Reusable hygiene and incontinence items

Abstract

The present invention primarily relates to a reusable sanitary or incontinence article having a multi-layer structure, comprising an inner layer including a gusset area closest to the wearer's skin for taking up and / or transporting bodily fluids from the wearer, an outer layer including a sealed portion for providing a barrier against bodily fluids and side edge portions, an absorbent core between the inner layer and the outer layer, and a liquid-tight joint connecting the inner layer, the outer layer, and optionally the absorbent core to each other along at least a portion of the periphery of the gusset area, wherein the sealed portion is made of a woven fabric coated with an adhesive coating material that forms a continuous impermeable coating that covers at least the gusset area and extends to the side edge portions, and the side edge portions extend from opposite the outside of the gusset area, are folded over the side edges of the inner layer, and are connected to the inner layer, forming a liquid-tight joint between the inner layer and the outer layer along the side edges of the gusset area.

Description

[Technical Field]

[0001] The present invention relates to reusable, washable, and launderable sanitary or incontinence articles, and more particularly to reusable sanitary or incontinence articles having a multi-layer structure including a sealed portion made of an elastomer-coated fabric, reusable sanitary or incontinence undergarments configured to removably receive an absorbent, and corresponding manufacturing methods.

[0002] Background technology 200 million people worldwide suffer from incontinence, the body's inability to control the excretory functions of urination or defecation, and this is likely to rise with the increasing number of elderly people in the region. By 2022, sales of incontinence products are expected to exceed 3 billion euros in Europe alone.

[0003] Beyond incontinence as an actual disease or syndrome, menstruating women regularly need articles capable of absorbing bodily fluids, including blood. Feminine hygiene products are personal care products used for menstruation, vaginal secretions, and other bodily functions related to the vulva and vagina. Products used during menstruation are sometimes called menstrual hygiene products or hygiene articles.

[0004] Most incontinence and hygiene products are disposable; some are reusable. Reusable products must be able to be washed thoroughly and dried in a reasonable amount of time. These criteria are often contradictory, resulting in either products that dry easily but do not absorb large amounts of liquid, or hygiene products that require a long time to dry but have good absorption capacity. This problem can be overcome by drying in a tumble dryer. However, no commercially available hygiene products can be repeatedly washed and dried at 90°C without compromising their integrity and performance. Washability offers the advantage of eliminating antibacterial coatings, as bacteria are killed between 60°C and 90°C. It should be noted that antibacterial coatings worn directly on the skin or on another layer, such as underwear or inserts, are controversial for environmental and health reasons. Furthermore, most reusable products use membranes as a water barrier. Disadvantages of this include poor breathability, short lifespan, poor heat resistance, and perceptible rustling noise.

[0005] The present invention therefore aims to alleviate the above problems, and in particular to provide a reusable hygiene or incontinence article that can be washed and dried repeatedly efficiently, is comfortable, maintains separation (i.e., is largely silent), and maintains fluid retention. A further object is to keep the complexity of the article, and therefore manufacturing costs, to a minimum. These and other objects that will become apparent hereinafter are achieved by the invention as defined in the appended claims.

[0006] Summary of the Invention In a first aspect, the present invention relates to a reusable hygiene or incontinence article having a multilayer structure. The article includes an inner layer including a gusset area closest to the wearer's skin to absorb bodily fluids from the wearer; an outer layer including a sealed portion extending over at least the gusset area and providing a bodily fluid barrier; and an absorbent core between the inner and outer layers, the absorbent core including one or more absorbent layers. A liquid-tight joint connects the inner layer, outer layer, and optionally the absorbent core along the periphery of the gusset area. The sealed portion is made of a fabric coated with an adhesive coating material with sealing properties, such as an adhesive or sealant. Self-adhesive elastomers, particularly silicone, are preferred. The elastomers used are, for example, thermoplastic elastomers that become soft or liquid when heated and harden when cooled. When heated, the elastomer can be applied in dots, lines, or areas and penetrate the fabric of the fabric layer, resulting in a strong and permanent bond to the fabric layer after the elastomer hardens. Other coatings that can be used include rubber, polyvinyl chloride, polyurethane, fluoropolymers, and / or wax. The coating is preferably continuous, at least within the gusset area. However, it can also be applied over the entire surface or consist of several partial surfaces sealed together.

[0007] In one embodiment, the outer layer includes side edge portions extending from the opposite outer side of the gusset area, folded over and connected to the side edges of the inner layer. This means that the opposite side edge portions (left and right portions from the wearer's perspective) of the outer layer are folded over and connected to the side edges of the inner layer. The joint connecting the folded portions to the inner layer is preferably the same joint connecting the outer layer to the inner layer, but may be a different joint.

[0008] In a further embodiment, the side edge portions of the outer layer are hermetically connected to the inner layer. For example, one or more layers of the multi-layer structure may be bonded to one another using an adhesive coating material, preferably an elastomer, particularly silicone. In this embodiment, the side edge portions do not need to extend from the opposite outer side of the gusset area or be folded over the side edges.

[0009] The present invention is based on the innovative discovery that a preferably continuous coating renders textiles impermeable to bodily fluids. A membrane is not required. As mentioned above, articles with membranes produce a rustling noise when a person moves. In contrast, the hygiene or incontinence articles of the invention produce little noise and can be repeatedly washed and dried at temperatures up to 90°C without losing their fluid-retaining properties. The coating can penetrate the textile structure and therefore adheres to it without additional means. Therefore, the coated textile can be handled like a single layer. This is a significant advantage over membrane-based technologies. Handling of the coated textile during the manufacture of the inventive article is simplified. Furthermore, a waterproof textile stretch layer is obtained. Furthermore, the folded and / or sealed side edges help prevent bodily fluids from spreading outside the sealed areas and creating a wet feel on the skin.

[0010] The inner layer absorbs bodily fluids and transports them rapidly to the interior of the multi-layer structure. The inner layer has an outer surface facing away from the absorbent core and an inner surface facing the absorbent core. The surface structure is preferably perforated, but can also be textured or smooth. The inner layer is preferably formed from a woven fabric. As used herein, the term "woven fabric" refers to a woven, knitted, stitch-bonded, or otherwise prepared fabric. Woven fabrics may be made from natural fibers, synthetic, or chemically produced yarns, including blends.

[0011] If the outer layer has an outer surface facing away from the absorbent core and an inner surface facing the absorbent core, only the outer surface of the outer layer, or only the inner surface, or both the inner and outer surfaces may be coated with an adhesive coating material, preferably an elastomer, especially a silicone.

[0012] The main purpose of the coating is to make the outer layer impermeable to body fluids. To this end, the coating is applied (preferably continuously) over at least the entire area above the gusset area. Optionally, the coating extends outside the gusset area. A preferred elastomer is silicone. Silicone is available in medical grade. It has virtually no allergenic activity. Preferably, the coating is adhered to the outer layer by screen printing, although other manufacturing processes such as rolling, spraying, and transfer printing are also envisioned. This results in a very uniform coating.

