Patent Description:
The following discussion of the background to the invention is intended to facilitate understanding of the present invention. However, it should be appreciated that the discussion is not an acknowledgment or admission that any of the material referred to was published, known or a part of the common general knowledge in any jurisdiction as at the priority date of the application. Disposable absorbent materials that are able to absorb liquids such as bodily fluids are useful in/for various applications. As an example application, adult diapers designed for a person with a body larger than that of an infant or toddler may be used by adults with various conditions, such as incontinence, mobility impairment, severe diarrhea or dementia. Consequently, adult diapers prevent structures such as beds and sofas from being stained. Adult diapers may be made in various forms, including those resembling traditional child diapers, underpants, and pads resembling sanitary napkins. However, usage of adult diapers can lead to negative emotions such as embarrassment and depression because of the stigma associated with adult diapers.

Current disposable absorbent materials may be made from fibrous substances that make these absorbent materials fluffy and bulky. As such, it may be difficult to transport, store and/or dispose of such absorbent materials. Consequently, there may be increased costs associated with manufacturing, transporting, storing and disposing of such absorbent materials.

Furthermore, existing disposable absorbent materials may be thick and non-breathable. Consequently, users may have an increased likelihood to suffer from bedsores.

<CIT> discloses disposable sheet with an absorbent pad comprising multiple layers.

<CIT> discloses an absorbent article comprising an absorbent member intervening between a liquid-permeable surface sheet and a backside sheet.

In light of the above, there exists a need to develop an absorbent material that ameliorates or overcomes the above disadvantages.

In an aspect of the present disclosure, there is provided an absorbent material including: a first layer comprising a hydrophilic non-woven fabric; and a second layer comprising a hydrophobic film, the second layer arranged adjacent to the first layer; wherein the first layer is adapted to allow a first fluid and a second fluid to pass through; and wherein the second layer is adapted to allow the first fluid to pass through and is adapted to minimize or block the second fluid from passing through.

In various aspects, the hydrophilic non-woven fabric comprises a polymer.

In various aspects, the polymer is polypropylene or polyethylene.

In various aspects, the hydrophobic film comprises polyethylene.

In various aspects, the hydrophilic non-woven fabric consists of polypropylene and the hydrophobic film consists of polyethylene.

In various aspects, the thickness of the absorbent material is <NUM> millimetres (mm) to <NUM>.

The second layer is laminated adjacent to the first layer.

The first layer is made using a thermal bonding process.

In various aspects, the short fibers have an average length of <NUM> to <NUM>. The first fluid is air and the second fluid is a liquid.

The absorbent material consists of the first layer and the second layer.

In various aspects, the first layer is made of hydrophilic non-woven fabric consisting of polypropylene and the second layer is made of hydrophobic film consisting of polyethylene.

In various aspects, the absorbent material further comprises a super absorbent polymer.

In various aspects, the super absorbent polymer is integrated with the first layer or integrated with the second layer.

In various aspects, the first layer or the second layer is added with biodegradable additives.

In another aspect of the present disclosure, there is provided a bed sheet made of an absorbent material as described above.

In various aspects, the absorbent material of the bed sheet is disposable.

In another aspect of the present disclosure, there is provided a method of manufacturing an absorbent material, the method comprising: the step of thermal bonding to form a first layer comprising a hydrophilic non-woven fabric; the step of laminating a second layer comprising a hydrophobic film adjacent to the first layer; wherein the first layer is adapted to allow a first fluid and a second fluid to pass through; and wherein the second layer is adapted to allow the first fluid to pass through and is adapted to minimize or block the second fluid from passing through.

In various aspects, the step of laminating the second layer adjacent to the first layer comprises heat, mechanical or chemical means.

In various aspects, the step of thermal bonding comprises the step of carding.

In various aspects, the absorbent material consists of the first layer and the second layer.

In various aspects, the step of thermal bonding to form the first layer occurs at a temperature of <NUM> to <NUM>.

In various aspects, the method further comprises the step of manufacturing fibers for the hydrophilic non-woven fabric.

In various aspects, the step of manufacturing fibers for the hydrophilic non-woven fabric comprises the step of crimping.

In various aspects, the step of crimping occurs at a pressure of <NUM> bar to <NUM> bar.

