An absorbent front assembly for washable absorbent male underwear, washable absorbent male underwear and a method for production thereof

Abstract

Disclosed herein is an absorbent front assembly for integration in a washable absorbent male underwear. The absorbent front assembly has an extension in a longitudinal direction (y), in a transversal direction (x) and in a thickness direction (z) perpendicular to the longitudinal direction (y) and the transversal direction (x). The absorbent front assembly comprises a liquid permeable layer, a liquid impermeable layer and first and second absorbent layers located between the liquid permeable layer and the liquid impermeable layer. The absorbent front assembly is a three-dimensionally shaped absorbent front assembly comprising first and second side-panels joined along long curved side-edges by a curved central join extending in a longitudinal direction (y) from a top edge to a bottom edge of the absorbent front assembly. Each layer of the three-dimensionally shaped absorbent front assembly comprises first and second layer side-panels joined along long curved layer side-edges by a central layer join extending in the longitudinal direction (y) from a top edge to a bottom edge of the absorbent front assembly, and being curved in the thickness direction (z). The central join of the absorbent front assembly comprises the central layer joins, wherein the first and second layer side-panels of the first absorbent layer are joined by a flatlock stitch in class 600 according to the international standard ISO 4915. An absorbent male underwear comprising the absorbent front panel and methods for manufacturing the absorbent front panel and the absorbent male underwear are also disclosed.

Description

[0001] AN ABSORBENT FRONT ASSEMBLY FOR WASHABLE ABSORBENT MALE UNDERWEAR, WASHABLE ABSORBENT MALE UNDERWEAR AND A METHOD FOR PRODUCTION THEREOF

[0002] TECHNICAL FIELD

[0003] The disclosure pertains to an absorbent front assembly for integration in a washable absorbent male underwear, the absorbent front assembly comprising a liquid permeable top layer, a liquid impermeable layer and an absorbent core arranged between the liquid permeable layer and the liquid impermeable layer. The disclosure further pertains to a washable absorbent male underwear and to methods for producing the absorbent front assembly and the washable absorbent male underwear including the absorbent front assembly.

[0004] BACKGROUND

[0005] The present disclosure generally relates to the field of reusable and washable absorbent garments, and more particularly to a reusable washable absorbent male underwear for use by persons suffering from light to moderate urine incontinence.

[0006] It is a concern to provide such incontinence garments which as much as possible resemble ordinary underwear and which are comfortable and well-fitting. A reusable and washable absorbent male underwear preferably has an absorbent front assembly having a shaped pouch construction in order to provide space for the genitals, i e the penis and scrotum. However, by necessity reusable and washable incontinence protection garments include layers and materials which are not present in conventional underwear, such as a liquid permeable top layer which lets liquid pass through into at least one underlying absorbent layer. It is also generally preferred that a liquid barrier layer is arranged on a garment-facing side of the absorbent material to prevent liquid from escaping through the incontinence protection underwear and to wet the user’s outer garment. The additional layers add bulkiness to the underwear. Furthermore, the additional layers are joined to each other and to a pant-material by means of adhesives, stitched seams, etc. which may impart stiffness to parts of underwear for incontinence protection, particularly where multiple joins are arranged on top of each other. It is therefore a concern to arrange material layers in such a way that the flexibility of the underwear is decreased as little as possible and such that the part of the underwear which is provided for urine absorption is as slim and conformable as possible while offering adequate absorbency and leakage protection. A particular concern is to provide joins and seams which are flexible and nonchafing, while being strong enough to withstand repeated washing and use.

[0007] An object of the present disclosure is to offer an improved washable absorbent male underwear, having adequate absorbency for light to moderate urine incontinence and having adequate integrity to withstand repeated washing and wear.

[0008] SUMMARY

[0009] The above and further objects may be achieved with an absorbent front assembly for integration in a washable absorbent male underwear in accordance with claim 1, a method for manufacturing an absorbent front assembly in accordance with claim 15, a washable absorbent male underwear in accordance with claim 21, and a method for manufacturing a washable absorbent male underwear in accordance with claim 22. Variations of the disclosure are set out in the dependent claims and in the following description.

[0010] Disclosed herein is an absorbent front assembly for integration in a washable absorbent male underwear. The absorbent front assembly has an extension in a longitudinal direction (y), in a transversal direction (x) and in a thickness direction (z) perpendicular to the longitudinal direction (y) and the transversal direction (x). The absorbent front assembly comprises

[0011] - a liquid permeable layer,

[0012] - a liquid impermeable layer; and

[0013] - a first absorbent layer and a second absorbent layer located between the liquid permeable layer and the liquid impermeable layer.

[0014] The absorbent front assembly is a three-dimensionally shaped absorbent front assembly comprising first and second side-panels joined along long curved side-edges by a curved central join extending in a longitudinal direction (y) from a top edge to a bottom edge of the absorbent front assembly. Each layer of the three-dimensionally shaped absorbent front assembly comprises first and second layer side-panels joined along long curved layer side-edges by a central layer join extending in the longitudinal direction (y) from a top edge to a bottom edge of the absorbent front assembly, and being curved in the thickness direction (z). The central join of the absorbent front assembly comprises the central layer joins, wherein the first and second layer side-panels of the first absorbent layer are joined by a flatlock stitch in class 600 according to the international standard ISO 4915. The definition of class 600 according to the international standard ISO 4915 is “covering chain stitches”, and this is commonly known as “flatlock stitches”.

[0015] The absorbent front assembly structure is configured for use in an absorbent male underwear wherein the absorbent front assembly has a pouch-shaped construction adapted for persons with male genitalia and is capable of being applied over the male genitalia and to quickly absorb and store discharges resulting from urinary incontinence.

[0016] Technical benefits may include that the absorbent front assembly comprises four layers, each having different properties to ensure quick entry and absorption of any discharges in addition to subsequent high-capacity storage in a reliable and leak proof manner. The flatlock stitch in class 600 according to the international standard ISO 4915 is used to join the first and second layer side-panels of the first absorbent layer, creating a durable, flat and elastic seam between the first and second layer side-panels of the first absorbent layer. Flatlock stitches in class 600 interfere only to a small extent with the open internal structure of the first absorbent layer and therefore high liquid flow through and internally in the layer may take place also at the layer central join of the first absorbent layer.

[0017] The first absorbent layer may be arranged between the liquid permeable layer and the second absorbent layer and may be in direct contact with the liquid permeable layer. A technical benefit of this arrangement may be that the direct contact between the liquid permeable layer and the first absorbent layer enables the moisture to quickly enter the first absorbent layer and thereafter spread into the second absorbent layer arranged underneath the first absorbent layer.

[0018] Optionally, the curved side layer edges of the first and second layer side-panels in the first absorbent layer are arranged butt-to-butt before being joined by the flatlock stitch in class 600. A technical benefit may include that arranging the two side-panels butt-to-butt enables a flow of liquid between two adjacent side-panels and creates a continuous open internal network across the seam joining the first and second layer side-panels of the first absorbent layer. This provides an improved spread of liquid throughout the entire volume of the first absorbent layer and thereby improved transfer into the second absorbent layer arranged underneath the first absorbent layer as the liquid transfer may take place over a greater area of the first and second absorbent layers. Further, promotion of fluid flow in the x- and y- directions of the absorbent layers improves utilization of the absorbent material in the absorbent front assembly and minimizes the risk of the material of the initial wetting point being saturated by liquid. If the absorbent material becomes saturated by liquid, additional liquid may flow on the surface of the absorbent front assembly and may even flow out past the edges of the liquid impermeable layer and leak through the underpant material onto a user’s outer garment.