[0013] The outer layer fabric itself provides a planar support and a uniform appearance for the elastomeric coating. The fabric can be made from natural fibers, synthetic or chemically produced yarns, and can also include mixed forms.

[0014] Typically, the gusset area can be described as substantially rectangular, particularly pyramidal or hourglass-shaped, or any other shape, with a long axis, the longitudinal axis, extending from the front to the back and a short axis, extending from the side (left to right), relative to the wearer's perspective, and can have a one-part or multi-part design. As already mentioned above, the sealing portion may extend outside the gusset area. In particular, the sealing portion may extend outside the gusset area beyond the opposite edges of the gusset area, or the sealing layer may extend outside the gusset area beyond the front and rear edges of the gusset area. Preferably, the sealing portion extends outside the gusset area beyond the side edges of the gusset area.

[0015] In a preferred embodiment of the invention, the outer layer includes flocking embedded in and protruding from the elastomeric coating. Flocking is well known to those skilled in the art. Several advantages are associated with a flocked outer layer, particularly a flocked sealing portion. When the flocking is attached to the inner surface of the sealing portion, it helps absorb body fluids, thus acting as a sole or additional means of absorption. As already mentioned above, some known types of incontinence articles produce rustling noises when a person moves, which arise from the plastic membrane around the absorbent core. Therefore, flocking attached to the inner surface of the outer layer can further help reduce such noises. On the other hand, when the flocking is attached to the outer surface of the outer layer, it not only reduces rustling noises but also helps to hold the outer layer in place, i.e., prevents the hygiene or incontinence article from slipping. This is particularly useful when the article is a liner or pad, or any other article that does not have an attachment means for connecting to the wearer, but is secured to the wearer by a separate undergarment. The length of the flocs may vary as required, but is preferably in the range of 0.2 to 20 mm, preferably 0.4 to 15 mm, more preferably 0.6 to 10 mm (referring to the visible part of the floc). Viscose floc is particularly preferred. Other floc-forming materials include flocs formed from natural and / or chemical raw materials or in mixed forms.

[0016] In a further embodiment of the invention, the absorbent core comprises one or more layers of terry cloth, fleece, moleton, polyester, or any other material formed independently. The absorbent core captures and retains bodily fluids. Depending on the need and absorbent capacity, it can have a single-layer or multi-layer structure. For example, the absorbent core may comprise one, two, three, four, five, or more than five absorbent layers. Instead of or in addition to the number of absorbent layers, the absorbent capacity can be controlled by the thickness of the absorbent core. When there are multiple absorbent layers, the absorbent layers may be the same or different. The absorbent core is preferably formed from one or more layers of woven, knitted, stitch-bonded, fleece-covered, or other fabric. The fabric can be made from natural fibers, synthetic, or chemically produced yarns, including blends.

[0017] The various connections and joints described herein may be independently selected from the group consisting of seam joints, adhesive joints, and welded joints. The advantage of seam joints, such as a (zigzag) lock stitch or a five-thread cover stitch or another sewing stitch type, is that the hygiene or incontinence article can be repeatedly washed up to 90°C. On the other hand, adhesive joints and welded joints can usually only withstand washing temperatures of at least 60°C. Generally, all seams mentioned herein can be made with waterproof or water-repellent sewing threads.

[0018] Optionally, the sewing holes are then sealed by applying an adhesive coating material, preferably an elastomer, especially silicone, and / or a thread that provides a sealing effect through heat or mechanical action. For example, a thread made of a thermoplastic elastomer may be heated so that the softened material fills the gap. Swelling threads can also be used. The sewing holes can also be sealed by applying, for example, spraying, an adhesive coating material as defined herein, such as silicone. In this case, conventional threads can be used. Ultrasound can be used to heat and soften the thread, thereby filling any remaining gaps.

[0019] According to a further embodiment, the inventive article further comprises front and rear covers folded over and sandwiching the front and rear edges of the multi-layer structure.

[0020] For example, the front and rear edges (from the wearer's perspective) of the outer layer and the front and rear edges of the inner layer may be trimmed with folded ribbons or tape, respectively. The joint between the outer layer and the inner layer is preferably the same as the joint encasing the absorbent core, but may also be a separate joint. More preferably, the joint is provided using any type of sewing stitch. To prevent or reduce the risk of bodily fluids leaking through the front and rear covers, the bodily fluids are preferably formed from a waterproof or water-repellent material.

[0021] The front and back covers can essentially cover the entire front and back edges of the multi-layer structure. Also, at each corner of the multi-layer structure, the side edges of the front and back covers can abut the side edges of the side edge portions. To reinforce the corners, the front and back cover portions can be sewn or differently textured to the adjacent side edge portions. Preferably, the sewn portions include bar tacks, for example, using a double backstitch or a zigzag stitch.

[0022] As will be appreciated by those skilled in the art, the use of rear and front covers is particularly useful, but not limited to, panty liners or pads. Thus, in one embodiment, the reusable hygiene or incontinence article is a panty liner or pad.

[0023] Panty liners are absorbent pieces of material used for feminine hygiene. They are worn in the gusset of a woman's panties for the absorption of daily vaginal secretions, light menstrual flow, tampon and menstrual cup back-up, spotting, post-coital discharge, and urinary incontinence. Panty liners are related in basic structure to menstrual pads, but are usually thinner and often narrower than pads. As a result, they absorb less fluid than pads, making them ideal for light discharge and everyday cleanliness. They are generally not suitable for heavy flow during the middle of the menstrual cycle and require more frequent changes.

[0024] Menstrual pads, or simply pads, are absorbent products worn inside a woman's underwear during menstruation, bleeding after childbirth, recovering from gynecological surgery, experiencing a miscarriage or abortion, or other situations in which blood flow from the vagina needs to be absorbed. Menstrual pads are worn externally. Pads are typically changed by removing them from pants and panties, removing the old pad, and sticking a new pad inside the panties and re-wearing them.

[0025] In another embodiment of the invention, the reusable hygiene or incontinence article is a pair of pants (male or female) or a diaper.

[0026] Pants are underwear worn on the lower body by men or women.

[0027] A diaper (also called a nappy) is a type of underwear that allows the wearer to urinate or defecate without using a toilet, absorbing or containing waste products to prevent soiling of outer clothing or the external environment. Diapers are made of cloth or synthetic disposable materials. Cloth diapers are composed of layers of fabric and can be washed and reused multiple times. Diapers are primarily worn by infants, toddlers who are not yet toilet trained, and children who experience bedwetting. They are also used by adults under certain circumstances or for various conditions, such as incontinence.