In various aspects, the step of crimping occurs at a temperature of <NUM> to <NUM>.

Other aspects of the disclosure will become apparent to those of ordinary skill in the art upon review of the following description of specific aspects of the disclosure in conjunction with the accompanying drawings.

The disclosure will now be described, by way of example only, with reference to the accompanying drawings, in which:.

Other arrangements of the disclosure are possible and, consequently, the accompanying drawings are not to be understood as superseding the generality of the preceding description of the disclosure.

Particular aspects of the present disclosure will now be described with reference to the accompanying drawings. The terminology used herein is for the purpose of describing particular aspects only and is not intended to limit the scope of the present disclosure. Other definitions for selected terms used herein may be found within the detailed description of the disclosure and apply throughout the description. Additionally, unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one or ordinary skill in the art to which the present disclosure belongs. Where possible, the same reference numerals are used throughout the figures for clarity and consistency.

Throughout the specification, unless the context requires otherwise, the word "comprise" or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers.

Throughout the specification, unless the context requires otherwise, the word "include" or variations such as "includes" or "including", will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers.

Throughout the specification, unless the context requires otherwise, the term "fluid" includes but is not limited to a liquid such as water and bodily fluid(s). The bodily fluid(s) may include blood, urine, and a combination thereof. The fluid may include one or more gas(es) and can include air which is a mixture of gases.

Throughout the specification, unless the context requires otherwise, the term "breathable" refers to the ability of the absorbent material or a layer thereof to allow air and/or water vapour to pass through.

Throughout the specification, unless the context requires otherwise, the term "flexible" refers to the ability to be folded for storage and/or transportation purposes, but rigid enough to resist tear when the absorbent material is in use.

Throughout the specification, unless the context requires otherwise, the term "durable" refers to the ability of the absorbent material to retain its original shape and size under application of an external force, and to resist wear and tear. In the context of the disclosure, the term "durable" refers to the ability of the absorbent material to resist being torn apart when subjected to a position or weight, such as a position of the adult when lying down on a bed or the weight of an adult.

In accordance with an aspect of the disclosure or disclosure there is an absorbent material including a first layer made of a hydrophilic non-woven fabric; and a second layer made of a hydrophobic film, the second layer arranged adjacent to the first layer; wherein the first layer is adapted to allow a first fluid and a second fluid to pass through; and wherein the second layer is adapted to allow the first fluid to pass through and is adapted to minimize or block the second fluid from passing through.

With the arrangement and selection of the material used for the first layer, the first layer is permeable to the first fluid. The first fluid may be air which is able to pass through the first layer, contact the second layer and pass through the second layer. As such, the first layer and the second layer of the absorbent material are permeable to the first fluid. In addition, the first layer is permeable to the second fluid. The second fluid may be a liquid such as water, urine, blood or a combination thereof is able to pass through the first layer, contact the second layer and then be minimized or blocked from passing through the second layer. As such, the second layer differs from the first layer in that the second layer is adapted to allow the first fluid to pass through and is adapted to minimize or block the second fluid from passing through. In various aspects, the second fluid passes through the first layer via capillary action which will be described in further detail.

The absorbent material consists only of two layers, i.e. the first layer and the second layer. As such, there is no need for any additional layer(s) disposed between the first layer and the second layer or adjacent to the first layer or adjacent to the second layer. Advantageously, the absorbent material may be relatively thin, light weight and relatively easy to transport, store and/or dispose of. Consequently, the absorbent material is relatively cheap, easy to manufacture and desirable for use as a disposable absorbent material.

Notwithstanding the above, various aspects may also contribute to making the absorbent material relatively cheap, easy to manufacture and desirable for use as a disposable material. As such, it would be appreciated by a person skilled in the art that an important consideration by the inventors of the present disclosure is affordability of the absorbent material for the intended application(s).

In contrast, prior art absorbent materials typically consists of more than two layers and is therefore relatively more expensive to manufacture.

In various aspects, the absorbent material further comprises at least one additive such as a super absorbent polymer or biodegradable additive. In some aspects, the additive can be integrated with the first layer. In some aspects, the additive can be integrated with the second layer. In some aspects, the super absorbent polymer may be applied to the first layer and/or the second layer by spraying. As such, the super absorbent polymer may be in the form of small beads. In an aspect, the absorbent material does not comprise of or contain any additive. Consequently, the absorbent material is relatively cheap, easy to manufacture and desirable for use as a disposable material.