[0019] Optionally, also the central join of the first and second layer side-panels of the second absorbent layer may be joined by a flatlock stitch in class 600 according to the international standard ISO 4915.

[0020] The absorbent front assembly may also comprise one or more further absorbent layers. A technical benefit may be that an absorbent front panel with improved absorption capacity and / or liquid handling properties may be provided. Further absorbent layer(s) may be located between the liquid permeable layer and the first absorbent layer and / or between the second absorbent layer and the liquid impermeable layer. Also, the central join of the first and second layer side-panels of the additional absorbent layers may be joined by a flatlock stitch in class 600 according to the international standard ISO 4915.

[0021] Furthermore, also the curved side layer edges of the first and second layer side-panels in the second absorbent layer and / or any additional absorbent layer(s) may be arranged butt-to-butt before being joined by a flatlock seam.

[0022] The first absorbent layer may be a liquid transfer layer arranged between the liquid permeable layer and the second absorbent layer. A technical benefit may be that a liquid transfer layer has a high internal liquid wicking capacity which enables an efficient spread of the volume of the fluid over a wider receiving area in the first absorbent layer to increase the overall wicking capacity of the absorbent front assembly and thereby improving utilization of the available absorbent capacity in the absorbent front assembly. The high wicking capacity provides efficient spread of moisture into a wider area of an underlying second absorbent layer having a liquid absorbing capacity. Since the first absorbent layer may be arranged in direct contact with the liquid permeable layer, discharged urine is quickly transferred away from the wearer-facing side of the absorbent front panel to provide a dry feel at the surface. The first absorbent layer may also have some liquid retaining properties. The first absorbent layer may be a spacer fabric comprising a top layer and a bottom layer and an interconnecting layer of pile filaments or other spacer elements between the top layer and the bottom layer. Absorbent material such as a spacer material typically benefit from being joined by flatlock seams because the fabric is relatively thick and a flatlock seam enables the material to keep its thickness.

[0023] The second absorbent layer may be a liquid absorbing layer arranged between the first absorbent layer and the liquid impermeable layer. A technical benefit of using a second liquid absorbing layer is that it may hold liquid received from the first absorbent layer and store it in capillaries between the fibers of the material creating a high-capacity storage space for the absorbed liquid.

[0024] The liquid impermeable layer forms a barrier layer in the absorbent front panel to prevent the absorbed urine from passing from the second absorbent layer to an outer fabric layer or to outer clothing. Advantageously, the liquid impermeable layer is breathable, letting air and water vapor pass through the liquid impermeable layer, yet forming a barrier to liquid.

[0025] The liquid impermeable layer may be laminated to the second absorbent layer forming an absorbent liquid impermeable laminate. A technical benefit of using an absorbent liquid impermeable laminate may be that the barrier layer may serve as a reinforcement to the second absorbent layer, whereby the integrity of the second absorbent layer may be improved during use and washing of the absorbent male underwear.

[0026] The second absorbent layer and the liquid impermeable layer may also form separate layers in the absorbent front assembly, and not being laminated together. If the second absorbent layer is not laminated to the liquid impermeable layer, advantageously, the central join of the first and second layer side-panels of the second absorbent layer may be joined by a flatlock stitch in class 600 according to the international standard ISO 4915.

[0027] The flatlock stitch may be one of 602, 603, 604, 605, 606, 607, 608 or 609. A technical benefit of using any of those above flatlock stitches in class 600 may be that such stitches are formed with two or more groups of threads and have a general characteristic that two of the groups cover both surfaces of the material. Loops of the first group of threads are passed through the loops of the third group already cast on the surface of the material and then through the material where they are interlooped with loops of the second group of threads on the underside of the material. The stitches in the 600 series form strong, durable, flat and elastic seams and cause a minimum of chafing if used in layers worn next to the skin.

[0028] The first and second layer side-panels of the first absorbent layer may be joined by one of flatlock stitches 602, 603, 604, 605, 606, 607, 608 or 609. Furthermore, the first and second layer side-panels of the first absorbent layer may be joined by flatlock stitch type 607. A technical benefit of using flatlock stitch 607 may be that it is formed with six threads: four needle threads (1, 2, 3 and 4), one looper thread (a) and one cover thread (z). Loops of the needle threads 1, 2, 3 and 4 are passed through loops of cover thread Z already laid across the needle side of the material, through the material, and through four separate loops of looper thread a. They are then interlooped with a further loop of thread a, and the interloopings are drawn against the material. The relatively broad flatlock stitch type 607 enables a strong and flat seam to be formed between the side-panels of the first absorbent layer without the need for an overlap between the side-panels. The flatlock stitch type 607 ensures that the edges of the two side-panels in the first absorbent layer remain aligned butt-to-butt without exerting undue compression of the material along the join. This way a flow of liquid is enabled also between two adjacent side-panels improving the spread of liquid throughout the layer. The seam is strong since six threads are used to uphold the integrity of the join.

[0029] The central layer join joining the first and second side-panels of the liquid impermeable layer may be covered by a liquid impermeable sealing strip on the garment-facing side of the liquid impermeable layer. It is important to maintain the liquid impermeability also after the first and second side-panels have been joined by the central seam making up the central join. The seam making up the central layer join of the liquid impermeable layer, or the absorbent-liquid impermeable laminate, is an area that is very prone to leakage due to the holes from the needle passing through the material while creating the seam.

[0030] Therefore, application of a liquid impermeable strip on the liquid impermeable side of the layer side-panels may prevent unwanted leakage of liquid through the central layer join to the underwear or surrounding garments. Optionally, the sealing strip is breathable.

[0031] A folded-over sealing strip may be provided along the entire peripheral region of the absorbent front assembly joining all layers of the absorbent front assembly preventing liquid absorbed by the first and second absorbent layers to leak therefrom. A technical benefit may be that the peripheral edge of the absorbent front assembly may be prone to leakage and application of a liquid barrier strip prevents liquid from leaking through the edge of the absorbent front assembly to the underwear or surrounding garments.

[0032] The folded-over sealing strip may be a thermo-adhesive strip applied by pressure and heat. A technical benefit may be that a very strong bond between the folded-over sealing strip and the absorbent front assembly is created.

[0033] A method of manufacturing the absorbent front assembly described herein is also disclosed herein. The method comprises providing a liquid permeable material, a liquid impermeable material, a first absorbent material and a second absorbent material.

[0034] The absorbent front assembly is formed by providing pairs of two substantially symmetrically curve-shaped layer side-panels of each of the liquid permeable material, the first absorbent material, the second absorbent material and the liquid impermeable material for each layer of material. Thereafter each pair of layer side-panels is joined along the curved layer edges by a central layer join extending in the longitudinal direction (y) from a top edge to a bottom edge of the absorbent front assembly and being curved in the thickness direction (z). The pair of layer side-panels from the first absorbent material is joined by a flatlock stitch in class 600 according to the international standard ISO 4915. A liquid impermeable sealing strip is applied onto the central layer join on the garmentfacing side of the liquid impermeable layer.