[0028] In principle, the aforementioned features can be fully integrated into pants or a diaper. In particular, the use of front and rear covers does not preclude the use of the article as pants or a diaper. Rather, the multilayer structure including the front and rear covers (with or without side edge portions) can be attached, for example, by sewing or gluing, to a pants- or diaper-shaped base structure. Specifically, if the base structure has an inner surface facing the wearer's skin and an outer surface facing away from the wearer's skin, the multilayer structure can be attached to the inner surface of the base structure in the crotch region. However, from the standpoints of simple structure, comfortable fit, and efficient use of materials, it is preferable that the outer layer textile include, in addition to the sealing portion, a base portion that, together with the sealing portion, provides the shape and / or structure of pants or a diaper. The base portion does not necessarily have to, and preferably does not, include all layers of the multilayer structure.

[0029] The base portion may be coated with an elastomer. Additionally, the base portion may include flocking protruding from the elastomer coating on its inner surface, i.e., the surface facing and / or resting on the wearer's skin, and / or on its outer surface. When provided on the inner surface of the base portion, the flocking provides comfort when worn. When provided on the outer surface of the base portion, the flocking may help hold the article in place and / or may have an aesthetic function. As previously mentioned, the flocking may be applied to the inner or outer surface, or both the inner and outer surfaces.

[0030] The elastomer used to coat the base portion is preferably the same as the elastomer used to coat the sealing portion, but may be different. This may equally apply to the flock, provided that the sealing portion includes flock. That is, the flock in the sealing portion may be the same (e.g., same length and same material) as the flock in the base portion, or it may be different. However, the sealing portion may be flock-free, the base portion may include flock, or both the sealing portion and the base portion may be flock-free, or both the sealing portion and the base portion may include flock. The following variations are specifically mentioned: (i) The sealing portion comprises a flocked elastomer and the base portion does not comprise elastomer or flock. (ii) The sealing portion and the base portion comprise a flocked elastomer. (iii) The sealing portion comprises a flocked elastomer and the base portion comprises a non-flocked elastomer. (iv) The sealing portion and the base portion comprise a non-flocked elastomer.

[0031] Non-flocked elastomeric coatings can be uncomfortable in direct contact with the skin. To avoid this, the elastomeric coating may be covered by a textile layer. For example, the textile layer may be loosely overlapping or may be adhered to the elastomeric coating. The textile layer may be an additional layer that may be formed of the same material as the inner layer or the same material as the outer layer textile. However, other materials are also contemplated herein.

[0032] The pants and diapers of the invention can include various edge finishes. For example, the base portion can include flocked leg cut edges and / or flocked waist cut edges. As another example, the base portion can include folded leg cut edges and / or folded waist cut edges. For example, the leg cut edges and / or waist cut edges of the base portion can be folded over and connected to portions of the inner layer and / or base portion. Furthermore, the base portion can include trimmed leg cut edges and / or trimmed waist cut edges. To this end, the leg cut edges and / or waist cut edges can be trimmed by folding a ribbon or tape and connecting it to the respective edges. The leg cut edges in or adjacent to the gusset area can be treated in the same manner as other leg cut edge regions. The leg cut edges can also be formed by introducing an adhesive coating material, preferably an elastomer, especially silicone, between different layers of a multi-layer structure to seal the layers together.

[0033] The pants may further include a seam on each side (left and right from the wearer's perspective). As described herein, the seam may be provided by a stitch, such as a four-thread coverstitch or overlock stitch, by adhesive and / or welding, or other seam.

[0034] The article, whether pants, diapers, panty liners or pads, may also optionally include an odor control agent and / or an antimicrobial agent such as colloidal silver or activated carbon in a layer, for example, in one of the layers mentioned herein and / or in a separate layer.

[0035] In another aspect of the invention, a method for manufacturing a reusable sanitary or incontinence article having a multi-layer structure as described herein comprises the following steps.

[0036] providing a first fabric layer defining an inner layer (as described herein) closest to the wearer's skin for capturing bodily fluids from the wearer; providing a second fabric layer defining an outer layer (as described herein); providing one or more absorbent layers (as described herein) defining an absorbent core between inner and outer layers; coating (preferably continuously) at least a portion of the second fabric layer with an elastomer (as described herein), the portion defining a sealing portion (as described herein) that provides a barrier for bodily fluids; overlapping the first fabric layer, the one or more absorbent layers, and the second fabric layer such that the one or more absorbent layers are disposed between the first fabric layer and the second fabric layer and the sealed portion extends over at least the gusset area; connecting the first layer, the second layer, and optionally one or more absorbent layers to one another by a liquid-tight joint (as described herein) along the periphery of the gusset area; cutting the first layer, the second layer, and the one or more absorbent layers to shape (e.g., before or after the overlapping step or before or after the connecting step) so that the second layer includes side edge portions (as described herein) extending from opposite sides of the gusset area; Folding the side edge portions over the side edges of the first fabric layer and connecting them to the first fabric layer.

[0037] Features and embodiments described with respect to a reusable sanitary or incontinence article should be understood to describe corresponding features and embodiments of a method for manufacturing said reusable sanitary or incontinence article. This means, for example, that if the outer layer has an outer surface facing away from the absorbent core and an inner surface facing the absorbent core, the method may further comprise coating the outer surface and / or the inner surface of the outer layer with an elastomer.

[0038] Additionally, the method may further include flocking an outer layer over the area of ​​the elastomeric coating. The absorbent core may be one or more independently formed layers of terry cloth, fleece, moleton, polyester, or any other material. The joints may be provided by stitched, adhesive, and / or welded joints or any other manufacturing process.

[0039] The method can further include folding the front and rear covers to sandwich the front and rear edges of the multi-layer structure. Additionally, portions of the front and rear covers can be attached to adjacent portions of the side edge portions, for example by stitching.

[0040] The hygiene or incontinence articles produced by the method of the invention are preferably selected from the group consisting of panty liners, pads, pants and diapers, and any other hygiene or incontinence article.

[0041] The outer layer may be cut to shape to include a base portion (in addition to the sealing portion), which together with the sealing portion provides the shape of the pants or diaper. The base portion may also be coated with an adhesive coating material, preferably an elastomer, especially silicone, and optionally the base portion may be flocked in the area of ​​the coating. Furthermore, the method according to the invention may include flocking, folding, or trimming the leg cut edges and / or the waist cut edges.

[0042] The concept underlying the present invention is equally applicable to undergarments, particularly pants or diapers, or any other product that can be used with an external, e.g., separately provided, absorbent material, such as a panty liner, pad, or similar hygiene and incontinence article, that is made liquid-tight with an adhesive coating material, preferably an elastomer, particularly silicone, as described herein. Accordingly, another aspect of the present invention relates to a reusable hygiene or incontinence undergarment that includes or consists of a textile layer in the form of an undergarment; a layer of adhesive coating material, preferably an elastomer, particularly silicone, that is applied directly to the textile layer, the coating layer being continuous or designed in multiple sections, at least in the gusset area; and, optionally, a layer of flocking embedded in and protruding from the coating layer. The gusset area is configured to removably receive an absorbent material for absorbing and retaining body fluids. The gusset area does not include any permanent layer other than the textile layer, the coating layer, and the flocking layer. The term "permanent layer" refers to a sheet of material that cannot be removed from the underwear without compromising the integrity of the underwear, particularly without causing damage. Therefore, a removable absorbent material is not considered a permanent layer. Optionally, the undergarment includes leg cut edges and / or waist cut edges that are flocked, folded, or trimmed as described above.

