for contact with the user's body to directly absorb and retain moisture from the user's body, the insert comprising at least one nonwoven material inner layer comprising or in the form of a plurality of nonwoven fibers; An inner layer of nonwoven material is provided, the nonwoven material comprising or in the form of multiple nonwoven fibers, and located on the outer side of the insert; A stabilizing layer is provided, the stabilizing material being configured to bond the nonwoven fibers by an adhesive and / or thermal bonding. An outer cover layer is provided, the outer cover layer being configured to define an outer layer of the article; as well as The insert, the innermost layer, the stabilizing layer, and the outer cover layer are assembled in the following manner: The innermost layer, the insert, the stabilizing layer, and the outer cover layer are positioned such that the insert is located between the outer cover layer and the stabilizing layer, at least a first portion of the stabilizing layer is located between the innermost layer and the insert, and at least a second portion of the stabilizing layer is also configured to adhere to the outer cover layer. At least a portion of the innermost layer is bonded to the stabilizing layer by applying heat and / or adhesive bonding. At least a portion of the insert is bonded to the stabilizing layer by applying the heat and / or adhesive. At least a portion of the outer cover layer is bonded to the second portion of the stabilizing layer by applying heat and / or adhesive, with the insert located between the outer cover layer and the stabilizing layer.

37. A reusable moisture-absorbing article comprising a plurality of nonwoven fibers stabilized using the method according to any one of claims 1 to 36.

38. The article of claim 37, wherein the article of claim 37 is any one of the following: diaper, sanitary napkin, Incontinence pad, Incontinence bag, Female incontinence underwear, Male incontinence underwear, Nursing pads, Protective pad, Baby changing diaper pads, or Baby crib protector.

39. A reusable moisture-absorbing article manufactured using the method according to any one of claims 1 to 36.

40. A reusable moisture-absorbing article, said article comprising: At least one nonwoven material, said nonwoven material comprising or in the form of a plurality of nonwoven fibers; At least one stabilizing material; At least one nonwoven layer and at least one stabilizing layer are bonded together by applying the stabilizing material to at least a portion or all of the nonwoven material, such that the stabilizing material is applied to at least some or all of the plurality of nonwoven fibers; and The plurality of nonwoven fibers to which the stabilizing material is applied are bonded to the stabilizing material using adhesives and / or thermal bonding.

41. An underwear comprising or incorporating articles constructed using the method according to any one of claims 1 to 36.

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