WO2025125361A1

WO2025125361A1 - Laid fabric

Info

Publication number: WO2025125361A1
Application number: PCT/EP2024/085744
Authority: WO
Inventors: Kathryn MEDROW; Justin Harris; Matthew S. GOLDHAWK; Ashley Smith; Callie BAILEY-WICKINS; Meghan WATKINS
Original assignee: Saint Gobain Adfors SAS
Current assignee: Saint Gobain Adfors SAS
Priority date: 2023-12-12
Filing date: 2024-12-11
Publication date: 2025-06-19
Anticipated expiration: 2026-06-12

Abstract

A laid fabric is provided. The laid fabric includes a first set of filaments extending generally parallel in a first direction; a second set of filaments extending generally parallel in a second direction, wherein the second set of filaments are laid adjacent to the first set of filaments; a third set of filaments extending generally parallel in the first direction, wherein the third set of filaments are laid adjacent to the second set of filaments; wherein the first set of filaments, the second set of filaments, the third set of filaments, or combination thereof include a biodegradable yarn; and a binder coating the first set of filaments, the second set of filaments, the third set of filaments, or combination thereof, wherein the binder includes a biodegradable polymer. Further provided is an absorbent article and an erosion blanket.

Description

LAID FABRIC

TECHNICAL FIELD

The present disclosure relates to a laid fabric, an absorbent article, and an erosion blanket.

BACKGROUND ART

Fabric is useful in many industries to reinforce other products. For instance, fabrics can be used to provide structure and strength to products ranging from personal hygiene products to outdoor landscaping materials. The use of fabric is widespread and, in many cases, it might be desirable to provide a material that biodegrades. Biodegradability is advantageous to reduce waste as well as desirable for products that should have a limited lifespan when exposed to outdoor conditions, such as compost and soil.

As such, an improved reinforcing fabric is desired.

SUMMARY

In an embodiment, a laid fabric includes: a first set of filaments extending generally parallel in a first direction; a second set of filaments extending generally parallel in a second direction, wherein the second set of filaments are laid adjacent to the first set of filaments; a third set of filaments extending generally parallel in the first direction, wherein the third set of filaments are laid adjacent to the second set of filaments; wherein the first set of filaments, the second set of filaments, the third set of filaments, or combination thereof include a biodegradable yarn; and a binder coating the first set of filaments, the second set of filaments, the third set of filaments, or combination thereof, wherein the binder includes a biodegradable polymer.

In another embodiment, an absorbent article is provided. The absorbent article includes a first layer comprising absorbent fibers; a second layer adjacent to the first layer, the second layer including a laid fabric, wherein the laid fabric includes: a first set of filaments extending generally parallel in a first direction; a second set of filaments extending generally parallel in a second direction, wherein the second set of filaments are laid adjacent to the first set of filaments; a third set of filaments extending generally parallel in the first direction, wherein the third set of filaments are laid adjacent to the second set of filaments; wherein the first set of filaments, the second set of filaments, the third set of filaments, or combination thereof includes a biodegradable yarn; a binder coating the first set of filaments, the second set of filaments, and the third set of filaments, wherein the binder includes a biodegradable polymer; and a third layer adjacent to the laid fabric, wherein the third layer includes absorbent fibers.

In yet another embodiment, an erosion blanket is provided. The erosion blanket includes at least one laid fabric including: a first set of filaments extending generally parallel in a first direction; a second set of filaments extending generally parallel in a second direction, wherein the second set of filaments are laid adjacent to the first set of filaments; a third set of filaments extending generally parallel in the first direction, wherein the third set of filaments are laid adjacent to the second set of filaments; wherein the first set of filaments, the second set of filaments, the third set of filaments, or combination thereof include a biodegradable yarn; and a binder coating the first set of filaments, the second set of filaments, and the third set of filaments, wherein the binder includes a biodegradable polymer; and at least one mat including a naturally occurring material.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure may be better understood, and its numerous features and advantages made apparent to those skilled in the art by referencing the accompanying drawings.

FIG. 1 includes a perspective view of an exemplary laid fabric.

FIG. 2 includes a side view of a portion of an absorbent article.

FIG. 3 includes a side view of a portion of an erosion blanket.

The use of the same reference symbols in different drawings indicates similar or identical items.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

The following description in combination with the figures is provided to assist in understanding the teachings disclosed herein. The following discussion will focus on specific implementations and embodiments of the teachings. This focus is provided to assist in describing the teachings and should not be interpreted as a limitation on the scope or applicability of the teachings. However, other teachings can certainly be used in this application.

Before addressing details of the embodiments described below, some terms are defined or clarified. The term “filament” is intended to mean an elongated structure or fiber of any suitable length. The term “scrim” is intended to mean a woven or non-woven fabric that includes at least two filaments oriented in two different directions, including but not limited to a mesh. The term “laid scrim” is intended to mean a scrim in which at least one filament overlies at least one other filament to create the scrim. A “knitted fabric” typically includes fabrics produced by interloping chains of filaments, roving, or yarn. In a particular embodiment, the absorbent fibers are in the form of a scrim. The term “mat” is intended to mean a woven or non-woven fabric that includes any suitable arrangement of filaments other than an arrangement of filaments in a scrim, including an arrangement of randomly oriented filaments. A “chopped strand” typically describes randomly oriented chopped filaments or fibers, wherein the chopped filaments or fibers are randomly oriented individually or in a group. Unless indicated otherwise, all measurements are at room temperature, i.e. about 25°C. For instance, values for viscosity are at about 25°C, unless indicated otherwise.

As used herein, the terms “comprises”, “comprising”, “includes”, “including”, “has”, “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

Also, the use of “a” or “an” is employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include one or at least one and the singular also includes the plural, or vice versa, unless it is clear that it is meant otherwise. For example, when a single item is described herein, more than one item may be used in place of a single item. Similarly, where more than one item is described herein, a single item may be substituted for that more than one item.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The materials, methods, and examples are illustrative only and not intended to be limiting. To the extent not described herein, many details regarding specific materials and processing acts are conventional and may be found in reference books and other sources within the structural arts and corresponding manufacturing arts.

In an embodiment, the present invention provides a laid fabric. The laid fabric includes a first set of filaments, a second set of filaments laid adjacent to the first set of filaments, and a third set of filaments laid adjacent to the second set of filaments. In an embodiment, the first set of filaments and the third set of filaments extend generally in a first direction. The second set of filaments extends generally in a second direction. In an embodiment, the first set of filaments, the second set of filaments, the third set of filaments, or combination thereof include a biodegradable yarn. The laid fabric further includes a binder that coats the first set of filaments, the second set of filaments, the third set of filaments, or combination thereof. The binder coating includes a biodegradable polymer. “Biodegradable” as used herein refers to a material that decomposes by a living organism, such as a microorganism. In particular, “biodegradable” as used herein refers to the conversion of carbon in the material to carbon dioxide (CO₂) via microbial activity. Advantageously, the laid fabric biodegrades in aerobic conditions, including, but not limited to soil, fresh water, marine, home composting, industrial compost conditions, or combination thereof. In an embodiment, the laid fabric is used in any reasonable product where biodegradability is desired. For instance, the laid fabric is used in an absorbent article, an erosion blanket, and the like.