[0043] Furthermore, the textile layers, coatings, and flocking of the inventive undergarments may have the same characteristics as the corresponding components of the inventive sanitary or incontinence articles, and the front, back, and side edges may be covered as described for the inventive sanitary or incontinence articles, and the undergarments may have a seal portion and a base portion with the characteristics described above.

[0044] A method of manufacturing reusable sanitary or incontinence underwear is another aspect of the present invention. The method includes providing a fabric layer, coating at least a portion of the fabric layer with an adhesive coating material, the portion defining a sealing portion in the gusset area and providing a barrier for bodily fluids, cutting the fabric layer to shape, optionally flocking the elastomeric coating to provide a flock layer, and optionally flocking, folding, or trimming the leg cut edges and / or waist cut edges. Furthermore, the gusset area does not include any existing layers other than the fabric layer, woven layer, or any other form of layer, coating, and flock layer. Preferably, the coating is continuous through at least the gusset area.

[0045] As will be readily understood by those skilled in the art, additional features of the inventive undergarments require corresponding additional steps and / or the use of additional and / or specific components. Such additional steps and / or additional and / or specific components are intended to form corresponding embodiments of the inventive manufacturing methods. For example, as described herein in connection with pants and diapers, the undergarments can include various edge finish configurations. For example, the woven fabric can include flocked leg cut edges and / or flocked waist cut edges. As another example, the woven fabric can include folded leg cut edges and / or folded waist cut edges. For example, the leg cut edges and / or waist cut edges of the woven fabric can be folded over and connected to respective portions of the woven fabric forming a double-layered woven fabric structure. Furthermore, the woven fabric can include trimmed leg cut edges and / or trimmed waist cut edges. For this purpose, the leg cut edges and / or waist cut edges can be trimmed by folding and connecting ribbons or tapes to the respective edges. The leg cut edges in or adjacent to the gusset area can be treated equally as other leg cut edge regions. The pants may also include a seam on each side (left and right from the wearer's perspective). As described herein, the seam can be provided by a stitch, such as a four-thread cover stitch or overlock stitch, or any other sewn stitch type, or by adhesive or welding.

[0046] The most preferred embodiments of the invention are detailed below, with reference to the above for advantages, definitions and explanations.

[0047] The reusable sanitary or incontinence article of the invention has a multi-layer structure. The multi-layer structure includes an inner layer, an outer layer, an absorbent core, and a liquid-tight joint. The inner layer includes a gusset area closest to the wearer's skin to absorb and / or transport bodily fluids from the wearer. The outer layer includes a sealing portion for providing a barrier against bodily fluids and side edge portions. The absorbent core is located between the inner and outer layers. The liquid-tight joint connects the inner layer, outer layer, and optionally the absorbent core to each other along at least a portion of the periphery of the gusset area (i.e., at least along the side edges of the gusset area). The sealing portion is made of a woven fabric coated with an adhesive coating material that forms a continuous, impermeable coating that covers at least the gusset area and extends to the side edge portions. The side edge portions extend from the opposite outer side of the gusset area and are folded over and connected to the side edges of the inner layer to form a liquid-tight joint between the inner and outer layers along the side edges of the gusset area. In this and the following embodiments, the side edge portions are part of (integral with) the outer layer, as opposed to separate woven tapes or the like.

[0048] In a preferred embodiment, the outer layer of the multi-layer structure forms the outermost layer of the reusable hygiene or incontinence article, or the layer adjacent to the outermost layer. In particular, in the case of women's pants, the outer layer forms the outermost layer of the reusable hygiene or incontinence article. This allows the thickness of the pants to be kept thin. In the case of men's pants, the outer layer may form the layer adjacent to the outermost layer of the reusable hygiene or incontinence article. A thin thickness is less important for men's pants, but allows for a more robust design. Preferably, the reusable hygiene or incontinence article is women's pants or men's pants.

[0049] Another preferred embodiment is when the outer layer has an outer surface facing away from the absorbent core and an inner surface facing the absorbent core, and the outer and / or inner surface of the outer layer is coated with an adhesive coating material. The advantages achieved by this variant are explained above.

[0050] A preferred reusable hygiene or incontinence article has an outer layer with flock embedded in the coating. The flock may be on the inner surface, the outer surface, or both the inner and outer surfaces of the outer layer. The advantages achieved by this variation are explained above.

[0051] Preferably, the absorbent core includes one or more absorbent layers or pieces. Preferably, the one or more layers or pieces are independently formed from or comprise terry cloth, fleece, moleton, polyester, or superabsorbent polymer. A particularly preferred feature of the invention is a superabsorbent polymer piece that can be inserted into and removed from a pocket formed in the article (as further described herein). That is, the superabsorbent polymer piece is removable. To facilitate insertion into the pocket, the piece may have an elongated shape, such as a cylindrical elongated shape or a rectangular elongated shape. Its dimensions are preferably in the range of 2 to 8 cm, preferably 3 to 7 cm, more preferably 4 to 6 cm, and most preferably about 5 cm in width, and 10 to 35 cm, preferably 12 to 30 cm, more preferably 15 to 25 cm, and most preferably about 20 cm in length. The thickness may vary depending on the desired absorbency and may generally be in the range of 0.5 mm to 10 mm, preferably 0.5 to 5.0 mm, and more preferably 1.0 to 2.0 mm.

[0052] Further preferred embodiments include an open pocket formed in the multi-layer structure for replacing the absorbent core or one or more absorbent layers or pieces thereof. The open pocket may be accessible from the exterior (side facing away from the wearer) or interior (side facing the wearer) of the reusable hygiene or incontinence article. It should be understood that this variation may be implemented not only in pants, but also in other articles, such as pads as shown in Figures 9 and 10.

[0053] A particularly preferred structure of the absorbent core comprises a superabsorbent polymer piece (as defined above) surrounded by at least two textile-based absorbent layers. Preferably, the superabsorbent polymer pieces are replaceable, and the at least two textile-based absorbent layers are fixedly attached to the multilayer structure to form an open pocket. The at least two textile-based absorbent layers are preferably configured to readily absorb and transport body fluids solely, or at least primarily, toward the superabsorbent polymer pieces. This allows the superabsorbent polymer pieces sufficient time to absorb body fluids while providing a dry feeling.

[0054] In preferred reusable hygiene or incontinence articles, the joints are selected from the group consisting of seam joints, adhesive joints, and welded joints, and combinations thereof. More preferably, they are formed by a combination of seam joints and adhesive joints, or a combination of seam joints and welded joints. The advantages of this structure will become apparent from the more specific embodiments below.