[0035] Thereafter the absorbent front assembly is assembled by arranging the pairs of layer sidepanels formed from the first and second absorbent material between the pairs of layer side-panels formed from the liquid permeable and liquid impermeable materials, thereby forming a layered stack of materials. The layered stack of materials is joined to form a three-dimensionally shaped absorbent front assembly by applying a folded-over sealing strip around the entire perimeter of the layered stack of materials forming the absorbent front assembly.

[0036] The method for manufacturing an absorbent front assembly for use in an absorbent male underwear provides an absorbent front assembly having a pouch-shaped construction adapted for persons with male genitalia and being capable of quickly absorbing and storing discharges resulting from urinary incontinence.

[0037] A technical benefit may include that the method provides an absorbent front assembly comprising four layers, each having different properties to ensure quick entry and absorption of any discharges in addition to subsequent high-capacity storage in a reliable and leak proof manner. The flatlock stitch in class 600 according to the international standard ISO 4915 is advantageously used to join the first and second layer side-panels of the first absorbent layer since it creates a durable, flat and elastic seam. Flatlock stitches in class 600 interfere only to a small extent with the internal structure of the first absorbent layer and therefore ensure a high liquid flow through the layer also along the layer central join of the first absorbent layer is ensured.

[0038] The pair of layer side-panels formed from the first absorbent material may be arranged in direct contact with the pair of layer side-panels formed from the liquid permeable material. A technical benefit direct contact between the first absorbent layer and the liquid permeable layer may be that moisture can quickly enter the first absorbent layer and thereafter spread into the second absorbent layer arranged underneath the first absorbent layer.

[0039] Optionally, the liquid impermeable material may be laminated onto the second absorbent material forming an absorbent-liquid impermeable laminate material before joining each pair of liquid impermeable and second absorbent layer side-panels along the curved layer edges by a central layer join. A technical benefit of using an absorbent-liquid impermeable laminate may be that the barrier layer may serve as a reinforcement to the second absorbent layer, whereby the integrity of the second absorbent layer may be improved during use and washing of the absorbent male underwear.

[0040] The curved side layer edges of the first and second layer side-panels in the first absorbent layer may be arranged butt-to-butt before being joined by the flatlock stitch in class 600. A technical benefit may include that arranging the two side-panels butt-to-butt enables a flow of liquid between two adjacent side-panels which provides an improved spread of liquid throughout the entire volume of the first absorbent layer and thereby improved transfer into the second absorbent layer arranged underneath the first absorbent layer.

[0041] The flatlock stitch may be one of 602, 603, 604, 605, 606, 607, 608 or 609. A technical benefit of using any of those above flatlock stitches in class 600 may be that they are formed with two or more groups of threads and have a general characteristic that two of the groups cover both surfaces of the material. Loops of the first group of threads are passed through the loops of the third group already cast on the surface of the material and then through the material where they are interlooped with loops of the second group of threads on the underside of the material. These stitches form strong, durable, flat and elastic seams and reduce the risk of chafing if used in layers worn next to the skin.

[0042] The pair of layer side-panels of the first absorbent layer may be joined by flatlock stitch type 607. A technical benefit of using flatlock stitch 607 may be that it is formed with six threads: four needle threads (1, 2, 3 and 4), one looper thread (a) and one cover thread (z). Loops of threads (1, 2, 3 and 4) are passed through loops of thread z already laid across the needle side of the material, through the material, and through four separate loops of thread a. They are then interlooped with a further loop of thread a, and the interloopings are drawn against the material. The flatlock stitch type 607 ensures that the edges of the two side-panels in the first absorbent layer remain aligned butt-to-butt without exerting undue compression of the material along the join. This way a flow of liquid is enabled also between two adjacent side-panels improving the spread of liquid throughout the layer. The seam is strong since six threads are used to uphold the integrity of the join.

[0043] Further disclosed herein is a washable absorbent male underwear comprising the absorbent front assembly described herein. The absorbent male underwear has an extension in a longitudinal direction (y) and in a transversal direction (x) and comprises a front waist portion, a rear waist portion and a crotch portion bridging the front and rear waist portions. The absorbent front assembly is arranged on a wearer facing side of the front waist portion and forms an integrated, non-removable and non-replaceable part of the absorbent male underwear.An absorbent male underwear is provided comprising the absorbent front assembly described herein, wherein the absorbent front assembly has a pouch-shaped construction adapted for persons with male genitalia and is capable of quickly absorbing and storing discharges resulting from urinary incontinence.

[0044] A technical benefit may include that the absorbent front assembly of the absorbent male underwear comprises four layers of material, each material having different properties to ensure quick entry and absorption of any discharges in addition to subsequent high- capacity storage in a reliable and leak proof manner. The flatlock stitch in class 600 according to the international standard ISO 4915 is used to join the first and second layer side-panels of the first absorbent layer since it creates a durable, flat and elastic seam. Flatlock stitches in class 600 interfere only to a small extent with the internal structure of the side-panels of the first absorbent layer and therefore high liquid flow through the layer also along the layer central join of the first absorbent layer is ensured.

[0045] A method for manufacturing a washable absorbent male underwear comprising the absorbent front assembly described herein is also disclosed. The method comprises providing a liquid permeable material, a liquid impermeable material, a first absorbent material and a second absorbent material. The absorbent front assembly is formed by providing pairs of two substantially symmetrically curve-shaped layer side-panels of each of the liquid permeable material, the first absorbent material, the second absorbent material and the liquid impermeable material for each layer of material. Thereafter each pair of layer side-panels is joined along the curved layer side edges by a central layer join extending in the longitudinal direction (y) from a top edge to a bottom edge of the absorbent front assembly and being curved in the thickness direction (z). The pair of layer side-panels from the first absorbent material is joined by a flatlock stitch in class 600 according to the international standard ISO 4915. A liquid impermeable and breathable sealing strip is applied onto the central layer join on a garment-facing side of the liquid impermeable layer.

[0046] Thereafter the absorbent front assembly is assembled by arranging the pairs of layer sidepanels formed from the first and second absorbent materials between the pairs of layer side-panels formed from the liquid permeable and liquid impermeable materials, thereby forming a layered stack of materials. The layered stack of materials is joined to form a three-dimensionally absorbent front assembly by applying a folded-over sealing strip around the entire perimeter of the layered stack of materials forming the absorbent front assembly.

[0047] Thereafter the absorbent front assembly is integrated into a male underpant by arranging the liquid impermeable layer of the absorbent front assembly towards a wearer-facing side of the waist front portion of the male underpant and joining the absorbent front assembly to the male underpant by providing a seam along the entire perimeter of the absorbent front assembly.

[0048] Thus, a method is provided for manufacturing an absorbent male underwear comprising the absorbent front assembly described herein, wherein the absorbent front assembly has a pouch-shaped construction adapted for persons with male genitalia and is capable of quickly absorbing and storing discharges resulting from urinary incontinence.