The laid fabric includes a first set of filaments. In a particular embodiment, the first set of filaments includes a plurality of filaments of monofilaments or multifilaments that are generally parallel to each other. “Monofilaments” include filaments that are composed of the same material. “Multifilaments” include filaments that are composed of two or more different materials. The plurality of filaments that are parallel to each other may be evenly spaced or randomly spaced, depending on the configuration and measurement resolution desired. In an example, the first set of filaments extends along any length envisioned of the laid fabric. In an example, the first set of filaments extends along the entire length of the main direction of the laid fabric. Further, the first set of filaments is oriented at any suitable angle. For instance, any suitable angle may be any angle measured relative to the main direction of the laid fabric. In an embodiment, the first set of filaments can be oriented at any angle between 0 degrees and 90 degrees relative to the main direction of the laid fabric. In a particular embodiment, the first set of filaments extends generally parallel to a main direction of the laid fabric, i.e. 0 degrees. In another embodiment, it is envisioned that the first set of filaments can be oriented at a suitable angle relative to the main direction of the laid fabric and also can be oriented at a positive value, a negative value, or a combination thereof. Any suitable positive or negative value is envisioned. For example, the first set of filaments is oriented at a first angle (e.g., 45°), and also can be oriented at a positive value of the first angle (e.g., +45°), a negative value of the first angle (e.g., -45°), or a combination thereof.

In an embodiment, the laid fabric further includes a second set of filaments that are laid adjacent to the first set of filaments in a second direction. The second direction is different than the first direction. In a particular embodiment, the second set of filaments is directly in contact with the first set of filaments. In a particular embodiment, the second set of filaments includes a plurality of filaments of monofilaments or multifilaments that are generally parallel to each other that may be evenly spaced or randomly spaced. In a more particular embodiment, the second set of filaments crosses over the first set of fiber filaments at a crossing angle. In an embodiment, the second set of filaments can be oriented at any angle between 0 degrees and 90 degrees relative to the main direction of the laid fabric. In a particular embodiment, the second set of filaments extends generally parallel to a cross direction (i.e. 90 degrees relative to the main direction) of the laid fabric. In another embodiment, it is envisioned that the second set of filaments can be oriented at a suitable angle and also can be oriented at a positive value, a negative value, or a combination thereof. Any suitable positive or negative value is envisioned. In an example, the second set of filaments extends along any length envisioned of the laid fabric. In an example, the second set of filaments extends along the entire width in the cross direction of the laid fabric.

In an embodiment, the laid fabric further includes a third set of filaments that are laid adjacent to the second set of filaments. In a particular embodiment, the third set of filaments is directly in contact with the second set of filaments. In a particular embodiment, the third set of filaments includes a plurality of filaments of monofilaments or multifilaments that are generally parallel to each other that may be evenly spaced or randomly spaced. In a more particular embodiment, the third set of filaments is laid in the same direction as the first set of filaments. In an embodiment, the third set of filaments is laid in a direction that is different than the first set of filaments. In an embodiment, the third set of filaments can be oriented at any angle between 0 degrees and 90 degrees relative to the main direction of the laid fabric. In a particular embodiment, the third set of filaments extends generally parallel to the main direction of the laid fabric, i.e. 0 degrees. In another embodiment, it is envisioned that the third set of filaments can be oriented at a suitable angle and also can be oriented at a positive value, a negative value, or a combination thereof. Any suitable positive or negative value is envisioned. In an example, the third set of filaments extends along any length envisioned of the laid fabric. For instance, the third set of filaments extends along the entire length of the main direction of the laid fabric.

The first set of filaments, the second set of filaments, the third set of filaments, or combination thereof can include, for example, one or more filaments of any suitable material. Any suitable material includes, but is not limited to, a biodegradable yam such as, for example, a polymer, a naturally occurring material, or combination thereof. In an embodiment, the biodegradable yarn includes polyester, cellulose, wood pulp, hemp, polylactic acid (PLA), polyhydroxyalkanoates (PHA), polycaprolactone (PCL), jute, flax, glass, or combination thereof. In an embodiment, the first set of filaments, the second set of filaments, and the third set of filaments may be the same material or different materials.

The first set of filaments, the second set of filaments, the third set of filaments, or combination thereof can include any number of filaments per assembly, such as greater than 1 filament, greater than 2 filaments, or greater than 5 filaments. In an embodiment, the assembly includes less than 1,000 filaments per assembly, such as less than 500 filaments, or less than 100 filaments. A typical range can be 1 to 1,000 filaments per assembly. Any reasonable value between the minimum and maximum values are envisioned. In an embodiment, the filaments can have any reasonable diameter. For instance, the diameter of the core of the first set of filaments, the second set of filaments, or the third set of filaments without any coating may be greater than about 50 micrometer, such as about 50 micrometer to about 500 micrometers. Any reasonable value between the minimum and maximum values are envisioned.

The first set of filaments, the second set of filaments, and the third set of filaments of the laid fabric may be stabilized and fixed with a binder. In an embodiment, laid fabric includes a binder coating the first set of filaments, the second set of filaments, and the third set of filaments, or combination thereof. The binder provides a bond between adjacent sets of filaments such as the first set of filaments to the second set of filaments and the second set of filaments to the third set of filaments.

In an embodiment, any suitable binder may be envisioned that provides a bond to an adjacent layer. In a particular embodiment, the binder can include a biodegradable polymer, such as a re-meltable thermoplastic polymer, a thermoset polymer, or any combination thereof. In an example, the thermoplastic polymer includes polyvinyl alcohol (PVOH), polyurethane (PU), dextrose, gelatin, polycaprolactone (PCL), natural wax, starch, cellulose, polyacrylate, polyester, or combination thereof. In a particular embodiment, the coated binder re-melts at a temperature of less than about 250°C, such as 30°C to about 250°C. A re- meltable binder is desirable to adhere the laid fabric to any adjacent layer when the appropriate heat is applied. For instance, when the laid fabric is placed adjacent to at least one sheet of tissue, such as between two sheets of tissue, and heat and/or pressure is applied, the binder re-melts and flows through the tissue layers to provide a reinforced tissue product. Further, the laid fabric with the re-meltable binder has a minimum adhesion strength of 100 gf to an adjacent tissue layer, the measured force required to peel off a top tissue layer from the laid fabric at 180°. In an embodiment, the adjacent tissue layer is the at least one layer of absorbent fibers as described for the absorbent article.