[0055] According to certain embodiments, the outer layer has an outer surface facing away from the absorbent core and an inner surface facing the absorbent core. The inner layer has an outer surface facing away from the absorbent core and an inner surface facing the absorbent core. The seam joint includes a hardened melt film on the inner surface of the outer layer and / or a hardened melt film on the inner surface of the inner layer. The hardened melt film at least partially seals the thread-through holes of the seam joint. By sealing from the inside of the multi-layer structure, the hardened melt film does not cause discomfort or interfere with ironing. At the same time, the seam joint helps ensure that the joint can withstand washing and drying at approximately 90°C.

[0056] The melt film preferably comprises or consists of a thermoplastic polymer, especially a thermoplastic polyurethane.

[0057] According to a further preferred embodiment, the outer layer includes a rear cover portion sealingly connecting the multi-layer structure, the continuous impermeable coating extending into the rear cover portion, the rear cover portion being folded over and connected to the rear edge of the inner layer to form a liquid-tight joint between the inner and outer layers along the rear edge of the gusset area. The rear cover portion is understood to be part of the outer layer. The embodiment does not feature a front cover portion, but at this location allows access to an open pocket formed in the multi-layer structure for removably introducing an absorbent core.

[0058] In an alternative embodiment, the outer layer includes rear and front cover portions that hermetically connect the multi-layer structure, and a continuous impermeable coating extends within the rear and front cover portions, which are folded over and connected to the rear and front edges of the inner layer, respectively, to form a liquid-tight joint between the inner and outer layers along the rear and front edges of the gusset area. According to this alternative embodiment, a circumferential joint is formed that surrounds the gusset area, and the absorbent core cannot be replaced.

[0059] In a further embodiment, the closure tape extends widthwise over the side edge portions and the rear cover portion and, if present, the front cover portion.

[0060] The reusable hygiene or incontinence article of the present invention may be selected from the group consisting of panty liners, pads, pants, and diapers as described elsewhere herein. For example, the pad in the form of a multi-layer structure described herein may be used for placement in conventional pants. Alternatively, the pad in the form of a multi-layer structure described herein may be provided or used as a pre-assembled product for attachment to pants, for example, by sewing or gluing. Attachment may be spot or full-surface. Furthermore, the pad may take on a variety of shapes and sizes. For example, the pad may cover the entire width of the back seam.

[0061] The method for manufacturing the above-described reusable sanitary or incontinence article includes the following steps: a first textile layer is provided, defining an inner layer (as described herein) closest to the wearer's skin, including a gusset area for capturing and / or transporting bodily fluids from the wearer; a second textile layer is provided, defining an outer layer (as described herein); one or more absorbent layers and / or pieces are provided, defining an absorbent core (as described herein) between the inner and outer layers; at least a portion of the second textile layer is coated with an adhesive coating material, which defines a sealing portion (as described herein) that provides a barrier against bodily fluids. The first fabric layer, one or more absorbent layers and / or pieces, and the second fabric layer are overlapped such that the one or more absorbent layers and / or pieces are disposed between the first and second fabric layers, and the sealed portion extends over at least the gusset area to the side edge portions (as described herein) of the second layer. The first layer, the second layer, and optionally the one or more absorbent layers and / or pieces are connected to each other along at least a portion of the periphery of the gusset area by a liquid-tight joint (as described herein). Optionally, the first layer, the second layer, and the one or more absorbent layers and / or pieces are cut to shape. The side edge portions of the second layer are hermetically connected to the multilayer structure. Furthermore, the side edge portions extend from the opposite outer side of the gusset area, fold over the side edges of the first fabric layer, and are connected to the inner layer along the side edges of the gusset area, forming a liquid-tight joint between the inner and outer layers.

[0062] Another reusable sanitary or incontinence undergarment of the present invention comprises or consists of: a first textile layer in the shape of an undergarment and forming the outermost layer of the undergarment; a second textile layer adjacent to the first textile layer is optional (depending primarily on whether the undergarment is for women or men); a third layer forms the innermost layer, including the gusset area closest to the wearer's skin; a layer of adhesive coating material applied directly to the first textile layer and / or the second textile layer, if present, forms a continuous impermeable coating extending over at least the gusset area; a layer of flock is embedded in and protrudes from the coating layer; and the gusset area is configured to removably receive an absorbent core for absorbing and retaining bodily fluids.

[0063] Reusable sanitary or incontinence undergarments as described above may be manufactured by a method comprising the steps of providing a first textile layer, optionally providing a second textile layer, providing a third textile layer, coating at least a portion of the first textile layer and / or, if present, at least a portion of the second textile layer with an adhesive coating material, which portion defines a sealing portion extending over at least the gusset area to provide a barrier to body fluids, optionally cutting the first and third textile layers, and, if present, the second textile layer, to shape, flocking the coating to provide a flock layer, and connecting the first textile layer with the third textile layer along a portion of the periphery of the gusset area, thereby forming an open pocket for receiving and / or replacing an absorbent core or one or more absorbent layers or pieces thereof.

[0064] Finally, it should be noted that each feature described with respect to a particular aspect or embodiment means that it can be combined with other aspects or embodiments, unless the combination is technically meaningless or impossible.

[0065] The inventive concept, non-limiting embodiments, and further advantages of the inventive concept will now be described with reference to the drawings. [Brief explanation of the drawings]

[0066] [Figure 1] 1 illustrates an exemplary multi-layer structure for a hygiene or incontinence article. [Figure 2a] 1 illustrates an exemplary method for manufacturing a multi-layer structure. [Figure 2b] 1 illustrates an exemplary method for manufacturing a multi-layer structure. [Figure 2c] 1 illustrates an exemplary method for manufacturing a multi-layer structure. [Figure 2d] 1 illustrates an exemplary method for manufacturing a multi-layer structure. [Figure 2e] 1 illustrates an exemplary method for manufacturing a multi-layer structure. [Figure 3] 10 shows the finished configuration of the open cut portion of a pant configured for use with replaceable absorbent. [Figure 4] 10 shows the finished configuration of the open cut portion of a pant configured for use with replaceable absorbent. [Figure 5] 1 illustrates an exemplary exchangeable absorbent. [Figure 6] 1 shows a pant that provides access to a removable absorbent core. [Figure 7] 1 shows a pant that provides access to a removable absorbent core. [Figure 8] 1 shows a pad that provides access to a removable absorbent core. [Figure 9] 1 shows a pad that provides access to a removable absorbent core. [Figure 10] An example of a pair of men's pants having a coated, flocked layer adjacent to the outermost layer and a permanent and / or replaceable absorbent. [Figure 11] An example of a pair of men's pants having a coated, flocked layer adjacent to the outermost layer and a permanent and / or replaceable absorbent. [Figure 12] An example of a pair of men's pants having a coated, flocked layer adjacent to the outermost layer and a permanent and / or replaceable absorbent. [Figure 13] 1 shows another example of an article of the invention in the form of a pad. [Figure 14] 1 illustrates an exemplary method of manufacturing and / or assembling men's pants according to one embodiment of the invention. [Figure 15] 1 shows variations in the opening positions of open pockets on exemplary men's pants. [Figure 16] 1A-1D illustrate the manufacture and / or assembly of women's pants according to one embodiment of the invention. [Figure 17] Detail shows that the side edges of the pant base extend outside the gusset area and fold over the side edges of the inner layer. [Figure 18] 17 is a cross-sectional view of the crotch area of ​​a pair of women's pants made by the process shown in FIG. 16. [Figure 19] FIG. 19 is a cross-sectional view of the crotch area of ​​the women's pant of FIG. 18, showing the seal from the inside. [Figure 20] Shown are the open (slide-in) positions for introducing and removing the removable absorbent core.