With reference to <FIG> and <FIG>, the absorbent material <NUM> comprises a first layer <NUM> made of/ formed of a hydrophilic non-woven fabric; a second layer <NUM> adjacent to the first layer <NUM>; wherein the second layer <NUM> is made of/ formed of a hydrophobic film. As may be appreciated, the non-woven fabric is hydrophilic and may therefore allow a fluid such as urine, blood, water vapour, and/or water to pass through.

In some aspects, the absorbent material <NUM> is breathable. This is at least because the first layer <NUM> and the second layer <NUM> are both breathable. At least a part of the first layer <NUM> and at least a part of the second layer <NUM> are breathable, although it is more advantageous that the entire first layer <NUM> and the entire part of the second layer <NUM> are both breathable. The first layer <NUM> comprises the hydrophilic non-woven fabric which appreciably is breathable.

It is appreciable that as the non-woven fabric first layer <NUM> is hydrophilic, it is capable of wicking away a fluid from the user when the first layer <NUM> is in contact with the user. In other words, there is a wicking effect. In particular, the wicking effect is caused by movement of the fluid away from the user via capillary action. As such, the first layer <NUM> may minimize or eliminate wetness of the user because there is no or minimal build-up of the fluid. Presence of the fluid may facilitate the growth of bacteria and/or mould. Consequently, use of the absorbent material <NUM> may be relatively more comfortable and hygienic compared to currently known absorbent materials, as will be explained below.

In contrast, prior art absorbent materials may have a first layer that is made of a hydrophobic non-woven fabric, which would not wick away a fluid from the user when the first layer is in contact with the user. Furthermore, some prior art absorbent materials may allow air to pass through but are not capable of wicking away a fluid from the user, whereby the fluid is a liquid such as urine, blood and/or water. As such, prior art absorbent materials may be uncomfortable and unhygienic to the user because a portion of the user may be wet due to the fluid and possibly remain wet. Consequently, growth of bacteria and/or mould may be facilitated due to build-up of the fluid.

In some aspects, the absorbent material <NUM> may be cheap to manufacture and comfortable to the user because of the material used for the first layer <NUM> and/or the second layer <NUM>. Furthermore, the specific combination of the material used for the first layer <NUM> and the second layer <NUM> may be important and lead to one or more advantages.

In various aspects, the non-woven fabric is made of a polymer. In some aspects, the polymer is polypropylene (PP) or polyethylene (PE) or a combination thereof. In some aspects, the non-woven fabric may be predominantly polypropylene. In some aspects, the non-woven fabric consists of polypropylene. In other words, the non-woven fabric does not contain polyethylene or a polyester. As such, the non-woven fabric may be used in bulk quantities because polypropylene is relatively cheap compared to other materials such as polyethylene. The use of polypropylene is particularly suitable for the first layer <NUM> because it is substantially inert towards a wide range of chemicals. In addition, polypropylene is more inert towards chemicals and organic solvents compared to polyethylene. Consequently, the non-woven fabric of the present disclosure may be attractive to the user because it may be comfortable to the user. For instance, there may be no or negligible skin irritation if a part of the user comes into contact with the non-woven fabric.

In various aspects, the non-woven fabric is smooth and soft to the touch. At the same time, there is sufficient rigidity such that the non-woven fabric may retain its integrity, such that it is capable of not being torn apart when subjected to a weight, such as the weight of an adult, whereby the adult may be laying down. Consequently, the use of the non-woven fabric may make it attractive to the user because it may be comfortable to the user.

As mentioned above, the second layer <NUM> is made of/formed of a hydrophobic film which allows a first fluid (e.g. air) to pass through but is impermeable to a second fluid (e.g. water, urine, blood) etc. In various aspects, the hydrophobic film is made of a polymer. In some aspects, the polymer is polyester, polyethylene, polyurethane or a combination thereof. In some aspects, the hydrophobic film may be predominantly polyethylene. In some aspects, the hydrophobic film consists of polyethylene.

