Field of the Invention

The present invention relates to the design of absorbent core used in baby diapers, sanitary pads, adult diapers, adult underpad, children underpad and panty diapers which will be defined as hygiene products in the following sections. More specifically, the present invention relates to a hygiene product, which enables to eliminate the problems of sagging and agglomerating which disturb the baby and/or the end user by enabling the Super Absorbent Polymer and paper pulp raw materials or combined and commercially sold forms of these two raw materials after being wrapped by an absorbent core liner to maintain integrity in a wet state when exposed to urine, blood, bodily fluids, soft and hard feces, which will be referred to as bodily wastes in the following sections. Additionally, since the specially designed absorbent core rapidly distributes the bodily wastes to the front and back along the hygiene product to enable them to be absorbed across the entire hygiene product, it also improves important critical performance parameters of a hygiene product such as the absorbance time value and the amount of wetness given back to the skin.

Background of the Invention

In a hygiene product production line, a molded drum equipment is used to mix the Super Absorbent Polymer and Pulp raw materials, which are the materials forming the absorbent core, and which will be referred to as the "absorbent core fluid retaining region" in the following sections. The molded drum equipment resembles a round wheel as shown in Figure 1. There is provided a plurality of molds on the molded drum. Each mold alone carries a mixture of varying proportions of the absorbent core fluid retaining region of a hygiene product. The super absorbent polymer and pulp are fed separately or in a premixed form to the molded drum and they are enabled to be mixed so as to shape the region that will form the absorbent core fluid retention feature when being filled into the mold under vacuum. The vacuum on the molded drum also varies according to the regions. While the vacuum value at the point, where the superab sorbent polymer and the pulp are mixed and fed to the molded drum, is high to enable the mixture to fill into the mold; the vacuum value at the lower point of the molded drum, where the mixture is placed on the nonwoven fabric surface surrounding the absorbent core, is minimized so that the mixture is transferred from the molded drum mold to the nonwoven fabric surface which is the absorbent core liner.

In the commonly used prior art applications, the super absorbent polymer and pulp mixture is mixed homogenously and/or by being phased at different ratios to different parts of the core in the molded drum equipment, and thus it is fed to the system at the same density and/or different densities by predetermined ratios in each region of the molded drum mold. However, when the consumer habits are assessed, it is observed that the consumers generally tend to change the diapers of the babies and other end users before the body wastes reach the front and rear end portions of the hygiene products. In this case, the front and rear end portions of the absorbent core layer remain dry since the hygiene product is not used at full capacity. The super absorbent polymer and pulp mixture, which is wetted in the absorbent core layer, breaks apart from the unwetted mixture in pieces and thus the core integrity is impaired. Depending on the movement of the baby and the end user, the adhesive strength of the wetted absorbent core portions is weakened in wet state and lumps of agglomeration occur in the hygiene product. These also create the problems of downward sagging and leakage in the hygiene product when the end user continues to excrete body wastes. The sagging, agglomerating and leaking hygiene product is likely to cause skin irritation problems because the absorbent core integrity is impaired. A prior art study claims rapid absorption of the body fluid when it is being distributed to the front and rear parts of the hygiene product and effective use of the capacity of the hygiene product by means of the channel technology. It has been stated that the absorbent core layer of the hygiene product is obtained from a dual-molded drum system. According to this system, the super absorbent polymer particles are fed into the air tight / vacuum first molded drum which includes channels/cavities thereon. The super absorbent polymer particles are placed in these channels by the impact of the vacuum that is applied. An adhesive is applied on the surface of the nonwoven fabric which in turn is fed into the second molded drum. At the point where the first and second molded drums intersect, the super absorbent polymer particles leaving the grooves of the molds in the first molded drum adhere to the adhesive applied on the surface of the nonwoven fabric. The position of the superabsorbent polymer particles is fixed on the nonwoven fabric in the form of a channel by the effect of the grooves in the first molded drum during adherence. Adhesive is applied again to this junction, which leaves from the intersection point of the molds, and the second nonwoven fabric layer is adhered thereon and thus a C-shaped core liner is obtained (US008568566B2, P&G, (2013)).

