Reusable underwear with absorbent crotch assembly

Abstract

A reusable underwear, the reusable underwear comprising an underwear fabric comprising a continuous waistband and a front portion and a rear portion extending from the continuous waistband, a crotch assembly. The crotch assembly includes a fabric topsheet, a barrier sheet, and at least one absorbent layer located between the fabric topsheet and the barrier sheet. The fabric topsheet has an outer surface facing the body and an inner surface facing the barrier sheet. The body-facing outer surface may be a fibrous material and the inner surface includes a hydrophobic fibrous material. The barrier sheet is liquid impermeable to prevent leakage of liquid through the barrier sheet. And at least one absorbent layer having a front edge, a rear edge, two side edges and a perimeter, the at least one absorbent layer being disposed between the fabric topsheet and the barrier sheet. At least a first hydrophobic treatment may be disposed around the perimeter of the at least one absorbent layer at least along the two side edges to inhibit fluid flow to the side edges of the at least one absorbent layer. The crotch assembly has an absorption capacity of at least about 20 grams, an absorption rate of at least about 0.1 mL / sec, and a back infiltration% of less than about 20%.

Description

Background Technology

[0001] Sanitary protective products (such as sanitary napkins and panty liners) are well-known products that consumers use to protect their underwear from unintentional menstrual discharge or urinary incontinence. Traditionally, these products are disposable and discarded after use.

[0002] In recent years, consumers have become increasingly aware of the environmental impact of single-use products and are looking for more sustainable options.

[0003] Reusable hygiene products, such as period panties, are available on the market. Some period panties contain detachable absorbent elements or inserts, which does not completely solve sustainability issues; others have permanently attached absorbent cores, are fully washable, and therefore offer a more durable option.

[0004] Beyond these sustainability concerns, consumers are unwilling to compromise on the effectiveness of their hygiene products, as menstrual or urine stains can be extremely embarrassing. Reusable menstrual underwear should have absorbent elements constructed to prevent leakage, be sufficiently absorbent to minimize the feeling of dampness on the skin (backflow) to avoid irritation and / or discomfort, and be thin enough to remain inconspicuous and comfortable to wear.

[0005] All these requirements are difficult to meet simultaneously in a single product. For example, in the past, thin absorbent elements with high absorbency were obtained by blending superabsorbent polymers into fibers. However, this type of polymer is incompatible with washable products because it loses all its effectiveness after a single wash cycle. Another solution to increase absorbency is to increase the amount of absorbent material, thus increasing the thickness of the product, which is detrimental to comfort and inconspicuousness as the product becomes bulky. Finally, reusable hygiene products must be washable at sufficiently high temperatures to ensure thorough sterilization, which may be incompatible with heat-sensitive polymers or adhesives.

[0006] The goal is to offer consumers menstrual underwear that meets all the aforementioned performance requirements (absorbency, backflow prevention, leak prevention) while remaining comfortable, inconspicuous, and washable at temperatures such as 60°C or higher. Summary of the Invention

[0007] We have discovered that a surprisingly effective reusable underwear can be formed, comprising underwear fabric, a crotch assembly, the underwear fabric including a continuous waistband and front and back portions extending from the continuous waistband, the crotch assembly having a front edge, a back edge, and two side edges, the front edge being attached to the front portion of the underwear fabric, the back edge being attached to the back portion of the underwear fabric to form the crotch portion of the underwear, and the two side edges defining two leg openings together with the underwear fabric. The crotch assembly includes a fabric top sheet, a barrier sheet, and at least one absorbent layer located between the fabric top sheet and the barrier sheet. The fabric top sheet has an outer surface facing the body and an inner surface facing the barrier sheet, wherein the outer surface facing the body comprises a fibrous material, and the inner surface comprises a hydrophobic fibrous material. The barrier sheet is liquid-impermeable to prevent liquid leakage through it. The at least one absorbent layer has a front edge, a back edge, two side edges, and a periphery, and is disposed between the fabric top sheet and the barrier sheet. At least a first hydrophobic treatment is disposed along at least two side edges around the periphery of at least one absorbent layer to inhibit fluid flow toward the side edges of at least one absorbent layer. The crotch assembly has an absorption capacity of at least about 20 grams, an absorption rate of at least about 0.1 mL / s, and a reabsorption rate of less than about 20%.

[0008] In an alternative embodiment, the reusable underwear includes underwear fabric and a crotch assembly. The underwear fabric includes a continuous waistband and front, back, and side portions extending from the continuous waistband toward the crotch portion, and two leg openings. The crotch assembly is attached to the front and back portions of the underwear fabric and, together with the underwear fabric, defines the two leg openings. The crotch assembly has a front edge, a back edge, and two side edges, and includes a fabric top sheet, a barrier sheet, and at least one absorbent layer located between the fabric top sheet and the barrier sheet. The top sheet has an outer surface facing the body and an inner surface facing the barrier sheet, wherein the outer surface facing the body comprises a fibrous material, and the inner surface comprises a hydrophobic fibrous material. The barrier sheet is liquid-impermeable to prevent liquid leakage through the barrier sheet. The crotch assembly has an absorbency of at least about 20 grams, an absorption rate of at least about 0.1 mL / s, and a rewetting rate of less than about 20%.

[0009] In one embodiment, reusable underwear includes underwear fabric and a crotch assembly. The underwear fabric includes a continuous waistband and front, back, and side portions extending from the continuous waistband toward the crotch portion, as well as two leg openings. The crotch assembly is attached to the front and back portions of the underwear fabric and, together with the underwear fabric, defines the two leg openings. The crotch assembly has a front edge, a back edge, and two side edges, and includes a fabric top sheet, a barrier sheet, and at least one absorbent layer located between the fabric top sheet and the barrier sheet. The fabric top sheet has a front edge, a back edge, two side edges, and a periphery. The body-facing fabric material has a body-facing outer surface and an inner surface facing the barrier sheet. The barrier sheet is liquid-impermeable to prevent liquid leakage. The at least one absorbent layer has a front edge, a back edge, two side edges, and a periphery. At least a first hydrophobic treatment is disposed around the periphery of at least one absorbent layer at least along at least two side edges to inhibit fluid flow toward the side edges of at least one absorbent layer, and the crotch assembly has an absorption capacity of at least about 20 grams, an absorption rate of at least about 0.1 mL / s, and a reabsorption rate of less than about 20%.