In various aspects, the hydrophobic film may be durable and flexible. When a durable hydrophobic film is used, the absorbent material <NUM> would not easily tear when it comes into contact with a liquid. When a flexible hydrophobic film is used, the absorbent material <NUM> may be easily folded to reduce the surface area, thereby making it easier for transportation and/or storage. As the hydrophobic film may be durable and flexible, the absorbent material <NUM> may be folded without the formation of creases i.e. the absorbent material <NUM> may be in a compact position without the formation of creases. Consequently, the absorbent material <NUM> may be folded for storage purposes when not in use. Conversely, the absorbent material <NUM> may be unfolded without the formation of undesired creases when in use.

In various aspects, the hydrophobic film may be soft. In various aspects, negligible sound will be produced when the user moves.

In various aspects, the first layer <NUM> is made of a different material from the second layer <NUM>. As the first layer <NUM> is hydrophilic and the second layer <NUM> is hydrophobic, the first layer <NUM> wicks away a fluid from the user and the second layer <NUM> functions as a barrier for preventing the fluid from wetting a surface adjacent to the second layer <NUM>. The surface may be part of a structure such as a bed. Consequently, the first layer <NUM> and the second layer <NUM> synergistically work together in minimizing or eliminating wetness of the user and the surface adjacent to the second layer <NUM>. In some aspects, the first layer <NUM> is predominantly made of polypropylene and the second layer <NUM> is predominantly made of polyethylene. In some aspects, the first layer <NUM> consists of polypropylene and the second layer <NUM> consists of polyethylene.

The second layer <NUM> is laminated adjacent to the first layer <NUM>. Advantageously, the first layer <NUM> and the second layer <NUM> are substantially integrated or bonded to each other, such that it is difficult if not impossible to separate the two layers from each other, particularly when in use. As such, if the absorbent material <NUM> comes into contact with a liquid, the liquid would not be able to cause the two layers to separate, thereby maintaining the integrity of the absorbent material <NUM>. The step of laminating may make use of heat, mechanical or chemical means.

The first layer <NUM> comprises short fibers. Short fibers allows movement of a fluid from the user via capillary action. In other words, there is a wicking effect. As such, the first layer <NUM> may minimize or eliminate wetness of the user. The short fibers of the first layer <NUM> have an average length of about <NUM> millimeters (mm) to about <NUM>.

In various aspects, the first layer <NUM> and/or second layer <NUM> may be coloured to provide an attractive colour to attract the attention of a user. The first layer <NUM> and/or second layer <NUM> may be coloured with a dye, wherein the colour of the dye is at least one colour selected from red, blue, green, yellow, violet, orange, black, gold, silver, grey or white.

In various aspects, the first layer <NUM> and/or second layer <NUM> may have prints such as words or images on it. The prints may advantageously enhance the visual appearance and attractiveness of absorbent material <NUM> because the prints may be visually appealing words or images. The prints may be opaque, partially opaque or translucent. The presence of prints may be useful when the target audience is adults because the prints may help reduce negative emotions such as embarrassment and depression when used in various applications, including, but not limited to, adult diapers. In some aspects, the prints may be a wet indicator that reacts when exposed to a fluid such as a liquid, thereby indicating that the absorbent material <NUM> or a part thereof is wet.

Depending on the dimensions of the absorbent material <NUM>, the absorbent material <NUM> may be applied to various applications including, but not limited to, sanitary napkins, diapers for children, diapers for adults that may be made in various forms, including those resembling traditional child diapers, underpants, and pads resembling sanitary napkins, protective covers for structures, such as but not limited to household furniture, and protective clothing, such as but not limited to the medical field. Examples include bed sheets, table cloths, covers for pet cages, isolation gowns, surgical gowns, surgical drapes and covers, surgical masks, surgical scrub suits and caps, and medical packaging. In a preferred aspect, the absorbent material <NUM> is used to make protective covers for bedding, such as bed sheets. In another preferred aspect, the absorbent material <NUM> is intended for disposable use, which may be one-time or single use.