Another study used in the prior art claims providing effective fluid diffusion throughout the hygiene product by producing one or more channeled structures in the vertical plane on the absorbent core layer in the hygiene product comprising about 80% Super Absorbent Polymer. The channels consist of gaps that do not contain any Super Absorbent Polymer or Pulp. The acquisition and distribution layer (ADL) and any other intermediate layers located between the absorbent core layer and the topsheet (the uppermost layer of the hygiene product contacting the baby's skin) are similarly not located in the areas where the channels are located. It has been mentioned that shorter small channels can also be found in the front and rear regions of the hygiene product (US20150073366A1, P&G, (2015)). Another study claims that the hygiene product should have a three-dimensional and channeled absorbent layer to enable body adaptation, comfort, and forward and backward transmission of the body wastes throughout the hygiene product. It is stated in the study that the elasticity of the absorbent layer in the structures having two longitudinal channels is increased throughout the hygiene product and the anatomical structure is more compatible with the body of the user, and that the fastest absorption of body wastes is achieved with the two-channel structure and the risk of leakage is minimized (US20150038931A1, P&G, (2015)).

However, widespread production of the hygiene products with one or more channels in the current applications causes the structure to get hardened as a result of the swelling of the absorbent core layer, which particularly comprises Super Absorbent Polymers upon exposing the body wastes, making it difficult to adapt to the user’s body. In addition, the usage capacity of the diaper is reduced due to the reduction of the amount of absorbent material because of the space spared for the channels in the absorbent layer, and this situation gives way to leakage complaints and skin irritation (US008568566B2, US20150073366A1,

US20150038931A1).

Upon realizing several channeled hygiene product applications produced by means of the known art, the integrity of the core comprising super absorbent polymer and pulp mixture is improved to some extent. However, in the case of use of the hygiene product for a long period, the absorbent core, which is exposed to excessive body waste, becomes unable to protect the core integrity and causes agglomeration since the special core glues used in this part become dysfunctional. In some hygiene products produced with the techniques of the known art, while the core integrity is improved to some extent by means of the channeled structure effect, due to the fact that optimization of the super absorbent polymer and pulp ratios of the absorbent core could not be carried out well, the hygiene product swells excessively and thus making it difficult to fit to the body of the end user anatomically. This in turn restricts the end user's freedom of movement. In products produced with the current technologies, homogeneous distribution of the super absorbent polymer and pulp so as to form a single-piece absorbent zone in the absorbent core layer is widely used. In this case, more capacity is used on the middle and front parts of the product which are exposed to the body wastes more intensely and the product is often disposed of without the rear parts getting wet. As the integrity of the absorbent core is compromised between the wetted and unwetted areas of the hygiene product, fractures occur, the wetted area is separated from the unwetted area in the absorbent core, and this causes sagging / agglomeration problem on the end user.

No technology has been found in the literature and in existing applications that combine the claims of rapid absorption of bodily wastes, high absorption and retention capacity and anatomical compatibility, and an absorbent core design that does not sag during use on the end user.

Problems Solved by the Invention

The object of the present invention is to develop a hygiene product which, by means of an absorbent core having an improved original design, enables the super absorbent polymer and pulp mixture to maintain its integrity in wet state after encountering with the body waste and prevents it from agglomerating and sagging.

The present invention also improves performance of the product as the absorbent core, which is exposed to body wastes, rapidly spreads the body wastes towards the front and rear portions of the hygiene product and allows rapid absorption. Since the absorbent core of the present invention rapidly cuts contact of the end user’s skin with the body waste, it enables to eliminate the skin irritation and leakage problems which may be caused by the performance of the finished product. In addition, by ensuring the body wastes to be distributed to the front and rear portions along the diaper, the capacity of the front and rear regions of the absorbent core is enabled to be used more efficiently than the products produced with the current technology.

The product of the present invention designed with an original absorbent core, in which the problem of agglomerating/sagging can be avoided, is the first product to provide high absorption and retention capacity simultaneously in addition to significantly improving the features of the amount of wetness returned to the skin and the suction time which are the main performance criteria.