[0010] Another aspect of the invention relates to an absorbent crotch assembly for reusable underwear. The assembly has a front edge, a back edge, and two side edges, and includes a fabric top sheet, a barrier sheet, and at least one absorbent layer located between the fabric top sheet and the barrier sheet. The fabric top sheet has a front edge, a back edge, two side edges, and a periphery, with a body-facing fabric material having a body-facing outer surface and an inner surface facing the barrier sheet. The barrier sheet is liquid-impermeable to prevent liquid leakage. At least one absorbent layer has a front edge, a back edge, two side edges, and a periphery. At least a first hydrophobic treatment is disposed at least along the two side edges around the periphery of at least one absorbent layer to inhibit fluid flow to the side edges of at least one absorbent layer, and the crotch assembly has an absorbency of at least about 20 grams, an absorbency rate of at least about 0.1 mL / s, and a rewetting rate of less than about 20%. Attached Figure Description

[0011] Figure 1 This is a front view of one embodiment of reusable underwear according to the present invention.

[0012] Figure 2 yes Figure 1 Rear view of reusable underwear.

[0013] Figures 3A to 3C show the combinations that can form Figure 1 A plan view of the front fabric section, the back fabric section, and the crotch fabric section of the implementation scheme.

[0014] Figure 4This is a schematic exploded cross section along line IV-IV of the crotch section in Figure 3C.

[0015] Figure 5 This is an exploded schematic cross-section along line IV-IV of an alternative embodiment of the crotch section in Figure 3C.

[0016] Figure 6 This is an exploded schematic cross-section along line IV-IV of the second alternative embodiment of the crotch section in Figure 3C.

[0017] Figure 7 It is an enlarged cross-section of the fabric top piece in the crotch section of the alternative implementation scheme.

[0018] Figure 8 This is an alternative implementation scheme for the fabric top piece of the crotch section of the alternative implementation scheme.

[0019] Figure 9 This is an enlarged view of the body-facing outer surface of the fabric top piece of the crotch section in an alternative embodiment.

[0020] Figure 10 This is a table showing the maximum absorption capacity of embodiments of the present invention and commercially available prior art products before leakage.

[0021] Figure 11 This is a table showing the backflow values ​​of embodiments of the present invention and commercially available prior art products.

[0022] Figure 12 This is a table showing the wicking time of embodiments of the present invention and commercially available prior art products.

[0023] Figure 13 This is a table showing the wicking speed of embodiments of the present invention and commercially available prior art products. Detailed Implementation

[0024] As used in the specification and claims, the term "microfiber" and its variations refer to multifilament synthetic yarns having a single filament that is extremely fine (≤1 dtex) and whose yarn count is described in dtex, which means a certain weight (grams) in 10,000 meters of yarn.

[0025] like Figure 1 and Figure 2As shown, the present invention relates to reusable underwear 100 having an absorbent crotch assembly 200 arranged and configured to capture and absorb bodily fluids (such as menstrual fluid and urine). The reusable underwear 100 has a front portion 110, a back portion 120, and the absorbent crotch assembly 200. In the embodiments shown in Figures 3A to 3C, the reusable underwear includes a continuous waistband 102 and front portions 110 and 120 formed of underwear fabric extending from the continuous waistband. The absorbent crotch assembly 200 has a front edge 202 attached to the front portion 110 of the underwear fabric and a rear edge 204 attached to the back portion 120 of the underwear fabric. Two side edges 206 of the absorbent crotch assembly 200 cooperate with the underwear fabric to define two leg openings 208.

[0026] Underwear fabrics can be made from multi-directional stretchable fabrics such as spandex, cotton, cotton blends, or other materials. These fabrics are typically (but not always) knitted fabrics. In one embodiment of the invention, the underwear fabric may comprise a blend of polyamide and elastic fibers having a basis weight between 150 gsm and 300 gsm, optionally between 200 gsm and 250 gsm.

[0027] The continuous waistband 102, the front portion 110, and the rear portion 120 can be formed by removing portions of the continuous fabric tube and folding a portion of the stretchable fabric at the waist portion to form multiple layers of the stretchable fabric.

[0028] Alternatively, the continuous waistband 102, the front portion 110, and the rear portion 120 can be formed by removing portions of the continuous fabric tube and forming a fabric bag at the waist portion, enclosing an elastic material (such as a mesh, belt, thread, and / or rope) therein. Preferred elastic materials include fiber mesh or belt.

[0029] Alternatively, the continuous waistband 102, the front portion 110, and the rear portion 120 can be formed by connecting the individual front portion 110 and rear portion 120 and securing them together via side seams. Similarly, a fabric bag can be formed at the waist portion to enclose an elastic material therein, such as a fiber web, belt, thread, and / or rope. Preferred elastic materials include fiber webs or belts.

[0030] In addition, the continuous fabric tube can extend into the crotch portion of the underwear, that is, into the portion of the underwear corresponding to the absorbent crotch assembly 200.

[0031] The absorbent crotch assembly 200 includes a fabric top sheet 210, a barrier sheet 220 that is substantially impermeable to liquids (especially bodily fluids), and at least one absorbent layer 230 disposed between the top sheet 210 and the barrier sheet 220.

[0032] exist Figure 4 In one embodiment, the absorbent crotch assembly 200 includes a fabric top sheet 210, a barrier sheet 220, and an absorbent layer 230 disposed between the fabric top sheet and the barrier sheet. Each of the fabric top sheet 210, the barrier sheet 220, and the absorbent layer 230 has a front edge, a rear edge, and two side edges corresponding to the front edge 202, the rear edge 204, and the side edges 206 of the absorbent crotch assembly 200. The absorbent crotch assembly 200 may also include an underwear fabric layer 104. The underwear fabric layer 104 may be formed as part of the absorbent crotch assembly 200, or it may be a continuation of the underwear fabric from the aforementioned front portion 110 and rear portion 120.