One advantage to the use of the biodegradable binder when applied to one of the layers of the laid fabric is its ability to increase the shear strength of a product (e.g., an absorbent article or erosion blanket) into which it is incorporated. A second advantage is that a binder provides less bulk or weight to the laid fabric than stitching. Yet another advantage is that a binder can be applied to one or more layers of the laid fabric during its production at a much faster rate than another means of stabilizing or fixing the layers of the laid fabric (e.g., stitching) during its production. A still further advantage to using a binder is the stability that the binder affords to the laid fabric. In an embodiment, the binder adheres the first set of filaments and the third set of filaments to the second set of filaments at an intersection. In a particular embodiment, the binder is thicker at the intersection of the first set of filaments, the second set of filaments, and the third set of filaments.

Any reasonable coating method is envisioned to apply the binder, such as by dip coating, vacuum deposition, screen printing, extrusion coating, wet coating, transfer coating, or combination thereof. In an embodiment, the binder may be applied in a water-based dispersion. In another embodiment, the binder is stable at room temperature. In an embodiment, the bond between adjacent sets of filaments may be activated under conditions such as heat, pressure, or a combination thereof. During manufacturing, the laid fabric may be heated to allow the binder to secure the set of filaments of the laid fabric to one another and to fix the filaments to each other to enhance the stability, durability, and strength of the laid fabric. In an exemplary embodiment, when heated, the binder coating secures the filament through the evaporation of the water in the binder (via drying). In another embodiment, the laid fabric does not use stitching to join the sets of filaments together.

Additionally, the binder can be provided with any reasonable additive. Exemplary additives include a biocide, an anti-stick agent, an anti-blocking agent, a biodegradable additive, a defoamer, a viscosity modifier, a coloring agent, the like, or combination thereof. Any reasonable amount of additive is envisioned. In an embodiment, the biodegradable binder is provided within a solvent. Any reasonable solvent is envisioned, such as an aqueous solution, paraffin oil-based solvent, an alcohol ethoxylate, or combination thereof.

In a particular embodiment, the binder is present on the laid fabric depending on the final use desired. For instance, the binder is present at an amount of at least about 5% dry pick-up (DPU), such as about 5% DPU to about 200% DPU, such as about 5% DPU to about 175% DPU, such as about 5% DPU to 50% DPU, or about 90% DPU to about 175% DPU. When the laid fabric is used, for example, in an absorbent article, the binder may be present at about 90% DPU to about 175% DPU. In another embodiment, when the laid fabric is used in an erosion blanket, the binder may be present at about 5% DPU to about 50% DPU. The binder may be coated on individual strands of filaments or after the first set of filaments, the second set of filaments, and the third set of filaments are assembled. In an embodiment, the binder coats a front surface, a back surface, or combination thereof of the laid fabric. In an embodiment, the binder coats a combination of both the front surface and the back surface of the laid fabric. In an embodiment, the filaments are coated with the binder with some exposed filament surfaces. In another embodiment, the filaments are coated with the binder without any exposed surface of the filaments. In a more particular embodiment, the binder provides a continuous coating on the filaments without any exposed surface of the filaments. For instance, the binder substantially coats the filaments at any reasonable thickness. In an embodiment, the binder forms globular points of contact, particularly at the intersection of the filaments. In a particular embodiment, the binder substantially coats the filaments such that the coated filaments have an average diameter of about 50 micrometers (pm) to about 2000 pm. For instance, the coated filaments include, for example, a 77 tex polyester at 50% DPU to a 275 tex glass coated at 200% DPU. It will be appreciated that the thickness of the coating can be within a range between any of the minimum and maximum values noted above. In particular, the amount of binder coated on the yam can be tailored, depending on the final properties desired. For instance, a higher amount of coating (i.e. DPU) would typically provide for a higher adhesion strength of the laid fabric to an adjacent layer.

As discussed, the first set of filaments, the second set of filaments, and the third set of filaments of the laid fabric include a plurality of filaments that are generally parallel to each other. Any suitable spacing is envisioned between adjacent filaments. The first set of filaments, the second set of filaments, and the third set of filaments can have the same or different spacing between adjacent filaments depending upon the specific tensile and weight considerations desired for the laid fabric. For example, assemblies of filaments that are more closely spaced and that include a higher modulus and denier can create a stronger laid fabric. Assembly spacing can also be affected by the particular material or materials used in the laid fabric to meet an industrial specification and/or desired property. Any reasonable spacing is envisioned. Spacing between adjacent filaments includes, for instance, at least 0.5 filaments per inch. Any reasonable value above the minimum values is envisioned. Spacing between adjacent filaments provides an open area of the laid fabric to the total area of the laid fabric. For instance, the ratio of the open area of the laid fabric to a total area of the laid fabric is greater than about 50%, such as greater than about 60%, such as greater than about 70%, such as greater than about 80%, or even greater than about 90%.

In a particular embodiment, the laid fabric can include a 0/90 non-woven scrim, where the cross direction of the laid fabric is generally perpendicular to the main direction of the laid fabric. The first set of filaments and the third set of filaments extend generally parallel in the main direction and the second set of filaments extend generally parallel in the cross direction. In an embodiment, the laid fabric can include any number of sets of filaments, each of which can include different configurations, different angles, different spacing between the filaments, and different filamentary materials. In a particular embodiment, the filaments of the laid fabric are non-woven.

In an embodiment, the laid fabric has a thickness of about 50 micrometers (pm) to about 1000 pm prior to coating. In an embodiment, the laid fabric may also possess an ultimate tensile strength of at least about 1.5 pounds per inch (Ibs/in) or even greater in the machine direction and in the cross-machine direction. It will be appreciated that the areal weight, thickness, and tensile strength can be within a range between any of the minimum and maximum values noted above.