In one embodiment of the invention, the non- sagging hygiene product comprises an absorbent core having an absorbent core fluid retaining region including a mixture for absorbing the body waste, and a nonwoven absorbent core liner surrounding the absorbent core fluid retaining region and including a nonwoven absorbent core liner upper layer and a nonwoven absorbent core liner lower layer; and fixing members, which are preferably rope and/or rubber and which are applied in a first direction and/or a second direction to the mixture in the absorbent core fluid retaining region by sewing for fixing the absorbent core fluid retaining region. This embodiment may also include an acquisition and distribution layer fixed onto the nonwoven absorbent core liner; a fluid permeable topsheet fixed onto the acquisition and distribution layer; and a fluid impermeable backsheet fixed to the lower layer of the non-woven absorbent core liner; and the fixing members may be applied to the mixture directly or via the nonwoven absorbent core liner lower layer and/or the nonwoven absorbent core liner upper layer, the acquisition and distribution layer or the topsheet (5).

In one embodiment of the invention, the non- sagging hygiene product comprises an absorbent core having an absorbent core fluid retaining region including a mixture for absorbing the body waste, and a nonwoven absorbent core liner surrounding the absorbent core fluid retaining region and including a nonwoven absorbent core liner upper layer and a nonwoven absorbent core liner lower layer; an acquisition and distribution layer fixed onto the nonwoven absorbent core liner; a fluid permeable topsheet fixed onto the acquisition and distribution layer; a fluid impermeable backsheet fixed to the non-woven absorbent core liner lower layer; and fixing members (4) which are preferably rubber and which are applied in a first direction and/or a second direction to the mixture in the absorbent core fluid retaining region, or nonwoven absorbent core liner or the acquisition and distribution layer or the topsheet by means of glue for fixing the absorbent core fluid retaining region.

In one embodiment of the invention, the non- sagging hygiene product comprises an absorbent core having an absorbent core fluid retaining region including a mixture for absorbing the body waste, and a nonwoven absorbent core liner surrounding the absorbent core fluid retaining region and including a nonwoven absorbent core liner upper layer and a nonwoven absorbent core liner lower layer; an acquisition and distribution layer fixed onto the nonwoven absorbent core liner; a fluid permeable topsheet fixed onto the acquisition and distribution layer; a fluid impermeable backsheet fixed to the non-woven absorbent core liner lower layer; and fixing members which are preferably rope and/or rubber and which are applied in a first direction and/or a second direction to the mixture in the absorbent core fluid retaining region, or nonwoven absorbent core liner or the acquisition and distribution layer or the topsheet by means of ultrasonic bonding method for fixing the absorbent core fluid retaining region. Also in this embodiment, the said fixing members may be previously sewn on the mentioned surfaces and ultrasonic bonding may be applied on these sewn fixing members.

In one embodiment of the invention, the non- sagging hygiene product comprises an absorbent core having an absorbent core fluid retaining region including a mixture for absorbing the body waste, and a nonwoven absorbent core liner surrounding the absorbent core fluid retaining region and including a nonwoven absorbent core liner upper layer and a nonwoven absorbent core liner lower layer; an acquisition and distribution layer fixed onto the nonwoven absorbent core liner; a fluid permeable topsheet fixed onto the acquisition and distribution layer and a fluid impermeable backsheet fixed to the non-woven absorbent core liner lower layer; and the mixture in the absorbent core fluid retaining region is fixed so as to form one or more grooves by means of ultrasonic bonding applied to the mixture in the absorbent core fluid retaining region or nonwoven absorbent core liner or the acquisition and distribution layer or the topsheet in a first direction and/or a second direction.

Detailed Description of the Invention

An absorbent core for hygiene products developed to fulfill the objectives of the present invention is illustrated in the accompanying figures, in which:

Figure 1. is a schematic view of the molded drum equipment.