[0033] Figure 4 The absorbent layer 230 of the embodiment has at least a first hydrophobic treatment disposed around the periphery of the absorbent layer along two side edges (e.g., side edges 234 and optionally front edge 202 of the absorbent layer). The hydrophobic treatment inhibits fluid transport to and / or fluid absorption into the side edges 234 of the absorbent layer material. A representative non-limiting list of useful hydrophobic treatments includes hydrophobic thermoplastic structural strips, permanent hydrophobic fiber finishing, hydrophobic material impregnation, overcompression of the material forming the absorbent layer 230, etc.

[0034] Hydrophobic thermoplastic construction tapes can be used to attach adjacent layers of an absorbent crotch assembly together and can also impart fluid inhibition and / or barrier properties to the side edges 234 and optionally the front edge 202 of the absorbent layer 230. Preferred hydrophobic thermoplastic construction tapes maintain lamination integrity at temperatures above 40°C and more preferably above 60°C. A representative, non-limiting list of useful hydrophobic thermoplastic construction tapes includes polyurethanes, natural and synthetic rubbers, styrene-isoprene-styrene block copolymers, polyolefins (such as polyethylene), etc. In one embodiment of the invention, the polyurethane tape is a thermoplastic polyurethane tape with a thickness between about 0.025 mm and about 0.150 mm, preferably between about 0.05 mm and about 0.10 mm, and an adhesive softening point greater than about 125°C, preferably greater than about 140°C and less than 200°C.

[0035] A permanent hydrophobic fiber finish makes the hydrophilic and / or absorbent elements of the absorbent layer hydrophobic, thereby imparting fluid inhibition and / or barrier properties to the side edges 234 and optionally the front edge 202 of the absorbent layer 230. Preferred hydrophobic fiber finishes are heat-resistant and do not dissipate or remove during washing processes at temperatures above 40°C and more preferably above 60°C.

[0036] Hydrophobic materials may also be impregnated into the side edges 234 and optionally the front edge 202 of the absorbent layer 230. Preferred hydrophobic impregnating materials are heat-resistant and do not dissipate or remove during washing processes at temperatures above 40°C, and more preferably above 60°C. A representative, non-limiting list of useful hydrophobic impregnating materials includes waxes, including paraffin wax, beeswax and plant-based waxes, hydrocarbon polymers, siloxane polymers, fluorocarbons, etc.

[0037] Furthermore, the absorbent crotch assembly 200 includes an elastic webbing 240 that encloses the side edges of the fabric top sheet 210, the barrier sheet 220, and the absorbent layer 230, and preferably extends beyond the side edges 206 of the absorbent crotch assembly 200 to the underwear fabric and around each leg opening 208. These components are secured together along the side edges of the absorbent crotch assembly 200 via at least one seam 250. Specifically, at least one seam 250 is sewn through the side edge 234 of the absorbent layer 230.

[0038] exist Figure 5 In one embodiment, the absorbent crotch assembly 200 includes a fabric top sheet 210, a barrier sheet 220, and two absorbent layers 230a and 230b disposed between the fabric top sheet and the barrier sheet. Each of the fabric top sheet 210, the barrier sheet 220, and the two absorbent layers 230a and 230b has a front edge, a rear edge, and two side edges corresponding to a front edge 202, a rear edge 204, and a side edge 206 of the absorbent crotch assembly 200. A first absorbent layer 230a is disposed adjacent to the fabric top sheet 210, and a second absorbent layer 230b is disposed below the first absorbent layer 230a. The second absorbent layer 230b is wider than the first absorbent layer 230a, and the side edges of the second absorbent layer 230b extend outward beyond the corresponding side edges of the first absorbent layer 230a. Therefore, the portion of the second absorbent layer extending outward beyond the first absorbent layer 230a defines a side edge 234 of the second absorbent layer 230b. The absorbent crotch assembly 200 may also include an underwear fabric layer 104. The underwear fabric layer 104 may be formed as part of the absorbent crotch assembly 200, or it may be a continuation of the underwear fabric from the aforementioned front portion 110 and back portion 120.

[0039] Figure 5The first absorbent layer 230a and the second absorbent layer 230b of the embodiment have at least a first hydrophobic treatment disposed around the periphery of the first absorbent layer 230a and the second absorbent layer 230b along their two side edges (e.g., the side edges 234 and optionally the front edge 202 of the second absorbent layer 230b). The hydrophobic treatment inhibits fluid transport to and / or fluid absorption into the side edges 234 of the absorbent layer material. A representative non-limiting list of useful hydrophobic treatments includes hydrophobic thermoplastic structural strips, permanent hydrophobic fiber finishing, hydrophobic material impregnation, overcompression of the material forming the absorbent layer 230, etc.

[0040] Hydrophobic thermoplastic construction strips can be used to attach adjacent layers of the absorbent crotch assembly together, and can also impart fluid inhibition and / or barrier properties to the side edges 234 and optionally the front edge 202 of the second absorbent layer 230b. Figure 5 In one embodiment, the hydrophobic thermoplastic structural material 236 can be configured to adhere the first absorbent layer 230a and the second absorbent layer 230b together. Preferred hydrophobic thermoplastic structural tapes maintain lamination integrity at temperatures above 40°C and more preferably above 60°C. A representative, non-limiting list of useful hydrophobic thermoplastic structural tapes includes polyurethanes, natural and synthetic rubbers, styrene-isoprene-styrene block copolymers, polyolefins (such as polyethylene), etc. In one embodiment of the invention, the polyurethane tape is a thermoplastic polyurethane tape with a thickness between about 0.025 mm and about 0.150 mm, preferably between about 0.05 mm and about 0.10 mm, and an adhesive softening point greater than about 125°C.

[0041] A permanent hydrophobic fiber finish makes the hydrophilic and / or absorbent elements of the absorbent layer hydrophobic, thereby imparting fluid inhibition and / or barrier properties to the side edges 234 and optionally the front edge 202 of the second absorbent layer 230b. The preferred hydrophobic fiber finish is heat-resistant and does not dissipate or remove during washing processes at temperatures above 40°C and more preferably above 60°C.