[0049] A technical benefit may include that the method provides an absorbent male underwear comprising an absorbent front assembly with at least four layers, each having different properties to ensure quick entry and absorption of any discharges in addition to subsequent high-capacity storage in a reliable and leak proof manner. The flatlock stitch in class 600 according to the international standard ISO 4915 is advantageously used to join the first and second layer side-panels of the first absorbent layer since it creates a durable, flat and elastic seam. Flatlock stitches in class 600 interfere only to a small extent with the internal structure of the first absorbent layer and therefore ensure high liquid flow through the layer also along the layer central join of the first absorbent layer.

[0050] The pair of layer side-panels formed from the first absorbent material may be arranged in direct contact with the pair of layer side-panels formed from the liquid permeable material. A technical benefit of having direct contact between the first absorbent layer and the liquid permeable layer may be that moisture can quickly enter the first absorbent layer and thereafter spread into the second absorbent layer arranged underneath the first absorbent layer.

[0051] The curved side layer edges of the first and second layer side-panels in the first absorbent layer may be arranged butt-to-butt before being joined by the flatlock stitch in class 600. A technical benefit may include that a butt-to-butt seam is non-bulky and flexible. Furthermore, arranging the two side-panels butt-to-butt enables a flow of liquid between two adjacent side-panels which provides an improved spread of liquid throughout the entire volume of the first absorbent layer and thereby improved transfer into the second absorbent layer arranged underneath the first absorbent layer. The flatlock stitch may be one of 602, 603, 604, 605, 606, 607, 608 or 609. A technical benefit of using any of those above flatlock stitches in class 600 may be that they are formed with two or more groups of threads and have a general characteristic that two of the groups cover both surfaces of the material. Loops of the first group of threads are passed through the loops of the third group already cast on the surface of the material and then through the material where they are interlooped with loops of the second group of threads on the underside of the material. These stitches form strong, durable, flat and elastic seams and reduce the risk of chafing if used in layers worn next to the skin.

[0052] The pair of layer side-panels of the first absorbent layer may be joined by flatlock stitch type 607. A technical benefit of using flatlock stitch 607 may be that it is formed with six threads: four needle threads 1, 2, 3 and 4, one looper thread (a) and one cover thread (Z). Loops of threads 1, 2, 3 and 4 are passed through loops of thread Z already laid across the needle side of the material, through the material, and through four separate loops of thread a. They are then interlooped with a further loop of thread a, and the interloopings are drawn against the material. The flatlock stitch type 607 ensures that the edges of the two side-panels in the first absorbent layer remain aligned butt-to-butt without exerting undue compression of the material along the join. This way a flow of liquid is enabled also between two adjacent side-panels improving the spread of liquid throughout the layer. The seam is strong since six threads are used to uphold the integrity of the join.

[0053] Features of the disclosed front absorbent insert, washable absorbent male underwear and their methods for production, examples (including any preferred examples), and / or accompanying claims may be suitably combined with each other as would be apparent to anyone of ordinary skill in the art. Additional features and advantages are disclosed in the following description, claims, and drawings, and in part will be readily apparent therefrom to those skilled in the art or recognized by practicing the disclosure as described herein.

[0054] BRIEF DESCRIPTION OF THE DRAWINGS

[0055] Fig. 1 shows a pair of absorbent male underwear seen from the outer, garment-facing side;

[0056] Fig. 2 shows a pair of absorbent male underwear of a different style from that in Fig. 1, seen from the inner, wearer-facing side;

[0057] Fig. 3 shows a perspective view of an absorbent assembly as disclosed herein, as seen from the side which will be facing a wearer during use; Fig. 4a shows an exploded cross-sectional view taken along the line IVa - IVa in Fig. 3;

[0058] Fig. 4b shows a cross-sectional view taken along the line IVb - IVb in Fig. 3, showing all components in their assembled state;

[0059] Fig. 5 shows a cross-sectional view of the different layers of a spacer material;

[0060] Fig. 6a shows a pair of flat side-panels as seen from the inner, wearer-facing side and before being joined to each other;

[0061] Fig. 6b shows the inner, wearer-facing side of a cup-shaped absorbent front assembly formed by joining side-panels as shown in Fig. 6a to each other;

[0062] Fig. 6c shows the outer, garment-facing side of the absorbent front assembly in Fig. 6b;

[0063] Fig. 7a shows the upper side of a 607 stitch-type flatlock seam;

[0064] Fig. 7b shows the bottom side of a 607 stitch-type flatlock seam;

[0065] Fig. 7c shows an exploded view of the 607 stitch-type flatlock seam;

[0066] Fig. 8a shows an exploded view of the 602 stitch-type flatlock seam;

[0067] Fig. 8b shows an exploded view of the 603 stitch-type flatlock seam;

[0068] Fig. 8c shows an exploded view of the 604 stitch-type flatlock seam;

[0069] Fig. 8d shows an exploded view of the 605 stitch-type flatlock seam;

[0070] Fig. 8e shows an exploded view of the 606 stitch-type flatlock seam;

[0071] Fig. 8f shows an exploded view of the 608 stitch-type flatlock seam;

[0072] Fig. 8g shows an exploded view of the 609 stitch-type flatlock seam;

[0073] DETAILED DESCRIPTION

[0074] Different aspects of the present disclosure will be described more fully hereinafter with reference to the drawings. The washable absorbent male underwear disclosed herein should not be construed as being limited to the aspects set forth herein but can be varied within the scope of the appended claims.

[0075] As used herein, the term “absorbent underwear” refers to garments that are worn and intended to be placed against the skin of the wearer to absorb and contain body fluids such as urine. The underwear is an undergarment, or underpant for male use. The absorbent underwear is a fabric underwear, and not a diaper. The underwear according to the present disclosure is intended to be worn in the same manner as conventional underwear and to be laundered after use for reuse as an absorbent underwear.

[0076] The washable absorbent male underwear is configured to be washable. Washable should be understood as being suitable to undergo at least 10 washing cycles at a temperature of at least 30° Celsius, without disintegrating. During the washing, the absorbent male underwear releases the absorbed fluids, thereby regenerating the absorptive functioning, enabling the washable absorbent underwear to be reused for the same purpose again. The absorbent male underwear may thus be subjected to an aqueous solution containing detergent without losing its structural features. This aqueous solution may be heated as part of the laundering process, e.g. to 30°C, 40°C or 60°C. The laundering may be performed by a machine.

[0077] The term “fabric” as used in the present disclosure may refer to single or multiple layers of fabrics. The fabric may be knitted or woven wherein knitting is a method of constructing a fabric by interlocking a series of loops of one or more yarns. There are two major classes of knitting namely warp and weft knitting. Weaving is a method or process of interlacing two yarns of similar materials so that they cross each other at right angles to produce woven fabric. The warp yarns run lengthwise in the fabric and the filling threads (weft) or picks, run from side to side.

[0078] When used herein “permanently attached”, means that the absorbent assembly is not intended to be separated from the body fabric before, during, or after use. The absorbent assembly is not necessarily directly bonded to the fabric, but instead may be attached via the leg opening seams or bonded by other means such as a sealing tape.