Figure 2. A) is a schematic view of the nonwoven absorbent core leaving the molded drum mold wherein an original glue/sewing/ultrasonic bonding (adhesion of two layers to each other under the influence of the vibration caused by high-frequency sound waves) operation is applied by using rubber, rope or both which will be referred as fixing members in the following sections.

B) is a schematic view of the nonwoven absorbent core leaving the molded drum mold wherein an original glue/sewing/ultrasonic bonding (adhesion of two or more layers to each other under the influence of the vibration caused by high-frequency sound waves) operation is applied by using rubber, rope or both which will be referred as fixing members in the following sections.

Figure 3. is a side view of the absorbent core when rubber/rope or both are applied, in a state wherein it is / they are applied to the nonwoven core liner lower layer. Figure 4. is a side view of the absorbent core when rubber/rope or both are applied in a state wherein it is / they are applied to the nonwoven absorbent core liner lower and upper layers.

Figure 5. is a side view of the absorbent core when rubber/rope or both are applied in a state wherein it is / they are applied to the nonwoven absorbent core liner lower layer at different numbers

Figure 6. is a side view of the absorbent core when rubber/rope or both are applied in a state wherein it is / they are applied to the nonwoven core liner lower layer at different numbers.

Figure 7. is a side view of the absorbent core when rubber/rope or both are applied in a state wherein it is / they are applied to the nonwoven absorbent core liner lower and upper layers at different numbers

Figure 8. is a side view of the absorbent core when rubber/rope or both are applied in a state wherein it is / they are applied to the nonwoven absorbent core liner lower and upper layers at different numbers.

Figure 9. A) is a schematic view on the absorbent core when different rubber/rope or both are applied.

B) is another schematic view on the absorbent core when different rubber/rope or both are applied.

Figure 10. A) is a schematic view on the absorbent core when different rubber/rope or both are applied.

B) is another schematic view on the absorbent core when different rubber/rope or both are applied.

Figure 11. A) is a schematic view on the absorbent core when different rubber/rope or both are applied.

B) is another schematic view on the absorbent core when different rubber/rope or both are applied.

Figure 12. is a side schematic representation of the components of a hygiene product.

The components in the figures are given reference numbers as follows: 1. Absorbent Core

2. Absorbent Core Fluid Retaining Region

3. Nonwoven Absorbent Core Liner

3.1. Nonwoven Absorbent Core Liner Upper Layer

3.2. Nonwoven Absorbent Core Liner Lower Layer

4. Fixing Member

5. Topsheet

6. Backsheet

7. Acquisition and Distribution Layer

D. Molded Drum Equipment

K. Molded Drum Mold

MD. Machine Direction

CD. Cross Direction

The non- sagging hygiene product of the present invention essentially comprises an absorbent core (1) having an absorbent core fluid retaining region (2) including a mixture preferably comprised of super absorbent polymer and pulp for absorbing the body waste, and a nonwoven absorbent core liner (3) surrounding the absorbent core fluid retaining region (2) and including a nonwoven absorbent core liner upper layer (3.1) and a nonwoven absorbent core liner lower layer (3.2); and one or more fixing members (4), which are preferably rope and/or rubber and which are applied in a first direction and/or a second direction to the mixture in the absorbent core fluid retaining region (2) so as to obtain a grooved structure by sewing and/or glue and/or ultrasonic bonding for fixing the absorbent core fluid retaining region (2) in the absorbent core (1).

In one embodiment of the invention, the non- sagging hygiene product comprises an absorbent core (1) having an absorbent core fluid retaining region (2) including a mixture for absorbing the body waste, and a nonwoven absorbent core liner (3) surrounding the absorbent core fluid retaining region (2) and including a nonwoven absorbent core liner upper layer (3.1) and a nonwoven absorbent core liner lower layer (3.2); and fixing members (4), which are preferably rope and/or rubber and which are applied in a first direction and/or a second direction to the mixture in the absorbent core fluid retaining region (2) by sewing for fixing the absorbent core fluid retaining region (2). In addition; the non-sagging hygiene product may comprise an acquisition and distribution layer (7) fixed on the nonwoven absorbent core liner (3); a fluid permeable topsheet (5) fixed on the acquisition and distribution layer (7); and a fluid impermeable backsheet (6) fixed to the non- woven absorbent core liner lower layer (3.2). In this embodiment, the fixing members (4) may be applied to the mixture directly or via the nonwoven absorbent core liner lower layer (3.2) and/or the nonwoven absorbent core liner upper layer (3.1), the acquisition and distribution layer (7) or the topsheet (5).