[0042] Hydrophobic materials may also be impregnated into the side edges 234 of the second absorbent layer 230b, and optionally into the leading edge 202. Preferred hydrophobic impregnating materials are heat-resistant and do not dissipate or remove during washing processes at temperatures above 40°C, and more preferably above 60°C. A representative, non-limiting list of useful hydrophobic impregnating materials includes waxes, including paraffin wax, beeswax and plant-based waxes, hydrocarbon polymers, siloxane polymers, fluorocarbons, etc.

[0043] Furthermore, the absorbent crotch assembly 200 includes an elastic webbing 240 that encloses the side edges of the fabric top sheet 210, the barrier sheet 220, and the absorbent layer 230, and preferably extends beyond the side edges 206 of the absorbent crotch assembly 200 to the underwear fabric and around each leg opening 208. These components are secured together along the side edges of the absorbent crotch assembly 200 via at least one seam 250. Specifically, at least one seam 250 is sewn through the side edge 234 of the absorbent layer 230.

[0044] exist Figure 6 In one embodiment, the absorbent crotch assembly 200 includes a fabric top sheet 210, a barrier sheet 220, and two absorbent layers 230a and 230b disposed between the fabric top sheet and the barrier sheet. Each of the fabric top sheet 210, the barrier sheet 220, and the two absorbent layers 230a and 230b has a front edge, a rear edge, and two side edges corresponding to a front edge 202, a rear edge 204, and a side edge 206 of the absorbent crotch assembly 200. A first absorbent layer 230a is disposed adjacent to the fabric top sheet 210, and a second absorbent layer 230b is disposed below the first absorbent layer 230a. The second absorbent layer 230b is wider than the first absorbent layer 230a, and the side edges of the second absorbent layer 230b extend outward beyond the corresponding side edges of the first absorbent layer 230a. Therefore, the portion of the second absorbent layer extending outward beyond the first absorbent layer 230a defines a side edge 234 of the second absorbent layer 230b. The absorbent crotch assembly 200 may also include an underwear fabric layer 104. The underwear fabric layer 104 may be formed as part of the absorbent crotch assembly 200, or it may be a continuation of the underwear fabric from the aforementioned front portion 110 and back portion 120.

[0045] Figure 6 The first absorbent layer 230a and the second absorbent layer 230b of the embodiment are joined by at least two stitching seams 252, one stitching seam being disposed towards the left edge and the other stitching seam being disposed towards the right edge.

[0046] Figure 5 The first absorbent layer 230a and the second absorbent layer 230b of the embodiment have at least a first hydrophobic treatment disposed around the periphery of the first absorbent layer 230a and the second absorbent layer 230b along their two side edges (e.g., the side edges 234 and optionally the front edge 202 of the second absorbent layer 230b). The hydrophobic treatment inhibits fluid transport to and / or fluid absorption into the side edges 234 of the absorbent layer material. A representative non-limiting list of useful hydrophobic treatments includes hydrophobic thermoplastic structural strips, permanent hydrophobic fiber finishing, hydrophobic material impregnation, overcompression of the material forming the absorbent layer 230, etc.

[0047] Hydrophobic thermoplastic construction strips can be used to help attach adjacent layers of the absorbent crotch assembly together, and can also impart fluid inhibition and / or barrier properties to the side edges 234 and optionally the front edge 202 of the second absorbent layer 230b. Figure 6 In one embodiment, the hydrophobic thermoplastic structural material 236 may be configured to enhance the attachment of the first absorbent layer 230a and the second absorbent layer 230b. Preferred hydrophobic thermoplastic structural tapes maintain lamination integrity at temperatures above 40°C and more preferably above 60°C. A representative, non-limiting list of useful hydrophobic thermoplastic structural tapes includes polyurethanes, natural and synthetic rubbers, styrene-isoprene-styrene block copolymers, polyolefins (such as polyethylene), etc. In one embodiment of the invention, the polyurethane tape is a thermoplastic polyurethane tape with a thickness between about 0.025 mm and about 0.150 mm, preferably between about 0.05 mm and about 0.10 mm, and an adhesive softening point greater than about 125°C.

[0048] A permanent hydrophobic fiber finish makes the hydrophilic and / or absorbent elements of the absorbent layer hydrophobic, thereby imparting fluid inhibition and / or barrier properties to the side edges 234 and optionally the front edge 202 of the second absorbent layer 230b. The preferred hydrophobic fiber finish is heat-resistant and does not dissipate or remove during washing processes at temperatures above 40°C and more preferably above 60°C.

[0049] Hydrophobic materials may also be impregnated into the side edges 234 of the second absorbent layer 230b, and optionally into the leading edge 202. Preferred hydrophobic impregnating materials are heat-resistant and do not dissipate or remove during washing processes at temperatures above 40°C, and more preferably above 60°C. A representative, non-limiting list of useful hydrophobic impregnating materials includes waxes, including paraffin wax, beeswax and plant-based waxes, hydrocarbon polymers, siloxane polymers, fluorocarbons, etc.

[0050] Furthermore, the absorbent crotch assembly 200 includes an elastic webbing 240 that encloses the side edges of the fabric top sheet 210, the barrier sheet 220, and the absorbent layer 230, and preferably extends beyond the side edges 206 of the absorbent crotch assembly 200 to the underwear fabric and around each leg opening 208. These components are secured together along the side edges of the absorbent crotch assembly 200 via at least one seam 250. Specifically, at least one seam 250 is sewn through the side edge 234 of the absorbent layer 230.

[0051] In an alternative embodiment, the barrier sheet 220 is wrapped around at least the side edge of the absorbent layer 230 in the side edge 234 of the absorbent layer 230.

[0052] exist Figure 7In the illustrated embodiment, the fabric top sheet 210 has an outer surface 212 facing the body and an inner surface 214 facing the barrier sheet 220 in the absorbent crotch assembly 200. The outer surface 212 facing the body comprises a fibrous material 216, and the inner surface 214 comprises a hydrophobic fibrous material 218.

[0053] The fabric topsheet 210 provides a body-facing surface, which is preferably comfortable for the wearer and has desired fluid transport qualities. Therefore, the fabric topsheet can be formed from fibers selected from the group consisting of: natural and synthetic cellulose fibers, polyamide fibers, polyester fibers, acrylic fibers, and combinations thereof.