Turning to FIG. 1, a laid fabric 100 is illustrated from a perspective view. In an embodiment illustrated in FIGS. 1-3, the laid fabric 100 comprises a first set of filaments 102 including elongate filaments 104 which are arranged to extend generally parallel in a first direction. A second set of filaments 106 are laid adjacent to the first set of filaments 102, the second set of filaments 106 including elongate filaments 108 arranged to extend generally parallel in a second direction that is different than the first direction. In an embodiment, the second set of filaments 106 are directly in contact with the first set of filaments 102. A third set of filaments 110 are laid adjacent to the second set of filaments 106, the third set of filaments 110 including elongate filaments 112 arranged to extend generally parallel in the first direction. The third set of filaments 110 are directly in contact with the second set of filaments 106. As seen in FIG. 1, elongate filaments 104, 112 intersect with elongate filaments 108. More specifically, the elongated filaments 104, 108, and 112 are arranged in a grid including parallel filaments 104, 112 extending in the machine-direction 114 and parallel filaments 108 extending in the cross-direction 116 defining rectangular openings 118 in the laid fabric 100. Among other things, the openings 118 permit liquid to flow substantially unhindered through the laid fabric 100, enhancing biodegradability of the laid fabric 100. The elongate filaments 104 and 112 are secured to elongate filaments 108 where they intersect to create a lattice providing strength and stability to the laid fabric 100. As discussed, a binder (not shown) coats and secures the elongate filaments 104, 112, and 108. Any width and length desirable are envisioned for the laid fabric 100, depending on the final use of the laid fabric 100.

As discussed, the laid fabric may be used in an absorbent article. Absorbent articles include any article typically used to absorb body extrudate or industrial applications. In an embodiment, the absorbent article includes, for example, a diaper, training underwear, a feminine care article, an adult incontinence garment, a bandage, and the like. In an embodiment, the absorbent article includes an industrial wipe for cleaning up any kind of spill such as, for example, water, oil, solvents, and the like. The absorbent article may include any configuration. In an embodiment, the absorbent article includes absorbent fibers. Typically, absorbent fibers are hydrophilic and wettable. Examples of suitable absorbent fibers include naturally occurring organic fibers composed of intrinsically wettable material, such as cellulosic fibers including wood pulp fibers which can be curled, crosslinked or otherwise mechanically or chemically modified. Other examples of suitable absorbent fibers include synthetic fibers composed of cellulose or cellulose derivatives, such as rayon fibers; inorganic fibers composed of an inherently wettable material, such as glass fibers; synthetic fibers made from inherently wettable thermoplastic polymers, such as particular polyester or polyamide fibers; and synthetic fibers composed of a nonwettable thermoplastic polymer, such as polypropylene fibers, which have been hydrophilized by appropriate means. The fibers may be hydrophilized, for example, by treatment with silica, treatment with a material that has a suitable hydrophilic moiety and is not readily removable from the fiber, or by sheathing the nonwettable, hydrophobic fiber with a hydrophilic polymer during or after the formation of the fiber. For the purposes of the present invention, it is contemplated that selected blends of the various types of fibers mentioned above may also be employed. In a particular embodiment, the absorbent fibers are typically cellulose based, such as, cellulosic fibers, wood pulp fluff, or combination thereof. Any additive may be included in the absorbent fiber to provide any desirable properties such as an absorbent gelling material, an absorbent particle, or combination thereof.

Any assembly of the absorbent fibers is envisioned. In an embodiment, the absorbent fibers may be in the form of a scrim, a woven mat, a non-woven mat, a braided fabric, a knitted fabric, a chopped strand, or combination thereof. In an embodiment, the assembly of absorbent fibers includes a non-woven mat. In an embodiment, a “non-woven mat” may have filaments, fibers, or swirled continuous filament that are randomly-oriented or oriented in a specified configuration. In an embodiment, the non-woven mat includes randomly oriented absorbent fibers. Typically, the laid fabric may be positioned anywhere adjacent to the absorbent fibers. In a particular embodiment, the laid fabric is directly in contact with the absorbent fibers. In an example, the absorbent article includes a first layer of absorbent fibers, a second layer of a laid fabric, and a third layer of absorbent fibers. Any thickness of the first layer and the third layer is envisioned and may be the same or different, depending on the final properties desired for the absorbent article. Further, any number of layers of absorbent fibers is envisioned. Although not to be bound by theory, the laid fabric sandwiched between two layers of absorbent fibers has desirable porosity to allow entanglement of the absorbent fibers of the first layer and the second layer with the laid fabric as well as fluid flow therethrough.

As seen in FIG. 2, the laid fabric 100 is incorporated into an absorbent article 200. FIG. 2 includes a side-view of an exemplary absorbent article 200. The absorbent article 200 includes an absorbent core 202 of the absorbent article 200. The absorbent core 202 includes a first layer 204 of absorbent fibers 206 and a second layer 208 of absorbent fibers 210. The absorbent fibers 206 and 208 may be the same or different. It has been found that the laid fabric 100 may help the absorbent core 202 hold its shape in conformance with the wearer's body thereby improving fit and increasing comfort. Any size and shape of the laid fabric 100 and absorbent core 202 is envisioned.

The laid fabric 100 may be incorporated in the absorbent core 202 in a suitable manner. The laid fabric 100 may be laminated between first layer 204 and second layer 208. For instance, a first layer 204 is provided, the laid fabric 100, and then the second layer 208, with the laid fabric 100 in the center of the absorbent core 202. Subsequently, the first layer 204, the laid fabric 100, and the second layer 208 may be passed through a heated drum to remelt the binder. Any temperature is envisioned to re-melt the binder. Further pressure may be applied to the first layer 204, the laid fabric 100, and the second layer 208 to promote the flow of the binder and adhere the laid fabric 100 to the first layer 204 and the second layer 208. In an embodiment, entanglement and post-formation entanglement such as by needle punching or hydroentangling is not necessary to augment any connection between the laid fabric 100 and the first layer 204 and the second layer 208.

In an embodiment, the biodegradable binder on the laid fabric 100 provides adhesion of the first layer 204, the laid fabric 100, and the second layer 208. As discussed, the biodegradable binder may be re-melted under heat and/or pressure to provide adhesion of the first layer 204 to the laid fabric 100 as well as the laid fabric 100 to the second layer 208. In an embodiment, the absorbent article 200 is substantially free of stitching, any additional adhesive, or combination thereof to produce a robust and durable absorbent core.

In use, the laid fabric 100 holds the matrix of the fibrous material in the absorbent core 202 together against loads applied through movement of the wearer and by liquid in the absorbent core 202 after receiving one or more insults. These loads tend to cause the absorbent fibrous material (and hence the absorbent core 202) to tear apart. The laid fabric 100 resists forces applied to the absorbent core 202 such as but not limited to tensile force, compressive force, and shear force. In a particular embodiment, the laid fabric 100 allows the absorbent core 202 to have a lower basis weight of fibrous material because of the additional strength. Accordingly, the construction of a thinner absorbent core 202 and a thinner absorbent structure 200 can be achieved compared to an absorbent core 202 without a laid fabric 100.

Any other layers or features desired may be present in the absorbent article, depending on the final use for the absorbent article. The absorbent article can include any non-limiting number of additional features such as a backsheet layer, a wrap layer, a reinforcing layer, a carrier layer, an adhesive, a release liner, a fastener, the like, or combination thereof. When present, any suitable configuration or placement of any additional feature is envisioned to produce the absorbent article. Any material is envisioned and is dependent on the final article desired.