In one embodiment of the invention, the non- sagging hygiene product comprises an absorbent core (1) having an absorbent core fluid retaining region (2) including a mixture for absorbing the body waste, and a nonwoven absorbent core liner (3) surrounding the absorbent core fluid retaining region (2) and including a nonwoven absorbent core liner upper layer (3.1) and a nonwoven absorbent core liner lower layer (3.2); an acquisition and distribution layer (7) fixed onto the nonwoven absorbent core liner (3); a fluid permeable topsheet (5) fixed onto the acquisition and distribution layer (7); a fluid impermeable backsheet (6) fixed to the non-woven absorbent core liner lower layer (3.2); and fixing members (4) which are preferably rubber and which are applied in a first direction and/or a second direction to the mixture in the absorbent core fluid retaining region (2) or nonwoven absorbent core liner (3) or the acquisition and distribution layer (7) or the topsheet (5) by means of glue for fixing the absorbent core fluid retaining region (2).

In one embodiment of the invention, the non- sagging hygiene product comprises an absorbent core (1) having an absorbent core fluid retaining region (2) including a mixture for absorbing the body waste, and a nonwoven absorbent core liner (3) surrounding the absorbent core fluid retaining region (2) and including a nonwoven absorbent core liner upper layer (3.1) and a nonwoven absorbent core liner lower layer (3.2); an acquisition and distribution layer (7) fixed onto the nonwoven absorbent core liner (3); a fluid permeable topsheet (5) fixed onto the acquisition and distribution layer (7); a fluid impermeable backsheet (6) fixed to the non-woven absorbent core liner lower layer (3.2); and fixing members (4) which are preferably rope and/or rubber and which are applied in a first direction and/or a second direction to the mixture in the absorbent core fluid retaining region (2) or nonwoven absorbent core liner (3) or the acquisition and distribution layer (7) or the topsheet (5) by means of ultrasonic bonding for fixing the absorbent core fluid retaining region (2). In this embodiment of the invention, the said fixing members (4) may be previously sewn to the mentioned surfaces (the mixture in the absorbent core fluid retaining region (2) or the nonwoven absorbent core liner (3) or the acquisition and distribution layer (7) or the top sheet (5)) and ultrasonic bonding can also be applied on these sewn fixing members (4).

If the structures in Figures 2 to 11 are sewn with rope and/or rubber, additional equipment performing the sewing operation is used in the production process. While this equipment can perform sewing directly through the absorbent core fluid retaining region (2), it can as well perform it via the absorbent core liner (3), the acquisition and distribution layer (7) and the topsheet (5). The rubber can also be applied to the mixture in the absorbent core fluid retaining region (2), the nonwoven absorbent core liner (3), topsheet (5) or acquisition and distribution layer (7) by means of glue application. For this, a head is used in the production process to apply the glue. When the said rubber is stretched, it is glued to said one or more layers (the mixture in the absorbent core fluid retaining region (2), the nonwoven absorbent core liner (3), the top sheet (5) or the acquisition and distribution layer (7)) and when it is released, it returns to its original state (unstretched initial state) thereby ensuring that the fluid in the absorbent core fluid retaining region (2) is compressed and fixed. In applications wherein rope or rubber is used as the fixing member (4), ultrasonic bonding can also be applied to the absorbent core fluid retaining region (2), the absorbent sore liner (3), the topsheet (5) or the acquisition and distribution layer (7) in the production process by means of an additional equipment for this bonding.