[0054] In some embodiments, the fabric top piece 210 is formed of at least two different fibers, at least one of which is hydrophobic. We have found that knitted fabrics provide a moderate level of stretch, which is desirable for enabling the absorbent crotch assembly 200 to move with the user. Particularly useful knitted fabrics are double-faced knitted fabrics, such as those described in the following article by Vasconcelos, FB et al., “Moisture Management Evaluation in Double Face Knitted Fabrics with Different Kind of Constructions and Fibers,” Journal of Fashion Technology Textile Engineering (2017). However, unlike the objective of that reference, the present invention places a hydrophilic material (preferably a natural or synthetic cellulose fiber material) in contact with the wearer's skin and places a hydrophobic fiber material on the opposing surface to distribute it to the absorbent layer 230.

[0055] exist Figure 8 In the illustrated embodiment, the fabric top sheet 210 comprises a double-knitted fabric. The body-facing outer surface 212 comprises a fibrous material 216, and the inner surface 214 comprises a hydrophobic fibrous material 218.

[0056] In another embodiment, the fiber material 206 comprises a fibrous cellulose material, preferably cotton, and the hydrophobic fiber material 218 comprises a hydrophobic polymer fiber material, preferably polyester.

[0057] In a particularly preferred embodiment, the fiber material 206 comprises a natural fibrous cellulose material, preferably organic cotton, and the hydrophobic fiber material 218 comprises a hydrophobic polymer fiber material, preferably polyester.

[0058] exist Figure 9 In the illustrated embodiment, the double-knitted fabric top sheet 210 comprises an elongated mesh knitted fabric. The elongated mesh comprises a repeating pattern of yarns intersecting at an acute angle α, and the bisector of angle α defines the major axis X of the elongated mesh. The major axis X of the elongated mesh extends between the front and rear edges of the absorbent crotch assembly. Orienting the elongated mesh substantially longitudinally (between the front and rear edges of the absorbent crotch assembly) appears to minimize lateral movement of fluid deposited on the fabric top sheet (between the leg openings), thereby minimizing side leakage.

[0059] In one embodiment of the invention, the fabric top sheet may have a basis weight of about 100 gsm to about 200 gsm, optionally about 150 gsm to about 200 gsm.

[0060] The absorbent layer 130 of the absorbent crotch assembly 200 may be formed of fabric arranged and configured to absorb bodily fluids (such as menstrual blood and / or urine) and to release such fluids during household washing conditions. Preferably, the absorbent crotch assembly 200 and the reusable underwear 100 are washable at up to about 40°C, preferably up to about 60°C, at least 30 washes without deterioration, such as deterioration that occurs through delamination or other degradation of the integrity of the product.

[0061] The absorbent layer 130 may be formed of fibers selected from the group consisting of: natural and synthetic cellulose fibers, polyamide fibers, polyester fibers, acrylic fibers, and combinations thereof.

[0062] In one embodiment of the invention, the absorbent layer 130 is a fabric comprising hydrophilic fibers, such as natural and synthetic cellulose fibers and / or polyamide fibers. Additional fibers may also be incorporated into the absorbent layer 130, and these additional fibers may also include hydrophobic fibers, such as polyester. For example, terry knitted fabrics or microfiber fabrics formed from polyamide and polyester have produced the desired absorbent crotch assembly 200, either as a single layer or, more preferably, as a multilayer structure. To enhance durability, the multilayer structure can be modularized via seam 252. The barrier sheet 220 can be any useful washable, liquid-resistant (preferably impermeable) sheet. Useful barrier sheets include, but are not limited to, polymer films and laminates of polymer films and fabric sheets.

[0063] In one embodiment of the invention, the blended fiber fabric that can be used for the absorbent layer comprises 70% to 90% by weight, optionally 80% to 85% by weight, polyester fibers and 10% to 30% by weight, optionally 15% to 20% by weight, polyamide fibers. The absorbent layer may have a thickness of at least about 3.5 mm, optionally at least about 4 mm, or at least about 5 mm. Preferably, the layer may have a thickness between about 4 mm and 5 mm. The absorbent layer may have a basis weight of about 250 gsm to about 500 gsm, optionally between about 300 gsm and about 450 gsm, or between about 350 gsm and about 400 gsm.

[0064] In one embodiment of the invention, the barrier sheet 220 comprises a laminate of a fabric and a continuous polymer film. A representative, non-limiting list of useful fabrics includes woven fabrics, nonwoven fabrics, and knitted fabrics.

[0065] In one example, a basis weight of at least about 50 g / m can be used. 2 The barrier sheet is a breathable laminate of polyester fabric and polyurethane film, optionally at least about 100 gsm, or 125 gsm or 150 gsm. The barrier sheet preferably has a basis weight of less than 300 gsm, optionally less than 250 gsm or 200 gsm.

[0066] In one embodiment of the invention, the polymer film is oriented toward the absorbent layer. This orientation is believed to allow fluid in contact with the film to be readily absorbed by the absorbent layer.

[0067] In an alternative embodiment, the fabric layer faces the absorbent layer. This orientation is believed to allow fluid in contact with the fabric to be distributed to less saturated portions of the absorbent layer.

[0068] The laminate may comprise a woven or nonwoven polyester fabric and a thermoplastic polyurethane film. Alternatively, the laminate may comprise a polyester microfiber terry knitted fabric and a thermoplastic polyurethane film.

[0069] Various types of stitching and threading can be used in the various exemplary underwear disclosed herein, including Figure 1 and Figure 2 Underwear. Those skilled in the art will recognize suitable stitching patterns, such as straight stitch, triple straight stitch, double-needle overlay stitch, zigzag stitch, three-step zigzag stitch, lightning bolt stitch, honeycomb stitch, overlock / binding stitch, feather stitch, or combinations thereof.

[0070] In one embodiment of the invention, various components are attached together using hydrophobic thread (preferably polyester thread) and the edges are finished by binding or the like.