[0079] Fig. 1 shows a pair of absorbent male underwear 1 described herein seen from the outer, garment-facing side 2. The absorbent male underwear 1 comprises a male underpant 10 of e.g., boxer style or a brief pant, which includes an absorbent front assembly 100 shaped to accommodate the male genitalia. In Fig. 1, the absorbent male underwear 1 is exemplified by a boxer style pant, while in Fig. 2, the absorbent male underwear 1 is exemplified by a brief-style pant.

[0080] Fig. 2 discloses a brief-style male underpant 10 which has an extension in a longitudinal direction (y) and in a transversal direction (x), (which equally divides the overall length L), a front waist portion 11, a rear waist portion 16 and a crotch portion 15 bridging the front and rear waist portions 11,16. The male underpant includes left and right leg opening edges 13a, 13b. The front waist portion 11 has a front waist edge 12 and the rear waist portion 16 has a rear waist edge 17. The male underpant 10 may include a waist band 20, such as an elastic waist band for retention of the underpant 10. The absorbent front assembly 100 as described herein is arranged on the wearer-facing side of the front waist portion 11.

[0081] The fabric of the underpant 10 may be constructed of any suitable fabric, including fabrics constructed from natural fibers, regenerated cellulose fibers or synthetic fibers, or a combination thereof.

[0082] The fibers may be recycled fibers. The fabric may comprise a stretchable fiber, e.g., elastane, so that the absorbent male underwear 1 can provide a firm fit while at the same time adapting to the wearer’s movements thus preventing any leakage from migrating through the leg openings and keeping the absorbent front assembly 100 in place. The fabric is preferably breathable to allow vapor to escape from the wearer’s skin and from the absorbent front assembly 100.

[0083] The absorbent front assembly 100 is integrated with the male underpant 10 and is located in a region of the underpant 10 mostly prone to be exposed to male incontinence, i.e., an area extending from the waist edge 12,17 along the longitudinal axis (y) of the front waist portion 11 towards the crotch portion 15 as best seen in Fig 2.

[0084] The absorbent front assembly 100 as disclosed herein is a three-dimensionally shaped absorbent front assembly 100 having an extension in a longitudinal direction (y) from a top edge 104 to a bottom edge 105, in a transversal direction (x) and in a thickness direction (z) perpendicular to the longitudinal direction (y), and the transversal direction (x) as seen in Fig. 3. The absorbent front assembly 100 provides a shaped pouch construction adapted for persons with male genitalia, different in part because the penis is likely to leak urine from a place higher up the ventral abdomen, and partly in order to provide space for the genitals, i.e., the penis and the scrotum, for comfort.

[0085] The absorbent front assembly 100 comprises several layers of different materials arranged on top of each other to form a reliable absorbent structure capable of quickly absorbing and storing discharges resulting from urinary incontinence. The absorption front assembly 100 comprises a liquid permeable layer 120, a liquid impermeable layer 150; and at least a first absorbent layer 130 and a second absorbent layer 140 located between the liquid permeable layer 120 and the liquid impermeable layer 150. Each layer will now be described in more detail with reference to Fig. 4a which shows an exploded cross-sectional view taken along the line IVa - IVa in Fig. 3, and with reference to Fig. 4b which shows a cross-sectional view taken along the line IVb - IVb in Fig. 3 and showing all components in their assembled state. The absorbent front assembly 100 comprises at least the following layers, as seen in a direction from an inner wearer-facing surface 3 of the absorbent male underwear 1 towards an outer garment-facing surface 2 of the absorbent male underwear 1: a liquid permeable layer 120; a first absorbent layer 130; a second absorbent layer 140; and a liquid impermeable layer 150.

[0086] The liquid permeable layer 120 is arranged closest to the inner wearer-facing surface 3 of the absorbent male underwear when the absorbent front panel is integrated in the underpant 10. The liquid permeable layer 120 may be any suitable material which can withstand repeated washing, such as material made from natural fibers, regenerated cellulose fibers or synthetic fibers, or a combination thereof. The liquid permeable layer 120 may be provided with openings.

[0087] The absorbent front assembly 100 comprises at least two absorbent layers wherein a first absorbent layer 130 is a material which has liquid transferring or wicking properties, and may also have some liquid retaining properties. The first absorbent layer 130 is arranged in direct contact with the liquid permeable layer 120 to enable the moisture to quickly spread away from the wearer and into the second absorbent layer 140 arranged underneath the first absorbent layer 130.

[0088] Optionally, the first absorbent layer 130 is a spacer fabric 138 comprising a top layer 138a and a bottom layer 138b and an interconnecting layer 138c of pile filaments between the top layer 138a and the bottom layer 138b as seen in Fig. 5. The first absorbent layer 130 may contain natural fibers, regenerated cellulose fibers or synthetic fibers, or a combination thereof. Absorbent material such as a spacer material 138 described herein typically benefit from being joined by flatlock seams because the fabric is relatively thick, and a flatlock seam enables the material to keep its thickness. The flatlock seam enables the spacer fabric to be joined butt-to-butt, and since the spacer fabric is relatively thick this is good for comfort reason.

[0089] The second absorbent layer 140 is arranged to receive liquid from the first absorbent layer 130, e.g., from a spacer layer. The second absorbent layer 140 may be made from a high- loft absorbent textile material serving as a liquid absorbing layer which can hold liquid in capillaries between the fibers of the material or be absorbed by the fibers themselves. The second absorbent layer 140 may contain natural fibers, regenerated cellulose fibers or synthetic fibers, or a combination thereof.

[0090] The constituent threads or yams of the second absorbent layer 140 may be knitted in a manner that imparts a relatively lofty and / or densely fibrous network having a high degree of void volume and capillarity making it suitable for absorbing fluid. In some examples, the knit may be a knitted terry cloth, or even a knitted / sheared terry cloth. The constituent threads or yarns may be or may include microfibers, for increased fiber surface area per unit surface area of the second absorbent layer 140.

[0091] The absorbent front assembly 100 may comprise one or more further absorbent layers, such as three, four, five or further absorbent layers. The further absorbent layers may have the same or different absorption properties as the first and second absorbent layers 130,140. The third, fourth, fifth or further absorbent layers may be arranged between the first and second absorbent layers 130,140. Alternatively, the third, fourth, fifth or further absorbent layers may be arranged between the liquid permeable layer 120 and first absorbent layer 130.

[0092] A liquid impermeable layer 150 is included as a barrier layer in the absorbent front panel 100 to prevent the absorbed urine from passing from the second absorbent layer 140 to an outer fabric layer or to outer clothing. The liquid impermeable layer 150 is typically a polymer film, made in whole or in part of polyurethane or polyester. The polymer film is preferably breathable, letting air and water vapor pass through the film yet forming a liquid barrier. The liquid impermeable layer 150 may be laminated onto an outward-facing surface of the second absorbent layer 140 to form an absorbent-liquid impermeable laminate 145. Alternatively, the second absorbent layer 140 and the liquid impermeable layer 150 form separate layers in the absorbent front assembly.

[0093] For the purpose of hindering growth of microorganisms supported by absorbent urine, which may cause odor, it may be advantageous to include one or more anti-microbial agents in or among the materials present in the absorbent front assembly 100 and / or in any other element of the underpant 10.