In various embodiments of the invention, when rubber, which is a flexible/bendable and extendable/shrinkable element, or a derivative thereof is used as the fixing member (4); the sewing operation, ultrasonic bonding or glue application can be applied alone as well as in combination with each other. In various disclosed embodiments of the invention, when rope, which is not a flexible/bendable or extendable/shrinkable element, or a derivative thereof is used as the fixing member (4); the sewing operation or ultrasonic bonding can be applied alone as well as in combination with each other. In various disclosed embodiments of the invention, when rope or rubber, or derivatives thereof are used as the fixing member (4) for the sewing operation; the said fixing members (4) enable to fix the said mixture by connecting at least half, half, half, more than half or all of the thickness of the mixture in the absorbent core fluid retaining region (2).

In order to ensure the absorbent core fluid retaining region (2) integrity of the hygiene products, preferably one of the special commercially available absorbent core (1) glues is used in order to fix the fluid retaining mixture (preferably the mixture of super absorbent polymer and pulp) in the absorbent core fluid retaining region (2) forming the said absorbent core (1), and in addition to this special absorbent core (1) glue, as shown in Figure 2 form the top, the absorbent core fluid retaining region (2) mixture leaving the molded drum mold (K) is fixed from certain parts thereof by the help of a fixing member (4) (e.g. rubber and/or rope). There are four different preferred embodiments of the invention for fixing the super absorbent polymer and the pulp, which form the mixture in the absorbent core fluid retaining region (2), by a sewing/gluing/ultrasonic bonding (adhesion) process to be applied directly or indirectly to the mixture in the absorbent core fluid retaining region (2). In the first preferred embodiment, the fixing members (4) are directly applied to the mixture; in the second embodiment, the fixing members (4) are applied via the nonwoven absorbent core liner upper layer (3.1) and/or the nonwoven absorbent core liner lower layer (3.2); in the third embodiment, the fixing members (4) are applied to the mixture via an acquisition and distribution layer (7) that is adhered on the nonwoven absorbent core liner (3); and in the last embodiment, the fixing members (4) are applied to the mixture via a topsheet (5) (uppermost layer) fixed (preferably adhered) on an acquisition and distribution layer (7) that is fixed (preferably adhered) on the nonwoven absorbent core liner (3). The hygiene products produced using these preferred embodiments of the invention are described in detail below respectively.

In the first preferred embodiment of the invention, the absorbent core fluid retaining region (2) mixture leaving the molded drum mold (K), as shown from the top in Figures 2A, 2B, 9A, 9B, 10A, 10B, 11A and 11B and other similar figures, is subjected to gluing/sewing/ultrasonic bonding processes by means of fixing members (4) to fix the absorbent core fluid retaining region (2) mixture. In this embodiment, the superab sorbent polymer and pulp mixture leaving the molded drum mold (K) is first fixed preferably in machine direction (MD) and/or cross direction (CD) by means of sewing and/or gluing and/or ultrasonic bonding preferably by using 1 to 20 fixing members (4); and then it is surrounded by the nonwoven absorbent core liner (3) and fixed to the backsheet (6) (the lowermost layer) from the nonwoven absorbent core liner lower layer (3.2) by means of glue. The acquisition and distribution layer (7), schematically shown in Figure 12, is fixed on the absorbent core (1), in other words, on the nonwoven absorbent core liner upper layer (3.1) by means of glue. The topsheet (5), which is the uppermost fluid permeable nonwoven fabric layer of the hygiene product that contacts the skin, is adhered onto the acquisition and distribution layer (7) by means of glue. This way, strength of the absorbent core fluid retaining region (2) mixture in wet state is ensured to be protected. The number of fluid passages obtained is one minus the number of fixing members (4) that are used. The lines shown in the said figures show the fastening members (4) which are applied to the mixture by sewing and/or gluing and/or ultrasonic bonding method. The fixing members (4) partly or completely join the upper and lower surfaces of the mixture in the absorbent core fluid retaining region (2). Grooves are formed in the parts where these fixing members (4) are located, and fluid flow paths are formed in the parts remaining between the fixing members (4). The body wastes can move toward the other parts of the mixture along these grooves and fluid flow paths.