[0071] Example

[0072] Test methods

[0073] The performance measurements reported in Table 1 below were performed by Hohenstein Laboratories GmbH & Co. KG. in accordance with the protocol published in "Femtech Standards publication. Reusable Absorbent undergarment Testing Protocol", FEMTECHMAS-6513-1:2022.

[0074] A copy of this agreement can be requested from MAS's FemTech at the following address:

[0075] https: / / femtech.twinery.co / #download-form

[0076] result

[0077] In Table 1, Examples 1, 2, and 3 of the present invention correspond to the absorbent articles according to the present invention. The absorbent structures of Examples 1, 2, and 3 of the present invention are as follows:

[0078] Example 1

[0079] Underwear fabric: Polyamide / elastic fiber blend (87% / 13%) knitted fabric.

[0080] Absorbent crotch assembly:

[0081] Fabric top piece: A double-knitted fabric formed of organic cotton (64%) and polyester (36%), wherein the outer surface facing the body is made of cotton and the inner surface is made of polyester. The double-knitted fabric has an elongated mesh defined by a long axis extending between the side edges of the crotch assembly.

[0082] Absorbent layer: two layers of polyester (85%) + polyamide (15%), thickness: 4.4 mm per layer, available from Kukuroğlu, Pınarkent Mahallesi 208 sokak No:1 Pamukkale / Denizli (Turkey).

[0083] Barrier layer: Polyester / polyurethane laminate (polyester micro-terry knitted fabric / polyurethane film laminate, purchased under the trade name BREEZE PES LIGHT from AKBEZ Tekstil Sanayi ve Ticaret A.Ş., Merkez Mah.EskiEdirne Asfaltı No:42 / K 34245 Gaziosmanpaşa, Istanbul, TURKEY)

[0084] The barrier layer extends into the back of the underwear, all the way to the waistband.

[0085] Example 2

[0086] Underwear fabric: Polyamide / elastic fiber blend (87% / 13%) knitted fabric.

[0087] Absorbent crotch assembly:

[0088] Fabric top piece: A double-knitted fabric formed of organic cotton (64%) and polyester (36%), wherein the outer surface facing the body is made of cotton and the inner surface is made of polyester. The double-knitted fabric has an elongated mesh defined by a long axis extending between the side edges of the crotch assembly.

[0089] Absorbent layer: two layers of polyester (85%) + polyamide (15%), thickness: 5.2 mm per layer, available from Kukuroğlu, Pınarkent Mahallesi 208 sokak No:1 Pamukkale / Denizli (Turkey).

[0090] Barrier layer: Polyester / polyurethane laminate (polyester micro-terry knitted fabric / polyurethane film laminate, purchased under the trade name BREEZE PES LIGHT from AKBEZ Tekstil Sanayi ve Ticaret A.Ş., Merkez Mah.EskiEdirne Asfaltı No:42 / K 34245 Gaziosmanpaşa, Istanbul, TURKEY)

[0091] The barrier layer extends into the back of the underwear, all the way to the waistband.

[0092] Example 3

[0093] Underwear fabric: Polyamide / elastic fiber blend (87% / 13%) knitted fabric.

[0094] Absorbent crotch assembly:

[0095] Fabric top piece: A double-knitted fabric formed of organic cotton (64%) and polyester (36%), wherein the outer surface facing the body is made of cotton and the inner surface is made of polyester. The double-knitted fabric has an elongated mesh defined by a long axis extending between the front and rear edges of the crotch assembly.

[0096] Absorbent layer: two layers of polyester (85%) + polyamide (15%), thickness: 4.4 mm per layer, available from Kukuroğlu, Pınarkent Mahallesi 208 sokak No:1 Pamukkale / Denizli (Turkey).

[0097] Barrier layer: Polyester / polyurethane laminate (polyester micro-terry knitted fabric / polyurethane film laminate, purchased under the trade name BREEZE PES LIGHT from AKBEZ Tekstil Sanayi ve Ticaret A.Ş., Merkez Mah.EskiEdirne Asfaltı No:42 / K 34245 Gaziosmanpaşa, Istanbul, TURKEY)

[0098] The barrier layer is confined to the absorbent crotch assembly and does not extend into the back portion of the underwear.

[0099] Comparative Examples 4 through 19 are commercially available products. These products are sold by the following brands (listed alphabetically, regardless of the order of the comparative examples in Table 1):

[0100] ALWAYS, DIM, ESSITY, FACELLE natural, INTIMY, JESSA, MODIBODY heavy-overnight, NOBLOOD.FR, NUR DIE, OOIA, SCHIESSER, SELENACARE 25ml, SELENACARE 35ml, SKIN UP FREEDOM (ERGOTEKS), THE FEMALE COMPANY, UNIQLO.

[0101] Table 1

[0102]

[0103] As can be seen from the results in Table 1, the product according to the present invention has a maximum pre-leakage absorption capacity of 25 ml of fluid greater than or equal to 25 ml. A higher pre-leakage absorption capacity is more desirable for consumers. Compared to competing products, this absorption performance is superior. Figure 10The examples are better illustrated below. Only competing products associated with Comparative Examples 10, 15, and 17 showed similar pre-leakage absorption capacity.

[0104] When considering the mass of fluid released from the absorbent structure of the article, the article according to the invention also exhibits a rewetting rate of less than 4g; or when considering the percentage of fluid released from the absorbent structure of the article, the article according to the invention exhibits a rewetting rate of less than or equal to 13%. Lower rewetting is more desirable for consumers. Compared to competing products, this rewetting performance is... Figure 11 As better illustrated, the figure shows a rewetting percentage. No comparative examples show a rewetting percentage similar to or lower than that of the present invention. This is a significant advantage of the present invention over the prior art, as it provides increased comfort to the user when using absorbent articles by minimizing the unpleasant sensation of skin contact with a wet surface.

[0105] The article of the present invention also exhibits a wicking time of less than 28 seconds for 3 ml of fluid. The shorter the wicking time, the more desirable it is for consumers. Compared to competing products, this 3 ml fluid wicking time performance is superior. Figure 12 The following examples illustrate this better. Only competing products related to Comparative Examples 4, 5, 6, 10, 12, and 16 showed similar wicking times of 3 ml of fluid. Wicking rates, expressed in ml / s, confirm this observation. The article according to the invention also shows wicking rates higher than 0.1 ml / s. Higher wicking rates are more desirable for consumers. Compared to competing products, this wicking rate performance is superior. Figure 13 The following is a better illustration. Only competing products related to Comparative Examples 4, 5, 6, 10, 12, and 16 showed similar wicking speeds, confirming the results presented in Figure 3 regarding wicking time for 3 ml of fluid.