[0067] MODE FOR CARRYING OUT THE INVENTION The description of the invention provided herein is given purely by way of example and should not be construed as limiting the scope or scope of the invention in any way. The invention will be described with reference to an exemplary range of undergarments, such as underwear, pants, shorts, briefs or panties, or slips.

[0068] In the following description, the concepts of the present invention are described with reference to reusable, washable and dryable hygiene and incontinence articles.

[0069] FIG. 1 shows an exemplary multi-layer structure 100, 101 for a hygiene or incontinence article. The structure 100 is conformable to the human body and comprises an outer layer 10, an adhesive coating layer 20, an absorbent core 30, and an inner layer 40. When worn, the inner layer 40 is adjacent to the skin in the crotch area. The absorbent core 30 is disposed between the inner layer 40 and the coating layer 20. The coating layer 20 is between the outer layer 10 and the absorbent core 30; for example, the coating layer 20 is adhered to the inner surface of the outer layer 10 over its entire surface. However, the coating layer 20 may also be adhered to the outer surface of the outer layer 10 over its entire surface.

[0070] The structure 101 is compatible with the human body and is composed, in that order, of an outer layer 10, a coating layer 20, a flock layer 50, an absorbent core 30, and an inner layer 40. The coating layer 20 is adhered to the inner surface of the outer layer 10 over its entire surface. Similarly, the flock layer 50 is adhered to the inner surface of the coating layer 20 over its entire surface. However, the coating layer 20 can also be adhered to the outer surface of the outer layer 10 over its entire surface, while the flock layer 50 can be adhered to the outer surface of the coating layer 20 over its entire surface.

[0071] While the structures 100, 101 are shown and described as consisting of the layers listed, they may primarily include additional layers. Furthermore, the structures 100, 101 are in the form of hygiene or incontinence pads. However, they may also be part of another hygiene or incontinence article, such as underwear. Furthermore, the absorbent core 30, while shown as one layer, may be comprised of two or more layers, such as two, three, four, five, or more layers.

[0072] 2a-2e illustrate an exemplary method for manufacturing a multi-layer structure 200, which may be identical to one of the multi-layer structures 100, 101. As seen in FIG. 2a, the absorbent core 30 and inner layer 40 are provided in the shape of the pad to be manufactured in this example, either finely cut, roughly cut, or otherwise, while the material 11 from which one or more outer layers 10 can be cut is provided roughly cut. The material 11 is coated with an adhesive coating material that forms a coating layer 20 on the outer layer 10. Optionally, the coating may be flocked. After drying, for example in a drying oven or hot press, the material 11 is cut to shape, leaving side edge portions 12a, 12b that extend over the respective side edges of the absorbent core 30 and inner layer 40. FIG. 2b shows the layers stacked on top of each other in the desired order. The side edge portions 12a, 12b are then folded over the respective side edges of the absorbent core 30 and the inner layer 40 and attached to the inner layer 40 (see FIG. 2c). Attachment can be achieved by sewing, welding, or any other form of attachment between the folded side edge portions 12a, 12b and the inner layer 40 with a heat-press adhesive, an adhesive coating material, preferably an elastomer, particularly silicone, and / or by stitching the folded side edge portions 12a, 12b onto the inner layer 40. If desired, the front and rear edges of the multi-layer structure can be trimmed with the respective front and rear covers 60a, 60b (see FIG. 2d). Furthermore, corner seams 62 may extend over corners of the multi-layer structure so that portions of the rear covers 60a, 60b are attached to adjacent portions of the side edge portions 12a, 12b (see FIG. 2e).

[0073] 3-4 show open cut sections of pants configured for use with replaceable absorbents. FIG. 3 shows examples of different flocking patterns. Generally, the pants are constructed with a pant-shaped conformable outer layer 310, at least in the crotch / gusset area, and an elastomeric layer 320 inside the outer layer. In these examples, the elastomeric layer 320 extends over the entire inner surface of the outer layer. In pants 300, the elastomeric layer 320 has no flocking. Pants 301 are flocked with a flocking layer 350 only in the gusset area. In pants 302, the flocking layer 350 extends over the entire surface of the elastomeric layer. Further variations are shown in pants 303, 304, 305, 306, and 307. Notably, in pants 300, the coated outer layer lacks flocking over the entire inner surface of the outer layer. In pants 301, the coated outer layer includes flocking only in the gusset and leg opening / waistband areas. In pants 302, the coated outer layer has flocking only in the gusset area. In pants 303, the coated outer layer includes flocking only in the leg opening / waistband areas. In pants 304, the coated outer layer includes flocking over the entire inner surface of the outer layer. In pants 305, the coated outer layer includes a coating and flocking only in the gusset and leg opening / waistband areas. In pants 306, the coated outer layer includes a coating and flocking only in the gusset area. In pants 307, the coated outer layer includes a coating and flocking only in the leg opening / waistband areas.

[0074] FIG. 4 shows different possibilities for finishing the leg and waist cuts. The finishing configurations can be combined with any of the multi-layer structures and flocking patterns described herein. Pants 400 show flocked leg cut edges 450a and flocked waist cut edges 450b. Pants 401 have folded leg cut edges 412a and folded waist cut edges 412b. The folded cut edges 412a, 412b can be attached to the outer layer, flock layer, and / or coating layer by adhesive, stitching, ultrasonic, or any other bonding method. Leg cutouts in the gusset area can be similarly finished.

[0075] An exemplary replaceable absorbent is shown in FIG. 5. The pants and / or the absorbent may include means for reversibly connecting them to one another. For example, the pants may include a pocket into which the absorbent may be inserted (see FIG. 5d). To facilitate grasping and removing the absorbent from the pocket, as shown in FIG. 5a, the absorbent 800 is provided with a strap or tab 880. As shown in FIG. 5b, the absorbent 801 may also include side wings 890 that may be connected to the pants by other connecting means, such as buttons 892 or Velcro fasteners.

[0076] The absorbent may have a multi-layer structure similar to that of the articles described herein. However, if the pants are sealed with an elastomer layer directly bonded to the pants / outer layer, the replaceable absorbent may largely omit the elastomer layer. However, when applied to the outermost surface, as shown in Figure 5c, an elastomer coating and / or flocking layer can not only prevent drying, but also prevent the replaceable absorbent from slipping within the pants, especially when the absorbent is placed loosely within the pants, as shown in Figure 5e.