In the second preferred embodiment of the invention, as shown from the top in Figures 2A, 2B, 9A, 9B, 10A, 10B, 11A and 11B and other similar different figures, the absorbent core (1) layer is first fixed via the nonwoven absorbent core liner (3) surrounding the mixture in the absorbent core fluid retaining region (2) preferably in machine direction (MD) and/or cross direction (CD) by means of sewing and/or gluing and/or ultrasonic bonding preferably by using 1 to 20 fixing members (4); and then it is fixed to the backsheet (6), which is the outermost layer of the hygiene product that prevents bodily fluids from contaminating the underwear of the user, from the nonwoven absorbent core liner lower layer (3.2) by means of glue. The acquisition and distribution layer (7), which is placed on the fixed absorbent core (1), in other words, on the nonwoven absorbent core liner upper layer (3.1), is fixed by means of glue. The topsheet (5), which is the uppermost layer of the hygiene product that contacts the skin, is adhered onto the acquisition and distribution layer (7) by means of glue. This way, strength of the absorbent core (1) layer in wet state is ensured to be protected. The number of fluid passages obtained is one minus the number of fixing members (4) that are used.

In the third preferred embodiment of the invention, as shown from the top in Figures 2A, 2B, 9A, 9B, 10A, 10B, 11A and 11B and other similar different figures, the absorbent core (1) layer is first fixed via the acquisition and distribution layer (7) located on the nonwoven absorbent core line upper layer (3.1) preferably in machine direction (MD) and/or cross direction (CD) by means of sewing and/or gluing and/or ultrasonic bonding preferably by using 1 to 20 fixing members (4); and then it is fixed to the backsheet (6) from the nonwoven absorbent core liner lower layer (3.2) by means of glue. The acquisition and distribution layer (7) is fixed to the topsheet (5) from the upper part thereof. This way, strengths of the absorbent core (1) layer and the acquisition and distribution layer (7) in wet state are ensured to be protected. The number of fluid passages obtained is one minus the number of fixing members (4) that are used.

In a fourth preferred embodiment of the invention, as shown from the top in Figures 2A, 2B, 9A, 9B, 10A, 10B, 11A and 11B and other similar different figures, the absorbent core (1) layer, the acquisition and distribution layer (7) and the topsheet (5) arranged one on top of another are fixed together via the topsheet (5) preferably in machine direction (MD) and/or cross direction (CD) by means of sewing and/or gluing and/or ultrasonic bonding preferably by using 1 to 20 fixing members (4); and then they are fixed to the backsheet (6) from the absorbent core liner lower layer (3.2) by means of glue. This way, strengths of the absorbent core (1) layer, the acquisition and distribution layer (7) and the topsheet (5) in wet state are ensured to be protected. The number of fluid passages obtained is one minus the number of fixing members (4) that are used.

The said sewing/gluing and ultrasonic fastening processes are provided by a unit integrated in the hygiene product production line for the preferred four methods.

In one embodiment of the invention, for the rubber/rope application described as the fastening member (4), there are typically 1-20, more commonly 1-15, preferably 2-10 rubber/rope applications in x, y and z axes (vertical, horizontal and depth axes), however the invention is not limited thereto, and different numbers of rubber and/or rope applications can also be made.

In one embodiment of the invention, generally rubber (spandex yam) with a thickness of 500-25,000 dtex (decitex), more commonly 500-20,000 dtex and preferably 1000-15,000 dtex is preferred for the rubber used as the fixing member (4), however the invention is not limited to these values of thickness, rubbers of different thicknesses can also be used.

In one embodiment of the invention, threads produced from fibers such as polyester, nylon, aramid, etc. in different thicknesses are preferred in case of use of a fastening rope instead of rubber as the fixing member (4), however the invention is not limited thereto, and yams of different types and thicknesses may also be used.

Figures 5 and Figure 6 show a side cross-sectional view of the absorbent core (1) in the case of applying different number of rubber/rope only on the nonwoven absorbent core liner lower layer (3.2).

Figures 7 and Figure 8 show a side cross-sectional view of the absorbent core (1) in the case of applying different number of rubber/rope both on the nonwoven absorbent core liner lower layer (3.2) and the nonwoven absorbent core liner upper layer (3.1).