In various aspects, the thickness of absorbent material <NUM> may range from about <NUM> to about <NUM>, about <NUM> to about <NUM>, about <NUM> to about <NUM>, about <NUM> to about <NUM>, about <NUM> to about <NUM>, about <NUM> to about <NUM>, about <NUM> to about <NUM> or about <NUM> to about <NUM>. In a preferred aspect, the thickness of the absorbent material <NUM> may be about <NUM> to about <NUM>. As such, the absorbent material <NUM> is relatively thin and lightweight, thereby making it easier to transport, store and dispose compared to thicker and bulkier absorbent materials currently known.

One or more dimensions of the absorbent material <NUM>, such as a height, a length, or a width of the absorbent material <NUM> may be adjusted according to the application. Advantageously, as the absorbent material <NUM> is made of a relatively cheap material, adjusting the height and width of the absorbent material <NUM> does not substantially increase the manufacturing costs.

In various aspects, the height of the absorbent material <NUM> may range from about <NUM> centimeters (cm) to about <NUM> so that the absorbent material <NUM> may cover, such as but not limited to, a single size bed, a queen size bed, a king size bed or a super king size bed. In various aspects, the width of the absorbent material <NUM> may range from about <NUM> to about <NUM> so that the absorbent material <NUM> may cover, such as but not limited to, a single size bed, a queen size bed, a king size bed or a super king size bed.

It is appreciable that the first layer <NUM> and the second layer <NUM> of the absorbent material <NUM> work in tandem to achieve one or more of the following results:-.

In accordance with another aspect of the disclosure or disclosure there is a bed sheet comprising an absorbent material as described above. Advantageously, bedsores may be minimized or prevented because the absorbent material is breathable. Furthermore, the bed sheet may be relatively cheap, easy to manufacture and desirable for disposability.

In accordance with another aspect of the disclosure or disclosure there is a method of manufacturing an absorbent material comprising the step of thermal bonding to form a first layer comprising a hydrophilic non-woven fabric; and a step of arranging a second layer comprising a hydrophobic film adjacent to the first layer; wherein the first layer is adapted to allow a first fluid and a second fluid to pass through; wherein the second layer is adapted to allow the first fluid to pass through and is adapted to minimize or block the second fluid from passing through.

In various aspects, the method further comprises the step of providing the second layer comprising a hydrophobic film.

In various aspects, the properties of the absorbent material such as strength, thickness, drape and softness may be altered depending on the method of manufacturing used so as to achieve desirable properties. The desirable properties may be selected based on the type of application(s) relating to the use of the absorbent material. In an aspect, the absorbent material is used to make protective covers for structures, such as bed sheets.

In various aspects, the step of thermal bonding makes use of short fibers to form the first layer. In contrast, spun bonding makes use of continuous fibers to form the first layer. Advantageously, the presence of short fibers in the first layer allows movement of a fluid from the user via capillary action. In other words, short fibers produce or facilitate a wicking effect. As such, the first layer may minimize or eliminate wetness of the user.

In various aspects, the step of thermal bonding may advantageously lead to an appropriate thickness, sufficient strength, drape and softness of the absorbent material at a relatively low cost. Advantageously, the cost of mass production may be relatively low, thereby making it relatively affordable for use as a disposable absorbent material. In contrast, other methods such as adhesive bonding may generate sufficient strength but cause stiffness of the absorbent material because of the presence of an adhesive, thereby lowering the drape and softness of the absorbent material.

In various aspects and as illustrated in <FIG> and <FIG>, the method of manufacturing an absorbent material comprises the step of manufacturing staple fibers or fibers for a non-woven fabric (step <NUM>). Accordingly, a first control panel is provided to set parameters for the production of fibers from polymer chips, such as PP chips. In some aspects, the PP chips have a unit melt flow rate (<NUM>, <NUM>) of about <NUM> to about <NUM> grams per <NUM> (g/<NUM>), preferably about <NUM> to about <NUM>/<NUM>. In various aspects and as illustrated in <FIG>, the polymer for the first layer <NUM> is melted in an extruder <NUM> to form a molten material, and the molten material is transferred to a die block <NUM> via a pump such as spin pump <NUM>, thereby forming fibers <NUM>. The control panel sets the temperature for the PP chips to melt in the extruder <NUM>, thereby forming thin strands of fibers <NUM>, which then exit through at least one spinneret (not illustrated). In addition, the control panel ensures that the melting point and the melt flow rate of the PP chips entering the extruder <NUM> are correct. Although the polymer starting material may come in the form of pellets or other particulate form and melted to a liquid (which can be in a pumpable state), other fiber-forming liquids such as a polymer solution could also be used.