[0077] FIG. 6 shows the pants from the outside (FIG. 6a) and inside (FIG. 6b) and in cross section (FIG. 6c). In this example, the inside provides access to an open pocket (indicated by the arrow) for receiving an absorbent core or a layer or piece thereof. For example, a layer of microfiber material or a piece of superabsorbent material can function as a replaceable absorbent. Exemplary pant layers in cross section are shown in FIG. 6c. Specifically, the outer layer (L1) comprises a stretch knitwear (polyester / elastane) with an impermeable, flocked coating. The absorbent core (L2) is replaceable in this example but may be permanent in other examples. The inner layer (L3) represents the gusset material. FIG. 6c further illustrates the folding of the outer layer over the side portions of the gusset material with the lower L1 layer.

[0078] Figure 7 shows another pair of pants that provides access to the open pocket from the outside of the pants, as indicated by the arrow in Figure 7a, but is otherwise identical to the multi-layer construction shown in Figure 6c.

[0079] Figures 8 and 9 show a pad that provides access to an open pocket, as indicated by the arrows in Figures 8b and 9b. The open pocket may be configured to receive absorbent material. The layers of an exemplary pad in cross section are shown in Figure 9c. The structure is similar to that shown in Figure 6c, except that the flock forms the outermost layer and the stretch knitwear (polyester / elastane) is closer to the user than the flock (L1). The absorbent core (L2) is replaceable in this example but may be permanent in other examples. Furthermore, replaceable absorbent material can be combined with non-replaceable absorbent material. The inner layer (L3) represents the gusset material. Figure 9c further shows that the outer layer (L1) is folded over the sides of the gusset material (L3).

[0080] Figures 10, 11, and 12 are examples of men's pants with a stretch knitwear (cotton / elastane) as the outermost layer, a coating and flock layer of stretch knitwear (polyester / elastane) adjacent to the outermost layer, and a permanent or replaceable absorbent and mesh (Figure 12) or gusset material (Figures 10, 11) as the innermost layer. In the examples of Figures 10 and 12, the open pocket is accessible from the inside of the pants (Figures 10b, 12b). In the example of Figure 11, the open pocket is accessible from the outside of the pants (Figure 11b). Corresponding multilayer structures are shown in Figures 10c, 11c, and 12c.

[0081] FIG. 13 shows another example of a pad similar to those shown in FIGS.

[0082] FIG. 14 illustrates an exemplary method of manufacturing and / or assembling men's pants according to one embodiment of the invention. An absorbent core material (one or more layers) forming the absorbent core 1030 and a gusset material forming the inner layer 1040 are provided. The layers are stacked and connected to each other along their side edges using seams / stitches 1080 (Steps A and B). The structure is then attached, e.g., sewn, to the inside of the outer layer 1010a in the crotch area along the side and bottom edges (alongside a sealing / adhesive tape 1081). An open pocket 1090 is formed between the outer layer 1010a and the inner layer 1040 for introducing a replaceable absorbent core. The seam may be covered by the sealing tape 1081 (Step C). The back side of the outer layer 1010b is made impermeable by an elastomeric layer, which may or may not be flocked. In this example, the elastomeric layer is flocked on the left fabric side. This layer structure is then attached (step D) to the crotch area of ​​men's pants 1000. In the final pants 1000, reference numeral 1010a denotes a leak protection area, i.e., an impermeable area, thus preventing bodily fluids from dripping through the pants 1000.

[0083] Figure 15 shows variations in the opening positions of the open pockets 1090, 1090a. In Figure 15a, which shows the inside (left fabric side) on the left and the outside (right fabric side) on the right, the opening of the open pocket 1090 is formed on the inside (left fabric side) of the pants, similar to Figure 14. In Figure 15b, the opening of the open pocket 1090a is formed on the outside (right fabric side) of the pants.

[0084] 16 illustrates the manufacture and / or assembly of women's pants. An absorbent core material (one or more layers) forming an absorbent core 1130 and a gusset material forming an inner layer 1140 are provided. The layers are stacked and connected to each other along their side edges using seams / stitches 1180 (steps A and B). On both sides of the structure, a sealing tape 1190 is attached to the side edge regions (step C). Optionally, the flocked side may be covered with a mesh layer.

[0085] A women's pant base 1200 is provided. The base 1200 has the shape of a women's pant and is composed of an outer layer 1110 that includes a coated and optionally flocked portion. Region 1111 indicates a sealed portion that is coated with an elastomer to make the portion impermeable. Side edges 1115 of the sealed portion 1111 that extend outside the gusset area are free of flocking, while the remainder of the sealed portion 1111 is flocked. Region 1112 indicates the coated and flocked leg cutouts and waist edges.

[0086] The top edge of the laminated structure 1220 of the inner layer 1140 and the absorbent core 1130 is folded and sewn along the stitch line 1222. Next, the structure 1220 is attached to the crotch area of ​​the base 1200 (Step D).

[0087] Next, the structure 1220 is attached, e.g., sewn, to the inside of the base 1200 in the crotch region along stitch lines near the side edges of the structure 1220. The side edges 1115 of the base 1200 extending outside the gusset area are folded over and sewn to the side edges of the structure 1220 (step E). Next, the stitches 1202 in the side edge regions are sealed from the inside by heat-melting the closure tape added in step C (steps F and G). Finally, closure tape is attached to the top and bottom edges 1204 of the gusset region.

[0088] FIG. 17 shows in more detail step E, i.e., folding the side edges 1115 of the pant base over the side edges of the inner layer (IL) and extending outside the gusset area. The layers are indicated with different patterns: IL = inner layer (gusset), BF = body fabric, FL = flock layer / coating, EL = elastomeric layer / coating without flock. In the example of FIG. 17a, it can be seen that the side edges 1115 folded over the inner layer (IL) are elastomeric coated and devoid of flock. FIG. 17b shows that the width of the flock-free area is variable. As shown on the left side of FIG. 17b, the flock-free area is quite wide, while on the right side of FIG. 17b, the side edges are fully flocked, i.e., there is no flock-free area in the side edge region.

[0089] Figure 18 is a cross-sectional view of the crotch area of ​​a pair of women's pants made by the process shown in Figure 16. Shown are the absorbent core 1130, inner layer 1140, seams / stitch lines 1180, closure tape 1190, coated and flocked outer layer 1110, seams / stitch lines 1222, and optional mesh layer 1170 (not shown in Figure 16).

[0090] FIG. 19 is a cross-sectional view of the crotch area of ​​the women's panties of FIG. 18, showing how a closure tape 1190 included in the layer structure is sealed from the inside by applying heat and pressure in the direction of the arrows to heat melt the closure tape.

[0091] Figure 20 shows the opening (slide-in) positions for introducing and removing the removable absorbent core. The arrows indicate the opening location and the direction of absorbent core introduction. The positions shown are front inside (top left), front outside (top right), back inside (bottom left), and back outside (bottom right).