Figure 9, Figure 10 and Figure 11 show the top views of the absorbent core (1) layer for different rubber/rope applications.

Figure 9 shows at least two fixing members (4) applied in the machine direction (MD) so as to obtain a grooved structure and at least two opposite fixing members (4) applied in cross direction (CD) at the front and back of the former fixing members (4) so as not to contact them.

Figure 10 shows the fixing members (4) which are applied such that they cross each other perpendicularly.

Figure 11 shows a plurality of fixing members (4) applied in the cross direction (CD) and at least two fixing members (4) applied in the machine direction (MD) such that they will cross at least some of the said plurality of fixing members (4) perpendicularly.

In the said figures, one or more grooved structure(s) is/are obtained which allow the fluid to be distributed to the front and rear portions along the ropes/rubbers which enable the absorbent core (1) layer to be sewn in the machine direction (MD). At the moment of encountering the body fluid, the body fluid is enabled to be rapidly transmitted to the front and rear parts of the hygiene product through these grooves. By this means, unlike the hygiene products used in the current art, transport towards the front and rear parts, which do not directly contact the body fluid, is facilitated, and thus the absorbent core (1) layer capacity in the front and rear regions is efficiently used more efficiently. This will improve the hygiene product's absorption time to be shorter and increase the usage capacity.

The fixing members (4) used are defined as a physical sewing operation when only ropes and/or rubber are used. In the case of using rubber, gluing can be applied in addition to sewing.

The ultrasonic bonding process can be applied without using any fixing member (4) in addition to its use with rubber and/or rope. In this alternative embodiment of the invention in which a fixing member (4) is not used, the non-sagging hygiene product essentially comprises an absorbent core (1) having an absorbent core fluid retaining region (2) including a mixture fixed by ultrasonic bonding applied in a first direction and/or a second direction so as to form one or more grooves for absorbing the body waste, and a nonwoven absorbent core liner (3) surrounding the absorbent core fluid retaining region and including a nonwoven absorbent core liner upper layer (3.1) and a nonwoven absorbent core liner lower layer (3.2). In the same alternative embodiment, similar to the previous embodiments, there are four different preferred embodiments of the invention for fixing the super absorbent polymer and the pulp, which form the mixture in the absorbent core fluid retaining region (2), by ultrasonic bonding process to be applied directly or indirectly to the mixture in the absorbent core fluid retaining region (2). In the first one of these preferred embodiments, ultrasonic bonding is directly applied to the mixture; in the second embodiment, ultrasonic bonding is applied via the nonwoven absorbent core liner upper layer (3.1) and/or the nonwoven absorbent core liner lower layer (3.2); in the third embodiment, ultrasonic bonding is applied to the mixture via an acquisition and distribution layer (7) that is adhered on the nonwoven absorbent core liner (3); and in the last embodiment, ultrasonic bonding is applied to the mixture via a topsheet (5) (uppermost layer) fixed (preferably adhered) on an acquisition and distribution layer (7) that is fixed (preferably adhered) on the nonwoven absorbent core liner

(3).

The grooves formed in the absorbent core fluid retaining region (2) as a result of the fastening carried out via the ultrasonic bonding method are as shown in Figures 2-11. The upper and lower surfaces of the mixture in the absorbent core fluid retaining region (2) are partly or completely joined and fixed by means of the said ultrasonic bonding method. The lines shown in the said figures show the fixing regions applied to the mixture by the ultrasonic bonding method, and grooves are formed at the parts where these fixing regions (lines) are located, and the parts between these fixing regions form fluid flow paths. The body wastes can move toward the other parts of the mixture along these grooves and fluid flow paths.

As a result, the invention provides a novel hygiene product, which is produced by means of four preferred methods and fixed by sewing and/or gluing and/or ultrasonic bonding methods, and which is ensured to maintain its integrity and thus does not sag/agglomerate , has high absorbance capacity, cuts contact of the skin with the bodily fluid rapidly, and is anatomically compatible to the baby’s and/or user’s body.