In an embodiment, the laid fabric is part of an erosion blanket. An erosion blanket is typically used to provide temporary coverage and support on ground surfaces, such as bare soil or low vegetation areas. An erosion blanket includes, for example, at least one laid fabric and at least one mat comprising a naturally occurring material. Any naturally occurring material is envisioned. In an embodiment, the naturally occurring material includes straw, coconut, wood, wool, other natural materials, the like, or combination thereof. In an embodiment, the at least laid fabric is secured to the at least one mat. Any means of securing the laid fabric to the mat in envisioned and includes, in an exemplary embodiment, stitching. In an exemplary embodiment, the stitching may be done with a biodegradable material as described above for the laid fabric.

As seen in FIG. 3, a cross-sectional view of a portion of an erosion blanket 300 is illustrated. The erosion blanket 300 includes at least one mat 302 of a naturally occurring material 304. The naturally occurring material 302 may include fibers 304 of randomly oriented naturally occurring material. The naturally occurring material may include a binder, such as a biodegradable coating to provide adhesion between adjacent fibers of the naturally occurring material. In another embodiment, the naturally occurring material is substantially free of a binder. In an embodiment, the mat 302 is adjacent to at least one laid fabric. As seen in FIG. 3, the mat 302 is directly in contact with at least one laid fabric. In a particular embodiment, the laid fabric is labelled as 100 and 100’, on the top surface 306 and/or the bottom surface 308 of the at least one mat 302. In an embodiment, the at least one laid fabric 100 and/or 100’ may be secured by stitching 310, such as via vertical stitching through the laid fabric 100 and 100’ and the at least one mat 302. Although illustrated as stitching 310 through an entire thickness of the laid fabric 100, 100’ and mat 302, any depth of the stitching is envisioned. As illustrated, the stitching secures both the laid fabric 100 and 100’ to the at least one mat 302. Any other methods of securing the erosion blanket are envisioned.

In use, the laid fabric 100 holds the at least one mat 302 of a naturally occurring material 304 in the erosion blanket 300 together against loads applied when the erosion blanket 300 is applied to an outdoor structure and to outdoor elements that the erosion blanket 300 is exposed after being placed on the outdoor structure. These loads tend to cause the naturally occurring material (and hence the erosion blanket 300) to tear apart. The laid fabric 100 resists forces applied to the erosion blanket 300 such as but not limited to tensile force, compressive force, and shear force. The laid fabric 100 allows the erosion blanket 300 maintain its strength and structure to keep the naturally occurring material in its desired placement to prevent erosion. Accordingly, the construction of a stronger and more stable erosion blanket 300 is achieved compared to an erosion blanket 300 without a laid fabric 100. Any number of mats of naturally occurring material may be envisioned as well as any number of layers of laid fabric, depending on the final properties desired for the erosion blanket. The laid fabric 100 has advantageous biodegradability such that when exposed to the outdoor elements, it can maintain its structure for a desired period of time as well as biodegrade to have a beneficial impact on the environment.

Any other materials or features desired may be present in the erosion blanket. The erosion blanket can include any non-limiting number of materials or additional features such as seeds for vegetation growth, additives to promote growth of vegetation such as fertilizer, additional binder for the layer of naturally occurring material, a reinforcing layer, a carrier layer, the like, or combination thereof. When present, any suitable configuration or placement of any additional feature is envisioned to produce the erosion blanket. Any material is envisioned and is dependent on the final article desired.

The laid fabric provides a product with advantageous properties such as desirable biodegradability. In an embodiment, the laid fabric has desirable biodegradability in soil and/or industrial compost conditions. For instance, the laid fabric has a desirable biodegradation rate of at least 90% in aerobic biodegradation conditions, following the test procedures outlined in ASTM D5988/ISO 17556 for soil degradation or the test procedures outlined in ISO 14851 for freshwater degradation or the test procedures outlined in ASTM D6691/ISO 23977 for marine degradation or the test procedures outlined in ISO 14855 for home composting degradation or the test procedures outlined in ASTM D6400/ISO 17088 for industrial compost degradation.

Many different aspects and embodiments are possible. Some of those aspects and embodiments are described herein. After reading this specification, skilled artisans will appreciate that those aspects and embodiments are only illustrative and do not limit the scope of the present invention. Embodiments may be in accordance with any one or more of the items as listed below.

Embodiment 1. A laid fabric including: a first set of filaments extending generally parallel in a first direction; a second set of filaments extending generally parallel in a second direction, wherein the second set of filaments are laid adjacent to the first set of filaments; a third set of filaments extending generally parallel in the first direction, wherein the third set of filaments are laid adjacent to the second set of filaments; wherein the first set of filaments, the second set of filaments, the third set of filaments, or combination thereof include a biodegradable yarn; and a binder coating the first set of filaments, the second set of filaments, the third set of filaments, or combination thereof, wherein the binder includes a biodegradable polymer.

Embodiment 2. The laid fabric in accordance with embodiment 1, wherein the first direction is 0 degrees and the second direction is 90 degrees.

Embodiment 3. The laid fabric in accordance with any one of embodiments 1-2, wherein the biodegradable yarn includes a polymer, a naturally occurring material, or combination thereof.

Embodiment 4. The laid fabric in accordance with any one of embodiments 1-3, wherein the biodegradable yarn includes polyester, cellulose, wood pulp, hemp, polylactic acid (PLA), polyhydroxyalkanoate (PHA), polycaprolactone (PCL), jute, flax, glass, or combination thereof.

Embodiment 5. The laid fabric in accordance with any one of embodiments 1-4, wherein the biodegradable binder includes a re-meltable thermoplastic polymer, a thermoset polymer, or combination thereof. Embodiment 6. The laid fabric in accordance with embodiment 5, wherein the thermoplastic polymer includes polyvinyl alcohol (PVOH), polyurethane (PU), dextrose, gelatin, polycaprolactone (PCL), natural wax, starch, cellulose, polyacrylate, polyester, or combination thereof.

Embodiment 7. The laid fabric in accordance with any one of embodiments 1-6, wherein the binder is present at an amount of at least about 5% dry pick-up (DPU), such as about 5% DPU to about 200% DPU, such as about 5% DPU to about 175% DPU, such as about 5% DPU to 50% DPU, or about 90% DPU to about 175% DPU.

Embodiment 8. The laid fabric in accordance with any one of embodiments 1-7, wherein the coated binder re-melts at a temperature of less than about 250°C, such as 30°C to about 250°C.