Claims

1. An inner layer including a gusset area closest to the wearer's skin, for taking in bodily fluids from the wearer and / or transporting said bodily fluids from the wearer, An outer layer including a sealing portion and a side edge portion for providing a barrier to the bodily fluids, The absorbent core between the inner layer and the outer layer, Along at least a portion of the periphery of the gusset area, there are liquid-sealing joints connecting the inner layer, the outer layer, and optionally the absorbent core to each other, The sealing portion consists of a fabric coated with an adhesive coating material that forms a continuous impermeable coating that covers at least the gusset area and extends to the side edge portion. The side edge portion extends from the opposite side of the outside of the gusset area, folds over and covers the side edge of the inner layer, connects to the inner layer, and forms a liquid-seal joint between the inner layer and the outer layer along the side edge of the gusset area. A reusable sanitary or incontinence article with a multi-layered structure.

2. The reusable sanitary or incontinence article according to claim 1, wherein the outer layer of the multilayer structure forms the outermost layer of the reusable sanitary or incontinence article, or a layer adjacent to the outermost layer.

3. The reusable sanitary or incontinence article according to claim 1 or 2, wherein the outer layer has an outer surface facing away from the absorbent core and an inner surface facing the absorbent core, and the outer surface and / or the inner surface of the outer layer are coated with the adhesive coating material.

4. The reusable sanitary or incontinence article according to claim 1 or 2, wherein the outer layer includes flocs embedded in the coating, the flocs being on the inner surface of the outer layer, or on the outer surface, or on both the inner and outer surfaces.

5. The reusable sanitary or incontinence article according to claim 1 or 2, wherein the absorbent core comprises one or more absorbent layers or pieces, preferably, the one or more layers or pieces are independently formed from or comprise a terry cloth, fleece, molton, polyester, or superabsorbent polymer.

6. The reusable sanitary or incontinence article according to claim 5, wherein the multilayer structure forms an opening pocket for replacing the absorbent core or one or more absorbent layers or pieces thereof.

7. The absorbent core comprises a superabsorbent polymer piece encased in at least two fabric-based absorbent layers, Preferably, the superabsorbent polymer piece is replaceable, and the at least two fabric-based absorbent layers are fixedly attached to the multilayer structure to form an open pocket, the reusable sanitary or incontinence article according to claim 1 or 2.

8. The reusable sanitary or incontinence article according to claim 1 or 2, wherein the joint is selected from the group consisting of a seam joint, an adhesive joint, and a welded joint, and the joint is preferably formed by a combination of a seam joint and an adhesive joint, or a combination of a seam joint and a welded joint.

9. The reusable sanitary or incontinence article according to claim 7, wherein the outer layer has an outer surface facing away from the absorbent core and an inner surface facing the absorbent core, the inner layer has an outer surface facing away from the absorbent core and an inner surface facing the absorbent core, the joint includes a cured molten film on the inner surface of the outer layer and / or a cured molten film on the inner surface of the inner layer, the cured molten film at least partially seals the thread through-holes of the seam joint, and the molten film preferably comprises or consists of a thermoplastic polymer, particularly a thermoplastic polyurethane.

10. The outer layer includes a rear cover portion that seals and connects the multilayer structure, the continuous impermeable coating extends within the rear cover portion, the rear cover portion folds over the trailing edge of the inner layer and connects to the inner layer, forming a liquid-seal joint between the inner layer and the outer layer along the trailing edge of the gusset area, or The outer layer includes rear and front cover portions that seal and connect the multilayer structure, the continuous impermeable coating extends within the rear and front cover portions, the rear and front cover portions fold over and connect to the respective rear and front edges of the inner layer, and form a liquid-seal joint between the inner layer and the outer layer along the rear and front edges of the gusset area. A reusable sanitary or incontinence article according to claim 1 or 2.

11. The reusable sanitary or incontinence article according to claim 9, wherein the sealing tape extends in the width direction, covering the side edge portion and the rear cover portion, and optionally the front cover portion.

12. The reusable sanitary or incontinence article according to claim 1 or 2, wherein the sanitary or incontinence article is selected from the group consisting of panty liners, pads, pants, and diapers.

13. To provide a first fabric layer defining the inner layer closest to the wearer's skin, including a gusset area for taking in bodily fluids from the wearer and / or transporting said bodily fluids from the wearer, To provide a second fabric layer that defines the outer layer, To provide one or more absorbent layers and / or pieces that define an absorbent core between the inner layer and the outer layer, Coating at least a portion of the second fabric layer with an adhesive coating material, wherein the portion defines a sealing portion that provides a barrier for the bodily fluids, The first fabric layer, the one or more absorbent layers and / or pieces, and the second fabric layer are overlapped such that the one or more absorbent layers and / or pieces are positioned between the first and second fabric layers, wherein the sealing portion covers at least the gusset area and extends to the side edge portion of the second layer. The first layer, the second layer, and optionally the one or more absorbent layers and / or pieces are connected to each other by liquid-seal joints along at least a portion of the perimeter of the gusset area, Depending on the circumstances, the first layer, the second layer and one or more absorbent layers and / or pieces may be cut into shape. The side edge portion of the second layer is sealed and connected to the multilayer structure, The aforementioned side edge portion extends from the opposite side of the outside of the gusset area, folds over and covers the side edge of the first fabric layer, connects to the inner layer, and forms a liquid-seal joint between the inner layer and the outer layer along the side edge of the gusset area, thus providing a sealed connection. A method for producing a reusable sanitary or incontinence article according to claim 1 or 2, comprising:

14. Reusable sanitary or incontinence underwear, The first fabric layer in the shape of the underwear forms the outermost layer of the underwear, Depending on the circumstances, a second fabric layer adjacent to the first fabric layer, A third layer forms the innermost layer, including the gusset area closest to the wearer's skin, A layer of adhesive coating material applied directly to the first fabric layer and / or, if present, the second fabric layer, wherein the coating layer forms a continuous, impermeable coating that extends to cover at least the gusset area, A layer of flocs embedded in the coating layer and protruding from the coating layer, including or consisting of The gusset area is configured to removably receive an absorbent material for absorbing and retaining bodily fluids. Reusable sanitary or incontinence underwear.

15. To provide a first woven fabric layer, In some cases, a second fabric layer may be provided. To provide a third woven layer, Coating at least a portion of the first fabric layer and / or, if present, at least a portion of the second fabric layer with an adhesive coating material, wherein the portion defines a sealing portion that covers and extends at least the gusset area to provide a barrier to the bodily fluids. Depending on the circumstances, the first and third fabric layers, and the second fabric layer, if present, may be cut into shape. The aforementioned coating is flocculated to provide a floc layer, Connecting the first fabric layer to the third fabric layer along a portion of the perimeter of the gusset area, thereby forming an open pocket for receiving and / or replacing an absorbent core, or one or more absorbent layers or pieces thereof; A method for manufacturing reusable sanitary or incontinence underwear according to claim 14.

Images