[0106] When analyzing the results obtained, it is important to consider absorbability, reabsorption, and wicking rate, as all of these characteristics are desirable simultaneously in reusable absorbent articles. It is noteworthy that only Comparative Example 10 performs similarly to the present invention in both absorbability (maximum absorbent capacity before leakage) and wicking rate (wicking time or wicking rate for 3 ml of fluid). However, the reabsorption (g or %) of Comparative Example 10 is significantly higher than that of the article according to the present invention.

[0107] It is difficult to simultaneously achieve suitable performance in terms of absorbency, reabsorption, and wicking rate; however, these properties are achieved by the article according to the invention.

Claims

1. A reusable pair of underwear with an absorbent crotch assembly, the reusable underwear comprising: (a) an underwear fabric, the underwear fabric comprising a continuous waistband and a front portion and a back portion extending from the continuous waistband; (b) A crotch assembly having a front edge, a rear edge, and two side edges, the front edge being attached to the front portion of the underwear fabric, the rear edge being attached to the rear portion of the underwear fabric to form the crotch portion of the underwear, the two side edges defining two leg openings together with the underwear fabric, the crotch assembly comprising: i. A fabric top sheet having an outer surface facing the body and an inner surface facing the barrier sheet, wherein the outer surface facing the body comprises a fibrous material and the inner surface comprises a hydrophobic fibrous material; ii. The barrier sheet, which is impermeable to liquid to prevent leakage through the barrier sheet; iii. At least one absorbent layer having a front edge, a rear edge, two side edges, and a periphery, the at least one absorbent layer being disposed between the fabric top sheet and the barrier sheet; and iv. At least a first hydrophobic treatment, said at least a first hydrophobic treatment being disposed at least along the two side edges around the periphery of said at least one absorbent layer to inhibit fluid flow toward said side edges of said at least one absorbent layer; The crotch assembly has an absorption capacity of at least about 20 grams, an absorption rate of at least about 0.1 mL / s, and a reabsorption rate of less than about 20%.

2. The reusable underwear according to claim 1, wherein, The crotch assembly also includes a layer of the underwear fabric adjacent to the barrier sheet, and the front edge of the crotch assembly is sewn to the front portion of the underwear fabric, the rear edge of the crotch assembly is sewn to the rear portion of the underwear fabric, and an elastic trim wraps around the edge of the leg opening and is sewn to the underwear fabric and the crotch assembly via a hydrophobic thermoplastic construction tape.

3. The reusable underwear according to any of the preceding claims, wherein, The fabric top sheet comprises a double-knitted fabric.

4. The reusable underwear according to claim 3, wherein, The double-knitted fabric includes an elongated mesh knitted fabric, wherein the elongated mesh defines a long axis extending between the front edge and the rear edge of the crotch assembly.

5. The reusable underwear according to claim 4, wherein, The body-facing surface of the double-knitted fabric comprises a fibrous cellulose material, and the inner surface comprises a hydrophobic polymer fiber material.

6. The reusable underwear according to claim 5, wherein, The fibrous cellulose material includes cotton, and the hydrophobic polymer fiber material includes polyester.

7. The reusable underwear according to any of the preceding claims, wherein, The crotch assembly also includes a layer of the underwear fabric adjacent to the barrier sheet.

8. The reusable underwear according to any of the preceding claims, wherein, The first hydrophobic treatment is selected from the group consisting of: hydrophobic thermoplastic structural strips, permanent hydrophobic fiber finishing, hydrophobic material impregnation, compression, and combinations thereof.

9. The reusable underwear according to any of the preceding claims, wherein, The underwear can be washed at up to about 40°C, preferably up to about 60°C, at least 30 times without delamination.

10. The reusable underwear according to any of the preceding claims, wherein, The at least one absorbent layer includes a first absorbent layer adjacent to the fabric top sheet and a second absorbent layer adjacent to the barrier sheet, wherein the second absorbent layer extends beyond the side edge of the first absorbent layer.

11. The reusable underwear according to claim 10, wherein, The first absorbent layer is stitched to the second absorbent layer.

12. A reusable pair of underwear with an absorbent crotch assembly, the reusable underwear comprising: (a) Underwear fabric, the underwear fabric comprising a continuous waistband and a front portion, a back portion and a side portion extending from the continuous waistband toward the crotch portion, and two leg openings; (b) A crotch assembly attached to the front and rear portions of the underwear fabric, and defining the two leg openings together with the underwear fabric, the crotch assembly having a front edge, a rear edge, and two side edges, and the crotch assembly comprising: i. A fabric top sheet having an outer surface facing the body and an inner surface facing the barrier sheet, wherein the outer surface facing the body comprises a fibrous material and the inner surface comprises a hydrophobic fibrous material; ii. The barrier sheet, which is impermeable to liquids to prevent leakage through the barrier sheet; and iii. At least one absorbent layer, said at least one absorbent layer being disposed between the fabric top sheet and the barrier sheet; The crotch assembly has an absorption capacity of at least about 20 grams, an absorption rate of at least about 0.1 mL / s, and a reabsorption rate of less than about 20%.

13. The reusable underwear according to claim 12, wherein, The fabric top sheet comprises a double-knitted fabric.

14. The reusable underwear according to any one of claims 12 to 13, wherein, The double-knitted fabric includes an elongated mesh knitted fabric, wherein the elongated mesh defines a long axis extending between the front edge and the rear edge of the crotch assembly.

15. The reusable underwear according to any one of claims 12 to 14, wherein, The body-facing surface comprises a fibrous cellulose material, and the inner surface comprises a hydrophobic polymer fiber material.

16. The reusable underwear according to claim 15, wherein, The fibrous cellulose material includes cotton, and the hydrophobic polymer fiber material includes polyester.