In various aspects, fibers <NUM> which are semi-processed, are transferred to a stretching chamber or a first stretch roller <NUM>, wherein a stream of air <NUM> or another gas for cooling is ejected to simultaneously draw down and cool the fibers <NUM> as the fibers <NUM> pass through the stretching chamber <NUM>. In various aspects, the stream of air or another gas may be heated to obtain a desired temperature of the extruded fibers <NUM> and/or to facilitate drawing of the fibers <NUM>. In a preferred aspect, the fibers <NUM> may be passed through a steam box, so that the fibers <NUM> may be subjected to steam before crimping. In other words, the fibers <NUM> may be conditioned by steam prior to passing through a crimper machine <NUM>.

In various aspects, the fibers <NUM> may optionally be passed through a second stretch roller (not illustrated).

In various aspects, the fibers <NUM> may be subjected to a stream of oil <NUM> (i.e. spin finished), which may assist in crimping the fibers <NUM> so as to form a mass of fibers <NUM> that may or may not be coherent and take the form of a tow <NUM>.

In various aspects, after passing through the stretching chamber <NUM>, but prior to collection, the mass of fibers <NUM> may be subjected to a number of additional processing steps. Upon collection, the mass of fibers <NUM> may be subjected to one or more apparatus such as but not limited to a bonding oven, calender, hydroentangling mechanical bonder, embossing station, laminator, cutter. In some aspects, air-through bonding is not used in the present disclosure.

In various aspects, after passing through the stretching chamber <NUM>, the tow <NUM> may be laid down on a belt <NUM> so that the tow <NUM> may be passed through a crimper machine or crimper <NUM>.

In various aspects, a second control panel is provided to control the stretching chamber <NUM>, and the second stretch roller if present, and guide the fibers <NUM> to the crimper machine <NUM>. The second control panel also controls the crimper machine <NUM>. As such, when the fibers <NUM> pass through the crimper machine <NUM>, the crimper machine <NUM> will press the fibers <NUM> so that they become crimp and form crimped fibers <NUM>. The step of crimping occurs at a pressure of about <NUM> bar to about <NUM> bar and at a temperature of about <NUM> to about <NUM>. Advantageously, crimping creates a softer fabric by reducing the "straightness" of the fibers <NUM>, between bond points created in the thermal bonding step, as well as fiber-to-fiber bonds. More advantageously, crimping leads to fibers <NUM> having better strength.

In various aspects and as illustrated in <FIG>, the crimped fibers <NUM> are passed through a dryer <NUM> to dry or anneal the crimped fibers <NUM>. At the same time, the fibers <NUM> will be cooled by passing through at least one roller to dry the fibers <NUM>, such as by air. Consequently, any oil, moisture and/or undesired substance may be removed from the fibers <NUM> and the fibers <NUM> are cooled to a suitable temperature for further processing. After the fibers <NUM> are dried, they are passed through a cutter box (not illustrated), which will cut the fibers <NUM> into a desired length, such as a length required by a customer. In various aspects, the fibers <NUM> are short and may have an average length of about <NUM> to about <NUM>, about <NUM> to about <NUM> or about <NUM> to about <NUM>.

In various aspects, the cut fibers <NUM> are optionally transported to a baler machine, whereby the transporting may be carried out using an air system. The baler machine compresses the cut fibers <NUM> into a compact form so that the fibers <NUM> are more suitable for packing. Subsequently, the fibers <NUM> are packed using PP strapping bands to form bales of fibers <NUM> and sent to a warehouse to set or relax the fibers <NUM> for a period of time, such as at least <NUM> hours, preferably for one week or two weeks.

In various aspects and as illustrated in <FIG>, the method of manufacturing the absorbent material comprises the step of manufacturing the non-woven fabric. The non-woven fabric is made using thermal bonding, which is described in steps <NUM>, <NUM>, <NUM>, <NUM>, <NUM> and <NUM>.