Embodiment 9. The laid fabric in accordance with any one of embodiments 1-8, wherein the first set of filaments and the third set of filaments are configured to intersect the second set of filaments.

Embodiment 10. The laid fabric in accordance with embodiment 9, wherein the binder adheres the first set of filaments and the third set of filaments to the second set of filaments at the intersection.

Embodiment 11. The laid fabric in accordance with embodiment 10, wherein the binder is thicker at the intersection of the first set of filaments, the second set of filaments, the third set of filaments, or combination thereof.

Embodiment 12. The laid fabric in accordance with embodiment 9, wherein the first set of filaments, the second set of filaments, and the third set of filaments are configured to have openings therebetween.

Embodiment 13. The laid fabric in accordance with embodiment 12, wherein the ratio of the open area of the laid fabric to a total area of the laid fabric is greater than about 50%, such as greater than about 60%, such as greater than about 70%, such as greater than about 80%, or even greater than about 90%.

Embodiment 14. The laid fabric in accordance with any one of embodiments 1-13, wherein the first set of filaments and the third set of filaments are continuous and linearly extend across the length of the laid fabric.

Embodiment 15. The laid fabric in accordance with any one of embodiments 1-14, wherein the second set of filaments are continuous and linearly extend across the width of the laid fabric. Embodiment 16. The laid fabric in accordance with any one of embodiments 1-15, wherein the coated first set of filaments, the coated second set of filaments, the coated third set of filaments, or combination thereof have a diameter of 50 pm to about 2000 pm.

Embodiment 17. The laid fabric in accordance with any one of embodiments 1-16, wherein the laid fabric is non-woven.

Embodiment 18. The laid fabric in accordance with any one of embodiments 1-17, wherein the laid fabric is substantially free of stitching.

Embodiment 19. The laid fabric in accordance with any one of embodiments 1-18, wherein the laid fabric has a biodegradation rate of 90% in aerobic biodegradation conditions, following the test procedures outlined in ASTM D5988/ISO 17556 for soil degradation or the test procedures outlined in ISO 14851 for freshwater degradation or the test procedures outlined in ASTM D6691/ISO 23977 for marine degradation or the test procedures outlined in ISO 14855 for home composting degradation or the test procedures outlined in ASTM D6400/ISO 17088 for industrial compost degradation.

Embodiment 20. An absorbent article including: a first layer comprising absorbent fibers; a second layer adjacent to the first layer, the second layer including a laid fabric, wherein the laid fabric includes: a first set of filaments extending generally parallel in a first direction; a second set of filaments extending generally parallel in a second direction, wherein the second set of filaments are laid adjacent to the first set of filaments; a third set of filaments extending generally parallel in the first direction, wherein the third set of filaments are laid adjacent to the second set of filaments; wherein the first set of filaments, the second set of filaments, the third set of filaments, or combination thereof includes a biodegradable yarn; a binder coating the first set of filaments, the second set of filaments, and the third set of filaments, wherein the binder includes a biodegradable polymer; and a third layer adjacent to the laid fabric, wherein the third layer includes absorbent fibers.

Embodiment 21. The absorbent article in accordance with embodiment 20, wherein the absorbent fibers include cellulosic fibers, wood pulp fluff, or combination thereof.

Embodiment 22. The absorbent article in accordance with any one of embodiments 20-21, wherein the laid fabric is entangled with absorbent fibers from the first layer and the third layer.

Embodiment 23. The absorbent article in accordance with embodiment 22, wherein the absorbent fibers are randomly oriented. Embodiment 24. The absorbent article in accordance with any one of embodiments 20-23, wherein the laid fabric has an adhesion strength to the absorbent layer of at least 100 gf, when tested as described in the Example.

Embodiment 25. The absorbent article in accordance with any one of embodiments 20-24, wherein the first direction is 0 degrees and the second direction is 90 degrees.

Embodiment 26. The absorbent article in accordance with any one of embodiments 20-25, wherein the biodegradable yam includes a polymer, a naturally occurring material, or combination thereof.

Embodiment 27. The absorbent article in accordance with any one of embodiments 20-26, wherein the biodegradable yam includes polyester, cellulose, wood pulp, hemp, polylactic acid (PLA), polyhydroxyalkanoate (PHA), polycaprolactone (PCL), jute, flax, glass, or combination thereof.

Embodiment 28. The absorbent article in accordance with any one of embodiments 20-27, wherein the biodegradable binder includes a re-meltable thermoplastic polymer, a thermoset polymer, or combination thereof.

Embodiment 29. The absorbent article in accordance with embodiment 28, wherein the thermoplastic polymer includes polyvinyl alcohol (PVOH), polyurethane (PU), dextrose, gelatin, polycaprolactone (PCL), natural wax, starch, cellulose, polyacrylate, polyester, or combination thereof.

Embodiment 30. The absorbent article in accordance with any one of embodiments 20-29, wherein the binder is present at an amount of at least about 5% DPU, such as about 5% DPU to about 200% DPU, such as about 5% DPU to about 175% DPU, such as about 5% DPU to 50% DPU, or about 90% DPU to about 175% DPU.

Embodiment 31. The absorbent article in accordance with any one of embodiments 20-30, wherein the coated binder re-melts at a temperature of less than about 250°C, such as 30°C to about 250°C.

Embodiment 32. The absorbent article in accordance with any one of embodiments 20-31, wherein the first set of filaments and the third set of filaments are configured to intersect the second set of filaments.

Embodiment 33. The absorbent article in accordance with embodiment 32, wherein the binder adheres the first set of filaments and the third set of filaments to the second set of filaments at the intersection. Embodiment 34. The absorbent article in accordance with embodiment 33, wherein the binder is thicker at the intersection of the first set of filaments, the second set of filaments, the third set of filaments, or combination thereof.

Embodiment 35. The absorbent article in accordance with embodiment 32, wherein the first set of filaments, the second set of filaments, and the third set of filaments are configured to have openings therebetween.

Embodiment 36. The absorbent article in accordance with embodiment 35, wherein the ratio of the open area of the laid fabric to a total area of the laid fabric is greater than about 50%, such as greater than about 60%, such as greater than about 70%, such as greater than about 80%, or even greater than about 90%.

Embodiment 37. The absorbent article in accordance with any one of embodiments 20-36, wherein the first set of filaments and the third set of filaments are continuous and linearly extend across the length of the laid fabric.

Embodiment 38. The absorbent article in accordance with any one of embodiments 20-37, wherein the second set of filaments are continuous and linearly extend across the width of the laid fabric.

Embodiment 39. The absorbent article in accordance with any one of embodiments 20-38, wherein the coated first set of filaments, the coated second set of filaments, the coated third set of filaments, or combination thereof have a diameter of 50 pm to about 2000 pm.