17. The reusable underwear according to any one of claims 12 to 16, wherein, The crotch assembly also includes a layer of the underwear fabric adjacent to the barrier sheet.

18. The reusable underwear according to any one of claims 12 to 17, wherein, The at least one absorbent layer includes a first absorbent layer adjacent to the fabric top sheet and a second absorbent layer adjacent to the barrier sheet, wherein the second absorbent layer extends beyond the side edge of the first absorbent layer.

19. The reusable underwear according to claim 18, wherein, The first absorbent layer is stitched to the second absorbent layer.

20. A reusable pair of underwear with an absorbent crotch assembly, the reusable underwear comprising: (a) Underwear fabric, the underwear fabric comprising a continuous waistband and a front portion, a back portion and a side portion extending from the continuous waistband toward the crotch portion, and two leg openings; (b) A crotch assembly attached to the front and rear portions of the underwear fabric, and defining the two leg openings together with the underwear fabric, the crotch assembly having a front edge, a rear edge, and two side edges, and the crotch assembly comprising: i. A fabric top sheet having a front edge, a rear edge, two side edges and a periphery, the body-facing fabric material having a body-facing outer surface and an inner surface facing the barrier sheet; ii. The barrier sheet, which is impermeable to liquid to prevent leakage through the barrier sheet; iii. At least one absorbent layer having a front edge, a rear edge, two side edges, and a periphery, the at least one absorbent layer being disposed between the fabric top sheet and the barrier sheet; and iv. At least a first hydrophobic treatment, said at least a first hydrophobic treatment being disposed at least along the two side edges around the periphery of said at least one absorbent layer to inhibit fluid flow toward said side edges of said at least one absorbent layer; The crotch assembly has an absorption capacity of at least about 20 grams, an absorption rate of at least about 0.1 mL / s, and a reabsorption rate of less than about 20%.

21. The reusable underwear according to claim 20, wherein, The reusable underwear can be washed at up to about 40°C, preferably up to about 60°C, at least 30 times without delamination.

22. The reusable underwear according to any one of claims 20 to 21, wherein, The fabric top sheet comprises a double-knitted fabric.

23. The reusable underwear according to claim 22, wherein, The double-knitted fabric includes an elongated mesh knitted fabric, wherein the elongated mesh defines a long axis extending between the front edge and the rear edge of the crotch assembly.

24. The reusable underwear according to any one of claims 20 to 23, wherein, The body-facing surface comprises a fibrous cellulose material, and the inner surface comprises a hydrophobic polymer fiber material.

25. The reusable underwear according to claim 24, wherein, The fibrous cellulose material includes cotton, and the hydrophobic polymer fiber material includes polyester.

26. The reusable underwear according to any one of claims 20 to 25, wherein, The crotch assembly also includes a layer of the underwear fabric adjacent to the barrier sheet.

27. The reusable underwear according to any one of claims 20 to 26, wherein, The first hydrophobic treatment is selected from the group consisting of: hydrophobic thermoplastic structural strips, permanent hydrophobic fiber finishing, hydrophobic material impregnation, compression, and combinations thereof.

28. The reusable underwear according to any one of claims 20 to 27, wherein, The at least one absorbent layer includes a first absorbent layer adjacent to the fabric top sheet and a second absorbent layer adjacent to the barrier sheet, wherein the second absorbent layer extends beyond the side edge of the first absorbent layer.

29. The reusable underwear according to claim 28, wherein, The first absorbent layer is stitched to the second absorbent layer.

30. An absorbent crotch assembly for reusable underwear, the assembly having a front edge, a back edge, and two side edges, and the assembly comprising: (a) A fabric top sheet having a front edge, a rear edge, two side edges and a periphery, the body-facing fabric material having a body-facing outer surface and an inner surface facing the barrier sheet. (b) the barrier sheet, wherein the barrier sheet is impermeable to liquid to prevent leakage through the barrier sheet; (c) At least one absorbent layer having a front edge, a rear edge, two side edges and a periphery, the at least one absorbent layer being disposed between the fabric top sheet and the barrier sheet; and (d) At least a first hydrophobic treatment, the at least first hydrophobic treatment being disposed at least along the two side edges around the periphery of the at least one absorbent layer to inhibit fluid flow toward the side edges of the at least one absorbent layer; The crotch assembly has an absorption capacity of at least about 20 grams, an absorption rate of at least about 0.1 mL / s, and a reabsorption rate of less than about 20%.

31. The absorbent crotch assembly of claim 30, wherein, The absorbent crotch assembly is capable of being washed at least 30 times at temperatures up to about 40°C, preferably up to about 60°C, without delamination.

32. The absorbent crotch assembly according to any one of claims 30 to 31, wherein, The fabric top sheet comprises a double-knitted fabric.

33. The absorbent crotch assembly of claim 32, wherein, The double-knitted fabric includes an elongated mesh knitted fabric, wherein the elongated mesh defines a long axis extending between the front edge and the rear edge of the crotch assembly.

34. The absorbent crotch assembly according to any one of claims 30 to 33, wherein, The body-facing surface comprises a fibrous cellulose material, and the inner surface comprises a hydrophobic polymer fiber material.

35. The absorbent crotch assembly of claim 34, wherein, The fibrous cellulose material includes cotton, and the hydrophobic polymer fiber material includes polyester.

36. The absorbent crotch assembly according to any one of claims 30 to 35, wherein, The crotch assembly also includes a layer of the underwear fabric adjacent to the barrier sheet.

37. The absorbent crotch assembly according to any one of claims 30 to 36, wherein, The first hydrophobic treatment is selected from the group consisting of: hydrophobic thermoplastic structural strips, permanent hydrophobic fiber finishing, hydrophobic material impregnation, compression, and combinations thereof.

38. The absorbent crotch assembly according to any one of claims 30 to 37, wherein, The at least one absorbent layer includes a first absorbent layer adjacent to the fabric top sheet and a second absorbent layer adjacent to the barrier sheet, wherein the second absorbent layer extends beyond the side edge of the first absorbent layer.

39. The absorbent crotch assembly of claim 38, wherein, The first absorbent layer is stitched to the second absorbent layer.

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