[0094] The pouched shape is formed by providing two substantially symmetrically shaped sidepanels with curved edges from each layer and stitching the edges together to form a central join. It is well known to skilled workers in many arts, including undergarment manufacture, that flexible sheet materials will deform and form three-dimensional shapes when curved edges are forced to come together by attachment means. As the pieces are sewn together, they bend and will provide a physical space along the lower ventral abdomen of the user for accommodating the genitals in a comfortable way.

[0095] Fig. 6a, is a view of first and second layer side-panels 121a, 121b, 131a, 131b, 141a, 141b, 151a, 151b which constitute mirror-symmetrical halves of a layer in an absorbent front assembly 100 as disclosed herein. The side-panels 121a, 121b, 131a, 131b, 141a, 141b, 151a, 151b each have an inner curved side-edge 122a, 122b, 132a, 132b, 142a, 142b, 152a, 152b. The inner curved side-edges 122a, 122b, 132a, 132b, 142a, 142b, 152a, 152b of the layer side-panels 121a, 121b, 131a, 131b, 141a, 141b, 151a, 151b in Fig. 6a are shown facing each other. As set out herein, each individual layer in the absorbent front assembly 100 is formed by joining the inner curved side-edges 122a, 122b, 132a, 132b, 142a, 142b, 152a, 152b of the layer side-panels 121a, 121b, 131a, 131b, 141a, 141b, 151a, 151b to each other along layer central joins 123, 133, 143, 153 as seen in Figs. 4a and 4b, extending in the longitudinal direction (y) from a top edge 124, 134, 144, 154 to a bottom edge 125, 135, 145, 155 in each layer of the absorbent front assembly 100. Hence, the central join 103 of the absorbent front assembly 100 comprises a number of separate seams 123,133,143,153, wherein each seam 123, 133, 143 ,153 connects panel parts 121a, 121b, 131a, 131b, 141a, 141b, 151a, 151b of different layers in the absorbent front assembly 100 as best seen in Figs. 4a and 4b. By joining the layer side-panels 121a, 121b, 131a, 131b, 141a, 141b, 151a, 151b along the inner curved side panels 122a, 122b, 132a, 132b, 142a, 142b, 152a, 152b each layer assumes a cup-shape resulting from the layer being curved in the z-direction of the absorbent front assembly 100.

[0096] As set out herein, the joins 123, 133, 143, 153 in the different layers may be made in different ways. The thin top layer side-panels 121a, 121b are joined together in an overlap seam, but the thin top layer side-panels 121a, 121b may also be arranged butt-to-butt before being joined. The side-panels 131a, 131b forming the first absorbent layer 130 are joined with the inner curved side-edges 132a, 132b of the layer side-panels 131 a, 131 b abutting each other and using a flatlock stitch in class 600 according to the international standard ISO 4915. Flatlock stitches in class 600 according to the international standard ISO 4915 have been found to provide the appropriate strength to the seam 133 between the panel parts 131 a, 131b of the first absorbent layer 130.

[0097] The international standard ISO 4915 classifies, designates, describes and illustrates various kinds of stitch types. Stitch types are divided into six classes (100-600) and advantageously covering chain stitches in class 600 may be used for joining the first and second side-panels 131 a, 131b of the first absorbent layer 130 described herein. Preferably the stitch is chosen from one of stitch types 602, 603, 604, 605, 606, 607, 608 or 609 in the 600 series.

[0098] Three groups of threads; needle-, cover-, and looper threads may be used to create a strong and flexible flatlock seam that is flat and virtually identical on either side. In flatlock seams the needle threads extend back and forth through the front and back sides of the fabric, while the cover thread extends back and forth between the panels only on the front side, and the looper thread extends back and forth between the panels only on the back side of the fabric. The cut edges on each side of the seam are advantageously abutted rather than overlapped, meaning there are no seam allowances to add bulk or potentially cause chafing. The raw edges of fabric are completely encased in the stitching with cover and looper threads. Thus, flatlock seams create flat seams that are strong since three or more threads are used to create the seams. A flatlock seam has a width perpendicular to its length, which means that the flatlock seam creates a band-shaped joining area along the curved side edges of the joined side panels. Such joining area may serve to distribute tensional forces in the material along the join.

[0099] Absorbent material such as e.g., the spacer material 138 described herein typically benefit from being joined by flatlock seams because the fabric is relatively thick. By joining the side-panels 131 a, 131b of the absorbent material using a flatlock stitch in class 600, the internal space of one panel part 131a is in direct contact with the internal space of the other panel part 132b, such that the flat-lock seam 133 interferes only to a small extent with the internal structure of e.g. the spacer material 138 of the first absorbent layer 130. Regular seams are not the best option for thick material because the seam allowance would make the seam extra bulky.

[0100] As mentioned above, it is crucial to the function of the first absorbent layer 130 that the internal reservoir structure is retained throughout the expected lifespan of the washable absorbent male underwear 1, and therefore preferably flatlock seam created by stitch type 607 is used to join the first and second side-panels 131 a, 131b of the first absorbent layer 130. Figs. 7 a and b illustrate the front and back side, respectively of two pieces of fabric wherein the side-edges 132a, 132b have been arranged butt-to-butt and joined together using the 607-flatlock stitch. Flatlock stitches 607 create durable, flat and elastic seams that ensure that the edges 132a, 132b of the two side-panels 131 a, 131b remain aligned butt-to-butt without exerting undue compression of the material along the join 133 / 607. This way a flow of liquid is enabled also between two adjacent side-panels 131 a, 131b. Fig. 7 c illustrates an exploded view of the flatlock stitch type 607 formed with six threads: four needle threads 1 , 2, 3 and 4, one looper thread (a) and one cover thread (Z). Loops of threads 1 , 2, 3 and 4 are passed through loops of thread Z already laid across the needle side of the material, through the material, and through four separate loops of thread a. They are then interlooped with a further loop of thread a, and the interloopings are drawn against the material. Thus, six threads are used to join two abutting edges 132a, 132b of two adjacent side-panels 131 a, 131b creating strong, durable and flat seams.

[0101] The two side-panels 121a, 121b in the liquid permeable layer be joined by any suitable seam. Figs. 8a-g show exploded views of each one of the stitch types 602, 603, 604, 605, 606, 607, 608 or 609 in class 600 according to the international standard ISO 4915.

[0102] The liquid impermeable layer 150 or, alternatively the absorbent-liquid impermeable laminate 145 has a special function in the absorbent front panel 100 since this layer forms a liquid barrier layer of the absorbent front assembly 100 that prevents any liquid accumulated in the absorbent layers 130,140 from passing to the fabric of the underpant 10 or other garments.

[0103] The liquid impermeable layer 150 alternatively the absorbent-liquid impermeable laminate 145 is arranged closest to the fabric of the underpant 10 with the liquid impermeable side of the laminate 145 facing the fabric. The most vulnerable area prone to leakage possibilities of the liquid barrier is the join 153 / 148 between the two side-panels 151a, 151b / 146a, 146b. To mitigate this risk for leakage, the central layer join 153 / 148 between the side-panels 151a, 151b / 146a, 146b of the liquid impermeable layer 150 or absorbent-liquid impermeable laminate 145 is advantageously covered by a sealing strip 156 on the garment facing-side of the layer 150 or laminate 145. The sealing strip 156 is preferably liquid impermeable and breathable. The sealing strip 156 may be a polymer tape, such as a polyurethane tape. The sealing strip 156 is advantageously hot glued onto the seam 153,148 whereby the sealing strip 156 is applied at an elevated temperature using pressure to improve the resistance to washing.