Embodiment 40. The absorbent article in accordance with any one of embodiments 20-39, wherein the laid fabric is non-woven.

Embodiment 41. The absorbent article in accordance with any one of embodiments 20-40, wherein the laid fabric is substantially free of stitching.

Embodiment 42. The absorbent article in accordance with any one of embodiments 20-41, wherein the laid fabric has a biodegradation rate of 90% in aerobic biodegradation conditions, following the test procedures outlined in ASTM D5988/ISO 17556 for soil degradation or the test procedures outlined in ISO 14851 for freshwater degradation or the test procedures outlined in ASTM D6691/ISO 23977 for marine degradation or the test procedures outlined in ISO 14855 for home composting degradation or the test procedures outlined in ASTM D6400/ISO 17088 for industrial compost degradation.

Embodiment 43. An erosion blanket including: at least one laid fabric including: a first set of filaments extending generally parallel in a first direction; a second set of filaments extending generally parallel in a second direction, wherein the second set of filaments are laid adjacent to the first set of filaments; a third set of filaments extending generally parallel in the first direction, wherein the third set of filaments are laid adjacent to the second set of filaments; wherein the first set of filaments, the second set of filaments, the third set of filaments, or combination thereof include a biodegradable yarn; and a binder coating the first set of filaments, the second set of filaments, and the third set of filaments, wherein the binder includes a biodegradable polymer; and at least one mat including a naturally occurring material.

Embodiment 44. The erosion blanket in accordance with embodiment 43, wherein at least one laid fabric is secured to the at least one mat.

Embodiment 45. The erosion blanket in accordance with embodiment 44, wherein the at least one laid fabric is stitched to the at least one mat.

Embodiment 46. The erosion blanket in accordance with any one of embodiments 43-

45, wherein the naturally occurring material includes straw, coconut, wood, wool, other natural materials, or combination thereof.

Embodiment 47. The erosion blanket in accordance with any one of embodiments 43-

46, wherein the naturally occurring material is randomly oriented.

Embodiment 48. The erosion blanket in accordance with any one of embodiments 43-

47, wherein the at least one mat is directly in contact with the at least one laid fabric.

Embodiment 49. The erosion blanket in accordance with any one of embodiments 43-

48, wherein the first direction is 0 degrees and the second direction is 90 degrees.

Embodiment 50. The erosion blanket in accordance with any one of embodiments 43-

49, wherein the biodegradable yarn includes a polymer, a naturally occurring material, or combination thereof.

Embodiment 51. The erosion blanket in accordance with any one of embodiments 43-

50, wherein the biodegradable yarn includes polyester, cellulose, wood pulp, hemp, polylactic acid (PLA), polyhydroxyalkanoate (PHA), polycaprolactone (PCL), jute, flax, glass, or combination thereof.

Embodiment 52. The erosion blanket in accordance with any one of embodiments 43-

51, wherein the biodegradable binder includes a re-meltable thermoplastic polymer, a thermoset polymer, or combination thereof.

Embodiment 53. The erosion blanket in accordance with embodiment 52, wherein the thermoplastic polymer includes polyvinyl alcohol (PVOH), polyurethane (PU), dextrose, gelatin, polycaprolactone (PCL), natural wax, starch, cellulose, polyacrylate, polyester, or combination thereof. Embodiment 54. The erosion blanket in accordance with any one of embodiments 43-

53, wherein the binder is present at an amount of at least about 5% DPU, such as about 5% DPU to about 200% DPU, such as about 5% DPU to about 175% DPU, such as about 5% DPU to 50% DPU, or about 90% DPU to about 175% DPU.

Embodiment 55. The erosion blanket in accordance with any one of embodiments 43-

54, wherein the coated binder re-melts at a temperature of less than about 250°C, such as 30°C to about 250°C.

Embodiment 56. The erosion blanket in accordance with any one of embodiments 43-

55, wherein the first set of filaments and the third set of filaments are configured to intersect the second set of filaments.

Embodiment 57. The erosion blanket in accordance with embodiment 56, wherein the binder adheres the first set of filaments and the third set of filaments to the second set of filaments at the intersection.

Embodiment 58. The erosion blanket in accordance with embodiment 57, wherein the binder is thicker at the intersection of the first set of filaments, the second set of filaments, the third set of filaments, or combination thereof.

Embodiment 59. The erosion blanket in accordance with embodiment 56, wherein the first set of filaments, the second set of filaments, and the third set of filaments are configured to have openings therebetween.

Embodiment 60. The erosion blanket in accordance with embodiment 59, wherein the ratio of the open area of the laid fabric to a total area of the laid fabric is greater than about 50%, such as greater than about 60%, such as greater than about 70%, such as greater than about 80%, or even greater than about 90%.

Embodiment 61. The erosion blanket in accordance with any one of embodiments 43-

60, wherein the first set of filaments and the third set of filaments are continuous and linearly extend across the length of the laid fabric.

Embodiment 62. The erosion blanket in accordance with any one of embodiments 43-

61, wherein the second set of filaments are continuous and linearly extend across the width of the laid fabric.

Embodiment 63. The erosion blanket in accordance with any one of embodiments 43-

62, wherein the coated first set of filaments, the coated second set of filaments, the coated third set of filaments, or combination thereof have a diameter of 50 pm to about 2000 pm.

Embodiment 64. The erosion blanket in accordance with any one of embodiments 43-

63, wherein the laid fabric is non-woven. Embodiment 65. The erosion blanket in accordance with any one of embodiments 43-

64, wherein the laid fabric is substantially free of stitching.

Embodiment 66. The erosion blanket in accordance with any one of embodiments 43-

65, wherein the laid fabric has a biodegradation rate of 90% in aerobic biodegradation conditions, following the test procedures outlined in ASTM D5988/ISO 17556 for soil degradation or the test procedures outlined in ISO 14851 for freshwater degradation or the test procedures outlined in ASTM D6691/ISO 23977 for marine degradation or the test procedures outlined in ISO 14855 for home composting degradation or the test procedures outlined in ASTM D6400/ISO 17088 for industrial compost degradation.

The following example is provided to better disclose and teach processes and compositions of the present invention. It is for illustrative purposes only, and it must be acknowledged that minor variations and changes can be made without materially affecting the spirit and scope of the invention as recited in the claims that follow.