In various aspects, a first bale of fibers <NUM> may be opened and placed inside at least one fiber opener to loosen the fibers <NUM> so that the fibers <NUM> are at least partially loosened. Subsequently, the at least partially loosened fibers <NUM> are transferred from the first fiber opener to a second fiber opener, which will further loosen the fibers <NUM>. If necessary, the loosened fibers <NUM> will be transferred to a third fiber opener, which comprises a control unit for determining how much fibers <NUM> to receive from the second fiber opener. Similar to the first fiber opener and the second fiber opener, the third fiber opener is configured to further loosen the fibers <NUM>.

In various aspects and as illustrated in <FIG>, the method may further comprise the step of passing the fibers <NUM> through a carding feeder such as a FBK unit manufactured by Trützschler GmbH & Co. KG (step <NUM>). The fibers <NUM> may be transferred from the cutter box or a fiber opener (such as the first fiber opener, the second fiber opener or the third fiber opener) to the FBK unit. The primary function of the FBK unit is to bring the loosened fibers <NUM> to a kiss roller machine which comprises of a plurality of carding rollers. Importantly, the FBK unit regulates or controls the flow of an amount of fibers <NUM> to the carding rollers. For example, if the production of <NUM> grams of non-woven fabric is desired, the FBK unit will release an amount of fibers <NUM> that corresponds to <NUM> grams of non-woven fabric to the carding rollers. At the FBK unit, the fibers <NUM> are pushed down to a stainless steel plate and into the kiss roller machine, which comprises of a plurality of carding rollers. The FBK unit may comprise an induced draft (ID) fan which pushes the loosened fibers <NUM> into the carding rollers of the kiss roller machine. In a preferred aspect, there are four carding rollers. The FBK unit may comprise a control panel that controls the FBK unit by determining how much fibers <NUM> to distribute across the plurality of carding rollers based on the desired grams per square meter of non-woven fabric, such as a grams per square meter (gsm) required by a customer. As such, the FBK unit is important for controlling the gsm of the non-woven fabric.

In various aspects and as illustrated in <FIG>, the method may further comprise the step of carding the fibers <NUM> (step <NUM>) using a carding machine. Carding is a mechanical process whereby clumps of fibers <NUM> are separated into individual fibers <NUM> by loosening or combing, thereby forming a coherent web. The loosening or combing is controlled by selecting the speed of a plurality of rollers that loosen or comb the fibers <NUM> to form the coherent web.

In various aspects and as illustrated in <FIG>, the method may further comprise the step of passing through a conveyor belt (step <NUM>) followed by passing through an embossed roller and a smooth roller (step <NUM>). Advantageously, the conveyor belt serves to guide the coherent web through the embossed roller and the smooth roller. The embossed roller and the smooth roller may be filled with thermal oil and heated up to a required temperature to melt the coherent web so as to form the non-woven fabric i.e. first layer <NUM>. In some aspects, the required temperature is about <NUM> to about <NUM>. In some aspects, the step of thermal bonding to form the first layer occurs at a temperature of <NUM> to <NUM>.

In various aspects and as illustrated in <FIG>, the method may further comprise the step of passing through a jumbo roll rewinding unit (step <NUM>), so that the non-woven fabric is wound to form a roll.

In various aspects and as illustrated in <FIG>, the method may further comprise the step of transporting the roll from step <NUM> to a slitting machine so that the non-woven fabric may be slit to a desired dimension, such as a dimension required by a customer (step <NUM>).

Advantageously, the first layer <NUM> may have zero or negligible lint. Linting may occur as fibers <NUM> are pulled off or released from the surface of the first layer <NUM> and may result in fibers <NUM> undesirably remaining on the skin of the user. As such, use of the absorbent material <NUM> may be relatively more comfortable compared to currently known absorbent materials because the fibers <NUM> of the first layer <NUM> are thermally bonded to each other and then carded, thereby eliminating or minimizing linting.

Claim 1:
An absorbent material (<NUM>) consisting of two layers:
a first layer (<NUM>) comprising a hydrophilic non-woven fabric; and
a second layer (<NUM>) comprising a hydrophobic film, the second layer laminated adjacent to the first layer such that the first and second layers are substantially integrated or bonded;
wherein the first layer is breathable and allows gas and liquid to pass through;
wherein the second layer is breathable and allows gas to pass through and minimizes or blocks liquid from passing through; and wherein the first layer comprises short fibers having an average length of <NUM> to <NUM>.