[0104] As the central join 153 in the impermeable layer 150, alternatively the absorbent-liquid impermeable laminate 145, is reinforced by the sealing strip 155, a simpler and less strong type of seam 153 may be used.

[0105] After joining all layer side-panels 121a, 121b, 131a, 131b, 141a, 141b, 151a, 151b to form the individual layers of the absorbent front assembly 100, the three-dimensionally shaped layers are stacked together and optionally attached to each other to produce an absorbent front assembly 100 as shown in Figs. 6b and 6c. The pair of side-panels 131 a, 131b formed from the first absorbent material may advantageously be arranged between the pairs of side-panels 121a, 121b, 151a, 151b / 146a, 146b formed from the liquid permeable material and the second absorbent material alternatively the absorbent-liquid impermeable laminate 145, such that the pair of side-panels 131a, 131b from the first absorbent material 130 is arranged in direct contact with the pair of side-panels 121a, 121b from the liquid permeable material 120. thereby forming a stack of layered materials. The stack of layered materials is thereafter joined by applying a folded-over sealing strip 108 around the entire perimeter 107 of the layered stack of materials forming the three-dimensionally shaped absorbent front assembly 100 to be integrated into the male underpant 10.

[0106] Advantageously a first edge portion 108a of the folded-over sealing strip 108 is applied and adhered to the outer surface 127 along the entire peripheral edge of the liquid permeable layer 120. Thereafter the folded-over sealing strip 108 is folded around the edge of the stack of layered material such that the middle section 180c of the barrier strip sticks to itself and the second edge portion 108b of the folded-over sealing strip 108 is adhered to the outer surface 157 along the entire peripheral edge on the garment-facing side of the liquid impermeable layer 150. Thereby a liquid tight seal is formed around the outer edge 107 of the absorbent front assembly 100, preventing any liquid leaking from absorbent front panel periphery 107.

[0107] The absorbent front assembly 100 is shown in Fig. 6b from the wearer-facing side, i.e. , from the liquid permeable layer 120 side and curves towards the viewer of the figure. In Fig. 6c, the absorbent front assembly 100 is shown from the garment-facing side, with the central portion of the absorbent front assembly 100 bulging towards the viewer of the figure. Fig. 6c shows the sealing strip 156 which is applied over the seam 153 / 148 joining the first and second side-panels 151a,151b / 146a,146b of the liquid impermeable layer alternatively the absorbent-liquid impermeable layer.

[0108] The absorbent front assembly 100 is attached to the wearer-facing side 3 along a midline of the front waist portion 11 extending from the front waist edge 12 or the waist band towards the crotch portion 15. The absorbent front assembly 100 is advantageously stitched to the underpant 10 with a straight seam 109 which is arranged around the periphery of the absorbent front assembly 100. The location of the straight seam 109 is the part of the folded-over sealing strip 108 which is arranged outside the peripheral edge of the absorbent front assembly 100 is indicated in Figs. 3 and 6b. By arranging the seam 109 at a distance from the edge of the absorbent front assembly 100, side leakage from the absorbent front assembly 100 is prevented. Thus, the absorbent front panel 100 is provided as an integrated part of a complete wearable underpant 10 and is not intended to be removable or replaceable.

Claims

CLAIMS1. An absorbent front assembly (100) for integration in a washable absorbent male underwear (1), the absorbent front assembly (100) having an extension in a longitudinal direction (y), in a transversal direction (x) and in a thickness direction (z) perpendicular to the longitudinal direction (y), and the transversal direction (x), the absorbent front assembly (100) comprising- a liquid permeable layer (120),- a liquid impermeable layer (150); and- a first absorbent layer (130) and a second absorbent layer (140) located between the liquid permeable layer (120) and the liquid impermeable layer (150), the first absorbent layer (130) being arranged between the liquid permeable layer (120) and the second absorbent layer (140), wherein the absorbent front assembly (100) is a three-dimensionally shaped absorbent front assembly (100) comprising first and second side-panels (121a, 121b, 131a, 131 b, 141a, 141 b, 151a, 151b) joined along long curved sideedges (122a, 122b, 132a, 132b, 142a, 142b, 152a, 152b) by a central join (123,133,143,153) extending in the longitudinal direction (y) from a top edge (104) to a bottom edge (105) of the absorbent front assembly (100) and being curved in the thickness direction (z), and wherein each layer (120,130,140,150) of the three- dimensionally shaped absorbent front assembly (100) comprises first and second layer side-panels (121a, 121 b, 131a, 131 b, 141a, 141 b, 151a, 151 b) joined along long curved layer side-edges (122a, 122b, 132a, 132b, 142a, 142b, 152a, 152b) by a central layer join (123,133,143,153) extending in the longitudinal direction (y) from a top edge (124,134,144,154) to a bottom edge (125,135,145,155) of the absorbent front assembly (100), the central join (103) of the absorbent front assembly (100) comprising the central layer joins (123,133,143,153), wherein the first and second layer side-panels (131 a, 131 b) of the first absorbent layer (130) are joined by a flatlock stitch in class 600 according to the international standard ISO 4915.

2. The absorbent front assembly (100) according to claim 1 , wherein the first absorbent layer (130) is in direct contact with the liquid permeable layer (120).

3. The absorbent front assembly (100) according to claim 1 or 2, wherein the curved side layer edges (132a, 132b) of the first and second layer side-panels (131 a, 131b)of the first absorbent layer (130) are arranged butt-to-butt before being joined by the flatlock stitch in class 600.

4. The absorbent front assembly (100) according to any one of the preceding claims, wherein the first absorbent layer (130) is a liquid transfer layer arranged between the liquid permeable layer (120) and the second absorbent layer (140).

5. The absorbent front assembly (100) according to any one of the preceding claims, wherein the first absorbent layer (130) is a spacer fabric (138) comprising a top layer (138a) and a bottom layer (138b) and an interconnecting layer (138c) of pile filaments between the top layer (138a) and the bottom layer (138b).

6. The absorbent front assembly (100) according to any one of the preceding claims, wherein the second absorbent layer (140) is a liquid absorbing layer arranged between the first absorbent layer (130) and the liquid impermeable layer (150).

7. The absorbent front assembly (100) according to any one of the preceding claims, wherein the liquid impermeable layer (150) is laminated to the second absorbent layer (140) forming an absorbent-liquid impermeable laminate (145).

8. The absorbent front assembly (100) according to any one of the preceding claims, wherein the absorbent front assembly (100) comprises one or more further absorbent layers.

9. The absorbent front assembly (100) according to any one of the preceding claims, wherein the flatlock stitch in class 600 is one of stitches 602, 603, 604, 605, 606, 607, 608 or 609.

10. The absorbent front assembly (100) according to claim 9, wherein the first and second layer side-panels (131 a, 131 b) of the first absorbent layer (130) are joined by flatlock stitch type 607.