EXAMPLES

Testing conditions for measuring the adhesion strength of the laid fabric in the absorbent article reinforcement application was as follows: The biodegradable laid fabric coated with biodegradable binder was pressed between four layers of absorbent articles in the Carver press. The press was programmed with a dwell time of 10 seconds, pressure of 6000 psi, and heated as appropriate for the specific binder. The entire layered sample was cut to be 5 inches wide in the cross-direction and 7 inches long in the machine-direction. A 180° peel test was performed on the sample using the IM ASS SP-2100 Slip/Peel tester with a 5 pound load cell connected. The Slip/Peel tester was programmed with an initial delay time of 4 seconds, averaging time of 50 seconds, and testing speed of 2.5 mm/second. The sample was attached to the 180° plate with the machine-direction in the testing direction using doublesided vinyl tape 6 inches in length. A second piece of 6-inch vinyl tape was adhered to the top of the sample for the clamp of the Slip/Peel tester to grip. As the test was run, the clamped tape peeled away the top layer of absorbent article from the laid fabric and measured the amount of force required to do so. Strength was reported in gram-force (gf) as the strength of adhesion between the binder-coated laid fabric to the absorbent tissue layer. The strength was within acceptable limits for commercially available absorbent articles.

Multiple laid scrims were formed:

A polyethylene fiber of 55 micrometers was laid in a scrim and dip coated with a PVOH binder, having a DPU of 135%. A polyethylene fiber of 60 micrometers was laid in a scrim and dip coated with a polyurethane (PU) binder, having a DPU of 92%.

A polyethylene fiber of 60 micrometers was laid in a scrim and dip coated with a combination of PVOH and PU binders, having a DPU of 143%.

A cellulose-based lyocell fiber of 400 micrometers was laid in a scrim and dip coated with a PVOH binder, having a DPU of 50%.

A cellulose-based lyocell fiber of 400 micrometers was laid in a scrim and dip coated with a PVOH binder, having a DPU of 30%.

Each exemplary laid scrim had a desirable biodegradability in aerobic environments.

Certain features, for clarity, described herein in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any subcombination. Further, reference to values stated in ranges includes each and every value within that range.

Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims.

The specification and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The specification and illustrations are not intended to serve as an exhaustive and comprehensive description of all of the elements and features of apparatus and systems that use the structures or methods described herein. Separate embodiments may also be provided in combination in a single embodiment, and conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any subcombination. Further, reference to values stated in ranges includes each and every value within that range. Many other embodiments may be apparent to skilled artisans only after reading this specification. Other embodiments may be used and derived from the disclosure, such that a structural substitution, logical substitution, or another change may be made without departing from the scope of the disclosure. Accordingly, the disclosure is to be regarded as illustrative rather than restrictive.

Claims

WHAT IS CLAIMED IS:

1. A laid fabric comprising: a first set of filaments extending generally parallel in a first direction; a second set of filaments extending generally parallel in a second direction, wherein the second set of filaments are laid adjacent to the first set of filaments; a third set of filaments extending generally parallel in the first direction, wherein the third set of filaments are laid adjacent to the second set of filaments; wherein the first set of filaments, the second set of filaments, the third set of filaments, or combination thereof comprise a biodegradable yarn; and a binder coating the first set of filaments, the second set of filaments, the third set of filaments, or combination thereof, wherein the binder comprises a biodegradable polymer.

2. The laid fabric in accordance with claim 1, wherein the biodegradable yarn comprises a polymer, a naturally occurring material, or combination thereof.

3. The laid fabric in accordance with any one of claims 1-2, wherein the biodegradable yarn comprises polyester, cellulose, wood pulp, hemp, polylactic acid (PLA), polyhydroxyalkanoate (PHA), jute, flax, polycaprolactone (PCL), glass, or combination thereof.

4. The laid fabric in accordance with any one of claims 1-3, wherein the biodegradable binder comprises a re-meltable thermoplastic polymer, a thermoset polymer, or combination thereof.

5. The laid fabric in accordance with claim 4, wherein the thermoplastic polymer comprises polyvinyl alcohol (PVOH), polyurethane (PU), dextrose, gelatin, polycaprolactone (PCL), natural wax, starch, cellulose, polyacrylate, polyester, or combination thereof.

6. The laid fabric in accordance with any one of claims 1-5, wherein the coated binder re-melts at a temperature of less than about 250°C, such as 30°C to about 250°C.

7. The laid fabric in accordance with any one of claims 1-6, wherein the first set of filaments and the third set of filaments are configured to intersect the second set of filaments.

8. The laid fabric in accordance with claim 7, wherein the first set of filaments, the second set of filaments, and the third set of filaments are configured to have openings therebetween.

9. The laid fabric in accordance with any one of claims 1-8, wherein the first set of filaments and the third set of filaments are continuous and linearly extend across the length of the laid fabric.

10. The laid fabric in accordance with any one of claims 1-9, wherein the laid fabric is non-woven.

11. The laid fabric in accordance with any one of claims 1-10, wherein the laid fabric has a biodegradation rate of 90% in aerobic biodegradation conditions, following the test procedures outlined in ASTM D5988/ISO 17556 for soil degradation or the test procedures outlined in ISO 14851 for freshwater degradation or the test procedures outlined in ASTM D6691/ISO 23977 for marine degradation or the test procedures outlined in ISO 14855 for home composting degradation or the test procedures outlined in ASTM D6400/ISO 17088 for industrial compost degradation.

12. An absorbent article comprising: a first layer comprising absorbent fibers; a second layer adjacent to the first layer, the second layer comprising a laid fabric, wherein the laid fabric comprises: a first set of filaments extending generally parallel in a first direction; a second set of filaments extending generally parallel in a second direction, wherein the second set of filaments are laid adjacent to the first set of filaments; a third set of filaments extending generally parallel in the first direction, wherein the third set of filaments are laid adjacent to the second set of filaments; wherein the first set of filaments, the second set of filaments, the third set of filaments, or combination thereof comprise a biodegradable yarn; a binder coating the first set of filaments, the second set of filaments, and the third set of filaments, wherein the binder comprises a biodegradable polymer; and a third layer adjacent to the laid fabric, wherein the third layer comprises absorbent fibers.

13. The absorbent article in accordance with claim 12, wherein the absorbent fibers comprise cellulosic fibers, wood pulp fluff, or combination thereof.

14. An erosion blanket comprising: at least one laid fabric comprising: a first set of filaments extending generally parallel in a first direction; a second set of filaments extending generally parallel in a second direction, wherein the second set of filaments are laid adjacent to the first set of filaments; a third set of filaments extending generally parallel in the first direction, wherein the third set of filaments are laid adjacent to the second set of filaments; wherein the first set of filaments, the second set of filaments, the third set of filaments, or combination thereof comprise a biodegradable yarn; and a binder coating the first set of filaments, the second set of filaments, and the third set of filaments, wherein the binder comprises a biodegradable polymer; and at least one mat comprising a naturally occurring material.

15. The erosion blanket in accordance with claim 14, wherein the naturally occurring material comprises straw, coconut, wood, wool, other natural materials, or combination thereof.