11. The absorbent front assembly (100) according to any one of the preceding claims, wherein the central layer join (153) joining the first and second side-panels(151 a, 151b) of the liquid impermeable layer is covered by a liquid impermeable sealing strip (156) on a garment-facing side of the absorbent-liquid impermeable layer side-panels (151a, 151 b).

12. The absorbent front assembly (100) according to claim 11 , wherein the liquid impermeable sealing strip (156) is a polyurethane sealing strip.

13. The absorbent front assembly (100) according to any one of the preceding claims, wherein a folded-over sealing strip (108) is provided along the entire peripheral edge of the absorbent front assembly (100) joining all layers of the absorbent front assembly (100).

14. The absorbent front assembly (100) according to claim 13, wherein the folded-over sealing strip (108) is a thermo-adhesive strip applied by pressure and heat.

15. A method of manufacturing the absorbent front assembly (100) of claims 1-14, the method comprising-providing a liquid permeable material, a liquid impermeable material, a first absorbent material and a second absorbent material; and- forming an absorbent front assembly (100) by providing pairs of two substantially symmetrically curve-shaped layer side-panels(121a, 121b, 131a, 131b, 141a, 141b, 151a, 151b) of each of the liquid permeable material, the first absorbent material, the second absorbent material and the liquid impermeable material; and- for each layer of material, joining each pair of layer side-panels(121a, 121b, 131a, 131b, 141a, 141b, 151a, 151b) along the curved layer edges (122a, 122b, 132a, 132b, 142a, 142b, 152a, 152b), by a central layer join(123.133.143.153) extending in the longitudinal direction (y) from a top edge(124.134.144.154) to a bottom edge (125,135,145,155) of the absorbent front assembly (100) and being curved in the thickness direction (z), wherein the first and second layer side-panels (131 a, 131b) of the first absorbent layer (130) are joined by a flatlock stitch in class 600 according to the international standard ISO 4915; and- applying a liquid impermeable sealing strip (156) onto the central layer join (153) on a garment-facing side of the liquid impermeable layer; and- assembling the absorbent front assembly (100) by arranging the pairs of layer side-panels (131 a, 131b, 141 a, 141b) formed from the first and second absorbent materials between the pairs of layer side-panels (121a, 121b, 151a, 151b) formed from the liquid permeable and liquid impermeable materials, thereby forming a layered stack of materials; and- joining the layered stack of materials to form a three-dimensionally absorbent front assembly (100) by applying a folded-over sealing strip (108) around the entire perimeter of the layered stack of materials forming the absorbent front assembly (100).

16. The method according to claim 15, wherein the pair of layer side-panels(131 a, 131b) from the first absorbent material is arranged in direct contact with the pair of layer side-panels (121 a, 121 b) from the liquid permeable material.

17. The method according to claim 16, wherein the liquid impermeable material is laminated onto the second absorbent material forming an absorbent-liquid impermeable laminate material before joining each pair of liquid impermeable and second absorbent layer side-panels (151 a, 151b, 141 a, 141 b) along the curved layer side edges (152a, 152b, 142a, 142b) by a central layer join 148.

18. The method according to claim 17, wherein the curved side layer edges (132a, 132b) of the first and second layer side-panels (131 a, 131b) in the first absorbent layer (130) are arranged butt-to-butt before being joined by the flatlock stitch in class 600.

19. The method according to claim 18, wherein the flatlock stitch in class 600 is one of stitches 602, 603, 604, 605, 606, 607, 608 or 609.

20. The method according to claim 19, wherein the pair of layer side-panels(131 a, 131b) of the first absorbent layer (130) are joined by flatlock stitch type 607.21 . A washable absorbent male underwear (1) comprising the absorbent front assembly (100) of claims 1-14, the absorbent male underwear (1) having an extension in a longitudinal direction (y) and in a transversal direction (x) and comprising a front waist portion (11), a rear waist portion (16) and a crotch portion (15) bridging the front and rear waist portions (11 ,16), the absorbent front assembly (100) being arranged on a wearer facing side 3 of the front waist portion (11) and forming an integrated, non-removable part of the absorbent male underwear (1).

22. A method for manufacturing a washable absorbent male underwear (1) comprising the absorbent front assembly (100) according to claims 1-14, the method comprising-providing a liquid permeable material, a liquid impermeable material, a first absorbent material and a second absorbent material; and- forming an absorbent front assembly (100) by providing pairs of two substantially symmetrically curve-shaped layer side-panels(121a121b, 131a, 131 b, 141a, 141b, 151a, 151 b) of each of the liquid permeable material, the first absorbent material, the second absorbent and the liquidimpermeable material; and- for each layer of material, joining each pair of layer side-panels(121 a121 b, 131a, 131b, 141a, 141b, 151a, 151b) along the layer curved edges (122a, 122b, 132a, 132b, 142a, 142b, 152a, 152b) by a central layer join(123.133.143.153) extending in the longitudinal direction (y) from a top edge(124.134.144.154) to a bottom edge (125,135,145,155) of the absorbent front assembly (100) and being curved in the thickness direction (z), wherein the pair of layer side-panels (131 a, 131b) from the first absorbent material is joined by a flatlock stitch in class 600 according to the international standard ISO 4915; and- applying a liquid impermeable and breathable sealing strip (156) onto the central layer join 153) on a garment-facing side of the liquid impermeable layer (150); and- assembling the absorbent front assembly (100) by arranging the pairs of layer side-panels (131a, 131b, 141a, 141b) formed from the first and second absorbent materials between the pairs of layer side-panels (121a, 121b, 151a, 151b) formed from the liquid permeable and liquid impermeable materials, thereby forming a layered stack of materials; and- joining the layered stack of materials to form a three-dimensionally absorbent front assembly (100) by applying a folded-over sealing strip (108) around the entire perimeter of the layered stack of materials forming the absorbent front assembly (100); and- integrating the absorbent front assembly (100) into a male underpant (10) by arranging the liquid impermeable layer (150) of the absorbent front assembly (100) towards a wearer-facing side (2) of a waist front portion of the male underpant (10) and joining the absorbent front assembly (100) to the male underpant (10) by providing a seam (109) along the entire perimeter of the absorbent front assembly (100).

23. The method according to claim 22, wherein the pair of layer side-panels(131 a, 131b) from the first absorbent material is arranged in direct contact with the pair of layer side-panels (121a, 121b) from the liquid permeable material.

24. The method according to claim 23, wherein the liquid impermeable material is laminated onto the second absorbent material forming an absorbent-liquid impermeable laminate (145) before joining each pair of liquid impermeable and second absorbent layer side-panels (141a, 141b, 151a, 151b) along the curved layer side-edges (142a, 142b, 152a, 152b) by a central layer join (148).

25. The method according to claim 24, wherein the curved layer side-edges (132a, 132b) of the first and second layer side-panels (131 a, 131b) in the first absorbent layer (130) are arranged butt-to-butt before being joined by the flatlock stitch in class 600.

26. The method according to claim 25, wherein the flatlock stitch in class 600 is one of stitches 602, 603, 604, 605, 606, 607, 608 or 609.

27. The method according to claim 26, wherein the pair of layer side-panels (131 a, 131b) of the first absorbent layer (130) are joined by flatlock stitch type 607.

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